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LG Floor Standing Type Air Conditioner: Installation Manual

This document provides installation instructions for an LG floor standing air conditioner. It discusses selecting indoor and outdoor unit locations, installing the units, connecting piping and cables, performing vacuum drying of pipes, and conducting a final test run. Safety precautions are also outlined, such as using a dedicated circuit, grounding, avoiding flammables and unit damage from weather.

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© © All Rights Reserved
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0% found this document useful (0 votes)
261 views20 pages

LG Floor Standing Type Air Conditioner: Installation Manual

This document provides installation instructions for an LG floor standing air conditioner. It discusses selecting indoor and outdoor unit locations, installing the units, connecting piping and cables, performing vacuum drying of pipes, and conducting a final test run. Safety precautions are also outlined, such as using a dedicated circuit, grounding, avoiding flammables and unit damage from weather.

Uploaded by

samer battat
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 20

website http://www.lgservice.

com
e-mail http://www.lgeservice.com/techsup.html

LG
LG Floor Standing Type
Air Conditioner
INSTALLATION MANUAL

IMPORTANT
• Please read this installation manual completely before
installing the product.
• Installation work must be performed in accordance with
the national wiring standards by authorized personnel
only.
• Please retain this installation manual for future reference
after reading it thoroughly.
P/No.: 3828A20025V
Floor Standing Type Air Conditioner Installation Manual

TABLE OF CONTENTS
OUT-LINE OF INSTALLATION

Safety Precautions..........................................................................................3
Installation of Indoor, Outdoor Unit ..............................................................6
1) Selection of the best location.................................................................................................................................6

2) Indoor Unit Installation ...........................................................................................................................................8

3) Outdoor unit installation .........................................................................................................................................8

4) Refrigerant amount ................................................................................................................................................8

5) Installation guide at the seaside ............................................................................................................................9

6) Installation method procedure..............................................................................................................................10

7) Preparation of installation parts and tools ...........................................................................................................11

8) Preparation of piping............................................................................................................................................12

9) Connection of piping ............................................................................................................................................13

10) Precautions in bending ......................................................................................................................................13

11) Connecting the cable to the indoor unit .............................................................................................................14

12) Connecting the piping to the outdoor unit..........................................................................................................15

13) Connecting the cable to the outdoor unit...........................................................................................................15

14) Power supply and wiring ....................................................................................................................................16

15) Vacuum drying of the connecting pipes and the indoor unit..............................................................................17

16) Form the pipe.....................................................................................................................................................18

Final Check and Test Run ..........................................................................................19

2 Floor Standing type Air Conditioner


Safety Precautions

Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions
must be followed.
■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness
is classified by the following indications.

WARNING This symbol indicates the possibility of death or serious injury.

CAUTION This symbol indicates the possibility of injury or damage.

■ Meanings of symbols used in this manual are as shown below.

Be sure not to do.

Be sure to follow the instruction.

WARNING
■ Installation
Do not use a defective or For electrical work, contact the Always ground the product.
underrated circuit breaker. Use dealer, seller, a qualified
this appliance on a dedicated electrician, or an Authorized
circuit. Service Center.
• There is risk of fire or • Do not disassemble or repair • There is risk of fire or
electric shock. the product. There is risk of electric shock.
fire or electric shock.

Install the panel and the cover of Always install a dedicated Use the correctly rated breaker
control box securely. circuit and breaker. or fuse.
• There is risk of fire or • Improper wiring or • There is risk of fire or
electric shock. installation may cause fire or electric shock.
electric shock

Installation Manual 3
Safety Precautions

Do not modify or extend the power cable. Be cautious when unpacking and installing the
product.
• There is risk of fire or electric shock. • Sharp edges could cause injury. Be especially
careful of the case edges and the fins on the
condenser and evaporator.

For installation, always contact the dealer or an Do not install the product on a defective
Authorized Service Center. installation stand.

• There is risk of fire, electric shock, explosion, • It may cause injury, accident, or damage to
or injury. the product.

Be sure the installation area does not Do not let the air conditioner run for a long time when
deteriorate with age. the humidity is very high and a door or a window is
left open.
• If the base collapses, the air conditioner could fall with • Moisture may condense and wet or damage
it, causing property damage, product failure, and furniture.
personal injury.

■ Operation
Do not store or use flammable gas or combustibles
near the product.

• There is risk of fire or failure of product.

Gasolin

4 Floor Standing type Air Conditioner


Safety Precautions

CAUTION
■ Installation
Always check for gas (refrigerant) leakage after Install the drain hose to ensure that water is
installation or repair of product. drained away properly.

• Low refrigerant levels may cause failure of • A bad connection may cause water leakage.
product.

Keep level even when installing the product. Do not install the product where the noise or hot air
from the outdoor unit could damage the
neighborhoods.
• To avoid vibration or water leakage. • It may cause a problem for your neighbors.

90˚

Use two or more people to lift and transport the Do not install the product where it will be
product. exposed to sea wind (salt spray) directly.

• Avoid personal injury. • It may cause corrosion on the product.


Corrosion, particularly on the condenser and
evaporator fins, could cause product
malfunction or inefficient operation.

Installation Manual 5
Installation of Unit

Installation of Unit

Selection of the best location


1. Indoor unit
• There should not be any heat source or
steam near the unit.
• There should not be any obstacles to 5cm
prevent the air circulation. 40cm
• A place where air circulation in the room 40cm
will be good. c m
100
• A place where drainage can be easily
obtained.
• A place where noise prevention is taken
into consideration.
• Do not install the unit near the door way.
• Ensure the spaces indicated by arrows
from the wall, ceiling, or other obstacles.
• The indoor unit must keep the
maintenance space.

2. Outdoor unit
• If an awning is built over the unit to prevent Su
nro
direct sunlight or rain exposure, be careful of
that heat radiation from the condenser is
not restricted. More than
50cm
• There should not be any animals or plants
which could be affected by hot air
discharged. More than
• Ensure the spaces indicated by arrows Fe 30cm
50cm
from the wall, ceiling, fence or other ob nce
sta or
obstacles. cle
s
More than 50cm
More than 100cm

6 Floor Standing type Air Conditioner


Installation of Unit

3. Piping length and the elevation

PIPE SIZE Max. Max.


MODEL
Length Elevation
(BTU/h)
GAS SIDE LIQUID SIDE A (m) B (m)
20k/28k/30k/40k 5/8" 3/8" 30 20
44k/48k/50k/55k/60k 3/4" 3/8" 40 25
80k 1" 5/8" 50 30

Indoor unit

B Outdoor unit

CAUTION:
• Capacity is based on standard length and maximum allowance length is on
the basis of reliability.
• Oil trap should be installed every 5~7 meters.

Installation Manual 7
Installation of Unit

The Indoor Unit Installation


Wall

Core Drill

200mm
70mm
70mm
90mm

1. The mounting floor should be strong and solid INSIDE OUTSIDE


enough to prevent it from vibration.
Wall
2. Drill the piping hole with 70mm diameter hole- Plastic tube
core drill at either the right or the left of indoor (Bushing)
unit. The hole should be sightly slant to the
outdoor side.
3. Insert the plastic tube through the hole. Tilt

4. Cut the extruded outside part of the plastic Cut if necessary


tube, if necessary.

More than 15mm

Outdoor unit Installation


1. Install the outdoor unit on the concrete or any solid base securely and horizontally by securing it
with bolts (Ø12mm) and nuts.
2. If there is any vibration transmitted to the building, mount the rubber underneath the outdoor unit.

Refrigerant amount
Before shipment, this air conditioner is filled MODEL REFRIGERANT CHARGE
with the rated amount of refrigerant including
additional amount required for air-purging, 20k/28k/30k/40k 30g/m (1.06oz/m)
subject to 7.5m piping length. (The rated (BTU/h)
amount of refrigerant is indicated on the name 44k/48k/50k/55k/60k 40g/m (1.41oz/m)
plate.) But when the piping length exceeds 7.5 (BTU/h)
meters, additional charge is required according 80k
to the following table. (BTU/h) 80g/m (2.82oz/m)

Example) 28k/30k
In case of 10m long pipe(one-way), the amount
of refrigerant to be replenished is:
(10-7.5) x 30 = 75g
(10-7.5) x 1.06 = 2.65oz

8 Floor Standing type Air Conditioner


Installation of Unit

Installation guide at the seaside


CAUTION
1. Air conditioners should not be installed in areas where corrosive gases, such as acid or alkaline gas, are produced.
2. Do not install the product where it could be exposed to sea wind (salty wind) directly. It can result corrosion
on the product. Corrosion, particularly on the condenser and evaporator fins, could cause product malfunc-
tion or inefficient performance.
3. If outdoor unit is installed close to the seaside, it should avoid direct exposure to the sea wind. Otherwise it
needs additional anticorrosion treatment on the heat exchanger.

Selecting the location(Outdoor Unit)


1. If the outdoor unit is to be installed close to the seaside, direct exposure to the sea wind should be avoided.
Install the outdoor unit on the opposite side of the sea wind direction.

Sea wind Sea wind

2. In case, to install the outdoor unit on the seaside, set up a windbreak not to be exposed to the sea wind.

Windbreak • It should be strong enough like concrete to prevent


the sea wind from the sea.
• The height and width should be more than 150% of
the outdoor unit.
Sea wind • It should be keep more than 70 cm of space
between outdoor unit and the windbreak for easy
air flow.

3. Select a well-drained place.

1. If you can’t meet above guide line in the seaside installation, please contact LG Electronics for the additional anticorrosion treatment.
2. Periodic ( more than once/year ) cleaning of the dust or salt particles stuck on the heat exchanger by using water

Installation Manual 9
Installation of Unit

Installation Method

No. Installation works Descriptions

1 Preparation of tools and installation parts Preparation of installation

2 Flaring the pipes To insert the flare nuts, mounted on the


connection parts of both indoor and
outdoor unit, onto the copper pipes.

3 Pipe bending To reduce the flow resistance of refrigerant.

4 Connection of installation parts Connection of long piping


(elbows, socket etc)

5 Tighten the flare nut (outdoor) Connecting the pipings of the outdoor unit.

6 Blowing the pipings To remove dust and scale in working.

7 Tighten the flare nut (indoor) Connecting the pipings of the indoor unit.

8 Check a gas-leakage of the connecting


part of the pipings.

9 Vacuum drying of the piping and indoor unit The air which contains moisture and which
remains in the refrigeration cycle may cause a
malfunction on the compressor

10 Open the 3-way (liquid side) and


3-way (gas side) valves.

11 Form the pipings To prevent heat loss and sweat

12 Checking the drainage (indoor unit) To ensure if water flow drain hose of indoor unit.

13 Connecting the cable between outdoor Preparation of the operating


and indoor unit

14 Connecting the main cable to outdoor unit

15 Supply the power to the crankcase heater To prevent the liquid back to the compressor.
(Before the operating the unit) (Heat pump only)

16 Cooling operation
(Use the remote control or display of the
indoor unit)

10 Floor Standing type Air Conditioner


Installation of Unit

Preparation of installation parts and tools


No. Installation Parts, Tools Use
1 Flaring tool (Ø 6.35 - Ø 19.05) Flaring the pipes
2 Remear Remove burrs from cut edges of pipes.
3 Pipe cutter (MAX 35mm Copper pipe) Cutting the pipings
4 Wrench (H5, H4 hexagonal wrench) To open the service valve
5 Pipe bender Bending the pipings
6 Leak detector Check a gas-leakage of connecting part
of the pipings
7 Manifold gauge To measure the pressure, to charge the refrigerant
8 Charge-nipple To connect the bombe
9 Vacuum pump To remove the air in the pipe.
10 Charge cylinder balance To measure the refrigerant amount
11 Bombe (Freon-22) Gas charge
Cleaning the pipe
12 Spanner To tighten the connecting parts of the pipings
13 Monkey spanner
14 Driver( , )
15 Benchi (150mm) Cutting the wires
16 Tapeline To measure the length
17 Core drill To make holes through the concrete wall and blocks
18 Voltmeter, Amperemeter, Clampmeter To measure the current and voltage
19 Insulation resistance tester To measure the insulation resistance
20 Glass thermometer To measure the intake and outlet air temperature of the indoor unit
21 Copper tubes To use the connecting pipings
22 Insulation material To cover the connecting pipings
23 Tape To finish the connecting pipings
24 Electrical Leakage Breaker To shut off the main power
25 Cable To connect the cable from outdoor unit to indoor unit
26 Drain hose sockets, elbows To remote the condensing water

Installation Manual 11
Installation of Unit

Preparation of Piping
Main cause of gas leakage is defect in flaring
work. Carry out correct flaring work in the
following procedure. Copper
tube 90° Slanted Uneven Rough

1. Cut the pipes and the cable.


• Use the accessory piping kit or the pipes
purchased locally.
• Measure the distance between the indoor
and the outdoor unit. Pipe

• Cut the pipes a little longer than measured Reamer


distance.
• Cut the cable 1.5m longer than the pipe Point down
length.

2. Burrs removal
• Completely remove all burrs from the cut
cross section of pipe/tube.
Flare nut
• Put the end of the copper tube/pipe to
downward direction as you remove burrs in
order to avoid to let burrs drop in the tubing. Copper tube

3. Putting nut on
• Remove flare nuts attached to indoor and
outdoor units, than put them on pipe/tube
having completed burr removal.
(Not possible to put them on after flaring work)
Handle
Bar Bar
4. Flaring work "A" Yoke
• Carry out flaring work using dedicated Cone
flaring tool for R-22 as shown below.
Outside diameter A Copper pipe
mm inch mm
Ø6.35 1/4 1.1~1.3 Clamp handle
Red arrow mark
Ø9.52 3/8 1.5~1.7
Ø12.7 1/2 1.6~1.8
Ø15.88 5/8 1.6~1.8 Smooth all round
Ø19.05 3/4 1.9~2.1 Inside is shining without scratches

Firmly hold copper tube in a bar(or die) as


= Improper flaring =
indicated dimension in the table above.

5. Check
Inclined Surface Cracked Uneven
• Compare the flared work with figure below. damaged thickness
Even length
• If flare is noted to be defective, cut off the all round
flared section and do flaring work again.

12 Floor Standing type Air Conditioner


Installation of Unit

Connection of piping
1. Move the indoor tubing and drain hose to the hole
• Remove tubing holder and pull the tubing out of the chassis.
2. Replace the tubing holder into original position
3. Route the tubing and the drain hose staight backwards.
4. Insert the connecting cable into the indoor unit through the hole.
• Do not connect the cable to the indoor unit
• Make a small loop with the cable for easy connection later.
5. Tape the tubing and the connecting cable.
6. Indoor unit installation.
7. Connecting the pipings to the indoor unit.

PIPE SIZE TORQUE


1/4" 1.8~2.5 kgf·m
3/8" 3.4~4.2 kgf·m
1/2" 5.5~6.6 kgf·m
5/8" 6.3~8.2 kgf·m
3/4" 9.9~12.1 kgf·m Indoor unit tubing Flare nut Pipings

• Align the center of the pipings and suffciently


tighten the flare nut with fingers.
• Finally, tighten the flare nut with troque
wrench until the wrench clicks. Spanner Torque wrench
When tightening the flare nut with troque
wrench, ensure the direction for tightening
follows the arrow on the wrench.

Precautions in bending
1. If it is necessary to bend or stretch the
tubing, use the spring which is attached to Spring
the tubing in stead of pipe bender.
• Please make a careful notice to make a
smooth line. R70mm
• Hold the tubing with your two hands closely
and then bend or stretch it slowly not to
make any crack.
• Remember that the radius (R) should not (Fig. 1)
exceed 70mm (Refer to Fig. 1)
2. Do not repeat the bending process to prevent
the tubing from cracking or crushing. R
3. Keep in mind that the bending part should
not be cracked and make the radius (R) as
long as possible (Refer to Fig. 2)

(Fig. 2)

Installation Manual 13
Installation of Unit

Connecting the Cable to Indoor Unit


• The inside and outside connecting cable can be connected after opening the inlet grille.
1. Open the inlet grille manually.(Fig.1)
2. Open the terminal block cover with driver( ).
3. Connect the cables(LG doesn't sypply) to the Terminal Block in the front Bracket. (Fig.2)
4. Secure the terminal block cover to the original position with the screw.
5. Insert the plastic tube(Bushing)in small hole in order to prevent the connecting wires
from being cut by sharp edge of the hole. (Fig. 3) , America, Canada only.
6. Close the inlet grille.

(Fig.1) (Fig.2)

Detail Wiring of Fig.2

1. Cooling Model 2. Heating Model


(America, Canada only)

1(L) 2(N) 3 4 5 3(L1) 4(L2) 5 6 7 1(L) 2(N) 3 4 5

Outdoor unit Outdoor unit Outdoor unit

Insert the plastic tube


(America, Canada only)

(Fig.3)

14 Floor Standing type Air Conditioner


Installation of Unit

Connecting pipings to the outdoor unit .


1. Align the center of the pipings and
sufficiently tighten the flare nut with fingers.
2. Finally tighten the flare nut with torque
wrench until the wrench clicks.
• When tightening the flare nut with torque
wrench, ensure the direction for tightening Gas side piping
follows the arrow on the wrench.
Outdoor unit

Liquid side piping


PIPE SIZE TORQUE
1/4" 1.8~2.5 kgf·m
3/8" 3.4~4.2 kgf·m
Torque wrench
1/2" 5.5~6.6 kgf·m
5/8" 6.3~8.2 kgf·m
3/4" 9.9~12.1 kgf·m

Connecting the cables to the outdoor unit


1. Open the control board cover from the
outdoor unit by removing the screws.
2. Connect wires to the terminals on the control
board individually and secure the cables
onto the control board with clamp.
3. Secure the control board cover to the
original position with the screws.

CAUTION: Perform grounding


• This product should be grounded.
• Defective grounding could cause an
electric shock.

Terminals on the indoor unit 3(L1) 4(L2) 5 6 7

Terminals on the outdoor unit 1(L1) 2(L2) 3(L1) 4(L2) 5


(America, Canada Only)

POWER INPUT

(America, Canada Only)

Installation Manual 15
Installation of Unit

Power Supply and Wiring


The unit is completely wired internally at the
Voltage
factory according to general rule of electrical
technology, but local rules, if they are required,
Power source voltage
should be complied with.
working voltage
1. Power supply
Power source must fulfill the following Starting voltage
conditions:
• The working voltage should be higher than Starting point
90% and lower than 110% of the rated Time
voltage marked on the name plate.
• The starting voltage should be higher than
85% of the rated voltage marked on the
name plate.

2. Wiring
After the confirmation of the above conditions, prepare the wiring as follows:

• Use the power supply cord(Rubber • The screws which fasten the wiring in the
insulation, type Ho7RNF approved by HAR casing of electrical fittings are liable to
or SAA) suitable for the product's come loose from vibrations to which the
electriccal capacity. unit is subjected during the course of
UNIT Conductor transportation. Check them and make sure
VOLTS
(BTU/h) cross-sectional area that they are all tightly fastened.
20k/28k/ H/P 450/750V 4.0mm2 (If they are loose, it could give rise to burn-
30k/40k C/O 450/750V 4.0mm2 out of the wires.)
44k/48k/ H/P 450/750V 5.5mm2 • See to it that the starting voltage is
50k C/O 450/750V 5.5mm2 maintained at more than 90 percent of the
H/P 450/750V 8.0mm2 rated voltage marked on the name plate.
80k
C/O 450/750V 8.0mm2 • The following troubles would be caused by
voltage drop-down.
Vibration of a magnetic switch, damage on
• Provide a recognized circuit breaker as the contact point there of, fuse breaking,
below between power source and unit. disturbance to the normal function of a
A disconnection device to adequately overload protection device.
disconnect all supply lines must be fitted.
(for service operations) *Separate main and heater power supply for
Z model. (Do not connect together to the
UNIT (BTU/h) Circuit breaker capacity same power supply)
20K/28K/ H/P 30A
Unit (BTU/h) Breaker Conductor
30K/40K C/O 30A
Heater 20k/28k 30A 3.5mm2
1 Phase 44K/48K/ H/P 40A 30k/40k
Wiring
55K/60K C/O 40A Spec. 44k/48k 40A 5.5mm2
44K/48K/ H/P 30A 50k/60k
50K/60K 80k 50A 8mm2
C/O 30A
3 Phase
H/P 50A
80K
C/O 50A

16 Floor Standing type Air Conditioner


Installation of Unit

Vacuum Drying of the Connecting Pipes and the Indoor Unit


The air which contains moisture remaining in the refrigeration cycle may cause a malfunction on the
compressor.
1. Confirm that both the liquid side valve and the gas side valve are set to the closed position.
2. After connecting the piping, check the joints for gas leakage with gas leak detector.
3. Remove the service port nut, and connect the gauge manifold and the vacuum pump to the service
port by the charge hose.
4. Vacuum the indoor unit and the connecting pipes until the pressure in them lowers to below -
76cmHg.
5. Remove the valve stem nuts, and fully open the stems of the 2-way and 3-way valves with a hexagon
wrench.
6. Tighten the valve stem nuts of the 2-way valve and 3-way valve.
7. Disconnect the charge hose and fit the nut to the service port.
(Tightening torque: 1.8kg.m)

Indoor unit Liquid side


Closed Outdoor unit
2-way valve/
3-way valve

Gas side

3-way
valve
Closed

Vaccum pump

OPEN CLOSE

Installation Manual 17
Installation of Unit

Form the Piping


1. Wrap the connecting portion of indoor unit
with the insulation material and secure it with
two Plastic Bands. (for the right piping)
• If you connect an additional drain hose, Gas side
the end of the drain-outlet should be kept piping
distance from the ground. (Do not dip it Main cable
into water, and fix it on the wall to avoid
swinging in the wind.)

In case of the outdoor unit is installed below


position of the indoor unit.
Tube PE
Foam
2. Tape the Piping, and Connecting Cable from
Connecting
down to up. Cable
3. Form the piping gathered by taping along the Connecting
Cable
exterior wall and fix it onto the wall by saddle (For heater)
or equivalent.

Trap is required to prevent the electrical parts


from entering the water.

In case of the outdoor unit is installed upper


Seal a small opening around
position of the indoor unit. the piping with gum type sealer.

1. Tape the piping and connecting cable from Trap


down to up.
2. In order to prevent water from entering the
room, form a trap and tape the piping.
3. Fix the piping onto the wall with saddle or
bracket.

Trap

Drain water treatment of outdoor unit(Heat


Pump Only)

1. When using the drain elbow hose, use


a mount of 3cm of higher.
2. In the cold district (0°c(32°F) continued for 2~3
day), the drain water is frozen and the fan fail Drain elbow
to function, do not use the drain elbow. Hose(inner diameter ø20)

Arrange the hose downward slope without waving.

18 Floor Standing type Air Conditioner


Final Check and Test Run

Final Check and Test Run


After installing the unit, perform the final check Running test should be accomplished as follows:
and running test as follows:
Final check points
Is the unit securely mounted? Set operation switch at "FAN" and the fan
will start. Check to ensure that the fan
Is the installation location adequate? sounds normal.
Is the water piping work adequately and Next, set it at "COOL" and the
without leakage? compressor will start. Check to ensure
Are trapped drain lines installed at that the compressor sounds normal.
condensate drain connections?
Check discharge and suction pressure on
Has the refrigeration cooling cycle been the compound gauges.
kept sealed?
Check working voltage, phase balance
Is the electrical wiring adequate and are and running current.
the screws tightened on terminals?
Check to ensure that the thermistor
After the above final checkings, prepare the functions properly.
running test as follows:
Check to ensure that the high pressure
Connect compound gauges to the check control switch functions correctly.
joints at discharge and suction sides of
the compressor.
Turn all switches "OFF".
Turn the main switch "ON".

Installation Manual 19
Memo

20 Floor Standing type Air Conditioner

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