System Outdoor Unit SERVICE MANUAL R410A

Internal Use Only
http://biz.lgservice.com
System
Outdoor Unit R410A
SERVICE MANUAL R410A
MODEL : ARUN Series
CAUTION
Before Servicing the unit, read the safety precautions in General SVC manual.
Only for authorized service personnel.
Air Conditioner Service Manual
TABLE OF CONTENTS
Safety Precautions............................................................................................................................3
Part 1 General Information .............................................................................................................10
Model Names .............................................................................................................................11
External Appearance .................................................................................................................12
Combination of Outdoor Units .................................................................................................14
Nomenclature .............................................................................................................................15
Outdoor Units Information ........................................................................................................16
Part 2 Outdoor Units ................................................................................................................19
Part 3 PCB Setting and Test Run ........................................................................................57
Part 4 Trouble shooting guide ............................................................................................. 69
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
-2-
LGE Internal Use Only
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 to properties only.
■ Meanings of symbols used in this manual are as shown below.
Be sure not to do.
Be sure to follow the instruction.
WARNING
■ Installation
Have all electric work done by a licensed
electrician according to "Electric Facility
Engineering Standard" and "Interior Wire
Regulations" and the instructions given in
this manual and always use a special circuit.
• If the power source capacity is inadequate or
electric work is performed improperly, electric
shock or fire may result.
Ask the dealer or an authorized technician to
install the air conditioner.
• Improper installation by the user may result in
water leakage, electric shock, or fire.
Always ground the product.
• There is risk of fire or electric shock.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
Always intstall a dedicated circuit and breaker.
• Improper wiring or installation may cause fire or
electric shock.
-3-
LGE Internal Use Only
Safety Precautions
For re-installation of the installed product,
always contact a dealer or an Authorized
Service Center.
Do not install, remove, or re-install the unit
by yourself (customer).
• There is risk of fire, electric shock, explosion, or
injury.
• There is risk of fire, electric shock, explosion, or
injury.
Do not store or use flammable gas or
combustibles near the air conditioner.
• There is risk of fire or failure of product.
Use the correctly rated breaker or fuse.
• There is risk of fire or electric shock.
Gasolin
Prepare for strong wind or earthquake and
install the unit at the specified place.
• Improper installation may cause the unit to topple and result in injury.
When installing and moving the air conditioner to another site, do not charge it with a
different refrigerant from the refrigerant
specified on the unit.
• If a different refrigerant or air is mixed with the
original refrigerant, the refrigerant cycle may
malfunction and the unit may be damaged.
R410A
Do not install the product on a defective
installation stand.
• It may cause injury, accident, or damage to the
product.
Do not reconstruct to change the settings of
the protection devices.
• If the pressure switch, thermal switch, or other
protection device is shorted and operated
forcibly, or parts other than those specified by
LGE are used, fire or explosion may result.
R22
R407C
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LGE Internal Use Only
Safety Precautions
Ventilate before operating air conditioner
when gas leaked out.
• It may cause explosion, fire, and burn.
Securely install the cover of control box and
the panel.
• If the cover and panel are not installed securely,
dust or water may enter the outdoor unit and fire
or electric shock may result.
If the air conditioner is installed in a small room, measures must be taken to prevent the
refrigerant concentration from exceeding the safety limit when the refrigerant leaks.
• Consult the dealer regarding the appropriate measures to prevent the safety limit from being exceeded. Should the refrigerant leak and cause the safety limit to be exceeded, harzards due to lack of oxygen in the room could result.
■ Operation
Do not damage or use an unspecified power
cord.
• There is risk of fire, electric shock, explosion, or
injury.
Be cautious that water could not enter the
product.
• There is risk of fire, electric shock, or product
damage.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
Use a dedicated outlet for this appliance.
• There is risk of fire or electrical shock.
Do not touch the power switch with wet
hands.
• There is risk of fire, electric shock, explosion, or
injury.
-5-
LGE Internal Use Only
Safety Precautions
When the product is soaked (flooded or
submerged), contact an Authorized Service
Center.
• There is risk of fire or electric shock.
Be cautious not to touch the sharp edges
when installing.
• It may cause injury.
Take care to ensure that nobody could step
on or fall onto the outdoor unit.
Do not open the inlet grille of the product
during operation. (Do not touch the electrostatic filter, if the unit is so equipped.)
• This could result in personal injury and product
damage.
• There is risk of physical injury, electric shock, or
product failure.
CAUTION
■ Installation
Always check for gas (refrigerant) leakage
after installation or repair of product.
• Low refrigerant levels may cause failure of
product.
Keep level even when installing the product.
• To avoid vibration or water leakage.
Do not install the product where the noise or
hot air from the outdoor unit could damage
the neighborhoods.
• It may cause a problem for your neighbors.
Do not install the unit where combustible gas
may leak.
• If the gas leaks and
accumulates around the
unit, an explosion may
result.
Gasolin
90˚
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
-6-
LGE Internal Use Only
Safety Precautions
Use power cables of sufficient current
carrying capacity and rating.
• Cables that are too small may leak, generate
heat, and cause a fire.
Keep the unit away from children. The heat
exchanger is very sharp.
• It can cause the injury, such as cutting the finger.
Also the damaged fin may result in degradation
of capacity.
Do not use the product for special purposes,
such as preserving foods, works of art, etc. It
is a consumer air conditioner, not a precision
refrigeration system.
• There is risk of damage or loss of property.
When installting the unit in a hospital, communication station, or similar place, provide
sufficient protection against noise.
• The inverter equipment, private power generator,
high-frequency medical equipment, or radio communication equipment may cause the air conditioner to operate erroneously, or fail to operate. On the
other hand, the air conditioner may affect such
equipment by creating noise that disturbs medical
treatment or image broadcasting.
Do not install the product where it is exposed to sea wind (salt spray) directly.
• It may cause corrosion on the product. Corrosion, particularly on the condenser and evaporator fins,
could cause product malfunction or inefficient operation.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
-7-
LGE Internal Use Only
Safety Precautions
■ Operation
Do not use the air conditioner in special
environments.
• Oil, steam, sulfuric smoke, etc. can significantly
reduce the performance of the air conditioner or
damage its parts.
Make the connections securely so that the
outside force of the cable may not be applied
to the terminals.
• Inadequate connection and fastening may generate heat and cause a fire.
Do not block the inlet or outlet.
• It may cause failure of appliance or accident.
Be sure the installation area does not deteriorate with age.
• If the base collapses, the air conditioner could
fall with it, causing property damage, product
failure, or personal injury.
Install and insulate the drain hose to ensure that water is drained away properly based on the
installation manual.
• A bad connection may cause water leakage.
Be very careful about product transportation.
• Only one person should not carry the product if it weighs more
than 20 kg.
• Some products use PP bands for packaging. Do not use any PP
bands for a means of transportation. It is dangerous.
• Do not touch the heat exchanger fins. Doing so may cut your fingers.
• When transporting the outdoor unit, suspending it at the specified
positions on the unit base. Also support the outdoor unit at four
points so that it cannot slip sideways.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
-8-
LGE Internal Use Only
Safety Precautions
Safely dispose of the packing materials.
• Packing materials, such as nails and other metal or
wooden parts, may cause stabs or other injuries.
• Tear apart and throw away plastic packaging bags
so that children may not play with them. If children
play with a plastic bag which was
not torn apart, they face the
risk of suffocation.
Do not touch any of the refrigerant piping
during and after operation.
• It can cause a burn or frostbite.
Do not directly turn off the main power
switch after stopping operation.
• Wait at least 5 minutes before turning off the
main power switch. Otherwise
it may result in water leakage
or other problems.
Use a firm stool or ladder when cleaning or
maintaining the air conditioner.
• Be careful and avoid personal injury.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
Turn on the power at least 6 hours before
starting operation.
• Starting operation immediately after turning on
the main power switch can result in severe
damage to internal parts. Keep the power switch
turned on during the operational season.
Do not operate the air conditioner with the
panels or guards removed.
• Rotating, hot, or high-voltage parts can cause
injuries.
Auto-addressing should be done in condition of
connecting the power of all indoor and outdoour
units. Auto-addressing should also be done in
case of changing the indoor unit PCB.
Do not insert hands or other objects through
the air inlet or outlet while the air conditioner
is plugged in.
• There are sharp and moving parts that could
cause personal injury.
-9-
LGE Internal Use Only
Part 1
General Information
1. Model Names ................................................................11
1.1 Indoor Unit .............................................................11
1.2 Outdoor Unit ..........................................................11
2. External Appearance.....................................................12
2.1 Indoor Unit .............................................................12
2.2 Outdoor Unit ..........................................................13
3. Combination of Outdoor Units .....................................15
4. Nomenclature.................................................................17
4.1 Indoor Unit .............................................................17
4.2 Outdoor Unit ..........................................................17
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 10 -
LGE Internal Use Only
Model Names
1. Model Names
1.1 Indoor Unit
Category
Chassis
Name
SE
Wall Mounted
(General)
Capacity(MBh (kW))
7
(2.2)
9
(2.8)
12
(3.6)
15
(4.5)
Mirror
ART COOL
1 Way
TJ
2 Way
TL
TE
Ceiling
Cassette
4 Way
TP
28
(8.2)
36
42
48
76
96
(10.6) (12.3) (14.1) (22.4) (28)
ARNU183 ARNU243
S5*2
S5*2
ARNU073 ARNU093 ARNU123 ARNU153
SE*2
SE*2
SE*2
SE*2
ARNU183 ARNU243
S3*2
S3*2
S3
ART Cool
SF
Gallery
24
(7.1)
ARNU073 ARNU093 ARNU123 ARNU153
SE*2
SE*2
SE*2
SE*2
S5
SE
18
(5.6)
ARNU073 ARNU093 ARNU123
SF*2
SF*2
SF*2
ARNU073 ARNU093 ARNU123
TJ*2
TJ*2
TJ*2
ARNU183 ARNU243
TL*2
TL*2
ARNU073 ARNU093 ARNU123 ARNU153 ARNU183
TE*2
TE*2
TE*2
TE*2
TE*2
ARNU243 ARNU283
TP*2
TP*2
ARNU363
TN*2
TN
ARNU423 ARNU483
TM*2
TM*2
TM
BH ARNU073 ARNU093 ARNU123 ARNU153 ARNU183 ARNU243
BHA2
BHA2
BHA2
BHA2
BHA2
BHA2
High
Static
Ceiling
Concealed
Duct
ARNU283 ARNU363 ARNU423
BGA2
BGA2
BGA2
BG
ARNU483
BRA2
BR
URNU76 URNU96
3B8A2 3B8A2
B8
B1
Low Static
ARNU073 ARNU093 ARNU123 ARNU153
B1G2
B1G2
B1G2
B1G2
ARNU183 ARNU243
B2G2
B2G2
B2
B3
Built In
ARNU073 ARNU093 ARNU123 ARNU153
B3G2
B3G2
B3G2
B3G2
B4
Ceiling & Floor
VE
Ceiling Suspended
VJ
CE
With Case
ARNU183 ARNU243
B4G2
B4G2
ARNU093 ARNU123
VEA2
VEA2
ARNU183 ARNU243
VJA2
VJA2
ARNU073 ARNU093 ARNU123 ARNU153
CEA2
CEA2
CEA2
CEA2
ARNU183 ARNU243
CFA2
CFA2
CF
Floor
Standing
Without
Case
CE
ARNU073 ARNU093 ARNU123 ARNU153
CEU2
CEU2
CEU2
CEU2
CF
ARNU183 ARNU243
CFU2
CFU2
❈ *ART COOL- B: Blue, M:Metal, D:Wood, R:Mirror, W:White Wood, V:Silver, E:Red, G:Gold, 1: Kiss (Photo changeable)
*Wall Mounted- A: Basic, L:Plasma, *Ceiling Cassette- A: Basic, C:Plasma
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
1.2 Outdoor Unit
8HP
10HP
12HP
14HP
16HP
18HP
20HP
22HP
24HP
6.5ton
8.0ton
9.5ton
11.0ton
12.5ton
14.5ton
16.0ton
17.5ton
19.0ton
3Ø, 460V, 60Hz
076DT2
096DT2
115DT2
134DT2
154DT2
173DT2
192DT2
211DT2
230DT2
3Ø, 208/230V , 60Hz
076BT2
096BT2
115BT2
-
154BT2
173BT2
192BT2
211BT2
230BT2
26HP
28HP
30HP
32HP
20.5ton
22.5ton
24.0ton
25.5ton
250DT2
270DT2
290DT2
310DT2
Power Supply
Power Supply
3Ø, 460V, 60Hz
Heat Pump
ARUN
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
External Appearance
2. External Appearance
2.1 Indoor Units
Ceiling Cassette- 1Way
Ceiling Cassette -2Way
ARNU073TJ*2
ARNU093TJ*2
ARNU123TJ*2
ARNU183TL*2
ARNU243TL*2
* A:Basic, C:Plasma
Ceiling Cassette- 4Way
ARNU073TE*2
ARNU093TE*2
ARNU123TE*2
ARNU153TE*2
ARNU183TE*2
ARNU243TP*2
ARNU283TP*2
ARNU363TN*2
ARNU423TM*2
ARNU483TM*2
* A:Basic, C:Plasma
Ceiling Concealed Duct - High Static
ARNU363BGA2
ARNU423BGA2
ARNU483BRA2
URNU763B8A2
URNU963B8A2
ARNU073BHA2
ARNU093BHA2
ARNU123BHA2
ARNU153BHA2
ARNU183BHA2
ARNU243BHA2
ARNU283BGA2
* A:Basic, C:Plasma
Ceiling Concealed Duct - Low Static
ARNU073B1G2
ARNU093B1G2
ARNU123B1G2
ARNU153B1G2
ARNU183B2G2
ARNU243B2G2
Wall Mounted
ARNU073SE*2
ARNU093SE*2
ARNU123SE*2
ARNU153SE*2
ARNU183S5*2
ARNU243S5*2
* A:Basic, L:Plasma
Ceiling Concealed Duct – Built-in
ARNU073B3G2
ARNU093B3G2
ARNU123B3G2
ARNU153B3G2
ARNU183B4G2
ARNU243B4G2
ART COOL Mirror
ARNU073SE*2
ARNU093SE*2
ARNU123SE*2
ARNU153SE*2
ARNU183S3*2
ARNU243S3*2
S3: * B : Blue SE: * R:Mirror
V:Silver
M : Metal
B : Blue
D : Wood
R : Mirror
W:White Wood
Ceiling & Floor
ARNU093VEA2
ARNU123VEA2
Ceiling Suspended
ARNU183VJA2
ARNU243VJA2
ART COOL Gallery
ARNU073SF*2
ARNU093SF*2
ARNU123SF*2
* E:Red V:Silver
G:Gold 1: Kiss (Photo changeable)
Floor Standing
With case
ARNU073CEA2
ARNU093CEA2
ARNU123CEA2
ARNU153CEA2
ARNU183CFA2
ARNU243CFA2
Without case
ARNU073CEU2
ARNU093CEU2
ARNU123CEU2
ARNU153CEU2
ARNU183CFU2
ARNU243CFU2
These are model names of the basic function.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
External Appearance
2.2 Outdoor Units(460V)
ARUN076DT2
ARUN096DT2
ARUN115DT2
ARUN134DT2
ARUN154DT2
ARUN173DT2
ARUN192DT2
ARUN211DT2
ARUN230DT2
ARUN250DT2
ARUN270DT2
ARUN290DT2
ARUN310DT2
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
External Appearance
2.2 Outdoor Units(208/230V)
ARUN076BT2
ARUN096BT2
ARUN115BT2
ARUN154BT2
ARUN173BT2
ARUN192BT2
ARUN211BT2
ARUN230BT2
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Only for training and service purposes
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LGE Internal Use Only
Combination of Outdoor Units
3. Combination of Outdoor Units
3.1 460V
Module
System
Capacity
Number of Units
60Hz
8
10
12
14
16
8HP(6.5ton)
1
1
-
-
-
-
10HP(8.0ton)
1
-
1
-
-
-
12HP(9.5ton)
1
-
-
1
-
-
14HP(11.0ton)
1
-
-
-
1
-
16HP(12.5ton)
1
-
-
-
-
1
18HP(14.5ton)
2
1
1
-
-
-
20HP(16.0ton)
2
1
-
1
-
-
22HP(17.5ton)
2
1
-
-
1
-
24HP(19.0ton)
2
1
-
-
-
1
26HP(20.5ton)
2
-
-
1
1
-
28HP(22.5ton)
2
-
-
-
2
-
30HP(24.0ton)
2
-
-
-
1
1
32HP(25.5ton)
2
-
-
-
-
2
■ A maximum of 32HP can be obtained by combining 8, 10, 12, 14 and 16HP
3.2 208/230V
Module
System
Capacity
Number of Units
60Hz
8
10
12
8HP(6.5ton)
1
1
-
-
10HP(8.0ton)
1
-
1
-
12HP(9.5ton)
1
-
-
1
16HP(12.5ton)
2
2
-
-
18HP(14.5ton)
2
1
1
-
20HP(16.0ton)
2
-
2
-
22HP(17.5ton)
2
-
1
1
24HP(19.0ton)
2
-
-
2
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 16 -
LGE Internal Use Only
Nomenclature
4. Nomenclature
4.1 Indoor Unit
ARN
U
07
3
TJ
A
2
Generation
Combinations of functions
A:Basic function
L:Neo Plasma(Wall Mounted)
C:Plasma(Ceiling Cassette)
G: Low Static
ART COOL Type Panel Color
B:Blue D:Wood M:Metal R:Mirror W:White Wood
V: Silver E:Red G:Gold 1: Kiss (Photo changeable)
Chassis Name
Electrical Ratings
1:1Ø, 115V, 60Hz
2: 1Ø, 220V, 60Hz
6:1Ø, 220 ~ 240V, 50Hz 7: 1Ø, 100V, 50/60Hz
3:1Ø, 220 ~ 240V, 50Hz, 208/230V 60Hz
Total Cooling Capacity in Btu/h
EX) 5,000 Btu/h➞'05' 18,000 Btu/h➞'18'
Combination of Inverter Type and
Cooling Only or Heat Pump
N: AC Inverter and H/P V: AC Inverter and C/O
U: DC Inverter and H/P and C/O
System with
Indoor Unit using R410A
❈ LGETA:U Ex) URN
4.2 Outdoor Unit
ARU
N
096
D
T
2
Generation
Air Discharge Type
S:Side Discharge
T:Top Discharge
Electrical Ratings
8: 3Ø, 380 ~ 415V, 50Hz 9: 3Ø, 380V, 60Hz
A: 3Ø, 220V, 50Hz
B: 3Ø, 208/230V, 60Hz
L: 3Ø, 380 ~ 415V, 50Hz / 3Ø, 380V, 60Hz
D: 3Ø, 460V, 60Hz
Total Cooling Capacity in Btu/h
EX) 76,000 Btu/h ➞ '076' 96,000 Btu/h ➞ '096'
Combination of Inverter Type and
Cooling Only or Heat Pump
N: Inverter and H/P V: Inverter and C/O
B: Inverter and Heat Recovery
System with
Outdoor Unit using R410A
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 18 -
LGE Internal Use Only
Part 2
Outdoor Units
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 19 -
LGE Internal Use Only
ARUN Series
• Function ........................................................................................21
• Replacement procedure for Compressor ..................................57
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Only for training and service purposes
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LGE Internal Use Only
Function
Function
1. Basic control ...................................................................................................................22
1.1 Normal operation .......................................................................................................22
1.2 Compressor control....................................................................................................22
1.3 Master and slave unit's EEV control...........................................................................23
2. Special control ................................................................................................................24
2.1 Oil return control ........................................................................................................24
2.2 Defrost control............................................................................................................26
2.3 Oil equalizing control..................................................................................................27
3. Protection control ...........................................................................................................28
3.1 Pressure protection control ........................................................................................28
3.2 Discharge temperature control...................................................................................29
3.3 Inverter protection control ..........................................................................................29
3.4 Liquid back control .....................................................................................................30
3.5 Phase detection .........................................................................................................30
3.6 Pressure switch..........................................................................................................30
4. Other control ...................................................................................................................31
4.1 Initial setup .................................................................................................................31
4.2 Instant indoor unit checking mode .............................................................................33
4.3 Emergency operation .................................................................................................34
4.4 Refrigerant Auto Charging .........................................................................................36
4.5 Refrigerant Checking Function...................................................................................38
4.6 Pump Down................................................................................................................40
4.7 Pump Out ...................................................................................................................41
4.8 Auto Back Up Function_Inverter compressor ............................................................43
4.9 Auto Back Up Function_constant speed compressor ................................................44
4.10 Night Low Noise Function ........................................................................................45
4.11 Vacuum Mode ..........................................................................................................47
4.13 Black Box Function ..................................................................................................48
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LGE Internal Use Only
Function
1. Basic control
1.1 Normal operation
Actuator
Cooling operation
Heating operation
Stop state
Compressor
Fuzzy control
Fuzzy control
stop
Fan
Fuzzy control
Fuzzy control
stop
Main EEV
Full open
Fuzzy control
Before 15 min. : Max. pulse
After 15 min. : Min. pulse
Off
On
After 60 min. : Off
4 way valve
Subcooling
EEV
Fuzzy control
Indoor Unit
EEV
Superheat fuzzy
control
• Normal : minimum pulse Before 15 min. : Max. pulse
• Avoiding control of high
After 15 min. : Min. pulse
discharge temperature
Subcooling fuzzy control
Before 10 min. : Min. pulse
After 10 min. : Max. pulse
Note : Heating operation is not functional at an outdoor air temperature of 27°C(80°F) or more.
Cooling operation is not functional at an outdoor air temperature of 2°C(36°F) or less with indoor unit
combination of 10% or less
1.2 Compressor control
Fuzzy control : Maintain evaporating temperature(Te) to be constant on cooling mode and condensing temperature(Tc) on heating mode by Fuzzy control to ensure the stable system performance.
[Tc:47~51°C(117~124°F), Te:2~5°C(36~41°F)]
(1) Cooling mode
Te can be set by initial dip switch setting. (Normal mode, capacity up mode, and energy save mode)
(2) Heating mode
Tc can be set by initial dip switch setting. (Normal mode, capacity up mode, and energy save mode)
Fuzzy control start
Target
System Capacity
Note: By setting dip switch, Te and Tc are decided simultaneously.
Inverter
Comperssor
Constant Speed
Compressor
(Linear Control)
Inverter
Comperssor
C
Constant Speed Constant Speed
Compressor
Compressor
Inverter
Comperssor
Min. frequency
A
A
Constant Speed Constant Speed Constant Speed
Compressor
Compressor
Compressor
Stop(0Hz)
Inverter
Comperssor
B
B
B
Cooling and heating load
Fuzzy Control
Inverter linear control as cooling and heating load increasing
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LGE Internal Use Only
Function
1.3 Master and slave Unit's EEV control
(1) Main EEV control
Main EEV operates with fuzzy control rules to keep the degree of super Heat(Superheat) (about 3°C)at
the evaporator outlet stable during heating mode
The degree of Superheat = Tsuction - Tevaporation
Tsuction : temperature at suction pipe sensor(°C/°F)
Tevaporation : evaporation temperature equivalent to low pressure(°C/°F)
(2) Subcooling EEV control(about 15°C/58°F)
Subcooling EEV works with fuzzy rules to keep the degree of Subcool at the outlet of subcooler during
cooling mode
The degree of Subcool = Tcondensation - Tliquid
Tliquid : temperature at outlet of subcooler(°C/°F)
Tcondensation : condensation temperature equivalent to high pressure(°C/°F)
(3) Avoiding excessive high discharge temperature : when main EEV opens some given opening (R410A :
800 pls) and discharge temperature is above 85°C(185°F) in heating operation, subcooling EEV may control the "subcooling out temperature-evaporating temperature" to be some given difference.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 23 -
LGE Internal Use Only
Function
2. Special control
2.1 Oil return control
2.1.1 Oil return control on cooling mode
Oil return operation recovers oil amount in compressor by collecting oil accumulated in pipe.
Each cycle component operates as following table during oil return operation.
Outdoor Unit
Component
Starting
Running
Ending
Inv Compressor
25Hz
Setting Value
40Hz
Constant Speed Compressor
OFF
ON
OFF
FAN
Normal control
Normal control
Normal control
Main EEV
Max. pulse
Max. pulse
Max. pulse
Subcooling EEV
Normal control
Main. pluse
100 pulse
4way valve
OFF
OFF
OFF
Hot gas bypass valve
Normal control
Normal control
Normal control
Component
Starting
Running
Ending
Fan
Normal control
OFF
Normal control
Thermo on unit EEV
Normal control
1200 pulse
Normal control
Thermo off unit EEV
Min. pulse
1200 pulse
Min. pulse
Oil return signal
OFF
ON
OFF
Indoor Unit
■ Oil return operation time : 3 min for running step
■ Starting condition:every 6 hours operate
■ Oil return process ends if compressor protection control starts
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Function
2.1.2 Oil return control on heating mode
Outdoor Unit
Component
Starting
Running
Ending
Inv Compressor
25Hz
Setting Value
25Hz
Constant Speed Compressor
OFF
ON
OFF
FAN
Normal control
Normal control
Normal control
Main EEV
Max. pulse
Max. pulse
Max. pulse
Subcooling EEV
Normal control
Min. pulse
100 pulse
4way valve
OFF
ON
ON
Hot gas bypass valve
Normal control
Normal control
Normal control
Component
Starting
Running
Ending
Fan
Normal control
OFF
Normal control
Thermo on unit EEV
Normal control
1200 pulse
Normal control
Thermo off unit EEV
Min. pulse
1200 pulse
Min. pulse
Oil return signal
OFF
ON
OFF
Indoor Unit
■ Oil return operation time : 3 min for running step
■ Starting condition:same as cooling mode
■ Oil return process ends if compressor protection control starts
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 25 -
LGE Internal Use Only
Function
2.2 Defrost
Defrost operation eliminates ice attached on heat exchanger, recovering performance of heat exchanger.
Each cycle component operates as following table during defrost operation.
Outdoor Unit
Component
Starting
Running
Ending
Inv Compressor
25Hz
Setting Value
25Hz
Constant Speed Compressor
OFF
ON
OFF
FAN
Stop
High pressure control
50Hz
Main EEV
Normal control
Max. pulse
200 pulse
Subcooling EEV
Min. pulse
Min. pulse
Min. pulse
4way valve
On → OFF
OFF
ON
Hot gas bypass valve
Normal control
Normal control
Normal control
Component
Starting
Running
Ending
Fan
OFF
OFF
OFF
Thermo on unit EEV
Normal control
1200 pulse
Normal control
Thermo off unit EEV
Min. pulse
1200 pulse
Min. pulse
Indoor Unit
■ Ending condition
1) All heat exchanger pipe temperature are above 15°C(58°F)(UY2) or 20°C(68°F)(UW1) for 30 sec.
2) The running time of defrost operation is over 30% of the total heating time
3) If compressor protection control starts by high discharge temperature of compressor etc.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Function
2.3 Stopping operation
2.3.1 Stopping operation on cooling mode
Component
Operation
Note
Inv Compressor
0Hz
-
OFF
-
FAN
Stop
-
Main EEV
Max. pulse
Constant Speed Compressor
After 15 min.
(Before 15 min. : Min. pulse)
Subcooling EEV
Max. pulse
4way valve
OFF
Hot gas bypass valve
OFF
After 15 min.
(Before 15 min. : Min. pulse)
After 15 min.
(Before 15 Min. : ON)
2.3.2 Stopping operation on heating mode
Component
Operation
Note
Inv Compressor
0Hz
-
OFF
-
FAN
Stop
-
Main EEV
Max. pulse
Constant Speed Compressor
After 15 min.
(Before 15 min. : Min. pulse)
Subcooling EEV
Max. pulse
After 15 min.
(Before 15 min. : Min. pulse)
4way valve
OFF
Hot gas bypass valve
OFF
After 60 min.
After 15 min.
(Before 15 Min. : ON)
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 27 -
LGE Internal Use Only
Function
3. Protection control
3.1 Pressure protection control
3.1.1 Pressure control on cooling mode
■ High pressure control
Pressure Range
Compressor
Fan
Pd ≥ 4003 kPa (580.6 psi)
Stop
Stop
Pd > 3676 kPa (533.2 psi)
-5Hz/4sec.
+100RPM/4sec.
Pd ≥ 3448 kPa (500.1 psi)
Frequency holding
Normal control
Hot_gas
-
-
Normal control
Pd < 3284 kPa (476.3 psi)
■ Low pressure control
Pressure Range
Compressor
Fan
Ps ≤ 229 kPa (33.2 psi)
after 1min
Stop
Stop
Ps ≤ 229 kPa (33.2 psi)
1min
-5Hz/4sec.
-100RPM/4sec.
Ps ≤ 242 kPa (35.1 psi)
Normal control
Normal control
Ps ≥ 399 kPa (57.9 psi)
Normal control
Hot_gas
On
Off
❈ Frequency holding : frequency (or RPM) is not increasing ( can decrease )
3.1.2 Pressure control on heating mode
■ High pressure control
Pressure Range
Compressor
Fan
Hot_gas
Pd ≥ 4003 kPa (580.6 psi)
Stop
Stop
On
Pd > 3676 kPa (533.2 psi)
-5Hz/4sec.1)
-50RPM/4sec.
Pd ≤ 3448 kPa (500.1 psi)
Normal control
Normal control
Pd ≤ Target press
On
off
Normal control
■ Low pressure control
Pressure Range
Compressor
Fan
Ps ≤ 229 kPa (33.2 psi)
after 1min
Stop
Stop
2
Ps ≤ 229 kPa (33.2 psi)
1min
-5Hz/4sec.
+100RPM/4sec.
3
Ps ≤ 242 kPa (35.1 psi)
Frequency holding
Normal control
1
Ps ≤ 268 kPa (38.9 psi)
Hot_gas
On
Normal control
Off
Ps > 307 kPa (44.5 psi)
❈ Frequency holding : frequency (or RPM) is not increasing ( can decrease )
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 28 -
LGE Internal Use Only
Function
3.2 Discharge temperature control
■ Outdoor unit control
Temperature range
Tdis > 115°C(239°F)
105°C(221°F) <
Tdis
≤ 112°C(234°F)
98°C(208°F) <
Tdis
≤ 103°C(217°F)
Liquid injection
Compressor
Subcooling EEV
System stop
Max. limit
490 pulse
Frequency down +
const. Comp off
On
Liquid injection on
No frequency up
Keep state
OFF
(below 20°C(212°F))
Max. limit
490 pulse
Tdis ≤ 98°C(208°F)
Pressure control
Off
Max. limit
300 pulse
Tdis > 95°C(203°F)
Pressure control
Off
10 pulse open /10sec
■ Indoor unit control
Temperature range
EEV
Tdis > 115°C(239°F)
System stop
103°C(217°F) <
Tdis ≤ 112°C(234°F)
Emergency
SH control
98°C(208°F) < Tdis ≤ 103°C(217°F)
Keep current control
Tdis ≤ 98°C(208°F)
SH control
3.3 Inverter protection control
Normal Operation
Frequency Down
System Stop
AC Input Current
18A or less
18A or more
20A or more
Compressor Current
28A or less
28A or more
30A or more
❈ AC input current is inverter input current except constant speed compressor current(Noise filter passed current)
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 29 -
LGE Internal Use Only
Function
3.4 Liquid back control
■ Cooling mode
Discharge temperature
Indoor unit ’s EEV
Tdis < Tc + 12°C(54°F)
SH increasing control
Tdis > Tc + 16°C(60°F)
Normal SH control
■ Heating mode
Discharge temperature
Outdoor unit ’s EEV
Tdis < Tc + 17°C(62°F)
SH increasing control
Tdis > Tc + 18°C(64°F)
Normal SH control
❇ The logic starts after 9 min. on heating mode and 4 min. on cooling mode from the compressor running.
3.5 Phase detection
■ Main unit
If a phase is missed, 7-segment displays 50* on main PCB.
If phases are reversed, 7-segment displays 54* on main PCB.
3.6 Pressure switch
- Main has pressure sensing switch in series between compressor and power relay.
- The state of pressure sensing switch is normally on. It has small electric current from 220V AC. Never touch
the connecting terminal with hand nor short two wires directly.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 30 -
LGE Internal Use Only
Function
4. Other control
4.1 Initial setup
There are 4 initial setup steps before running.
All DIP switch setting must be completed before initial setup.
1) Step 1 : factory setting value display
Factory setting value is displayed in 7 segment on PCB for 24sec.
All dip switches must be set properly before step 1.
Power is on
Master model code is displayed (3sec)
Slave model code is displayed (3sec)
Total capacity including sub units is
displayed (2sec)
Heat pump : Display 2 is default value
Cooling only : no display
Factory setting(25 is normal)
Refrigerant display
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 31 -
LGE Internal Use Only
Function
2) Step 2 : Communication check
- If all model code is displayed in 7 segment including all Slave unit,
communication between outdoor units is normal.
- If 104* is displayed in 7-segment, check communication wires between outdoor units and Dip switch setting.
3) Step 3 : PCB error check
- After 40 sec, error check begins.
■ Master/ Slave unit
- All errors of units including Slave units are displayed in 7 segment.
- If communication between main PCB and inverter PCB isn't normal, 52* is displayed in 7-segment
If communication between main PCB and fan PCB isn't normal, 105* is displayed in 7-segment.
If error is displayed, check corresponding wires.
4) Step 4 : Auto addressing of indoor units
- Auto addressing begins when address(red) button in Main PCB is pressed for 6 sec.
- During auto addressing, 7 segment on main PCB displays "88"
- After auto addressing, the number of indoor units is displayed in 7 segment for 30 sec. The address of each
indoor unit is displayed on each wired remote controller.
ON
ON
Push address(red) button for 6 sec.
1
1
2
2
3
3
4
4
5
5
6
6
7
7
1
8
2 3 4 5 6 7
9 10 11 12 13 14
6 sec.
Auto address starts
Auto address is in progress (max. 15 min.)
The number of indoor units is displayed for 30 sec.
(35 indoor units found)
Auto address process is finished.
Every indoor unit displays its address on
wired remote controller and the 7 segment of
main PCB is off.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 32 -
LGE Internal Use Only
Function
4.2 Emergency operation
- If a compressor is out of order, the system can be run except the defective compressor by backup function.
■ Automatic emergency operation(automatic back up function)
If outdoor unit detect comp defect during operation,, automatic back up mode is set.
1) Inverter compressor automatic emergency operation(refer to ** page)
2) Constant compressor automatic emergency operation(refer to ** page)
■ Manual emergency operation(Manual back up function)
1) Check which compressor is broken.(refer to °∞Trouble Shooting Guide°±)
2) Turn off the power.
3) Set the dip S/W of defective outdoor unit.
- Inverter compressor defect : dip S/W No.3
- Unit defect : dip S/W No.4
4) Turn on the power.
MASTER
Normal
INV
C
MASTER
Inv. comp.
Fail of Slave
SLAVE
INV
C
SLAVE
DIP switch of Slave1
ON
INV
C
INV
C
1
1
ON
2
2
3
3
4
4
5
5
6
6
7
7
1
8
2 3 4 5 6 7
9 10 11 12 13 14
CAUTION
Emergency operation with inverter compressor failure should not last 48 hours. ➔ It causes other
compressor failure.
During the emergency operation, cooling/heating capacity may be lower.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 33 -
LGE Internal Use Only
Function
Note 1)
4.3 Sensor checking function
Sensor checking function judges whether the current temperature of indoor and outdoor unit sensors is right or
not. It checks 3 indoor temperature sensors, 9 outdoor temperature sensors, 2 outdoor pressure sensors.
It is used for judging sensor abnormality. Note 2)
Note
1. Sensor checking function is used with Refrigerant
Checking and Refrigerant Auto Charging.
2. Check abnormal sensor
3. It is displayed at the LED on the main PCB at each step.
4. Reference the sensor error in ** page.
5. Refer to service manual about refrigerant auto
charging
Start
Main PCB
SW01S
Wait for 3 min. after power
reset
Main PCB Set the DIP switch according to the function
Sensor Checking ➠ Refrigerant Auto Charging : 1,2,7 ON
SW01B
Sensor Checking ➠ Refrigerant Checking : 1,2,7,14 ON
SW02B
Would you perform
the Sensor
checking?
Yes
Main PCB
SW01V
Caution
1. Confirm auto addressing has been performed (Check
installed number of IDU).
2. The error can be displayed even if the sensor is
normal according to installation and temperature
condition. If error occurs, check the sensor and
judge abnormality.
Don’t Perform Sensor Checking
No
Note 3)
Press the black button for 2 sec. on main PCB.
Refrigerant Auto Charging
Press the black button
until '508' is displayed
Refrigerant Checking
Press the black button
until '608' is displayed.
Indoor/Outdoor units operate with
air circulation mode
Judging sensor
normality
No
Main pcb
LED
Main PCB
SW01V
Yes
Note 4)
Error Display
Refrigerant
Auto Charging
Press the black button on the main PCB for 2 sec.
Refrigerant
Checking
Press the black button for 2 sec. after turning off all
of SIP switch.
Completed.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 34 -
LGE Internal Use Only
Function
■ Sensor Check Error Code Display
In case error occurs during sensor checking process, error display is as shown below.
Following contents are displayed one after the other on the main PCB of master outdoor unit.
Indoor sensor error :
319
Outdoor sensor error :
309
Displaying error content
* 5 number of errors is displayed
continuously and repeatedly.
Displaying error content
■ Indoor unit error display
1.1st and 2nd number represents indoor unit number.
2. Last number represents sensor.
ex) Indoor unit No. 2 pipe inlet temperature sensor
error
1: Pipe inlet temperature sensor
2: Pipe outlet temperature sensor
3: Air temperature sensor
■ Displaying outdoor unit error
1.1st and 2nd number represents error content(code).
2.Last number represents outdoor unit number.
ex) Outdoor master unit liquid pipe temperature
sensor error
1 : Master
2 : Slave 1
3 : Slave 2
4 : Slave 3
* Indoor unit number follows auto addressing number.
1
2
3
4
5
6
7
8
9
10
11
Outdoor Air Temperature
Heat Exchanger 1
Heat Exchanger 2
Inverter Compressor Discharge Temperature
Constant Speed Compressor Discharge Temperature
Suction Temperature
Liquid Pipe Temperature
SC pipe in
SC pipe out
High Pressure Sensor
Low Pressure Sensor
ex) IDU No.2 pipe inlet temperature sensor error and master
ODU suction temperature sensor, slave 3 high pressure
sensor error
........
Caution
1. Up to 5 number of errors is displayed continuously and
repeatedly. In case 5 number of errors occurs, again
perform sensor checking after solving errors.
2. IDU in which error occurred operates air circulation mode.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 35 -
LGE Internal Use Only
Function
4.4 Refrigerant Auto Charging
This function charges appropriate amount of refrigerant automatically through cycle operation.
It can be used when refrigerant amount Isn't certain because of SVC and leakage.
Note
1. After installing the refrigerant charging
device
as shown below in figure,
open the valve.
2. In case air temperature is out of guaranteed
temperature, it may end without performing
auto charging.
3. Refrigerant Charging Time may change
according to the charging amount.
(Refrigerant Charging Time : about 1.5 min/lb)
Start
Main PCB
SW01S
Wait for 3 min. after power reset
Main PCB
SW01B
SW02B
Set the Dip S/W.
Refrigerant Auto Changing : 1,2,7 ON
Main PCB
SW01V
Press the black button on main PCB.
( Press until ‘508’ is displayed )
Main PCB
SW01V
Press the black button on main PCB.
IDU runs with cooling mode In designated order.
Is it necessary to
charge refrigerant?
Yes
*1)
No
Press the black button
Refrigerant Auto
Charging Process
IDU and ODU are turned off when Auto Charging
is completed. Close the valve.
Main PCB
SW01V
*2)
Press the black button
Press the black button for 2 sec. after turning off
all of dip S/W.
Completed.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 36 -
LGE Internal Use Only
Function
manifold
Capillary Assembly
Liquid Pipe
Gas Pipe
Procedure
1. Arrange manifold,capillary assembly, refrigerant vessel and scale
2. Connect manifold to the gas pipe service valve of ODU as shown in the figure.
3. Connect manifold and Capillary tube.
Use designated capillary assembly only.
If designated capillary assembly isn't used, the system may get damaged.
4. Connect capillary and refrigerant vessel.
5. Purge hose and manifold.
6. After
Is displayed, open the valve and charge the refrigerant
■ Error contents about auto refrigerant charging function
1.
: Temperature Range Error (In case that IDU or ODU is out of range)
2.
: Low Pressure Descent Error (In case the system runs at low pressure limit for over 10 minutes)
3.
: Judging rapid refrigerant inflow ( In case the liquid refrigerant flows in because of not using designated Capillary Assembly)
4.
: Instability Error( In case the high/low pressure target doesn't get satisfied for some time
after the starting operation)
CAUTION
1. Guaranteed temperature range (Error will occur if temperature is out of range)
IDU : 20°C(68°F) ~ 32°C(90°F)
ODU : 0°C(32°F) ~ 43°C (77°F)
2. For refrigerant charging, use designated device only. (Capillary Assem Set)
3. Set the IDU wired remote controller temperature sensing mode as IDU
4. Be careful that IDU should not be thermo off.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 37 -
LGE Internal Use Only
Function
4.5 Refrigerant Checking Function
1. This function charges appropriate amount of refrigerant automatically through cycle operation.
2. This function judges refrigerant leakage and overcharging.
3. It can be used with refrigerant auto charging function.
Start
Main
PCB
SW01S
Wait for 3 min. after power reset
Main
PCB
SW01B
SW02B
Set the Dip S/W.
Refrigerant Checking : 1,2,7,14 ON
Main
PCB
SW01V
Press the black button on main PCB.
( Press until ‘608’ is displayed )
Main
PCB
SW01V
Press the black button on main PCB
Note
1. In case air temperature is out of guaranteed
temperature, refrigerant checking function may end
without performing refrigerant checking. Use
guaranteed temperature range only.
2. During the process of judging refrigerant amount, if
the cycle isn't stable, refrigerant checking function
may end without performing refrigerant checking.
IDU runs with cooling mode in order.
Judging
Refrigerant
Amount
Excess of
Refrigerant
Scarcity of
Refrigerant
Impossible
To Judge
Note
Note 1)
IDU, ODU are turned off
Main
PCB
SW01V
Press the black button on main PCB
Press the black button for 2 sec. after
turning off all of dip S/W.
Completed
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 38 -
LGE Internal Use Only
Function
CAUTION
1. Guaranteed Temperature range(Error occurs out of guaranteed temperature range)
IDU : 20°C(68°F) ~ 32°C(90°F) ( buffer ±2°F)
ODU : 10°C(50°F) ~38°C(100°F) ( buffer ±2°F)
2. Set IDU wired remote controller temperature sensor setting as 'IDU'.
3. Make certain that IDU doesn't run with thermo off mode during operation.
[ Error contents about auto refrigerant charging function ]
1.
: Temperature Range Error (In case that IDU or ODU is out of range)
2.
: System Unstable Error (In case, After 45 min operating the system, it does not be stable)
How to Cope with Result of Refrigerant checking
1. If the temperature is not in guaranteed Temperature range, the system will not execute Refrigerant checking and the system will be OFF.
2. Excess of Refrigerant(619)
After remove the 20% of calculated total refrigerant, recharge the refrigerant by using Refrigerant Auto
Charging Function.
3. Scarcity of Refrigerant(629)
Charge the refrigerant by using Refrigerant Auto Charging Function.
4. Impossible to Judge(639)
IF the system is not in order, check the other problem except refrigerant.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 39 -
LGE Internal Use Only
Function
4.6 Pump Down
This function gathers the refrigerant present in the system to ODU
Use this function to store refrigerant of system in ODU for leakage or IDU replacement.
ODU SVC V/V Setting
Close liquid SVC v/v of each unit.
Open gas SVC v/v of each unit.
Open
Close
Main PCB
SW02B
Power Reset
after Master Unit Dip switch No.10 ON
Main PCB
SW01V
Press the black button
All IDU cooling operation
Ball Valve(Liquid Pipe)
Satisfy low
pressure target?
Note 2)
Elbow
No
Ball Valve(Gas Pipe)
ODU SVC V/V Setting
Yes
Note 1)
Low pressure < 229kpa(33.2psi)
Pump down completed
Close
Close
Press the black button
IDU, ODU OFF
Main PCB
SW02B
Ball Valve(Liquid Pipe)
Power reset after Dop switch No.10 off
Elbow
Ball Valve(Gas Pipe)
[Note]
If
is displayed, close gas SVC V/V of all ODU immediately.
If low pressure descends below 229 kPa(33.2 psi), the system turns off automatically. Close the gas SVC V/V immediately.
Caution
1.Use pump down function within guaranteed temperature range
IDU : 20°C(68°F) ~ 32°C(90°F)
ODU : 5°C(41°F) ~ 40°C(104°F)
2. Make certain that IDU doesn't run with thermo off mode during operation
3. Maximum operation time of pump down function is 30 min.
(in case low pressure doesn't go down)
4. Press black+red button during operation to end pump down.(IDU,ODU off)
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 40 -
LGE Internal Use Only
Function
4.7 Pump Out
This function gathers the refrigerant to other ODU and IDU.
Use this function in case of compressor failure, ODU parts defect, leakage.
Close liquid SVC V/V of each unit.
Open gas SVC V/V of each unit.
Close high/low pressure common pipe
of corresponding ODU
Main PCB
SW01B
SW02B
ODU SVC V/V Setting
Close
Power reset after Dip switch setting of ODU
General case: No.10,14 on
Inv Compressor failure:No.3,10,14 on
Main PCB
SW01V
Open
Press the black button
All IDU heating operation
Ball Valve(Liquid Pipe)
Satisfy low pressure target?
Note 2)
Elbow
No
Ball Valve(Gas Pipe)
ODU SVC V/V Setting
Yes
Note 1)
Low pressure > 229 kpa(33.2 psi)
Main PCB
SW02V
SW01V
Pump out completed
Close
Close
Press the black button
IDU, ODU OFF
Ball Valve(Liquid Pipe)
Power reset after Dip switch No.(3), 10, 14 off
Elbow
Ball Valve(Gas Pipe)
[Note]
If
is displayed, close gas SVC V/V of all ODU immediately.
If low pressure descends below 229 kPa (33.2 psi), the system turns off automatically. Close gas SVC V/V immediately.
Caution
1.Use pump out function within guaranteed temperature range
IDU : 10°C(50°F) ~ 30°C(86°F)
ODU : 5°C(41°F) ~ 40°C(104°F)
2. Make certain that IDU doesn't run with thermo off mode during operation
3. Pump out function takes 2~5 min. after compressor start.
Make certain that IDU doesn't run with thermo off mode during operation
(in case low pressure doesn't go down)
4. Press black+red button during operation to end pump out.(IDU,ODU off)
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 41 -
LGE Internal Use Only
Function
■ Example. Slave ODU Inv Comp failure
Heating mode
Slave
Heating mode
Master
Comp failure unit
gas
pipe
liquid
pipe
gas
pipe
liquid
pipe
1. Close liquid pipe and common pipe of the unit for pump out operation.
2. Operate pump out
3. Close gas pipe of unit after completion
4. End pump out
5. Close common pipe
6. Eliminate refrigerant in common pipe after opening the common pipe of corresponding ODU.
Replace compressor and perform vacuum.
7. Add the refrigerant with auto charging function
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 42 -
LGE Internal Use Only
Function
4.8 Auto Back Up Function_Inverter compressor
This function allows the system to operate in case of inverter compressor failure by backing up compressor
automatically.
SVC can be asked by displaying error to the customer every 6 hours.
Operation
Inverter compressor failure
(NO.21,22,26,27 error occur)
INV Comp Auto Back up Operation
IDU,ODU display error for 10 min.
IDU remote controller error clear
IDU operation possible
No
Timer > 6hr
Yes
Example) Slave1 Unit INV Comp start failure error occur
ODU unit
Error number
Caution
1. Request SVC immediately if error occurs.
2. Auto back up is set up to 1 inverter Comp
3. If Inverter Comp Auto Back up starts, error displays for 10 min. every 6 hours.
4. Error displays continuously at the corresponding ODU.
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LGE Internal Use Only
Function
4.9 Auto Back Up Function_constant speed compressor
This function allows the system to operate in case of constant speed compressor failure
by backing up compressor automatically.
Operation
Constant speed comp failure
Constant speed Comp Auto Backup
Error Display 173+Unit No
ODU Main PCB
Display
30min delay
Constant speed comp
permanent back up starts
Error clear
IDU,ODU off
Operation possible
Example) Slave1 Unit constant speed Comp failure(No.173)
ODU
Error number
Caution
1. Request SVC immediately if error occurs
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Function
4.10 Night Low Noise Function
In cooling mode, this function makes the ODU fan operate at low RPM to reduce the fan noise of ODU at night
which has low cooling load.
Max. RPM setting method
Dip S/W No.12+14 ON
Main PCB Power Reset
Master ODU
SW01B
Master ODU
SW01S
Note 1)
STEP 1: Max. RPM =510
Black button 1 time + red button 1 time
STEP 2: Max. RPM = 450
Black button 2 times + red button 1 time
SW01V
SW02V
STEP 3: Max. RPM = 400
Black button 3 times + red button 1 time
Setting Complete
Night Low Noise Start
8 hours after max. ODU temp. sensing,
Operates with setting RPM
Night Low Noise End
9 hours after Night Low Noise function
start, the function ends automatically.
Caution
1. Request installer to set the function during installation.
2. In case the function is not used, set the dip S/W OFF and reset the power.
3. If ODU RPM changes, cooling capacity may go down.
[Note]
1. Select appropriate RPM referencing noise table.
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Function
Flow chart
Start Condition Setting
End
Timer(A) increase
Timer(B) increase
Timer(A) > 10min
Yes
Timer(A)=0
T_out ≥ T_max
Yes
No
T_max=T_out
Timer(B)=0
Timer(B) ≥ 8hr
No
Yes
Tmax = 0
End Condition Setting
Start
Timer(C) increase
Timer(B)=0
Timer(C) ≥ 9hr
No
No
Timer(C)= 0
Step = 1
RPM_max=510
Step = 2
RPM_max=450
Step = 3
RPM_max=400
Error
End
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Function
4.11 Vacuum Mode
This function is used for creating vacuum in the system after compressor replacement, ODU parts replacement
or IDU addition/replacement.
Vacuum mode setting method
Vacuum mode cancellation method
Main PCB
SW01S
ODU power reset
Master Main PCB D/W OFF( No.11,14)
Main PCB
SW02B
Master Main PCB D/W ON ( No.11,14)
Power Reset
Main PCB
SW01V
Press the black button Main PCB (5 sec.)
Vacuum Mode cancellation
Vacuum mode setting
ODU V/V OPEN
Main Lev, SC Lev OPEN
IDU Lev OPEN
Caution
ODU operation stops during vacuum mode. Compressor can't operate.
4.12 Static pressure compensation mode
This function secures the air flow rate of ODU, in case static pressure has been applied like using duct at fan
discharge of ODU.
■ Static pressure compensation dip S/W setting method
High static pressure mode (Max. RPM 930) : Master ODU Main PCB SW02B NO.13 Dip S/W
Low static pressure mode (Max. RPM 900) : Master ODU Main PCB SW02B NO.12 Dip S/W
Static pressure compensation mode setting
method
Static pressure compensation mode cancellation
method
Dip SW setting
High static pressure:No. 13
Low static pressure:No.12
Dip SW OFF
Power Reset
Power Reset
Static pressure compensation mode is cancelled
Static pressure compensation mode is set
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Function
4.13 Black Box Function
This function saves data immediately before the error occurs in ODU main PCB, and thus making error analysis
cause possible.
Data Loading Method
IDU, ODU stop
Press the black button (5 sec.)
EEPROM ➠ Main Micom data Loading
Yellow LED(LED01C) stops when data is loading
After completion, it is starts blinking (about 20 sec.).
EEPROM data save to PC by using
<Save EEP data> in LGMV
■ Saving process : Making Data ➠ Save EEP data ➠ data saving place select ➠ file save
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Part 3
PCB Setting and Test Run
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 49 -
LGE Internal Use Only
Test Run
Test Run
1. Checks Before Test Run
1
Check to see whether there is any refrigerant leakage, and slack of power or transmission cable.
2
Confirm that 500 V megger shows 2.0 MΩ or more between power supply terminal block and ground.
Do not operate in the case of 2.0 MΩ or less.
NOTE: Never carry out megaohm check over terminal control board. Otherwise the control board
would be broken.
Immediately after mounting the unit or after leaving it turned off for an extended length of time,
the resistance of the insulation between the power supply terminal board and the ground may
decrease to approx. 2 MΩ as a result of refrigerant accumulating in the internal compressor.
If the insulation resistance is less than 2 MΩ, turning on the main power supply and energizing
the crankcase heater for more than 6 hours will cause the refrigerant to evaporate, increasing
the insulation resistance.
3
Check if high/low pressure common pipe, liquid pipe and gas pipe valves are fully opened.
NOTE: Be sure to tighten caps.
4
Check if there are any problems in automatic addressing or not:
Check and confirm that there are no error messages in the display of indoor units or remote controls
and LED in outdoor units.
CAUTION
when cutting main power of the Multi V
• Always apply main power of the outdoor unit during use of product
(cooling season/heating season).
• Always apply power before 6 hours to heat the crank case heater where performing test run after installation of product. It may result in burning out of the compressor if not preheating the crank case with
the electrical heater for more than 6 hours.(In case of the outdoor temperature below 10°C(50°F))
• When operating the unit after powering off, automatically run into in the preheat mode for 3 hours and
"PH" is indicated on the outdoor unit 7-Segment.
CAUTION
Preheat of compressor
• Start preheat operation for 3 hours after supplying main power.
• In case that the outdoor temperature is low, be sure to supply power 6 hours before operation so
that the heater is heated(insufficient heating may cause damage of the compressor.)
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Test Run
2. Troubleshooting
The phenomena from main component failure
Component
Phenomenon
Not operating
Outdoor
EEV
Check method and Trouble shooting
Motor insulation broken Check resistance between terminals and
chassis
Strainer clogged
Change strainer
Oil leakage
Check oil amount after opening oil port
Stop during running
Motor insulation failure
Check resistance between terminals and
chassis
Abnormal noise
during running
R-S-T misconnection
Check compressor R-S-T connection
High pressure error
at cooling
Motor failure,
Check the outdoor fan operation after being
bad ventilation around turned the outdoor units off for some time.
outdoor heat exchanger Remove obstacles around the outdoor units
Heating failure, frequent defrosting
Bad connector contact
Check connector
No operating sound
at applying power
Coil failure
Check resistance between terminals
Heating failure,
frozen outdoor heat
exchanger part
EEV clogged
Service necessary
Low pressure error
EEV clogged
or discharge temperature error
Service necessary
Compressor
Outdoor
fan
Cause
When system fault occurs, the error code is displayed at indoor unit display or remote control display, the trouble shooting guide is in the service manual
• When CH05/53/11 ERROR occurs, check if auto-addressing has done and communication wiring is ok.
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Test Run
3. DIP Switch Setting
3.1 Location of setting Switch
Main PCB
SW01B
(DIP S/W)
SW02B
(DIP S/W)
7 - Segment
SW02V
Auto addressing
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Test Run
■ Checking according to dip switch setting
1. You can check the setting values of the Master outdoor unit from the 7 segment LED.
The dip switch setting should be changed when the power is OFF.
2. It checks whether the input is properly performed without the bad contact of the dip switch or not
■ Checking the setting of the Master unit
The number is sequentially appeared at the 7 segment in 5 seconds after applying the power. This
number represents the setting condition.(For example, represents 3Ø 208/230V 20HP heat pump)
Master model code ➔ Slave1 model code ➔ total capacity ➔ 2 ➔ 25 ➔ 140
1 ~255 : Master model code
Refer to table code
1 ~255 : Slave1 model code
1 ~255 : Slave2 model code
8~32HP : HP number(sum of master capacity and slave capacity)
No display : cooling only 2 : heat pump 3 : Sync
25 : Nomal
140 : 3Ø 208/230V 160 : 3Ø 460V
}
Example) 3Ø 208/230V 20HP heat pump
151 ➔ 151 ➔ 20 ➔ 2 ➔ 25 ➔ 140
CAUTION
Product may not properly operate if the relevant DIP switch is not properly setup.
Model Code
3Ø 208/230V
Model Code
150
151
152
3Ø 460V
Unit (HP)
8
10
12
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
Model Code
171
172
173
174
175
- 53 -
Unit (HP)
8
10
12
14
16
LGE Internal Use Only
Test Run
■ Setting the DIP switch (SW03M)
• Set the dip switch with the power turned off. If you change the setting when the power is on, the changed
setting is not applied immediately. The changed setting is applied at the moment that the power is on.
• Instant indoor unit checking, data display mode, and forced oil collecting operation are used when theunits
are running. If you don't have to use those functions after using them, restore the dip switch setting.
1. Settings of main outdoor unit
Function
SW01B Setting
SW02B Setting
ON
Remarks
ON
Standard
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
Short Pipe
Length
3
4
5
6
7
ON
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Long Pipe Length
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Longest Pipe
Length
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
5
6
7
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
3
4
5
6
7
ON
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
Indoor Unit
Forced Operation
( Heating )
4
ON
ON
Indoor Unit
Forced Operation
( Cooling )
3
3
4
5
6
7
ON
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
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Only for training and service purposes
- 54 -
3
4
5
6
7
LGE Internal Use Only
Test Run
Function
SW01B Setting
SW02B Setting
ON
Remarks
ON
Dry Contact
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Snow
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Forced
Defrosting
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
Snow + Forced
Defrosting
Outdoor Unit Fan
Low Static
Pressure
Compensation
Outdoor Unit Fan
High Static
Pressure
Compensation
3
4
5
6
7
ON
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Night Low Noise
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Pump Down
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Forced Oil Return
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Vacuum Mode
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
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Only for training and service purposes
- 55 -
3
4
5
6
7
LGE Internal Use Only
Test Run
2. Settings of slave outdoor unit
Function
SW01B Setting
SW02B Setting
ON
Remarks
ON
Slave
1
2
3
4
5
6
7
1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9 10 11 12 13 14
3. Settings of corresponding outdoor unit
Function
SW01B Setting
SW02B Setting
ON
Remarks
ON
Inv Back Up
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Unit Back Up
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
ON
3
4
5
6
7
ON
Pump Out
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
7
8
9 10 11 12 13 14
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- 56 -
3
4
5
6
7
LGE Internal Use Only
Replacement procedure for Compressor
1. Replacement procedure for Compressor.................................58
1.1 Replacement procedure......................................................58
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LGE Internal Use Only
Replacement procedure for Compressor
Replacement procedure for Compressor
1) Collect the refrigerant by using refrigerant recovery unit
(Since the setting on outdoor unit PCB is required for
refrigerant recovery, refer to the warming plate
Precautions in service work attached on the switch
box cover)
2) Remove the sound insulator mat covering the
faulty compressor, and disconnect the power
Discharge pipe
Suction pipe
3) Disconnect the brazing sections of suction pipe
and discharge pipe by using brazing torch after the
refrigerant has been collected completely.
Oil Return pipe
4) Remove equalizing pipe nut.
5) Remove three bolts at cushion rubber section to
take out the faulty compressor outside the unit.
6) Install the new compressor in the unit.(Be sure to
insert the cushion rubbers before tightening the
fixing bolts of compressor.)
Equalizing seat outlet
7) Remove the rubber caps put on the suction and
discharge pipe of the new compressor to
release.the sealing nitrogen gas.(Take note that oil
may spout due to the pipe inside pressure if the
plug put on the equalizing seat is removed before
removing of rubber cap.)
8) Fasten equalizing pipe with nut.(10.3 ~ 13.3 lbf.ft)
9) Braze the suction and discharge pipe with brazing
torch to the compressor.
Cut section
10) Conduct air tight test to check the piping system
is free from leakage.
11) Connect power cable to the terminal board of
compressor and cover the compressor with
sound insulator mat.
12) Conduct vacuum drying.(Since the setting on outdoor unit PCB is required for vacuum drying, refer
to the warning plate recautions in service work”
attached on the switch box cover.)
13) Charge refrigerant after the completion of vacuum
drying, and check the function of compressor
with cooling or heating operation.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 58 -
LGE Internal Use Only
Part 4
Trouble shooting guide
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 59 -
LGE Internal Use Only
Trouble shooting guide
1. The phenomena from main component failure ..............................61
2. Checking Method for Key Components
2.1 Compressor ........................................................................................62
2.2 Fan Motor ............................................................................................63
2.3 Electronic Expansion Valve...............................................................64
2.4 Phase Bridge Diode Checking Method.............................................67
2.5 Inverter IPM Checking Method ................................................................68
2.6 Fan IPM Checking Method .......................................................................69
2.7 UW1 chassis 2Fan ....................................................................................69
2.8 Other ..........................................................................................................71
3. Self-diagnosis function .................................................................72
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
The phenomena from main component failure
1. The phenomena from main component failure
The phenomena from main component failure
Component
Phenomenon
Not operating
Outdoor
EEV
Check method and Trouble shooting
Motor insulation broken Check resistance between terminals and
chassis
Strainer clogged
Change strainer
Oil leakage
Check oil amount after opening oil port
Stop during running
Motor insulation failure
Check resistance between terminals and
chassis
Abnormal noise
during running
R-S-T misconnection
Check compressor R-S-T connection
High pressure error
in cooling mode
operation
Check the fan operation to confirm proper
Motor failure,
bad ventilation around motor functioning. Switch OFF the outdoor
outdoor heat exchanger unit and remove obstacles, if any, around
the HEX. Check connector
Heating failure, frequent defrosting
Bad connector contact
Check resistance between terminals
No operation sound
after switching ON
the power supply
Coil failure
Service necessary
Heating failure,
frozen outdoor heat
exchanger part
EEV clogged
Service necessary
Compressor
Outdoor
fan
Cause
EEV clogged
Low pressure error
or discharge temperature error
When system fault occurs, the error code is displayed on the indoor unit display or remote control display. The
trouble shooting guide is available in the service manual.
• When CH05/53/11 ERROR occurs, check if auto-addressing has done and communication wiring is ok.
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
2. Checking Method for Key Fompornents
2.1 Compressor
Check and ensure in following order when error related with the compressor or error related with power occurs
during operation:
No.
1
2
Checking Item
Symptom
Is how long power on during
operation?
Does failure appears again
when starting operation?
1) Power on for 12 hours or more
* Go to No.2.
2) Power on for 12 hours or less
* Go to No.2 after applying
power for designated time (12
hours).
* Check IMP may fail.
1) The compressor stops andsame
error appears again.
Method to measure insulation 2) If output voltage of the inverter is
resistance
stably output. *1
Comp.
pipe
Motor
Ω
Method to measure coil
resistance
Motor
U
Ω
V
W
* Check coil resistor and insulation resistor. If normal, restart
the unit. If same symptom
occurs, replace the compressor.
* Insulation resistor: 2MW or
more
Coil resistor:
3Ø208/230V
Inverter Constant
U-V 0.39±7%Ω 0.44±7%Ω
V-W 0.38±7%Ω 0.42±7%Ω
W-U 0.39±7%Ω 0.40±7%Ω
Figure 1.
Comp.
Countermeasure
3) If output voltage of the inverter is
unstable or it is 0V.
(When incapable of using a digital tester)
Figure 2.
3Ø460V
Inverter Constant
0.35±7%Ω 1.96±7%Ω
0.34±7%Ω 1.91±7%Ω
0.35±7%Ω 1.99±7%Ω
* Check the IPM.
If the IPM is normal, replace
the inverter board.
* Check coil resistor and insulation resistor.
[Cautions when measuring voltage and current of inverter power circuit]
Measuring values may differ depending on measuring tools and measuring circuits since voltage, current in the
power supply or output side of the inverter has no since waveform.
Especially, output voltage changes when output voltage of the inverter has a pattern of pulse wave.
In addition, measuring values appear largely differently depending on measuring tools.
1) If using a movable tester when checking that output voltage of the inverter is constant (when comparing relative voltage between lines), always use an analog tester. Especially exercise particular caution if the output
frequency of the inverter is low, when using a movable tester, where change of measured voltage values is
large between other lines, when virtually same values appear actually or where there is danger to determine
that failure of the inverter occurred.
2) You can use rectification voltmeter (
) if using commercial frequency tester when measuring output values
of the inverter (when measuring absolute values). Accurate measuring values cannot be obtained with a general movable tester (For analog and digital mode).
Copyright ©2007 LG Electronics. Inc. All right reserved.
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- 62 -
LGE Internal Use Only
2.2 Fan Motor
Checking Item
(1) The fan motor does not
operate.
Does failure appears
again when starting
operation?
Symptom
Countermeasure
1) When power supply is
abnormal
2) For wrong wiring
(2) Vibration of the fan
motor is large.
3) For failure of motor
4) For defective fuse
5) For failure of circuit board
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 63 -
* Modify connection status in front of or at the rear of
the breaker, or if the power terminal console is at
frosting condition.
* Modify the power supply voltage is beyond specified scope.
* For following wiring.
1. Check connection status.
2. Check contact of the connector.
3. Check that parts are firmly secured by tightening
screws.
4. Check connection of polarity.
5. Check short circuit and grounding.
* Measure winding resistance of the motor coils.
16.8±5%Ω
* Replace the fuse if there is defect (Fuse 800V
30A).
Replace the circuit board in following procedures if
problems occur again when powering on and if
there are no matters equivalent to items as specified in above 1) through 4).
(Carefully check both connector and grounding
wires when replacing the circuit board.)
1. Replace only fan control boards.
If starting is done, it means that the fan control
board has defect.
2. Replace both fan control board and the main
board.
If starting is done, it means that the main board
has defect.
3. If problems continue to occur even after countermeasure of No.1 and No.2, it means that both
boards has defect.
LGE Internal Use Only
Checking Method for Key Components
2.3 Electronic Expansion Valve
DC 12V
ø5
Red
5
Driving
circuit
ø4
White
4
ø4
ø3
Yellow
3
ø3
ø2
Orange
2
ø2
ø1
Blue
1
ø1
EEV
4
M
6
2
5
1
3
• Pulse signal output value and valve operation
Output(ø) No.
Output state
1
2
3
4
5
6
7
8
9
10
11
ø1
ON
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
ø2
ON
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
OFF
ø3
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
ø4
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
OFF
• Output pulse sequence
- In valve close state: 1 → 2 → 3 → 4 → 5 → 6 → 7 → 8 → 9 → 10 → 11 → 1
- In valve open state: 11 → 10 → 9→ 8 → 7 → 6 → 5 → 4 → 3 → 2 → 1 → 11
* 1. If EEV open angle does not change, all of output phase will be OFF
2. If output phase is different or continuously in the ON state, motor will not operate smoothly and start
vibrating.
• EEV valve operation
Valve
open
Angle
- At power ON, open angle signal of 1400 pulses output and valve position is set to
If valve operates smoothly, no noise and vibration
occurs and if valve is closed. noise occurs.
close
Full open
1350 pulses
open
- Noise from EEV can be confirmed by touching the
EEV surface with a screw driver and listening the
EEV noise.
- If liquid refrigerant is in EEV, the noise is lower.
pulse
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 64 -
LGE Internal Use Only
Checking Method for Key Components
• EEV Coil and body(Outdoor unit)
Coil part
Body
Lead wire
• Remove and assemble the coil
Remove
Assemble
• Grip the A part tightly, and pull up coil part
upward.
When the coil part is removed or assembled,
be careful not to bend the pipe of the body.
A part
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 65 -
LGE Internal Use Only
Checking Method for Key Components
• EEV failure check method
Failure mode
Microcomputer
Driving circuit
failure
Diagnosis
1.Disconnect the EEV connector form control board and
connect testing LED
1K
Repair process
Unit
Check and replace
Indoor unit control
board
Indoor
unit
LED
2. Main power ON, pulse signal is out from EEV for 17 sec.
If LEDs do not turn on, or are in on state continuously,
then driving circuit is abnormal
EEV locking
1.If EEV is locked, in no load state, the driving motor rotate,
and clicking sound always occurs
Replace EEV
Indoor
/ Outdoor
unit
EEV Motor coil
short or
misconnection
1. Check the resistance between coil terminal
(red-white, red-yellow, red-orange, red-blue)
2. If the estimated resistance value is in 52 ± 3Ω
then the EEV is normal
1. Check the resistance between coil terminal
(brown-white, brown-yellow, brown-orange, brown-blue)
2. If the estimated resistance value is in 150 ± 10Ω
then the EEV is normal
1. Operate indoor unit with FAN mode and operate another
indoor unit with COOLING mode
2. Check indoor unit(FAN mode) liquid pipe temperature
(from operation monitor of outdoor unit control board)
3. When fan rotate and EEV is fully closed, if there is any
leakage, then the temperature is down
Replace EEV
Outdoor
unit
Replace EEV
Indoor
unit
If the amount of
leakage is much,
Replace EEV
Indoor
unit
Full closing
(valve leakage)
If estimated temperature is very low in comparison with
suction temperature which is displayed at remote
controller then the valve is not fully closed
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 66 -
LGE Internal Use Only
Checking Method for Key Components
2.4 Phase Bridge Diode Checking Method
Internal circuit diagram
Appearance
R
S
T
1. Wait until inverter PCB DC voltage gets discharged, after the main power switch off.
2. Pull out all the connectors connected with 3 phase bridge diode.
3. Set multi tester in diode mode.
4. Measured value should be 0.4~0.7V measuring as below table.
5. In case the measured value is different from the table, set multi tester to resistance mode and measure. If
the value is small (0 Ω) or high (hundreds M Ω), PCB needs to be replaced.
6. In case that bridge diode is damaged, check if inverter PCB assembly(IPM) is needed to be replaced.
Diode terminal
+ terminal: black(-)
- terminal: red(+)
R(~) : red(+)
0.4 V ~ 0.7 V
-
S(~) : red(+)
0.4 V ~ 0.7 V
-
T(~) : red(+)
0.4 V ~ 0.7 V
-
R(~) : black(-)
-
0.4 V ~ 0.7 V
S(~) : black(-)
-
0.4 V ~ 0.7 V
T(~) : black(-)
-
0.4 V ~ 0.7 V
Tester terminal
✽ Red(+) and black(-) are the measuring terminals of multi tester.
Caution
• Check the electric parts of c/box, 10 minutes after switching off the main supply and
checking DC voltage is discharged. Otherwise, there is chance of getting electric
shock.
• There is chance of electric shock by charged voltage.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 67 -
LGE Internal Use Only
Checking Method for Key Components
2.5 Inverter IPM Checking Method
3Ø 460V
3Ø 208/230V
CN-P1
CN-N1
N terminal
N terminal
P terminal
P terminal
W terminal
U terminal
U,V,W connector
U terminal
V terminal
V terminal
W terminal
1. Wait until inverter PCB DC voltage is discharged after main power off.
2. Pull out CN-P1, CN-N1 connectors and U,V,W COMP connector connected with the inverter PCB.
3. Set multi tester to resistance mode.
4. If the value between P and N terminal of IPM is short(0Ω) or open(hundreds MΩ), PCB needs to be
replaced.(IPM damaged)
5. In the measured value with resistance mode should be within 28K Ω ±10%.
6. In case measured value is different from the table, PCB needs to be replaced.(PCB damaged).
P terminal : black (-)
N terminal : red (-)
U terminal : red(+)
28K Ω ± 10%
Open
V terminal : red(+)
28K Ω ± 10%
Open
W terminal : red(+)
28K Ω ± 10%
Open
P terminal : red(+)
N terminal : red (+)
U terminal : black(-)
Open
28K Ω ± 10%
V terminal : black(-)
Open
28K Ω ± 10%
W terminal : black(-)
Open
28K Ω ± 10%
✽ Red(+) and black(-) are the measuring terminals of multi tester.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 68 -
LGE Internal Use Only
Checking Method for Key Components
2.6 Fan IPM Checking Method
1. Wait until inverter PCB DC voltage gets discharged after the main power switch off.
2. Pull out DC connector and U,V,W fan motor connector connected with fan PCB
3. Set multi tester in resistance mode .
4. If the value between P and N terminal of IPM is small (0Ω) or tens KΩ, PCB needs to be replaced (IPM damaged).
5. In case the measured value is open(hundreds KΩ), measure resistance mode, and the value should be within
35 KΩ ±10% as shown below table.
6. If the measured value is different from the value given in the table, PCB is needs to be replaced.
P terminal : black (-)
N terminal : red (-)
U terminal : red(+)
35K Ω ± 10%
Open
V terminal : red(+)
35K Ω ± 10%
Open
W terminal : red(+)
35K Ω ± 10%
Open
P terminal : red(+)
N terminal : red (+)
U terminal : black(-)
Open
35K Ω ± 10%
V terminal : black(-)
Open
35K Ω ± 10%
W terminal : black(-)
Open
35K Ω ± 10%
✽ Red(+) and black(-) are the measuring terminals of multi tester.
2.7 UW1 chassis(2 Fan)
U terminal
V terminal W terminal U terminal V terminal W terminal
U,V,W connector
P terminal
U,V,W connector
N terminal
P terminal
N terminal
DC connector
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 69 -
LGE Internal Use Only
Checking Method for Key Components
2.8 Other
Electrolytic
and resistor
for voltage
Guide of capacitor
check electrolytic
capacitor
and distribution
resistor for voltage distribution
1) Disconnect an terminal of voltage distribution resistor from each DC link
electrolytic capacitor
2) Set the multi meter to resistance mode, connect the probe to +,- terminal
of the capacitor. If the estimated resistance value is increase
continuously without short(value is 0), then the resistor is normal
3) Set the multi meter to resistance mode, confirm that the resistance value
of the resistor is around 270 kOhm
Check and replace inferior
components
Caution
In case that the control box is opened and before checking electrical parts,
it should be checked that the LED 01Y turned off (wait 3 minutes after main power
OFF), otherwise it may cause electrical shock.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 70 -
LGE Internal Use Only
Self-diagnosis function
3. Self-diagnosis function
Self-Diagnosis Function
Error Indicator
• This function indicates types of failure in self-diagnosis and occurrence of failure for air condition.
• Error mark is displayed on display window of indoor units and wired remote controller, and 7-segment LED of
outdoor unit control board as shown in the table.
• If more than two troubles occur simultaneously, lower number of error code is first displayed.
• After error occurrence, if error is released, error LED is also released simultaneously.
Error Display
Indoor unit related error
1st,2nd LED of 7-segment indicates error number, 3rd LED indicates unit number.
Ex) 211 : No.21 error of master unit
213 : No.21 error of slave2
011 → 051 : No.105 error of master unit
Display
Title
0 1 - Air temperature sensor of indoor unit
0 2 - Inlet pipe temperature sensor of indoor unit
Communication error : wired remote controller
0 3 ↔ indoor unit
0 4 - Drain pump
Communication error : outdoor unit ↔ indoor
0 5 unit
0 6 - Outlet pipe temperature sensor of indoor unit
0 7 - Different operation mode
Serial No.
0 9 1
0
-
1
1
-
2
1
1
Outdoor unit related error
2
1
2
2
2
1
2
3
2
1
2
4
2
Cause of Error
Air temperature sensor of indoor unit is open or short
Inlet pipe temperature sensor of indoor unit is open or short
Failing to receive wired remote controller signal in indoor unit PCB
Malfunction of drain pump
Failing to receive outdoor unit signal in indoor unit PCB
Outlet pipe temperature sensor of indoor unit is open or short
Operation mode between indoor unit and outdoor unit is different
In case when the serial number marked on
EEPROM of Indoor unit is 0 or FFFFFF
Poor fan motor operation
Disconnecting the fan motor connector/Failure of indoor fan motor
lock
Communication error: indoor unit → main PCB When the addressing signal doesn't respond for 3mins. suddenly,
of outdoor.
while the indoor unit gets the calling signal from the outdoor unit,
Master Outdoor Unit Inverter Compressor
Master Outdoor Unit Inverter Compressor Drive IPM Fault
IPM Fault
Slave Outdoor Unit Inverter Compressor IPM Slave Outdoor Unit Inverter Compressor Drive IPM Fault
Fault
Inverter Board Input Over Current(RMS) of
Master Outdoor Unit Inverter Board Input Current excess (RMS)
Master Outdoor Unit
Inverter Board Input Over Current(RMS) of
Slave Outdoor Unit Inverter Board Input Current excess (RMS)
Slave Outdoor Unit
Master Outdoor Unit Inverter
Compressor DC link Low Voltage
Slave Outdoor Unit Inverter
Compressor DC link Low Voltage
Master Outdoor Unit High Pressure
Switch
Slave Outdoor Unit High Pressure
Switch
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
DC charging is not performed at Master outdoor unit after
starting relay turn on.
DC charging is not performed at Slave outdoor unit after
starting relay turn on.
System is turned off by Master outdoor unit high pressure
switch.
System is turned off by Slave outdoor unit high pressure
switch.
- 71 -
LGE Internal Use Only
Self-diagnosis function
Display
1
2
5
2
1
2
6
2
1
2
7
2
1
2
8
2
1
Outdoor unit related error
2
9
2
3
3
3
3
3
2
3
Cause of Error
Master Outdoor Unit Input Voltage
High/ Low Voltage
Slave Outdoor Unit Input Voltage
High/ Low Voltage
Master Outdoor Unit Inverter
Compressor Start Failure
Slave Outdoor Unit Inverter
Compressor Start Failure
Master Outdoor Unit PFC IPM
Fault error
Slave 1 Outdoor Unit PFC IPM
Fault error
Master Outdoor Unit Inverter DC
link High Voltage
Slave Outdoor Unit Inverter DC
link High Voltage
Master Outdoor Unit Inverter
Compressor Over Current
Slave Outdoor Unit Inverter
Compressor Over Current
Master Outdoor Unit Inverter
1 Compressor High Discharge
Temperature
Slave Outdoor Unit Inverter
2 Compressor High Discharge
Temperature
Master Outdoor Unit Constant
1 Speed Compressor High
Discharge Temperature
Slave Outdoor Unit Constant
2 Speed Compressor High
Discharge Temperature
Master Outdoor Unit input voltage is over 487V or
below 270V
Slave Outdoor Unit input voltage is over 487V or below
270V
The First Start Failure by Master Outdoor Unit Inverter
Compressor Abnormality
The First Start Failure by Slave Outdoor Unit Inverter
Compressor Abnormality
System is turned off by Master Outdoor unit PFC IPM
Fault Signal
System is turned off by Slave 1 Outdoor unit PFC IPM
Fault Signal
System is turned off by Master outdoor unit DC Voltage
Over Charging
System is turned off by Slave Outdoor unit DC Voltage
Over Charging
Master Outdoor Unit Inverter Compressor Fault OR
Drive Fault
Slave Outdoor Unit Inverter Compressor Fault OR
Drive Fault
System is turned off by Master outdoor unit Inverter
Compressor High Discharge Temperature
System is turned off by Slave Outdoor unit Inverter
Compressor High Discharge Temperature
System is turned off by Master Outdoor Uunit Constant
Speed High Discharge Temperature
System is turned off by Slave Outdoor Unit Constant
Speed High Discharge Temperature
1
High Pressure of Master Outdoor
Unit
System is turned off by excessive increase of high
pressure of Master outdoor unit
2
High Pressure of Slave Outdoor
Unit
System is turned off by excessive increase of high
pressure of Slave outdoor unit
4
5
Title
1 Low Pressure of Master Outdoor
Unit
System is turned off by excessive decrease of low pressure of Master outdoor unit
2
Low Pressure of Slave Outdoor
Unit
System is turned off by excessive decrease of low pressure of Slave outdoor unit
1
Transmission error : Inverter ➠
Converter
Failing to receiver the Inverter signal at converter
2
Transmission error : Inverter ➠
Converter
System is turned off by Slave 1 Outdoor unit PFC IPM
Fault Signal
8
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 72 -
LGE Internal Use Only
Self-diagnosis function
Display
4
4
4
Outdoor unit related error
4
4
4
4
4
4
Master Outdoor Unit Inverter
Compressor CT Sensor Fault
Master Outdoor Unit Inverter Compressor CT Sensor
open or short
2
Slave Outdoor Unit Inverter
Compressor CT Sensor Fault
Slave Outdoor Unit Inverter Compressor CT Sensor
open or short
Master Outdoor Unit Inverter
1 Compressor Discharge
Temperature Sensor Fault
Master Outdoor Unit Inverter Compressor Discharge
Temperature Sensor open or short
Slave Outdoor Unit Inverter
2 Compressor Discharge
Temperature Sensor Fault
Slave Outdoor Unit Inverter Compressor Discharge
Temperature Sensor open or short
1
Master Outdoor Unit Low Pressure Master Outdoor Unit Low Pressure Sensor open or
short
Sensor Fault
2
Slave Outdoor Unit Low Pressure
Sensor Fault
Slave Outdoor Unit Low Pressure Sensor open or
short
1
Master Outdoor Unit High
Pressure Sensor Fault
Master Outdoor Unit High Pressure Sensor open or
short
2
Slave Outdoor Unit High Pressure
Sensor Fault
Slave Outdoor Unit High Pressure Sensor open or
short
1
Master Outdoor Unit Air
Temperature Sensor Fault
Master Outdoor Unit Air Temperature Sensor open or
short
2
Slave Outdoor Unit Air
Temperature Sensor Fault
Slave Outdoor Unit Air Temperature Sensor open or
short
2
3
4
5
6
7
8
Cause of Error
1
0
1
Title
Master Outdoor Unit Heat
1 Exchanger Temperature
Sensor(A) Fault
Master Outdoor Unit Heat Exchanger Temperature
Sensor(A) Open or Short
Slave Outdoor Unit Heat
2 Exchanger Temperature
Sensor(A) Fault
Slave Outdoor Unit Heat Exchanger Temperature
Sensor(A) Open or Short
1 Master Outdoor Unit Suction
Temperature Sensor Fault
Master Outdoor Unit Suction Temperature Sensor
Open or Short
2 Slave Outdoor Unit Suction
Temperature Sensor Fault
Slave Outdoor Unit Suction Temperature Sensor Open
or Short
Master Outdoor Unit Constant
1 Speed Compressor Discharge
Temperature Sensor Fault
Master Outdoor Unit Constant Speed Compressor
Discharge Temperature Sensor Open or Short
2 Slave Outdoor Unit Constant
Speed Compressor Discharge
Temperature Sensor Fault
Slave Outdoor Unit Constant Speed Compressor
Discharge Temperature Sensor Open or Short
1 Master Outdoor Unit Heat
Exchanger Temperature
Sensor(B) Fault
Master Outdoor Unit Heat Exchanger Temperature
Sensor(B) Open or Short
Slave Outdoor Unit Heat
2 Exchanger Temperature
Sensor(B) Fault
Slave Outdoor Unit Heat Exchanger Temperature
Sensor(B) Open or Short
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 73 -
LGE Internal Use Only
Self-diagnosis function
Display
5
0
5
1
5
5
5
Outdoor unit related error
5
6
6
7
2
3
Title
Omitting connection of R, S, T
1 power of Master Outdoor unit
Omitting connection of Master outdoor unit
Omitting connection of R, S, T
2 power of Slave outdoor unit
Omitting connection of Slave outdoor unit
1
2 Communication error : inverter
PCB → Main PCB
Failing to receive inverter signal at main PCB of Slave
Outdoor Unit
1
Communication error : indoor unit
→ main PCB of outdoor unit
Failing to receive indoor unit signal at main PCB of outdoor Unit.
1
Reverse connection of R, S, T
power of Master Outdoor unit
Reverse connection or omitting connection of R, S, T
power of Master outdoor unit
2
Reverse connection of R, S, T
power of Slave outdoor unit
Reverse connection or omitting connection of R, S, T
power of Slave outdoor unit
1
Mixing Installation of Sub Outdoor
Unit
Mixing Installation of Old Sub outdoor unit and New
Slave Outdoor Unit
1
Inverter PCB EEPROM Error of
Master Outdoor Unit
Access Error of Inverter PCB of Master Outdoor Unit
2
Inverter PCB EEPROM Error of
Slave Unit
Access Error of Inverter PCB of Slave Outdoor Unit
1
Master Outdoor Unit Fan Lock
Restriction of Master Outdoor Unit
2
Slave Outdoor Unit Fan Lock
Restriction of Slave Outdoor Unit
1
Constant CT Sensor Error of
Master Outdoor Unit
Constant CT Sensor Error of
Slave Outdoor Unit
PFC CT Sensor Error of Master
Outdoor Unit
PFC CT Sensor Error of Slave
Outdoor Unit
Instant Over Current(Peak) of
Master Outdoor Unit PFC
Instant Over Current(Peak) of
Slave Outdoor Unit PFC
Master Outdoor Unit 3 Phase
Power unbalance
Slave Outdoor Unit 3 Phase
Power unbalance
Master Outdoor Unit Fan CT
Sensor Error
Slave Outdoor Unit Fan CT
Sensor Error
Constant CT Sensor open or short of Master Outdoor
Unit
Constant CT Sensor open or short of Slave Outdoor
Unit
Master Outdoor Unit PFC CT Sensor open or short
0
2
1
7
1
2
1
7
3
2
1
7
4
2
1
7
Excessive connection of indoor units compared to
capacity of outdoor unit
Failing to receive inverter signal at main PCB of Master
Outdoor Unit
0
7
Excessive capacity of indoor units
Communication error : inverter
1 PCB → Main PCB
4
9
Cause of Error
5
2
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
Slave Outdoor Unit PFC CT Sensor open or short
Instant Over Current(Peak) of Master Outdoor Unit
PFC
Instant Over Current(Peak) of Slave Outdoor Unit PFC
Master Outdoor Unit R-T Phase Difference is over 5A
Slave Outdoor Unit R-T Phase Difference is over 5A
Master Outdoor Unit Fan CT Sensor open or short
Slave Outdoor Unit Fan CT Sensor open or short
- 74 -
LGE Internal Use Only
Self-diagnosis function
Display
7
7
7
Outdoor unit related error
7
8
8
6
7
8
9
6
7
Title
Cause of Error
Master Outdoor Unit Fan DC Link
1 High Voltage Error
Master Outdoor Unit Fan DC Link High Voltage Error
2 Slave Outdoor Unit Fan DC Link
High Voltage Error
Slave Outdoor Unit Fan DC Link High Voltage Error
1 Master Outdoor Unit Fan Over
Current Error
Master Outdoor Unit Fan Current is over 5A
2 Slave Outdoor Unit Fan Over
Current Error
Slave Outdoor Unit Fan is over 5A
1 Master Outdoor Unit Fan Hall
Sensor Error
Master Outdoor Unit Fan Hall Sensor open or Short
2 Slave Outdoor Unit Fan Hall
Sensor Error
Slave Outdoor Unit Fan Hall Sensor open or Short
1 Master Outdoor Unit Fan Start
Failure Error
Master Outdoor Unit Fan First Position Sensing Failure
2 Slave Outdoor Unit Fan Start
Failure Error
Slave Outdoor Unit Fan First Position Sensing Failure
1 Master Outdoor Unit Main PCB
EEPROM Error
Communication Fail Between Master Outdoor Unit
Main MICOM and EEPROM or omitting EEPROM
2 Slave Outdoor Unit Main PCB
EEPROM Error
Communication Fail Between Slave Outdoor Unit Main
MICOM and EEPROM or omitting EEPROM
1 Master Outdoor Unit Fan PCB
EEPROM Error
Communication Fail Between Master Outdoor Unit Fan
MICOM and EEPROM or omitting EEPROM
2 Slave Outdoor Unit Fan PCB EEP- Communication Fail Between Slave Outdoor Unit Fan
ROM Error
MICOM and EEPROM or omitting EEPROM
8
8
1 0 4
1 0 5
1 Master Outdoor Unit PFC EEPROM Error
Communication fail between Master Outdoor unit
PFC MICOM and EEPROM or omitting EEPROM
2 Slave 1 Outdoor Unit PFC EEPROM Error
Communication fail between Slave 1 Outdoor unit
PFC MICOM and EEPROM or omitting EEPROM
Communication Error Between
1 Master Outdoor Unit and Other
Outdoor Unit
Failing to receive Slave Unit signal at main PCB of
Master outdoor unit
Communication Error Between
2 Slave Outdoor Unit and Other
Outdoor Unit
Failing to receive master and other Slave Unit signal at
main PCB of Slave outdoor unit
Master Outdoor Unit Fan PCB
1 Communication Error
Failing to receive fan signal at main PCB of master
unit.
Slave Outdoor Unit Fan PCB
2 Communication Error
Failing to receive fan signal at main PCB of Slave unit.
Instant Over Current at Master Outdoor Unit Fan IPM
Master Outdoor Unit FAN IPM
1 Fault Error
1 0 6
Instant Over Current at Slave Outdoor Unit Fan IPM
Slave Outdoor Unit FAN IPM Fault
2 Error
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 75 -
LGE Internal Use Only
Self-diagnosis function
Display
1 0 7
1 1
Outdoor unit related error
1 1
1 1
3
4
5
Title
1 Master Outdoor Unit Fan DC Link
Low Voltage Error
Master Outdoor Unit Fan DC Link Input Voltage is
under 380V
2 Slave Outdoor Unit Fan DC Link
Low Voltage Error
Slave Outdoor Unit Fan DC Link Input Voltage is under
380V
1 Master Outdoor Unit Liquid pipe
Temperature Sensor Error
Liquid pipe temperature sensor of Master outdoor unit
is open or short
2 Slave Outdoor Unit Liquid pipe
Temperature Sensor Error
Liquid pipe temperature sensor of Slave outdoor unit is
open or short
1 Master Outdoor Unit Subcooling
Inlet Temperature Sensor Error
Master Outdoor Unit Subcooling Inlet Temperature
Sensor open or short
2 Slave Outdoor Unit Subcooling
Inlet Temperature Sensor Error
Slave Outdoor Unit Subcooling Inlet Temperature
Sensor open or short
1 Master Outdoor Unit Subcooling
Outlet Temperature Sensor Error
Master Outdoor Unit Subcooling Outlet Temperature
Sensor open or short
2
Slave Outdoor Unit Subcooling
Outlet Temperature Sensor Error
Slave Outdoor Unit Subcooling Outlet Temperature
Sensor open or short
1
Failure of operation mode conversion at Master Outdoor Unit
Pressure unbalance between outdoor units
2
Failure of operation mode conversion at Slave Outdoor Unit
Pressure unbalance between outdoor units
1
Master Outdoor Unit Constant
Speed Compressor Fault
Comp locking, Check Valve leakage, comp dielectric
break down at Master Outdoor Unit
2
Slave Outdoor Unit Constant
Speed Compressor Fault
Comp locking, Check Valve leakage, comp dielectric at
Slave Outdoor Unit
1 5 1
1 7 3
1 9 3
Cause of Error
Excessive increase of Master
1 Outdoor Unit Fan PCB Heat Sink
Temperature
Master Outdoor Unit Fan Inverter PCB Temperature is
Over 95°C
Excessive increase of Slave
2 Outdoor Unit Fan PCB Heat Sink
Temperature
Slave Outdoor Unit Fan Inverter PCB Temperature is
Over 95°C
Master Outdoor Unit Fan PCB
1 Heat Sink Temperature Sensor
Error
1 9 4
Slave Outdoor Unit Fan PCB
2 Heat Sink Temperature Sensor
Error
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
Master Outdoor Unit Fan PCB Heat Sink Temperature
Sensor open or short
Slave Outdoor Unit Fan PCB Heat Sink Temperature
Sensor open or short
- 76 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
01
Indoor unit air sensor error
02
Indoor unit pipe inlet sensor error
06
Indoor unit pipe outlet sensor error
Main Reasons
1. Indoor unit PCB wrong connection
Indoor unit sensor is 2. Indoor unit PCB failure
open/short
3. Sensor problem (main reason)
■ Error diagnosis and countermeasure flow chart
Is sensor properly
connected to PCB?
No
Connect properly to PCB
Yes
Is the resistance value
of sensor normal?*
No
Change the sensor
Yes
Change the PCB
** In case the value is more than 100kΩ (open) or less than 100Ω (short), Error occurs
Refer: Resistance value maybe change according to temperature of temp sensor,
It shows according to criteria of current temperature(±5% margin) ➔ Normal
Air temp sensor: 10°C(50°F) = 20.7 kΩ, 25°C(76°F) = 10 kΩ, 50°C(122°F) = 3.4 kΩ
Pipe temp sensor: 10°C(50°F) = 10 kΩ, 25°C(76°F) = 5 kΩ, 50°C(122°F) = 1.8 kΩ
CN-ROOM : Indoor air temp sensor
CN-PIPE2 : Pipe outlet temp sensor
CN-PIPE1 : Pipe inlet temp sensor
Measure the resistance of outlet pipe temp sensor.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 77 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
03
Error Type
No communication between cabled
remote controller & indoor unit
Error Point
Main Reasons
1. Remote controller fault
The remote controller
did not receive the sig- 2. Indoor unit PCB fault
nal from indoor unit
3. Connector fault, Wrong connection
during specific time
4. Communication cable problem
■ Error diagnosis and countermeasure flow chart
Does the error happens
again if the remote
controller is replaced?*
No
Replace cabled remote
controller
Yes
Does the error occurred
when the cable of remote
controller is replaced?
No
Check connection &
Communication cable **
Yes
Replace indoor unit PCB ***
* If there is no remote controller to replace : Use another unit’s remote controller doing well
** Check cable : Contact failure of connected portion or extension of cable are main cause
Check any surrounded noise ( check the distance with main power cable)
➔ make safe distance from the devices generate electromagnetic wave
*** After replacing indoor unit PCB, do Auto Addressing & input unit’s address if connected to central controller.
(All the indoor units connected should be turned on before Auto Addressing
CN-REMO : Remote controller connection
❇ The PCB can differ from model to model.
Check from the right source.
Checking communication cable connection status
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 78 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
04
Error Type
Error Point
Main Reasons
Float switch is open due to 1. Drain pump/float switch fault
rising of condensate water 2. Improper drain pipe location, cloglevel because of drain
ging of drain pipe
pump fault or drain pipe
3. Indoor unit PCB fault
clogging
Drain pump error
■ Error diagnosis and countermeasure flow chart
Is the drain pan filled
half with condensate
water? (half level of
float switch)*
Is Float switch short
On measuring its
resistance?
No
No
Replace float switch
Yes
Yes
Replace Indoor PCB or
reconnect the connector
Is drain pump working?
(Sound/drain noise/
contact etc.)
In indoor unit PCB
Does the terminal voltage
for drain pump has
220V output?**
No
Yes
No
Replace indoor unit PCB
Yes
Replace Drain Pump
Drain pump blocked by
foreign particles?
No
Check the drain head height
and slope***
Checking float
switch
Yes
(Low position➠ short
0 hm
o )
Remove it & clean the pump
* If the float goes up higher than a half of float
switch then the circuit is open & the unit is
stopped automatically.
float
(High position➠ Open)
Condensate water
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- 79 -
LGE Internal Use Only
Troubleshooting Guide
float
*** Indoor PCB drain pump connector
A:Point to check rotating
(Check input of 220V)
(Marked as CN-DPUMP)
Float switch connector
Float switch Housing (CN-FLOAT)
[***] Standard of drain pipe head height / slope
MAX 450
700mm(27.6 inch)
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- 80 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
05
Error Type
Error Point
Main Reasons
1. Auto addressing is not done
2. Communication cable is not connected
3. Short circuit of communication cable
No signal communication 4. Indoor unit communication circuit fault
between indoor & outdoor 5. Outdoor unit communication circuit fault
6. Not enough distance between power and comunits.
munication cable?
Indoor & Outdoor unit
communication error
■ Error diagnosis and countermeasure flow chart
Does all the IDUs show
same error code CH05?
No
Is total number of indoor
units connected displayed
after auto addressing?
No
Replace the PCB of indoor unit
displayed error
Re-connect after check the
communication cable of indoor
unit displayed error**
Yes
END
Is outdoor PCB LED
blinking?
Check the main power
supply at the ODU
terminal block?
No
No
Replace outdoor PCB after
checking
Replace TRANS after checking
Yes
Yes
No
Is main circuit breaker off?
Yes
Check the insulation of inverter
/ constant compressor and replace
if required
Check the capacity of main circuit
breaker and replace if required
Improper connection of power supply cable
Main power supply problem
Check if the
communication cable is
properly connected
to indoor / outdoor
terminal block?*
Yes
No
If all ok,
Turn on main circuit breaker
Re connect communication cable
Outdoor PCB fault
Replace after checking
Indoor PCB fault
Replace after checking
* (Note1) communication from IDU is normal if voltage
fluctuation(-9V ~ +9V) exists when checking DC voltage
of communication terminal between IDU and ODU
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
* If the DC voltage between communication terminal A, B
of indoor unit is fluctuate within (-9V~+9V) then
communication from outdoor unit is normal
- 81 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Indoor unit outlet pipe
temperature sensor
error
06
Error
No.
Error Type
Refer to CH02
Indoor unit outlet pipe
temperature sensor open
or short
Error Point
All Indoor units are not
running in same mode
07
Main Reasons
The Indoor units started
later are operated in different mode from earlier
one.
Main Reasons
1. Indoor units are in different mode
2. PCB fault
3. cabled remote controller fault
❊ Checking ch07 method
IDU doesn’t operate as Operation mode is
flickering at IDU wired remote controller and IDU
display window.
■ Error diagnosis and countermeasure flow chart
Is operation mode of
outdoor & Indoor units
same?
No
Does error code
disappear
after set operation
mode same?**
No
Replace Indoor PCB***
Yes
Yes
END
Adjust outdoor main PCB
dip switch setting *
* Check mode selection setting of wired remote controller.
** Outdoor main PCB dip switch no.5 (Cooling) or no.6 (heating) is in On, different mode operation error
may occur because the operation mode is fixed by dip switch setting.
♦ Dip switch Setting ♦
ON
1
1
ON
2
2
3
3
4
4
5
5
6
6
7
7
ON
1
1
1
8
2 3 4 5 6 7
9 10 11 12 13 14
ON
2
2
3
3
4
4
5
5
6
6
7
7
1
8
2 3 4 5 6 7
9 10 11 12 13 14
*** Dissolution method CH07 with remote controller
1) Error removal method : Turn off remote controller by pressing the On/Off button on the cabled remote controller.
The error code will be removed automatically after few seconds.
With cableless remote controller: Turn off indoor unit, and then turn on by changing the operation
mode. The error will disappear.
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LGE Internal Use Only
Troubleshooting Guide
**** After replacing the indoor unit PCB, make sure to be done to do Auto addressing and input the address of central control
***** If ODU Dry Contact function is set , different mode operation error may be occurred because the operation mode is fixed.
Error
No.
09
Error Type
Error Point
Main Reasons
1. Error developed in transmission between the
micro- processor and the EEPROM on the surface of the PCB.
2. ERROR due to the EEPROM damage
Indoor unit EEPROM
error
■ Error diagnosis and countermeasure flow chart
- Replace the indoor unit PCB, and then make sure to perform Auto addressing and input the address of central control
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
10
Error Type
Indoor unit BLDC fan motor
failure
Error Point
Main Reasons
Indoor BLDC fan motor
feedback signal is absent
(for 50 sec.)
1. Motor connector connection fault
2. Indoor PCB fault
3. Motor fault
■ Error diagnosis and countermeasure flow chart
Is connector
connection proper?
No
Connect properly
Yes
No
Is fan motor
normal?*
Replace indoor unit fan motor
Yes
Replace indoor unit PCB **
* It is normal when check hall sensor of indoor fan motor as shown below
Each termainl with the tester
Tester
1
4 5 6 7
Normal resistance(±10%)
+
-
1
4
∞
∞
5
4
6
4
hundreds kΩ
∞
hundreds kkΩ
∞
7
4
hundreds kΩ
hundreds kΩ
TH chassis
TD chassis
<Checking connection state of fan motor connector>
** Replace the indoor unit PCB, and then make sure to do Auto addressing and input the
address of central control
(Notice: The connection of motor connector to PCB should be done under no power
supplying to PCB)
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
11
Error Type
Error Point
Main Reasons
Indoor unit communication error Indoor unit doesn’t get sig- 1. Indoor 485 communication PCB fault
nal from ODU for 3 minutes 2. After PCB replacing, auto addressing
continuously
was not done
■ Error diagnosis and countermeasure flow chart
After ODU main PCB
reset, error code
disappears?
No
After Auto addressing,
error code disappears?
Yes
No
Replace indoor unit 485
communication PCB
Yes
END
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 85 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
21*
Master Inverter PCB Assy IPM
211
Fault occur
Slave
212
Error Point
Main Reasons
1.Over current detection at Inverter compressor(U,V,W)
2.Compressor damaged (insulation damaged/Motor damaged)
IPM self protection circuit 3.IPM overheating
activation
(Heat sink fan damaged/Heat sink fan con(Overcurrent/IPM overheat- nector disconnected/Heat sink disassembled)
ing/Vcc low voltage)
4.Inverter compressor terminal disconnected
or loose
5.Inverter PCB assembly damaged
6.ODU input current low
■ Error diagnosis and countermeasure flow chart
Are the resistance
Between each phase and
insulation resistance of Inverter
compressor normal?
No
1. Check resistance between each terminal of compressor
(refer to page 63)
2. Check insulation resistance between compressor
terminal and pipe (over 50MΩ )
→ Replace compressor if abnormality found
Yes
Is compressor
Wire connection
condition normal?
No
Yes
Is inverter heat sink
cooling fan normal?
No
Yes
Is inverter PCB assembly
normal?
No
1.Check inverter PCB assembly U,V,W connector
connection condition
2. Check wire disconnection and wiring
3. Check compressor terminal connection condition
(bad contact)
→ Reassemble if abnormality found
1. Check heat sink cooling fan connector connection
condition
2. Check heat sink cooling fan wire disconnection and
wiring
→ Reassemble and change wire if abnormality found
3. Check heat sink cooling fan output voltage during
compressor operation
(Check main PCB assembly CN15 fan connector output
voltage : AC 220V)
→ Replace main PCB if output voltage isn't AC 220V
4. Check heat sink cooling fan motor wire disconnection
(measure resistance between each ends of motor
connector)
(measured value should be within 1.7kΩ ±10%)
→ Replace fan motor if motor wire is disconnected.
Check inverter PCB assembly IPM normality.
→ Replace inverter PCB assembly if abnormality found.
Yes
Recheck power and installation condition
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- 86 -
LGE Internal Use Only
Troubleshooting Guide
* Measuring resistance between
each terminal of compressor
* Heat sink cooling fan connector
* Heat sink cooling fan
* Compressor wire connector connection
point
* Measuring insulation resistance between Comp output terminal
and chassis
* IPM joining point
Check joining conditon
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
22*
Inverter PCB Assembly
Master AC Input Current Over Error input 3 phase power
221
current is over limited
value(22A)
Slave
222
Main Reasons
1. Overload operation (Pipe
clogging/Covering/EEV defect/Ref.
overcharge)
2. Compressor damage(Insulation
damage/Motor damage)
3. Input voltage low
4. Power Line Misconnection
5. Inverter PCB Assembly damage
(Input current sensing part)
■ Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal?
No
Yes
Are the resistance
Between each phase and
insulation resistance of Inverter
compressor normal?
No
1. Check Pipe clogging/distortion
2. Check Covering (Indoor/Outdoor Unit)
3. Check EEV connector assemble condition/normal
operation
4. Check refrigerant pressure
→ Reassemble or manage if abnormality found
1. Check resistance between each terminal of compressor
(0.34~0.35Ω ±7%)
2. Check insulation resistance between compressor
terminal and pipe (over 50MΩ )
→ Replace compressor if abnormality found
Yes
Is compressor
Wire connection
condition normal?
No
1. Check inverter PCB assembly U,V,W connector
connection condition
2. Check wire disconnection and wiring
3. Check compressor terminal connection condition
(bad contact)
→ Reassemble if abnormality found
Yes
Is inverter PCB assembly
power connection normal?
No
Check connection between inverter PCB assembly and
bridge diode(misconnection, disconnection)
→ wiring again if abnormality found
No
Check
R~S/S~T/T~R phase voltage : 460 ±10% (3Ø 460V)
208/230 ±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is
abnormal
No
Check inverter PCB assembly IPM normality
→ Replace inverter PCB assembly
Yes
Is input voltage normal?
Yes
Is inverter PCB assembly
normal?
Yes
Recheck power and installation condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Troubleshooting Guide
* Measuring resistance between
each terminal of compressor
* Inverter PCB & bridge diode wiring(3Ø 460V)
* Compressor wire connector
connection
Check joining condition
* Measuring input voltage
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
23*
Master Inverter Compressor DC
Link Low Voltage
231
DC Voltage isn't charged
after starting relay on
Slave
232
Main Reasons
1. DC Link terminal misconnection/terminal
contact fault
2. Starting relay damage
3. Condenser damage
4. Inverter PCB assembly damage
(DC Link voltage sensing part)
5. Input voltage low
■ Error Diagnosis and Countermeasure Flow Chart
Is input voltage normal?
No
Check
R~S/S~T/T~R Phase voltage : 460V±10% (3Ø 460V)
208/230V±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is
abnormal
Yes
Is inverter PCB assembly
power connection normal?
No
Check connection between inverter PCB assembly and
bridge diode(misconnection, disconnection)
→ wiring again if abnormality found
Yes
Is inverter PCB assembly normal?
No
Check inverter PCB assembly IPM normality
→ Replace inverter PCB assembly
Yes
Recheck power and installation condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Troubleshooting Guide
* Inverter PCB & bridge diode wiring(3Ø 460V)
* Measuring input voltage
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
25*
Master Input Voltage high/low
251
Input voltage is over limited 1. Input voltage abnormal (R~S/S~T/T~R)
value of the product (173V 2. Outdoor unit inverter PCB assembly damor less, 289V or more)
age (input voltage sensing part)
Slave
252
■ Error Diagnosis and Countermeasure Flow Chart
No
Is input voltage normal?
Check
R~S/S~T/T~R Phase voltage :460V±10% (3Ø 460V)
208/230V±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is
abnormal
Yes
Is inverter PCB assembly normal?
No
Replace inverter PCB assembly
Yes
Recheck power and installation condition
* Measuring input voltage
* Inverter PCB assembly power wiring
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
1. Overload operation
(Pipe clogging/Covering/EEV defect/Ref.
overcharge)
Master Inverter compressor starting Starting failure because of 2. Compressor damage
failure Error
compressor abnormality
261
(Insulation damage/Motor damage)
Slave
3. Compressor wiring fault
262
4. ODU inverter PCB damage (CT)
26*
■ Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal?
No
1. Check Pipe clogging/distortion
2. Check Covering (Indoor/Outdoor Unit)
3. Check EEV connector assemble condition/normal
operation
4. Check refrigerant pressure
→ Reassemble or manage if abnormality found
Yes
Are the resistance
Between each phase and
insulation resistance of Inverter
compressor normal?
No
1. Check resistance between each terminal of compressor
(refer to page 63)
2. Check insulation resistance between compressor
terminal and pipe (over 50MΩ )
→ Replace compressor if abnormality found
Yes
Is compressor
Wire connection
condition normal?
No
1. Check inverter PCB assembly U,V,W connector
connection condition
2. Check wire disconnection and wiring
3. Check compressor terminal connection condition
(bad contact)
→ Reassemble if abnormality found
No
Check inverter PCB assembly IPM normality
→ Replace inverter PCB assembly
Yes
Is inverter PCB assembly normal?
Yes
Recheck power and installation condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Troubleshooting Guide
* Measuring resistance
between each terminal of
compressor
* Compressor wire connection
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
27*
Master Inverter compressor starting Overcurrent on the IPM
failure Error
271
Slave
272
Main Reasons
1.Overcurrent on the PFC IPM (R,S,T)
2.IPM Overheat (Cooling Fan failure/Cooling
Fan connector disconnecte /Heat sink disassembled)
3.Reactor connector disconnected or loose
4.Inveter PCB Assy failure
5.Low power input voltage to the outdoor unit
■ Error Diagnosis and Countermeasure Flow Chart
Is the Reactor Wire
connection
Normal?
1.Check Inverter PCB Ass'y R,S,Tconnection
2.Check the wiring status
No
Yes
1.Check the cooling fan connection
2.Check the cooling fan wiring status
3.Check the cooling fan output voltage. (Main PCB Assy
CN15 FAN connctor voltage : AC 220V)
→ Change the Main PCB, when no output
voltage.
4.Check the cooling fan motor open(measured value should
be within 1.7kΩ ±10%)
→ Replace fan motor if motor wire is disconnected.
No
Is the Inverter Cooling
Fan normal?
Yes
1.Check the Inverter PCB Assy IPM
→ Replace inverter PCB assembly if abnormality found.
No
Is the Inverter PCB Assy
normal?
Yes
Recheck Power and Installation
Cooling Fan connector
Cooling Fan
Reactor Wire connector
IPM joing point
Check joining condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
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- 95 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
28*
Master Inverter DC link high
voltage error
281
1. Input voltage abnormal (R,S,T)
2. ODU inverter PCB damage
(DC Link voltage sensing part)
Inv PCB DC link voltage
supplied over 780V
Slave
282
■ Error Diagnosis and Countermeasure Flow Chart
No
Is input voltage normal?
Check
R~S/S~T/T~R Phase voltage : 460V+10% (3Ø 460V)
208/230V±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is
abnormal
Yes
No
Is inverter PCB assembly normal?
Replace inverter PCB assembly
Yes
Recheck power and installation condition
* Measuring input voltage
* Noise filter wiring
T
S
R
Noise filter output(lower part)
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T
S
R
Noise filter input (upper part)
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
29*
Master Inverter compressor over
current
291
Inverter compressor input
current is over 30A
Slave
292
Main Reasons
1. Overload operation
(Pipe clogging/Covering/EEV defect/Ref.
overcharge)
2. Compressor damage(Insulation
damage/Motor damage)
3. Input voltage low
4. ODU inverter PCB assembly damage
■ Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal?
No
1. Check Pipe clogging/distortion
2. Check Covering (Indoor/Outdoor Unit)
3. Check EEV connector assemble condition/normal
operation
4. Check refrigerant pressure
→ Reassemble or manage if abnormality found
Yes
Are the resistance
Between each phase and
insulation resistance of Inverter
compressor normal?
No
1.Check resistance between each terminal of compressor
(refer to page 63)
2.Check insulation resistance between compressor terminal
and pipe (over 50MΩ )
→ Replace compressor if abnormality found
Yes
Is compressor
Wire connection
condition normal?
No
Yes
Is input voltage normal?
No
1. Check inverter PCB assembly U,V,W connector
connection condition
2. Check wire disconnection and wiring
3. Check compressor terminal connection condition
(bad contact)
→ Reassemble if abnormality found
Check
R~S/S~T/T~R phase voltage : 460 ±10% (3Ø 460V)
208/230 ±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is
abnorma
Yes
Is inverter PCB assembly normal?
No
Check inverter PCB assembly IPM normality
→ Replace inverter PCB assembly
Yes
Recheck power and installation condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Troubleshooting Guide
* Measuring resistance between each
terminal of compressor
* Compressor wire connection
* Measuring input voltage
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
Compressor is off
32*
Over-increase discharge
because of over-increase
Master 321 temperature of inverter comdischarge temperature of
Slave 322 pressor at main outdoor unit
inverter compressor
1. Temperature sensor defect of inverter compressor discharge pipe
2. Refrigerant shortage / leak
3. EEV defect
4. Liquid injection valve defect
Over-increase discharge
33*
temperature of constant
Master 331 compressor at main conSlave 332 stant outdoor and sub constant outdoor unit
1. Temperature sensor defect of constant
compressor discharge pipe?
2. Refrigerant shortage/leak
3. EEV defect
4. Liquid injection valve defect
Compressor is off
because of over-increase
discharge temperature of
constant compressor at
main and sub outdoor unit
■ Error diagnosis and countermeasure flow chart
Is the amount of
refrigerant normal?
[refer refrigerant part]
No
Is there pipe crack
or trace of leakage?
No
Change the amount of
refrigerant
(Charge additive amount)
Yes
Yes
Weld / reconnect the cracked
portion and recharge refrigerant
Is the resistance of discharge
temperature sensor normal?*
No
* Resistance value of discharge temperature sensor
10°C(50°F) = 362kΩ, 25°C(76°F)= 200kΩ, 50°C(122°F)= 82kΩ,
100°C(212°C)= 18.5kΩ
Yes
Is EEV in
outdoor unit normal
at heating operation?
[refer electric
component part]
Replace discharge
temperature sensor
No
Replace outdoor unit EEV
Yes
Does liquid injection
corresponded
operate normally?
No
Check liquid injection
corresponded
No
Check another components
and operation conditions
/ Take measures
Yes
Is there pipe
(strainer etc.) clogging?
Yes
Replace strainer
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
34*
Master
341
Slave
342
Over-increase of discharge pressure of
compressor
Main Reasons
1. Defect of high pressure sensor
2. Defect of indoor or outdoor unit fan
3. Deformation because of damage of refrigerant pipe
Error happens
because of 3 times
4. Over-charged refrigerant
successive compres- 5. Defective indoor / outdoor unit EEV
sor off due to over6. When blocked
increase of high pres- Outdoor unit is blocked during cooling
sure by high pressure
- Indoor unit filter is blocked during heating
sensor
7. SVC valve is clogged
8. PCB defect of outdoor unit
10. Indoor unit pipe temperature sensor defect
■ Error diagnosis and countermeasure flow chart
Is service valve opened ?
No
Open service valve
Yes
Are transmission
cable / pipe connection
normal?
No
Check and repair transmission
cable / pipe connection
Yes
Is refrigerant
amount normal?
[refer refrigerant part]
No
Adjust refrigerant amount
Yes
Is fan normal?
(Indoor fan during heating
Outdoor fan during cooling)
No
Replace related parts
(Refer to Error 105~107)
No
Clean indoor filter (heating)
/outdoor heat exchanger (cooling)?
Yes
Is filter blocked
(Heating:indoor,
Cooling:outdoor
heat exchanger)?
Yes
Is value of high pressure
sensor same as Manifold
value(Is it high actually)?
No
Replace sensor of high pressure
Yes
Check indoor unit LEV
Check indoor unit PCB
Check in/outdoor installation
condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
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LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
35*
Master
351
Slave
352
Excessive drop of
discharge pressure
of compressor
Error Point
Main Reasons
Error happens
because of 3 times
successive compressor off due to excessive drop of low pressure by the low pressure sensor
1. Defective low pressure sensor
2. Defective outdoor/indoor unit fan
3. Refrigerant shortage/leakage
4. Deformation because of damage of refrigerant pipe
5. Defective indoor / outdoor unit EEV
6. Covering / clogging
(outdoor unit covering during the cooling mode/
indoor unit filter clogging during heating mode)
7. SVC valve clogging
8. Defective outdoor unit PCB
9. Defective indoor unit pipe sensor
■ Error diagnosis and countermeasure flow chart
Is service valve
opened?
Open service valve
Yes
Are transmission cable/
piping normal?
No
check transmission/
piping correction.
Yes
Is amount of refrigerant
normal?
[refer refrigerant part]
No
Is there pipe crack or trace
of refrigerant leakage?
Yes
No
Adjust the amount of
refrigerant (Additive charge)
Yes
Weld / reconnect the cracked
portion and recharge refrigerant
Is fan normal?
(in heating outdoor fan,
in cooling indoor fan)
No
Check and replace related parts
(error 105~108 reference)
Yes
Is strainer Ok?*
No
Replace the strainer
Yes
Are the values of manifold
No
and low pressure sensor same?
( Is the low pressure value
actually low?)
Replace the pressure sensor
Yes
Check indoor / outdoor unit LEV
Check Indoor unit PCB
Check indoor / outdoor unit
installation conditions
* If the temperature difference between inlet and outlet of strainer
is so large that frost or ice formation can be seen or confirmed
then clogging of strainer should be checked
(Notice: it is not full ice forming of strainer, in case that there is
not at inlet portion but at outlet portion)
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Error
No.
Error Type
Error Point
Main Reasons
40*
Master Inverter compressor CT
sensor error
401
1. Input voltage abnormal (R~S/S~T/T~R)
Micom input voltage isn't
within 2.5V ±0.3V at initial 2. ODU inverter PCB damage
state of power supply
(CT sensing part)
Slave
402
■ Error Diagnosis and Countermeasure Flow Chart
Is input voltage normal?
No
Check
R~S/S~T/T~R Phase voltage : 460V±10% (3Ø 460V)
208/230V±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is
abnormal
Yes
Is inverter PCB assembly normal?
No
Replace inverter PCB assembly
Yes
Recheck power and installation condition
* Measuring input voltage
* LGMV Part
* Inverter PCB assembly
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Error No.
Error Type
41*
(Inverter)
Master 411
Slave 412
47*
(Constant)
Master 471
Slave 472
Error Point
Main Reasons
1. Defective connection of the
compressor discharge pipe temperature sensor
Sensor measurement
2.
Defective
discharge pipe comvalve is abnormal
pressor sensor of the compres(Open/Short)
sor (open/short)
3. Defective outdoor PCB
Compressor discharge pipe temperature sensor
error
■ Error diagnosis and countermeasure flow chart
Sensor connection to PCB
is normal?
No
Insert sensor connector to PCB properly
Yes
Is the resistance of
sensor normal?*
No
Replace sensor
Yes
Is sensor resistance
value same as temperature
value of LGMV?
No
Replace corresponding outdoor PCB
Yes
Replace corresponding sensor
* Error is generated if the resistance is more than 5MΩ(open) and less than 2kΩ (short)
Note: Standard values of resistance of sensors at different temperatures (±5% variation)
10°C(50°F) = 362kΩ, 25°C(76°F)= 200kΩ, 50°C(122°F)= 82kΩ, 100°C(212°C)= 18.5kΩ
Check the resistance
inverter compressor
discharge temperature
sensor
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 103 -
Check the resistance
of constant compressor
discharge temperature
sensor
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
42*
Master 421 Sensor error of low
Slave 422 pressure
Abnormal value of
sensor
(Open/Short)
1. Bad connection of low pressure connector
2. Defect of low pressure connector (Open/Short)
3. Defect of outdoor PCB
43*
Sensor error of high
Master 431
pressure
Slave 432
Abnormal value of
sensor
(Open/Short)
1. Bad connection of high pressure connector
2. Defect of high pressure connector (Open/Short)
3. Defect of outdoor PCB
■ Error diagnosis and countermeasure flow chart
Is sensor connected
to PCB correctly?
No
Connect sensor to PCB correctly
Yes
After replacement of
outdoor unit main PCB
is the system normal?
No
Replace corresponding
pressure sensor
Yes
END
Low pressure sensor
High pressure sensor
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 104 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
Error Point
Main Reasons
44*
Master 441
Slave 442
1. Bad connection of air temperature connector
Sensor error of
Abnormal value of
outdoor air temper2. Defect of air temperature connector(Open/Short)
sensor (Open/Short)
ature
3. Defect of outdoor PCB
45*
Master 451
Slave 452
48*
Master 481
Slave 482
Piping temperature
sensor error of heat
exchanger in
Abnormal value of
master & slave out- sensor
door unit heat
(Open/Short)
exchanger (A,B)
46*
Master 461
Slave 462
Compressor suction temperature
sensor error
1. Bad connection of air temperature connector
2. Defect of air temperature connector(Open/Short)
3. Defect of outdoor PCB
1. Bad connection of air temperature connector
Abnormal value of
2. Defect of air temperature connector(Open/Short)
sensor (Open/Short)
3. Defect of outdoor PCB
■ Error diagnosis and countermeasure flow chart
No
Is sensor connected
to PCB correctly??
Connect sensor to PCB correctly
Yes
No
Is sensor value correct?*
Yes
Replace sensor
* If value is 100kΩ ↑(open) or 100 Ω↓(short), error occurs
Replace corresponding
outdoor unit PCB
NB: Resistance value of temperature sensor change according to
temperature
It is normal if value shown as below (±5% error)
Sensor of air temperature: 10°C(50°F) = 20.7kΩ, 25°C(76°F) = 100kΩ, 50°C(122°F) = 3.4kΩ
Sensor of piping temperature: 10°C(50°F) = 10kΩ, 25°C(76°F) = 5Ω, 50°C(122°F)=1.8kΩ
Error No.
Error Type
47*
Master 471
Slave 472
Discharge piping
temperature sensor error of constant compressor
48*
Master 481
Slave 482
Piping temperature
sensor error of heat
Refer to CH45
Exchanger in master Abnormal value of
& slave outdoor unit sensor (Open/Short)
heat exchanger (B)
Error Point
Main Reasons
Abnormal value of
Refer to CH41
sensor (Open/Short)
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 105 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
50*
Master ODU 3phase power omission error
501
Omitting one or more of
R,S,T input power
1. Input Voltage abnormal (R,S,T)
2. Check power Line connection condition
3. Main PCB damage
Slave
502
■ Error Diagnosis and Countermeasure Flow Chart
Check
R~S/S~T/T~R Phase voltage : 460V±10% (3Ø 460V)
208/230V±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is
abnormal
No
Is input voltage normal?
Yes
No
Is main PCB assembly normal?
Replace Main PCB assembly
Yes
Recheck power and installation condition
* Measuring input voltage
* Noise filter wiring
T
S
R
T
S
R
* Main PCB power connection
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 106 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
51
Error Type
Over-Capacity
(Sum of indoor unit capacity is more than outdoor
capacity)
Error Point
Main Reasons
1. 130% more than outdoor unit rated capacity
2. Wrong connection of communication
Sum of indoor unit capacicable/piping
ty exceed outdoor unit
3. Control error of slave outdoor unit Dip switch
capacity specification
4. Power supply defect of slave unit PCB
5. Defect of outdoor unit PCB
■ Error diagnosis and countermeasure flow chart
Is capacity sum of
indoor units less than
130% of outdoor unit
capacity at LGMV?
No
Are quantity and capacity
of indoor units installed
same as the data of LGMV?
No
Check communication cables
between indoor and outdoor
units
No
Supply main
power again
Yes
Yes
Check following
dip S/W setting is on
Slave1: No.5,7
Slave2: No. 6,7
Slave3: No. 5,6,7
Adjust the capacity of indoor
and outdoor unit
No
Adjust corresponding DIP switch
Yes
Is power of Slave PCB
On? (Check LED blinking)
No
Is main power really supplied?
(Terminal Block T-N)
Yes
Yes
Check and replace PCB,
Line Fuse, Transformer
Is communication
cables between outdoor units
connected correctly?*
No
Re-connect
Yes
Is error code released
No
in order(Slave2➠Slave1➠Main)
after power reset?
Replace Main or Slave PCB
Yes
End
* In order to check communication
cables between outdoor units,
check in order as below
: PCB connectors ➠
terminal block ➠
communication cables
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 107 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Communication error
52*
Master 521 between
Slave 522 (Inverter PCB ➔ Main PCB)
Error Point
Main Reasons
Main controller of Master
unit of Master unit can’t
receive signal from
inverter controller
1. Power cable or communication cable is not
connected
2. Defect of outdoor Main fuse/Noise Filter
3. Defect of outdoor Main / inverter PCB
■ Error diagnosis and countermeasure flow chart
Is communication
LED (Yellow) of inverter
compressor
PCB on?
No
Is noise filter or fuse
normal?
Yes
No
Replace noise filter or fuse
Yes
Replace inverter compressor PCB
Is communication cable
connected correctly?
No
Re-connect communication cable
Yes
No
Is MAIN PCB normal?
Replace MAIN PCB
Yes
Replace inverter compressor PCB
* The method of checking MAIN PCB and inverter compressor PCB (If normal, communication LED blinks)
Communication connector & LED in MAIN PCB
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
Communication connector & LED in inverter compressor PCB
- 108 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
53
Error Type
Communication error
(Indoor unit ➔ Main PCB)
Error Point
Main Reasons
1. Communication cables are not connected
In case Main PCB can’t
receive signal from indoor 2. Communication cables are short / open
3. Defect of outdoor Main / indoor PCB
unit
■ Error diagnosis and countermeasure flow chart
Are quantity of indoor
units installed same as
the data of LGMV?
No
Is indoor unit
quantity correct after
Auto Addressing?
No
Yes
Yes
End
Is power supplied
to indoor units?
No
Supply power
Yes
Replace indoor unit PCB or
communication PCB
after check defected indoor
In case of CH53, almost happened with CH05, the indoor units not operated actually are normal so check with
same method of CH05. and additionally check as shown as below and above flow chart
• Although the quantity of indoor units installed is same as LGMV data there may be a few indoor units with
which the number of communication is not increased with LGMV
• Although the quantity of indoor units installed is not same as LGMV data, and if communication of the indoor
unit displayed at LGMV is done well then the indoor unit suspected to have some problem (and is not appear at
LGMV) may have following problems
➀ wrong connection of communication cable or power cable
➁ fault of power / PCB / communication cable
➂ duplication of indoor unit number
• If communication is not doing well wholly then the Auto Addressing is not done
• The case that CH53 appear at indoor unit also Auto Addressing is not done so indoor unit address may be
duplicated
* After replacement of indoor unit PCB, Auto Addressing should be done, if central controller is installed then the
central control address also should be input.
In case that only communication PCB is replaced above process is not needed
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 109 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Wrong connection of 3Ø
54*
power supply cable
Master 541
(Reverse direction / missing
Slave 542
a phase)
Wrong connection of 3Ø
power supply cable
(Reverse direction / missing a phase)
Main Reasons
1. Main PCB defect
2. No power of R,S,T supplied
3. Wring connection of R,S,T cables
4. Main Pcb Fuse failure
■ Error diagnosis and countermeasure flow chart
Is connection and phase
order of power cables to main /
slave outdoor unit correct?*
No
Connect correctly
Yes
Is connection and phase
order of power distribution
panel correct?**
No
Connect power cables in
distribution panel correctly
Yes
Is CH 54 occurred again
after reset MAIN
circuit breaker?
No
End
Yes
No
Is main PCB fuse normal?
Replace Fuse
Yes
Replace main PCB
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 110 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
60*
1. EEPROM contact defect/wrong insertion
EEPROM Access error and
2. Different EEPROM Version
Check SUM error
3. ODU inverter PCB assembly damage
Master Inverter PCB EEPROM
error
601
Slave
602
■ Error Diagnosis and Countermeasure Flow Chart
No
Is EEPROM insertion normal?
1.Check EEPROM insert direction/connection condition
2.Check EEPROM Check SUM
→ Replace if abnormality found
Yes
No
Is inverter PCB assembly normal?
Replace inverter PCB assembly
Yes
Recheck power and installation condition
* Inverter EEPROM inserting point(3Ø 460V)
* Inverter EEPROM inserting point(3Ø 208/230V)
EEPROM enlarged picture
EEPROM enlarged picture
* Right inserting direction of inverter EEPROM
* Right inserting direction of inverter EEPROM
❊ Note : Replace after power off
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
❊ Note : Replace after power off
- 111 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
67*
Master
Fan Lock Error
671
Slave
672
Error Point
Main Reasons
1. Fan motor defect / assembly condition
abnormal
Fan RPM is 10RPM or less
2.
Wrong
connection of fan motor connector
for 5 sec. when ODU fan
(Hall
sensor,
U,V,W output)
starts or 40 RPM or less
after fan starting.
3. Reversing rotation after RPM target apply
4. Fan PCB assembly defect
■ Error Diagnosis and Countermeasure Flow Chart
Is ODU Fan Motor Assemble
condition normal?
No
Check ODU Fan Motor assemble condition and fan locking
→ Reassemble or replace if abnormality found
Yes
Is ODU Fan Motor normal?
No
1. Check resistance between each phase(U,V,W) of ODU
fan motor terminal (16.8Ω ±5% at 75°C(167°F))
2. Check insulation resistance between ODU fan motor
terminal(U,V,W)
→ Replace fan motor if abnormality found
Yes
Is wire connection of
ODU Fan Motor wire normal?
No
Check wiring between OUD fan motor and fan PCB
( Check if Hall Senor and Motor output terminal color is
matched)
→ Reassemble if abnormality found
Yes
Is Fan PCB assembly normal?
No
Replace Fan PCB assembly
Yes
Recheck power and installation condition
* Fan Motor resistance measuring * Hall Sensor connector
between each phase
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 112 -
* Fan Motor Wire connection
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
70*
Constant Speed
Master
Compressor CT Sensor
701
Error
Slave
702
Constant Speed
Compressor CT Sensor
Open/short
1. Constant Speed Compressor CT Sensor
defect
■ Error Diagnosis and Countermeasure Flow Chart
Is constant speed compressor
CT Sensor connection condition
normal?
No
Check constant speed compressor
CT Sensor wiring condition and locking
Yes
Recheck power and installation condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 113 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
71*
Master Inverter input current CT
sensor error
711
Slave
712
1. Input voltage abnormal
Micom input voltage isn't
within 2.5V ±0.3V at initial 2. ODU inverter PCB damage
state of power supply
(CT sensing part)
■ Error Diagnosis and Countermeasure Flow Chart
Is input voltage normal?
No
Check
R~S/S~T/T~R Phase voltage : 460V±10% (3Ø 460V)
208/230V±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is
abnormal
Yes
Is inverter PCB assembly normal?
No
Replace inverter PCB assembly
Yes
Recheck power and installation condition
* Measuring input voltage
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 114 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
73*
Master 731
Slave 732
Error Type
AC input instant over current error (Matter of software)
Error Point
Inverter PCB input 3 phase power
current is over 50A(peak) for 2ms
Main Reasons
1.Overload operation (Pipe clogging/Covering/EEV defect/Ref.
overcharge)
2.Compressor damage(Insulation
damage/Motor damage)
3.Input voltage abnormal(R,S,T)
4.Power line assemble condition
abnormal
5.Inverter PCB assembly
damage(input current sensing part)
■ Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal?
No
Yes
No
Is input voltage normal?
1.Check Pipe clogging/distortion
2.Check Covering (Indoor/Outdoor Unit)
3.Check EEV connector assemble condition/normal operation
4.Check refrigerant pressure
→ Reassemble or manage if abnormality found
Check
R~S/S~T/T~R Phase voltage : 460V±10% (3Ø 460V)
208/230V±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is abnormal
Yes
Is AC input Wire connection
condition normal?
No
1.Check R,S,T connection condition
2.Check wire disconnection and wiring
→ Reassemble if abnormality found
No
1.Check inverter PCB assembly U,V,W connector connection condition
2.Check wire disconnection and wiring
3.Check compressor terminal connection condition(bad contact)
→ Reassemble if abnormality found
Yes
Is compressor
Wire connection
condition normal?
Yes
Is inverter PCB assembly
normal?
No
Check inverter PCB assembly IPM normality
→ Replace inverter PCB assembly
Yes
Recheck power and
installation condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 115 -
LGE Internal Use Only
Troubleshooting Guide
Measuring input voltage
Compressor Wire Connection
Noise filter wiring
T
S
R
Noise filter input (upper part)
T
S
R
Noise filter output(lower part)
Inverter PCB assembly/Wiring power to inverter PCB on Noise filter
Inverter PCB assembly power
connection
Noise filter power connection
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 116 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
74*
Master 741
Slave 742
Error Type
Error Point
During operation(compressor frequency is over 50Hz), difference
3 Phase Power Unbalance
between R & T phase is 5A for 10
seconds.
Main Reasons
1. CT sensor defect
2. Capacity over of AVR
■ Error Diagnosis and Countermeasure Flow Chart
No
Is inverter PCB assembly
power wiring normal?
Check abnormal wiring between Inverter PCB assembly & bridge diode
(misconnection,disconnection)
→ Rewiring if abnormal wiring found
Yes
No
Is input voltage normal?
Check
R~S/S~T/T~R Phase voltage : 460V±10% (3Ø 460V)
208/230V±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is abnormal
Yes
Does indoor unit power
bridge R,S,T phase equally?
No
Bridge R-N,S-N,T-N voltage equally (3Ø 460V)
Yes
No
Is inverter PCB
assembly normal?
Replace inverter PCB assembly
Yes
Recheck power and
installing condition
Measuring input voltage
Inverter PCB & Bridge Diode wiring
Checking joining condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 117 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
75*
Master 751
Slave 752
Fan CT sensor error
Error Point
Main Reasons
Offset of micom which senses the 1.Input voltage is abnormal(not 15V)
fan motor phase current is not 2.5V 2.Fan PCB assembly defect
■ Error Diagnosis and Countermeasure Flow Chart
Checking 15V
No
Check 15V wire connection
→ Reassemble or manage if abnormality found
Is input voltage normal?
Yes
No
Is Fan PCB assembly normal?
Replace Fan PCB assembly
Yes
Recheck power and
installation condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 118 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
Error Point
Main Reasons
76*
Master 761
Slave 762
Fan DC Link High Voltage
Error
Fan PCB DC link voltage supplied
over 780V\
1.Input power abnormal
2.Fan PCB assembly defect
■ Error Diagnosis and Countermeasure Flow Chart
Check
R~S/S~T/T~R phase voltage : 460 ±10% (3Ø 460V)
208/230 ±10% (3Ø 208/230V)
→ Check connection condition and wiring if power is abnormal
No
Is input voltage normal?
Yes
No
Is Fan PCB assembly normal?
Replace Fan PCB assembly
Yes
Recheck power and
installation condition
Measuring input voltage
Noise filter wiring
T
S
Noise filter output(lower part)
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
T
R
S
R
Noise filter input (upper part)
- 119 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
77*
Master 771
Slave 772
Error Type
Fan Over Current Error
Error Point
Main Reasons
Output current is over 5A for 40ms
1.Overload operation
2.Fan Motor defect
3.Fan PCB assembly defect
■ Error Diagnosis and Countermeasure Flow Chart
Is installation
condition normal?
No
Check ODU fan motor assemble condition and locking
→ Reassemble or replace if abnormality found
Yes
Are the resistance
Between each phase and insulation
resistance of motor output
terminal normal?
No
Yes
Is motor wire connection
condition normal?
No
1.Check resistance between each motor output terminal
(refer to page 63)
2. Check insulation resistance between ODU fan motor terminal(U,V,W) and pipe
(over 100MΩ )
→ Replace fan motor if abnormality found
1.Check if color of motor output terminal(U,V,W) connector matched with PCB’s
2.Check wire disconnection and wiring
→ Reassemble or replace if abnormality found
No
Is Fan PCB assembly normal?
1. Check fan PCB assembly IPM normal
→ Replace Fan PCB assembly
Yes
Recheck power and
installation condition
Measuring fan motor phase
resistance
Hall Sensor connection
Fan motor wire connection
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 120 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
78*
Master 781
Slave 782
Error Type
Error Point
Fan Motor Hall Sensor
Error
Fan Motor Hall Sensor short/open
Main Reasons
1.Fan motor hall sensor defect
2.ODU fan motor hall sensor disconnection
3.ODU Fan Motor Hall Sensor wrong
insertion
4.Fan PCB assembly defect
■ Error Diagnosis and Countermeasure Flow Chart
Is fan motor assemble
condition normal?
No
Check ODU fan motor assemble condition and locking
→ Reassemble or replace if abnormality found
Yes
No
Is wiring between fan motor
and PCB normal?
Recheck f an motor hall sensor connection
→ Reassemble if abnormality found
Yes
No
Is connector color between
Hall Sensor PCB matched?
Check if connector color matched between fan motor hall sensor and PCB
→ Reassemble if abnormality found
Yes
No
Is fan PCB assembly normal?
Replace Fan PCB assembly
Yes
Recheck power and
installation condition
Fan motor wire connection
Hall sensor connection
❈ Note : If LED is blinking oppositely after connecting Hall Sensor connector,
U.V.W output terminal oppositely, replace the motor.
If LED is not blinking oppositely,replace fan PCB assembly.
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 121 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
Error Point
79*
Fan Starting Failure
Master 791
Error
Slave 792
Fan Motor initial starting failure
Main Reasons
1.Fan motor defect/ assemble condition abnormal
2.Fan motor connector misconnection(Hall sensor, U,V,W ouput)
3.Fan PCB defect
■ Error Diagnosis and Countermeasure Flow Chart
Is fan motor assemble
condition normal?
No
Check ODU fan motor assemble condition and locking
→ Reassemble or replace if abnormality found
Yes
Are the resistance
Between each phase and insulation
resistance of motor output
terminal normal?
No
No
Is fan motor connection
condition normal?
No
Is fan PCB assembly normal?
1. Check resistance between each motor output terminal
(16.8 Ω ±5% at 75°C)
2. Check insulation resistance between ODU fan motor terminal(U,V,W) and pipe
(over 100MΩ)
→ Replace fan motor if abnormality found
1. Check if color of motor output terminal(U,V,W) connector matched with PCB’s
2. Check wire disconnection and wiring
→ Reassemble or replace if abnormality found
Check fan PCB assembly IPM normal
→ Replace Fan PCB assembly
Yes
Recheck power and
installation condition
Measuring fan motor phase
resistance
Measuring insulation resistance
between fan terminal & chassis
Fan motor wire connection
Hall Sensor connection
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Only for training and service purposes
- 122 -
Fan wire wiring
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
Error Point
86*
Main PCB EEPROM
Master 861
Error
Slave 862
EEPROM Access Error
Main Reasons
1. No EEPROM
2. EEPROM wrong insertion
■ Error Diagnosis and Countermeasure Flow Chart
Is EEPROM assemble
condition normal?
No
Reset after checking EEPROM assemble condition
Yes
No
Is EEPROM 24C16?
Replace EEPROM with 24C16
Yes
Recheck power and
installation condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 123 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
Error Point
87*
Fan PCB EEPROM
Master 871
Error
Slave 872
Main Reasons
1.EEPROM bad contact/wrong insertion
Error occurs when checking the
EEPROM checksum as initializing 2.EEPROM Version is different
after power is supplied
3.ODU fan PCB assembly damage
■ Error Diagnosis and Countermeasure Flow Chart
No
Is EEPROM insertion normal?
1.Check EEPROM insertion direction/connection condition
2.Check EEPROM checksum
→ Replace EEPROM if abnormality found
Yes
No
Is Fan PCB assembly normal?
Replace fan PCB assembly
Yes
Recheck power and
installation condition
Fan EEPROM insertion
Inverter EEPROM insertion
direction
Same direction both socket
hole and EEPROM hole
❈ Note : Replace after power off
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 124 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
Error Point
104*
Master
11 → 041 Transmission Error
Between Outdoors
Slave
12 → 042
Master displays ODU number
which is not communicated.
Slave displays own error number
Main Reasons
1.Loose connection of power cable/communication cable(Open/Short)
2.Defect of each outdoor unit PCB
■ Error Diagnosis and Countermeasure Flow Chart
Is communication
cable installed
normally?
No
Connect communication cable
Yes
No
Is Slave Unit Dip SW
setting done?
Dip SW setting
Yes
No
Is main PCB power
supplied?
Connect power cable
Yes
Replace main PCB
* Slave Unit Dip SW
ON
ON
Slave
1
1
2
2
3
3
4
4
5
5
6
6
7
7
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Only for training and service purposes
1
8
2 3 4 5 6
9 10 11 12 13 14
- 125 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
Error Point
105*
Master Transmission error
11 → 051 (Fan PCB ↔ Inverter
Slave
PCB)
12 → 052
Main Reasons
1. Wrong connection between Inverter and
Fan PCB
Fan controller didn't receive signal
from inverter controller
2. Fan PCB power not supplied
3. ODU Inv/Fan PCB defect
■ Error Diagnosis and Countermeasure Flow Chart
Is fan PCB communication
LED(yellow) blinking
normally?
No
1. Check DC 15V power cable between Inverter PCB and fan PCB
2. Check communication cable between Inverter PCB and fan PCB
→ Reconnect or replace wire if abnormality found
Yes
Is inverter PCB
communication LED(yellow)
blinking normally?
No
Check communication cable between Inverter PCB and fan PCB
→ Reconnect or replace wire if abnormality found
Yes
No
No
Fan PCB assembly
Is fan PCB assembly normal?
Yes
Yes
Recheck power and
installation condition
Replace inverter PCB assembly
Checking 15V input
Fan communication
connection
Fan Error LED
Error LED
Communication connector
Communication LED
❈ Note : Check fan PCB assembly Error LED blinking (Check 108π¯ Error)
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 126 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
Error Point
106*
Master
ODU Fan PCB IPM
11 → 061
Fault
Slave
12 → 062
Main Reasons
1. Overload operation (Pipe clogging/Covering/EEV
defect/Ref. overcharge
IPM protection circuit activation 2. ODU fan motor assemble condition abnormal
(Coil disconnection/Short/Insulation damage)
(over current / overheating)
3. Fan PCB heatsink assemble condition abnormal
4. Fan PCB assembly defect
■ Error Diagnosis and Countermeasure Flow Chart
Is fan motor assemble
condition normal?
No
Check ODU fan motor assemble condition and locking
→ Reassemble or replace if abnormality found
Yes
No
1.Check fan motor U,V,W connector connection condition
→ Reassemble wire if abnormality found
2.Check fan motor wire disconnection
→ Replace ODU fan motor if abnormality found
No
1.Check fan PCB connector condition
→ Reassemble if abnormality found
2.Check assemble condition between fan PCB and Heatsink
→ Reassembleheatsink if abnormality found
Is fan motor wire connection
condition normal?
Yes
Is fan PCB assemble
condition normal?
Yes
No
Is fan PCB assembly normal?
Replace fan PCB assembly
Yes
Recheck power and
installation condition
Fan Motor Wire connection
Fan IPM assemble position
Check assemble condition
Hall Sensor connection
Fan Heatsink assemble position
Check assemble condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 127 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
Error Point
107*
Master Fan DC Link Low
11 → 071
Voltage Error
Slave
12 → 072
Fan PCB DC link voltage supplied
below 380V
Main Reasons
1. Wrong wiring between inverter PCB and
Fan PCB
2. Fan PCB assembly defect
■ Error Diagnosis and Countermeasure Flow Chart
Is wiring between fan motor
and PCB normal?
No
1. Check DC_Link Wire connection
2. DC_Link
→ Replace wire if abnormality found
Yes
No
Is DC_Link voltage normal?
Measure DC_Link voltage
→ Check inverter PCB if voltage is below 380V
Yes
No
Is Fan PCB assembly normal?
Replace fan PCB assembly
Yes
Recheck power and
installation condition
DC voltage connection
DC Volt connected
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 128 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
113*
Master
11 → 131
Slave
12 → 132
Error Type
Outdoor unit liquid pipe
(condenser) temperature
sensor error
Error No.
114*
Master
11 → 141
Slave
12 → 142
Error Point
Main Reasons
Abnormal sensor resistance value
(Open/Short)
1. Defective temperature sensor connection
2. Defective temperature sensor
(Open / Short)
3. Defective outdoor unit PCB
Error Point
Main Reasons
Abnormal sensor resistance value
(Open/Short)
1. Defective temperature sensor connecter connection
2. Defective temperature sensor
(Open/Short)
3. Defective outdoor PCB
Error Type
Outdoor unit sub-cooling
inlet / outlet temperature
sensor error
■ Error diagnosis and countermeasure flow chart
Is temperature sensor
connector connections
are normal?
No
Check and correct connection
Yes
Is the value of temperature
sensor resistance normal?*
No
Replace sensor
Yes
Replace outdoor unit PCB
* Sensor resistance 100 kΩover (open) or 100 Ω below (short) will generate error
Note: Temperate sensor resistance vary with temperature, So compare temperature sensor resistance value
according to outdoor unit temperature by referring below table (±5% tolerance)
Air temperature sensor: 10°C(50°F) = 20.7 kΩ, 25°C(76°F) = 10 kΩ, 50°C(122°F) = 3.4 kΩ
Pipe temperature sensor: 10°C(50°F) = 10 kΩ, 25°C(76°F) = 5 kΩ, 50°C(122°F) = 1.8 kΩ
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 129 -
LGE Internal Use Only
Troubleshooting Guide
Error
No.
Error Type
Error Point
Main Reasons
1. Wrong operation of 4way valve because of sludge
151*
etc. inflow
Function error of 4way
Master
2. No pressure difference because of compressor
Function error of outdoor
(reversing valve) in Main or
11→511
fault
4way (reversing valve)
Slave outdoor units
Slave
3. Wrong installation of In/outdoor common pipe
12→512
4. Defect of 4way valve
■ Error diagnosis and countermeasure flow chart
Is 4-Way valve connecter
connection are properly
connected?
No
Reconnect it
Yes
Is 4 Way valve coil
resistance normal?*
No
Change 4 Way valve coil
Yes
Is 4 way valve coil connected
to 4 way valve normally?**
No
Re-insert 4 way valve coil
Yes
In case of more than
2 units, does master outdoor
unit recognize
øπ as more
than 2 units? ***
No
Refer to CH 51 & make measure
Yes
After reset, can we
check supply voltage at PCB
when starting heating
mode operation****
No
Replace outdoor unit PCB
Yes
Is compressor working
normally?
No
Check and replace compressor,
Magnet switch, corresponding PCB
[refer electric component part]
Yes
After opposite
mode operation to present
mode, is the same error
occurred again?
No
If the same error is occurred in
near future replace 4way valve
Yes
Replace 4 way valve*****
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 130 -
LGE Internal Use Only
Troubleshooting Guide
Location of 4way valve connector on
Main PCB(marked as 4way,CN09)
* Measure the resistance of 4way valve
** Confirm the 4way valve coil is inserted to the end
**** Check the output voltage of terminal socket
during heating operation
*** When power is supplied in order as follow
(Slave → Mater)
ODU information is displayed one after the other at main PCB 7-segment
1. Model ID
2. Total Capacity
→ Displayed with HP
3. ODU Type
→ HEAT PUMP : 2, Sync : 3
4. Normal mode : 25
5. Refrigerant
→ 3Ø 208/230V : 140, 3Ø 460V : 160
***** Checking method for outdoor unit of 3unit system
(Master + Slave)
➀ Close all the SVC valves of high / low pressure common pipe
➁ Operate system
➂ Check the difference of high and low pressure with LGMV for each unit (Master, Slave)
➃ If there is a unit in which the difference is not increased then the 4way valve of that unit is defective
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
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LGE Internal Use Only
Troubleshooting Guide
Error No.
173*
Master
11 → 731
Slave
12 → 732
Error Type
Error Point
Main Reasons
Constant compressor
defect
Defect according to constant
compressor damage or locking, over current
1. Constant compressor damage
2. Constant compressor input over
current
3. Discharge temperature sensor defect
■ Error diagnosis and countermeasure flow chart
Is resistance value
(insulation & phase to phase)
of corresponding constant
compressor normal ?
[refer electric
component part]
No
Replace constant compressor
Yes
No
Is cables’ connection
of compressor normal? *
Adjust connection of cables
Yes
Is discharge temperature
sensor of compressor
normal? [refer electric
component part]
No
Replace discharge
temperature sensor
Yes
* cables connection between constant
compressor and magnetic switch
Replace outdoor unit PCB
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 132 -
LGE Internal Use Only
Troubleshooting Guide
Error No.
Error Type
193*
Master 11 → 931
Slave 12 → 932
Fan PCB heatsink
temperature high
Heat sink temperature is over 1. Heatsink temperature sensor defect
95°C
2. Fan PCB assembly defect
Fan PCB heatsink
temperature sensor
error
1. Heatsink temperature sensor
defect(Open/Short)
Heatsink temperature sensor
2. Wrong connection of temperature senabnormal
sor connector
3. Fan PCB assembly defect
194*
Master 11 → 941
Slave 12 → 942
Error Point
Main Reasons
■ Error diagnosis and countermeasure flow chart
Fan heat sink connection
No
Is temperature
sensor
’
inserted to fan PCB?
Check connection of heat sink
temperature connector
Yes
No
Is temperature
sensor
’
attached to heat sink?
Check connection condition of
heat sink and temperature sensor
Check connection condition
Yes
No
Is termperature
’
sensor normal?
Yes
Check heat sink temperature
sensor wire disconnection
➔ Measure temperature sensor
resistance(10kΩ ±5% at 77°F)
➔ Replace the sensor if
abnormality found
Checking temperature sensor disconnection
No
’
Is fan PCB assembly normal?
Replace fan PCB assembly
Yes
Recheck power and installation
condition
Copyright ©2007 LG Electronics. Inc. All right reserved.
Only for training and service purposes
- 133 -
LGE Internal Use Only
P/NO : MFL50459503
MAY, 2008
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