Single Zone HigH efficiency Standard Wall

Single Zone HigH efficiency Standard

Wall Mounted inStallation Manual

Single Zone High Efficiency:

LS090HSV4, LS120HSV4, LS180HSV4

ProPrietary data notice

This document, as well as all reports, illustrations, data, information, and other materials are the property of LG Electronics U.S.A., Inc., and are disclosed by LG Electronics U.S.A., Inc., only in confidence.

This document is for design purposes only.

Do not throw away, destroy, or lose this manual.

Please read carefully and store in a safe place for future reference.

Content familiarity required for proper installation.

The instructions included in this manual must be followed to prevent product malfunction, property damage, injury, or death to the user or other people. Incorrect operation due to ignoring any instructions will cause harm or damage. The level of seriousness is classified by the symbols described below.

A summary list of safety precautions begins on page 3.

IM-SZ-HighEfficiencyInverter_HSV4-01-15

For more technical materials such as submittals, engineering databooks, and catalogs, visit www.lghvac.com.

For continual product development, LG Electronics U.S.A., Inc., reserves the right to change specifications without notice.

©LG Electronics U.S.A., Inc.

This document, as well as all reports, illustrations, data, information, and other materials are the property of LG Electronics U.S.A., Inc.

Safety inStructionS

The instructions below must be followed to prevent product malfunction, property damage, injury or death to the user or other people. Incorrect operation due to ignoring any instructions will cause harm or damage. The level of seriousness is classified by the symbols described below.

taBle of SyMBolS

This symbol indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

This symbol indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

This symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

This symbol Indicates situations that may result in equipment or property damage accidents only.

This symbol indicates an action should not be completed.

inStallation

Don’t store or use flammable gas / combustibles near the unit.

There is risk of fire, explosion, and physical injury or death.

do not install, remove, or re-install the unit by yourself

(customer). ask the dealer or an authorized technician to install the unit.

Improper installation by the user may result in water leakage, fire, explosion, electric shock, physical injury or death.

for replacement of an installed unit, always contact an authorized lg service provider.

There is risk of fire, electric shock, explosion, and physical injury or death.

always check for system refrigerant leaks after the unit has been installed or serviced.

Exposure to high concentration levels of refrigerant gas may lead to illness or death.

Wear protective gloves when handling equipment. Sharp edges may cause personal injury.

the unit is shipped with refrigerant and the service valves closed. do not open service valves on the unit until all non-condensibles have been removed from the piping system and authorization to do so has been obtained from the commissioning agent.

There is a risk of physical injury or death.

dispose the packing materials safely.

• Packing materials, such as nails and other metal or wooden parts, may cause puncture wounds or other injuries.

• Tear apart and throw away plastic packaging bags so that children may not play with them and risk suffocation and death.

install the unit considering the potential for strong winds or earthquakes.

Improper installation may cause the unit to fall over, resulting in physical injury or death.

do not run the compressor with the service valves closed.

There is a risk of equipment damage, explosion, physical injury, or death.

Periodically check that the outdoor frame is not damaged.

There is a risk of explosion, physical injury, or death.

do not change the settings of the protection devices.

If the pressure switch, thermal switch, or other protection device is shorted and forced to operate improperly, or parts other than those specified by LG are used, there is risk of fire, electric shock, explosion, and physical injury or death.

replace all control box and panel covers.

If cover panels are not installed securely, dust, water and animals may enter the unit, causing fire, electric shock, and physical injury or death.

do not install the unit on a defective stand.

There is a risk of physical injury.

Due to our policy of continuous product innovation, some specifications may change without notification.

©LG Electronics U.S.A., Inc., Englewood Cliffs, NJ. All rights reserved. “LG” is a registered trademark of LG Corp.

3


inStallation - continued

if the air conditioner is installed in a small space, take measures to prevent the refrigerant concentration from exceeding safety limits in the event of a refrigerant leak.

Consult the latest edition of ASHRAE (American Society of Heating,

Refrigerating, and Air Conditioning Engineers) Standard 15. If the refrigerant leaks and safety limits are exceeded, it could result in personal injuries or death from oxygen depletion.

install the unit in a safe location where nobody can step on or fall onto it.

There is risk of physical injury or death.

Be very careful when transporting the product.

• Do not attempt to carry the product without assistance.

• Some products use polypropylene bands for packaging. Do not use polypropylene bands to lift the unit.

• Suspend the unit from the base at specified positions.

• Support the unit a minimum of four points to avoid slippage from rigging apparatus.

do not install the unit in a noise sensitive area.

don’t install the unit where it’s directly exposed to ocean winds.

Ocean winds may cause corrosion, particularly on the condenser and evaporator fins, which, in turn could cause product malfunction or inefficient performance.

When connecting refrigerant tubing, remember to allow for pipe expansion.

Improper piping may cause refrigerant leaks and system malfunction.

When installing the unit in a low-lying area, or a location that is not level, use a raised concrete pad or concrete blocks to provide a solid, level foundation.

This may prevent water damage and reduce abnormal vibration.

take appropriate actions at the end of HVac equipment life to recover, recycle, reclaim or destroy r410a refrigerant according to applicable u.S. environmental Protection agency (ePa) rules.

Properly insulate all cold surfaces to prevent “sweating.”

Cold surfaces such as uninsulated piping can generate condensate that may drip and cause a slippery floor condition and/or water damage to walls.

Periodically check that the outdoor frame is not damaged.

There is a risk of equipment damage.

When installing the unit in a hospital, mechanical room, or similar electromagnetic field (EMF) sensitive environment, provide sufficient protection against electrical noise.

Inverter equipment, power generators, high-frequency medical equipment, or radio communication equipment may cause the air conditioner to operate improperly. The unit may also affect such equipment by creating electrical noise that disturbs medical treatment or image broadcasting.

install the unit in a safe location where nobody can step on or fall onto it. do not install the unit on a defective stand.

There is risk of unit and property damage.

install the drain hose to ensure adequate drainage.

There is a risk of water leakage and property damage.

Don’t store or use flammable gas / combustibles near the unit.

There is risk of product failure.

4

do not use the product for special purposes such as preserving foods, works of art, wine coolers, or other precision air conditioning applications. the equipment is designed to provide comfort cooling and heating.

There is risk of property damage.

do not make refrigerant substitutions. use r410a only.

If a different refrigerant is used, or air mixes with original refrigerant, the unit will malfunction and be damaged.

Keep the unit upright during installation to avoid vibration or water leakage. always check for system refrigerant leaks after the unit has been installed or serviced.

Low refrigerant levels may cause product failure

the unit is shipped with refrigerant and the service valves closed. do not open service valves on the unit until all non-condensibles have been removed from the piping system and authorization to do so has been obtained from the commissioning agent.

There is a risk of refrigerant contamination, refrigerant loss and equipment damage

.




Wiring

High voltage electricity is required to operate this system. adhere to the national electrical codes and these instructions when wiring.

Improper connections and inadequate grounding can cause accidental injury or death.

always ground the unit following local, state, and national electrical codes.

turn the power off at the nearest disconnect before servicing the equipment.

Electrical shock can cause physical injury or death.

Properly size all circuit breakers or fuses.

There is risk of fire, electric shock, explosion, physical injury or death.

the information contained in this manual is intended for use by an industry-qualified, experienced, certified electrician familiar with the u.S. national electric code (nec) who is equipped with the proper tools and test instruments.

Failure to carefully read and follow all instructions in this manual can result in equipment malfunction, property damage, personal injury or death.

refer to local, state, and federal codes, and use power wires of sufficient current capacity and rating.

Wires that are too small may generate heat and cause a fire.

Secure all field wiring connections with appropriate wire strain relief.

Improperly securing wires will create undue stress on equipment power lugs. Inadequate connections may generate heat, cause a fire and physical injury or death.

all electric work must be performed by a licensed electrician and conform to local building codes or, in the absence of local codes, with the national electrical code, and the instructions given in this manual.

If the power source capacity is inadequate or the electric work is not performed properly, it may result in fire, electric shock, physical injury or death.



5


oPeration

Do not provide power to or operate the unit if it is flooded or submerged.

There is risk of fire, electric shock, physical injury or death.

use a dedicated power source for this product.


do not operate the disconnect switch with wet hands.


Periodically verify the equipment mounts have not deteriorated.

If the base collapses, the unit could fall and cause physical injury or death.

if gas leaks out, ventilate the area before operating the unit.

If the unit is mounted in an enclosed, low-lying, or poorly ventilated area, and the system develops a refrigerant leak, it may cause fire electric shock, explosion, physical injury or death.

do not allow water, dirt, or animals to enter the unit.


Periodically, check power cord and plug for damage.

Cord must be replaced by the manufacturer, its service agent, or similar qualified persons in order to avoid physical injury and/or electric shock.

avoid excessive cooling and periodically perform ventilation to the unit.

Inadequate ventilation is a health hazard.

do not touch the refrigerant piping during or after operation.

It can cause burns or frostbite.

do not open the inlet grille of the unit during operation. do not operate the unit with the panels or guards removed. do not insert hands or other objects through the inlet or outlet when the unit is plugged in. do not touch the electrostatic filter, if the unit includes one.

The unit contains sharp, rotating, hot, and high voltage parts that can cause personal injury and/or electric shock.

do not operate the unit with the panel(s) or protective cover(s) removed; keep fingers and clothing away from moving parts.

The rotating, hot, cold, and high-voltage parts of the unit can cause physical injury or death.

Securely attach the electrical part cover to the indoor unit and the service panel to the outdoor unit.

Non-secured covers can result in burns or electric shock due to dust or water in the service panel.

to avoid physical injury, use caution when cleaning or servicing the air conditioner.

6

Clean up the site after installation is finished, and check that no metal scraps, screws, or bits of wiring have been left inside or surrounding the unit.

do not use this equipment in mission critical or special- purpose applications such as preserving foods, works of art, wine coolers or refrigeration. the equipment is designed to provide comfort cooling and heating.

Oil, steam, sulfuric smoke, etc., can significantly reduce the performance of the unit, or damage its parts.

do not block the inlet or outlet.

Unit may malfunction.

Securely attach the electrical part cover to the indoor unit and the service panel to the outdoor unit.

Non-secured covers can result in fire due to dust or water in the service panel.

Periodically verify the equipment mounts have not deteriorated.

If the base collapses, the unit could fall and cause property damage or product failure.

Provide power to the compressor crankcase heaters at least six (6) hours before operation begins.

Starting operation with a cold compressor sump(s) may result in severe bearing damage to the compressor(s). Keep the power switch on during the operational season.

do not allow water, dirt, or animals to enter the unit.

There is risk of unit failure.



taBle of contentS

Safety Instructions ................................................................................ 3

General Data .......................................................................................... 8

Unit Nomenclature ............................................................................... 8

Single Zone High Efficiency Unit Specifications .................................. 9

Electrical ............................................................................................ 10

R410A Refrigerant ............................................................................. 10

General Installation Guidelines ...........................................................11

Location Selection ..............................................................................11

Oceanside Applications ..................................................................... 12

Mounting Bolt Location ...................................................................... 13

Required Clearances ......................................................................... 14

Mounting of Indoor Unit Installation Plate .......................................... 15

Mounting of Indoor Unit ..................................................................... 16

Piping Preparation ............................................................................. 17

Piping Materials and Handling ........................................................... 18

Piping Support ................................................................................... 23

Underground Piping ........................................................................... 24

Refrigerant Piping Connections ......................................................... 26

Refrigerant Piping System Limitations ............................................... 26

Installation Overview ......................................................................... 26

Directional Pipe Formation ................................................................ 27

Drain Hose ......................................................................................... 28

Outdoor Unit Connections ................................................................. 29

Indoor Unit Connections .................................................................... 30

Bundling and Cutting Line ................................................................. 31

Refrigerant Piping Insulation ........................................................32-34

Air Purging ......................................................................................... 35

Leak Test/Soap Method Check .......................................................... 36

Evacuation of Lines ........................................................................... 37

Finishing Up ....................................................................................... 37

Remote Controller ............................................................................. 37

Pump Down, Cooling Only Mode ...................................................... 38

Electrical Wiring .................................................................................. 39

General Information and Safety Guidelines ....................................... 39

Power Wiring Specifications and Best Practices ............................... 40

Controllers ......................................................................................... 41

Indoor Unit Electrical Connections ...............................................42-43

Outdoor Unit Electrical Connections .............................................44-45

Self Diagnosis Functions .............................................................46-47

LG SIMS - Self Diagnosis Functions ...........................................48-49

Troubleshooting .................................................................................. 50

Error Codes .................................................................................50-52

Refrigerant Leaks .............................................................................. 53

Installation Checklist ......................................................................54-55



7

general data

Unit Nomenclature

Single Zone Wall Mount indoor and outdoor units lS

Family

LS= High Efficiency Wall Mount / Standard / Extended Pipe / Mega

Type

N = Indoor Wall Mount Unit

U = Outdoor Heat Pump Unit

Nominal Capacity

(Nominal cooling capacity in Btu/h)

090/091 = 9,000

120/121 = 12,000

180/181 = 18,000

240 = 24,000

300/307 = 30,000

360 = 36,000

Indoor/Outdoor Product

HSV = High Efficiency

HV = Standard

HLV = Extended Pipe

HEV = Mega

HXV = Mega 115V

Generation

3 = Third

4 = Fourth

n 090 HSV 4

8



general data

Single Zone High Efficiency Unit Specifications

Table 1: Single Zone High Efficiency Unit Specifications

Type

System Model Number (IDU/ODU)

Nominal Cooling Capacity (Btu/h)

Cooling Power Input

1

(kW)

Nominal Heating Capacity (Btu/h)

Heating Power Input

COP

EER

SEER

HSPF

1

(kW)

Power Supply (V/Hz/Ø)

Outdoor Unit Operating Range

2

Cooling (°F DB)

Heating (°F WB)

Indoor Unit Operating Range

2

Cooling (°F WB)

Heating (°F DB)

Unit Data

1

Refrigerant Type

3

Refrigerant Control

IDU Sound Pressure

4

dB(A) (H/M/L/Sleep)

ODU Sound Pressure

4

dB(A)

Power/Communication Cable

5

(No. x AWG)

IDU Net/Shipping Weight (lbs)

ODU Net/Shipping Weight (lbs)

Compressor

Compressor Type (Qty)

Fan

IDU Type (Qty)

ODU Type (Qty)

Motor/Drive

Airflow Rate

IDU Max/H/M/L (CFM)

ODU Max (CFM)

Piping

Liquid Line (in, OD)

Vapor Line (in, OD)

Condensation Line (OD, ID)

Additional Refrigerant Charge (oz/ft)

Pipe Length

6

(ft) (Min./Max.)

Piping Length

6

(no add’l refrigerant, ft)

Max Elevation Difference (ft)

LS090HSV4

(LSN090HSV4/LSU090HSV4)

9,000

0.68

10,800

0.70

4.51

13.3

21.5

10.8

38/33/23/19

45

20/26

75/79

Single Rotary (1)

423/353/272/191

1,165

1/4

3/8

27/32, 5/8

0.22

6.6/65.6

41.0

32.8

Single Zone High Efficiency Units

LS120HSV4


11,200

0.90

13,300

1.0

3.90

12.5

21.5

11.0

208-230/60/1

14 to 118

-4 to +65

53 to 75

60 to 86

R410A

EEV

39/33/23/19

45

4 x 18

20/26

75/79

Single Rotary (1)

Cross Flow (1)

Propeller (1)

Brushless Digitally Controlled/Direct

423/353/272/191

1,165

1/4

3/8

27/32, 5/8

0.22

6.6/65.6

41.0

32.8

LS180HSV4


18,200

1.45

22,000

1.76

3.66

12.6

20.5

9.7

45/40/35/29

53

31/36

121/131

Twin Rotary (1)

735/622/509/399

2,119

3/8

5/8

27/32, 5/8

0.38

9.8/98.4

24.6

49.2

EEV: Electronic Expansion Valve IDU: Indoor Unit ODU: Outdoor Unit

1

Power Input is rated at high speed.

2

Optional Low Ambient Wind Baffle Kit allows operation down to 0°F in cooling mode.

3

Take appropriate actions at the end of HVAC equipment life to recover, recycle, reclaim or destroy

R410A refrigerant according to applicable regulations (40 CFR Part 82, Subpart F) under section 608 of

CAA.

4

Sound Pressure levels are tested in an anechoic chamber under ISO Standard 1996.

5

All power/communication cables to be minimum 18 AWG, 4-conductor, stranded, shielded and must comply with applicable and national code.

6

Piping lengths are equivalent.

Power wiring is field supplied and must comply with the applicable local and national codes.

This unit comes with a dry helium charge.

This data is rated 0 ft above sea level with 24.6 of refrigerant line per indoor unit and a 0 ft level difference outdoor and indoor units.

Cooling capacity rating obtained with air entering the indoor unit at 80ºF dry bulb (DB) and 67ºF wet bulb

(WB) and outdoor ambient conditions of 95ºF dry bulb (DB) and 75ºF wet bulb (WB).

Heating capacity rating obtained with air entering the indoor unit at 70ºF dry bulb (DB) and 59ºF wet bulb

(WB) and outdoor ambient conditions of 47ºF dry bulb (DB) and 43ºF wet bulb (WB).



9

general data

Electrical/R410A Refrigerant

electrical

Table 2: Single Zone High Efficiency Indoor Unit Electrical Data

Model Number

LS090HSV4

LS120HSV4

LS180HSV4

Nom. Tons

3/4

1

1-1/2

Compressor

Qty

1

1

1

Compressor

(A) Cool/Heat

8.3/8.3

8.3/8.3

14.6/14.6

Fan Qty ODU Fan (A) IDU Fan (A) MCA (A) MOP (A)

1

1

1

0.40

0.40

0.25

0.40

0.40

0.40

10

10

19

15

15

25

r410a refrigerant

R410A refrigerant has a higher operating pressure in comparison to R22 refrigerant and, therefore, all piping system materials installed must have a higher resisting pressure than the materials traditionally used in R22 systems.

R410A refrigerant is an azeotrope of R32 and R125, mixed at 50:50, so the ozone depletion potential (ODP) is 0. Many countries have approved of and encouraged R410A for use as an alternate refrigerant.

• To prevent the refrigerant cylinder from exploding, do not place it in direct sunlight.

• Do not use any piping that has not been approved for use in high-pressure refrigerant systems.

• Piping wall thickness must comply with the applicable local, state, and federal codes for the 551 psi design pressure of R410A.

• Because R410A is a combination of R32 and R125, the required additional refrigerant must be charged in its liquid state. If the refrigerant is charged in its gaseous state, its composition changes and the system will not work properly.

10



General InstallatIon GuIdelInes

Location Selection

selecting the Best location

DANGER

• Do not install the unit in a location where acidic solution and spray (sulfur) are often used as it can cause bodily injury or death.

• Do not use the unit in environments where oil, steam, or sulfuric gas are present as it can cause bodily injury or death.

Install a fence to prevent vermin from crawling into the unit or unauthorized individuals from accessing it.

Select a location for installing the outdoor unit that will meet the following conditions:

• Where the unit will not be subjected to direct thermal radiation from other heat sources.

• Where operating sound from the unit will not disturb inhabitants of surrounding buildings.

• Where the unit will not be exposed to direct, strong winds.

• Where there is enough strength to bear the weight of the unit.

• Include space for drainage to ensure condensate flows properly out of the unit when it is in heating mode.

• Include enough space for air flow and for service access.

To ensure the outdoor unit operates properly, certain measures are required in locations where there is a possibility of heavy snowfall or severe windchill or cold:

1. Prepare for severe winter wind chills and heavy snowfall, even in areas of the country where these are unusual phenomena.

2. Position the outdoor unit so that its airflow fans are not buried by direct, heavy snowfall. If snow piles up and blocks the airflow, the system may malfunction.

3. Remove any snow that has accumulated 3-15/16 inches or more on the top of the outdoor unit.

4. Place the outdoor unit on a raised platform at least 19-11/16 inches higher than the average annual snowfall for the area. In environments where there is a possibility of heavy snow, the frame height must be more than two (2) times the amount of average annual snowfall, and should not exceed the width of the outdoor unit. If the frame width is wider than the outdoor unit, snow may accumulate.

5. Install a snow protection hood.

6. To prevent snow and heavy rain from entering the outdoor unit, install the suction and discharge ducts facing away from direct winds.

7. Additionally, the following conditions should be taken into consideration when the unit operates in defrost mode:

• If the outdoor unit is installed in a highly humid environment (near an ocean, lake, etc.), ensure that the site is well-ventilated and has a lot of natural light. (Example: Install on a rooftop.)

• Sidewalks or parking lots near the outdoor unit may accumulate moisture after unit operates in defrost mode that can turn to ice.

The indoor unit may take longer to provide heat, or heating performance will be reduced in winter if the unit is installed:

1. In a narrow, shady location.

2. Near a location that has a lot of ground moisture.

3. In a highly humid environment.

4. In an area in which condensate does not drain properly.

ambient air Conditions

• Avoid exposing the outdoor unit to steam, combustible gases, or other corrosive elements.

• Avoid exposing the unit to discharge from boiler stacks, chimneys, steam relief ports, other air conditioning units, kitchen vents, plumbing vents, or substances that may degrade performance or cause damage to the unit.

• When installing multiple outdoor units, avoid placing the units where discharge of one outdoor unit will blow into the inlet side of an adjacent unit.

Avoid exposing the unit to sources of extreme temperature or gases to prevent serious bodily injury.



11


Oceanside Applications

oceanside applications

Use of a Windbreak to Shield from Sea Wind

Figure 1: Oceanside Placement Using Windbreak

Ocean winds may cause corrosion, particularly on the condenser and evaporator fins, which, in turn could cause product malfunction or inefficient performance.

• The unit should be installed in a soundproofed mechanical room.

• Avoid installing the outdoor unit where it would be directly exposed to ocean winds.

• Install the outdoor unit on the side of the building opposite from direct ocean winds.

• Select a location with good drainage.

• Periodically clean dust or salt particles off of the heat exchanger with water.

• If the outdoor unit must be placed in a location where it would be subjected to direct ocean winds, install a concrete windbreak strong enough to block any winds.

• Windbreak should be more than 150% of the outdoor unit’s height.

There must be 2 to 3-1/2 inches of clearance between the outdoor unit and the windbreaker for purposes of air flow.

Windbreak

Sea wind

Additional anti-corrosion treatment may need to be applied to the outdoor unit at oceanside locations.

oceanside applications

Use of a Building to Shield from Sea Wind

If a windbreak is not possible, a building or larger structure must be used to shield the outdoor unit from direct exposure to the sea wind. The unit should be placed on the side of the building directly opposite to the direction of the wind as shown in Figure 2.

Figure 2: Placement Using Building as Shield

Building

Sea wind

Sea wind

Building



12


Mounting Bolt Location

General Mounting

Securely attach the outdoor unit to a condenser pad, base rails, or another mounting platform that is securely anchored to the ground or building structure. Attach the outdoor unit with a bolt and nut on a concrete or rigid mount. See Figure 3. Follow applicable local codes for clearance, mounting, anchor and vibration attenuation requirements.

Figure 3: Outdoor Unit Mounting Methods

All referenced materials are to be field-supplied. Images are not to scale.

Mounting Platform

The underlying structure or foundation must be designed to support the weight of the unit. Avoid placing the unit in a low lying area where water may accumulate. When installing the outdoor unit on the wall, or roof top, anchor the mounting base securely to account for wind, earthquake or vibration.

tie-downs and Wind restraints

The strength of the Duct-free Split Single Zone Inverter system frame is adequate to be used with field-provided wind restraint tiedowns. The overall tie-down configuration must be approved by a local professional engineer.

Bolt

Placement

& Anti-Vibration

Pad

Top of Unit

Foundation

Always refer to local code when designing a wind restraint system.

Piping Connection

snow and Ice Conditions

In climates that experience snow build-up, place the unit on a raised platform to ensure condenser airflow. The raised support platform must be high enough to allow the unit to remain above possible snow drifts. Mount the unit on a field-provided snow stand at a minimum height that is equal to the average annual snowfall plus 20 inches. Design the mounting base to prevent snow accumulation on the platform in front or back of the unit case. If necessary, provide a field fabricated hood to keep snow and ice and/or drifting snow from accumulating on the coil surfaces. Use inlet and discharge duct or hoods to prevent snow or rain from accumulating on the fan inlet and outlet guards. Best practice prevents snow from accumulating on top of the unit. Consider tie-down requirements in case of high winds or where required by local codes.

When deciding on a location to place the outdoor unit, be sure to choose an area where run-off from defrost will not accumulate and freeze on sidewalks or driveways.

Proper airflow through the Single Zone outdoor unit coil is critical for correct unit operation. When installing, consider service, inlet and outlet, and minimum allowable space requirements as illustrated in the diagrams below.

Minimum Clearance requirements for single Zone

Outdoor Unit Clearance

Specific clearance requirements in the diagrams on the next page are for the single zone wall mount systems. Figure 4 shows the overall minimum clearances that must be observed for safe operation and adequate airflow around the outdoor unit.

When placing the outdoor unit under an overhang, awning, sunroof or other “roof-like structure, observe the clearance requirements (as shown in Figure 5) for height in relation to the unit. This clearance ensures that heat radiation from the condenser is not restricted around the unit. See

Figures 6 and 7 for recommendations when other obstacles are present.

Adhere to all clearance requirements if installing the unit on a roof. Be sure to level the unit and ensure that the unit is adequately anchored.

Consult local codes for rooftop mounting requirements.



13


Required Clearances

Outdoor Unit Clearance

Figure 4: Outdoor Unit Clearances

24

Figure 5: Outdoor Unit Sunroof/Awning Clearances

Sunroof

More than

12

12

12

28

24

Unit : inch

Fence or obstacle s

More than

28

More than

24

More than

12

Unit : inch

Do not place the unit where animals and/or plants will be in the path of the warm air, or where the warm air and/or noise will disturb neighbors.

Figure 6: Clearances Where There Are Obstacles on Both Air

Inlet and Outlet Sides (Obstacle on the Outlet Side is Lower

Than the Outdoor Unit)

Figure 7: Clearances Where There are Obstacles Above and on Both Air Inlet and Outlet Sides (Obstacle on the Outlet Side is Lower Than the Outdoor Unit)

78-3/4

Unit: Inch

23-5/8

Minimum 27-5/8

Unit: Inch

Indoor Unit Clearance

Follow recommended best practices when choosing an indoor location for the Single Zone indoor unit.

• Keep unit away from any indoor steam or excessive heat.

• No obstacles should be placed around unit.

• Condensation drain (Leakage piping) should be routed away from the unit.

• Do not install near doorway.

• Clearance gap between any wall or enclosure and the left or right side of the unit must be greater than 4 inches.

• From the top of the unit to the ceiling there must be greater than 5 or 8 inches of clearance (depending on indoor unit model).

• Unit should be at least 6.5 feet from the floor for adequate clearance.

14

Figure 8: Indoor Unit Clearance Recommendations

More than 4

At least 6.5 from the floor



9/12k Indoor Units: ≥5

18k Indoor Units: ≥8

More than 4

Unit: Inch


Mounting of Indoor Unit Installation Plate

Mounting Installation Plate to Wall (090HsV4, 120HsV4, 180HsV4)

Follow the procedure and best practices below when mounting the indoor unit’s plate to a wall.

Procedure

1. Before installation of the plate, confirm the position the screw types (A or B) between chassis and installation plate.

Figure 9: Installation Plate Screws - 090HSV4, 120HSV4

Unit

Outline

Place a level on raised tab

A Type : 442

B Type : 434

A Type : 442

B Type : 439

2. Mount the installation plate horizontally by aligning the centerline using a leveling tool.

3. Use provided screws when mounting the plating.

• If mounting the unit on concrete wall, use field supplied anchor bolts.

4. Observe the left and right rear piping clearance when drilling into the wall, as shown in Figure 11 (090HSV4, 120HSV4) and Figure

12 (180HSV4).

Ø65

123

175

Installation Plate

A Type B Type

A Type : 95

B Type : 170

217

(Unit : mm)

Figure 10: Installation Plate Screws - 180HSV4

Select location carefully. Unit should be anchored to a strong wall to prevent unnecessary vibration.

• When choosing a location for the wall mount plate, be sure to take into consideration routing of wiring for power outlets within the wall.

Contacting wiring can cause serious bodily injury, or death.

• Use caution when drilling holes through the walls for the purposes of piping connections. Power wiring can cause serious bodily injury, or death.

Refer to “Drilling Piping Hole in the Wall” on page 16 as you follow procedure to install plate.

A-Type

B-Type

Figure 11: Installation Plate - 090HSV4, 120HSV4

Installation Plate


Unit Outline

090HSV4, 120HSV4

17-13/32 17-13/32

Figure 12: Installation Plate - 180HSV4


Unit Outline

18-3/32 22-13/32

180HSV4

Ø2-19/32

4-

27/32

6-

29/32

Unit: Inch

Ø2-19/32

3- 24/32

8-

17/32

Ø2-19/32

Left rear piping

2 -11/16

4-3/32

Installation Plate

Measuring Tape

Measuring Tape

Hanger



Ø2-19/32

Right rear piping

2-3/16

8-3/32

Unit: Inch

15


Mounting of Indoor Unit

drilling Piping Hole in the Wall

Follow the left or right piping clearance recommendations as shown in Figure 9 and 10.

1. Using a 2-5/8 (ø 65mm) inch hole core drill bit, drill a hole at either the right or left side of the wall mounting (Figure 13).

• The slant of the hole should be 3/16” to 5/16” from level with the slant being upward on the indoor unit side and downward on the outdoor unit side.

2. Finish off the newly drilled hole as shown with bushing and sleeve covering.

• Sleeve and bushing prevents damage to the tubing/bundling of the piping.

Figure 13: Drilling Piping Hole

WALL

Indoor

Core Drill

Bushing

Sleeve

Outdoor

Mounting the Indoor unit to the Installation Plate

1. Hook the indoor unit onto the upper portion of the installation plate (Figure 14).

2. Engage the hooks at the top of the indoor unit with the upper edge of the installation plate.

• Ensure that the hooks are properly seated on the installation plate by moving it left and right.

3. Move the bottom of indoor unit towards the installation plate to anchor to wall (Figure

145).

• It helps to press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots.

• You will hear a clicking sound as the bottom attaches to the installation plate successfully.

4. Finish by inserting and tightening two type “C” screws into the bottom of the installation plate (Figure 16).

• Pay attention to the positioning of the piping through any wall as shown in the figure, as you insert the screws to the indoor unit.

Figure 14: Mounting Unit on Installation Plate

2

1

Indoor unit

Installation plate

3”

Preparing for Piping/electrical Connection

1. To prepare indoor unit for piping, disengage bottom on indoor unit from installation plate by reversing step 3 from previous procedure.

• This step will separate the indoor unit’s bottom side from the wall mount in order to route drain hose correctly. See Figure 17 for a reference of the rear view of the indoor unit.

2. Swing drain hose holder (L-bracket) out and anchor as shown in Figure 15, against installation plate.

3. Optionally, go to Refrigerant Piping Connections section of this manual to continue with piping connections to the indoor unit.

4. Optionally, go to Electrical Connections section of this manual to continue with conduit/electrical wiring to the indoor unit.

Figure 17: Rear View of IDU

Drain Hose

Holder

L-bracket

Piping

Through

Wall

Spacer

Installation Plate

Figure 16: Mounting Bottom of Unit to Installation Plate

Installation Plate

Drain Hose

Drain Hose Holder

Indoor Unit

Type 'C' Screws

16




Piping Preparation

Piping Preparation

• Do not allow the refrigerant to leak during brazing; if the refrigerant combusts, it generates a toxic gas which can cause physical injury or death.

• Do not braze in an enclosed location, and always test for gas leaks before/after brazing. Gas leaks can cause physical injury or death.

• After brazing, check for refrigerant gas leaks. Refrigerant gas leaks can cause physical injury or death.

Single Zone Pipe Connections

1. Do not use kinked pipe caused by excessive bending in one specific area on its length.

2. Braze the pipes to the service valve pipe stub of the outdoor unit.

Creating a Flare Fitting

When selecting flare fittings, always use a 45° fitting rated for use with high pressure refrigerant R410A. Failure to do so may result in refrigerant leaks which in turn could result in personal injuries or death from oxygen depletion. Selected fittings must also comply with local, state, or federal standards.

Figure 19: Creating a Flare Fitting

1.

Copper tube

90°

Slanted Uneven Rough

One of the main causes of refrigerant leaks is defective flared connections. Create flared connections using the procedure at right (Figure 19).

1. Cut the pipe to length.

• Measure the distance between the indoor unit and the outdoor unit.

• Cut the pipes a little longer than measured distance.

• Cut the cable 4.9 ft longer than the pipe length.

2A. Remove the burrs.

• Completely remove all burrs from pipe ends.

• When removing burrs, point the end of the copper pipe down to avoid introducing foreign materials in the pipe.

2B. Slide the flare nut onto the copper tube.

3. Flaring the pipe end.

• Use the proper size flaring tool to finish flared connections as shown.

• ALWAYS create a 45° flare when working with R410A. See Warning on this page.

4. Carefully inspect the flared pipe end.

• Compare the geometry with the figure to the right and dimensions as detailed in Figure 18.

• If the flare is defective, cut it off and re-do procedure.

• If flare looks good, blow clean the pipe with dry nitrogen.

2A.

3.

4.

Bar

Smooth

Pipe

Reamer

"A"

Bar

Copper pipe

Clamp handle

2B.

Copper tube

Flare nut

Handle

Yoke

Cone

Red arrow

Inside is shiny with no scratches

Incorrect Flares

Figure 18: Dimensions of the Flare

90°

2

A

45°

2

R=0.4~0.8

Even length

Slanted Damaged surface

Cracked Uneven thickness

Table 3: Flared Connection Dimensions

Pipe “A” Thickness

Vapor (in. O.D.) Liquid (in. O.D.) Vapor (in.) Liquid (in.) Vapor (in.) Liquid (in.)

1/2

5/8

1/4

3/8

1/8

1/8

1/16

1/16

1/8

1/16

1/8

1/8



17


Piping Preparation/Piping Materials and Handling

Tightening the Flare Nuts

Table 4: Tightening Torque for Flare Nuts.

Pipe size (Inches O.D.)

1/4Ø

3/8Ø

1/2Ø

5/8Ø

Tightening torque (ft-lbs) Width of the flare (A [inches])

13.9 - 18

24.5 - 30.3

39.7 - 47.7

45.5 - 59.2

1/8

1/8

1/8

1/16

Figure 20: Tightening the Flare Nuts.

1. When connecting the flare nuts, coat the flare (inside and outside) with polyvinyl ether (PVE) refrigeration oil only.

2. Initially hand tighten the flare nuts using three (3) or four (4) turns.

3. To finish tightening the flare nuts, use both a torque wrench and a backup wrench.

4. After all the piping has been connected and the caps have been tightened, check for refrigerant gas leaks.

Union

Do not use polyolyester (POE) or any other type of mineral oil as a thread lubricant. These lubricants are not compatible with PVE oil used in this system and create oil sludge leading to equipment damage and system malfunction.

Loosening the Flare Nuts

Always use two (2) wrenches to loosen the flare nuts.

Figure 21: Keep Piping Capped While Storing

Piping Materials and Handling

Pipes used for the refrigerant piping system must include the specified thickness, and the interior must be clean.

While handling and storing, do not bend or damage the pipes, and take care not to contaminate the interior with dust, moisture, etc. See Table 5 for care of piping.

Table 5: Three Principles of Refrigerant Piping

Dry

Principles No moisture should be inside the piping.

Moisture

Clean

No dust should be inside the piping.

Dust

Airtight

No leaks should occur.

Leaks

18

Problems

Caused

- Significant hydrolysis of refrigerant oil.

- Refrigerant oil degradation.

- Poor insulation of the compressor.

- System does not operate properly.

- EEVs, capillary tubes are clogged.

Solutions - Remove moisture from the piping.

- Piping ends should remain capped until

connections are complete.

- Do not install piping on a rainy day.

- Connect piping properly at the unit’s side.

- Remove caps only after the piping is

cut, the burrs are removed, and after

passing the piping through the walls.

- Evacuate system to a minimum of 500

microns and ensure the vacuum holds at

that level for 24 hours




- EEVs and capillary tubes become

clogged.

- Remove dust from the piping.

- Piping ends should remain capped until

connections are complete.

- Connect piping properly at the side of

the unit.

- Remove caps only after the piping is cut

and burrs are removed.

- Retain the cap on the piping when

passing it through walls, etc.

- Refrigerant gas leaks / shortages.




- Test system for air tightness.

- Perform brazing procedures that comply

with all applicable standards.

- Perform flaring procedures that comply

with all applicable standards.

- Perform flanging procedures that

comply with all applicable standards.

- Ensure that refrigerant lines are pressure

tested to 550 psig.




Piping Materials and Handling

Brazing Practices

Figure 22: Refrigerant Pipe Brazing.

It is imperative to keep the piping system free of contaminants and debris such as copper burrs, slag, or carbon dust during installation. Contaminants can result in mechanical failure of the system.

Nitrogen

Taping

Valve

All joints are brazed in the field. Duct Free System Single Zone Inverter refrigeration system components contain very small capillary tubes, small orifices, electronic expansion valves, oil separators, and heat exchangers that can easily become blocked. Proper system operation depends on the installer using best practices and utmost care while assembling the piping system.

• While brazing, use a dry nitrogen purge operating at a minimum pressure of three (3) psig and maintain a steady flow.

• Blow clean all pipe sections with dry nitrogen prior to assembly.

• Use a tubing cutter, do not use a saw to cut pipe. De-burr and clean all cuts before assembly.

• Store pipe stock in a dry place. Keep pipe capped and clean.

• Use adapters to assemble different sizes of pipe.

• Do not use flux, soft solder, or anti-oxidant agents.

• Use a 15% silver phosphorous copper brazing alloy to avoid overheating and produce good flow.

• Protect isolation valves, electronic expansion valves, and other heat-sensitive control components from excessive heat with a wet rag or a heat barrier spray product.

refrigerant Piping system Insulation

All refrigerant piping, field-provided isolation ball valves, service valves, and elbows shall be completely insulated using closed cell pipe insulation. The liquid and vapor lines must be insulated separately.

To prevent heat loss/heat gain through the refrigerant piping, all refrigerant piping including liquid lines and vapor lines shall be insulated separately.

Insulation shall be a minimum 1/2″ thick, and thickness may need to be increased based on ambient conditions and local codes.

All insulation joints shall be glued with no air gaps. Insulation material shall fit snugly against the refrigeration pipe with no air space between it and the pipe. Insulation passing through pipe hangers, inside conduit, and/or sleeves must not be compressed. Protect insulation inside hangers and supports with a second layer. All pipe insulation exposed to the sun and outdoor elements shall be properly protected with PVC, aluminum vapor barrier, or alternatively placed in a weather-resistant enclosure such as a pipe rack with a top cover and meet local codes.

The design engineer should perform calculations to determine if the factory-supplied insulation jackets are sufficient to meet local codes and avoid sweating. Add additional insulation if necessary. Mark all pipes at the point where the insulation jacket ends. Remove the jacket. Install field provided insulation on the run-out and main trunk pipes first. Peel the adhesive glue protector slip from the insulation jacket and install the clam-shell jacket over the fitting.

For specific insulation procedures, see Refrigerant Piping Connections section in this installation manual.



19



selecting Field-supplied Copper tubing

Copper is the only approved refrigerant pipe material for use with Duct Free System Single Zone products, and LG recommends seamless phosphorous deoxidized ACR type copper pipe, hard-drawn rigid type “K” or “L”, or annealed-tempered, copper pipe.

• Drawn temper (rigid) ACR copper tubing is available in sizes 3/8 through 2-1/8 inches (ASTM B 280, clean, dry, and capped).

• Annealed temper (soft) ACR copper tubing is available in sizes 1/4 through 2-1/8 inches (ASTM B 280, clean, dry, and capped).

Tube wall thickness should meet local code requirements and be approved for an operating pressure of 551 psi. If local code does not specify wall thickness, LG suggests using tube thickness per table below. When bending tubing, try to keep the number of bends to a minimum, and use the largest radii possible to reduce the equivalent length of installed pipe; also, bending radii greater than ten (10) pipe diameters can minimize pressure drop. Be sure no traps or sags are present when rolling out soft copper tubing coils.

Table 6: ACR Copper Tubing Material

Type

Class

Straight Lengths

Coils

Seamless Phosphorous Deoxidized

UNS C12200 DHP

H58 Temper

O60 Temper

Table 7: Piping Tube Thicknesses

OD (in)

Material

Min. Bend

Radius (in)

Min. Wall

Thickness (in)

1/4 3/8 1/2

Rigid Type “K” or “L” and Soft ACR Acceptable

.563

.03

.9375

.03

1.5

.035

5/8

2.25

.040

3/4

3.0

.042

7/8 1-1/8

Rigid Type “K” or “L” Only

3.0

.045

3.5

.050

1-3/8

4.0

.050

1-5/8

4.5

.050

Table 8: ACR Copper Tubing Dimensions and Physical Characteristics

1-4

Nominal Pipe

Outside

Diameter (in)

1/4

3/8

1/2

5/8

Actual Outside

Diameter (in)

0.250

0.375

0.500

0.625

Nominal Wall

Thickness (in)

--

0.030

0.035

0.040

Drawn Temper

Weight (lb/ft)

--

0.126

0.198

0.285

Cubic ft per

Linear ft

--

.00054

.00101

.00162

Nominal Wall

Thickness (in)

0.030

0.032

0.032

0.035

Annealed Temper

Weight (lb/ft)

0.081

0.134

0.182

0.251

3/4

7/8

0.750

0.875

0.042

0.045

0.362

0.455

.00242

.00336

0.042

0.045

0.362

0.455

1-1/8 1.125

0.050

0.655

.00573

0.050

0.655

1

All dimensions provided are in accordance with ASTM B280 – Standard.

2

Design pressure = 551 psig.

3

ACR Tubing is available as hard drawn or annealed (soft) and are suitable for use with R410A refrigerant.

4

The Copper Tube Handbook, 2010, Copper Development Association Inc., 260 Madison Avenue, New York, NY 10016.

Cubic ft per

Linear ft

.00020

.00053

.00103

.00168

.00242

.00336

.00573

• Commercially available piping often contains dust and other materials. Always blow it clean with a dry inert gas.

• Prevent dust, water or other contaminants from entering the piping during installation. Contaminants can cause mechanical failure.

20





no Pipe size substitutions

Use only the pipe size recommended by this installation manual. Using a different size is prohibited and may result in a system malfunction or failure to work at all.

obstacles

Figure 23: Installing Piping Above and Below an Obstacle.

When an obstacle, such as an I-beam or concrete T, is in the path of the planned refrigerant pipe run, it is best practice to route the pipe over the obstacle. If adequate space is not available to route the insulated pipe over the obstacle, then route the pipe under the obstacle. In either case, it is imperative the length of the horizontal section of pipe above or below the obstacle be a minimum of three

(3) times the longest vertical rise (or fall) at either end of the segment.

3X

Copper expansion and Contraction

Under normal operating conditions, the vapor pipe temperature of a Duct Free System can vary as much as 280°F. With this large variance in pipe temperature, the designer must consider pipe expansion and contraction to avoid pipe and fitting fatigue failures.

Refrigerant pipe along with the insulation jacket form a cohesive unit that expands and contracts together. During system operation, thermal heat transfer occurs between the pipe and the surrounding insulation.

If the pipe is mounted in free air space, no natural restriction to movement is present if mounting clamps are properly spaced and installed. When the refrigerant pipe is mounted underground in a utility duct stacked among other pipes, natural restriction to linear movement is present. In extreme cases, the restrictive force of surface friction between insulating jackets could become so great that natural expansion ceases and the pipe is “fixed” in place. In this situation, opposing force caused by change in refrigerant fluid/vapor temperature can lead to pipe/fitting stress failure.

The refrigerant pipe support system must be engineered to allow free expansion to occur. When a segment of pipe is mounted between two fixed points, provisions must be provided to allow pipe expansion to naturally occur. The most common method is the inclusion of expansion Loop or U-bends. Each segment of pipe has a natural fixed point where no movement occurs. This fixed point is located at the center point of the segment assuming the entire pipe is insulated in a similar fashion. The natural fixed point of the pipe segment is typically where the expansion Loop or U-bend should be.

Linear pipe expansion can be calculated using the following formula:

LE = C x L x (T r

– T a

) x 12

L

T

LE =

C =

T

R a

=

12 =

=

=

Anticipated linear tubing expansion (in.)

Constant (For copper = 9.2 x 10

-6

in./in.°F)

Length of pipe (ft.)

Refrigerant pipe temperature (°F)

Ambient air temperature (°F)

Inches to feet conversion (12 in./ft.)

1. From Table 9 find the row corresponding with the actual length of the straight pipe segment.

2. Estimate the minimum and maximum temperature of the pipe.

In the column showing the minimum pipe temperature, look up the anticipated expansion distance. Do the same for the maximum pipe temperature.

3. Calculate the difference in the two expansion distance values.

The result will be the anticipated change in pipe length.

Example:

A system is installed and the design shows that there is a 100 foot straight segment of tubing between an indoor unit and the outdoor unit. In heating, this pipe transports hot gas vapor to the indoor units at 120°F. In cooling, the same tube is a suction line returning refrigerant vapor to the outdoor unit at 40°F. Look up the copper tubing expansion at each temperature and calculate the difference.

Vapor line

Transporting Hot Vapor: 100 ft. pipe at 120 °F = 1.40 in.

Transporting Suction Vapor: 100 ft. pipe at 40 °F = 0.40 in.

Anticipated Change in Length: 1.40 in. – 0.40 in. = 1.00 in.

Liquid Line

The liquid temperature remains relatively the same temperature; only the direction of flow will reverse. No significant change in length of the liquid line, therefore, is anticipated.

When creating an expansion joint, the joint height should be a minimum of two times the joint width. Although different types of expansion arrangements are available, the data for correctly sizing an Expansion Loop is provided in Table 1010. Use soft copper with long radius bends on longer runs or long radius elbows for shorter pipe segments. Using the anticipated linear expansion (LE) distance calculated, look up the Expansion Loop or U-bend minimum design dimensions. If other types of expansion joints are chosen, design per

ASTM B-88 Standards.



21



See table below for precalculated anticipated expansion for various pipe sizes and lengths of refrigerant tubing.

To find the anticipated expansion value:

1. From the table below, find the row corresponding with the actual feet of the straight pipe segment.

2. Estimate the minimum and maximum temperature of the pipe.

3. In the column showing the minimum pipe temperature, look up the anticipated expansion distance corresponding to the segment length.

Do the same for the maximum pipe temperature.

4. Calculate the difference in the two expansion distance values. The result will be the change in pipe length.

Table 9: Linear Thermal Expansion of Copper Tubing in Inches

Pipe

Length

1

Fluid Temperature °F

35° 40° 45° 50° 55° 60° 65° 70° 75° 80° 85° 90° 95° 100° 105° 110° 115° 120° 125° 130°

10

0.04 0.04 0.05 0.06 0.06 0.07 0.08 0.08 0.09 0.09 0.10 0.10 0.11 0.11 0.11 0.12 0.13 0.14 0.15 0.15

20

0.08 0.08 0.10 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.22 0.23 0.26 0.28 0.29 0.30

30

0.12 0.12 0.15 0.18 0.20 0.21 0.23 0.24 0.26 0.27 0.29 0.30 0.32 0.33 0.32 0.35 0.39 0.42 0.44 0.45

40

0.16 0.16 0.20 0.24 0.26 0.28 0.30 0.32 0.34 0.36 0.38 0.40 0.42 0.44 0.43 0.46 0.52 0.56 0.58 0.60

50

0.20 0.20 0.25 0.30 0.33 0.35 0.38 0.40 0.43 0.45 0.48 0.50 0.53 0.55 0.54 0.58 0.65 0.70 0.73 0.75

60

0.24 0.24 0.30 0.36 0.39 0.42 0.45 0.48 0.51 0.54 0.57 0.60 0.63 0.66 0.65 0.69 0.78 0.84 0.87 0.90

1

Pipe length baseline temperature = 0°F. "Expansion of Carbon, Copper and Stainless Steel Pipe," The Engineers' Toolbox, www.engineeringtoolbox.com.

Figure 24: Coiled Expansion Loops and Offsets

L L

R

L

R

Large Tubing U-bend (>3/4 in.) Loop

Table 10: Radii of Coiled Expansion Loops and Developed Lengths of Expansion Offsets

Anticipated Linear

Expansion (LE) (inches)

1/2

R

1

L

2

1

1-1/2

2

2-1/2

3

3-1/2

4

R

1

L

2

R

1

L

2

R

1

L

2

R

1

L

2

R

1

L

2

R

1

L

2

R

1

L

2

1/4

6

38

9

54

11

66

12

77

14

86

15

94

16

102

17

109

16

99

17

109

12

77

14

89

19

117

20

126

Nominal Tube Size (OD) inches

3/8

7

44

10

63

1/2

8

86

16

99

18

50

11

70

14

111

19

122

21

131

22

140

Small Tubing U-bend (<3/4 in.)

143

25

155

26

166

117

21

131

23

83

16

101

19

3/4

9

59

13

22




Piping Materials and Handling / Piping Support

Pipe Bends

When bending soft copper, use long radius bends. Refer to the "Radii of Coiled Expansion Loops and Developed Lengths of Expansion

Offsets” table for minimum radius specifications, as shown on previous page.

In-line refrigeration Components

Components such as oil traps, solenoid valves, filter-dryers, sight glasses, tee fittings, and other after-market accessories are not permitted on the refrigerant piping system between the outdoor unit and the indoor unit.

Duct Free Single Zone systems are provided with redundant systems that assure oil is properly returned to the compressor. Sight-glasses and solenoid valves may cause vapor to form in the liquid stream.

Over time, dryers may deteriorate and introduce debris into the system. The designer and installer should verify the refrigerant piping system is free of traps, sagging pipes, sight glasses, filter dryers, etc.

Field-provided Isolation Ball Valves

LG allows the installation of field-supplied ball valves with Schrader ports at each indoor unit. Full-port isolation ball valves with Schrader ports (positioned between valve and indoor unit) rated for use with R410A refrigerant should be used on both the liquid and vapor lines.

If valves are not installed and a single indoor unit needs to be removed or repaired, the entire system must be shut down and evacuated.

Position valves with a minimum distance of three (3) to six (6) inches of pipe on either side of the valve, and placed between six (6) and twelve (12) inches from the run-out pipe to the upstream main pipe. If ball valves are installed closer to the indoor unit, a section of pipe becomes a dead zone when the valves are closed where oil may accumulate.

using elbows

Field-supplied elbows are allowed as long as they are designed for use with R410A refrigerant. The designer, however, should be cautious with the quantity and size of fittings used, and must account for the additional pressure losses in equivalent pipe length calculation.

The equivalent pipe length of each elbow must be added to each pipe segment (Table 11).

Table 11: Equivalent Piping Length for Piping Components

Component

Elbow (ft.)

1/4

0.5

3/8

0.6

Size (Inches)

1/2

0.7

5/8

0.8

3/4

1.2

Pipe supports

Figure 25: Pipe Hanger Details

A properly installed pipe system should be adequately supported to avoid pipe sagging. Sagging pipes become oil traps that lead to equipment malfunction.

Pipe supports should never touch the pipe wall; supports shall be installed outside (around) the primary pipe insulation jacket (see Figure 25). Insulate the pipe first because pipe supports shall be installed outside (around) the primary pipe insulation jacket. Clevis hangers should be used with shields between the hangers and insulation. Field provided pipe supports should be designed to meet local codes. If allowed by code, use fiber straps or split-ring hangers suspended from the ceiling on all-thread rods (fiber straps or split ring hangers can be used as long as they do not compress the pipe insulation). Place a second layer of insulation over the pipe insulation jacket to prevent chafing and compression of the primary insulation within the confines of the support pipe clamp.



23


Piping Support / Piping Sleeves

Pipe Supports, continued.

A properly installed pipe system will have sufficient supports to avoid pipes from sagging during the life of the system. As necessary, place supports closer for segments where potential sagging could occur. Maximum spacing of pipe supports shall meet local codes.

If local codes do not specify pipe support spacing, pipe shall be supported:

• Maximum of five feet (5′) on center for straight segments of pipe up to 3/4" outside diameter size.

• Maximum of six feet (6′) on center for pipe up to one inch (1″) outside diameter size.

• Maximum of eight feet (8′) on center for pipe up to two inches (2″) outside diameter size.

Wherever the pipe changes direction, place pipe clamps within twelve (12) inches on one side and within twelve to nineteen (12 to 19) inches of the bend on the other side as shown in Figure 26.

Figure 26: Typical Pipe Support Location—

Change in Pipe Direction

Pipe

Clamps

A

B

A + B ≈ 12”–19”

Pipe sleeves at Penetrations

LG requires that all pipe penetrations through walls, floors, and pipes buried underground be properly insulated and routed through an appropriate wall sleeve of sufficient size to prevent compression of refrigerant pipe insulation and free movement of the pipe within the sleeve

(Figure 27). Underground refrigerant pipe shall be routed inside a protective sleeve to prevent insulation deterioration. Refer to Figure 26.

Figure 27: Pipe Sleeve Options.

Diameter of penetrations shall be determined by pipe diameter plus the thickness of the insulation.

24




Underground Piping

underground refrigerant Piping

Refrigerant pipe installed underground should be routed inside a vapor tight protective sleeve to prevent insulation deterioration and water infiltration. Refrigerant pipe installed inside underground casing must be continuous without any joints. Underground refrigerant pipe must be located at a level below the frost line.

Table 12: Utility Conduit Sizes.

Liquid Pipe

1/4 (1.0)

3

3/8 (1-1/8)

3

1

3/8 (1-1/8

2,3

)

4

4

Vapor Pipe

1/2 (2.0

4

4

2,4

)

1

5/8 (2-1/8

4

4

2,4

)

1

OD pipe diameter in inches; Values in parenthesis () indicate OD of pipe with insulation jacket.

2

Diameter of pipe with insulation. Thickness of pipe insulation is typical. Actual required thickness may vary based on surrounding ambient conditions and should be calculated and specified by the design engineer.

3

Insulation thickness (value in parenthesis) = 3/8 inch.

4

Insulation thickness (value in parenthesis) = 1 inch.

Figure 28: Typical Arrangement of Refrigerant Pipe and Cable(s) in a

Utility Conduit.

Vapor Line

Insulation Material

Liquid Line

Cable

Pipe Sleeve

Table 13: Heat Pump Unit Refrigerant Pipe Connections

(All Brazed Type)

Model

LSU090HSV4, LSU120HSV4

LSU180HSV4

Liquid Conn.

(inches)

1/4

3/8

Vapor Conn.

(inches)

3/8

5/8



25

RefRigeRant PiPing ConneCtions

Refrigerant Piping System Limitations/Installation

Connection Limitations

Single zone systems consist of one outdoor unit and one indoor unit. One of the most critical elements of a single zone system is the refrigerant piping. Table 14 lists pipe length limits that must be followed in the design of a Single Zone Wall Mount refrigerant pipe system. Refer to Figure 27 for maximum length and elevation of piping.

Figure 27: Single Zone System Layout

Unit = Feet

Indoor unit

Max Length = A

Max Elevation = B

Outdoor unit

A

A

B

B

Table 14: Single Zone High Efficiency Refrigerant Piping System Limitations

Outdoor unit

Indoor unit

Pipe Length

(ELF = Equivalent Length of pipe in Feet)

Elevation

(All Elevation Limitations are

Longest total equivalent piping length

Shortest total equivalent piping length

LS090HSV4 LS120HSV4 LS180HSV4

65.6

6.6

65.6

6.6

98.4

Distance between fittings and indoor units or outdoor units ≥20 inches ≥20 inches ≥20 inches

If outdoor unit is above indoor unit

32.8

32.8

9.8

49.2

Measured in Actual Feet)

If outdoor unit is below indoor unit

Additional Refrigerant Needed (oz/ft)

32.8

0.22

32.8

0.22

49.2

0.38

installation

Duct Free Single Zone Wall Mounts are a one-to-one system. There is a direct piping connection between the outdoor unit and the indoor unit. Figure 28 Illustrates the basic pipe connections between the outdoor and indoor unit. Refer back to this illustration as you proceed with pipe connections. This illustration shows the indoor unit being installed at a higher position than the outdoor unit, however, should you install the outdoor unit at a higher position than the indoor unit, the basic pipe connections should be the same.

Refer back to the table within the “Connection Limitations” section (above) for specific length limitations in conjunction with outdoor unit and indoor unit positioning.

Figure 28: Installation and Piping Connection Overview

Installation Overview

• As you proceed with the piping connections be sure to adhere to pipe support spacing lengths as shown in Figure 29 below. Refer back to “Pipe Supports” section for in-depth information regarding using elbows, clamps and pipe supporting materials.

• Always adhere to local codes regarding piping and accurate support spacing along the outdoor pipe line.

Figure 29: Pipe Support Lengths - Outdoors

Installation plate

Sleeve

Bushing-Sleeve

Putty(Gum Type Sealant)

Bend the pipe as closely on the wall as possible, but be careful that it doesn't break.

Saddle

Vinyl tape (Wide)

• Apply after carrying out a

drainage test.

26

Pipe

Clamps

A

Air Inlet

Air Outlet

Base Plate

B

A + B ≈ 12”–19”

Additional accessories/parts/tools that will be needed for installation but are not provided by LG.



Gas side piping

Liquid side piping

Additional drain pipe

Vinyl tape (Narrow)

Drain Hose

Connecting cable

Tubing Cover


Directional Pipe Formation

Pipe Bundling

See Figure 30 for proper pipe and cable bundling. Note the placement of the piping along with the necessary insulation material.

1. Be sure to wrap each pipe with proper insulation material.

2. Secure the piping by wrapping vinyl tape around the pipe.

• Use the narrow size tape for wrapping the actual pipe.

3. You can include the drain hose within the bundled piping and wrap all of them together using the wider vinyl tape as shown in Figure 31.

• The end of the drain hose outlet must be routed above the ground.

Figure 30: Cutaway of Proper Pipe and Cable Bundling

Vapor Line

Insulation Material

Liquid Line

Pipe Sleeve

Cable

Indoor Unit Installed Above Outdoor Unit

1. Refer to Figure 32 while following the procedures below.

2. Tape the piping, drain hose and connecting cable from down to up.

3. Secure the taped piping along the exterior wall using pipe clamps.

4. Create trap above the electrical connections cover, in order to prevent water from penetrating electrical components and wiring.

Figure 31: Bundling and Taping

Bundling Piping

Drain hose

Pipe

Vinyl tape(narrow)

Indoor Unit Installed Below Outdoor Unit

1. Refer to Figure 33 while following the procedures below.

2. Tape the piping, drain hose and connection cable from down to up.

3. Secure the taped piping along the exterior wall using pipe clamps.

4. Create trap above the electrical connections cover, in order to prevent water from entering the room.

Figure 32: IDU Above ODU - Piping and Trap

Indoor Unit Installed ABOVE

Outdoor Unit - Piping/Trap

Seal small openings around pipings with a gum type sealant.

Pipe Clamps to Secure Pipe

Against Wall

Connecting cable

Pipings

Figure 33: IDU Below ODU - Piping and Trap

Indoor Unit Installed BELOW

Outdoor Unit - Piping/Trap

Trap

Taping

Drain hose

Pipe Clamps to Secure Pipe

Against Wall

Trap

Trap is required to prevent water from entering into electrical parts.



27


Drain Hose

Drain Hose Guidelines

Refer to the diagrams below and follow proper installation and the running of the drain hose along the pipe installation line to avoid leakage. Once drain hose is set in place, always follow with evacuation and leakage testing of all piping to be sure all piping is properly sealed. Re-check and retest as necessary.

Drain hose is routed from the indoor unit through the structure (wall) to the outdoor. It should slope at an angle where it is higher at the indoor unit and lower toward the outdoor area, thereby letting gravity push any condensation down and out. See Figure 34 for proper drainage slope. Avoid piping the drain hose as shown in Figure 35.

These methods are incorrect and can cause leakage at the indoor unit site.

Figure 34: Correct Slope Angle for Drain Hose

Figure 35: Correct Slope Angle for Drain Hose

Indoor Unit

Incorrect Drainage Setup

Water leakage

Upward slope to outdoor can cause indoor leaks!

Correct Drainage Slope

Downward slope to outdoor for proper drainage

Indoor Unit

Accumulated drain water

Air

Indoor

Unit

Water leakage

Waving

Piping

Tip of drain hose dipped in water

Indoor Unit

Water leakage

Ditch

Drain Hose

Less than

2 Inch gap from ground

28




Outdoor Unit Connections

single Zone High efficiency Wall Mount outdoor Unit Connections

1. Remove the tubing cover by loosening the fastening screws.

See Figure 36.

2. Align the center of the refrigerant pipe and corresponding connection as shown in Figure 37.

Figure 36: Outdoor Unit Connection Cover Removal (HSV4)

3. Refer to Figure 38 for correct liquid and gas pipe attachment onto outdoor unit.

4. Place a couple of drops of refrigerant oil on the opening rim of the flare before assembling. Ensure you do not add any contaminants. Tighten the flare nut initially by hand.

5. Finish tightening the flare nut with a torque wrench until the wrench clicks. Follow torque guidelines in Table 15. See Figure

38 for correct connection points.

Tubing Cover

When tightening the flare nut with a torque wrench, ensure the direction for tightening follows the arrow on the wrench.

Table 15: Torque Wrench Tightening

Outside Diameter (inches)

1/4

3/8

1/2

5/8

Torque (lbs-ft)

13-18

24.6-30.4

39.8-47.7

45.6-59.3

Do not thread liquid or gas piping through bracket used to hold main power cables.

Figure 37: Pipe Attachment

Bracket for

Main Power Cables

Figure 38: Outdoor Unit Piping Connection (HSV4)

Outdoor Unit

Liquid Piping

(Smaller diameter)

Torque Wrench

Bracket for

Main Power

Cables



Gas Piping

(Larger diameter)

29


Indoor Unit Connections

single Zone High efficiency Wall Mount Piping to indoor Unit

Follow the steps below and refer to the illustrations on this page to connect piping to the Single Zone indoor unit. To see specific bundling of piping and drain hose, see Section, “Bundling and Cutting Line” on page 31. Also, refer back to “Drain Hose Guidelines”

section for proper drainage slope during piping procedure.

1. Pull the screw cap at the bottom of the indoor unit (Figure 39).

2. Unscrew the three (3) screws at the bottom of the chassis cover.

3. Remove the chassis cover, being careful not to scratch the main horizontal vane.

Figure 39: Removing Chassis Cover from Indoor Unit.

4. From the rear of the indoor unit, pull the tubing holder away from the unit as shown in Figure 40.

5. Remove the pipe port cover.

6. Position the tubing by unfolding the tubing and bending the tubing slowly downward first, as shown below.

Bending the tubing directly left or right, without bending downward first, may cause damage.

Figure 40: Bending Pipe Tubing at Rear of Indoor Unit.

Unfold slowly downward

30

Chassis cover

Do not bend tubing directly backwards or to the sides without bending downward first!

This may cause damage!

Bend from downward position




Bundling and Cutting Line

Piping and cabling must be insulated and bundled together correctly for safety and usage. Follow proper methods and procedures as outlined here and on the next pages to ensure installation and piping are correctly installed.

Figure 41: Piping with Insulation Material

As shown in Figure 41, the connection pipe, along with the indoor unit pipe are fully encased in insulation material.

1. Bind together the two pipes, using vinyl tape. Make sure there are no gaps during the binding.

2. Be sure the tube cutting line is placed upward (Figure 42).

3. Verify that rear piping house section is wrapped with vinyl tape.

• Use a narrow type of vinyl tape for this step.

4. Continue to wrap the indoor unit pipe as connected to the outdoor connection pipe as shown in Figure 43.

Insulation material

Figure 42: Correct Cutting Line Placement

Cutting Line

Figure 43: Wrapping Connection Pipe to Indoor Unit’s Pipe

Connection pipe

Vinyl tape (wide)

Indoor unit pipe

Wrap with vinyl tape

Connecting cable

Pipe

Vinyl tape(narrow)

Gas Pipe

Liquid Pipe

Correct Incorrect

Cutting Line

5. Using a wider vinyl tape, bundle the piping and drain hose together (Figure 44).

• Tape should be sufficient to cover the piping in order to fit into the rear piping housing area at the back of the indoor unit (Figure 45).

Figure 45: Bundling and Placement at Rear of IDU

Figure 44: Bundling Pipe and Drain Hose, Rear of IDU

Wrap with vinyl tape

Pipe

Vinyl tape(wide)

Drain hose

Tape

Connecting cable

Drain hose

Connecting pipe

Drain hose



31


Refrigerant Piping Insulation

Refrigerant Piping insulation

To prevent heat loss/heat gain through the refrigerant piping, all refrigerant piping including liquid lines and vapor lines must be insulated separately. Insulation must be a minimum 1/2″ thick, and thickness may need to be increased based on ambient conditions and local codes.

All refrigerant piping including field-provided isolation ball valves, service valves, and elbows must be completely insulated using closed-cell pipe insulation. All insulation joints must be glued with no air gaps. Insulation material must fit snugly against the refrigeration pipe with no air space between it and the pipe. Insulation passing through pipe hangers, inside conduit, and/or sleeves must not be compressed. Protect insulation inside hangers and supports with a second layer. All pipe insulation exposed to direct sunlight and deterioration-producing elements must be properly protected with a PVC-aluminum vapor barrier jacket, or alternatively placed in a weather-resistant enclosure such as a pipe rack with a top cover. The design engineer should perform calculations to determine if the factory-supplied insulation jackets have sufficient thickness to meet local codes and to avoid sweating at jobsite conditions. Maximum refrigerant pipe temperature is 227°F; minimum refrigerant pipe temperature is -4°F. Add additional insulation if necessary.

Figure 47: Typical Insulation

Butt-Joint at Indoor Unit Casing

Figure 48: Typical Refrigerant

Flare Fitting Insulation Detail

Figure 46: Typical Pipe Insulation, Power Wire and

Communications Cable Arrangement

C

D

D

B

A

E

C

D

E

A

B

Liquid Pipe

Gas Pipe

Power Wiring

Insulation

Communication Cables

Surface of

Indoor Unit Casing

Field-Provided

Pipe Insulation

• Do not insulate gas and liquid pipes together as this can result in pipe leakage and malfunction due to extreme temperature fluctuations.

• Be sure to fully insulate the piping connections.



32


Refrigerant Piping Insulation

Minimum Refrigerant Pipe Ethylene Propylene Diene Methylene (EPDM) Insulation Wall Thickness Requirements

Follow locals codes when selecting EPDM insulation wall thickness.

Table 16: Insulation Guidelines for Typical and Special Circumstances

Classification

Air-conditioned location

1. Typical location 2. Special location

Liquid pipe

Vapor pipe

ø1/4 inch

ø3/8 inch

≥ø1/2 inch

ø3/8 inch

ø1/2 inch

ø5/8 inch

ø3/4 inch

ø7/8 inch

ø1 inch

ø1-1/8 inches

ø1-1/4 inches

ø1-3/8 inches

ø1-1/2 inches

ø1-3/4 inches

1/2 inch

1/2 inch

1/2 inch

3/4 inch

1/2 inch

1/2 inch

3/4 inch

1 inch

Non-air conditioned location

3. Typical location 4. Special location

1/2 inch 1/2 inch

1/2 inch 1/2 inch

3/4 inch

1 inch

1 inch

1. Typical location (Air-conditioned location): When the piping passes through an indoor area where the indoor unit operates.

• Apartment, classroom, office, mall, hospital, etc.

2. Special location (Air-conditioned location):

1. When the location is air conditioned, but there is severe temperature/humidity difference due to high ceilings

• Church, auditorium, theater, lobby, etc.

2. When the location is air conditioned, but internal temperature/humidity are high

• Bathroom, swimming pool, locker room, etc.

3. Typical location (Non-Air conditioned location): When the piping passes through an indoor area where the indoor unit does not operate.

• Hallway or a dormitory or school, etc.

4. Special location (Non-Air conditioned location): If conditions 1 and 2 below are present.

1. When the piping passes through an indoor area where the indoor unit does not operate.

2. When the humidity is high and there is no air flow in the location where the piping is installed.

• The thickness of the above insulation material is based on heat conductivity of 0.61 Btu/in/h/ft

2

/°F.



33


Pipe Sleeves at Penetrations

Pipe sleeves at Penetrations

LG requires that all pipe penetrations through walls, floors, and pipes buried underground be properly insulated and routed through an appropriate wall sleeve of sufficient size to prevent compression of refrigerant pipe insulation and free movement of the pipe within the sleeve. Underground refrigerant pipe shall be routed inside a protective sleeve to prevent insulation deterioration.

Figure 49: Pipe Sleeves at Penetrations

Inside wall (concealed)

A

B

C

D

Outside wall

A

Floor (fire-resistance)

D

F

G

B

Roof pipe shaft

G

D

B

H

B

Outside wall (exposed)

E

B

A

40 in

I

Area between fire-resistant insulation and boundary wall

I

J

40 in

Sleeve

Insulation

Lagging

Caulk

Band

Water-resistant layer

Sleeve with edge

Lagging

Mortar or other fire-resistant caulk

Fire-resistant insulation

When filling an access hole with mortar, cover the area with steel plate so that the insulation will not fall through. For this area, use fire-resistant materials for both the insulation and cover. (Vinyl cover should not be used.)

All floor and wall penetrations should be properly sized and large enough to accommodate pipe diameter plus insulation thickness.

34




Air Purging

air Purging Best Practices

Air purging is done to the piping system after all piping has been connected between the indoor and outdoor unit. This step is necessary to be sure that air refrigerant can flow through the system without danger of leakage or pressure issues. Air and moisture that is left in the piping can lead to undesirable results and can cause damage to the working unit. It is important to go through a complete air purging cycle to be sure that the lines are cleared out. Note that you may have to repeat this process should any air or moisture be found to remain in the piping.

After air purging and evacuating the lines, be sure to take a leak test for all piping and tubing.

Figure 50: Removing Service Valve Caps - Outdoor Unit

Insufficient or incorrectly done air purging may lead to the following:

• Pressure in the system can rise.

• Operating current can rise.

• Cooling or heating efficiency falls.

• Moisture in the refrigerant circuit may freeze and block capillary tubing.

• Water can lead to corrosion of parts in the system.

Air Purging with a Vacuum Pump - Preparation Steps

1. Verify that each set of pipes (liquid and gas) are properly connected between the indoor and outdoor unit.

• Verify that all wiring for a test run has been completed.

2. Remove service valve caps from the gas and liquid valves at the outdoor unit (Figure 50).

• Both the liquid and gas side service valves at the outdoor unit should be kept closed at this step.

3. Set up the purging, hose connections by referring to Figure 51.

4. Do a Leak Test, by proceeding to Soap Water Method - Leak

Testing section on next page.

• Successful leak testing must be performed before Evacuation can begin.

5. Go to Evacuation section, on page 37 to complete the purging process.

Outdoor Unit

Evacuation

Gas side

Liquid side

Figure 51: Evacuation Setup

Air Purging/ Evacuation Setup

Indoor Unit

Valve

Caps

• Be sure to use a manifold valve for air purging. If it is not available, use a stop valve for this purpose.

• Be sure that the knob of the three-way valve is always kept close.

Table 17: Evacuation Table

Tubing = Less than 33 ft.

Evacuation Table*

Tubing = More than 33 ft.

10 minutes or more 15 minutes or more

* Required time for evacuation when 30 gal/h vacuum pump is used.

Outdoor Unit

Piping Bundle

Pressure

Gauge

Manifold Valve

Lo Hi

Lo=Open Hi=Close

Charge Hose

Vacuum Pump



35


Leak Test/Soap Method Check

Leak test

Perform the leak test by pressurizing nitrogen gas to 550 psi on both the liquid and gas pipes. Test with the piping service valves closed. If the pressure does not drop for twenty-four (24) hours, the system passes the test. If the pressure drops, there is a nitrogen leak in the system. Find the leak, repair, and then test again.

Pressure Gauge Hookup

1. Connect the manifold valve (which includes the pressure gauges), along with dry nitrogen gas cylinder to the service valves using charge hose (Figure 52).

2. Pressurize the system to maximum 150 P.S.I.G. with dry nitrogen gas and close the cylinder valve when the gauge reading reaches

150 P.S.I.G.

Figure 52: Leak Test Diagram.

Leak Test Using Nitrogen Tank

Indoor Unit

Manifold Valve

Lo Hi

Charge Hose

Use of combustible gases including oxygen, may result in fire or explosion.

Piping Bundle

Using nitrogen runs the risk of fire and explosion. Inert gas (nitrogen) should be used when checking plumbing leaks, cleaning or repairs of pipes, etc.

Nitrogen Gas

Tank (Upright

Position)

Outdoor Unit

• To avoid nitrogen entering the refrigerant system in a liquid state, the top of the cylinder must be higher than its bottom when you pressurize the system.

• Be sure cylinder is used in a vertical standing position.

Soap Water Method - Leak Testing

1. Remove the caps from the 2-way and 3-way valves. See Figure 50.

2. To open the 2-way valve, turn the valve stem counter-clockwise approximately 90°, wait for about 2 to 3 seconds, and close it.

3. While running the nitrogen gas tank hookup, apply a soap water or a liquid neutral detergent on the indoor unit connection or outdoor unit connections by using a soft brush.

4. While running the pressure gauge system, observe the connections for any leaks.

• If you see bubbles appearing at any of the connection points/joints

(at either inside and outside units), it is an indication of a leak.

5. Make a note of where the leaks are coming from along the liquid and gas piping.

6. Disengage the nitrogen pressure by loosening the charge hose connector at the nitrogen cylinder (Figure 52 above).

7. Once system pressure is reduced back to normal range, disconnect hose from the cylinder.

8. At this point you will need to make all repairs to connections and piping where bubbles were observed.

9. Once all repairs are made, repeat soap testing using nitrogen cylinder and check for any further leaks.

10. Once system is leak free, proceed to Evacuation steps.

36

Leak Test Ambient Temperature Correction

If the ambient temperature changed between the time when pressure was applied and when the pressure drop was checked, adjust results by factoring in approximately 1.45 psi for each 2°F of temperature difference.

Correction formula = (Ambient temperature when pressure was applied - Ambient temperature when pressure drop was checked) x 0.01.

Example:

When pressure (550 psig) was applied, the ambient temperature was 80.6 °F; 24 hours later when pressure drop (540 psi) was checked, ambient temperature was 68°F.

Thus, 80.6 - 68 x 0.01 = 0.126. In this case, the pressure drop of

0.126 was due to temperature difference, therefore, there is no leak in the refrigerant piping system.




Evacuation of Lines/Finishing Up/Remote Controller

evacuation

After successful leak testing has been performed, follow Evacuation procedure. Follow the same steps for charge hose hookup to the system.

See Figure 51 on page 35 for proper hookup.

Procedure

1. Confirm that the “Lo” knob of the manifold valve is open. Refer back to Figure 51.

2. Confirm that the “Hi” knob of the manifold valve is left closed.

3. Run the Vacuum pump.

• Operate pump until the system has been evacuated down to 300 microns.

• Run pump an additional 15 minutes after reaching micron level.

4. Turn off the pump and leave the connections secured to the two service valves.

5. Wait 5 minutes.

6. If the system fails to hold 500 microns or less, check all connections for tight fit and repeat the evacuation procedure.

7. Once, desired vacuum is reached, close the “Lo” knob of the manifold valve and stop the vacuum pump.

8. Proceed to Finishing the Job section, below.

The duration of the operation of the vacuum pump will vary according to pipe length and the capacity of the pump. Refer to Table 17 for accurate time duration.

finishing the Job

Once the Evacuation procedure has been performed, follow the steps below to turn off all valves at the outdoor unit and safely disengage the manifold valve, along with the vacuum pump. Refer back to the illustrations and tables on the previous pages as you go through the steps below.

Procedure

1. Using a wrench, turn the valve of the liquid stem counter-clockwise to fully open the valve (refer back to Figure 51).

2. Turn the valve of the gas stem counter-clockwise to fully open the valve.

3. Loosen the charge hose connected to the gas side service port slightly to release the pressure, and then remove the hose.

4. Replace the flare nut and its cap on the gas service port and fasten the flare nut securely using an adjustable wrench.

• This process is very important to prevent leakage from the system.

5. Replace the valve caps at both gas and liquid side service valves and then fasten them tightly.

• Once done, this will complete the air purging process with a vacuum pump.

test Running

After leakage testing, and evacuation procedure the system should be ready to start up for a test run. Follow the guidelines below for proper procedure.

• Check that all tubing, piping and wiring are properly connected.

• Make sure that the gas and liquid service valves are fully open.

• Start up the system and do a test run.

• As system is up and running verify all is in working order and make notes as needed to work around any issues that might crop up.

installing Batteries into Remote Controller

Figure 53: Remote Controller - Installing Batteries

As part of test running, you will need to insert batteries and power on the remote controller.

To insert the batteries follow the steps below. For information on using the remote controller, refer to its owner’s manual.

Procedure

Single Zone Remote Controller - Rear View

Battery

Cover

Battery Cover

Tab

1. The remote controller needs two AAA (1.5V) batteries for operation. Remove the battery cover from the back of the remote controller (Figure 53).

• Push downward on the tab at the top of the battery cover and then lift up to remove.

2. Insert the two new batteries.

1. Push down on tab

2. Lift cover

3. Insert batteries

3

• Align batteries by the (+) and (-) sides.

• The interior battery compartment of the remote controller will have clear markings for the (+) and (-) placement.

3. Verify that the batteries have “clicked” into the compartment and are firmly engaged with the contacts on either side of them.

4. Reattached the back cover of the remote controller.

5. Proceed with powering on the remote controller and usage as needed.



37


Pump Down, Cooling Only Mode

Never air purge with refrigerant as it can lead to refrigerant leakage which can cause bodily harm and injury, especially if inhaled.

Use a vacuum pump that can evacuate down to 500 microns.

1. If moisture remains in the piping after the system is evacuated for two (2) hours, break the vacuum (down to 7.5 psi with nitrogen gas).

2. Evacuate the system again with the vacuum pump for at least one (1) hour to 500 microns

3. If the system does not reach 500 microns within two (2) hours, repeat the vacuum break and evacuation procedure until the gauge does not rise.

Pump Down Procedure

This procedure is performed when a unit has to be relocated or the refrigerant circuit is serviced. “Pumping down” is a term used to mean collecting all refrigerant into the outdoor unit without the loss of any refrigerant. Follow the procedure and guidelines below to safely collect refrigerant back into the outdoor unit. Always adhere to and be familiar with local codes regarding the handling of refrigerant.

The system must be placed in Cooling mode in order to proceed with the pump down procedure. If needed, refer to the sections below for proper steps to place the unit into Cooling Mode.

1. Connect a low-pressure gauge with manifold hose to the charge port on the gas line service valve.

2. Open the gas line service valve halfway.

3. Purge the air in the manifold hose using the refrigerant.

4. Close the liquid line service valve all the way.

5. Turn on the units power switch and start the cooling mode operation.

6. Observe the pressure gauge reading. When it gets to 1 to 0.5 kg/cm

2

(14.2 to 7.1 P.S.I.G), fully close the gas line valve and then immediately turn the unit off.

• Pump down procedure is complete at this time and all refrigerant should be collected into the outdoor unit.

Never inhale or handle refrigerant directly. Doing so may cause bodily harm and injury.

enabling Cooling only Mode

Before running the Pump Down procedure, you must place the unit into Cooling Only Mode. In order to be able to run Cooling Only

Mode, you must enter the unit into the Installer Mode by pressing the

Reset button and the JET MODE button simultaneously.

1. Shut down power to system completely.

2. Enter the Installer Mode as stated in the paragraph above.

3. Set code to 45.

4. Press Power-ON button and select the code number 45.

• Unit should beep to acknowledge that code has been received.

5. Turn off power.

• Let unit cycle off for a minimum of 30 seconds.

6. Turn power back on to system.

Perform Pump Down procedure only in the cooling mode.

Disabling Cooling only Mode

After Pump Down procedure has been performed, you will need to disable Cooling Only Mode, and place the unit back into normal operating mode. Follow the procedure below.

1. Shut down power to system completely.

2. Enter the Installer Mode.

3. Set code to 46.

4. Press Power-ON button and select the code number 46.

• Unit should beep to acknowledge that code has been received.

5. Turn off power.

• Let unit cycle off for a minimum of 30 seconds.

6. Turn power back on to system.

• Once the system is in Installer Mode (with Cooling Only Mode initiated), automatic operation is suspended.

• Once Cooling Only Mode is disabled, the unit will return to normal operation.

• Installer Code cannot be entered if the unit is running. The system must be completely powered off.

• All Installer Code numbers must be entered into the system during Power Off state. (Compete shutdown of the system.)

• WLAN Module’s communication time will lag by about 1 minute after unit is turned back on, and in normal operating mode.

• Entire lock or Mode lock cannot be set if you set heating or automatic operation through the central controller.

38



ElEctrical Wiring

General Information and Safety Guidelines

• All power wiring and communication cable installation must be performed by authorized service providers working in accordance with local, state, and National Electrical Code regulations related to electrical equipment and wiring, and following the instructions in this manual.

• Undersized wiring may lead to unacceptable voltage at the unit and may cause unit malfunction and be a fire hazard.

• Properly ground the Single Zone outdoor and indoor unit. Ground wiring is required to prevent accidental electrical shock during current leakage.

• Ground wiring must always be installed by a qualified technician.

• Do not connect ground wire to refrigerant, gas, or water piping; to lightning rods; to telephone ground wiring; or to the building plumbing system. Failure to properly provide a National Electrical

Code-approved earth ground can result in electric shock, physical injury or death.

• Install appropriately sized breakers / fuses / overcurrent protection switches and wiring in accordance with local, state, and National

Electrical Code regulations related to electrical equipment and wiring, and following the instructions in this manual. Using an oversized breaker or fuse may result in electric shock, physical injury or death.

• Consider ambient conditions (temperature, direct sunlight, inclement weather, etc.) when selecting, installing, and connecting the power wiring.

• Properly ground the Single Zone outdoor and indoor unit. Improperly ground wire can cause communication problems from electrical noise, and motor current leakage. Ground wiring must always be installed by a qualified technician.

• If the system operates in reversed phase, it may damage the compressors and other components.

• If there is a possibility of reversed phase, phase loss, momentary blackout, or the power goes on and off while the system is operating, install a field-supplied phase loss protection circuit.

• Do not connect ground wire to refrigerant, gas, or water piping; to lightning rods; to telephone ground wiring; or to the building plumbing system. Failure to properly provide a National Electrical

Code-approved earth ground can result in property damage and equipment malfunction.

• Install appropriately sized breakers / fuses / overcurrent protection switches and wiring in accordance with local, state, and National

Electrical Code regulations related to electrical equipment and wiring, and following the instructions in this manual. Using an oversized breaker or fuse may result in equipment malfunction and property damage.

Separating Power Wires and communication cables

• Position the power wiring a minimum of two (2) inches away from the communication cables to avoid operation problems caused by electrical interference. Do not run both in the same conduit.

• If it is necessary to run the power wiring and communication cable alongside each other and cannot be avoided, see Table 18 below for minimum recommended distances.

Table 18: Power Wire and Communications Cable Minimum Required Separation Minimum Allowable Distances

Capacity of Power Supply Wiring (current)

10A

100V or more

50A

100A

Recommended Minimum Distance

1,2

12 inches

20 inches

40 inches

2

1

Exceed 100A 60 inches

The figures above are based on parallel lengths up to 328 feet long. For lengths in excess of 328 feet, the distances will have to be recalculated in direct proportion to the additional line lengths involved.

If the power supply waveform continues to exhibit some distortion, the space between the power wiring and communication cable should be increased.

• Do not secure the power wiring and communication cables together.

• Do not run the power wiring and the communication cable in the same conduit. Doing so will result in communication issues due to electrical noise and motor current leakage.



39


Power Wiring Specifications and Best Practices

Power Supply / Power Wiring Specifications

• Single Zone systems operate at 1Ø, 208-230V, 60Hz.

• Power supply, wire type and size should be selected based on National Electrical Code and local codes. Maximum allowable voltage fluctuation ±10% or nameplate rated value. Refer to Figure 54 for wiring guidelines.

• Properly ground the Single Zone outdoor unit and indoor unit per National Electrical Code and local codes.

• Use only copper wiring that is stranded and shielded with the wires separately insulated.

• Ground wire should be longer than the common power/communication wires.

• Refer to the inside of the Chassis Cover for Circuit and Terminal Block Diagrams for your model unit.

• Always match color codes of each wire and follow wiring diagram.

connecting the Power Wiring guidelines

Best practice dictates using ring or spade terminals to terminate power wiring at the power terminal block (Figure 55).

If ring terminals or spade clips are not available, then:

Figure 54: Single Zone Outdoor and Indoor Wiring and Communications Cable Diagram

Line Voltage

(208/230V)

For 9/12K Indoor Units: AWG 14

For 18K Indoor Units: AWG 12

6/16” ± 2/16”

Do not terminate different gauge wires to the power terminal block. Slack in the wiring may generate heat and fire.

GN/YL

Power Wiring, Ground to Outdoor Unit

• When terminating wires of the same thickness, follow the instructions demonstrated in the illustrations below at Figure 56.

• Firmly attach the wire; secure in a way to prevent external forces from being imparted on the terminal block.

• Use an appropriately sized screwdriver for tightening the terminals.

• Do not over tighten the connections; overtightening may damage the terminals.

13/16”

For 9/12/18K Indoor Units: AWG 18

6/16” ± 2/16”

Power Wiring, Ground,

Communication Cable

From Outdoor Unit

To Indoor Unit

Figure 55: Close up of a Typical Ring Terminal

Ring Terminal

Power Wiring

GN/YL

13/16”

GN/YL = (Ground, Yellow)

Figure 56: Proper and Improper Power Wiring Connections

:Copper Wire

40

Terminate multiple power wires of the same gauge to both sides.

Do not terminate two wires on one side.

Do not terminate different gauge wires to a terminal block.




Power Wiring Specifications and Best Practices/Controller Options

Power Supply/Power Wiring Specifications, continued

• If power wires are not properly terminated and firmly attached, there is risk of fire, electric shock, and physical injury or death.

• Never ground the shield of the communications cable to the indoor unit frame or other grounded entities of the building.

• Never apply line voltage power to the communications cable terminal block. If contact is made, the PCBs may be damaged.

• Always include some allowance in the wiring length when terminating. Provide some slack to facilitate removing the electrical panels while servicing.

general communication cable Specifications

• Use a four (4) conductor, shielded, stranded cable between the

Single Zone outdoor unit and the indoor unit.

• Firmly attach the cable; provide slack but secure in a way to prevent external forces from being imparted on the terminal block.

• Minimum 18 gauge shielded CVVS or CPEVS cable.

• Insulation material as required by local code.

• Rated for continuous exposure of temperatures up to 140°F.

• Maximum allowable cable length: 984 feet.

• Wiring should be completed without splices.

• Terminate the cable shield to a grounded surface at the outdoor unit only.

• Always verify the communication cable is connected to a communications terminal on the Single Zone unit. Never apply line voltage power to the communication cable connection. If contact is made, the PCBs may be damaged.

• The shield of the communications cable connecting the outdoor unit to the indoor unit should be grounded only to the outdoor unit frame.

• Tie the shield of each cable segment together using a wire nut at each indoor unit. Maintain polarity throughout the communication network.

• Position the outdoor unit communications cables away from the power wiring. Refer to minimum spacing requirements provided in

Table 18.

• Never use a common multiple-core communications cable. Each communications bus shall be provided a separate cable (i.e., between outdoor unit and indoor unit).

communication cables Between the Single Zone Unit and the controller

• Simple Controllers: field-provided, 18 gauge, stranded four-conductor communication cable (shielded).

• All other Central Controllers: field-provided, 18 gauge, stranded two-conductor communication cable (shielded).

• Insulation material as recommended by local code.

• Connect all central control devices such as ACP, BACnet

® and LonWorks

®

gateways, and energy recovery ventilators all on the same cable. Order does not matter. Polarity does. Keep “A” terminals with “A” terminals, and “B” terminals with “B” terminals.

• Starting at the outdoor unit, terminate the cable on terminals Internet A and Internet B. Route the cable as needed between each device.

controller Options

Refer to Table 19 as to which remote controller models is used for each system. Once all wiring is connected to the indoor and outdoor units be sure to test the accompanying remote controllers for performance. As always, follow all safety warnings and notes when operating the

Single Zone units using the remote controller. Additionally, most of the Single Zone High Efficiency outdoor models can use the following controllers when accompanied with the PI 485 VNet Accessory:

• AC Smart • LonWorks®

Table 19: Single Zone Models and Associated Remote Controller Model

• ACP

• BACnet®

• LGMV

Single Zone Model Type

Singe Zone High Efficiency System

Remote Controller Model

LS090HSV4, LS120HSV4

LS180HSV4

AKB73835317

AKB73835317



41


Indoor Unit Electrical Connections

Overview - connecting indoor Unit Electrical Wiring

The general guidelines for connecting electrical and communication cables to the indoor unit are the same for each Single Zone High Efficiency Wall Mount system, however, the actual connections on the terminal block will differ. See each illustration for the model that you are wiring for correct contact on each terminal block. Depending on your indoor unit, the location of the terminal block on the indoor unit might vary slightly from the images shown in this section.

Figure 57: Latch over Screws on Bottom Panel, Indoor Unit

• Be sure that main power to the unit is completely off before proceeding with these steps.

• Follow all safety and warning information outlined at the beginning and throughout this manual. Failure to do so may cause bodily injury.

• Follow all safety and warning information outlined at the beginning and throughout this manual. Failure to do so, may cause unit failure.

• Some units might require you to remove the Control Cover from the terminal block area. Most Control Covers are attached with a phillips screw head.

• Connect the electrical cable to the indoor unit by connecting the wires to the terminals on the control board individually according to the outdoor unit connection. Be sure that the color of the wires at the outdoor unit along with the terminal numbers are the same as those for the indoor unit.

Figure 58: Remove Screws from Bottom Panel

Procedure

Be sure there is no power going through the Single Zone system before proceeding with these connections as there may be a risk of electrical shock and bodily injury.

1. At the bottom panel of the indoor unit, unsnap the latches which cover the phillips screw heads as shown in Figure 57.

• Normally, there are three (3) screws on the panel, however, your indoor unit model may differ.

2. Using a phillips head screwdriver, remove the screws from the bottom panel of the indoor unit and set aside (Figure 58).

3. Remove the bottom panel (Figure 59).

• Removal is necessary to gain access to the terminal block which is situated at the bottom of most indoor units.

• Note that the electrical/communications wiring is usually routed through the back/bottom of the indoor unit (through a knockout panel) as shown on the next page (Figure 60).

4. Using a screwdriver, connect the wires as shown on the next page (Figure 61).

• Each wire should be securely attached to the terminal block.

• Pay attention to the location/connection of the green/yellow ground cable.

Figure 59: Remove (and Reattachment) Bottom Panel

42




Indoor Unit Electrical Connections

Connecting Indoor Unit Electrical Wiring - Continued

5. When done, reattach the bottom panel to the indoor unit, being careful to align panel using the rear tabs.

• You might need to give the panel a gentle tap with the palm of your hand to be sure it engages at the bottom.

6. Using a phillips screwdriver, reattach the screws to the bottom panel and secure.

7. Once screws are in place, re-snap the latches over the screws.

• Refer back to Figure 57 as an example.

8. If all other piping and electrical wiring to the outside unit has been completed at this stage, you can turn the system on to test.

• If you have not completed the piping connections, do not turn power on at this time and proceed to complete all other piping, (along with drain hose) and wiring to the system.

Figure 60: Indoor Unit Knockout (Communication Wires) Figure 61: Indoor Unit Terminal Block with Grounding Cable

(Example Only)

terminal Block connection for

090HSV4, 120HSV4, 180HSV4

See Figure 62 for specific terminal block wiring for all Single Zone

High Efficiency models:

LSN090HSV4

LSN120HSV4

LSN180HSV4

• Pay special attention to the location of the grounding cable and the cable restrainer around the other electrical/communication cables when connecting.

• Note that the terminal block is located behind the drain hose and bundled piping on these units.

Figure 62: 090HSV4, 120HSV4, 180HSV4 Indoor Units - Terminal

Block Connections

090HSV4,120HSV4,

180HSV4

Grounding

Cable



Terminal Block

Connecting Cables

Cable Restrainer

43


Outdoor Unit Electrical Connections

connecting Outdoor Unit Electrical Wiring

The general guidelines for connecting electrical and communication cables to the outdoor unit are the same for each Single Zone High Efficiency Wall Mount system, however, the actual connections on the terminal block will differ. See each illustration for the model that you are installing for correct wiring of each terminal block.

• Be sure that main power to the unit is completely off before proceeding with these steps. Follow all safety and warning information outlined at the beginning of this manual. Failure to do so, may cause bodily injury.

• Be sure that a circuit breaker or some other emergency power cutoff device is in place before any power wiring is done to the system.

Failure to do so, may cause bodily injury or death.

• Never touch any power lines or live cables before all power is cutoff to the system. To do so, may cause bodily injury or death.

Procedure

Refer to Figure 63 at right for an example of how a circuit breaker should be wired through to the Single Zone system.

Figure 63: Circuit Breaker

Main Power Source

• Be sure there is no power going through the Single Zone system before proceeding with these connections as it may result in electric shock.

• Familiarize yourself with the location of the circuit breaker and be sure that all power is cut to the Single Zone unit as it may result in electric shock.

Air

Conditioner

1. Using a phillips head screwdriver, remove the conduit panel cover from the outside unit.

Circuit Breaker

Use a circuit breaker or time delay fuse

2. Before proceeding, inspect all wiring inside the casing to be sure they are secure and have not come loose during transportation and installation of the outdoor unit.

• Loose wires can cause the wiring to burn out quickly.

• Inspect wires for any damage or cracks (manufacturing defects).

3. Confirm that electrical power supply capacity is sufficient to run the unit. See specifications sheets at the beginning of this installation manual for details on power.

4. Confirm that you are using the right gauge size for wiring to proceed.

5. Using a screwdriver, connect the wires as shown in Figures 64 and 65.

• Each wire should be securely attached to the terminal block.

• Bundle the cabling by using a cable restrainer.

• Pay attention to the location/connection of the green/yellow grounding cable; as in some models the connection may be located to the side of the actual terminal block.

• Maintain a minimum of .2” of wire length from terminal block to cable bundle.



44


Outdoor Unit Electrical Connections

terminal Block connection for

090HSV4, 120HSV4

See Figure 64 for specific terminal block wiring for the following

Single Zone High Efficiency outdoor unit models:

LSU090HSV4

LSU120HSV4

Figure 64: 090HSV4, 120HSV4 Outdoor Unit - Electrical Connections

090HSV4, 120HSV4

terminal Block connections for

180HSV4

See Figure 65 for 180HSV4 Single Zone High Efficiency terminal block connections.

Figure 65: 180HSV4 Outdoor Unit - Electrical Connections

180HSV4

Electrical Connections

Terminal Block

Over 0.2"

Tubing Cover

Conduit Panel

090HSV4, 120HSV4

Connection/Communication

Cable (Leading to Indoor Unit)

Power Cord

180HSV4

Outdoor Unit

Terminal Block

Over 0.2”

Power Cord

Conduit Panel Cover

1(L1) 2(L2) 1(L1) 2(L2 ) 3

Conduit Panel



45


Self Diagnosis Functions

lg Monitoring View (lgMV) Diagnostic Software

LGMV software (PRCTSL1 and PRCTFE1) allows the service technician or commissioning agent to connect a computer USB port to the

Single Zone unit’s main printed circuit board (PCB) using an accessory cable without the need for a separate interface device. The monitoring screen for LGMV allows the user to view the following real time data on one screen (Figure 66):

• Actual inverter compressor speed

• Target inverter compressor speed

• Actual outdoor fan speed

• Target outdoor unit fan speed

• Actual superheat

• Target superheat

• Actual subcooler circuit superheat

• Target subcooler circuit superheat

• Main EEV position

• Subcooling EEV position

• Inverter compressor current transducer value

• Outdoor air temperature

• Actual high pressure/saturation temperature

• Actual low pressure/saturation temperature

• Suction temperature

• Inverter compressor discharge temperature

• Front outdoor coil pipe temperature

• Back outdoor coil pipe temperature

• Liquid line pipe temperature

• Subcooler inlet temperature

• Subcooler outlet temperature

• Average indoor unit (IDU) pipe temperature

• Inverter compressor operation indicator light

• Liquid injection valves’ operation indicator lights

• Hot gas bypass valve operation indicator light

• Four-way reversing valve operation indicator light

• Pressure graph showing actual low pressure and high pressure levels

• Error code display

• Operating mode indicator

Figure 66: MV Real-time Data Screen

• Target high pressure

• Target low pressure

• PCB (printed circuit board) version

• Software version

• Installer name

• Model number of IDUs

• Site name

• Total number of connected IDUs

• Communication indicators

• IDU capacity

• IDU operating mode

• IDU fan speed

• IDU EEV position

• IDU room temperature

• IDU inlet pipe temperature

• IDU outlet pipe temperature

• IDU error code

Additional screens can be accessed by tabs on the main screen.

Additional screens include the following:

1. Cycleview (Figure 67): Graphic of internal components including:

• Compressors showing actual speeds

• EEVs

• IDUs

• Temperature and pressure sensors

• Four-way reversing valve

Figure 67: MV Cycleview

2. Graph: Full screen graph of actual high and low pressures and high and low pressure limits. A sliding bar enables user to go back in time and view data.

3. Control FTN: Enables user to turn on IDUs in 1.8°F increments.

4. Useful Tab

• Unit Conversion: Converts metric values to imperial values.

Images on these pages are examples of LGMV screenshots. Actual images may differ depending on the version of the software and the unit installed.

46




Self Diagnosis Functions

LG Monitoring View (LGMV) Diagnostic Software and Cable - Continued

5. Data (Figure 68)

• Data Saving Start: Recording of real time data to a separate file created to be stored on the user’s computer.

• Data Loading Start: Recorded data from a saved “.CSV” file can be loaded to create an LGMV session.

6. Monitoring

• Electrical: The lower half of main screen is changed to show Inverter

Compressor Amps, Volts, Power Hz, Inverter control board fan Hz.

Figure 68: MV Control Indoor Units Screen

Error codes

LGMV software helps the service technician or commissioning agent to troubleshoot system operation issues by displaying malfunction codes (Figure 69). These error codes can be seen on the main screen of the LGMV software program. For an overview of Single

Zone unit error codes, see Error Codes section. For detailed information on how to troubleshoot individual error codes, see the Single

Zone Service Manual.

Figure 69: Error Code Screen

The software is available in a high version with all of the features listed above. The low version has all features as the high version without

Target High Pressure and Target Low Pressure values shown on main screen.

In lieu of connecting to the Water Source Unit (WSU), user has the option to connect to IDU with the use of a USB to RS-485 connector kit.

When connected through IDU, user will not be able to record data.

This software can be used to both commission new systems and troubleshoot existing systems. LGMV data can be recorded to a “.CSV” file and emailed to an LG representative to assist with diagnostic evaluations.

Recommended Minimum PC Configuration:

• CPU: Pentium

®

IV 1.6 GHz

• Main Memory: 1G

• Operating System: Windows

®

XP/Vista/7 32 bit (recommended),

64 bit

• Hard Disk: 600 MB when operating

• MS Office 2003, 2007 (recommended) for select reporting functions

Images on these pages are examples of LGMV screenshots. Actual images may differ depending on the version of the software and the units installed.



47


LG SIMS - Self Diagnosis Functions

The SIMs WLAN module and the smart phone app together provide monitoring and troubleshooting capability for LG Duct Free Systems. SIMs functions only with LG Duct Free products (Figure 70).

SIMs can display and graph operational data for the air conditioner system including the indoor unit and the outdoor unit. SIMs also displays error codes and a troubleshooting guide. A full copy of the LG SIMs Smart Inverter Monitoring System User’s Manual is available on the www.lghvac.com website.

To use SIMs you must be a trained HVAC service technician familiar with variable refrigerant flow (VRF) systems in general and with LG’s Duct Free System products. You should understand the inverter air conditioning operation cycle, the meaning of the data displayed by SIMs, and how to use the data to troubleshoot the system.

Figure 71 shows a Multi F configuration used with the SIMs module and app. LG SIMs can also be used with Single Zone one-to-one configurations such as the Single Zone Wall Mount systems.

Figure 70: LG SIMs App and WLAN Module

High voltages capable of causing death are used in this equipment. Outdoor unit power remains connected during this procedure. Take extreme caution not to touch electrical components or connections. Failure to observe this warning can result in death or severe injury.

Figure 71: SIMs WLAN Module to a Typical Multi F System

• The Duct Free System air conditioning system must run for at least 15–20 minutes before data collected by SIMs 2.0 is valid for troubleshooting.

• You must have the free SIMs app correctly installed on your smart phone before using SIMs.

• Some ODUs have an LGMV extension cable accessed by removing the side handle cover. If the ODU does not have this extension cable, access the LGMV connector by removing the top cover of the ODU.

SIMs App Main Info Screen

The main screen is the first screen displayed after wireless connection is established. Tap the Main Info tab to display current readings regarding your indoor and outdoor unit(s). The Operational Info area of the screen will show active functions or modes by illuminating the light to the right of the function (Figure 72).

Additional Help information can be accessed by tapping the Help Menu buttons at the bottom of this screen.

LG SIMs App on Smart Phone

LG SIMs

WLAN Module

Figure 72: SIMs App Main Info Screen

Operational

Information

AC Cycle

Information on

Main Info Tab

Help Menu

(File is Factory Use Only)



48

SiMs app Screens

Outdoor Info/

Component Screen

Displays the following information:

• Frequency

• FAN1 RPM

• FAN2 RPM

• DC Link

• Current

• Voltage

• EEV Mode

• Restart Timer

• Comp Mode

• EEV


LG SIMS - Self Diagnosis Functions

Outdoor Info/

Temperature Screen


• Inv TD

• Suction

• Discharge

• Cond Mid

• Cond Out

• Heatsink

• Air Temp

Indoor Info Tab


• Frequency

• Operation

• THM Mode

• REM Mode

• FAN

• EEV

• Air Temp

• Pipe-in

• Pipe-mid

• Pipe-out

Graph Info Tab

This tab, has three sub sections:

• IDU - Indoor Unit

Temperature graph.

Displays IDU information in graph format. Information displayed is for the IDU # selected on the Main screen.

• ODU - Outdoor Unit

Temperature and Frequency graph. Displays

ODU information in graph format.

• ODU Electric - Outdoor Unit Electric data graph is displayed.



49

trOUBlESHOOting

Error Codes

troubleshooting Using Error codes

Refer to Tables 20 and Table 22 for error codes that are generated from the indoor and outdoor units. These codes are the most common that will manifest through these units. Your particular model duct free system might generate additional codes not listed here.

Please contact LG Support if you see these types of errors and a simple power down and boot up has not corrected the issue. You should not attempt to fix the system yourself.

Error Codes

• Refer to the figures below for your particular indoor unit’s LED configuration.

• Indicate different types of unit failures, assists in self-diagnosis and to track the frequency of occurrence.

• Error codes are shown on the LEDs of indoor units, wired remote controller, the Single Zone unit control board, and LG Monitoring

View (LGMV) Diagnostic Software.

• If two or more errors occur simultaneously, the lower error code number is displayed first.

• After error is resolved, the error code does not display.

Decoding the Error Display

The first and second number on the LED indicates error number.

Example: 21 = LED1 (Green light) 2x blink, LED2 (Red light) 1x blink

Error Code Nomenclature Definitions

• MICOM: Non-volatile memory chip where unit setup information is stored.

• EPROM: Non-volatile memory chip where device identification, size, and factory defined default component operating parameters are stored.

Figure 73: IDU LS-HSV4 Models

LED 1

(UNITS PLACE)

LED 2

(TENS PLACE)

Receiver

Table 20: Single Zone Wall Mounted Indoor Unit Error Codes

Error

Code

Description

1 Indoor unit room temperature sensor error

2 Indoor unit inlet pipe sensor error

4 Float switch error (optional)

5 Communication error between indoor unit and outdoor units

6 Indoor unit outlet pipe sensor error

9 Indoor unit EPROM error

10 Indoor unit BLDC motor fan lock

12 Indoor unit middle pipe sensor error

No. of Times Indoor Unit

LEDs Blink

LED1

(Plasma LED)

LED2

(Power LED)

1X

6X

9X

-

2X

2X

4X

-

-

1X

1X

-

-

-

-

5X

50



trOUBlESHOOting

Error Codes

troubleshooting Using Error codes - continued

Table 21: Single Zone Wall Mounted Indoor Unit Error Codes - Continued

Error

Code

Description

21 DC Peak (IPM Fault); Compressor DC voltage was too high

22 Current Transformer2 (CT2) error; Alternating current (AC) input too high

23 DC Link Low Volt

25 AC Low/High Volt

26 DC Comp Position Error (not providing rotation), Locking

27 PSC Fault; Current to inverter compressor between AC and DC converter circuit too high

28 Inverter compressor DC voltage is too high

29 Inverter compressor amperage is too high

31 Current-to-current transformer (CT) thermistor is too low

32 Inverter Compressor Discharge Pipe (D-Pipe) Overheat

40 CT Sensor Error; Thermistor is disconnected or shorted out

41 D-Pipe Sensor INV is disconnected or shorted out

44 Outdoor Air Sensor is disconnected or shorted out

45 Middle thermistor of outdoor unit condenser coil is disconnected or shorted out

46 Outdoor unit suction line thermistor is disconnected or shorted out

48 Outdoor unit coil outlet (liquid line) thermistor is disconnected or shorted out

53 Communication failure from outdoor unit to indoor unit

60 Outdoor unit printed circuit board (PCB) EPROM check sum error

61 Outdoor unit condenser coil temperature is too high

62 Outdoor unit inverter compressor PCB heat sink temperature is too high

63 Condenser coil pipe thermistor temperature is too low

65 Heat sink thermistor has disconnected or has shorted out

67 Outdoor brushless direct current (BLDC) fan motor lock error

No. of Times Indoor Unit

LEDs Blink

LED1

(Plasma LED)

LED2

(Power LED)

2X 1X

4X

4X

4X

2X

3X

3X

2X

2X

2X

2X

2X

2X

6X

6X

6X

6X

6X

6X

4X

4X

4X

5X

-

1X

4X

9X

1X

2X

6X

7X

8X

2X

3X

5X

-

1X

2X

3X

5X

7X

5X

6X

8X

3X

Refer to Service Manuals posted on www.lghvac.com for a full description of all error codes and workarounds.



51

trOUBlESHOOting

Error Codes

Single Zone Wall Mounted Outdoor Unit Error codes

The Single Zone Wall Mounted outdoor unit error codes are visible on the outdoor unit, as well as, from the indoor unit. The indoor unit error codes, however, are only visible from the indoor unit and will not display at the outdoor unit. When troubleshooting the system, be sure to verify if the error codes that are being displayed are specific for indoor or outdoor units.

Table 22: Single Zone Wall Mounted Outdoor Unit Error Codes

Error

Code

21

Description

DC Peak (IPM Fault); Compressor DC voltage was too high

22 Current Transformer2 (CT2) error; Alternating current (AC) input too high

23 DC Link Low Volt

25 AC Low/High Volt

26 DC Comp Position Error (not providing rotation), Locking

27 PSC Fault; Current to inverter compressor between AC and DC converter circuit too high

28 Inverter compressor DC voltage is too high

29 Inverter compressor amperage is too high

31 Current-to-current transformer (CT) thermistor is too low

32 Inverter Compressor Discharge Pipe (D-Pipe) Overheat

40 CT Sensor Error; Thermistor is disconnected or is shorted out

41 D-Pipe Sensor INV is disconnected or shorted out

44 Outdoor Air Sensor is disconnected or shorted out

45 Middle thermistor of outdoor unit condenser coil is disconnected or shorted out

46 Outdoor unit suction line thermistor is disconnected or shorted out

48 Outdoor unit coil outlet (liquid line) thermistor is disconnected or shorted out

53 Communication failure from outdoor unit to indoor unit

60 Outdoor unit printed circuit board (PCB) EPROM check sum error

61 Outdoor unit condenser coil temperature is too high

62 Outdoor unit inverter compressor PCB heat sink temperature is too high

63 Condenser coil pipe thermistor temperature is too low

65 Heat sink thermistor has disconnected or has shorted out

67 Outdoor brushless direct current (BLDC) fan motor lock error

No. of Times Outdoor Unit

LEDs Blink

LED1

(Plasma LED)

2X

LED2

(Power LED)

1X

4X

4X

4X

2X

2X

3X

3X

4X

2X

2X

2X

2X

2X

4X

4X

5X

6X

6X

6X

6X

6X

6X

1X

4X

5X

8X

9X

1X

2X

-

2X

3X

5X

6X

7X

6X

8X

3X

-

1X

2X

3X

5X

7X

Refer to Service Manuals posted on www.lghvac.com for a full description of all error codes and workarounds.



52

caUtiOnS fOr rEfrigErant lEakS

Refrigerant Leaks

cautions for refrigerant leaks/introduction

ASHRAE Standards 15-2010 and 34-2010 offer guidelines that address refrigerant safety and the maximum allowable concentration of refrigerant in an occupied space. Refrigerant will dissipate into the atmosphere, but a certain volume of air is required for this to occur safely. For

R410A refrigerant, the maximum allowable concentration is 0.026 lbs./ft

3

per 1,000 ft

3

of air in an occupied space. Buildings with twenty-four

(24) hour occupancy allow half of that concentration.

1

ASHRAE Standards 15 and 34 assume that if a system develops a leak, its entire refrigerant charge will dump into the area where the leak occurs. To meet ASHRAE Standards 15 and 34, calculate the refrigerant concentration that may occur in the smallest room volume on the system, and compare the results to the maximum allowable concentration number (see below for information on how to calculate the refrigerant concentration).

1

Also consult state and local codes in regards to refrigerant safety.

Verify the maximum refrigerant concentration level in the space where the indoor unit will be mounted meets the concentration limit for the application. If the refrigerant leaks and safety limits are exceeded, it could result in personal injuries or death from oxygen depletion.

Take appropriate actions at the end of HVAC equipment life to recover, recycle, reclaim or destroy R410A refrigerant according to applicable

US EPA rules.

To calculate the potential refrigerant concentration level (RCL):

1. Measure the occupied space dimensions (in feet).

2. Calculate the cubic foot volume of air in the smallest occupied space. (To obtain a detailed overview of the RCL, perform the same calculations to the second smallest zone, the third smallest zone until the RCL is obtained for all zones. Also, pay special attention to areas such as basements, etc., where refrigerant cannot dissipate easily.)

3. Divide the refrigerant charge of the Single Zone system serving the area in pounds by the results of step 1.

4. If the calculation indicates that the potential refrigerant concentration level is higher than the allowed RCL, increase the cubic volume of the smallest occupied space or modify the piping system design.

5. The allowable RCL limit for most applications must be equal to or less than 0.026 lbs./ft

3

. In special occupied spaces, however, such as hospitals and nursing homes where occupants may have limited mobility, the allowable RCL limit is cut in half. See ASHRAE

Standard 34-2007 and local codes for detailed information.

1

Refrigerant Concentration Limit (RCL) Calculations

To calculate total refrigerant amount per system:

Amount of

Factory-Charged

Refrigerant per

Outdoor Unit

+

Amount of

Additional

Refrigerant

Trim Charge

=

Total System

Refrigerant

Charge

RCL (lbs./ft

3

) =

Total System Refrigerant Charge (lbs.)

Volume of Smallest Occupied Space (ft

3

)

1

American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE). Atlanta, GA. ASHRAE, Inc. Information about

ASHRAE Standard 15-2010 / 34-2010 and addenda current as of the date of this publication.



53

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PagE 1

Major component rough-in

Description

Single Zone unit was connected properly per local code and the product installation procedures.

All literature and bagged accessories have been removed from the fan discharge.

Indoor unit was installed, properly supported, and located indoors in a non-corrosive environment.

Single Zone unit’s gravity condensate drain line was connected and routed where it properly drains away or, if installed in a mechanical room, was connected and properly routed to a drain terminal.

Piping and insulation

Description

Copper

Over 5/8 inches—Rigid ACR only.

5/8 inches and under—Can use soft ACR.

15% silver brazing material only.

All refrigerant pipes and valves were insulated separately. Insulation butts up against the walls of the indoor units. No gaps or cracks. Insulation was not compressed at clamps and hangers.

Brazing Practices

Description

Medical grade (there are 4 available) dry nitrogen for purging during brazing was used (constant 3 psi while brazing).

Check

Check

Check installation

(For more information on any procedure, refer to the detail provided in the installation section.)

refrigerant Piping

Description

All pipe materials were properly stored, capped, and clean. All burrs were removed after cutting and pipe ends were reamed before brazing.

During refrigerant pipe installation, for each segment of pipe, a record was made of the pipe length (including expansion loops, offsets, double-back sections), and sizes, as well as the quantity and type of elbows used.

All long runs of straight pipe were provided with expansion loops.

A torque wrench and backup wrench were used to tighten all flare connections.

The back side of all flares were lubricated with a small drop of PVE refrigeration oil before tightening flare fittings.

Ensure all field made flares are 45°. Use factory-supplied flare nuts only.

Pipe segments were properly supported and all wall penetrations were sleeved.

Pipe insulation was not compressed at any point.

No oil traps, solenoid valves, sight glasses, filter driers, or any other unauthorized refrigerant specialties were present.

Best practice including a minimum of 20″ of straight pipe was installed between each elbow.

Check

54



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PagE 2

condensate Pump / Drain installation

Power Wire and communications cables

Description

Power wiring was connected to a single phase 208-230V source.

Ground wire was installed and properly terminated at the unit.

The power supplied was clean with voltage fluctuations within specifications. (±10% of nameplate).

Power wiring to the Single Zone outdoor unit was installed per all local electrical code requirements.

Power wiring to the indoor unit was installed per all local electrical code requirements.

LG-supplied cable was used between the indoor unit and its zone controller. No cables were spliced and no wire caps are present.

Communication type RS-485–BUS type.

All communications cables were a minimum of 18-AWG, four (4) conductor, shielded, and stranded, with insulation material per local code. Cable segment shields were tied together.

Used appropriate crimping tool to attach ring or spade terminals at all power wiring and control cable terminations.

All power and control wires were properly separated using the recommended distance provided in the product installation manual.

Check

For further technical materials such as submittals, engineering manuals, service manuals, and catalogs, visit www.lghvac.com.



55

20001747

LG ELECTRONICS INC.

ISO 9001: 2008

LG Electronics U.S.A., Inc.

Commercial Air Conditioning Division

11405 Old Roswell Road

Alpharetta, Georgia 30009 www.lghvac.com

LG Customer Information Center, Commercial Products

1-888-865-3026 USA

Follow the prompts for commercial A/C products.

IM-SZ-HighEfficiencyInverter_HSV4-01-15

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