DELUXE HIGH WALL MINI SPLIT

SERVICE MANUAL

MODEL : HMC030KD1

HMH030KD1

CAUTION

-

BEFORE SERVICING THE UNIT, READ THE "SAFETY

PRECAUTIONS" IN THIS MANUAL.

-

ONLY FOR AUTHORIZED SERVICE PERSONNEL.

International Comfort Products

Contents

Functions .................................................................................................................................3

Product Specifications ..........................................................................................................5

Dimensions ..............................................................................................................................7

Refrigeration Cycle Diagram ..................................................................................................9

Pipe Length and the Elevation .............................................................................................10

Wiring Diagram......................................................................................................................11

Operation Details ..................................................................................................................13

Display Function ...................................................................................................................20

Self-diagnosis Function........................................................................................................20

Installation .............................................................................................................................21

Operation ...............................................................................................................................37

Disassembly of the parts (Indoor Unit) ...............................................................................39

3-way Valve ............................................................................................................................43

Cycle Troubleshooting Guide...............................................................................................48

Electronic Parts Troubleshooting Guide.............................................................................49

Electronic Control Device.....................................................................................................55

Schematic Diagram ...............................................................................................................58

Exploded View and Replacement Parts List.......................................................................60

- 2 -

Functions

Indoor Unit

Operation ON/OFF by Remote controller

Sensing the Room Temperature

• Room temperature sensor (THERMISTOR)

Room temperature control

• Maintains the room temperature in accordance with the Setting Temp.

Starting Current Control

• Indoor fan is delayed for 5 seconds at the starting.

Time Delay Safety Control

• Restarting is inhibited for approx. 3 minutes.

Indoor Fan Speed Control

• High, Med, Low and Auto

Operation indication Lamps (LED)

--- Lights up in operation

--- Lights up in Sleep Mode

--- Lights up in Timer Mode

--- Lights up in Defrost Mode or Hot Start Mode (only Heating Model)

OUT

DOOR

--- Lights up during compressor running (only Cooling Model)

Healthy Dehumidification Mode

• Intermittent operation of fan at low speed

Sleep Mode Auto Control

• The fan is switched to low(Cooling), med(Heating) speed.

• The unit will be stopped after 1, 2, 3, 4, 5, 6, 7 hours.

Auto Air Control by the unit electronic control

• The fan is switched to intermittent or irregular operation.

• The fan speed is automatically switched from high to low speed.

Chaos Swing

• The louver can be set at the desired position or swing up and down automatically.

Defrost control(Heating)

• Both the indoor and outdoor fan stops during defrosting.

• Hot start will be operated after defrosting ends.

Hot-start Control (Heating)

• The indoor fan stops until the indoor pipe temperature will be reached at 28°C(82°F).

- 3 -

Remote Controller

Operation ON/OFF

Operation Mode Selection

(Cooling model only)

(Heating model only)

Fan Speed Selection

Cooling Operation Mode.( )

Healthy Dehumidification Operation Mode.( )

Auto Operation Mode.( )

Heating Operation Mode.( )

(CHAOS) (Low) (Med)

Room, Temperature Display

: (High:39°C Low:11°C)

Temperature Setting

TEMPERATURE LOW HIGH

Cooling

Down to 18°C

Up to 30°C

JET COOL

(High)

Heating

Down to 16°C

Up to 30°C

Setting the Time or Timer

Timer Selection

ON OFF

Timer Setting

SET

Timer Cancel

CANCEL

: OFF, ON, OFF ON

Sleep Operation

Airflow Direction Control

: Cancel Sleep Mode, Timer ON or Timer OFF

Fan Operation Mode

: 1, 2, 3, 4, 5, 6, 7, Off Timer

Horizontal Airflow Direction Control Button(Option)

: Fan Operates without cooling or heating.

Reset

- 4 -

Product Specifications(Cooling Only)

Power Supply

Cooling Capacity

Input

Running Current

COMP. Locked Rotor AMP.

E.E.R

Air Circulation

Moisture Removal

Noise Level

(Sound

Pressure, 1m)

Features

Items m

Unit

ø, V, Hz

BTU/h

W

A

A

BTU/hW

3 /min(cfm)

Indoor, High

Med

Low

Outdoor, Max l/h(pts/hr) dB(A) dB(A) dB(A) dB(A)

Temperature Control

Air Deflection

Steps, Fan/Cool

Airflow Direction Control(up&down)

Refrigerant(R-22) Charge

Power cord

Fuse or breaker Capacity

Connecting Cable

Connecting Tube

(ø. Socket Flare)

Dimensions

(WxHxD)

Liquid Side

Gas Side

Length, std

Additional Drain Hose(Outer Dia.)

Indoor

Outdoor

Airflow Direction Control(left&right)

Remocon Type

Setting Temperature Range, Cooling Mode

Temperature Increment

Auto Operation(electronic control)

Self Diagnosis

Timer

Sleep Operation

Healthy Dehumidification Mode

Restart Delay minutes g(oz)

AWG #: P*mm 2

A

AWG #: P*mm mm(in) mm(in) m(ft) mm(in) mm in

2

Net Weight Indoor

Outdoor mm in kg(lbs) kg(lbs)

* Design and Specifications subject to change without prior notice for product improvement.

Auto

Manual

Wireless LCD

64~86°F

2°F

Yes

Yes

24hr, On/Of

Yes

Yes

3

2550(89.9)

14:3*2.5

30A

16:4*0.75

HMC030KD1

230/208,60

28,000/27,000

3,600/3,450

16.0/16.5

68

7.81/7.79

21(740)

3.7(7.8)

49

46

43

63

Thermistor

4-way

3/3

6.35(1/4)

12.7(1/2)

7.62(25)

15.5(5/8)

1259*349*205

49.6*13.7*8.1

870*800*320

34.3*31.5*12.6

20

71

- 5 -

Product Specifications(Cooling & Heating)

Items Unit

Power Supply

Cooling Capacity

Heating Capacity

Input

Running Current

COMP. Locked

Rotor AMP.

E.E.R

C.O.P

Air Circulation

Moisture Removal

Noise Level

(Sound

Pressure, 1m)

Features

Cooling

Heating

Cooling

Heating

Cooling

Heating

ø, V, Hz

BTU/h

BTU/h

W

W

A

A

A

A

BTU/hW

Indoor, High

Med

Low

Outdoor, Max m 3 /min(cfm) l/h(pts/hr) dB(A) dB(A) dB(A) dB(A)

Temperature Control

Air Deflection

Steps, Fan/Cool/Heat

Airflow Direction Control(up&down)

Airflow Direction Control(left&right)

Remocon Type

Refrigerant(R-22) Charge

Power cord

Fuse or breaker Capacity

Connecting Cable

Setting Temperature Range, Cooling Mode

Heating Mode

Temperature Increment

Auto Operation(electronic control)

Self Diagnosis

Timer

Sleep Operation

Healthy Dehumidification Mode minutes Restart Delay

Defrost Control

Hot Start g(oz)

AWG #: P*mm 2

A

AWG #: P*mm 2 mm(in) mm(in)

Connecting Tube

(ø. Socket Flare)

(WxHxD)

Outdoor

Liquid Side

Gas Side

Length, std

Additional Drain Hose(Outer Dia.)

Dimensions Indoor mm

Net Weight

Outdoor

Indoor kg(lbs) m(ft) mm(in) mm in

770*540*245 in kg(lbs)

33(72.8)

* Design and Specifications subject to change without prior notice for product improvement.

HMH030KD1

Thermistor

4-way

3/3/3

Auto

Manual

Wireless LCD

64~86°F

60~86°F

2°F

Yes

Yes

24hr, On/Off

Yes

Yes

3

Yes

Yes

2550(89.9)

14:3*2.5

30A

1,230/208,60

28,000/27,000

29,000/28,000

3,600/3,450

3,750/3,550

16.0/16.5

16.5/17.0

68

68

7.78/7.82

2.26/2.30

21(740)

3.7(7.8)

49

46

43

63

18:4*0.75

9.52(3/8)

15.88(5/8)

7.62(25)

15.5(5/8)

1259*349*205

49.6*13.7*8.1

870*800*320

34.3*31.5*12.6

20

71

- 6 -

Dimensions

(1) Indoor Unit

D

W

H

Tubing hole cover

Installation plate

Tubing hole cover

Model

Dimension

W

H

D mm(inch) mm(inch) mm(inch)

- 7 -

30K SERIES

1,259(49.6)

349(13.7)

205(8.1)

(2) Outdoor Unit

W

L7 L6 L8 L9

DIM

L3

L4

L5

L6

L7

L8

L9

L10

L11

W

H

D

L1

L2

MODEL mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch) mm(in ch)

30K SERIES

870(34.3)

800(31.5)

320(12.6)

370(14.6)

340(13.4)

25(1.0)

775(30.5)

25(1.0)

546(21.5)

162(6.4)

162(6.4)

54(2.1)

74.5(2.9)

79(3.1)

Gas side

3-way valve

Liquid side

3-way valve

Refrigeration Cycle Diagram

(1) Cooling Only Models

INDOOR UNIT

Evaporator Line

OUTDOOR UNIT

CAPILLARY TUBE

HEAT

EXCHANGER

(EVAPORATOR)

HEAT

EXCHANGER

(CONDENSER)

Suction Line

(2) Cooling & Heating Models

INDOOR UNIT

Evaporator Line

3-WAY VALVE

HEAT

EXCHANGER

(EVAPORATOR)

COMPRESSOR

OUTDOOR UNIT

CHECK VALVE

(Heating Model only)

CAPILLARY TUBE

HEAT

EXCHANGER

(CONDENSER)

Suction Line

3-WAY VALVE

ACCUMU

LATOR

COMPRESSOR

REVERSING

VALVE

(Heating Model Only)

COOLING

HEATING

- 9 -

Pipe length and the elevation

Capacity

(Btu/h)

30k

(50Hz, 60Hz)

GAS

Pipe Size

LIQUID

5/8" 3/8"

Standard

Length m(ft)

7.5(25)

Max.

Elevation

B m(ft)

15(50)

Max.

Length

A m(ft)

30(100)

Additional

Refrigerant g/m(oz/ft)

30(0.32)

Outdoor unit

Indoor unit

A

B

Outdoor unit

Oil trap

Indoor unit

A

B

In case more than 5m (16.4ft)

CAUTION

* Capicity is based on standard length and maximum allowance length is the basis of reliability.

* Oil trap should be installed per 5~7 meters(16.4~23.0ft).

- 10 -

Wiring Diagram

(1) Indoor Unit (Cooling Only Models, & Heating Models)

WIRING DIAGRAM

OR

MOTOR

BK

CN-MOTOR TRIAC

ZNR

SH-CAPA.

THERMISTOR

STEP

MOTOR

(UP/DOWN)

CN-POWER

FUSE

AC250V/T2A

3(L) 4(N) 5

PILLAR

TERMINAL

CN-DISP

TO OUTDOOR UNIT

DISPLAY PCB ASM

AUTO RESTART

FORCED OPERATION

H.V.B ASM

STEP

MOTOR

(L/R)

Negative ion

LIMITS S/W

STEP

MOTOR

(L/R)

OPTION

3854A20065A

- 11 -

(2) Outdoor Unit

• Cooling Only Models

WIRING DIAGRAM

5

4(L2)

3(L1)

RD

BL

BR

GN/YL

2(L2)

1(L1)

BL

BR

CN-POWER

FUSE(250V,3A)

MAIN

PCB ASM

T/B

CN-FAN

OLP

RD

BL

BK

BK

OR

H

YL BR

C

S

R

Comp(B)

C F

CAPACITOR(B)

YL

OR BK

FMo

CN-CON

CN-COMP

BK

H

BL

RD

C

S

BK

R

Comp(A)

C CAPACITOR(A)

PIPE-IN

TEMP-IN

COIL EXPANSION

3854A20153W

• Heating Models

- 12 -

Operation Details

(1) The function of main control

1. Time delay Safety Control

• 3min.; The compressor operation is delayed for 3 minutes to balance the pressure of cycle.

(Protection of compressor)

• 5sec.; The indoor fan is delayed for 5 seconds, when operating initially, to prevent noises occurred by the vertical louver and wind.

• 2min.; The reversing valve is delayed for 2 minutes to prevent the refrigerant-gas for abnormal noise when the heating operation is OFF or switched to the other operation mode while compressor is off.

While compressor is running, it takes 3~5 seconds to switch.

2. Chaos Swing Mode

• By the Chaos Swing key input, the upper/lower vane automatically operates with the Chaos Swing or they are fixed to the desired direction.

• While in Chaos Swing mode, the angles of cooling and heating cycle operations are different.

< Cooling Mode >

CLOSED

< Heating Mode >

CLOSED

8

°

8

°

OPEN OPEN

3. Cooling Operation Mode

• When selecting the Cooling( ) Mode Operation, the unit will operate according to the setting by the remote control and the operation diagram is shown below.

INTAKE AIR TEMP.

SETTING TEMP. +1°F

(Compressor ON)

SETTING TEMP. -1°F

(Compressor OFF) More than

3 minutes

More than

3 minutes

INDOOR FAN SPEED

COMPRESSOR

Setting fan speed

ON

Low

OFF

Setting fan speed

ON

Low

OFF

Setting fan speed

ON

■

Protection of the indoor heat exchanger from frosting

• Compressor and outdoor fan stop when indoor pipe temperature is below 0°C(32°F) and restart at the pipe temperature is above 7°C(45°F).

- 13 -

. Auto Operation (Electronic control mode)

• The operation procedure is shown below. (Cooling & Heating Model)

Press Start/Stop Button

Select Auto Operation Mode

Check the Room temperature

Operation mode

Indoor fan speed

Setting temperature are decided automatically by the unit electronic control.

Intake-air temperature below 70°F

Over

70°F

~ below

76°F

Operation Mode

Heating

Soft Dry

❋

If initial mode is decided, that mode is continued without the room temperature changing.

Over 76°F

Cooling

■

Auto Operation for Cooling

Operation Condition

When Auto Operation initial start

When pressing room temperature setting button during Auto

Operation

Intake-air Temperature Setting Temperature

Over 78°F 77°F

Over 76°F~below 78°F

Over 72°F~below 76°F

Intake air -1°C

Intake air -0.5°C

Over 68°F~below 72°F Intake air temperature below 64°F 64°F

Over 64°F~below 86°F below 64°F over 86°F

Electronic control

64°F

86°F

Fan Speed

Controlled by the electronic control

Air Direction Control

In this mode, when pressing the vertical air direction control button, vertical louver swings up and down automatically.

INTAKE AIR TEMP.

SETTING TEMP. +1°F

(Compressor OFF)

SETTING TEMP. -1°F

(Compressor ON)

INDOOR FAN SPEED

COMPRESSOR ON

The electronic control operation

OFF ON

- 14 -

OFF

■

Auto Operation for Dehumidification(only Heating Model)

• The Setting temperature will be same that of the auto operation for cooling.

- Compressor ON temperature; Setting temperature +2°F

- Compressor OFF temperature; Setting temperture -1°F

Intake-air temp.

below 68°F Over 68°F~below 70°F

Setting temp.

68°F Intake air temperature +1°F over 86°F

86°F

■

Auto Operation for Heating(only Heating Model)

- Compressor ON temperature; Setting temperature

- Compressor OFF temperature; Setting temperature +6°F

■

Vertical louver auto operation : During Auto Operation, pressing the chaos swing button makes the horizontal louvers swing up and down automatically.

If you want to stop auto-swing, press chaos swing button again.

- 15 -

5. Healthy Dehumidification

• When the dehumidification operation input by the remote control is received, the intake air temperature is detected and the setting temp is automatically set according to the intake air temperature.

26°C

≤

Intake Air Temp

24°C

≤

Intake Intake Air Temp<26°C

18°C

≤

Intake Intake Air Temp<24°C

➲

➲

➲

25°C

Intake Air Temp-1°C

Intake Air Temp-0.5°C

Intake Air Temp<18°C

➲

18°C

• While in compressor off, the indoor fan repeats low airflow speed and pause.

• While the intake air temp is between compressor on temp. and compressor off temp., 10-min dehumidification operation and 4-min compressor off repeat.

Compressor ON Temp.

➲

Setting Temp+0.5°C

Compressor OFF Temp.

➲

Setting Temp-0.5°C

• In 10-min dehumidification operation, the indoor fan operates with the low airflow speed.

- 16 -

6. Heating Operation Mode(only Heating Model)

The unit will operate according to the setting conditions by the remote controller.

The operation diagram is shown below.

INTAKE AIR TEMP.

SETTING TEMP. +6°F

(Compressor OFF)

A

B

SETTING TEMP.

(Compressor ON) minimum

10sec.

minimum

1 min.

A minimum

10sec.

INDOOR FAN SPEED

Selecting fan speed

ON

Low OFF Low

Selecting fan speed

ON

Low OFF

COMPRESSOR OFF OFF

• A point; While the indoor pipe temperature is higher than 95°F, indoor fan operates at low speed. When the indoor pipe temperature becomes lower than 95°F, indoor fan stops.

• B point; When the indoor pipe temperature is higher than 38°C(100°F), fan operates at selected fan speed.

■

Hot-Start Control

• The indoor fan stops until the indoor pipe temperature will be reached at 82°F.

• During heating operation, if indoor pipe temperature falls below 78°F fan stops.

• The operation diagram is shown below.

INDOOR PIPE

TEMP.

82°F

78°F

1min

INDOOR FAN SPEED

COMPRESSOR

OFF

- 17 -

LOW

ON

Selecting fan speed

OFF

7. Cooling or Heating Mode with Sleep Mode Auto Control

• When selecting the Cooling( ) or the Heating( ) combined with the Sleep Mode Auto Control( ), the operation diagram is as following.

■

Cooling Mode with the Sleep Mode

• The setting temperature will be automatically raised by 2°F 30 minutes later and by 4°F 1 hour later.

• The operation will be stopped after 1, 2, 3, 4, 5, 6, 7 hours.

30 minutes 30 minutes

INTAKE AIR TEMP.

2°F

SETTING TEMP. +1°F

(Compressor ON)

SETTING TEMP. -1°F

(Compressor OFF)

INDOOR FAN SPEED

COMPRESSOR

Low

ON

More than

3 minutes

Low

OFF

Low

ON

More than

3 minutes

Low

OFF

Low

ON

2°F

■

Heating Mode with the Sleep Mode(only Heating Model)

• The operation will be stopped after 1, 2, 3, 4, 5, 6, 7 hours.

INTAKE AIR TEMP.

SETTING TEMP. +6°F

(Compressor OFF)

SETTING TEMP.

(Compressor ON)

INDOOR FAN SPEED

COMPRESSOR

Med

ON

More than

3 minutes

Low or OFF

OFF

Med

ON

More than

3 minutes

Low or OFF

OFF

Med

ON

More than

3 minutes

Low or OFF

OFF

- 18 -

8. Forced Operation

To operate the appliance by force in case that the remote controller is lost, the forced operation button is on the main unit of the appliance to operate the appliance in the standard conditions.

• Press the forced operation button, the forced operation is carried out.

• Press the forced operation button once again to stop operation.

In case the power comes on again after power failure on the Forced

Operation position, the operating conditions are automatically set as follows:

During Forced Operation, the initial mode continues.

FORCED

OPERATION

Cooling Heat pump Model

Model Room Temp.

≥

24°C(76°F) 21°C(70°F)

≤

Room Temp. < 24°C(76°F) Room Temp. < 21°C(70°F)

Operating mode Cooling Cooling Healthy Dehumidification Heating

Indoor FAN Speed High

Setting Temperature 22°C(72°F)

High

22°C(72°F)

Healthy Dehumidification Rule

23°C(74°F)

High

24°C(76°F)

9. AUTO RESTART

In case the power comes on again after a power failure, Auto Restarting

Operation is the function to operate procedures automatically to the previous operating conditions.

If you want to use this operation. The autorestart button is on the main unit of the appliance in the standard condition.

• press the auto restart button, to make this function active.

• If you do not want to use this operation, free the auto restart button once again.

If you do not want to use this operation, move the Slide Switch to the

Remote Control position.

AUTO

RESTART

- 19 -

Display Function

Signal Receptor

Receives the signals from the remote control.(Signal receiving sound: two short beeps or one long beep.)

Operation Indication Lamps

On/Off

: Lights up during the system operation.

Timer or Sleep Mode

: Lights up during Timer operation or Sleep mode.

Defrost Mode

: Lights up during Defrost Mode or Hot

Start operation. (Heat pump model only)

Outdoor unit operation : Lights up during outdoor unit operation. (Cooling model only)

Auto Restart Mode

: Lights up during if Restart Button is pressed.

Auto Restart Button

: In failure of electric power, if the button is pressed the unit runs as previous setting operation when power returns.

Forced Operation Button : Operation starts, when this button is pressed and stops when you press the button again.

Self-diagnosis Function

Error

Code

1

2

5

Error LED

(Indoor body operation LED)

(once)

3sec

(twice)

3sec 3sec

3sec

(5times)

3sec

3sec

Error contents

• Indoor room temperature thermistor open/short

• Indoor pipe temperature thermistor open/short.

SVC check point

• Indoor TH assy check

• Outdoor pipe temperature thermistor open/short.

• Outdoor TH assy check

• Poor communication.

• Communication line/circuit check

- 20 -

Installation

Read completely, then follow step by step.

1. Installation of Indoor,

Outdoor unit

Installation Parts Provided

1. Type "A" screw

2. Installation Plate

3. Type "B" screw

4. Holder Remote Control

2. Outdoor unit

■

If an awning is built over the unit to prevent direct sunlight or rain exposure, make sure that heat radiation from the condenser is not restricted.

■

Ensure that the space around the back and sides is more than

10cm(4"). The front of the unit should have more than

70cm(28") of space.

■

Do not place animals and plants in the path of the warm air.

■

Take the air conditioner weight into account and select a place where noise and vibration are minimum.

■

Select a place so that the warm air and noise from the air conditioner do not disturb neighbors.

More than

60cm(24")

More than

10cm(4")

More than

10cm(4")

1) Select the best location

1. Indoor unit

■

Do not have any heat or steam near the unit.

■

Select a place where there are no obstacles in front of the unit.

■

Make sure that condensation drainage can be conveniently routed away.

■

Do not install near a doorway.

■

Ensure that the space around the left and right of the unit is more than 30cm(12"). The unit should be installed as high on the wall as possible, allowing a minimum of 12cm(4.8") from ceiling.

■

Use a stud finder to locate studs to prevent unnecessary damage to the wall.

More than

30cm(12")

More than

12cm(4.8")

More than

30cm(12")

More than

70cm(28")

More than

60cm(24")

■

Rooftop Installations:

If the outdoor unit is installed on a roof structure, be sure to level the unit. Ensure the roof structure and anchoring method are adequate for the unit location.

Consult local codes regarding rooftop mounting.

If the outdoor unit is installed on root structures or walls, this may result in excessive noise and vibration, and maybe also classed as non serviceable installation.

2) Piping length and elevation

Capacity

(Btu/h)

30k

Pipe Size

GAS LIQUID

5/8"

Standard

Length m(ft)

Max.

Elevation

B m(ft)

Max. length

A m(ft)

Additional

Refrigerant g/m(oz/ft)

3/8" 7.5(25) 15(50) 30(100) 30(1.102)

Outdoor unit

Outdoor unit

More than 2.3m(7.5ft)

Indoor unit

A

Oil trap

Indoor unit

A

B

CAUTION

Install the indoor unit on the wall where the height from the floors more than 2.3meters(7.5ft).

A minimum pipe run of 7.5meters(25ft) is required to minimise vibration & excessive noise.

B

- 21 -

In case more than 5m(16.4ft)

CAUTION

• Capacity is based on standard length and maximum allowance length is on the basis of reliability.

• Oil trap should be installed In case more than 5~7meters

(16.4~23.0ft).

3) How to fix installation plate

The wall you select should be strong and solid enough to prevent vibration

1. Mount the installation plate on the wall with four type A screws. If mounting the unit on a concrete wall, use anchor bolts.

Mount the installation plate horizontally by aligning the centerline using a level.

4) Drill a hole in the wall

■

Drill the piping hole with a ø70mm (0.76") hole core drill. Drill the piping hole at either the right or the left with the hole slightly slanted to the outdoor side.

WALL

Indoor Outdoor

Installation Plate

Type "A" screw

(+1 D4.0 L38.0 MSR3/FZW)

2. Measure the wall and mark the centerline. It is also important to use caution concerning the location of the installation plate-routing of the wiring to power outlets is through the walls typically.

Drilling the hole through the wall for piping connections must be done safely.

Left rear piping Right rear piping

50mm(2.0")

30K

180mm

(7.2")

ø

70mm(2.76")

- 22 -

2. Flaring Work and Connection of Piping

1) Flaring work

Main cause for gas leakage is due to defect in flaring work. Carry out correct flaring work in the following procedure.

1. Cut the pipes and the cable.

■

Use the piping kit accessory or the pipes purchased locally.

■

Measure the distance between the indoor and the outdoor unit.

■

Cut the pipes a little longer than measured distance.

■

Cut the cable 1.5m(59.1") longer than the pipe length.

Copper pipe

90

°

Slanted Uneven Rough

4. Flaring work

■

Carry out flaring work using flaring tool as shown below.

Outside diameter mm

ø6.35

ø9.52

ø12.7

ø15.88

inch

1/4

3/8

1/2

5/8

A mm

0 ~ 0.5

0 ~ 0.5

0 ~ 0.5

0 ~ 1.0

Firmly hold copper pipe in a die in the dimension shown in the table above.

2. Burrs removal

■

Completely remove all burrs from the cut cross section of pipe/tube.

■

Put the end of the copper tube/pipe in a downward direction as you remove burrs in order to avoid dropping burrs into the tubing.

Pipe

Reamer

Bar

Bar

Handle

Yoke

Cone

Copper pipe

Clamp handle

Red arrow mark

Point down

5. Check

■

Compare the flared work with figure below.

■

If flare is noted to be defective, cut off the flared section and do flaring work again.

3. Putting nut on

■

Remove flare nuts attached to indoor and outdoor unit, then put them on pipe/tube having completed burr removal.

(not possible to put them on after flaring work)

Flare nut

Copper tube

Smooth all round

Inside is shiny without scratches

= Improper flaring =

Even length all round

Inclined Surface damaged

Cracked Uneven thickness

- 23 -

2) Connection of piping-Indoor

1. Remove the 2 screws of right side panel.

Right side panel

CAUTION

When install, make sure that the remaining parts must be removed clearly so as not to damage the piping and drain hose, especially power cord and connecting cable.

2. Remove the front right side panel by the arrow.

■

The connector can be disconnected by pulling it while pressing the connector's hook.

■

Remove the 1 screw for fixing lower panel.

For left rear piping

1. Route the indoor tubing and the drain hose in the direction of rear left.

Lower panel

Main PCB

Drain hose

2. Insert the connecting cable into the indoor unit from the outdoor unit through the piping hole.

■

Do not connect the cable to the indoor unit.

■

Make a small loop with the cable for easy connection later.

3. Remove the lower panel by the arrow.

■

Take care not to scratch the wall and mat to drop.

Lower panel

- 24 -

5. Connecting the pipings to the indoor unit and drain hose to drain pipe.

■

Align the center of the pipings and sufficiently tighten the flare nut by hand.

Loop

Connecting cable

Drain hose

Gas side piping

Liquid side piping

NOTE: If the drain hose is routed inside the room, insulate the hose with an insulation material* so that dripping from "sweating"(condensation) will not damage furniture or floors.

*Foamed polyethylene or equivalent is recommended.

4. Indoor unit installation

■

Hook the indoor unit onto the upper portion of the installation plate.(Engage the three hooks of the rear top and rear lower of the indoor unit with the upper edge and lower edge of the installation plate.) Ensure that the hooks are properly seated on the installation plate by moving it left and right.

Installation plate Setting line

Indoor unit tubing Flare nut Pipings

■

Tighten the flare nut with a wrench.

Connection pipe

Flare nut

Spanner (fixed)

Capacity

(Btu/h)

30K

Indoor unit tubing

Torque wrench

Pipe Size[Torque]

Suction Evaporator

5/8"[6.6kg.m] 3/8"[4.2kg.m]

■

When extending the drain hose at the indoor unit, install the drain pipe.

Drain pipe

Indoor unit drain hose

Adhesive

Vinyl tape(narrow)

Indoor unit

Three upper hooks

Installation plate

Three lower hooks

- 25 -

6. Wrap the insulation material around the connecting portion.

■

Overlap the connection pipe insulation material and the indoor unit pipe insulation material. Bind them together with vinyl tape so that there is no gap.

Plastic bands

Insulation material

For right rear piping

1. Route the indoor tubing and the drain hose to the required piping hole position.

Drain hose

■

Wrap the area which accommodates the rear piping housing section with vinyl tape.

2. Insert the piping, drain hose and the connecting cable into the piping hole.

Connection pipe

Vinyl tape

(wide)

Wrap with vinyl tape

Indoor unit pipe Connecting cable

Drain pipe

Connecting cable

Vinyl tape(narrow)

Pipe

3. Insert the connecting cable into the indoor unit.

■

Don't connect the cable to the indoor unit.

■

Make a small loop with the cable for easy connection later.

■

Bundle the piping and drain hose together by wrapping them with vinyl tape over the range within which they fit into the rear piping housing section.

Wrap with vinyl tape

Pipe

4. Tape the drain hose and the connecting cable.

• Connecting cable

Vinyl tape(wide)

Drain hose

- 26 -

5. Indoor unit installation

■

Hook the indoor unit onto the upper portion of the installation plate.(Engage the three hooks of the rear top and rear lower of the indoor unit with the upper edge and lower edge of the installation plate.) Ensure that the hooks are properly seated on the installation plate by moving it left and right.

Installation plate Setting line

Indoor unit

Three upper hooks

Installation plate

Three lower hooks

6. Connecting the pipings to the indoor unit and the drain hose to drain pipe.

■

Align the center of the pipings and sufficiently tighten the flare nut by hand.

■

When extending the drain hose at the indoor unit, install the drain pipe.

Drain hose

Indoor unit drain hose

Adhesive

Vinyl tape (narrow)

7. Wrap the insulation material around the connecting portion.

■

Overlap the connection pipe heat insulation and the indoor unit pipe heat insulation material. Bind them together with vinyl tape so that there is no gap.

Plastic bands

Insulation material

■

Wrap the area which accommodates the rear piping housing section with vinyl tape.

Connection pipe

Vinyl tape

(wide)

Wrap with vinyl tape

Indoor unit piping

Indoor unit tubing Flare nut Pipings

■

Tighten the flare nut with a wrench.

Spanner (fixed)

Flare nut

Connection pipe

Torque wrench

Indoor unit tubing

Capacity

(Btu/h)

30K

Pipe Size[Torque]

Suction Evaporator

5/8"[6.6kg.m] 3/8"[4.2kg.m]

Connecting cable

Pipe

Vinyl tape(narrow)

- 27 -

■

Bundle the piping and drain hose together by wrapping them with cloth tape over the range within which they fit into the rear piping housing section.

Drain hose

Pipe

Vinyl tape(narrow)

9. Reinstall the parts to the original position.

■

Refix the lower panel to the original position.

Wrap with vinyl tape(wide)

Lower panel

■

Connect display conductor.

8. Reroute the pipings and the drain hose across the back of the chassis.

Main PCB

Piping for passage through piping hole

■

Refix the front right side panel to the original position with the two screws.

- 28 -

3) Connection of the drain hose

■

The drain hose can be connected at two different positions. Use the most convenient position and, if necessary, exchange the position of the drain pan, rubber cap and the drain hose.

➊

Drain pan

➋

Rubber cap

➌

Drain hose

➍

Exchange if necessary

■

Remove the drain hose.

■

Securely insert both the rubber plug and drain hose into the drain outlets.

Be sure the rubber the cap is securely fastened so that there is no leakage.

4) Connection of piping-Outdoor

1. Align the center of the pipings and sufficiently tighten the flare nut by hand.

2

1

4

3

2. Finally, tighten the flare nut with torque wrench until the wrench clicks.

■

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

Capacity

(Btu/h)

Pipe Size[Torque]

Suction Evaporator

30K 5/8"[6.6kg.m] 3/8"[4.2kg.m]

Outdoor unit

Gas side piping

(Bigger diameter)

Liquid side piping

(Smaller diameter)

Torque wrench

- 29 -

3. Connecting the cable between indoor unit and outdoor unit

1) Connect the cable to the indoor unit by connecting the wires to the terminals on the control board individually according to

the outdoor unit connection. (Ensure that the color of the wires of the outdoor unit and the terminal No. are the same as those of the indoor unit.)

Terminals on the indoor unit

Color of Wires

3(L1) 4(L2) 5

G/Y BROWN BLUE RED

CAUTION

The power supply cord connected to the outdoor unit should be complied with the following specifications (UL and CSA recognized one).

Color of Wires

Terminals on the outdoor unit 1(L1) 2(L2)

G/Y BROWN BLUE RED

3(L1) 4(L2) 5

GN/YL

20mm

(0.79in)

AWG #12

The connecting cable connected to the indoor and outdoor unit should be complied with the following specifications (UL and CSA recognized one).

POWER INPUT

GN/YL

20mm

(0.79in)

AWG #20

CAUTION

Wiring must be as following diagram.

Main power source

Indoor unit

Disconnect Switch (Optional)

• May be required by local codes

• Must be rated for 15 amps

61cm max

(24 in max)

- 30 -

Outdoor Disconnect Switch

• Must be rated for 30 amps

Outdoor unit

61cm max

(24 in max)

2) Connect the cable to the outdoor unit

1. Remove the control cover from the unit by loosening the screw.

Connect the wires to the terminals on the control board individually.

2. Secure the cable onto the control board with the cord clamp.

3. Refix the control cover to the original position with the screw.

4. Use a recognized circuit breaker 30A (30k, 32k),

35A (36k, 38k) between the power source and the unit. A disconnecting device to adequately disconnect all supply lines must be fitted.

Connecting cable

The power connecting cable

Outdoor Unit

Terminal block

Over 5mm

Cover control

30K

CAUTION

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

1) Never fail to have an individual power circuit specifically for the air conditioner. As for the method of wiring, be guided by the circuit diagram posted on the inside of control cover.

2) The screw which fasten the wiring in the casing of electrical fittings are liable to come loose from vibrations to which the unit is subjected during the course of transportation. Check them and make sure that they are all tightly fastened. (If they are loose, it could cause burn-out of the wires.)

3) Specification of power source.

4) Confirm that electrical capacity is sufficient.

5) See to that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the name plate.

6) Confirm that the cable thickness is as specified in the power source specification.

(Particularly note the relation between cable length and thickness. (Refer to page 30))

7) Always install an earth leakage circuit breaker in a wet or moist area.

8) The following would be caused by voltage drop.

• Vibration of a magnetic switch, which will damage the contact point, fuse breaking, disturbance of the normal function of the overload.

9) The means for disconnection from a power supply shall be incorporated in the fixed wiring and have an air gap contact separation of at least 3mm in each active(phase) conductors.

- 31 -

1) Checking the drainage

1. Remove the right side panel.

Right side panel

4. To check the drainage.

■

Pour a glass of water on the drain pan.

■

Ensure the water flows through the drain hose of the indoor unit without any leakage and goes out the drain exit.

2. Remove the lower panel by the arrow.

Lower panel

3. Remove the left side panel.

(Remove the two screws.)

Left side panel

5. Drain piping

■

The drain hose should point downward for easy drain flow.

Downward slope

- 32 -

■

Do not make drain piping.

Water leakage

Do not raise

Accumulated drain water

Air

Water leakage

Waving

Water leakage

Tip of drain hose dipped in water

Ditch

Less than

50mm gap

2) Form the piping

1. Form the piping by wrapping the connecting portion of the indoor unit with insulation material and secure it with two kinds of vinyl tapes.

■

If you want to connect an additional drain hose, the end of the drain outlet should be routed above the ground. Secure the drain hose appropriately.

3. In cases where the Outdoor unit is installed above the Indoor unit perform the following.

■

Tape the piping and connecting cable from down to up.

■

Secure the taped piping along the exterior wall.

Form a trap to prevent water entering the room.

■

Fix the piping onto the wall by saddle or equivalent.

2. In cases where the outdoor unit is installed below the indoor unit perform the following.

■

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

■

Secure the tapped piping along the exterior wall using saddle or equivalent.

Seal small openings around pipings with a gum type sealer.

Seal a small opening around the pipings with gum type sealer.

Trap

;;

Trap

30K

Taping

Drain hose

;;

;;

Pipings

Connecting cable

;;

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

30K

- 33 -

4. AIR PURGING

1) Air purging

Air and moisture remaining in the refrigerant system have undesirable effects as indicated below.

■

Pressure in the system rises.

■

Operating current rises.

■

Cooling(or heating) efficiency drops.

■

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

■

Water may lead to corrosion of parts in the refrigeration system.

Therefore, the indoor unit and tubing between the indoor and outdoor unit must be leak tested and evacuated to remove any noncondensables and moisture from the system.

2) Air purging with vacuum pump

1. Preparation

■

Check that each tube(both liquid and gas side tubes) between the indoor and outdoor units have been properly connected and all wiring for the test run has been completed. Remove the service valve caps from both the gas and the liquid side on the outdoor unit. Note that both the liquid and the gas side service valves on the outdoor unit are kept closed at this stage.

2. Leak test

■

Connect the manifold valve(with pressure gauges) and dry nitrogen gas cylinder to this service port with charge hoses.

CAUTION

Be sure to use a manifold valve for air purging. If it is not available, use a stop valve for this purpose. The "Hi" knob of the manifold valve must always be kept close.

■

Pressurize the system to no more than 150 P.S.I.G.

with dry nitrogen gas and close the cylinder valve when the gauge reading reached 150 P.S.I.G.

Next, test for leaks with liquid soap.

CAUTION

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. Usually, the cylinder is used in a vertical standing position.

- 34 -

■

Do a leak test of all joints of the tubing(both indoor and outdoor) and both gas and liquid side service valves.

Bubbles indicate a leak. Be sure to wipe off the soap with a clean cloth.

■

After the system is found to be free of leaks, relieve the nitrogen pressure by loosening the charge hose connector at the nitrogen cylinder.

When the system pressure is reduced to normal, disconnect the hose from the cylinder.

Indoor unit

30K

Outdoor unit

Manifold valve

Pressure gauge

Lo Hi

Charge hose

Nitrogen gas cylinder(in vertical standing position)

Soap water method

(1) Remove the caps from the gas side and liquid side valves.

(2) Remove the service-port cap from the gas side valve.

(3) To open the gas side valve turn the valve stem counterclockwise approximately 90°, wait for about 2~3 sec, and close it.

(4) Apply a soap water or a liquid neutral detergent on the indoor unit connection or outdoor unit connections by a soft brush to check for leakage of the connecting points of the piping.

(5) If bubbles come out, the pipes have leakage.

3. Evacuation

■

Connect the charge hose end described in the preceding steps to the vacuum pump to evacuate the tubing and indoor unit.

Confirm the "Lo" knob of the manifold valve is open. Then, run the vacuum pump.

The operation time for evacuation varies with tubing length and capacity of the pump. The following table shows the time required for evacuation.

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

If tubing length is less than 10m (33 ft).

10 min. or more

If tubing length is longer than 10m (33 ft).

15 min. or more

■

When the desired vacuum is reached, close the

"Lo" knob of the manifold valve and stop the vacuum pump.

4. Finishing the job

■

With a service valve wrench, turn the valve stem of liquid side valve counter-clockwise to fully open the valve.

■

Turn the valve stem of gas side valve counterclockwise to fully open the valve.

■

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

■

Replace the flare nut and its bonnet on the gas side service port and fasten the flare nut securely with an adjustable wrench. This process is very important to prevent leakage from the system.

■

Replace the valve caps at both gas and liquid side service valves and fasten them tight.

This completes air purging with a vacuum pump.

The air conditioner is now ready to test run.

3-way valve

(Close)

3-way valve

(Open)

Indoor unit

30K

Outdoor unit

Manifold valve

Pressure gauge

Open

Lo Hi

Close

Gas side

Liquid side

Hexagonal wrench

Cap

Vacuum pump

- 35 -

5. TEST RUNNING

1. Check that all tubing and wiring have been properly connected.

2. Check that the gas and liquid side service valves are fully open.

1. Prepare remote control

Remove the battery cover by pulling it according to the arrow direction.

Insert new batteries making sure that the (+) and (–) of battery are installed correctly.

Reattach the cover by pushing it back into position.

NOTE:

• Use 2 AAA(1.5volt) batteries. Do not use rechargeable batteries.

• Remove the batteries from the remote control if the system is not going to be used for a long time.

2. Settlement of outdoor unit

■

Anchor the outdoor unit with a bolt and nut(ø10mm) tightly and horizontally on a concrete or rigid mount.

■

When installing on the wall, roof or rooftop, anchor the mounting base securely with a nail or wire assuming the influence of wind and earthquake.

■

In the case when the vibration of the unit is conveyed to the hose, secure the unit with an anti-vibration rubber.

Bolt

Tubing connection

3. Evaluation of the performance

Operate unit for 15~20 minutes, then check the system refrigerant charge:

1. Measure the pressure of the gas side service valve.

2. Measure the temperature of the intake and discharge of air.

3. Ensure the difference between the intake temperature and the discharge is more than 8°C

(Cooling) or reversely (Heating).

Intake temperature

Discharge air

Discharge temperature

4. For reference; the gas side pressure of optimum condition is as below.(Cooling)

Outside ambient TEMP The pressure of the gas side service valve

35°C(95°F)

4~5kg/cm 2 G(56.8~71.0 P.S.I.G.)

NOTE: If the actual pressure are higher than shown, the system is most likely over-charged, and charge should be removed. If the actual pressure are lower than shown, the system is most likely undercharged, and charge should be added.

The air conditioner is now ready for use.

PUMP DOWN

This is performed when the unit is to be relocated or the refrigerant circuit is serviced.

Pump Down means collecting all refrigerant in the outdoor unit without loss in refrigerant gas.

CAUTION:

Be sure to perform Pump Down procedure with the unit cooling mode.

Pump Down Procedure

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

2. Open the gas side service valve halfway and purge the air from the manifold hose using the refrigerant gas.

3. Close the liquid side service valve(all the way in).

4. Turn on the unit's operating switch and start the cooling operation.

5. When the low-pressure gauge reading becomes 1 to

0.5kg/cm 2 G(14.2 to 7.1 P.S.I.G.), fully close the gas side valve stem and then quickly turn off the unit. At that time, Pump Down has been completed and all refrigerant gas will have been collected in the outdoor unit.

- 36 -

Operation

(1) Name and Function-Remote Control (Cooling Models)

Remote Controller

1

2

3

8

Signal transmitter.

Transmits the signals to the room air conditioner.

Signal transmitter

ON OFF

SET CANCEL

°

C /

°

F

6

7

4

5

9

1

ON/OFF TIMER BUTTONS

Used to set the time of starting and stopping operation.

2

TIME SETTING BUTTONS

Used to adjust the time.

3

TIMER SET/CANCEL BUTTONS

Used to set the timer when the desired time is obtained and to cancel the Timer operation.

4

SLEEP MODE AUTO BUTTON

Used to set Sleep Mode Auto operation.

5

AIR CIRCULATION BUTTON

Used to circulate the room air without cooling or heating

(turns indoor fan on/off).

6

ROOM TEMPERATURE CHECKING BUTTON

Used to check the room temperature.

7

°C / °F SELECTING BUTTON

Choose temperature unit °C or °F alternatively.

8

HORIZONTAL AIRFLOW DIRECTION CONTROL

BUTTON (NOT ON ALL MODELS)

Used to set the desired horizontal airflow direction.

9

RESET BUTTON

Used prior to resetting time or after replacing batteries.

- 37 -

(2) Name and Function-Remote Control (Heat Pump Models)

Remote Controller

1

2

3

8

Signal transmitter.

Transmits the signals to the room air conditioner.

Signal transmitter

ON OFF

SET CANCEL

°

C /

°

F

4

5

6

7

9

1

ON/OFF TIMER BUTTONS

Used to set the time of starting and stopping operation.

2

TIME SETTING BUTTONS

Used to adjust the time.

3

TIMER SET/CANCEL BUTTONS

Used to set the timer when the desired time is obtained and to cancel the Timer operation.

4

SLEEP MODE AUTO BUTTON

Used to set Sleep Mode Auto operation.

5

AIR CIRCULATION BUTTON

Used to circulate the room air without cooling or heating

(turns indoor fan on/off).

6

ROOM TEMPERATURE CHECKING BUTTON

Used to check the room temperature.

7

°C / °F SELECTING BUTTON

Choose temperature unit °C or °F alternatively.

8

HORIZONTAL AIRFLOW DIRECTION CONTROL

BUTTON (NOT ON ALL MODELS)

Used to set the desired horizontal airflow direction.

9

RESET BUTTON

Used prior to resetting time or after replacing batteries.

- 38 -

Disassembly of the parts (Indoor unit)

Warning :

Disconnect the unit from power supply before making any checks.

Be sure the power switch is set to “OFF”.

1. To remove the Grille from the Chassis.

➊

Remove the 2 screws of right side panel.

Right side panel

➋

Remove the front right side panel by the arrow.

■

The connector can be disconnected by pulling it while pressing the connector's hook.

■

Remove the 1 screw for fixing low panel.

Main PCB

Low panel

➌

Remove the lower panel by the arrow.

■

Take care not to scratch the wall and mat to drop.

Lower panel

➍

Remove the left side pane.

(Remove the 2 screws.)

Left side panel

- 39 -

➎

Remove the grille from the chassis.

• Remove the 4 securing screws.(30K, 32K)

• Remove the 5 securing screws.(36K, 38K)

• To remove the Grille, pull the lower left and right side of the grille toward you (slightly tilted) and lift it straight upward.

30K

2. To remove the sensor, housing connector, earth conductor and step motor conductor with sensor holder, Motor, Evaporator and P.C.B.

Earth

Conductor

32K

Motor

Conductor

Power

Conductor

Sensor

Conductor

Step Motor

Conductor

- 40 -

3. To remove the Control Box.

• Remove the 5 securing screws.

• Pull the control box out from the chassis carefully.

Screw

4. To remove the Discharge Grille.

• Remove the 3 securing screw.

• Pressing the right side of the discharge grille downward slightly, unhook the discharge grille.

• Pull the discharge grille out from the chassis carefully.

5. To remove the Evaporator.

• Remove 3 screws securing the evaporator(at the left 2EA, at the right 1EA).

• Remove 2 screws securing the evaporator clamp.

Screw

Screw

(for clamp)

Screw

• Unhook the tab on the right inside of the chassis at the same time, slightly pull the evaporator toward you until the tab is clear of the slot.

- 41 -

6. To remove the Fan motor

• Loosen the screw securing the cross-flow fan to the fan motor (do not remove).

Fan motor

Screw

• Loosen the screw securing the mount motor.

Screw

Mount motor

• Separate the fan motor from the cross-flow fan.

• Take care not to drop the motor.

7. To remove the Cross-Flow Fan

• Loosen the screw securing the holder bearing.

• Lift up the cross-flow fan.

- 42 -

Holder bearing

Screw

Fan motor

3-way Valve

1. Pump down

Indoor unit

Liquid side

3-Way valve

Open

Gas side

3-Way valve

Closed

Outdoor unit

CLOSE

Purge the air

Lo

CLOSE

• Procedure

(1) Confirm that both liquid side and gas side valves are set to the open position.

– Remove the valve stem caps and confirm that the valve stems are in the raised position.

– Be sure to use a hexagonal wrench to operate the valve stems.

(2) Operate the unit for 10 to 15 minutes.

(3) Stop operation and wait for 3 minutes, then connect the charge set to the service port of the Gas side valve.

– Connect the charge hose to the service port.

(4) Air purging of the charge hose.

– Open the low-pressure valve on the charge set slightly to air purge from the charge hose.

(5) Set the liquid side valve to the closed position.

(6) Operate the air conditioner in cooling mode and stop it when the gauge indicates

1kg/cm 2 g.

(7) Immediately set the Gas side valve to the closed position.

– Do this quickly so that the gauge ends up indicating 3 to 5kg/cm 2 g.

(8) Disconnect the charge set, and mount the

Liquid side and Gas side valve’s stem nuts and the service port nut.

– Use torque wrench to tighten the service port nut to a torque of 1.8 kg.m.

– Be sure to check for gas leakage.

- 43 -

1) Re-air purging

(Re-installation)

Indoor unit

Liquid side

3-Way

Closed valve

Gas side

3-Way valve

Closed

Gas cylinder

R22

OPEN

Lo

CLOSE

Outdoor unit

• Procedure

(1) Confirm that both the liquid side valve and the gas side valve are set to the closed position.

(2) Connect the charge set and a gas cylinder to the service port of the Gas side valve.

– Leave the valve on the gas cylinder closed.

(3) Air purging.

– Open the valves on the gas cylinder and the charge set. Purge the air by loosening the flare nut on the liquid side valve approximately 45° for 3 seconds then closing it for 1 minute; repeat 3 times.

– After purging the air, use a torque wrench to tighten the flare nut on liquid side valve.

(4) Check for gas leakage.

– Check the flare connections for gas leakage.

(5) Discharge the refrigerant.

– Close the valve on the gas cylinder and discharge the refrigerant until the gauge indicates

3 to 5 kg/cm 2 g.

- 44 -

(6) Disconnect the charge set and the gas cylinder, and set the Liquid side and Gas side valves to the open position.

– Be sure to use a hexagonal wrench to operate the valve stems.

(7) Mount the valve stem nuts and the service port nut.

– Use torque wrench to tighten the service port nut to a torque of 1.8 kg.m.

– Be sure to check for gas leakage.

* CAUTION:

Do not leak the gas in the air during Air

Purging.

2) Balance refrigerant of the 3-way valve

(Gas leakage)

Indoor unit

Liquid side

3-Way valve

Open

Outdoor unit

Gas side

3-Way valve

Open

OPEN

Lo

CLOSE

• Procedure

(1) Confirm that both the liquid side and gas side valves are set to the back seat.

(2) Connect the charge set to the 3-way valve’s port.

– Leave the valve on the charge set closed.

– Connect the charge hose to the service port.

(3) Open the valve (Lo side) on the charge set and discharge the refrigerant until the gauge indicates 0 kg/cm 2 G.

– If there is no air in the refrigerant cycle (the pressure when the air conditioner is not running is higher than 1 kg/cm 2 G), discharge the refrigerant until the gauge indicates 0.5 to 1 kg/cm 2 G. if this is the case, it will not be necessary to apply a evacuatin.

– Discharge the refrigerant gradually; if it is discharged too suddenly, the refrigeration oil will also be discharged.

- 45 -

2. Evacuation

(All amount of refrigerant leaked)

Indoor unit

Liquid side

3-Way valve

Open

Outdoor unit

Gas side

3-Way valve

Open

Vacuum pump

OPEN

Lo

CLOSE

• Procedure

(1) Connect the vacuum pump to the center hose of charge set center hose

(2) Evacuation for approximately one hour.

– Confirm that the gauge needle has moved toward -76 cmHg (vacuum of 4 mmHg or less).

(3) Close the valve (Lo side) on the charge set, turn off the vacuum pump, and confirm that the gauge needle does not move (approximately 5 minutes after turning off the vacuum pump).

(4) Disconnect the charge hose from the vacuum pump.

– Vacuum pump oil.

If the vacuum pump oil becomes dirty or depleted, replenish as needed.

- 46 -

3. Gas Charging

(After Evacuation)

Indoor unit

Liquid side

3-Way valve

Open Outdoor unit

Charging cylinder

Check valve

Lo

(1)

OPEN

Gas side

3-Way valve

Open

CLOSE

• Procedure

(1) Connect the charge hose to the charging cylinder.

– Connect the charge hose which you dis-connected from the vacuum pump to the valve at the bottom of the cylinder.

– If you are using a gas cylinder, also use a scale and reverse the cylinder so that the system can be charged with liquid.

(2) Purge the air from the charge hose.

– Open the valve at the bottom of the cylinder and press the check valve on the charge set to purge the air. (Be careful of the liquid refrigerant). The procedure is the same if using a gas cylinder.

(3) Open the valve (Lo side on the charge set and charge the system with liquid refrigerant.

– If the system can not be charged with the specified amount of refrigerant, it can be charged with a little at a time (approximately 150g each time) while operating the air conditioner in the cooling cycle; however, one time is not sufficient, wait approximately 1 minute and then repeat the procedure (pumping down-pin).

\

This is different from previous procedures.

Because you are charging with liquid refrigerant from the gas side, absolutely do not attempt to charge with larger amounts of liquid refrigerant while operating the air conditioner.

(4) Immediately disconnect the charge hose from the 3-way valve’s service port.

– Stopping partway will allow the gas to be discharged.

– If the system has been charged with liquid refrigerant while operating the air conditioner turn off the air conditioner before disconnecting the hose.

(5) Mount the valve stem nuts and the service port nut.

– Use torque wrench to tighten the service port nut to a torque of 1.8 kg.m.

– Be sure to check for gas leakage.

- 47 -

Cycle Troubleshooting Guide

Trouble analysis

1. Check temperature difference between intake and discharge air and operating current.

Temp. difference : approx. 0°C

Current : less than 80% of rated current

• All amount of refrigerant leaked out. Check refrigeration cycle.

Temp. Difference

Temp. difference : approx. 8°C(14°F)

Current : less than 80% of rated current

• Refrigerant leakege

Clog of refrigeration cycle

Defective compressor

Operating Current

Temp. difference : less than 8°C(14°F)

Current : over the reated current

• Excessive amount of refrigerant

Temp. difference : over 8°C(14°F)

• Normal

Notice :

Temperature difference between intake and discharge air depends on room air humidity. When the room air humidity is relativery higher, temperature difference is smaller. When the room air humidity is relatively lower temperature difference is larger.

2. Check temperature and pressure of refrigeration cycle.

Suction pressure

(Compared with

Temperature

(Compared with the normal value) the normal valve)

High

Higher

Normal

Cause of Trouble

Defective compressor

Defective 4-way reverse valve

Excessive amount of refrigerant

Description

Current is low.

Lower Higher

Insufficient amount of

Clogging

High pressure does not quickly rise at the beginning of operation.

Current is low.

Current is low.

Notice :

1. The suction pressure is usually 4.5~6.0 kg/cm 2 G(Cooling) at normal condition.

2. The temperature can be measured by attaching the thermometer to the low pressure tubing and wrap it with putty.

- 48 -

Electronic Parts Troubleshooting Guide

1. Product does not operate at all.

(* Refer to Electronic Control Device drawing and Schematic diagram.)

Turn off Main Power

(After 10 seconds)

Turn on Main Power

NO

Does "beeping" sound is made from the Indoor Unit?

YES

Primarily, the operating condition of Micom is OK.

Check the voltage of power(About AC 220V/AC240V, 50Hz)

• Main power's voltage

• Voltage applied to the unit

• Connecting method of Indoor/Outdoor connecting cable

• Check PWB Ass'y

- Fuse

- Pattern damage

- Varistor(ZNR01J)

Check each load(Indoor/Outdoor Fan Motor,

Compressor, Stepping Motor) and contacting condition of related connector

Check the connection housing for contacting

• Connector related to CN-POWER

• Connector related to CN-MOTOR

• Connector contacting of Outdoor Fan/Compressor

• Display PWB Ass'y Check

- Input Voltage

Items

• Power Transformer

(Outdoor unit)

- Output Voltage

• IC02D(7805) Output (Outdoor unit)

IC04D(7805) Output (Indoor unit)

• IC01A(KIA7036, Reset IC)

OSC01B(8MHz) (Indoor unit)

• IC01A(KIA7036, Reset IC)

OSC01B(4MHz) (Outdoor unit)

PCB Board Operation Check

• DC +5V

Content

• Voltage of Micom No. 2, (Indoor unit)

(DC +4.5V over) and Soldering condition.

No. 5 (Outdoor unit)

Remedy

- About AC220V/240V±10% - Check the power voltage

- About AC14±3V

• Replace Trans

• IC01D(7812) Output (Outdoor unit)

• DC +12V

• Replace IC01D

(Outdoor unit)

• Replace IC02D

(Outdoor unit)

IC04D(Indoor unit)

• Replace faulty parts

- 49 -

2. The product is not operate with the remote controller.

Turn on Main Power

While the compressor has been stopped, the compressor does not operate owing to the delaying function for 3 minutes after stopped.

When the compressor stopped Indoor Fan is driven by a low speed.

At this point the wind speed is not controlled by the remote controller.

(When operated in the Sleeping Mode, the wind speed is set to the low speed by force.)

Cause by the remote controller Caused by other parts except the remote controller

When the mark( ) is displayed in LCD screen, replace battery.

Check the contact of CN-DISP connector.

When the detect switch(double key) inside the remote controller door is fault, it is impossible to operate temperature regulating( / ) and wind speed selecting.

Check DISP PWB Ass'y

- Voltage between CN DISP - : DC +5V

Check the connecting circuit between the remote controller

MICOM (No. ) - R17(2

Ω

) - IR LED - Q1 - R16(2.2K

Ω

).

Check point

• Check the connecting circuit between PIN -

Rø1L(1K) - Cø1L(680PF) - MICOM PIN

• Check Receiver Ass'y

- 50 -

3. Compressor/Outdoor Fan are unable to drive.

Turn on Main Power

Operate "Cooling Mode( )" by setting the desired temperature of the remote controller is less than one of the indoor temperature by 1°C at least.

When in Air Circulation Mode, Compressor/Outdoor Fan is stopped.

Check the sensor for indoor temperature is attached as close as to be effected by the temperature of Heat Exchanger(EVA).

When the sensor circuit for indoor temperature and connector are in bad connection or are not engaged, Compressor/Outdoor Fan is stopped.

• Check the related circuit of R02H(12.1K), R04H(6.2K), Micom (No.3.4) (Indoor unit).

• Check the related circuit of R04H (6.2K) Micom (No.3) (Output unit).

• Check the indoor temperature sensor is disconnected or not(About 10k

Ω

/ at 25°C).

Check Relay(RY - COMP2) for driving compressor.(Outdoor unit)

• When the power(About AC220V/240V) is applied to the connecting wire terminal support transferred to compressor, PWB Ass'y is normal.

• Check the circuit related to the relay.

Check point

Between Micom(No.15) and GND

Between Relay (G5N-1A) (No.1) and (G5N-1A) (No.4)

Between CN-COMP2 and CN-POWER 2(N)

COMP ON

DC5V

DC12V

AC 208/230V

COMP OFF

DC0V

DC0V

Below AC 10V

Turn off Main Power

• Check the electrical wiring diagram of outdoor side.

• Check the abnormal condition for the component of Compressor/Outdoor Fan Motor.

• Check the "open" or "short" of conmecting wires between indoor and outdoor.

- 51 -

4. When indoor Fan does not operate.

Turn off Main power

Check the connection of CN-MOTOR

Check the Fan Motor

Check the Fuse(AC250V/T2A)

Check the related circuit of indoor Fan Motor.

• The pin NO 63 of Micom, and the part for driving TRIAC(the input and output signal of IC01M, PIN NO 2, 15)

• Check the pattern

• Check the TRIAC

- TRIAC Open: Indoor Fan Motor never operate

- TRIAC short: Indoor Fan Motor always operates in case of ON or OFF.

Turn ON Main Power

Check the TRIAC high speed operation by Remocon.

(The Indoor Fan Motor is connected)

The voltage of PIN NO 1(blue) and 3(yellow) of CN-MOTOR.

About AC 180V over

TRIAC is not damaged

About AC 50V over

TRIAC Check

- 52 -

5. When Vertical Louver does not operate.

• Confirm that the Vertical Louver is normally geared with the shaft of

Stepping Motor.

• If the regular torque is detected when rotating the Vertical Louver with hands Normal

• Check the connecting condition of CN-U/D Connector

• Check the soldering condition(on PWB) of STEP(U/D) Connector

Check the operating circuit of the Vertical Louver

• Confirm that there is DC +12V between pin (RED) of CN-U/D and

GND.

• Confirm that there is a soldering short at following terminals.

- Between

58

,

59

,

60 and

61 of MICOM

- Between , , and of IC01M

- Between , , and of IC01M

If there are no problems after above checks

• Confirm the assembly conditions that are catching and interfering parts in the rotation radial of the Vertical Louver

6. When Heating does not operate

Turn ON Main Power

Operate “Heating Mode( )” by setting the desired temperature of the remote controller is higher than one of the indoor temperature by

2°C(4°F) at least.

In heating Mode, the indoor fan operates in case the pipe temperature is higher than 28°C(50°F).

- 53 -

Check the connector of intake and pipe sensor(thermistors)

• Check the related circuit of R02H(12.1K), R04H(6.2K), R03H(1.0K),

Micom(No. 3, 4).

• Check the indoor room temperature is disconnected or not (about

10K

Ω

/at 25°C).

• Check the indoor pipe temperature is disconnected or not (about

5K

Ω

/at 25°C).

Check the DC voltage on the PWB ASS’Y

• The details of check are as followings

• Comp Relay.

CHECK POINT

Between Micom

(No.15) and GND

Between RY-COMP.

(No.1) and (No.4)

Between

CN-COMP2 and

CN-POWER 2(N)

COMP. ON

DC5V

About DC12V

AC 208/230V

COMP. OFF

DC0V

DC0V

Below AC10V

• Outdoor fan Relay

CHECK POINT

Between Micom

(No.14) and GND

Between RY-FAN

(No.1) and (No.4)

Between CN-FAN and

CN-POWER 2(N)

COMP. ON

DC5V

About DC12V

AC 208/230V

COMP. OFF

DC0V

DC0V

Below AC10V

• 4 way Relay

CHECK POINT

Between Micom

(No.13) and GND

Between RY-4WAY

(No.1) and (No.4)

Between CN-4WAY and

CN-POWER 2(N)

COMP. ON

DC5V

About DC12V

AC 208/230V

COMP. OFF

DC0V

DC0V

Below AC10V

Turn off Main Power

• Check the electrical wiring diagram of outdoor side.

• Check the abnormal condition for the component of

Compressor/Outdoor Fan Motor, 4 way.

• Check the "open" or "short" of connecting wires between indoor and outdoor.

- 54 -

Electronic Control Device

(1) INDOOR UNIT P.W.B. ASSEMBLY

P/No.: 6871A10153 (PCB ASSEMBLY, MAIN)

- 55 -

(2) OUTDOOR UNIT P.W.B. ASSEMBLY

TOP VIEW

BOTTOM VIEW

- 56 -

(3) DISPLAY P.W.B. ASM

■

Model: HMC030KD1, HMH030KD1

- 57 -

Schematic Diagram

(1) Heat Pump/Cooling Only Series(Indoor Unit)

- 58 -

(2) Heat Pump Series (Outdoor Unit)

OP2

OP3

OP4

OP5

OP6

R02F

R03F

R04F

R05F

R06F

- 59 -

Exploded View and Replacement Parts List

1. Indoor Unit

733010

342801

131410

352390-1

359011-1

342800

135311

359011-2

352390-2

346810

135301

146811-2

354210

135313

135314

152313

135312 135315

159901

352150

146811-1

263230

35211B

268714

249951

267110

W0CZZ

152302

268712

152302

- 60 -

Parts List(Indoor)

LOCATION

NO.

DESCRIPTION

147582

152302

152313

159901

249951

263230

267110

268712

131410

135311

135312

135313

CHASSIS ASSEMBLY

GRILLE ASSEMBLY,DISCHARGE(INDOOR)

GRILLE ASSEMBLY,FRONT(INDOOR)

GRILLE ASSEMBLY,INLET

135314

135315

GRILLE,INLET

GRILLE ASSEMBLY,FRONT(INDOOR)

146811-1 MOTOR ASSEMBLY,STEP

146811-2 MOTOR ASSEMBLY,STEP

LOUVER,VERTICAL

FILTER(MECH),A/C

FILTER ASSEMBLY,DEODORIZER

VANE,HORIZONTAL

CONTROL BOX ASSEMBLY,INDOOR

THERMISTOR ASSEMBLY

REMOTE CONTROLLER ASSEMBLY

PWB(PCB) ASSY,DISPLAY

268714

342800

342801

346810

PWB(PCB) ASSEMBLY,MAIN

BEARING

BEARING

MOTOR ASSEMBLY,INDOOR

35211B

352150

TUBE ASSY,TUBING

HOSE ASSY,DRAIN

352390-1 AIR GUIDE ASSEMBLY

352390-2 AIR GUIDE ASSEMBLY

354210 EVAPORATOR ASSEMBLY,FIRST

359011-1 FAN ASSY,CROSS FLOW

359011-2 FAN ASSY,CROSS FLOW

733010 PLATE ASSY,INSTALL

W0CZZ CAPACITOR,DRAWING

PART NO.

HMC030KD1 HMH030KD1

3141A10001D

3531A10056M

3531A10058M

3531A10060F

3530A10042B

3531A10057V

4681AR2727B

-

4758A30018A

5230A10001A

5231A20032F

5990A20003B

4995A20337H

6323A20002C

6711A20025M

6871A20108A

6871A10153B

4280A20003A

4280A20001A

4681AP2632H

5211A20200A

5251AR1222P

5239A10001A

5239A10001B

5421A20058A

5901AR2441G

5901AR2441F

3301A10001A

3H01487G

6871A10153B

4280A20003A

4280A20001A

4681AP2632H

5211A20200A

5251AR1222P

5239A10001A

5239A10001B

5421A20057A

5901AR2441G

5901AR2441F

3301A10001A

3H01487G

3141A10001D

3531A10056M

3531A10058M

3531A10060F

3530A10042B

3531A10057V

4681AR2727B

-

4758A30018A

5230A10001A

5231A20032F

5990A20003B

4995A20337H

6323A20002C

6711A20025M

6871A20108A

NOTE)

*

Please ensure GCSC since these parts may be changed depending upon the buyer's request.

(GCSC WEBSITE http://biz.LGservice.com)

REMARKS

- 61 -

2. Outdoor Unit

435512

137213-1

137213-2

437210

554031

435301

559010

546810

549610

447910

430410

552111

435511

W0CZZ-2

W0CZZ-1

668711

263230

552201

649950

552202

552203-2

554160-1

552203-1

550140-1 550140-2

- 62 -

554160-2

567502

552116

561410

566000

Parts List(Outdoor)

LOCATION

NO.

DESCRIPTION

137213-1 PANEL ASSEMBLY,SIDE

137213-2 PANEL ASSY,SIDE

263230

430410

THERMISTOR ASSEMBLY

BASE ASSY,OUTDOOR

435301

435511

435512

437210

GRILLE,DISCHARGE

COVER ASSY,CONTROL(OUTDOOR)

COVER ASSEMBLY,TOP(OUTDOOR)

PANEL ASSY,FRONT SUB

447910

546810

BARRIER ASSEMBLY,OUTDOOR

MOTOR ASSEMBLY,AC

549610 MOUNT ASSY,MOTOR(OUTDOOR)

550140-1 ISOLATOR,COMP

550140-2 ISOLATOR,COMP

552111 TUBE ASSEMBLY,CAPILLARY

552116

552201

TUBE ASSEMBLY,REVERSING

VALVE,CHECK

552202 VALVE,REVERSING

552203-1 VALVE,SERVICE

552203-2 VALVE,SERVICE

554031 CONDENSER ASSEMBLY,BENT

554160-1 COMPRESSOR SET

554160-2 COMPRESSOR SET

559010

561410

FAN ASSEMBLY,PROPELLER

COIL ASSEMBLY,REVERSING VALVE

566000

567502

649950

668711

W0CZZ

W0CZZ

SWITCH,PRESSURE

O.L.P

CONTROL BOX ASSEMBLY,OUTDOOR

PWB(PCB) ASSEMBLY,MAIN(OUTDOOR)

CAPACITOR,DRAWING

CAPACITOR,DRAWING

PART NO.

HMC030KD1 HMH030KD1

-

2A00393H

2A00392N

6140AP2096A

2520UKVK2BA

2520UHAK2AA

1A00195G

-

-

6750U-L063A

4995A20383D

6871A20514A

6120AR2194F

2A00986Y

1A00202F

1A00202C

6323A20002L

3041AP2741L

3530A20007J

3551AR7184T

3H03266H

1A00197C

4791A30004G

4681A20008E

2A01035T

4H00982E

4H00637A

5211A20034X

-

3A01020H

3A02027J

2A00393H

2A00392N

6140AP2096Q

2520UKVK2BA

2520UHAK2AA

1A00195G

6141AR3733R

3A02524A

6750U-L063A

4995A20383C

6871A20514B

6120AR2194F

2A00986Y

1A00202F

1A00202C

6323A20002L

3041AP2741L

3530A20007J

3551AR7184T

3H03266H

1A00197C

4791A30004G

4681A20008E

2A01035T

4H00982E

4H00637A

5211A20034X

5211A20057B

3A01020H

REMARKS

- 63 -

P/No.: 3828A20390Q

April 2004

Printed in Korea