Internal Use Only http://biz.lgservice.com Window Air Conditioner SVC MANUAL MODEL : LP121CEM-Y8 CAUTION Before Servicing the unit, read the safety precautions in General SVC manual. Only for authorized service personnel.
1. Specification Model Cooling Capacity Heating Capacity ( for Heat Pump models) Electric Heater capacity Power Input Running Current Starting current Electric Heater Current EER COP Power Supply Power Factor Air Flow Rate Moisture Removal Sound Level (SoundPressure,1m) Refrigerant & Charge Compressor Cooling/Heating Cooling/Heating Cooling/Heating Indoor,Max Outdoor,Max Indoor,H/M/L Outdoor,Max Type Model Motor Type Oil Type Oil Charge O.L.
1.2 FEATURES AND BENEFITS The PTAC has many features, some of which are different than those found on conventional PTAC units. The servicer must be familiar with these features in order to properly service the unit.
• Indoor Filters The unit uses two indoor filters which slide in and cut easily. The filters may be cleaned by washing and brushing without removing the front grille. • Rotary Compressor The unit uses a rotary compressor for quiet, reliable operation and long life. • 2 Position Discharge Grille The discharge grille can provide air flows upward at an angle of 40 off vertical or 15 degree off vertical.
1.3 CONTROL LOCATIONS • OPERATION COOLING ONLY MODEL ELECTRIC HEATING MODEL TEMPERATURE CONTROL Set the Thermostat control to the desired temperature mark 5 (the mid-point is a good starting position). If the room temperature is not satisfactory after a reasonable time, adjust the control to a cooler or warmer setting, as appropriate. OPERATION MODE SELECTOR OFF Turns air conditioner off. LOW FAN Low speed fan operation without cooling. HIGH FAN High speed fan operation without cooling.
1.4 ADDITIONAL CONTROLS • REMOVING THE FRONT GRILLE Additional controls are available after removing the front grille and option cover of control box. To remove the front grille, pull out the bottom of front grille and then lift up. To replace the front grille, place the tabs over the top of the unit and push the bottom of front grille until the clips snap into place. • ADDITIONAL CONTROLS The additional controls are located behind the option cover of control box.
• REMOTE/LOCAL CONTROL When remote/local switch #1 is on, it allow the unit to operate by the control of Remote Wall Thermostat. The unit control by knobs are not available. • ENERGY SAVER The energy saver switch #2 is on. This switch is set at continuous fan to provide continuous fan operation in cool or heat modes. When the switch is off the continuous fan allows continuous circulation of room air and make the more balanced temperature of the room.
2. Disassembly Instructions — Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord. 2.1 MECHANICAL PARTS 2.1.1 FRONT GRILLE 1. Remove the front grille. (See Figure 1) 2. To remove the front grille, pull out the bottom of the front grille and then lift up. Re-install the component by referring to the removal procedure. 3. To replace the front grille, place the tabs over the top of the unit and push the bottom of front grille until the clips snap into place.
2.1.2 CONTROL BOX 1. Remove the front grille. (Refer to section 2.1.1) 2. Remove the two screws which fasten the control box. (See Figure 2) 3. Pull the control box from the Air guide. Figure 2 4. Remove the control box cover. (See Figure 3) 5. Disconnect wire housings on the control box. Figure 3 6. Pull the control box assembly out from the unit. (See Figure 4) 7. Re-install the components by referring to the removal procedure. Figure 4 Copyright ©2008 LG Electronics. Inc. All right reserved.
2.2 AIR HANDLING PARTS 2.2.1 ELECTRIC HEATER (ELECTRIC HEATER MODEL ONLY) 1. Remove the front grille.(Refer to section 2.1.1) 2. Remove the control box assembly. (Refer to section 2.1.2) 3. Remove the 4 screws which fasten the Evaporator. (See Figure 5) Figure 5 4. Remove the top cover assembly, net steel, brace. (See Figure 6) Figure 6 5. Remove the 6 screws which fasten the Air-guide. 6. Pull the Air-guide assembly out from the unit. (See Figure 7) Figure 7 7.
2.2.2 CROSS FLOW FAN 1. Remove the front grille. (Refer to section 2.1.1) 2. Remove the control box assembly. (Refer to section 2.1.2) 3. Remove the Air-Guide Assembly from the unit. (Refer to section 2.2.1) 4. Loosen the screw on the cross flow fan. (See Figure 9) Figure 9 5. Remove the 4 screws which fasten the indoor motor and the earth wire. (See Figure 10) 6. Remove the supports on both sides. 7. Pull the cross flow fan out from the air-guide. 8.
2.2.4 SHROUD 1. Remove the axial fan. (Refer to section 2.2.3) 2. Remove the 4 screws which fasten the condenser with the shroud and the basepan. (See Figure 11) 3. Remove the shroud. 4. Re-install the component by referring to the removal procedure. 2.3. ELECTRICAL PARTS 2.3.1 OUTDOOR MOTOR 1. Remove the clamp cord and disconnect a wire housing in control box. (Refer to section 2.1.2) 2. Remove the axial fan. (Refer to section 2.2.3) 3. Remove the 2 screws which fasten the motor. (See Figure 14) 4.
2.3.5 POWER CORD 1. Remove the control box. (Refer to section 2.1.2) 2. Disconnect the grounding screw from the control box. 3. Disconnect 2 receptacles. 4. Remove a screw which fastens the clip cord. 5. Separate the power cord from the control box. (See Figure 17) 6. Re-install the component by referring to the removal procedure, above. (Use only one ground-marked hole for ground connection.) 7. If the supply cord of this appliance is damaged, it must be replaced by an exact replacement part.
2.4 REFRIGERATION CYCLE CAUTION Discharge the refrigerant system using a refrigerant recovery system. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the refrigerant. Leave the valve in place after servicing the system. 2.4.1 CONDENSER 1. Remove the brace and the shroud. (Refer to section 2.2.2) 2. Remove the 4 screws which fasten the shroud. (Refer to section 2.2.2) 3.
NOTES — Replacement of the refrigeration cycle. 1. When replacing the refrigeration cycle, be sure to discharge the refrigerant system using a refrigerant recovery system. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the refrigerant. Leave the valve in place after servicing the system. 2. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes. 3.
Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment. pinch-off tool capable of making a vapor-proof seal, leak detector, tubing cutter, hand tools to remove components, service valve. COMPOUND GAUGE CONDENSER (HIGH PRESSURE SIDE) MANIFOLD GAUGE A B CAPILLARY TUBE SEE INSETS BELOW EVAPORATOR (LOW PRESSURE SIDE) COMPRESSOR LOW HI A B B A EXTERNAL VACUUM PUMP CHARGING CYLINDER C Figure 21 A-Pulling Vacuum Copyright ©2008 LG Electronics. Inc. All right reserved.
3. Installation Dimension of air conditioner 3.1 HOW TO INSTALL THE UNIT CAUTION 1,066 mm (42") • There are sharp edges that can cause serious cuts. • When lifting the air conditioner, it is HEAVY. Use 2 people to lift. For existing sleeve, you should measure the wall sleeve dimensions. Install the new air conditioner according to these installation instructions to achieve the best performence.
3.2 WALL SLEEVE INSTALLATION 3.2.1 Wall Case Installation Data For new construction, early planning with the architect is necessary. Unit location, electrical connection locations, and wall openings of the proper dimensions are essential to avoid the necessity of rework, fillers, framing, moving electrical outlets, and other expensive modifications.
3.2.2 PREPARATION OF THE FRONT GRILLE Carefully remove shipping tape from the front grille. Shipping Tape Brick, Frame, Stucco and Shingle Construction For new construction, the opening for the wall case should be framed and the wall case inserted into the opening during construction. Lintels should be used when the building material is heavy and is not self supporting (such as brick). The wall case will fit an opening of six courses of standard brick or five courses of jumbo brick.
Copyright ©2008 LG Electronics. Inc. All right reserved.
Copyright ©2008 LG Electronics. Inc. All right reserved. Only for training and service purposes - 21 - LGE Internal Use Only WALL RECEPTACLE (BY OTHERS) 2" MIN. CAULK* POWER SUPPLY CONDUIT OUTDOOR GRILLE STEEL LINTEL CAULK* 1/4" MIN. WALL CASE MOUNTING SCREWS BY INSTALLER 20-7/8" (RAB71) 21" (RAB77) RAB71 13-3/4" RAB77 13-7/8" *Caulk around perimeter of wall case all four sides where it joins the building - Interior and Exterior.
3.2.3 UNIT INSTALLATION 1. Remove the shipping screw from the ventilation door. (See Figure 24) Figure 24 2. Remove the front gille by pulling it out at the bottom to release it, then lift it up along the unit top front. (See Figure 25) Figure 25 3. Slide the unit into the wall sleeve and secure with 6 screws through the unit flange holes. (See Figure 26) Figure 26 4. Reinstall the front grille by hooking the top over the unit top, then pushing it in at the bottom.
3.3 ELECTRICAL REQUIREMENTS 3.3.1 ELECTRICAL DATA (FOR 230/208V MODEL) CAUTION 1. Do not use an extension cord with this unit. 2. When the unit is in the OFF position, the power supply to the electrical controls is still energized. 3. Disconnect the power to the unit before servicing the unit. 4. Remove the power cord from the wall receptacle. 5. Remove or turn off the protective device (fuses or circuit breaker).
4. Field Installed Accessories Note: The installation and servicing of this equipment must be performed by qualified, experienced technicians NOTICE: Warnings and Cautions appear at appropriate sections throughout this manual. Read these carefully. WARNING - Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION - Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
Condensate Disposal Pump Kit Installation 1. Remove front plastic cover by rotating bottom outward and then lifting up and out from chassis. Part No: AYSB2101 2. Unplug and remove the PTAC chassis from the wallsleeve. Movethe chassis where the front and back of the chassis can be easily accessed. Description The internal condensate pump serves as a means for disposing of condensate generated during heat pump operation by transferring it to the indoor coil.
7. Remove the screw that attaches the electric heater wire to the side of the indoor fan housing. 11. Install tube #1 and tube #2 (ref. fig. 38) on the pump assembly using the rubber elbows as shown in fig. 35. 8. Remove the 3 screws which fasten the top cover assembly. Figure 35 Figure 33 9. Position water spraying plastic tube into the electric heater cover. Make sure that the three pairs(total of six) of plastic tongues snap into the corresponding metal slots of the heater frame as shown in fig. 34.
15. Assembly the unit back following the reverse order of disassembly. NOTE: All tube should be inserted into rubber elbows by at least 1/2 inch Figure 38 Spraying Tube Pump assembly Figure 39 Tube #1 Rubber elbows(3) Tube #2 14. Connect the condensate pump to the ICR relay of the terminal of the board as shown in fig. 40 Make sure to fasten the pump wire through the wire clip on the back side of the control barrier as shown in fig. 39 Copyright ©2008 LG Electronics. Inc. All right reserved.
Architecture Grille Aluminum - Single Pack Note: A baffle kit must not be used with a stamped aluminum grille on any PTAC installation. Part No: AYAGALA01 Stamped Aluminum Grille Stamped Aluminum Grille 1. Prepare the wall sleeve for installation of the grille by removing the cardboard stiffener and rear enclosure panel from the sleeve. These items may be removed from inside of the building.
4. Secure the grille to the sleeve by tightening the four screws to their corresponding holes in the grille. 5. Remove the wire handle after the installation is complete. Note: The stamped aluminum grille includes 6 screws, washers, nuts, and plastic grommets. The architectural grille includes 4 screws. Receiving Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt.
contact the front edge of sleeve. Secure the chassis to the wall sleeve on each side with screws provided. Figure 42 – Outdoor Drain Kit Installation Re-install the cabinet front. DRAIN FITTING PLATE B 1/2" DRAIN FITTING See the following pages for installation instructions of indoor drain kit. BLANK-OFF PLATE C Figure 43 Figure 44 GASKETS A MTG.
Indoor Drain Kit Installation Leveling Legs The internal drain is installed on the bottom of the wall sleeve when it is required to drain the condensate into a drain system inside of the building. The components of the wall sleeve drain kit are shown in Detail A. Use components C (2), D, E, mounting screws (6) and the Outdoor drain fitting. Part No: AYLL101 1. The components D, E, and drain fitting of the kit are mounted on the bottom of the wall sleeve prior to the installation of the sleeve.
Leveling Leg Assembly Installation on Wall Sleeve To install the leveling leg assembly, complete the following: 1. Drill four 1/8-inch diameter holes in the wall sleeve, two on each side, using the leveling legs as a template. Caulk around screws to prevent water leaks. 1. Drill two 1/8-inch holes in each side of the wall sleeve, as shown in Figure 48, using the leveling leg assembly as a template. Locations near the front of the sleeve provide more support. 2.
Hard Wire Kit WARNING Hazardous Voltage! Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power can not be inadvertently energized. Failure to disconnect power before servicing could result in death or serious injury.
208/230 Volt Units Figure 50 - Mounting Hard Wire Junction Box Kit 1. Remove and discard the white lead from the wire assembly. Wall Sleeve 2. Connect the black lead to the line 2 terminal on the control board. 3. Connect the red lead to the common (C) terminal on the capacitor. Ground Wie with Eyelet Terminal 4. Connect the ground wire to the partition panel where the ground wire on the power cord was located. Use the supplied green ground screw. Cover plate 5.
Remote Escutcheon Kit Part No: AYRE110 Description This kit provides an attractive replacement escutcheon (see Figure 53). The kit allows the removal of control knobs and graphics, which are not required when a wall thermostat is used to control the unit. Receiving Figure 54 Upon receipt of the product, inspect the shipping carton for signs of visible damage. Report any damage or shortage to the carrier and note it on the delivery receipt.
5. Replace the escutcheon with the one from this kit by inserting the tabs at the top of the escutcheon into the retaining holes and laying the escutcheon flat on the control panel. Installation The installation and servicing of the equipment referred to in this booklet should be performed by qualified, experienced technicians. 6. Replace the front by reversing steps 1 through 4. 7.
Note: The proper subbase must be ordered to obtain the correct electrical receptacle. (Figure 61) Figure 59 - Dimensions 13 3/4" 8. After wiring is complete, mount covers A and F to the subbase with provided screws. (Figure 58) Wall Sleeve (Outdoor Side) 9. When installing optional accessories to the subbase, refer to each installation instruction for that accessory.
5. Troubleshooting Guide 5.1 OUTSIDE DIMENSIONS 406mm (16") 1,066mm (42") 406mm (16") 505mm (20") 5.2 PIPING SYSTEM Following is a brief description of the important components and their functions in the refrigeration system. Refer to Figure 62 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.
5.3 TROUBLESHOOTING GUIDE In general, possible trouble is classified in two causes. The one is Starting Failure which is caused from an electrical defect, and the other is Ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application. Unit is running but cooling is ineffective Ineffective Cooling Check of cold air circulation for smooth flow. Check of outdoor coil (heat exchanger) & the fan operation. Dirty indoor coil (Heat exchanger) Check gas leakage.
Fails to Start Check power source. Check circuit breaker and fuse. Check control switch setting. Gas leakage of feeler bulb of thermostat Check control switch. Only compressor fails to start. Only fan fails to start. Improper wiring. Drop of power voltage. Improper thermostat setting Defect of fan motor capacitor. Defect of compressor capacitor. Loose terminal connection. Check capacitor. Irregular motor resistance ( ). Irregular motor insulation ( ). Improper wiring Replacement.
COMPLAINT Fan motor will not run. CAUSE REMEDY No power Check voltage at outlet. Correct if none. Power supply cord Check voltage to rotary switch. If none, check power supply cord. Replace cord if circuit is open. Rotary switch Check switch continuity. Refer to wiring diagram for terminal identification. Replace switch if defective. Wire disconnected or connection loose Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal.
COMPLAINT Compressor will not run, but fan motor runs. CAUSE REMEDY Voltage Check voltage. See the limits on the preceding. page. If not within limits, call an electrician. Wiring Check the wire connections, if loose, repair or replace the terminal. If wires are off, refer to wiring diagram for identification, and replace. Check wire locations. If not per wiring diagram, correct. Rotary Check for continuity, refer to the wiring diagram for terminal identification.
COMPLAINT Compressor cycles on overload. Insufficient cooling or heating Excessive noise. REMEDY CAUSE Voltage Check the voltage. See the limits on the preceding page. If not within limits, call an electrician. Overload Check overload, if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool, and retest.) Fan motor If not running, determine the cause. Replace if required. Condenser air flow restriction Remove the cabinet.
6. Piping Diagrams CAPILLARY TUBE Th2 Th1 HEAT EXCHANGER (CONDENSER) HEAT EXCHANGER (EVAPORATOR) COMPRESSOR LOC. Description PCB Connector Th1 Thermistor for indoor Air temperature CN-IDAT Th2 Thermistor for Evaporator pipe temperature CN-IDPT Copyright ©2008 LG Electronics. Inc. All right reserved.
7. Schematic Diagram In part "A", there are 3 types. Type.1 1 OUTDOOR FAN MOTOR YL 2 BK BL RD OR(BR) YL BK OR(BR) YL 3 4 Type.2 OUTDOOR FAN MOTOR OR OR RD YL BK BL RD OR(BR) YL BL OR(BR) YL Type.3 OUTDOOR FAN MOTOR BK BL RD OR(BR) YL RD OR(BR) YL In part "B", there are 3 types. Type.1 INDOOR FAN MOTOR BK BL RD OR BR YL BL RD OR BR YL BK BL RD OR BR YL RD OR BR YL GN/YL Type.2 Type.
8.
CONDENSER (OUTDOOR) SERVICE REPLACEMENT PROCEDURE: In this Model Aluminum Condenser is applied. In case you need to replace the condenser follow the below mentioned steps: 1. Cover the brazing point (Section A) between copper pipe and aluminum pipe with wet towel. 2. Remove the copper pipe and copper connector of aluminum condenser(Section B) by brazing and replace the condenser with a new one. 3. Make sure that the direction of brazing flame is away from the aluminum condenser.
P/NO : MFL42137114 FEBRUARY, 2008
