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Service Manual

Table of Contents

Part

Ⅰ

: Technical Information

.......................................................................1

1. Summary

......................................................................................................................1

2. Specifications

..........................................................................................................2

2.1 Specification Sheet

...........................................................................................................2

2.2 Operation Characteristic Curve

........................................................................................6

2.3 Capacity Variation Ratio According to Temperature

.........................................................6

2.4 Cooling and Heating Data Sheet in Rated Frequency

.....................................................7

2.5 Noise Curve

......................................................................................................................7

3. Outline Dimension Diagram

........................................................................9

3.1 Indoor Unit ........................................................................................................................9

3.2 Outdoor Unit

...................................................................................................................10

4. Refrigerant System Diagram

....................................................................11

5. Electrical Part

.........................................................................................................13

5.1 Wiring Diagram ...............................................................................................................13
5.2 PCB Printed Diagram .....................................................................................................16

6. Function and Control

......................................................................................19

6.1 Remote Controller Introduction

.....................................................................................19

6.2 Brief Description of Modes and Functions

......................................................................23

Part

Ⅱ

: Installation and Maintenance

.................................................32

7. Notes for Installation and Maintenance

..........................................32

8. Installation

................................................................................................................35

8.1 Installation Dimension Diagram ......................................................................................35

8.2 Installation Parts-checking

............................................................................................37

8.3 Selection of Installation Location ....................................................................................37

8.4 Requirements for Electric Connection

...........................................................................37

8.5 Installation of Indoor Unit ................................................................................................37

8.6 Installation of Outdoor Unit

.............................................................................................40

8.7 Vacuum Pumping and Leak Detection

...........................................................................41

8.8 Check after Installation and Test Operation

...................................................................41

Table of Contents

Summary of Contents for Y8369

Page 1: ...u for selecting LENNOX air conditioners Service Manual Models LI012CI 180P432 LI012CO 180P432 LI012HI 180P432 LI012HO 180P432 LI024CI 180P432 LI024CO 180P432 LI024HI 180P432 LI024HO 180P432 Refrigeran...

Page 2: ...13 5 1 Wiring Diagram 13 5 2 PCB Printed Diagram 16 6 Function and Control 19 6 1 Remote Controller Introduction 19 6 2 Brief Description of Modes and Functions 23 Part Installation and Maintenance 3...

Page 3: ...60 10 1 Indoor Unit 60 10 2 Outdoor Unit 64 11 Removal Procedure 72 11 1 Removal Procedure of Indoor Unit 72 11 2 Removal Procedure of Outdoor Unit 82 Appendix 92 Appendix 1 Reference Sheet of Celsiu...

Page 4: ...vice Manual 1 Summary Part Technical Information Indoor Unit LI012CI 180P432 LI012HI 180P432 LI024CI 180P432 LI024HI 180P432 Outdoor Unit LI012CO 180P432 LI012HO 180P432 LI024CO 180P432 LI024HO 180P43...

Page 5: ...unit LI012CI 180P432 LI012HI 180P432 Indoor Unit Product Code Y8369 Y8381 Fan Type Cross flow Cross flow Diameter Length DXL inch 3 7 8X25 3 7 8X25 Fan Motor Cooling Speed SH H M L r min 1350 1200 100...

Page 6: ...Motor Capacitor F Air Flow Volume of Outdoor Unit CFM 1600 1600 Fan Type Axial flow Axial flow Fan Diameter inch 15 3 4 15 3 4 Defrosting Method Automatic Defrosting Climate Type T1 T1 Isolation I I M...

Page 7: ...ndoor unit LI024CI 180P432 LI024HI 180P432 Indoor Unit Product Code Y8373 Y8385 Fan Type Cross flow Cross flow Diameter Length DXL inch 4 1 4X32 11 16 4 1 4X32 11 16 Fan Motor Cooling Speed SH H M L r...

Page 8: ...inch 33 5 16X1 3 4X26 33 5 16X1 3 4X26 Fan Motor Speed rpm 800 800 Output of Fan Motor W 60 60 Fan Motor RLA A 0 4 0 4 Fan Motor Capacitor F Air Flow Volume of Outdoor Unit CFM 3200 3200 Fan Type Axia...

Page 9: ...F WB60 F Outdoor DB19 94 F WB19 04 F Indoor air flow High Pipe lengt 24 6ft Conditions Indoor DB70 F WB60 Outdoor DB19 94 F WB19 04 F Indoor air flow High Pipe lengt 24 6ft Conditions Indoor DB80 F W...

Page 10: ...CO 180P432 130 142 in 46 4 51 8 out 51 8 57 2 in 167 181 4 out 98 6 118 4 Super High High 75 Rated heating condition F DB WB Model Pressure of gas pipe connecting indoor and outdoor unit Inlet and out...

Page 11: ...M H SH Indoor fan motor rating speed Noise dB A 46 48 50 52 54 56 58 60 20 30 40 50 60 70 80 90 100 Compressor frequency Hz Noise dB A Heating Cooling Indoor side noise Outdoor side noise LI024CI 180...

Page 12: ...11 16 8 1 8 27 7 5 16 2 3 4 2 3 4 MODEL W H D LI012CI 180P432 LI012CO 180P432 LI012HI 180P432 LI012HO 180P432 33 1 4 11 3 8 8 1 4 LI024CI 180P432 LI024CO 180P432 LI024HI 180P432 LI024HO 180P432 42 7 1...

Page 13: ...10 Technical Information Service Manual Unit inch 3 2 Outdoor Unit 30 9 16 21 1 4 12 5 8 28 11 1 4 20 10 1 8 LI024CO 180P432 LI024HO 180P432 Unit inch 35 13 3 8 27 9 16 15 5 8 38 14 5 16 22...

Page 14: ...alve Discharge Suction Heat exchanger evaporator Heat exchanger condenser Valve Valve Liquid pipe side Gas pipe side Strainer Electron expansion valve Strainer Accumlator Compressor Indoor unit Outdoo...

Page 15: ...er Electron expansion valve Strainer Accumlator Compressor Indoor unit Outdoor unit Accumlator COOLING Discharge Suction Heat exchanger evaporator Heat exchanger condenser Valve Valve Liquid pipe side...

Page 16: ...RD Red BU Blue Grounding wire YEGN Yellow Green BK Black VT Violet OG Orange Note Jumper cap is used to determine fan speed and the swing angle of horizontal lover for this model 600007000575 67 33 1...

Page 17: ...9 8 203 203 9 8 8 5 0 1 7 5 1 32 5 1 1 1 75 2 0 62 7 21 6 7 1 8 5 8 5 1 1 1 1 8 1 1 02725 1 1 2 1 5 5 725 2 0 1 7 5 1 9 1 7521 3 16 21 9 9 0 1 225 81 7 JURXQG RQO LURQ VKHOO PRWRU DSSOLHV WR WKH 0RWR...

Page 18: ...51 1 0 1 7 5 1 0 1 7 5 1 3 57 57 1 1 5 8 35 17 5 8 7 2 5 3 1 211 725 8 5 1 1 8 1 1 0 1 7 5 1 9 9 3 16 21 7521 9 0 2 1 1 02725 1 LURQ VKHOO PRWRU RQO DSSOLHV WR WKH 1RWH 0RWRU JURXQG 3OHDVH GRQ W WRXF...

Page 19: ...unction neutral wire 4 Interface of neutral wire 5 Interface of fan 6 Interface of health function live wire 7 Jumper cap 8 Auto button 9 Up down swing interface 10 Feedback interface of indoor unit 1...

Page 20: ...4 4 way valve 5 Interface of earthing wire 6 Interface of live wire 7 Interface of netural wire 8 Interface of communication 9 Interface of electronic expansion valve 10 Overload interface of compress...

Page 21: ...rface Terminal of system high pressure protection Compressor overload protection terminal Terminal of electronic expansion valve Terminal for low pressure protection Interface of fan 4 way valve termi...

Page 22: ...ndoor ambient temp Sleep mode Clock Heat mode Fan mode Dry mode Cool mode Auto mode Operation mode I feel X fan mode health function Note After putting through the power the air conditioner will give...

Page 23: ...n Press this button to set up down swing angle which circularly changes as below This remote controller is universal If any command or is sent out the unit will carry out the command as indicates the...

Page 24: ...turn on the display s light and press this button again to turn off the display s light If the light is turned on is displayed If the light is turned off disappears 16 X FAN Button Pressing X FAN but...

Page 25: ...to indoor unit during operation Replace new batteries of the same model when replacement is required When you don t use remote controller for a long time please take out the batteries If the display...

Page 26: ...re is the set value under each condition Ambient temperature is Tamb Tcompensation for heat pump unit and Tamb for cooling only unit 4 If theres I feel function Tcompensation is 0 Others are same as a...

Page 27: ...be still in standby mode after finishing refrigerant recycling if the unit is in ON status before refrigerant recycling it will still run in original operation mode 11 Ambient temperature display cont...

Page 28: ...the compressor is shut down and Tsetup Tindoor ambient temperature Tcooling indoor ambient temperature compensation 32 9 F start up the machine for cooling the cooling operation will start 2 During o...

Page 29: ...ed on 2 Defrosting a Defrosting starts the compressor is shut down and restarts it after 55 second delay b Defrosting ends the compressor stops then starts it after 55 second delay 2 Outer Fans Contro...

Page 30: ...it should not be started and should be stopped to treat according to the overload protection Clear the trouble at the mode of power turn off heating and the protection times are not counted 2 Frequen...

Page 31: ...ature at normal speed during discharging you should limit the frequency raising of compressor 3 Reducing frequency at normal speed and stopping machine If Tfrequency reducing temperature at normal spe...

Page 32: ...e compressor frequency by reducing 30Hz 90s till the lower limit After it was running 90s at the lower limit if Tfrequency reducing temperature at normal speed of module T Module you should stop the m...

Page 33: ...regarded as four way valve reversion abnormity And then it can run if stop the reversion abnormity protection for four way valve 3 min and if it still cant run when the reversion abnormity protection...

Page 34: ...eration 3 When 32 F Toutdoor amb 35 6 F the electric heating of chassis will keep original status 7 Electric Heating Function of Compressor 1 When Toutdoor amb 23 F compressor stops operation while th...

Page 35: ...the unit adequately grounded The grounding wire cant be used for other purposes 6 Must apply protective accessories such as protective boards cable cross loop and wire clip 7 The live wire neutral wi...

Page 36: ...sure rise or compressor rupture resulting in injury 4 During refrigerant recovery make sure that liquid valve and gas valve are fully closed and power is disconnected before detaching the connection p...

Page 37: ...ng tape 4 Electroprobe 7 Electronic leakage detector 10 Pipe pliers pipe cutter 2 Screw driver 5 Universal meter 8 Vacuum pump 11 Pipe expander pipe bender 3 Impact drill drill head electric drill 6 T...

Page 38: ...8 inch At least 5 7 8 inch Space to the wall S p a c e t o t h e o b s t r u c t i o n r o o l f e h t o t e c a p S A t l e a s t 1 1 8 i n c h Space to the obstructio At least 78 5 8 inch Space to...

Page 39: ...ang the indoor unit Make the bound pipes pass through the wall hole and then connect outdoor unit Neaten the pipes Vacuum pumping and leakage detection Check after installation and test operation Fini...

Page 40: ...d near the power socket 4 Select a location which is out of reach for children 5 The location should be able to withstand the weight of indoor unit and wont increase noise and vibration 6 The applianc...

Page 41: ...ed frame As show in Fig 1 5 Connect the Pipe of Indoor Unit 1 Aim the pipe joint at the corresponding bellmouth As show in Fig 5 2 Pretightening the union nut with hand 3 Adjust the torque force by re...

Page 42: ...1 Bind up the connection pipe power cord and drain hose with the band As show in Fig 14 2 Reserve a certain length of drain hose and power cord for installation when binding them When binding to a ce...

Page 43: ...utdoor unit on the selected location with expansion screws 5 Connect Outdoor Electric Wire 1 Let the connection wire sleeve go through the two holes of baffle tighten the connection joint of sleeve an...

Page 44: ...r press ON OFF button on the remote controller to start operation Press MODE button to select AUTO COOL DRY FAN and HEAT to check whether the operation is normal or not If the ambient temperature is l...

Page 45: ...sor open or short circuit Outdoor tube sensor open or short circuit Outdoor ambient sensor open or short circuit Indoor tube sensor open or short circuit Indoor ambient sensor open or short circuit In...

Page 46: ...inboard broken Malfunction diagnosis process Is the wiring terminal between the temperature sensor and the controller loosened or poorly contacted Start Insert the temperature sensor tightly Yes Yes Y...

Page 47: ...e connection of PG motor control terminal is firm Turn on the unit again measure whether the output voltage on control terminal for PG motor is more than 50V within 1 min after the louvers are opened...

Page 48: ...the mainboard is defined abnormal Malfunction diagnosis process Start Is there jumper cap on the mainboard Is the jumper cap inserted correctly and tightly Replace the jumper cap with the same model...

Page 49: ...harges slowly The zero cross detectioncircuit of the mainboard is defined abnormal Malfunction diagnosis process Turn power off for 1minute the turn back on The unit returns to normal Conclusion U8 is...

Page 50: ...anual Start Is malfunction eliminated The end check if the connection wire are correctly connected Replace the detecting plate with the same model Replace the mainboard with the same model Yes Yes No...

Page 51: ...in the system System is blocked inside dirt block ice block oil block Y valve no fully open Compressor doesn t work normally Strange noise or leakage occurs Make compressor run normally Casing is too...

Page 52: ...ith the voltage testing circuit on control panel AP1 Replace the control panel AP1 Measure the AC voltage between terminalL andN on wiring board XT power supply Voltage within 210VAC 250VAC Shut down...

Page 53: ...ure Loose Is the connection in correct order Is the voltage input of the machine within normal range Use AC voltmeter to measure the voltage between terminal L and N on the wiring board XT Is the comp...

Page 54: ...oltage between the two ends of capacitor C2 until the voltage is lower than 20V Replace the capacitor C2 Then energize and start the unit Replace the control panel AP1 Take corrective actions accordin...

Page 55: ...gh temperature protection Is outdoor ambient temperature higher than 53 20 minutes after the complete unit is powered off Is heat dissipation of the indoor unit and outdoor unit abnormal Normal protec...

Page 56: ...for compressor stopping enough Fault diagnosis process Y N Y N N Y Y N Power on the unit Is stop time of the compressor longer than 3 minutes Restart it up after 3 minutes Does startup fail Are the w...

Page 57: ...e compressor connected correctly Is connection sequence right Is the connection made in clockwise direction Connect the wires correctly Replace the control panel AP1 If the fault is eliminated Replace...

Page 58: ...20 minutes after the complete unit is powered off Is the terminal FA for the electronic expansion valve connected correctly Connect the wires correctly Resistances between the first four pins close t...

Page 59: ...ny damage or short circuit Replace it as per the wiring diagram and reconnect the wires If the fault is eliminated Remove the PFC capacitor and measure resistance between the two terminals Is the resi...

Page 60: ...pment operate normally before the failure occurs The AP1 voltage detection circuit is at fault Check wiring inside of the indoor and outdoor units Are wires broken Check the communication circuit of t...

Page 61: ...hod for details Malfunction of compressor Compressor cant operate Refer to point 5 of maintenance method for details 9 3 Troubleshooting for Normal Malfunction 1 Air Conditioner Cant be Started Up 2 P...

Page 62: ...pipe Replace drain pipe Wrapping is not tight Water leaking from the pipe connection place of indoor unit Wrap it again and bundle it tightly 5 Compressor Cant Operate Possible causes Discriminating m...

Page 63: ...Installation and Maintenance Service Manual 10 Exploded View and Parts List 10 1 Indoor Unit The component picture is only for reference please refer to the actual product LI012CI 180P432 LI012HI 180P...

Page 64: ...ma Generator 14 Evaporator Assy 0100297601 0100297601 1 15 Wall Mounting Frame 01252484 01252484 1 16 Cross Flow Fan 10352056 10352056 1 17 Fan Motor 1501214604 1501214604 1 18 Connecting pipe clamp 2...

Page 65: ...Service Manual LI024CI 180P432 LI024HI 180P432 36 35 37 38 1 8 2 3 4 6 7 9 10 12 13 14 15 17 18 19 20 21 22 23 24 26 27 28 29 30 31 33 5 25 11 16 34 8 32 The component picture is only for reference pl...

Page 66: ...001000095 1 16 Cold Plasma Generator 17 Wall Mounting Frame 01252229 01252229 1 18 Motor Press Plate 26112515 26112515 1 19 Fan Motor 1501214501 1501214501 1 20 Connecting pipe clamp 26112514 26112514...

Page 67: ...64 Installation and Maintenance Service Manual LI012CO 180P432 The component picture is only for reference please refer to the actual product 10 2 Outdoor Unit...

Page 68: ...2 11 Valve 07133082 1 12 Cable Cross Plate 2 02123014P 1 13 Right Side Plate Assy 013030713 1 14 Cover of pass wire 01413069 1 15 Inhalation Tube Sub assy 030010000181 1 16 Discharge Tube 03500800033...

Page 69: ...66 Installation and Maintenance Service Manual LI012HO 180P432 The component picture is only for reference please refer to the actual product...

Page 70: ...Block 26113017 2 13 Cover of Pass Wire 01413069 1 14 Right Side Plate Assy 013030713 1 15 Cable Cross Plate 2 02123014P 1 16 Magnet Coil 4300040050 1 17 Electric Expansion Valve Sub Assy 030026000192...

Page 71: ...n and Maintenance Service Manual LI024CO 180P432 The component picture is only for reference please refer to the actual product 24 8 7 6 5 4 3 2 1 16 9 15 14 13 12 11 10 23 20 18 30 25 29 28 27 26 21...

Page 72: ...y 03005700125 1 13 Valve Cover 22245002 1 14 Right Side Plate 0130329208 1 15 Retaining Plate 02115006P 1 16 Handle Assy 02113109 1 17 Wire Clamp 71010003 1 18 Temperature Sensor 3900030902 1 19 Rear...

Page 73: ...70 Installation and Maintenance Service Manual 31 The component picture is only for reference please refer to the actual product LI024HO 180P432...

Page 74: ...Sub Assy 07133843 1 13 Right Side Plate 0130509002P 1 14 Valve Cover 22245002 1 15 Retaining Plate 02115006P 1 16 Handle Assy 02113109 1 17 Wiring Clamp 26115007 1 18 Temperature Sensor 3900030902 1 1...

Page 75: ...sembly 2 Remove horizontal louver Front panel Front case Right filter Groove Left filter Open the front panel Push the left filter and right filter until they are separate from the groove on the front...

Page 76: ...assy and bottom case Lift up the front case sub assy and take it out Electric box cover2 Detecting plate for 12K for 09K Detecting plate Screw Screw 5 Remove front case sub assy 6 Remove vertical louv...

Page 77: ...ounding screw Remove the wiring terminals of motor and stepping motor Remove the electric box assy Twist off the screws that are locking each lead wire and rotate the electric box assy Twist off the s...

Page 78: ...terminals 2 Pull out the holder for some terminals at first holder is not available for some wiring terminal hold the connector and then pull the terminal circlip soft sheath holder connector Procedu...

Page 79: ...he screws at the connection place of cross flow blade and motor lift the motor and cross flow blade upwards to remove them Remove the bearing holder sub assy Remove the screw fixing step motor and the...

Page 80: ...the axile bush on horizontal louver Bend the horizontal louver with hand and then separate the horizontal louver from the crank shaft of step motor to remove it Separate the panel rotation shaft from...

Page 81: ...ferent models Note Open the screw caps before removing the screws arround the air outlet case sub assy is different for different models Loosenn the connection clasps between vertical louver and botto...

Page 82: ...the indoor tube temperature sensor Screw off one grounding screw Remove the wiring terminals of motor and stepping motor Remove the electric box assy Screw off the screws that are locking each lead w...

Page 83: ...lation and Maintenance Service Manual R ear case assy First remove the left side of evaporator from the groove on the rear case assy Then remove the right side from the clasp on the rear case assy Gro...

Page 84: ...81 Installation and Maintenance Service Manual...

Page 85: ...plate 2 and valve cover 2 Remove top cover Before disassamble Remove 3 connection screw fixing cable cross plate 2 and then remove the Cable cross plate 2 Remove 1 connection screw fixing valve cover...

Page 86: ...Then remove the front grille Remove connection screws connecting the front panel with the chassis and the motor support and then remove the front panel Remove the nut fixing the blade and then remove...

Page 87: ...nsolder the 4 weld spots connecting the 4 way Valve Assy to take it out Note Refrigerant should be discharged firstly Welding process should be as quickly as possible and keep wrapping cotton wet all...

Page 88: ...otor Remove the 2 tapping screws fixing the motor support Lift motor support to re move it 9 Remove motor and motor support Motor Motor support 10 Remove clapboard sub assy Loosen the screws of the Cl...

Page 89: ...alve and air return pipe and remove the gas valve Note it is necessary to warp the gas valve when unsoldering the welding spot Remove the 2 screws fixing liquid valve Unsolder the weld ing spot connec...

Page 90: ...crew connecting the valve cover and right side plate and then remove the valve cover 2 Remove grille and outer case grille Remove the 4 screws connecting the grille and outer case and then remove the...

Page 91: ...ide plate and left side plate and then remove the outer case Remove the screws connecting the right side plate with electric box assy valve support chassis and condenser side plate and then remove the...

Page 92: ...e 2 screws connecting the motor support and chassis and then loosen the stopper to remove the motor support Remove the screws fixing the electric box sub assy loosen the wire bundle pull out the wirin...

Page 93: ...hen remove the isolation plate Unsolder the welding joints connecting the 4 way valve assy with capillary sub assy compressor and condenser remove the 4 way valve Note Before unsoldering the welding j...

Page 94: ...of discharge pipe and suction pipe from foreign objects Remove the screws connecting the support condenser and condenser assy and then remove the support condenser Remove the 2 screws fixing the cond...

Page 95: ...gree and Celsius degree Tf Tcx1 8 32 Ambient temperature Fahrenheit display temperature Fahrenheit Celsius Fahrenheit display temperature Fahrenheit Celsius Fahrenheit display temperature Fahrenheit C...

Page 96: ...teps A Cut the pip Confirm the pipe length according to the distance of indoor unit and outdoor unit Cut the required pipe with pipe cutter B Remove the burrs Remove the burrs with shaper and prevent...

Page 97: ...358 233 6 0 717 24 8 60 23 95 9 779 165 2 2 28 235 4 0 697 26 6 57 18 96 8 9 382 167 2 206 237 2 0 678 28 4 54 31 98 6 9 003 168 8 2 133 239 0 66 30 2 51 59 100 4 8 642 170 6 2 064 240 8 0 642 32 49 0...

Page 98: ...95 13 04 165 2 3 04 235 4 0 93 26 6 76 24 96 8 12 51 167 2 94 237 2 0 904 28 4 72 41 98 6 12 168 8 2 844 239 0 88 30 2 68 79 100 4 11 52 170 6 2 752 240 8 0 856 32 65 37 102 2 11 06 172 4 2 663 242 6...

Page 99: ...342 8 77 49 19 147 2 10 54 217 4 3 04 8 6 323 9 78 8 47 08 149 10 18 219 2 2 955 10 4 306 2 80 6 45 07 150 8 9 827 221 2 872 12 2 289 6 82 4 43 16 152 6 9 489 222 8 2 792 14 274 84 2 41 34 154 4 9 165...

Page 100: ...Visit us at www lennox com or contact us at 1 877 726 0024 by Lennox Industries Inc please visit www lennox com 2014 Lennox Industries Inc For a complete list of the registered and common law tradema...

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