LG ARND DCR4 Series Installation Manual Download

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Variable Refrigerant Flow Split Compact DOAS
ARND***DCR4 Series
(1,500 and 2,000 CFM)

LG SPLIT COMPACT DEDICATED

OUTDOOR AIR SYSTEM (DOAS)

INSTALLATION MANUAL

Summary of Contents for ARND DCR4 Series

Page 1: ...Variable Refrigerant Flow Split Compact DOAS ARND DCR4 Series 1 500 and 2 000 CFM LG SPLIT COMPACT DEDICATED OUTDOOR AIR SYSTEM DOAS INSTALLATION MANUAL ...

Page 2: ...tent familiarity is required for proper installation The instructions included in this manual must be followed to prevent product malfunction property damage injury or death to the user or other people Incorrect operation due to ignoring any instructions will cause harm or damage The level of seriousness is classified by the symbols described by the summary list of safety precautions on page 4 Thi...

Page 3: ... Drainage System 16 General Refrigerant Piping System 17 24 LG Air Conditioner Technical Solution LATS 17 18 Refrigerant Safety Selecting Piping 19 Piping Handling 20 Brazing Procedure 21 DOAS Layout Example Selecting the Piping Size 22 23 Insulation 24 Electrical System 25 36 General Information 25 Wiring Connections 26 Internal Routing 27 Outdoor Unit to DOAS Wiring Cable System 28 29 Electrical...

Page 4: ...injury Dispose of the packing materials safely Packing materials such as nails and other metal or wooden parts may cause puncture wounds or other injuries Tear apart and throw away plastic packaging bags so that children may not play with them and risk suffocation and death Do not install the unit in any location exposed to open ÀDPH RU H WUHPH KHDW Do not touch the unit with wet hands 7KHUH LV UL...

Page 5: ... GDPDJH WR walls Do not use the product for special purposes such as pre serving foods works of art wine coolers or other precision air conditioning applications There is risk of property damage Do not make refrigerant substitutions Use R410A only If a different refrigerant is used or air mixes with original refrigerant the unit will malfunction and become damaged Do not install the unit in a nois...

Page 6: ...instruments Failure to carefully read and follow all instructions in this manual can result in injury or death Ensure the unit is connected to a dedicated power source that provides adequate power If the power source capacity is inadequate or the electric work is not SHUIRUPHG SURSHUO LW PD UHVXOW LQ UH HOHFWULF VKRFN SK VLFDO LQMXU RU death Refer to local state and federal codes and use power wir...

Page 7: ... Keep the power switch on during the operational season Do not block the inlet or outlet Unit may malfunction Securely attach the electrical cover to the unit 1RQ VHFXUHG FRYHUV FDQ UHVXOW LQ UH GXH WR GXVW RU ZDWHU LQ WKH VHUYLFH panel Periodically verify the equipment mounting hardware has not deteriorated If the base collapses the unit could fall and cause property damage or product failure Do ...

Page 8: ...s reserved LG is a registered trademark of LG Corp UNIT NOMENCLATURE ARN D 20 3 DC Electrical Ratings U 208 230V 460V 50 60Hz 3 Phase 3 208 220V 60Hz 1 Phase Air Flow Rate CFM 15 1 500 CFM 20 2 000 CFM Type D Dedicated Outdoor Air System DOAS Family ARN Multi V Indoor Unit R410A Refrigerant 4 Generation 4 Fourth Chassis DB Type B Rooftop DOAS DC Type C Compact DOAS R Energy Recovery Wheel R Withou...

Page 9: ...Electronics U S A Inc Englewood Cliffs NJ All rights reserved LG is a registered trademark of LG Corp PRODUCT OVERVIEW Split Compact DOAS Interior Components Control Box Web UI BACnet IP Modbus RTU Filters MERV 8 Main Coil Hot Gas Reheat Coil 3D Plug Fan ECM Motor Bottom Access Panel Fan Motor Assembly Heat Recovery Unit ...

Page 10: ...D 1 2 Brazed 1 2 Brazed High Pressure Vapor Connection Size in O D 3 4 Brazed 7 8 Brazed Low Pressure Vapor Connection Size in O D 1 1 8 Brazed 1 1 8 Brazed Condensate Drain OD in 1 1 Filter Outdoor 2 Merv 8 25 x 20 2 Merv 8 25 x 20 EEV Electronic Expansion Valve ECM Electronically Commutated Motor 3RZHU ZLULQJ LV HOG VXSSOLHG DQG PXVW FRPSO ZLWK WKH DSSOLFDEOH ORFDO DQG QDWLRQDO codes This data i...

Page 11: ...rved LG is a registered trademark of LG Corp ELECTRICAL DATA Table 2 Split Compact DOAS Electrical Data Model Voltage Range MCA MOP Power Supply Hz Volts Phase ARND153DCR4 187 253 7 3 15 60 208 230 1 ARND203DCR4 MCA Minimum Circuit Ampacity MOP Maximum Overcurrent Protection 3RZHU ZLULQJ LV HOG VXSSOLHG DQG PXVW FRPSO ZLWK WKH applicable local and national codes Electrical Data ...

Page 12: ...ing storage The user assumes responsibility of the unit and accessories while in storage The manu facturer will not be responsible for damage during storage These suggestions are provided solely as a convenience to the user The ideal environment for storing the units and accessories designed for indoor applications is indoors above grade in a low humidity at mosphere that is sealed to prevent dust...

Page 13: ...ay cause personal injury Tear apart and throw away plastic packaging so that children may not play with them and risk suffocation and death WARNING Failure to follow proper instructions could result in property damage Service Clearances Allow service clearances as indicated in the figures below Refer to NEC and local guidelines for minimum clearances around the unit and control panel Figure 1 Inst...

Page 14: ...nsate Drain Connection All condensate drain connections must be properly trapped and primed before operating the unit Failure to SURSHUO WUDS D GUDLQ ZLOO UHVXOW LQ ÀRRGLQJ WKH GUDLQ SDQ DQG SRWHQWLDO ZDWHU GDPDJH WR WKH XQLW RU EXLOGLQJ Split Compact DOAS has a factory mounted condensate pump that operates continuously while the unit is in cooling mode The pump has an internal high level float sw...

Page 15: ...show the layout of the condensate drain connection The distance from the drain pan outlet to the horizontal run of the P trap should be a distance of twice the static pressure in the drain pan Drain Piping Drain piping must have down slope 1 50 to 1 100 Any holes through the ceilings walls etc must be large enough to accommodate the drain piping and insulation 7R SUHYHQW UHYHUVDO ÀRZ GR QRW SURYLG...

Page 16: ...away Drain all generated condensate from the external condensate pan to an appropriate area Install a trap in the condensate lines as near to the indoor unit coil as possible To prevent overflow the outlet of each trap must be positioned below its connection to the condensate pan All traps must be primed insulated and leak tested It is recommended that a dedicated drain pipe be installed for the a...

Page 17: ...gs LATS Revit integrates the LG LATS program with Revit software It permits engineers to layout and validate Multi V VRF systems directly into Revit drawings AutoCAD and Revit are both registered marks of Autodesk Inc Features All LG product design criteria have been loaded into the program making LATS simple to use double click or drag and drop the component choices Build systems in Tree Mode whe...

Page 18: ... design on the Shop Drawing including as built straight lines and elbows This Mark Up drawing must be returned to the design engineer or Rep who must input contractor changes into the LATS file Copy the original LATS soft ware file save and rename as a separate file and modify all piping lengths by double clicking on each length and editing information Like the shop drawing the Auto Piping and Sys...

Page 19: ...KH 0XOWL 9 QVWDOODWLRQ 0DQXDO RQ ZZZ OJKYDF FRP LG prefers the use of hard drawn copper in pipe segments connecting a Dedicated Outdoor Air System DOAS product and a heat recovery outdoor unit Table 5 ACR Rated Copper Tubing Material Table 6 ACR Rated Piping Wall Thicknesses Type Seamless Phosphorous Deoxidized Class UNS C12200 DHP Straight Lengths H58 Temper Coils O60 Temper OD in 1 4 3 8 1 2 5 8...

Page 20: ...ot operate properly EEVs and capillary tubes become clogged Refrigerant gas leaks shortages Refrigerant oil degradation Poor insulation of the compressor System does not operate properly Solutions Remove moisture from the piping Piping ends should remain capped until connections are complete Do not install piping on a rainy day Connect piping properly at the unit s side Remove caps only after the ...

Page 21: ...ing perform a nitrogen replacement procedure or charge nitrogen into the refrigerant piping during brazing WKHQ FRQQHFW WKH XQLW WR WKH 0XOWL 9 2 6 XQLW WARNING Figure 9 Refrigerant Pipe Brazing Pressure reducing Valve Valve Taping Nitrogen Pipe to be brazed Refrigerant Piping Brazing Procedure 5 Always use a non oxidizing material for brazing Do not use flux soft solder or anti oxidant agents If ...

Page 22: ...re applicable Sub1 heat recovery outdoor unit capacity must be greater than or equal to the Sub2 heat recovery outdoor unit capacity Connection piping from branch to branch cannot exceed the main SLSH GLDPHWHU XVHG E WKH 0XOWL 9 KHDW UHFRYHU RXWGRRU XQLW Install the Y branches or DOAS units so that the pipe distances between the between the connected DOAS units are minimized Large differences in p...

Page 23: ... XQLW feet Length Total Pipe Length Longest Actual Pipe Length Equivalent Pipe Length IW P IHHW P 656 feet 200m Conditional Applications IHHW P 1 738 feet 225m Conditional Applications L Longest Pipe Length after First Branch IHHW P Maximum 295 feet 90m Conditional Applications Elevation 1 OHYDWLRQ LIIHUHQFH 2XWGRRU 8QLW Ľ 2 6 8QLW HLJKW IHHW P Elevation 2 OHYDWLRQ LIIHUHQFH 2 6 8QLW Ľ 2 6 8QLW HL...

Page 24: ... must be properly protected with PVC aluminum vapor barrier or alternatively placed in a weather resistant enclosure such as a pipe rack with a top cover and meet local codes LG provided Y branches are shipped from the factory with pre formed peel and stick foam insulation jackets with a 1 84 lb ft3 density 1 2 inch thickness and meet UL94 MF 1 flammability The design engineer must perform calcula...

Page 25: ...akers fuses overcurrent protection switches and wiring in accordance with local state and NEC regulations related to electrical equipment and wiring and following the instructions in this manual Generated overcurrent could include some amount of direct current Using an oversized breaker or fuse will result in electric shock physical injury or death Do not connect ground wire to refrigerant gas or ...

Page 26: ...ted to the terminal block Use an appropriately sized screwdriver for tightening the terminals Do not overtighten the connections overtightening will damage the terminals If ring terminals or fork terminals are not available then Do not terminate different gauge wires to the power terminal block Slack in the wiring will generate heat When terminating wires of the same thickness follow the instructi...

Page 27: ...he floor pan immediately underneath the control center or through a field cut hole in the side of the unit casing The terminals labeled GND are NOT ground terminals The terminals labeled ARE ground terminals Polarity matters Always connect A to A and B to B Always create a wiring diagram that contains the exact sequence in which all the DOAS are wired in relation to the heat recovery outdoor unit ...

Page 28: ...S A Inc Englewood Cliffs NJ All rights reserved LG is a registered trademark of LG Corp ELECTRICAL SYSTEM Figure 16 Example of on Outdoor Unit to DOAS Communications Cable and DOAS Power Wiring Schematic Figure 17 Communications Cable Between Outdoor Unit and DOAS Unit Figure 18 Communications Cable Between Main Outdoor Unit and Sub Outdoor Unit Outdoor Unit to DOAS Wiring Cable System ...

Page 29: ...ded to the Main outdoor unit chassis only Do not ground the outdoor unit to DOAS communication cable at any other point Wiring must comply with all applicable local and national codes Inadequate connections may generate heat cause a fire and physical injury or death The GND terminal at the main PCB is a negative terminal for dry contact not a ground Inadequate connections may generate heat cause a...

Page 30: ...ood Cliffs NJ All rights reserved LG is a registered trademark of LG Corp ELECTRICAL SYSTEM Electrical Components Table 14 Electrical Components Legend Electrical Component No Description 1 CAREL Controller 2 Main Module 3 UI Module 4 NTC Module 5 Main Coil EEV Module 6 Reheat Coil EEV Module 7 Heat Recovery Unit PCB 8 SMPS 9 Trans 10 RS 485 1 11 RS 485 2 12 Relay 1 13 Relay 2 Electrical Component...

Page 31: ...he control boards and indicate DI Digital Inputs DC Normal Close DO Normal Open DO Digital Outputs DC Normal Close DO Normal Open AI Analog Inputs AO Analog Outputs UI Universal Inputs UO Universal Outputs RI Resistance Input CAREL Control Board Terminal Connections See image below for general board layout See the tables on the following pages for standard terminal connection points See the wiring...

Page 32: ...0 F UI4 Supply Air Relative Humidity Field Option 0 10Vdc 0 100 UI5 Differential Pressure Sensor For SA flow rate monitoring and CFM Modulation 0 10Vdc 0 30 wc UI6 Unassigned 0 10Vdc UI7 Unassigned UI8 Space CO2 Sensor Field Option 0 10Vdc 0 3 000ppm 4 DI1 Forced Stop NC Open Unit Stop DI2 Unit On Off NO Closed Unit On DI3 Float Switch NC Open Unit Stop 5 AO1 Unassigned 0 10Vdc AO2 Unassigned 0 10...

Page 33: ...Drawing Reference Label Unit Connection Type Position Indicates Range 2 CH1 CH1 port of Other module for communication RS 485 3 DI1 Occupancy NO Closed Occupied DI2 Supply Air filter Switch NO Closed Dirty DI3 Return Air filter Switch Field Option NO Closed Dirty 4 UI1 Unassigned UI2 Unassigned UI3 Unassigned UI4 Unassigned UI5 Space Return Duct Temperature Field Option 0 10Vdc 130 210 F UI6 Space...

Page 34: ...ndicates Range 2 CH1 CH1 port of Other module for communication RS 485 3 RI1 Space Return Duct Temperature Field Option NTC 10k 130 210 F RI2 Unassigned NTC 10k 130 210 F RI3 Outdoor Air Temperature NTC 10k 130 210 F RI4 Leaving Air Temperature Main Coil 1 NTC 10k 130 210 F RI5 Leaving Air Temperature Main Coil 2 NTC 10k 130 210 F RI6 Exhaust Air Temperature NTC 10k 130 210 F RI7 Supply Air Temper...

Page 35: ...rt of other module for communication RS 485 CH2 IDU_Bus_A B To Outdoor Unit RS 485 3 RI1 Main Coil 1 Refrigerant temperature Pipe In NTC 5k 130 210 F RI2 Main Coil 1 Refrigerant temperature Pipe out NTC 5k 130 210 F 4 EEV1 Unassigned EEV2 Main Coil No 1 EEV Step Control 0 1 350 Drawing Reference Label Unit Connection Type Position Indicates Range 2 CH1 CH1 port of other module for communication RS...

Page 36: ...ng the table below Table 21 Space Temperature Sensor Terminations Space Temperature Sensor Type No 1 NTC 10k Terminal Strip TB NTC Module RI1 G Type No 2 0 10Vdc Terminal Strip TB UI Module UI5 G LG recommends NTC type sensors MAMAC SYSTEMS TTE 205 EX 12 0 for temperature sensors MAMAC SYSTEMS HU 225 IRU KXPLGLW VHQVRUV EXW LI WKH a 9GF W SH RI VHQVRU LV LQVWDOOHG LW needs an additional setting on...

Page 37: ...or 24 hours to make sure the piping system is leak free After the gauge reading reaches 550 psig isolate the system by first closing the gauge manifold then close the nitrogen cylinder valve Check the flared and brazed con nections for leaks by applying a bubble solution to all joints DANGER 8VLQJ FRPEXVWLEOH JDVHV LQFOXGLQJ R JHQ ZLOO UHVXOW LQ UH RU H SORVLRQ DQG UHVXOW LQ VHYHUH SHUVRQDO LQMXU ...

Page 38: ... be a solution designed for refrigerant leak testing Common soap solution must never be used on refrigerant piping as those contain chemicals that could corrode copper and brass and cause product malfunction 7 If the pressure does NOT drop for 24 hours the system passes the test See how ambient conditions will affect the pressure test below 8 If the pressure drops and it is not due to ambient cond...

Page 39: ... removed and an auxiliary service port can used Make sure to re install the original Schrader core before operating the system Evacuate through all three 3 hot gas line high pressure vapor liquid line and suction low pressure vapor refrigerant lines The outdoor unit service valves must remain closed and the stem head access caps tight Do not open the outdoor unit service valves and release the fac...

Page 40: ...ontinue to step 4 4 Break vacuum with 50 psig nitrogen purge for an appropriate amount of time this is to sweep moisture from piping 5 Purge nitrogen from the system until the pressure drops down to 1 to 3 psig 6 Evacuate to 1 000 micron level Isolate the pump by closing the manifold gauges and the vacuum pump valve and then watch the micron level Micron level could rise a bit but MUST eventually ...

Page 41: ... Englewood Cliffs NJ All rights reserved LG is a registered trademark of LG Corp PRE COMMISSIONING Figure 25 Evacuation Procedure for a System Designed with a DOAS Unit Triple Evacuation Farthest Sub outdoor unit is the Sub outdoor unit installed farthest away from the refrigerant piping system DOAS unit Main Outdoor Unit Farthest Sub Outdoor Unit ...

Page 42: ...nit Refrigerant Charge Worksheet 1 CF Ref Correction Factor for Refrigerant Charge 2 For refrigerant charge purposes consider only the liquid line ignore the vapor line s DANGER Refrigerant gas is heavier than air and replaces oxygen A large leak especially in enclosed spaces like basements will result in oxygen depletion and an asphyxiation hazard will result in serious injury or death If refrige...

Page 43: ...g the filters during building construction Replace any dirty pleated filters and clean the aluminum mesh filters in the intake hood Verify proper drain trap installation 2 Field wiring Be sure that the field wiring has been carried out according to the instructions described in Electrical System section on pages 29 36 according to the wiring diagrams and to local state and federal codes 3 Power su...

Page 44: ...hrough an optional hand held keypad display hardwired or can be connected to a building management system interface Electrical Specifications The DOAS controller receives 24 VAC CAREL and 12 VDC LG power from a transformer on the main control panel and is ener gized when the main disconnect is on CAREL is a registered trademark of CAREL INDUSTRIES in Italy and or other countries Connecting to the ...

Page 45: ...Altitude Go to the Main Ctrl Variables Advanced Unit Setting screen IP Address Go to the Main Settings Network Settings screen BMS AC Smart Communication Go to the Main Ctrl Variables Advanced Network Settings screen to set up network communication To communicate with ACP AC Smart MODBUS Sub Address must be set and ACP AC Smart should be set to MODBUS protocol IP Address The controller s IP addres...

Page 46: ... All rights reserved LG is a registered trademark of LG Corp PRE COMMISSIONING DOAS Controller Setup DOAS Unit Address Settings continued Figure 32 06 RQ JXUDWLRQ 02 86 Figure 31 06 RQ JXUDWLRQ QHW 3 Sub Address Sub 1 Main Sub 1 Sub Address Sub 2 Sub 1 Main Main Main Modbus Sub Address 6 Modbus Sub Address 4 Modbus Sub Address 5 Main Sub 1 Main Modbus Sub Address 1 Modbus Sub Address 2 Modbus Sub ...

Page 47: ...n active alarm Press to view active alarms Press twice to go to the alarms reset screen Escape Access from the Main Menu to view the Unit Status screen Press to navigate one menu level back Press when editing a variable to cancel editing Up Navigates through the menus screens Press after entering a variable to increase a current value Enter Press to enter a highlighted menu or screen item Press to...

Page 48: ...e every three 3 seconds depending on options and sen sors installed Upper Left Quadrant Displays the current value of the primary control variable For example this could be supply air temperature room air temperature return air temperature or coil leaving temperature Upper Right Quadrant Displays all temperature and humidity values that pertain to the air handler Lower Left Quadrant Displays the s...

Page 49: ...c Englewood Cliffs NJ All rights reserved LG is a registered trademark of LG Corp PRE COMMISSIONING Menu Map The Menu Map shows screen order when using either the Handheld Keypad or the Virtual Keypad Display on the web interface See the Navigation section for instructions about moving through menu screens Figure 36 Menu Map DOAS Controller Setup ...

Page 50: ...37 Uploading the Software Update Process 1 Prepare the USB Create a new folder UPGRADE in USB Driver and copy the file to UPGRADE folder 2 Connect the USB 3 Go to the System Menu three 3 to five 5 seconds 4 Navigate to the UPGRADE menu Press Enter 5 Check the software file that will be uploaded Press Enter 6 Press Enter to start the upgrade 7 After uploading press Enter and then controller will re...

Page 51: ...r later must be used with the DOAS controller 1 Confirm control wiring between DOAS controller and AC Smart 5 Channel 1 or ACP Channel 6 Wiring is 18 AWG 2 conductor twisted stranded shielded and must comply with all applicable local and national codes Figure 44 DOAS Controller to Central Controller Connections 2 On the CAREL controller under SVC Configuration Network Setting set the Modbus Sub Ad...

Page 52: ...dding Units Step 5 Figure 51 Clicking Send All to Finish Adding Devices Step 6 6PDUW 3 RQWUROOHU 6HWXS 1 Under the AC Smart ACP Settings tab find and click on Installing 2 Press on the AC Smart 00 tab go to Registration Status and change the CH1 set ting to MODBUS_9600 For ACP Press on the ACP 00 tab and change the CH6 setting to MODBUS_9600 3 Click Auto Search to find the devices connected to the...

Page 53: ...p 9 Figure 55 Selecting Info Step 10 AC Smart ACP Controller Setup continued 7 Under the AC Smart ACP Control tab find and select Device Control 8 Find the Installation tab and select AC Smart or ACP A list of devices available for view will appear in the middle of the screen 9 Click on the device to be viewed A new section will appear on the right side of the screen Click View Details 10 A detail...

Page 54: ... 2 ż I040_EATemperature Exhaust Air Temperature ReadCOV_NoWrite 0 5 30041 Input 2 ż I041_CO2 Space CO2 value Read_NoWrite 30042 Input 2 I042_SAFlowDiffPressure Differential Pressure Value Read_NoWrite 30043 Input 2 I043_EAFlowDiffPressure Differential Pressure Value if equipped Read_NoWrite 30044 Input 2 I046_OADewpoint Outside Air Dew Point Read_NoWrite 30047 Input 2 ż I047_OAEnthalpy Outside Air...

Page 55: ...ssure Sensor is equipped ReadCOV_NoWrite 2 30088 Input 2 I9004_ODU1_HighPressureTrace ODU Main High Pressure Read_NoWrite 39005 Input 2 I9005_ODU1_LowPressureTrace ODU Main Low Pressure Read_NoWrite 39006 Input 2 I9012_ODU1_Inv1Trace ODU Main Inverter 1 Compressor Hz Read_NoWrite 39013 Input 2 I9014_ODU1_Inv2Trace ODU Main Inverter 2 Compressor Hz Read_NoWrite 39015 Input 2 I9015_ODU1_Fan1Trace OD...

Page 56: ...d_NoWrite 39115 Input 2 I9115_ODU2_Fan1Trace ODU Sub 1 Fan 1 RPM Read_NoWrite 39116 Input 2 I9116_ODU2_Fan2Trace ODU Sub 1 Fan 1 RPM Read_NoWrite 39117 Input 2 I9123_ODU2_AirTemp ODU Sub 1 Ambient Temperature Read_NoWrite 39124 Input 2 ż I9124_ODU2_SuctionTemp ODU Sub 1 Suction to Accumulator Temperature Read_NoWrite 39125 Input 2 ż I9125_ODU2_CondeseTemp ODU Sub 1 Condenser Temperature Read_NoWri...

Page 57: ...UHWH QSXW D000_OperationStatus DOAS Status Read_NoWrite 10001 Discrete D001_ErrorStatus Error Status Read_NoWrite 10002 Discrete D002_AlarmStatus Alarm status of DOAS and ODU Read_NoWrite 10003 Discrete D016_SAFanStatus Status of Supply Fan On off Read_NoWrite 10017 Discrete D017_EAFanStatus Status of Supply Fan On off Read_NoWrite 10018 Discrete D018_ERWStatus Status of Energy Recovery Wheel On o...

Page 58: ...LG Electronics U S A Inc Air Conditioning Technologies 4300 North Point Parkway Alpharetta Georgia 30022 www lghvac com New Issue IM_Split_Compact_DOAS_02_21 20001747 ISO 9001 2008 LG ELECTRONICS INC ...

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