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Refrigerant Piping Connections

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REFRIGERANT PIPING CONNECTIONS

Air Purging

Air Purging Best Practices

Air purging is done to the piping system after all piping has been connected between the indoor and outdoor unit. This step is necessary to

be sure that air refrigerant can flow through the system without danger of leakage or pressure issues. Air and moisture that is left in the pip-

ing can lead to undesirable results and can cause damage to the working unit. It is important to go through a complete air purging cycle to be

sure that the lines are cleared out. Note that you may have to repeat this process should any air or moisture be found to remain in the piping.

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

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

Pressure in the system can rise.

• Operating current can rise.
•

Cooling or heating efficiency falls.

• Moisture in the refrigerant circuit may freeze and block capillary tubing.
• Water can lead to corrosion of parts in the system.

Air Purging with a Vacuum Pump - Preparation Steps

Verify that each set of pipes (liquid and gas) are properly con

nected between the indoor and outdoor unit.

•

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

2. Remove service valve caps from the gas and liquid valves at the

outdoor unit (Figure 50).

• Both the liquid and gas side service valves at the outdoor unit

should be kept closed at this step.

3. Set up the purging, hose connections by referring to Figure 51.
4.

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

Testing section on next page.

• Successful leak testing must be performed before Evacuation can

begin.

5. Go to

Evacuation

section, on page 37 to complete the purg-

ing process.

Evacuation

Outdoor Unit

Gas side

Liquid side

Valve

Caps

2-way valve(Close)

3-way valve(Close)

2-way valve(Close)

3-way valve(Close)

Figure 50: Removing Service Valve Caps - Outdoor Unit

Figure 51: Evacuation Setup

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

use a stop valve for this purpose.

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

Outdoor Unit

Lo Hi

Manifold Valve

Vacuum Pump

Charge Hose

Pressure

Gauge

Lo=Open

Hi=Close

Indoor Unit

Air Purging/ Evacuation Setup

Piping Bundle

Evacuation Table*

Tubing = Less than 33 ft.

Tubing = More than 33 ft.

10 minutes or more

15 minutes or more

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

Table 17: Evacuation Table

Содержание LS090HSV2

Страница 1: ...SINGLE ZONE HIGH EFFICIENCY STANDARD WALL MOUNTED INSTALLATION MANUAL Single Zone High Efficiency LS090HSV4 LS120HSV4 LS180HSV4 ...

Страница 2: ...s begins on page 3 For more technical materials such as submittals engineering databooks and catalogs visit www lghvac com For continual product development LG Electronics U S A Inc reserves the right to change specifications without notice LG Electronics U S A Inc This document as well as all reports illustrations data information and other materials are the property of LG Electronics U S A Inc P...

Страница 3: ...all non condensibles have been removed from the piping sys tem and authorization to do so has been obtained from the commissioning agent There is a risk of physical injury or death Do not run the compressor with the service valves closed There is a risk of equipment damage explosion physical injury or death Periodically check that the outdoor frame is not damaged There is a risk of explosion physi...

Страница 4: ...member to allow for pipe expansion Improper piping may cause refrigerant leaks and system malfunction Take appropriate actions at the end of HVAC equipment life to recover recycle reclaim or destroy R410A refrigerant according to applicable U S Environmental Protection Agency EPA rules Periodically check that the outdoor frame is not damaged There is a risk of equipment damage Install the unit in ...

Страница 5: ...n industry qualified experienced certified electrician familiar with the U S National Electric Code NEC who is equipped with the proper tools and test instruments Failure to carefully read and follow all instructions in this manual can result in equipment malfunction property damage personal injury or death All electric work must be performed by a licensed electrician and conform to local building...

Страница 6: ... injury or death Do not operate the disconnect switch with wet hands There is risk of fire electric shock physical injury or death Periodically verify the equipment mounts have not deteriorated If the base collapses the unit could fall and cause physical injury or death If gas leaks out ventilate the area before operating the unit If the unit is mounted in an enclosed low lying or poorly ventilate...

Страница 7: ...ndling 18 Piping Support 23 Underground Piping 24 Refrigerant Piping Connections 26 Refrigerant Piping System Limitations 26 Installation Overview 26 Directional Pipe Formation 27 Drain Hose 28 Outdoor Unit Connections 29 Indoor Unit Connections 30 Bundling and Cutting Line 31 Refrigerant Piping Insulation 32 34 Air Purging 35 Leak Test Soap Method Check 36 Evacuation of Lines 37 Finishing Up 37 R...

Страница 8: ...p GENERAL DATA Single Zone Wall Mount Indoor and Outdoor Units LS N 090 HSV 4 Generation 3 Third 4 Fourth Indoor Outdoor Product HSV High Efficiency HV Standard HLV Extended Pipe HEV Mega HXV Mega 115V Nominal Capacity Nominal cooling capacity in Btu h 090 091 9 000 120 121 12 000 180 181 18 000 240 24 000 300 307 30 000 360 36 000 Type N Indoor Wall Mount Unit U Outdoor Heat Pump Unit Family LS H...

Страница 9: ... 1 165 1 165 2 119 Piping Liquid Line in OD 1 4 1 4 3 8 Vapor Line in OD 3 8 3 8 5 8 Condensation Line OD ID 27 32 5 8 27 32 5 8 27 32 5 8 Additional Refrigerant Charge oz ft 0 22 0 22 0 38 Pipe Length6 ft Min Max 6 6 65 6 6 6 65 6 9 8 98 4 Piping Length6 no add l refrigerant ft 41 0 41 0 24 6 Max Elevation Difference ft 32 8 32 8 49 2 Table 1 Single Zone High Efficiency Unit Specifications EEV El...

Страница 10: ...0 50 so the ozone depletion potential ODP is 0 Many countries have approved of and encouraged R410A for use as an alternate refrigerant Electrical Do not use any piping that has not been approved for use in high pressure refrigerant systems Improper piping may cause refrigerant leaks and system malfunction Piping wall thickness must comply with the applicable local state and federal codes for the ...

Страница 11: ...airflow the system may malfunction 3 Remove any snow that has accumulated 3 15 16 inches or more on the top of the outdoor unit 4 Place the outdoor unit on a raised platform at least 19 11 16 inches higher than the average annual snowfall for the area In environments where there is a possibility of heavy snow the frame height must be more than two 2 times the amount of average annual snowfall and ...

Страница 12: ...more than 150 of the outdoor unit s height There must be 2 to 3 1 2 inches of clearance between the outdoor unit and the windbreaker for purposes of air flow Additional anti corrosion treatment may need to be applied to the outdoor unit at oceanside locations Ocean winds may cause corrosion particularly on the condenser and evaporator fins which in turn could cause product malfunction or inefficie...

Страница 13: ...ossible snow drifts Mount the unit on a field provided snow stand at a minimum height that is equal to the average annual snowfall plus 20 inches Design the mounting base to prevent snow accumulation on the platform in front or back of the unit case If necessary provide a field fabricated hood to keep snow and ice and or drifting snow from accumulating on the coil surfaces Use inlet and discharge ...

Страница 14: ...Follow recommended best practices when choosing an indoor loca tion for the Single Zone indoor unit Keep unit away from any indoor steam or excessive heat No obstacles should be placed around unit Condensation drain Leakage piping should be routed away from the unit Do not install near doorway Clearance gap between any wall or enclosure and the left or right side of the unit must be greater than 4...

Страница 15: ...be sure to take into consideration routing of wiring for power outlets within the wall Contacting wiring can cause serious bodily injury or death Use caution when drilling holes through the walls for the purposes of piping connections Power wiring can cause serious bodily injury or death Mounting Installation Plate to Wall 090HSV4 120HSV4 180HSV4 Ø2 19 32 4 27 32 3 24 32 Left rear piping Installat...

Страница 16: ... view of the indoor unit 2 Swing drain hose holder L bracket out and anchor as shown in Figure 15 against installation plate 3 Optionally go to Refrigerant Piping Connections section of this manual to continue with piping connections to the indoor unit 4 Optionally go to Electrical Connections section of this manual to continue with conduit electrical wiring to the indoor unit Figure 14 Mounting U...

Страница 17: ...m pipe ends When removing burrs point the end of the copper pipe down to avoid introducing foreign materials in the pipe 2B Slide the flare nut onto the copper tube 4 Carefully inspect the flared pipe end Compare the geometry with the figure to the right and dimensions as detailed in Figure 18 If the flare is defective cut it off and re do procedure If flare looks good blow clean the pipe with dry...

Страница 18: ...oisture etc See Table 5 for care of piping Dry Clean Airtight Principles No moisture should be inside the piping No dust should be inside the piping No leaks should occur Problems Caused Significant hydrolysis of refrigerant oil Refrigerant oil degradation Poor insulation of the compressor System does not operate properly EEVs capillary tubes are clogged Refrigerant oil degradation Poor insulation...

Страница 19: ...on valves and other heat sensitive control components from excessive heat with a wet rag or a heat barrier spray product Refrigerant Piping System Insulation All refrigerant piping field provided isolation ball valves service valves and elbows shall be completely insulated using closed cell pipe insulation The liquid and vapor lines must be insulated separately To prevent heat loss heat gain throu...

Страница 20: ...ust water or other contaminants from entering the piping during installation Contaminants can cause mechanical failure Selecting Field Supplied Copper Tubing Copper is the only approved refrigerant pipe material for use with Duct Free System Single Zone products and LG recommends seamless phosphorous deoxidized ACR type copper pipe hard drawn rigid type K or L or annealed tempered copper pipe Draw...

Страница 21: ...ided to allow pipe expansion to naturally occur The most common method is the inclusion of expansion Loop or U bends Each segment of pipe has a natural fixed point where no movement occurs This fixed point is located at the center point of the segment assuming the entire pipe is insulated in a similar fashion The natural fixed point of the pipe segment is typically where the expansion Loop or U be...

Страница 22: ... 20 0 08 0 08 0 10 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 22 0 23 0 26 0 28 0 29 0 30 30 0 12 0 12 0 15 0 18 0 20 0 21 0 23 0 24 0 26 0 27 0 29 0 30 0 32 0 33 0 32 0 35 0 39 0 42 0 44 0 45 40 0 16 0 16 0 20 0 24 0 26 0 28 0 30 0 32 0 34 0 36 0 38 0 40 0 42 0 44 0 43 0 46 0 52 0 56 0 58 0 60 50 0 20 0 20 0 25 0 30 0 33 0 35 0 38 0 40 0 43 0 45 0 48 0 50 0 53 0 55 0 54 0 58 0 65 0 ...

Страница 23: ...and evacuated Position valves with a minimum distance of three 3 to six 6 inches of pipe on either side of the valve and placed between six 6 and twelve 12 inches from the run out pipe to the upstream main pipe If ball valves are installed closer to the indoor unit a section of pipe becomes a dead zone when the valves are closed where oil may accumulate Using Elbows Field supplied elbows are allow...

Страница 24: ...ght segments of pipe up to 3 4 outside diameter size Maximum of six feet 6 on center for pipe up to one inch 1 outside diameter size Maximum of eight feet 8 on center for pipe up to two inches 2 outside diameter size Wherever the pipe changes direction place pipe clamps within twelve 12 inches on one side and within twelve to nineteen 12 to 19 inches of the bend on the other side as shown in Figur...

Страница 25: ...nt Pipe and Cable s in a Utility Conduit Table 12 Utility Conduit Sizes 1 OD pipe diameter in inches Values in parenthesis indicate OD of pipe with insulation jacket 2 Diameter of pipe with insulation Thickness of pipe insulation is typical Actual required thickness may vary based on surrounding ambient conditions and should be calculated and specified by the design engineer 3 Insulation thickness...

Страница 26: ... after carrying out a drainage test Saddle Gas side piping Liquid side piping Additional drain pipe Vinyl tape Narrow Drain Hose Base Plate Air Outlet Air Inlet Connecting cable Tubing Cover Sleeve Bushing Sleeve Putty Gum Type Sealant Bend the pipe as closely on the wall as possible but be careful that it doesn t break Installation plate Installation Overview Additional accessories parts tools th...

Страница 27: ...down to up 3 Secure the taped piping along the exterior wall using pipe clamps 4 Create trap above the electrical connections cover in order to prevent water from penetrating electrical components and wiring Indoor Unit Installed Below Outdoor Unit 1 Refer to Figure 33 while following the procedures below 2 Tape the piping drain hose and connection cable from down to up 3 Secure the taped piping a...

Страница 28: ...rain hose is routed from the indoor unit through the structure wall to the outdoor It should slope at an angle where it is higher at the indoor unit and lower toward the outdoor area thereby letting gravity push any condensation down and out See Figure 34 for proper drainage slope Avoid piping the drain hose as shown in Figure 35 These methods are incorrect and can cause leakage at the indoor unit...

Страница 29: ...f the flare before assembling Ensure you do not add any contami nants Tighten the flare nut initially by hand 5 Finish tightening the flare nut with a torque wrench until the wrench clicks Follow torque guidelines in Table 15 See Figure 38 for correct connection points Figure 36 Outdoor Unit Connection Cover Removal HSV4 Tubing Cover Bracket for Main Power Cables When tightening the flare nut with...

Страница 30: ... 1 Pull the screw cap at the bottom of the indoor unit Figure 39 2 Unscrew the three 3 screws at the bottom of the chassis cover 3 Remove the chassis cover being careful not to scratch the main horizontal vane Figure 39 Removing Chassis Cover from Indoor Unit 4 From the rear of the indoor unit pull the tubing holder away from the unit as shown in Figure 40 5 Remove the pipe port cover 6 Position t...

Страница 31: ... placed upward Figure 42 3 Verify that rear piping house section is wrapped with vinyl tape Use a narrow type of vinyl tape for this step 4 Continue to wrap the indoor unit pipe as connected to the outdoor connection pipe as shown in Figure 43 Figure 41 Piping with Insulation Material Figure 42 Correct Cutting Line Placement Figure 43 Wrapping Connection Pipe to Indoor Unit s Pipe Figure 44 Bundli...

Страница 32: ...he refrigeration pipe with no air space between it and the pipe Insulation passing through pipe hangers inside conduit and or sleeves must not be compressed Protect in sulation inside hangers and supports with a second layer All pipe insulation exposed to direct sunlight and deterioration producing elements must be properly protected with a PVC aluminum vapor barrier jacket or alternatively placed...

Страница 33: ...r school etc Minimum Refrigerant Pipe Ethylene Propylene Diene Methylene EPDM Insulation Wall Thickness Requirements 4 Special location Non Air conditioned location If conditions 1 and 2 below are present 1 When the piping passes through an indoor area where the indoor unit does not operate 2 When the humidity is high and there is no air flow in the location where the piping is installed The thick...

Страница 34: ...stant caulk Fire resistant insulation When filling an access hole with mortar cover the area with steel plate so that the insulation will not fall through For this area use fire resistant materials for both the insulation and cover Vinyl cover should not be used Pipe Sleeves at Penetrations LG requires that all pipe penetrations through walls floors and pipes buried underground be properly insulat...

Страница 35: ...orrosion of parts in the system Air Purging with a Vacuum Pump Preparation Steps 1 Verify that each set of pipes liquid and gas are properly con nected between the indoor and outdoor unit Verify that all wiring for a test run has been completed 2 Remove service valve caps from the gas and liquid valves at the outdoor unit Figure 50 Both the liquid and gas side service valves at the outdoor unit sh...

Страница 36: ...close the cylinder valve when the gauge reading reaches 550 psig Lo Hi Outdoor Unit Manifold Valve Charge Hose Nitrogen Gas Tank Upright Position Pressure Gauge Indoor Unit Piping Bundle Leak Test Using Nitrogen Tank To avoid nitrogen entering the refrigerant system in a liquid state the top of the cylinder must be higher than its bottom when you pressurize the system Be sure cylinder is used in a...

Страница 37: ...hose hookup to the system See Figure 51 on page 35 for proper hookup Evacuation of Lines Finishing Up Remote Controller Procedure 1 Confirm that the Lo knob of the manifold valve is open Refer back to Figure 51 2 Confirm that the Hi knob of the manifold valve is left closed 3 Run the Vacuum pump Operate pump until the system has been evacuated down to 300 microns Run pump an additional 15 minutes ...

Страница 38: ...s complete at this time and all refrigerant should be collected into the outdoor unit Perform Pump Down procedure only in the cooling mode Enabling Cooling Only Mode Before running the Pump Down procedure you must place the unit into Cooling Only Mode In order to be able to run Cooling Only Mode you must enter the unit into the Installer Mode by pressing the Reset button and the JET MODE button si...

Страница 39: ...or unit Improp erly ground wire can cause communication problems from electrical noise and motor current leakage Ground wiring must always be installed by a qualified technician If the system operates in reversed phase it may damage the com pressors and other components If there is a possibility of reversed phase phase loss momentary blackout or the power goes on and off while the system is operat...

Страница 40: ...minate different gauge wires to a terminal block Ring Terminal Power Wiring Connecting the Power Wiring Guidelines Best practice dictates using ring or spade terminals to terminate power wiring at the power terminal block Figure 55 If ring terminals or spade clips are not available then Do not terminate different gauge wires to the power terminal block Slack in the wiring may generate heat and fir...

Страница 41: ...mpleted without splices Terminate the cable shield to a grounded surface at the outdoor unit only Always verify the communication cable is connected to a communications terminal on the Single Zone unit Never apply line voltage power to the communication cable connection If contact is made the PCBs may be damaged The shield of the communications cable connecting the outdoor unit to the indoor unit ...

Страница 42: ...h cover the phillips screw heads as shown in Figure 57 Normally there are three 3 screws on the panel however your indoor unit model may differ 2 Using a phillips head screwdriver remove the screws from the bottom panel of the indoor unit and set aside Figure 58 3 Remove the bottom panel Figure 59 Removal is necessary to gain access to the terminal block which is situated at the bottom of most ind...

Страница 43: ... the latches over the screws Refer back to Figure 57 as an example 8 If all other piping and electrical wiring to the outside unit has been completed at this stage you can turn the system on to test If you have not completed the piping connections do not turn power on at this time and proceed to complete all other piping along with drain hose and wiring to the system Terminal Block Connection for ...

Страница 44: ...r time delay fuse Figure 63 Circuit Breaker Procedure Refer to Figure 63 at right for an example of how a circuit breaker should be wired through to the Single Zone system Be sure there is no power going through the Single Zone system before proceeding with these connections as it may result in elec tric shock Familiarize yourself with the location of the circuit breaker and be sure that all power...

Страница 45: ...120HSV4 Outdoor Unit Electrical Connections 180HSV4 Electrical Connections Outdoor Unit Terminal Block Over 0 2 Conduit Panel Connection Communication Cable Leading to Indoor Unit Power Cord Conduit Panel Cover 1 L1 2 L2 1 L1 2 L2 3 180HSV4 Figure 64 090HSV4 120HSV4 Outdoor Unit Electrical Connections Figure 65 180HSV4 Outdoor Unit Electrical Connections Terminal Block Connections for 180HSV4 See ...

Страница 46: ...or discharge temperature Front outdoor coil pipe temperature Back outdoor coil pipe temperature Liquid line pipe temperature Subcooler inlet temperature Subcooler outlet temperature Average indoor unit IDU pipe temperature Inverter compressor operation indicator light Liquid injection valves operation indicator lights Hot gas bypass valve operation indicator light Four way reversing valve operatio...

Страница 47: ... use of a USB to RS 485 connector kit When connected through IDU user will not be able to record data This software can be used to both commission new systems and troubleshoot existing systems LGMV data can be recorded to a CSV file and emailed to an LG representative to assist with diagnostic evaluations Recommended Minimum PC Configuration Error Codes LGMV software helps the service technician o...

Страница 48: ...lso be used with Single Zone one to one configurations such as the Single Zone Wall Mount systems The Duct Free System air conditioning system must run for at least 15 20 minutes before data collected by SIMs 2 0 is valid for troubleshooting You must have the free SIMs app correctly installed on your smart phone before using SIMs Some ODUs have an LGMV extension cable accessed by removing the side...

Страница 49: ...estart Timer Comp Mode EEV Indoor Info Tab Displays the following information Frequency Operation THM Mode REM Mode FAN EEV Air Temp Pipe in Pipe mid Pipe out Graph Info Tab This tab has three sub sections IDU Indoor Unit Temperature graph Displays IDU informa tion in graph format In formation displayed is for the IDU selected on the Main screen ODU Outdoor Unit Temperature and Fre quency graph Di...

Страница 50: ...ed remote controller the Single Zone unit control board and LG Monitoring View LGMV Diagnostic Software If two or more errors occur simultaneously the lower error code number is displayed first After error is resolved the error code does not display Error Codes Decoding the Error Display The first and second number on the LED indicates error number Example 21 LED1 Green light 2x blink LED2 Red lig...

Страница 51: ...40 CT Sensor Error Thermistor is disconnected or shorted out 4X 41 D Pipe Sensor INV is disconnected or shorted out 4X 1X 44 Outdoor Air Sensor is disconnected or shorted out 4X 4X 45 Middle thermistor of outdoor unit condenser coil is disconnected or shorted out 4X 5X 46 Outdoor unit suction line thermistor is disconnected or shorted out 4X 6X 48 Outdoor unit coil outlet liquid line thermistor is...

Страница 52: ...d or shorted out 4X 1X 44 Outdoor Air Sensor is disconnected or shorted out 4X 4X 45 Middle thermistor of outdoor unit condenser coil is disconnected or shorted out 4X 5X 46 Outdoor unit suction line thermistor is disconnected or shorted out 4X 6X 48 Outdoor unit coil outlet liquid line thermistor is disconnected or shorted out 4X 8X 53 Communication failure from outdoor unit to indoor unit 5X 3X ...

Страница 53: ...ill be mounted meets the concentration limit for the application If the refrigerant leaks and safety limits are exceeded it could result in personal injuries or death from oxygen depletion 1 American Society of Heating Refrigeration and Air Conditioning Engi neers Inc ASHRAE Atlanta GA ASHRAE Inc Information about ASHRAE Standard 15 2010 34 2010 and addenda current as of the date of this publicati...

Страница 54: ...amps and hangers Brazing Practices Description Check Medical grade there are 4 available dry nitrogen for purging during brazing was used constant 3 psi while brazing Installation For more information on any procedure refer to the detail provided in the installation section Refrigerant Piping Description Check All pipe materials were properly stored capped and clean All burrs were removed after cu...

Страница 55: ...ll local electrical code requirements Power wiring to the indoor unit was installed per all local electrical code requirements LG supplied cable was used between the indoor unit and its zone controller No cables were spliced and no wire caps are present Communication type RS 485 BUS type All communications cables were a minimum of 18 AWG four 4 conductor shielded and stranded with insulation mater...

Страница 56: ...lpharetta Georgia 30009 www lghvac com IM SZ HighEfficiencyInverter_HSV4 03 15 Supersedes IM SZ HighEfficiencyInverter_HSV4 01 15 LG Customer Information Center Commercial Products 1 888 865 3026 USA Follow the prompts for commercial A C products 20001747 ISO 9001 2008 LG ELECTRONICS INC ...

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