LG Hydro Kit Installation Manual
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LG Hydro Kit Installation Manual

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INSTALLATION MANUAL
AIR-TO-WATER
HEAT PUMP
Please read this installation manual completely before installing the product.
Installation work must be performed in accordance with the national wiring
standards by authorized personnel only.
Please retain this installation manual for future reference after reading it thoroughly.
Hydro Kit
Original instruction
[Representative] LG Electronics Inc. EU Representative : LG Electronics European Shared
Service Center B.V. Krijgsman 1, 1186 DM Amstelveen, The Netherlands
[Manufacturer] LG Electronics Inc. Changwon 2nd factory 84, Wanam-ro, Seongsan-gu,
Changwon-si, Gyeongsangnam-do, KOREA
MFL67086712
Rev.03_082119
Copyright © 2018 - 2019 LG Electronics Inc. All Rights Reserved.
www.lg.com

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Summary of Contents for LG Hydro Kit

  • Page 1 Please retain this installation manual for future reference after reading it thoroughly. Hydro Kit Original instruction [Representative] LG Electronics Inc. EU Representative : LG Electronics European Shared Service Center B.V. Krijgsman 1, 1186 DM Amstelveen, The Netherlands [Manufacturer] LG Electronics Inc. Changwon 2nd factory 84, Wanam-ro, Seongsan-gu, Changwon-si, Gyeongsangnam-do, KOREA www.lg.com...

  • Page 2: Table Of Contents

    External Controller External pump Wi-fi Modem Smart Grid SYSTEM SET-UP DIP Switch Setting Group Control Setting Installer Setting TEST RUN Caution before Operation Test Operation Test of Water Pipe Troubleshooting Airborne Noise Emission Limiting concentration Model Designation 2 Hydro Kit...

  • Page 3: Safety Precautions

    • Do not modify or extend the power cable. - There is risk of fire or electric shock. • Do not install, remove, or reinstall the unit by yourself (customer). - There is risk of fire, electric shock, explosion, or injury. Hydro Kit Installation Manual 3...
  • Page 4 • Do not touch (operate) the unit with wet hands. - There is risk of fire or electric shock. • Do not place a heater or other appliances near the power cable. - There is risk of fire or electric shock. 4 Hydro Kit...
  • Page 5 - There is risk of fire, electric shock, explosion, or injury. • If the unit is not used for long time, we strongly recommend not to switch off the power supply to the unit. - There is risk of water freezing. Hydro Kit Installation Manual 5...
  • Page 6 • Use a firm stool or ladder when cleaning or maintaining the unit. - Be careful and avoid personal injury. • Do not unplug the power supply plug of Hydro Kit when stopping Hydro Kit operation. Always turn Hydro Kit off, using the wired remote controller.

  • Page 7: Installation Parts

    Please retain this installation manual for future reference after reading it thoroughly Hydro Kit Original instruction [Representative] LG Electronics Inc. EU Representative : LG Electronics European Shared Service Center B.V. Krijgsman 1, 1186 DM Amstelveen, The Netherlands [Manufacturer] LG Electronics Inc. Changwon 2nd factory 84, Wanam-ro, Seongsan-gu, Changwon-si, Gyeongsangnam-do, KOREA www.lg.com...

  • Page 8: General Information

    General Information General Information With advanced inverter technology, Hydro Kit is suitable for applications like under floor heating, and hot water generation. By Interfacing to various accessories user can customize the range of the application. Model Information Model name and related information •...
  • Page 9 High side : 4.2 MPa / Low Side : 2.4 MPa - Max Allowable water temperature High side : 80 °C / Low side : 10 °C - Max Allowable water pressure 0.98 MPa (0.3~10 kgf/cm Hydro Kit Installation Manual 9...

  • Page 10: General Information

    General Information General Information To extend the functionality of Hydro Kit, there are various external auxiliary apparatus called as "accessories". They are classified by "accessories" and "3rd party accessories" according to the manufacturer. Accessories are presented LG Electronics, and 3rd party accessories are presented by related manufacturers.

  • Page 11: Installation

    - When carrying the unit, be sure to support it at 6-points. Carrying and lifting the unit with 4- point support may make it unstable, resulting in a fall. Hydro Kit Installation Manual 11...

  • Page 12: Selection Of The Best Location

    • The unit of values is mm(inch). <For Medium Temperature> 520(20-15/32) 400(15-3/4) (Unit: mm(inch)) 100(3-15/16) space Piping space Product 330(13) (front side) Service space 600(23-5/8) 100(3-15/16) (front side) 100(3-15/16) space (Unit: mm(inch)) 100(3-15/16) H-Beam supporter 200(7-7/8) 12 Hydro Kit...
  • Page 13 400(15-3/4) (Unit : mm(inch)) 100(3-15/16) space Piping space 350(13-25/32) (front side) Service space (left side) Service space 600(23-5/8) (front side) (Unit : mm(inch)) Anti Vibration material 100(3-15/16) 100(3-15/16) space 100(3-15/16) H-Beam supporter 200(7-7/8) Concrete supporter Hydro Kit Installation Manual 13...

  • Page 14: Foundation For Installation

    392(15-7/16) (Unit: mm(inch)) Drain pipe connection (For Medium Temperature) - Hydro Kit does not use the drain pump. - Do not install in upward direction. - Install the drain pipe in downward direction (1/50-1/100). - Hydro Kit drain connection pipe is PT 1.

  • Page 15: Water Piping And Water Circuit Connection

    - Install the service port facing downward. (Within left/right 45 degrees) - Check if there is any leakage on the connecting part. - Clean the strainer periodically. (Once a year or more frequent) Water In Strainer Front Side Hydro Kit Installation Manual 15...
  • Page 16 10. Install the strainer (6) at the inlet water pipe connection to protect the PHE. Do not charge water into the water pipe directly during Hydro Kit operation. If the strainer is not installed, component malfunction of Hydro Kit may occur.
  • Page 17 Flow switch (included in product) (Sanitary Water) Tank NOTICE Install the closed loop type water pipe system. Balancing valve with flow meter is recommended to ensure 100 % of the nominal flow. DHW : Domestic Hot Water. Hydro Kit Installation Manual 17...

  • Page 18: Installation Scenes

    Shut-off valves position for spare water pump and water pump service, Flexible joint installation to prevent noise and vibration. 1) Space Heating/Cooling Installation Wired Remote Wi-fi Module PQRSTA0 Controller (PWFMDD200) LG Supply Field Supply (Cooling → Close) Water Supply Drainage 18 Hydro Kit...
  • Page 19 ‘Dip switch #3’ setting. *please refer the “System Set-Up, Dip Switch Setting” - Wi-Fi module(PWFMDD200/105 cm) connected to ‘CN-WF’ on Hydro kit PCB. To increase the length between Wi-Fi modem and Hydro Kit, please purchase USB Extension Cable(PWYREW000,...
  • Page 20 14 Water Tank temperature Sensor (12 m) Water Supply - For water tank(DHW) operation, dip switch #2 in Hydro Kit PCB should be set correctly, please refer the “System Set-Up, Dip Switch Setting” - Wi-Fi module(PWFMDD200, 105 cm) is connected to ‘CN-WF” on Hydro Kit PCB.
  • Page 21 ‘Dip switch #3’ setting. *please refer the “System Set-Up, Dip Switch Setting” - Wi-Fi module(PWFMDD200/105 cm) connected to ‘CN-WF’ on Hydro kit PCB. To increase the length between Wi-Fi modem and Hydro Kit, please purchase USB Extension Cable(PWYREW000,...
  • Page 22 ‘Dip switch #3’ setting. *please refer the “System Set-Up, Dip Switch Setting” - Wi-Fi module(PWFMDD200/105cm) connected to ‘CN-WF’ on Hydro kit PCB. To increase the length between Wi-Fi modem and Hydro Kit, please purchase USB Extension Cable(PWYREW000,...
  • Page 23 An anode protects the DHW tank against corrosion. It consist of a bar of magnesium oxide. A correct working anode is crucial to increase the lifetime of a Non-stainless steel DHW tank while it makes the tank cathodic and prevent against corrosion. Hydro Kit Installation Manual 23...
  • Page 24 Consult your Hydro Kit unit supplier for locally approved solutions in your area. Calculate the approximate volume of water in the system. (Except the Hydro Kit unit.) And add antifreeze solution to the total volume to allow for the water contained in Hydro Kit unit.

  • Page 25: Refrigerant Piping

    The thickness of the above insulation material is based on thermal conduction rate of 0.036 W/m °C. When installing independent power module, refrigerant piping should be installed in accordance with the manual of independent power module Hydro Kit Installation Manual 25...
  • Page 26 - Pipe-searching process error may occur if the pipe temperature does not increase. Ø 22.2 Gas pipe Ø 9.52 Liquid pipe - It is recommended that Hydro Kit (8, 10 HP model) is connected to No.1 valve and No.2 valve. DIP S/W setting Example Indoor Unit Indoor Unit...
  • Page 27 - Flow water in the Hydro Kit when pipe-searching process is performed. - Pipe-searching process error may occur if the pipe temperature does not increase. - It is recommended that Hydro Kit (8, 10 HP model) is connected to No.1 valve and No.2 valve. SW01D SW01D...

  • Page 28: How To Connect Wirings

    When connecting the power and communication cable, always use the terminal connector (O-ring, Y-ring). Communication cable Communication Power cable cable Power cable Make sure to tighten so that the screw of the terminal does not get loose. 28 Hydro Kit...

  • Page 29: Wiring Connection

    2) Incorrect wiring confirmation test method : Measure the resistance across the power terminals (L,N) using a multi meter. - Resistance value of a normal connection: 1 MΩ or more - Incorrect wiring resistance value: 500 mΩ or less Hydro Kit Installation Manual 29...
  • Page 30 < 75 ~ 100 A 2 Unit 10 ~ 16 100 mA 0.1 sec < 125 ~ 150 A 3 Unit 25 ~ 35 100 mA 0.1 sec < 175 ~ 200 A 4 Unit 100 mA 0.1 sec 30 Hydro Kit...

  • Page 31: Connecting Cables

    • Consider the surrounding conditions(surrounding temperature, direct sunlight, rain water, etc.) when wiring the cable. • The thickness of the power cable is the minimum thickness of metal conductor cable. Use thicker cable considering the voltage drop. Hydro Kit Installation Manual 31...
  • Page 32 - Please connect not to make a gap at the remote controller and setup board’s upper and lower, right and left part. - Before assembly with the installation board, arrange the Cable not to interfere with circuit parts. 32 Hydro Kit...
  • Page 33 • If you install the extension cable in the opposite direction, the connector will not be connected. • Specification of extension cable: 2547 1007 22# 2 core 3 shield 5 or above. Hydro Kit Installation Manual 33...

  • Page 34: Independent Power Module

    Independent power module is required to protect a plate heat exchanger burst. When the outdoor unit is operating, if Hydro Kit is suddenly powered off, a plate heat exchanger burst may happen during oil-return and defrosting cycle in cooling mode.
  • Page 35 Otherwise, the independent power kit can not fully close the EEV due to the lack of the charging power. For more detailed information, refer to the installation manual of Independent Power Module. Hydro Kit Installation Manual 35...

  • Page 36: Accessories Installation

    Refrigerant leak detector locking location (CN-LEAK-ROOM2) Water tank temperature sensor locking location (CN-TH4) Wi-Fi module locking location (CN-WF) Dry contact board locking location (CN-CC) External pump connecting location (TB-EXT-PUMP) PUMP(A) 3WAY VALVE THERMOSTAT (Hydro kit) (Default : 230 V AC) 36 Hydro Kit...
  • Page 37 After checking each part carefully, install external parts respectively. • Connect the cable of each accessory to the terminal block of the control box in the Hydro Kit. • Check the label attached on the terminal block to prevent wrong connection.

  • Page 38: Main Pump Connection

    PDB) • Use the pump with enough capacity to guarantee the loss of entire water pressure and to supply the Hydro Kit with water. Relay • Select a suitable relay for pump capacity when connecting the pump to the unit.

  • Page 39: Thermostat

    • Thermostat can not be located where the area may be hidden when door is open. • Thermostat can not be located where external thermal influence may be applied. (such as above heating radiator or open window) Direct Sun ray contact area 1.5 m Hydro Kit Installation Manual 39...
  • Page 40 • If above conditions are not kept, the unit can not operation properly. • Heating / Cooling Thermostat must send cooling or heating signal immediately when temperature condition is satisfied. No delay time while sending cooling or heating signal is permitted. 40 Hydro Kit...
  • Page 41 Never connect external electric loads such as valves, fan coil units, etc. If connected, Main PCB Assembly 1 can be seriously damaged. (L) : Live signal from PCB to Thermostat (N) : Neutral signal from PCB to Thermostat (H) : Heating signal from Thermostat to PCB Hydro Kit Installation Manual 41...
  • Page 42 Set DIP switch No. 8 to ‘ON’ (Check the system set-up of Chapter 7). Otherwise, the unit can not recognize the thermostat. • Remote Controller : - ‘Thermostat’ text is displayed on the remote controller. - Button input is prohibited. 42 Hydro Kit...

  • Page 43: Remote Temperature Sensor

    3. Choose the place where the heating devices do not affect the remote sensor. 4. Choose the place where the outlet of the cooling fan do not affect the remote sensor. 5. Choose the place where the remote sensor isn't affected when door is open. Hydro Kit Installation Manual 43...

  • Page 44: 3Way Valve

    (W) : Live signal (Water tank heating) from PCB to 3way valve (U) : Live signal (Under floor heating) from PCB to 3way valve (N) : Neutral signal from PCB to 3way valve WARNING Mice can not be appeared to prevent entering the unit or attacking wires. 44 Hydro Kit...
  • Page 45 • Is water circuit (both under floor water loop and sanitary water tank loop) fully charged? If not, additional water charging is required. • Fast valve operation yields noise and vibration. Appropriated valve operating time is 60~90 seconds. Hydro Kit Installation Manual 45...

  • Page 46: 2Way Valve

    - Water should not flow into under floor loop in cooling mode. - To verify the flow direction, check temperature at the water inlet of the under floor loop. - If correctly wired, this temperatures should not be approached to 6 °C(42 °F) in cooling mode. 46 Hydro Kit...

  • Page 47: Dry Contact

    Accessories Installation Dry Contact LG Dry Contact is a solution for automatic control of HVAC system at the owner's best. In simple words, it's a switch which can be used to turn the unit On/Off after getting the signal from external sources like key-in lock, door or window switch etc specially used in Hotel rooms.
  • Page 48 For input contact voltage : DC 12 V, AC 24 V Thermostat LG does not supply this section (Field supply) Connect separate External voltage of DC 12 V, AC 24 V 48 Hydro Kit...

  • Page 49: External Controller

    - 2: Dry contact (simple contact) - 3: Emergency stop only for indoor unit - 4: Reattachment / absence - 5: Emergency stop of all indoor units (It can be set only when indoor unit has emergency stop function) Hydro Kit Installation Manual 49...

  • Page 50: External Pump

    Step 3. Connect signal cable to terminal block (TB_EXT_PUMP) fully. Indoor PCB Indoor PCB TB_W_PUMP_C TB_W_PUMP_C Contact Signal (Non Voltage) Relay Power Source (30 V DC / 1 A, 250 V AC / 1 A) Relay External Pump 50 Hydro Kit...

  • Page 51: Wi-Fi Modem

    Step 4. Connect the Wi-Fi modem to the USB cable fully. CN_WF CN_WF CN_WF Step 5. Refer to the image below to install the Wi-Fi modem in the marked position. CN_WF CN_WF Indoor PCB Indoor PCB Indoor PCB Indoor PCB Indoor PCB USB Cable Hydro Kit Installation Manual 51...

  • Page 52: Smart Grid

    Step 1. Check if the power of the unit is turned off. Step 2. Disassemble front panels and distinguish terminal block in Indoor PCB. Step 3. Connect signal cable to terminal block in PCB (TB_SG2, TB_SG1) fully as shown below. Indoor PCB Indoor PCB TB_SG2 TB_SG2 TB_SG1 TB_SG1 52 Hydro Kit...

  • Page 53: System Set-Up

    DIP Switch Setting CAUTION Turn off electric power supply before setting DIP switch • Whenever adjusting DIP switch, turn off electric power supply to avoid electric shock. General Information Indoor PCB OFF is selected ON is selected Hydro Kit Installation Manual 53...
  • Page 54 Mode Setting Reserved (Don’t Select) Always Flow Switch ● ○ Detection While water pump is on ○ Not Use x ● Electric Heater ● x Setup Reserved (Don’t Select) ● ● ○ Not installed Thermostat ● Connection Installed 54 Hydro Kit...
  • Page 55 Option Switch 3 ● : OFF : On DIP switch setting Description Function Default ○ Sensor (Air) in Hydro Kit (RS3) Sensor Selection ● Air Sensor (PQRSTA0) ○ Not Use (connect short key) Antifreeze ● Operation mode Use (disconnect short key)

  • Page 56: Group Control Setting

    System Set-Up Group Control Setting Group Control - Wired remote controller 1 + Many of Hydro Kit LGAP Network System Slave Slave Slave Master Display Error Message Only connect serial signal and GND lines between slave indoor unit Signal 12 V...
  • Page 57 • Group control is not possible between hydro kit and air conditioner. • Group control is not possible between mid temperature hydro kit and high temperature hydro kit. 4. In case that the indoor unit has an abnormal problem an error code will be displayed on the wired remote controller.
  • Page 58 Depending on the status of slight / heavy / critical trouble, pop-up phrase is guided separately on display. - Slight trouble : Heating/Cooling Operable - Heavy trouble : Heating Operable only - Critical trouble : Service center request AWHP operates when user pressed OK button on pop-up window. 58 Hydro Kit...
  • Page 59 - In normal condition, the product operating information is restored and automatically restarted after main electricity power is reset. - But in emergency operation, automatic re-start is prohibited to protect the product. - Therefore, user must restart the product after power reset when emergency operation has been running. Hydro Kit Installation Manual 59...

  • Page 60: Installer Setting

    LG warrenty. h Installer setting password Main screen →...
  • Page 61 DHW set temp. Heating Flow Temperature' in domestic - Lower limitation 30 °C ~ 40 °C - Lower limitation 30 °C ~ 45 °C hot water tank heating mode. (40 ℃ default) (45 ℃ default) Hydro Kit Installation Manual 61...
  • Page 62 - 1~12 hours (1 hour default) not reached, stop disinfect regarding this timer. Function for AWHP except for Hydro Kit. When it is necessary to change the weight of heating water source in the hot water tank depending on the user's environment.
  • Page 63 The function to enable / disable the SG Smart Grid (SG) - Use Ready function and to set the reference - Step 0, Step 1 , Step 2 (Mode Selection) value at the step 2. Hydro Kit Installation Manual 63...
  • Page 64 The function to display the operating time IDU operation time and to measure the life of the product. CAUTION There is no disinfection function in Medium Temperature Hydro Kit. So, external control equipment should be installed for disinfection function. 64 Hydro Kit...
  • Page 65 • Pump test run The pump test run is the function to test run by operating the water pump. This function can be used for air vents / flow sensors and others. Hydro Kit Installation Manual 65...
  • Page 66 Determine heating setting temperature range when DHW temperature is selected as setting temperature. NOTICE Only available when DHW tank feature is installed. • DHW tank and DHW tank kit should be installed. • DIP switch No. 2 and 3 should be set properly. 66 Hydro Kit...
  • Page 67 • Cooling / Heating only mode Set the Operation mode lock when Multi V Indoor unit is used only cooling mode in summer and Hydro Kit is used only heating in winter. Temperature Control Parameter Setting • Water supply off temp. during cooling Determine leaving water temperature when the product is turned off.
  • Page 68 • When Disinfection active is set as ’Use’, that is ‘enable disinfection mode’, Start date is displayed at the position of Disinfection active and Start time is displayed at the position of Start date. 68 Hydro Kit...
  • Page 69 Session B : Heating by water heater Session C : No heating (Water heater is Off) Session D : Heating by water heater NOTICE DHW heating does not operate when it is disabled. Hydro kit only performs the heating priority function. Hydro Kit Installation Manual 69...
  • Page 70 • TH on/off Variable, cooling water Setting the step value to adjust water temperature gap in cooling mode Th On Th Off 0.5 ℃ -0.5 ℃ 1 ℃ -1 ℃ 2 ℃ -2 ℃ 3 ℃ -3 ℃ 70 Hydro Kit...
  • Page 71 Determine the difference between target inlet water temperature and target outlet water temperature from water flow rate. Water flow rate (l/min) Setting value 4 HP 10 HP 20~22 45~50 23~24 51~55 25~26 56~60 27~28 61~65 29~30 66~70 31~32 71~75 33~34 76~80 35~37 81~85 38~39 86~90 91~92 Hydro Kit Installation Manual 71...
  • Page 72 Function Setting - Low noise operation time menu is inactivated 2) Setting remote control management of low noise operation Low noise operation switch setting of outdoor unit PCB is ignored. Function Setting - Low noise operation time menu is activated. 72 Hydro Kit...

  • Page 73: Test Run

    • Check whether it is 2.0 MΩ or above, when insulation resistance between the terminal block and ground is measured with DC mega tester (DC 500 V). • Never check insulation resistance for the connector of the control board. Operation Test of Water Pipe Hydro Kit Installation Manual 73...

  • Page 74: Troubleshooting

    Test Run Troubleshooting If Hydro Kit operates not properly or it does not start operation, please check following list. Error Type Main Reasons Error No. Air temperature sensor disconnection or short Air temperature sensor error circuit Gas side temperature sensor disconnection or...
  • Page 75 Inverter PCB heat generation, causing the rise of temperature heatsink temperature Inverter heatsink temperature Inverter heatsink temperature sensor sensor defect disconnection or short circuit Overcurrent (Peak) detected at Error by overcurrent detection at inverter input inverter input Hydro Kit Installation Manual 75...

  • Page 76: Airborne Noise Emission

    Combination of Inverter Type and Cooling Only or Heat Pump N: AC Inverter and H/P V: AC Inverter and C/O U: DC Inverter and H/P and C/O H: Hydro Kit System with Indoor Unit using R410A ❈ LGETA:U Ex) URN...

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