LG ARWN160BA2 Installation Manual
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LG ARWN160BA2 Installation Manual

LG ARWN160BA2 Installation Manual

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INSTALLATION MANUAL
AIR CONDITIONER
• 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.your set and retain it for future reference.
MODELS: ARWN Series (3Ø, 220V, 60Hz)
P/NO : MFL67008801
www.lg.com

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Summary of Contents for LG ARWN160BA2

  • Page 1 • 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.your set and retain it for future reference. MODELS: ARWN Series (3Ø, 220V, 60Hz) www.lg.com P/NO : MFL67008801...

  • Page 2: Table Of Contents

    ARWN Series Outside unit Installation Manual TABLE OF CONTENTS Safety Precautions ......................3 Installation Process .......................7 Outside units Information....................8 Environment-friendly Alternative Refrigerant R410A ..........9 Select the Best Location....................9 Installation space ......................10 Water control .......................12 Lifting method ......................14 Installation ........................15 Refrigerant piping installation ..................19 Protection device unit....................24 Refrigerant piping system ..................26 Y branch pipe and header branch pipe type .............43...

  • Page 3: Safety Precautions

    Safety Precautions Safety Precautions To prevent injury to the user or other people and property damage, the following instructions must be followed. n Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications. This symbol indicates the possibility of death or serious injury.
  • Page 4 Safety Precautions When installing and moving the air condition- Do not reconstruct to change the settings of er to another site, do not charge it with a the protection devices. different refrigerant from the refrigerant specified on the unit. • If a different refrigerant or air is mixed with the original •...
  • Page 5 Safety Precautions n Installation Always check for gas (refrigerant) leakage Do not install the product where the noise or after installation or repair of product. hot air from the outside unit could damage the neighborhoods. • Low refrigerant levels may cause failure of •...
  • Page 6 Safety Precautions Be very careful about product transportation. • Only one person should not carry the product if it weighs more than 20 kg. • Some products use PP bands for packaging. Do not use any PP bands for a means of transportation. It is dangerous. •...

  • Page 7: Installation Process

    Installation Process Installation Process Indicate clearly who is to be responsible for switch settings Determination of division work Make relationship between outside, indoor, remote controller, and option connections clear. Preparation of contract drawings (Prepare control circuit diagram) Take account of gradient The foundation must be level even Sleeve and insert work Outside unit foundation work...

  • Page 8: Outside Units Information

    3)Over 130%, capacity is same as capacity of 130%, Same remark is valid for power input. Power Supply: Outside Unit (3Ø, 220V, 60Hz) Unit 1 Unit 2 Units System(HP) Model ARWN80BA2 ARWN160BA2 ARWN240BA2 ARWN80BA2 ARWN160BA2 ARWN160BA2 ARWN80BA2 Product Charge 8.8 + 7.3 CF(Correction Factor) Max.

  • Page 9: Environment-Friendly Alternative Refrigerant R410A

    Environment-friendly Alternative Refrigerant R410A Environment-friendly Alternative Refrigerant R410A • The refrigerant R410A has the property of higher operating pressure in comparison with R22. Therefore, all materials have the characteristics of higher resisting pressure than R22 ones and this character- istic should be also considered during the installation. R410A is an azeotrope of R32 and R125 mixed at 50:50, so the ozone depletion potential (ODP) of R410A is 0.

  • Page 10: Installation Space

    Installation space Installation space Individual Installation Required the minimum space as shown below for installation and check. If the space is not fit on this drawing, consult with LG. (unit : mm) : Service area Product (Outside unit) Water pipe...
  • Page 11 Installation space Two Layer Installation Space required for two layer installation as shown below considering passage for air and people. : Service area (unit : mm) H-Beam Support <Front View> Installation Manual 11...

  • Page 12: Water Control

    Installation space Water control Water control • Keep the water temperature between 10~45°C. Other it may cause the breakdown. - Standard water supply temperature is 30°C for Cooling and 20°C for heating. • Properly control the water velocity. Otherwise it may cause the noise, pipe vibration or pipe contraction, expansion according to the temperature.
  • Page 13 Water control Standard table for water purity control The water may contain many foreign substances and hence may influence the performance and lifetime of the prod- uct due to the corrosion of the condenser and water pipe. (Use water source that complies with the below standard table for water purity control.) If you use water supply other than the tap water to supply the water for the cooling tower, you must do a water quality inspection.

  • Page 14: Lifting Method

    Lifting method Lifting method • When carrying the suspended, unit pass the ropes under the unit and use the two suspension points each at the front and rear. • Always lift the unit with ropes attached at four points so that impact is not applied to the unit. •...

  • Page 15: Installation

    Installation Installation Location of anchor bolt (Unit: mm) The location of anchor bolt WARNING • Be sure to install unit in a place strong enough to withstand its weight. Any lack of strength may cause unit to fall down, resulting in a personal injury. •...
  • Page 16 Installation Preparation of Piping Main cause of gas leakage is defect in flaring work. Carry out correct flaring work in the following procedure. 1) Cut the pipes and the cable. n Use the accessory piping kit or the pipes purchased Copper Slanted Uneven Rough tube...
  • Page 17 Installation FLARE SHAPE and FLARE NUT TIGHTENING TORQUE Precautions when connecting pipes • See the following table for flare part machining dimensions. • When connecting the flare nuts, apply refrigerant oil to the inside and outside of the flares and turn them three or four times at first.
  • Page 18 Installation HEAT INSULATION 1. Use the heat insulation material for the refrigerant piping which has an excellent heat-resistance (over 120°C). Fastening band (accessory) 2. Precautions in high humidity circumstance: This air conditioner has been tested according to the "ISO Conditions with Mist" and confirmed that there is not any default.

  • Page 19: Refrigerant Piping Installation

    Refrigerant piping installation Refrigerant piping installation WARNING Always use extreme care to prevent the refrigerant gas (R410A) from leakage while using fire or flame. If the refrigerant gas comes in contact with the flame from any source, such as a gas stove, it breaks down and generates a poisonous gas which can cause gas poisoning.
  • Page 20 Refrigerant piping installation Connection of High/Low Pressure Common pipe Slave2 Outside Unit Slave Outside Unit Slave1 Outside Unit Main Outside Unit Master Outside Unit 2 Outside Units 3 Outside Units 1) For the high/low pressure common pipe, connect both master outside unit and slave outside units to the pipe by using elbows.
  • Page 21 Refrigerant piping installation 3 Outside Units (unit : mm) Connecting Combination specification Gas pipe Liquid pipe branch pipe Blow nitrogen while brazing Don't cut the pipe less I.D12.7 I.D19.05 I.D15.88 than 70mm I.D28.58 I.D34.9 I.D41.3 I.D22.2 I.D12.7 ARCNN20 I.D19.05 I.D38.1 I.D28.58 I.D34.9 I.D9.52...
  • Page 22 Refrigerant piping installation Installation of water pipe 1) Water pipe system diagram • The water pressure resistance of the water pipe system of this product is 1.98MPa • When the water pipe passes indoors, make sure to execute heat insulation on the pipe so that water drops do not form on the outer side of the water pipe.
  • Page 23 Refrigerant piping installation Pipe thickness Shear stress Tensile stress Bending moment Torque (N . m) (kgf . m) (N . m) (kgf . m) inch (kN) (kgf) (kN) (kgf) 12.7 19.05 1,200 11.5 25.4 1 1.2 1,120 15.5 31.8 1 1/4 14.5 1,450 87.5...

  • Page 24: Protection Device Unit

    Product protection device Device protection unit Strainer on water pipe To protect the water cooling type product, you must install a strainer with 50 mesh or more on the heat water supply pipe. If not installed, it can result in damage of heat exchanger by the following situation. 1.
  • Page 25 Product protection device Installation of flow switch • The flow switch must be installed at the horizontal pipe of the heat water supply out- let of the product and check the direction of the heat water flow before the installa- tion.

  • Page 26: Refrigerant Piping System

    Refrigerant piping system Refrigerant piping system Y branch method 1. When installing 1 outside unit independently Ex) 5 indoor units connected Indoor unit Ⓐ : Outside unit direction Ⓑ : 1st branch (Y branch) Ⓒ : Indoor units Ⓓ : Indoor unit L Below 150 m l Below 40 m Ú...
  • Page 27 Refrigerant piping system 2. When installing 2 outside units Slave Ex) 5 indoor units connected Ⓐ : Outside units Master Ⓑ : 1st branch Indoor unit Ⓒ : Indoor units Below 2m direction Ⓓ : Indoor unit direction Below 10m Ⓔ...
  • Page 28 Refrigerant piping system 3. When installing 3 outside units Slave2 Ex) 5 Indoor Units connected Slave1 Ⓐ : Outside Units Master Ⓑ : 1st branch (Y branch) Below Below 2m (h1) Ⓒ : Indoor Units Ⓓ : Downward Indoor Unit Ⓔ...
  • Page 29 Refrigerant piping system Header branch method 1. When installing 1 outside unit indepen- dently Ex) 6 indoor units connected Ⓐ Outside unit Ⓑ Header branch Ⓒ Indoor unit Ⓓ Seal L Below 150 m Ú Outside unit Ⓐ ~ Header branch Below 40 m part Ⓑ...
  • Page 30 Refrigerant piping system 2. When installing 2 outside units Slave Ex) 6 indoor units connected Ⓐ : Outside unit Ⓑ : Header branch Master Ⓒ : Indoor unit Below 2m Ⓓ : Seal Below 10m Ⓔ : Connecting branch pipe between out- side units h Connecting branch pipe between outside units: ARRCN20(Ⓔ)
  • Page 31 Refrigerant piping system 3. When installing 3 outside units Slave2 Ex) 6 Indoor Units connected Slave1 Ⓐ : Outside Units Master Below 2m Below 2m Below 2m Ⓑ : Header branch (h1) (h1) (h1) Ⓒ : Indoor Units 10m or Ⓓ...
  • Page 32 Refrigerant piping system Y/Header branch method 1. When installing 1 outside unit indepen- dently Ex) 5 indoor units connected Ⓐ : Outside unit Ⓑ : 1st Y branch Ⓒ : 2nd Y branch Ⓓ : Indoor unit Ⓔ : Header branch Ⓕ...
  • Page 33 Refrigerant piping system 2. When installing 2 outside units Slave Ex) 5 indoor units connected Ⓐ : Outside units Master Ⓑ : 1st Y branch Ⓒ : 2nd Y branch Below 2m Ⓓ : Indoor unit Ⓔ : Header branch Below 10m Ⓕ...
  • Page 34 Refrigerant piping system 3. When installing 3 outside units Slave2 Ex) 5 Indoor Units connected Slave1 Ⓐ : Outside Units Master Ⓑ : 1st branch(Y branch) Belo Below 2m Below 2m (h1) (h1) (h1) Ⓒ : Y branch Ⓓ : Indoor Unit 10m or less Ⓔ...
  • Page 35 Refrigerant piping system • When the pipe diameter (B) connected after 1st branching is larger than the main pipe diameter (A), Install the pipe with the pipe diameter (B) after 1st branching that is the same as the main pipe diameter (A). Ex) When connecting with 150% of the indoor unit to 8 HP.
  • Page 36 Refrigerant piping system Oil trap application method between outside units • Because of the possibility of oil being accumulated in the outside unit that has stopped, when there is a height difference between outside unit pipes or if the pipe distance between the outside units is over 2m, you must always apply an oil trap. (But, the oil trap between outside units is limited to 1 time and is only applied to the gas pipe.) •...
  • Page 37 Refrigerant piping system Calculation of amount of refrigerant The calculation of the additional charge should take into account the length of pipe. Product Charge(kg) Additional charge (kg) a : ø6.35, 10m Outside Unit Total liquid pipe (m): Ø22.2mm x 0.354(kg/m) b : ø6.35, 10m Indoor Unit c : ø6.35, 10m...
  • Page 38 Refrigerant piping system Note: Fill in the f-gas Label attached on outside about the quantity of the fluorinated greenhouse gases ① Manufacturing site (See Model Name label) ② Installation site (If possible being placed adjacent to the service points for the addition or removal of refrigerant) ③...
  • Page 39 Refrigerant piping system Caution 1. Use the following materials for refrigerant piping. • Material: Seamless phosphorous deoxidized copper pipe • Wall thickness : Comply with the relevant local and national regulations for the designed pressure 3.8MPa. We recommend the following table as the minimum wall thickness. Outer diameter 6.35 9.52...
  • Page 40 Refrigerant piping system Branch pipe Fitting Y branch To Outside Unit To Branch Piping or Indoor Unit • Ensure that the branch pipes are attached horizontally or vertically (see the diagram below.) Horizontal Facing Facing plane downwards upwards Within +/- 10° Viewed from point A in direction of arrow Within ±...
  • Page 41 Refrigerant piping system • When the number of indoor units to be connected to the branch pipes is less than the number of branch pipes available for connection then cap pipes should be fitted to the surplus branches. Pinched pipe •...
  • Page 42 Refrigerant piping system Thermal insulation of refrigerant piping Be sure to give insulation work to refrigerant piping by covering liquid pipe and gas pipe separately with enough thickness heat-resistant polyethylene, so that no gap is observed in the joint between indoor unit and insulating material, and insulating materials themselves.

  • Page 43: Y Branch Pipe And Header Branch Pipe Type

    Y branch pipe and header branch pipe type Y branch pipe and header branch pipe type Y branch pipe [unit:mm] Models Gas pipe Liquid pipe I.D12.7 I.D12.7 I.D6.35 I.D15.88 I.D15.88 I.D.6.35 I.D9.52 I.D9.52 I.D15.88 ARBLN01621 I.D.6.35 I.D12.7 I.D.9.52 I.D19.05 O.D9.52 O.D15.88 I.D12.7 I.D22.2...
  • Page 44 Y branch pipe and header branch pipe type Header [unit:mm] Models Gas pipe Liquid pipe ID12.7 ID6.35 ID6.35 ID12.7 4 branch ID9.52 ID15.88 ID9.52 ARBL054 ID15.88 ID12.7 ID9.52 ID15.88 ID19.05 ID12.7 ID6.35 7 branch ID12.7 ID9.52 ID15.88 120 150 ID15.88 ARBL057 ID9.52 ID15.88...

  • Page 45: Leakage Test And Vacuum

    Y branch pipe and header branch pipe type Leakage test and vacuum Leak test Leak test should be made by pressurizing nitrogen gas to 3.8 MPa(38.7kgf/cm ). If the pressure does not drop for 24 hours, the system passes the test. If the pressure drops, check where the nitrogen leaks. For the test method, refer to the following figure.
  • Page 46 Leakage test and vacuum Vacuum Vacuum drying should be made from the service port provided on the outside unitʼs service valve to the vacuum pump commonly used for liquid pipe, gas pipe and high/low pressure common pipe. (Make Vacuum from liquid pipe, gas pipe and high/low pressure common pipe with the service valve closed.) * Never perform air purging using refrigerant.

  • Page 47: Electrical Wiring

    Electrical Wiring Electrical Wiring 1. Follow ordinance of your governmental organization for technical standard related to electrical equipment, wiring regulations and guidance of each electric power company. Be sure to have authorized electrical engineers do the electric work using special circuits in accordance with regulations and this installation manual.
  • Page 48 Electrical Wiring Outside Unit Outside Unit Master Slave1 Slave2 Master Slave1 Slave2 Indoor Indoor Indoor Indoor Unit Unit Unit Unit Remote Remote Remote Remote controller controller controller controller Outside Unit Outside Unit Master Slave1 Slave2 Master Slave1 Slave2 Indoor Indoor Indoor Indoor Unit...
  • Page 49 Electrical Wiring Control Box and Wiring Location - Unscrew all the screw, pull out the panel. - Connect the transmission wire between outside unit and indoor unit, the connection between outside unit and central controller system pass through the sub PCB for central control. - When connecting indoor unit with the shield cable, ground at the grounding screw.
  • Page 50 Electrical Wiring Transmission and Power Lines 1) Transmission cable • Types : shielding wire • Diameter : over 1.25mm • Maximum allowable temperature: 60°C • Maximum allowable line length: under 300m 2) Remote control cable • Types : 3-core cable 3) Simple central control cable •...
  • Page 51 Electrical Wiring u Wiring of Main Power Supply and Equipment Capacity 1. Use a separate power supply for the Outside Unit and Indoor Unit. 2. Bear in mind ambient conditions (ambient temperature,direct sunlight, rain water,etc.) when proceed- ing with the wiring and connections. 3.
  • Page 52 Electrical Wiring 1. 60Hz u Example Connection of Transmission Cable 1 Outside Unit 3 Phase 3 Wires Power line(R, S, T) Transmission line (3 line): Wired remote control Single Phase of power supply line(L, N) Power supply switch Transmission line (2 shield line): Between Indoor Unit and Outside Unit (Switch fuse : ELCB) 3 Phase 3 Wires Power supply...
  • Page 53 Electrical Wiring u Example Connection of Transmission Cable 2 Outside Units Master ■ When the power source is connected 3 Phase 3 Wires Power line(R, S, T) In series between the units. Slave Transmission line (3 line): Wired remote control Single Phase of power supply line(L, N) Power supply switch Transmission line (2 shield line):...
  • Page 54 Electrical Wiring u Example Connection of Transmission Cable 3 Outside Units Master ■ When the power source is connected In series between the units. 3 Phase 3 Wires Power line(R, S, T) Slave1 Transmission line (3 line): Wired remote control Slave2 Single Phase of power supply line(L,N) Transmission line (2 shield line):...
  • Page 55 Electrical Wiring u Example Connection of Communication Cable [BUS type] • Connection of communication cable must be installed like below figure between indoor unit to outside unit. [STAR type] • Abnormal operation can be caused by communication defect, when connection of communication cable is installed like below figure(STAR type).
  • Page 56 Electrical Wiring Dip switch setting 1. Location of setting switch SW01B SW02B 7 segment SW01B SW02B 1 2 3 4 1 2 3 4 If the applicable dip switch is not set correctly, the product may not operate properly. 2. Dip switch setting 1) Set the dip switch and turn on the power of the outside unit to check whether the set value is correctly entered in the 7 segment.
  • Page 57 Electrical Wiring n Master Outside Setting SW01B Setting SW02B Setting Remark Normal mode at shipping factory 1 2 3 4 1 2 3 4 n Slave outside Setting (1 unit: master outside) SW01B Setting SW02B Setting Remark Normal mode at shipping factory 1 2 3 4 1 2 3 4...
  • Page 58 Electrical Wiring Function SW01B Setting SW02B Setting Remark Standard mode at shipping longest Pipe factory Length 1 2 3 4 1 2 3 4 Forced Oil Return 1 2 3 4 1 2 3 4 Vacuum Mode 1 2 3 4 1 2 3 4 Water Pipe For water pipe Solenoid...
  • Page 59 Electrical Wiring Indoor unit auto addressing • The address of indoor units would be set by auto addressing 1) Wait for 3 minutes after applying power supply (master and sub outside unit, indoor unit). 2) Press the switch of the outside unit (SW02V) for 5 seconds. 3) A "88"...
  • Page 60 Electrical Wiring Group Number setting Group Number setting for Indoor Units ① Confirm the power of whole system(Indoor Unit, Outside Unit) is OFF, otherwise turn off. ② The transmission lines connected to INTERNET terminal should be connected to central control of Outside unti with care for their polarity( A ’...
  • Page 61 Electrical Wiring Outside unit Dry Contact installation and connection • Connect wires as below figure at the hole of backside of Outside Unit Dry Contact. • Insert the wire in the connection hole pushing the "Push" button. • Setting Main PCB Dip SW of Master Outside Unit. Mode Change Outside Unit Heating...

  • Page 62: Test Run

    Test Run Test Run Water supply system test run • Before executing the test run for the product, you must first test the heat source water system. The test run for the product must be executed after checking the flow rate and temperature of the heat source water supplied.
  • Page 63 Test Run Precaution before test run Check whether the air is completely removed and the water supply is flowing smoothly. Check whether there is any refrigerant leakage of any disconnected or loose communication or power wire, or use the electric wiring diagram to check the wiring connection condition. Check whether the power and communication wire are connected.
  • Page 64 Test Run h When CH24 or CH180 error occurs during the test operation of the heater, the inside of the panel heat exchanger may be partially frozen and therefore, be sure to get rid of its cause and then, re-operate the device. (The root cause of partial freezing: The lack of flow of heat-sourced water, suspension of water, lack of cooling medium, infiltration of foreign substance inside of panel heat exchanger ) Maintenance of plate type heat exchanger...
  • Page 65 Test Run Daily check/management 1. Water quality control The plate type heat exchanger is not structured to be disassembled, cleaned or replaced with parts. To prevent corrosion or scaling on the plate type heat exchanger, special care must be taken to control the water quality. Water quality must satisfy the minimum criteria of the reference water quality items.
  • Page 66 Test Run Self-Diagnosis Function Error Indicator • This function indicates types of failure in self-diagnosis and occurrence of failure for air condition. • Error mark is displayed on display window of indoor units and wired remote controller, and 7-segment LED of outside unit control board as shown in the table.
  • Page 67 Test Run Display Error item Root cause of error number Slave2 outside unit inverter compressor opera- Initial operation failure due to slave2 outside unit inverter compressor 2 6 3 tion failure error error Master outside unit inverter DC link over-volt- Compressor turned Off due to master outside unit inverter DC voltage 2 8 1 age error...
  • Page 68 Test Run Display Error item Root cause of error number Slave2 outside unit inverter compressor CT Slave2 outside unit inverter compressor current detection (CT) sensor 4 0 3 sensor error disconnection or short circuit Master outside unit inverter compressor dis- Master outside unit inverter compressor discharge temperature sensor 4 1 1 charge temperature sensor error...
  • Page 69 Test Run Display Error item Root cause of error number Communication error with slave2 outside unit When the inverter controller signal is not received from the slave2 out- 5 2 3 inverter controller side unit inverter controller Communication error with master outside unit When the indoor unit control signal is not received from the master out- controller and indoor unit side unit controller...
  • Page 70 Test Run Display Error item Root cause of error number Slave1 outside unit over-cooling inlet tempera- Slave1 outside unit over-cooling inlet temperature sensor disconnec- 1 1 4 2 ture sensor error tion or short circuit Slave2 outside unit over-cooling inlet tempera- Slave2 outside unit over-cooling inlet temperature sensor disconnec- 1 1 4 3 ture sensor error...

  • Page 71: Cooling Tower Applied Method

    Cooling tower applied method Cooling tower applied method Open type Closed type cooling tower cooling tower side side Heat exchange [Open type cooling tower + Second heat exchanger] [Closed type cooling tower] Heat exchanger is installed between the cooling tower Heat source water of the cooling tower is supplied and outside unit system piping, and the temperature directly to the outside unit system.

  • Page 72: Caution For Refrigerant Leak

    Caution For Refrigerant Leak Caution For Refrigerant Leak The installer and system specialist shall secure safety against leakage according to local regulations or standards. The following standards may be applicable if local regulations are not available. Introduction Though the R410A refrigerant is harmless and incombustible itself , the room to equip the air conditioner should be large to such an extent that the refrigerant gas will not exceed the limiting concentration even if the refrigerant gas leaks in the room.
  • Page 73 Caution For Refrigerant Leak (3) With partition and without opening which serve as passage of air to adjoining room Outside unit Indoor unit Smallest room n Calculate refrigerant concentration Total amount of replenished In case the result of calculation exceeds refrigerant in refrigerant facility (kg) Refrigerant concentration the limiting concentration, perform the...

  • Page 74: Water Solenoid Valve Control

    Water Solenoid Valve Control Water Solenoid Valve Control Central Control (Use DDC Port) Water Water CN_26 C_Box MAIN PCB CN_24 CN_22 Flow Switch INTERNET 5( A) 5( B) Solenoid Valve Individual Control (Use 220V Out Port) Water Water CN_26 C_Box MAIN PCB CN_24 CN_22...

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