LG LP-8091PC User manual

Package
Air Conditioner
SERVICE MANUAL
MODEL: LP-8091PC
Библиотека СОК 

Contents
1. Preface .................................................................................................................................3
2. Wiring Diagram....................................................................................................................7
3. Dimensions..........................................................................................................................8
4. Operation Details ................................................................................................................9
5. Installation .........................................................................................................................11
6. Operation ...........................................................................................................................23
7. 3-Way Valve........................................................................................................................24
8. Troubleshooting Guide.....................................................................................................31
9. Electronic Control Device.................................................................................................42
10. Schematic Diagram.........................................................................................................44
11. Exploded View and Replacement Parts List.................................................................45
–2–

1. Preface
–3–
This service manual provides various service information, containing the mechanical and electrical parts and etc.
This package air conditioner was manufactured and assembled under the strict quality control system.
The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.
1.1 Safety Precautions
①When servicing the unit, set the main SWITCH to OFF and remove the POWER SUPPLY cables.
②Observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or
damaged by the short circuit.
③After servicing the unit, make an insulation resistance test to protect the customer from being exposed to shock
hazards.
1.2 Features
①Design for cooling
②Super energy efficiency
③Micom Control
④Whisper quiet operation
⑤Removable air filter
⑥3 minute delay circuit
⑦7 hour timer
⑧2 step speeds for cooling
⑨Auto Restart

1.3 Product Specifications
–4–
POWER SOURCE (ø, V, Hz)
COOLING CAPACITY Btu/h
W
INPUT W
CURRENT A
MAKER
TYPE
COMPRESSOR MODEL
INPUT W
LRA A
CAPACITY Kcal/h
NOISE INDOOR dB(A)
LEVEL(1m) OUTDOOR
AIR INDOOR CMM
VOLUME OUTDOOR
REFRIGERANT R-22 Kg
HEAT INDOOR R/C/FPI
EXCHANGER OUTDOOR R/C/FPI
FAN INDOOR TYPE
OUTDOOR
ROOM TEMPERATURE CONTROL
NET INDOOR Kg
WEIGHT OUTDOOR
DIMENSIONS INDOOR mm
(W × H × D) OUTDOOR
SVC LIQUID Inch
VALVE GAS (mm)
3, 220, 60
71,400
20,927
9,500
27.6
COPELAND
RECIPRO
QR90K2-ES8
9,500
110
91,000
64
66
50
104
5.4
3/27/17
2/18/17
SIROCO
PROPELLER
MICOM CONTROL
85
150
750
× 1,800 × 480
1,000
× 965 × 370
1/2
3/4
MODEL
LP-8091PC

–5–
1.4 Functions
Indoor Unit
Power Switch ON/OFF
Operation Mode Control
Sensing the room temperature
Controlling the room temperature
Starting Current Control
Sensing Heat Exchanger Temperature
Timer Delay Safety Control
Indoor Fan Speed Control
Operation Indication lamps
Temperature Setting
Airflow Direction Control
Room temperature Display
Timer Control
• Cooling, Fan ➔ Cooling Model
• Room temperature sensor (Thermistor)
• Maintains the room temperature in accordance with the setting temperature.
• Indoor fan is delayed for 3 sec at the starting.
• Heat exchanger temperature sensor (Thermistor)
• Restarting is inhibited for approx. 3 minutes.
• High, Low
• Up : up to 30°C
• Down : down to 16°C
• Airflow direction Manual control
• Low, 10° ~ 35°C, Hi
• Off Timer (1, 2, 3....7 hour)

–6–
Outdoor Unit
Outdoor Fan Speed Control
Sensing discharge pressure for compressor
• One speed
• Discharge pressure sensor(High Pressure Switch)

2. Wiring Diagram
Indoor Unit
–7–
ROOMTH
EVA TH
Tmo
THERMISTOR FOR INDOOR TEMP.
THERMISTOR FOR EVA TEMP.
TERMINAL BLOCK(OUTDOOR)
FMi
Ci INDOOR FAN MOTOR CAPACITOR FOR FAN(INDOOR) RY3 Tmi RELAY FOR COMP.
TERMINAL BLOCK(INDOOR)
P/No.:3854AP2687R
BL
BK
BR
OR
RD
NOTE
SUB PCB ASM
MAIN PCB ASM
Tmi
INDOOR OUTDOOR
FIELD WIRING
6
5
4
3
2
1Tmo
6
5
4
3
2
1
DISPLAY PCB ASM
ROOM
TH
EVA
TH
Ci
BR OR
CN1
CN2
YL
BL
RD
BK
WH
CN3
RY3
BK
BL
YL
FMi
RY2
RY1 FUSE
(10A)
FUSE
250V
T3.15L
:
:
:
:
:
BLUE
BLACK
BROWN
ORANGE
RED
WH
YL
GN
GN/YL
:
:
:
:
WHITE
YELLOW
GREEN
GREEN/YELLOW
SM
CONNECT TO CONTACT
"R", "T" OF OUTDOOR
TERMINAL BLOCK "A"(1ø,220V)
NOTICE
1. Basic wiring is 3ø,3W,220V,60Hz.
2. For changing the running
voltage to 380V, please change
the wiring by the next steps
1st) Remove the "a" wires from
the 'R' of the terminal block 'A'
and connect the wire to the
'N' of the terminal block 'A'.
2nd) Remove the "b" wire from the
'2' of 52C and connect the wire
to the 'N' of the terminal block 'A'.
3rd) Change the compressor
wires like an example.
4rd) For setting the E.O.C.R current
FIELD WIRING
380V WIRING
220V WIRING
TERMINAL
BLOCK 'A'
3ø3W
220V 60Hz
POWER SUPPLY
3ø4W
380V 60Hz
POWER SUPPLY
Co1
FMo1 FMo2
COMP
UZ
VWXY
Co2
BK
WH
BK TmiTmo
1
2
3
4
5
6
1
2
3
4
5
6
BK
BK
RD
WH
1
2
3
4
5
6
31
B
A
32
L1 L2 Tb Ta
YL BR BK OR YL BR BK OR
Tc
OR
BK
WH FUSE(5A)
FUSE
(
5A
)
RD WH
BK
RD
BL
BK
BK
51C
63H
BL
CH
WH
RD
RD
OR
52C
b
a
R S T N
BL
BK
BR
FMo1,2
Co1,2 OUTDOOR FAN MOTOR RUN CAPACITOR FOR FAN
(
OUTDOOR
)
63H
CH
HIGH PRESSURE SWITCH
CRANKCASE HEATER
51C
52C EOCR
(
COMP.
)
MAGNETIC CONTACTOR Tmo Tmi
P/NO ; 3854AP2687S
TERMINAL BLOCK(OUTDOOR)
TERMINAL BLOCK(INDOOR)
BLUE
BLACK
BROWN
:
:
:
OR
RD
WH
ORANGE
RED
WHITE
:
:
:
YL
GN
GN/YL
YELLOW
GREEN
GREEN/YELLOW
:
:
:
NOTE
Power supply
3ø,220V,60Hz
3ø,380V,60Hz
Current
(
A
)
40
24.2
Time
(
sec.
)
5
5
3ø,3 wires,220V.
UXY
ZXY Z
V
W
UV
W
3ø,4 wires,380V.
OUTDOOR INDOOR
Outdoor Unit

3. Dimensions
–8–
Indoor Unit
Outdoor Unit
Earth screw Drain hole
Connecting cable and
liquid/gas side piping hole
Liquid side piping hole
Air inlet vent
Air outlet vent
Window display
750
250728
1800
780
134 725
210
305
490
700 650
963 930
582
185
125
546
1245
700 50
260
95 80
Air Outlet Vent
Air Inlet Vent

–9 –
4. Operation details
■The function of main control
1. Time Delay Safety Control
•3min... The compressor is ceased for 3 minutes to balance the pressure in the refrigeration cycle.
(Protection of compressor)
•3sec... The indoor fan is ceased for 1~3 seconds to prevent relay noise.
(Protection of fan relay and micro chip)
2. Cooling Mode Operation
•When selecting the Cooling( ) Mode Operation, the unit will operate according to the setting by the
controller and the operation diagram is as following
3. Protection of the evaporator pipe from frosting
•Compressor and outdoor fan stop when indoor pipe temperature is below -2°C and restart at the pipe temperature
is above 12°C.
4. Child Lock function
The procedure is as the following
1st: Press the 2 buttons of the temperature control simultaneously, to raise-to lower on the Display Panel of the
product for more 3 seconds.
2nd: The buzzer sounds and then the window of Display Panel shows
LLOOCC
(LOC) mark.
3rd: To release this function, the reverse again the operating procedure could be done.
※During this function is operating, any buttons of Display Panel don't work.
Intake Air temp.
Setting Temp. +1°C
(Compressor ON)
Setting Temp. -1°C
(Compressor OFF)
Indoor Fan Speed Selecting
fan speed Selecting fan speed Selecting fan speed Selecting fan speed Selecting fan speed
3 minutes 3 minutes
Compressor ON OFF ON OFF ON

5. Off Timer Function
This function is to set the time of stopping the unit operation.
The procedure is as the following.
1st: Press the timer set button on the Remocon.
2nd: The buzzer sounds and then the display window shows the Off-Time to be set as 1:00→... →7:00 →0:00.
- The Off-Time is shifted as the following by each press.
- If you select '0:00', the Off-Timer function will be cancelled.
- During Off-Timer Operation, if you repress the timer set button, the rest time will be displayed.
6. Alarm mode display / only displayed while operating.
CCHH00
: The sensor for sensing room temperature is open or short.
CCHH11
: The sensor for sensing piping temperature of evaporator is open or short.
7. Function for test operation.
This function shall be operated while the set not operating and start while set temperature set button(▼) down
and start/stop buttons pressing continuously for 3 seconds.
If you press start/stop button continuously for 3 seconds while set temp down button pressing once more test
operation and the set shall be stopped.
After test operation operating and 18 minutes, test operation and the set shall be stopped.
If you press start/stop button while test operation operating, test operation shall be stopped and the set shall
start.
When test operation operating, the display of
8888::8888
shall be shifted to tESt
Regardless of outside temperature, the set operates when test operation.
8. Function of changing set temperature when re-operation after stop.
Cooling operation is set to the previous set temperature when re-operation with start/stop button.
1.Operation mode.
Cooling →Cooling mode
2. Setting the set temperature when cooling operation.
Room temperature > Set temperature: to be set to the previous set temperature.
Room temperature ≤Set temperature
a) Room temperature ≥26°C: to be set to 24°C
b) 22°C ≤Room temperature ≤25°C: to be set to 21°C
c) Room temperature ≤21°C:to be set to -1°C less than room temperature.
9. Auto Restart
In case the power comes on again a power failure, Auto Restarting Operation is the function to operate proce-
dures automatically to the previous operating conditions.
–10 –
1:00 2:00 3:00 4:00 5:00 6:00 7:00 0:00

5-1. Installation of Indoor, Outdoor unit
1) Selection of the best location
➀Indoor unit
•There should not be any heat source or steam
near the unit.
•There should not be any obstacles to prevent the
air circulation.
•A place where air circulation in the room will be
good.
•A place where drainage can be easily obtained.
•A place where noise prevention is taken into con-
sideration.
•Do not install the unit near the door way.
•Ensure the spaces indicated by arrows from the
wall, ceiling, fence, or other obstacles.
➁Outdoor unit
•If an awning is built over the unit to prevent direct
sunlight or rain exposure, be careful that heat
radiation from the condenser is not restricted.
•There should not be any animals or plants which
could be affected by discharged hot air.
•Ensure the space indicated by arrows from the
wall, ceiling, fence, or other obstacles.
–11–
5. Installation
5cm
A
B
Indoor unit
Outdoor unit
50cm 50cm
50cm
150cm
5cm 40cm
100cm
➂Piping length and the elevation
3/4" 1/2" 50 35
80K
(Btu/h)
PIPE SIZE
MODEL
GAS SIDE LIQUID SIDE
Max.
Length
A (m)
Max.
Elevation
B (m)

–12–
2) Indoor Unit installation
➀The mounting floor should be strong and solid
enough to prevent it from vibration.
➁Drill the piping hole with 70mm diameter hole-
core drill at either the right or the left of indoor
unit. The hole should be sightly slant to the out-
door side.
3) Outdoor unit Installation
➀Install the outdoor unit on the concrete or any
solid base securely and horizontally.
➁If there is any vibration transmitted to the build-
ing, mount the rubber underneath the outdoor
unit.
4) Refrigerant amount
Before shipment, this air conditioner is filled with
the rated amount of refrigerant including additional
amount required for air-purging, subject to 5m pip-
ing length. (The rated amount of refrigerant is indi-
cated on the name plate.) But when the piping
length exceeds 5 meters, additional charge is
required according to the following table.
(Unit: g)
Example) 72K~80K
In case of 10m long pipe(one-way), the amount of
refrigerant to be replenished is:
(10 - 5) ×80 = 400g
200mm
70mm 70mm
90mm
Wall
Core Drill
MODEL
80K
REFRIGERANT CHARGE
80 per 1m

No. Installation works Descriptions
1 Preparation of tools and installation parts Preparation of installation
2 Flaring the pipes To insert the flare nuts, mounted on the
connection parts of both indoor and
outdoor unit, onto the copper pipes.
3 Pipe bending To reduce the flow resistance of refrigerant.
4 Connection of installation parts Connection of long piping
(elbows, socket etc)
5 Tighten the flare nut (outdoor) Connecting the pipings of the outdoor unit.
6 Blowing the pipings To remove dust and scale in working.
7 Tighten the flare nut (indoor) Connecting the pipings of the indoor unit.
8 Check a gas-leakage of the connecting
part of the pipings.
9 Air purging of the piping and indoor unit The air which contains moisture and which
remains in the refrigeration cycle may cause a malfunction on the
compressor
10 Open the 3-way (liquid side) and
3-way (gas side) valves.
11 Form the pipings To prevent heat loss and sweat
12 Checking the drainage (indoor unit) To ensure if water flow drain hose of indoor unit.
13 Connecting the cable between outdoor Preparation of the operating
and indoor unit
14 Connecting the main cable to outdoor unit
–13–
5-2. Installation Method
1) Procedure

–14–
2) Preparation of installation parts and tools
No. Installation Parts, Tools Use
1 Pipe cutter (MAX 35mm Copper pipe) Cutting the pipings
2 Remear Remove burrs from cut edges of pipes.
3 Wrench (H5, H4 hexagonal wrench) To open the service valve
4 Pipe bender Bending the pipings
5 Leak detector Check a gas-leakage of connecting part
of the pipings
6 Manifold gauge To measure the pressure, to charge the refrigerant
7 Charge-nipple To connect the bombe
8 Vacuum pump To remove the air in the pipe.
9 Charge cylinder balance To measure the refrigerant amount
10 Bombe (Freon-22) Gas charge
Air purge
Cleaning the pipe
11 Spanner To tighten the connecting parts of the pipings
12 Monkey spanner
13 Driver( , )
14 Benchi (150mm) Cutting the wires
15 Tapeline To measure the length
16 Core drill To make holes through the concrete wall and blocks
17 Voltmeter, Amperemeter, Clampmeter To measure the current and voltage
18 Insulation resistance tester To measure the insulation resistance
19 Glass thermometer To measure the intake and outlet air temperature of the indoor unit
20 Copper tubes To use the connecting pipings
21 Insulation material To cover the connecting pipings
22 Tape To finish the connecting pipings
23 Electrical Leakage Breaker To shut off the main power
24 Cable To connect the cable from outdoor unit to indoor unit
27 Drain hose sockets, elbows To remote the condensing water

–15–
➀Cut the pipes and the cable
•Use the accessory piping kit or the pipes
purchased locally.
•Measure the distance between the indoor and
the outdoor unit.
•Cut the pipes a little longer than measured
distance.
•Cut the cable 1.5m longer than the pipe length.
➁Remove burrs.
•Remove burrs from cut edges of pipes.
•Turn the pipe end down to avoid the metal pow-
der entering the pipe.
Caution:
If burrs are not removed, they may cause a gas
leakage.
2) Connection of piping
➀Move the indoor tubing and drain hose to the hole
•Remove tubing holder and pull the tubing out of the chassis.
➁Replace the tubing holder into original position
➂Route the tubing and the drain hose staight backwards.
➃Insert the connecting cable into the indoor unit through the hole.
•Do not connect the cable to the indoor unit
•Make a small loop with the cable for easy connection later.
➄Tape the tubing and the connecting cable.
➅Indoor unit installation.
➆Connecting the pipings to the indoor unit.
•Align the center of the pipings and suffciently tighten the flare nut with fingers.
•Finally, tighten the flare nut with troque wrench until the wrench clicks.
When tightening the flare nut with troque wrench, ensure the direction for tightening follows the arrow on the
wrench.
90°
Pipe cutter
Slanted Rough
Pipe
Point down
Reamer
5-3. Piping of Indoor Unit
1) Preparation of piping

–16–
3) Precautions in bending
➀ If it is necessary to bend or stretch the tubing,
use the spring which is attached to the tubing in
stead of pipe bender.
•Please make a careful notice to make a smooth
line.
•Hold the tubing with your two hands closely and
then bend or stretch it slowly not to make any
crack.
•Remember that the radius (R) should not exceed
70mm (Refer to Fig. 1)
➁Do not repeat the bending process to prevent the
tubing from cracking or crushing.
➂Keep in mind that the bending part should not be
cracked and make the radius (R) as long as possible
(Refer to Fig. 2)`
Spring
R70mm
(Fig. 1)
(Fig. 2)
R
5-4. Connecting Piping to Outdoor Unit
1) Connecting pipings to the outdoor unit
➀Upon connecting 4-way valves, please weld connecting pipes using elbows instead of connecting pipes with
flare nuts.
5-5. Connecting the Cable
➀Open the control board cover from the outdoor unit by
removing the screws.
➁ Connect wires to the terminals on the control board
individually and secure the cables onto the control
board with clamp.

MODEL Circuit breaker capacity
80K 50A
(BTU/h)
–17–
5-6. Power Supply and Wiring
Voltage
Time
Starting point
Power source voltage
working voltage
Starting voltage
The unit is completely wired internally at the factory
according to general rule of electrical technology, but
local rules, if they are required, should be complied
with.
1) Power Supply
Power source must fulfill the following conditions:
①The working voltage should be higher than
90% and lower than 110% of the rated voltage
marked on the name plate.
②The starting voltage should be higher than
85% of the rated voltage marked on the name
plate.
②Provide a recognized circuit breaker as below
between power source and unit.
A disconnection device to adequately discon-
nect all supply lines must be fitted.
(for service operations)
③The screws which fasten the wiring in the cas-
ing of electrical fittings are liable to come loose
from vibrations to which the unit is subjected
during the course of transportation. Check
them and make sure that they are all tightly fas-
tened.
(If they are loose, it could give rise to burn-out
of the wires.)
④See to it that the starting voltage is maintained
at more than 90 percent of the rated voltage
marked on the name plate.
⑤The following troubles would be caused by volt-
age drop-down.
Vibration of a magnetic switch, damage on the
contact point there of, fuse breaking, distur-
bance to the normal function of a overload pro-
tection device.
2) Wiring
After the confirmation of the above conditions, pre-
pare the wiring as follows:
①Use the power supply cord(Rubber insula-
tion, type Ho7RNF approved by HAR or SAA)
suitable for the product's electriccal capacity.
MODEL
80K
(BTU/h)
VOLTS
Conductor
cross-sectional area
220/ 380V 5.5mm2

–18–
5-7. Air Purging of the Piping and Indoor Unit
No leakage found leakage found
leakage ceased
leakage ceased
leakage persists
Outdoor unit
To indoor unit
Hexagonal wrench
Service port cap
3-way valve cap
(liquid side)
3-way valve cap
(gas side)
The air which contains moisture and which remains in
the Refrigeration cycle may cause a malfunction on the
compressor.
①Remove the caps from the 4-way(liquid side)
and 4-way(gas side) valves.
②Remove the service-port cap from the 3-way
(gas side) valve.
③To open the valve, turn the valve stem of 3-way
(liquid side) valve counter-clockwise approx. 90°
and hold it there for ten seconds, then close it.
④Check a gas-leakage of the connecting portion
of the pipings.
⑤To open 3-way(liquid side) valve
again, turn the valve stem counter-
clockwise until it stops.
⑥To purge the air, push the pin on the service port
of 3-way(gas side) valve for three seconds using
with a hexagonal wrench and set it free for one
minute.
•Repeat this three times.
Result
•Re-tighten the connecting portion with
torque wrenches.

–19–
⑦ Set the both 3-way(liquid side) and 3-way(gas side) valves to open position with the Hexagonal
wrench for the unit operation.
⑧ Checking a gas leakage for the left piping
•Connect the manifold gauge to the service port of 3-way(gas side) valve.
Measure the pressure.
•Keep it for 5 - 10 minutes.
Ensure if the pressure indicated on the gauge is as same as that of measured at first time.
CLOSE CLOSE
Closed
Closed
Indoor unit
Outdoor unit
Liquid side
Gas side

–20–
5-8. Checking the Drainage and Form the Piping
1) Checking the Drainage
①Remove the inlet grille.
②Check the drainage.
•Pour a glass of water into the drain pan.
•Ensure if water flows drain hose of indoor unit.