LG PRLK594A0 Installation guide

Brand: LG

Model: PRLK594A0

Type: Installation guide

The LG PRLK594A0 is a modern EEV kit suitable for use with air conditioners. It helps to precisely control the refrigerant flow, leading to improved energy efficiency and enhanced cooling performance. The kit includes an EEV controller module, thermistors, and other necessary components for hassle-free installation. With the LG PRLK594A0, you can expect better temperature regulation, reduced energy consumption, and a more comfortable indoor environment.

MFL70524401

Rev.00_053018

INSTALLATION MANUAL

Applied(AHU)

EEV KIT

Original instruction

AIR

CONDITIONER

www.lghvac.com

www.lg.com

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.

ENGLISH

FRANÇAIS

ESPAÑOL

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TIPS FOR SAVING ENERGY

ENGLISH

• Do not cool excessively indoors. This may be harmful for your health and may consume more

electricity.

• Block sunlight with blinds or curtains while you are operating the air conditioner.

• Keep doors or windows closed tightly while you are operating the air conditioner.

• Adjust the direction of the air flow vertically or horizontally to circulate indoor air.

• Speed up the fan to cool or warm indoor air quickly, in a short period of time.

• Open windows regularly for ventilation as the indoor air quality may deteriorate if the air

conditioner is used for many hours.

• Clean the air filter once every 2 weeks. Dust and impurities collected in the air filter may block the

air flow or weaken the cooling / dehumidifying functions.

For your records

Staple your receipt to this page in case you need it to prove the date of purchase or for warranty

purposes. Write the model number and the serial number here:

Model number :

Serial number :

You can find them on a label on the side of each unit.

Dealer’s name :

Date of purchase :

Here are some tips that will help you minimize the power consumption when you use the air

conditioner. You can use your air conditioner more efficiently by referring to the instructions

below:

TIPS FOR SAVING ENERGY

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IMPORTANT SAFETY INSTRUCTIONS

READ ALL INSTRUCTIONS BEFORE USING THE APPLIANCE.

Always comply with the following precautions to avoid dangerous situations and ensure peak

performance of your product.

WARNING

It can result in serious injury or death when the directions are ignored.

CAUTION

It can result in minor injury or product damage when the directions are ignored.

WARNING

• Installation or repairs made by unqualified persons can result in hazards to you and others.

• Installation MUST conform with local building codes or, in the absence of local codes.

• The information contained in the manual is intended for use by a qualified service technician familiar

with safety procedures and 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 and/or death.

Installation

• Don’t use a power cord, a plug or a loose socket which is damaged.

- Otherwise, it may cause a fire or electrical shock.

• For electrical work, contact the dealer, seller, a qualified electrician, or an Authorized Service Center.

- Do not disassemble or repair the product. There is risk of fire or electric shock.

• Always ground the product.

- There is risk of fire or electric shock.

• Install the panel and the cover of control box securely.

- There is risk of fire or electric shock.

• Always install a dedicated circuit and breaker.

- Improper wiring or installation may cause fire or electric shock.

• Use the correctly rated breaker or fuse.

- There is risk of fire or electric shock.

• Do not modify or extend the power cable.

- There is risk of fire or electric shock.

• Do not let the air conditioner run for a long time when the humidity is very high and a door or a

window is left open.

- Moisture may condense and wet or damage furniture.

• Be cautious when unpacking and installing the product.

- Sharp edges could cause injury. Be especially careful of the case edges and the fins on the

condenser and evaporator.

• You need to use a safely insulated power supply which follows IEC61558-2-6 and NEC Class2.

- If you do not follow, It may cause fire, electric shock, explosion or injury.

• Securely attach the electrical part cover to EEV Controller Module.

- If the electric part cover of EEV Controller Module is not attached securely, it could result in a fire

or electric shock due to dust, water, etc.

• Do not keep or use flammable gases or combustibles near the equipment.

IMPORTANT SAFETY INSTRUCTIONS

ENGLISH

1,MFL70524401,영영 2018. 7. 23. 영영 5:04 Page 3

- Otherwise, it may cause a fire or the failure of product.

• Do not install, remove or reinstall the unit by yourself.

- Otherwise, it may cause a fire, electrical shock, explosion or injury.

• Do not disassemble or repair the product randomly.

- It will cause a fire or electrical shock.

• Do not install the product in a place where there is the concern of falling down.

- Otherwise, it may result in personal injury.

• Do not install the product on a defective installation stand.

- It may cause injury, accident, or damage to the product.

• Be sure the installation area does not deteriorate with age.

- If the base collapses, the air conditioner could fall with it, causing property damage, product failure,

and personal injury.

• There is a risk of fire and explosion.

- Inert gas (nitrogen) should be used when you check plumbing leaks, cleaning or repairs of pipes

etc. If you are using combustible gases including oxygen, product may have the risk of fires and

explosions.

Operation

• Do not store or use flammable gas or combustibles near the product.

- There is risk of fire or failure of product.

• Do not share the outlet with other appliances.

- It will cause an electric shock or a fire due to heat generation.

• Do not use the damaged power cord.

- Otherwise, it may cause a fire or electrical shock.

• Do not modify or extend the power cord randomly.

- Otherwise, it may cause a fire or electrical shock.

• Take care so that the power cord may not be pulled during operation.

- Otherwise, it may cause a fire or electrical shock.

• Unplug the unit if strange sounds, smell, or smoke comes from it.

- Otherwise, it may cause electrical shock or a fire.

• Keep flames away.

- Otherwise, may occur a fire.

• Take the power plug out if necessary, holding the head of the plug and do not touch it with wet

hands.

- Otherwise, it may cause a fire or electrical shock.

• Do not use the power cord near the heating tools.

- Otherwise, it may cause a fire and electrical shock.

• Do not allow water to run into electrical parts.

- Otherwise, it may cause the failure of machine or electrical shock.

• Hold the plug by the head when taking it out.

- It may cause electric shock and damage.

• Be cautious that water could not enter the product.

- Otherwise, it may cause a fire electrical shock or product damage.

• Do not step on the indoor/outdoor unit and do not put anything on it.

- It may cause an injury through dropping of the unit or falling down.

• Do not place a heavy object on the power cord.

- Otherwise, it may cause a fire or electrical shock.

• When the product is submerged into water, always contact the service center.

- Otherwise, it may cause a fire or electrical shock.

IMPORTANT SAFETY INSTRUCTIONS

ENGLISH

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IMPORTANT SAFETY INSTRUCTIONS

ENGLISH

CAUTION

Installation

• Always check for gas (refrigerant) leakage after installation or repair of product.

- Low refrigerant levels may cause failure of product.

• Install the drain hose to ensure that water is drained away properly.

- A bad connection may cause water leakage.

• Keep level even when installing the product.

- To avoid vibration or water leakage.

• Do not install the product where the noise or hot air from the outdoor unit could damage the

neighborhoods.

- It may cause a problem for your neighbors.

• Do not install the product where it will be exposed to sea wind (salt spray) directly.

- It may cause corrosion on the product. Corrosion, particularly on the condenser and evaporator

fins, could cause product malfunction or inefficient operation.

• Thickness of copper pipes used are as shown “Flaring work” Table.

- Never use copper pipes thinner than that in the table even when it is available on the market

• Do not use copper pipes having a collapsed.

- Otherwise, the expansion valve or capillary tube may become blocked with contaminants.

• For R410A model, use piping, flare nut and tools which is specified for R410A refrigerant.

- Using of (R22) piping, flare nut and tools may cause abnormally high pressure in the refrigerant

cycle (piping), and possibly result in explosion and injury.

• It is desirable that the amount of residual oil less than 40 mg/10m.

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BEFORE INSTALLATION

ENGLISH

CAUTION

• Don't install or operate the unit in rooms mentioned below.

① Where mineral oil, like cutting oil is present.

② Where the air contains high levels of salt such as air near the ocean.

③ Where sulphurous gas is present such as that in areas of hot spring.

④ In vehicles or vessels.

⑤ Where voltage fluctuates a lot such as that in factories.

⑥ Where high concentration of vapor spray are present.

⑦ Where machines generating electromagnetic waves are present.

⑧ Where acidic or alkaline vapor is present.

⑨ The option boxes must be installed with entrances downward.

BEFORE INSTALLATION

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2 TIPS FOR SAVING ENERGY

3 IMPORTANT SAFETY INSTRUCTIONS

6 BEFORE INSTALLATION

8 Installation Composition

9 EEV KIT installation

9 Product installation

10 Welding

13 ELECTRICAL CONNECTION

13 Cable connection

15 EEV CONTROLLER MODULE SPECIFICATION

15 Dimension

15 Installation

16 EEV CONTROLLER INSTALLATION

16 Electric wiring work (EEV Controller)

17 DIP switch setting

18 LEAK TEST AND VACUUM

18 Leak test

18 Vacuum

20 Electrical work

21 THERMISTORS INSTALLATION

21 Pipe thermistors Installation

TABLE OF CONTENTS

ENGLISH

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INSTALLATION COMPOSITION

ENGLISH

INSTALLATION COMPOSITION

཰

ི

ཱུ

ུ

ཱ

ཱི

ྲྀ

Liquid pipe

Gas pipe

Refrigerant pipe

Pipe sensor

Communication cable

Refrigerant ﬂow (air conditioning)

Refrigerant ﬂow (heating)

This EEV KIT is a product that connects an AHU with an outdoor unit with the following

composition.

installation components

No. Name Notes

1 AIR HANDLING UNIT -

2 AHU EEV KIT

Connectible outdoor unit capacity

PRLK396A0 22 ~ 40 HP

PRLK594A0 42 ~ 60 HP

3 AHU Comm. KIT -

4 Outdoor unit MULTI V

5 Pipe sensor_IN Sensor: Ø 5, length: 5m, cable color: Black

6 Pipe sensor_OUT Sensor: Ø 7, length: 5m, cable color: Red

7 90˚ elbow

PRLK396A0 Ø19.05 (5/8")

PRLK594A0 Ø19.05 (5/8")

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EEV KIT INSTALLATION

ENGLISH

Product installation

1) Remove the two screws

from the EEV KIT's base

plate. Move the screws to

separate the cover plate and

base plate of the EEV KIT.

2) Remove the base plate. 3) Remove the four

screws from the

cover plate

4) Remove the cover

plate.

Drill holes in the correct locations and use 4 screws (M5, not provided) to affix the EEV KIT.

1 Remove the screws to separate the cover plate and base plate of the EEV KIT.

Pipe diameter

Ø19.05 mm (5/8")

Hole size

Ø6 mm (1/4")

Pipe diameter

Ø19.05 mm (5/8")

Model name

length

A B

PRLK594A0

273 mm

(10-3/4")

250.3 mm

(9-6/7")

PRLK396A0

273 mm

(10-3/4")

190.3 mm

(7-1/2")

EEV KIT INSTALLATION

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EEV KIT INSTALLATION

ENGLISH

Welding

1 Check the inlet/outlet pipe before welding the EEV KIT.

AHU side

Outdoor

unit side

Outlet

Inlet

Air-conditioning

standard refrigerant ﬂow

2 Weld the connector pipe (not provided) at the outdoor unit.

3 When connecting the outdoor unit's connector pipe and the EEV KIT pipe, be sure to use a

socket (not provided) that meets the necessary specifications.

4 As the size of the EEV KIT pipe and the outdoor unit's connector pipe could vary, check the

sizes beforehand and use a socket that meets the necessary specifications.

5 When welding, make sure to follow the safety precautions at all times.

6 Be sure to insulate 'A' part after welding with insulation (15T or more).

CAUTION

• Be sure to pass nitrogen through when welding parts together. Failure to do so could lead

to the compressor not working properly or becoming damaged.

• It is essential that the part be wrapped with a wet towel before and after welding. Failure

to do so could result in the part becoming damaged.

• Use a protective panel or be especially cautious not to let welding sparks come in contact

with the AHU panel.

• After welding, be sure to test for any leakage.

• Failure to properly insulate after welding may result in leakage.

Outdoor unit connector pipe

(not included)

Connector socket

(not included)

Connector socket(Elbow)

(not included)

[AHU and Outdoor Unit Connection]

AHU Connection Part

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EEV KIT INSTALLATION

ENGLISH

When conducting welding, you must pass nitrogen through at about 0.02 MPa (0.2 kg/cm

Before proceeding to weld, you must remove all the air from inside the pipe using nitrogen.

Failure to use nitrogen results in the occurrence of oxidation inside the pipe, leading to the

malfunction of the compressor and blocking of the strainer.

WARNING

• While welding, always be careful that no refrigerant leaks.

• When refrigerant combusts, it creates a toxic gas that is harmful to the body.

• Do not conduct welding in an enclosed area.

• After welding a pipe, be sure to test for any leakage.

Welding area

Taping

Pressure regulator

High-pressure hose

Nitrogen

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EEV KIT INSTALLATION

ENGLISH

pipe cutting

1 Be sure to use a copper pipe cutter for the pipe cutting.

2 Remove any burrs.

(When cutting, have the pipe end tilted downward so that any burrs do not get inside of the

pipe.)

Copper

pipe cutter

90°

Incline Roughness

Pipe

Copper

pipe cutter

90°

Incline Roughness

Pipe

CAUTION

• Cut the cutting area in a straight line.

CAUTION

• The presence of burrs can result in refrigerant leakage, so be sure to remove any burrs

with a reamer.

• Cutting dust could lead to malfunctioning if it gets inside the pipe.

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ELECTRICAL CONNECTION

ENGLISH

Cable connection

1 Open the EEV KIT terminal box cover.

2 Check the marked color label and connect the cable using the driver (+).

• Example) Model PRLK594A0

※ PRLK396A0 is a model with one terminal block.

(Correct wiring)

■ AHU controller

Detail

■ AHU EEV controller

WARNING

• Please connect one controller with one terminal block of EEV KIT. Failure to do so may

result in component damage or fire. (Refer to correct wiring.)

• To connect with EEV KIT (PRLK594A0), the AHU EEV controller must be purchased

separately.

(Incorrect wiring)

■ AHU controller

WARNING

• Do not connect to the AHU controller after wiring the terminal blocks inside the EEV KIT.

Failure to do so may result in component damage or fire. (Refer to incorrect wiring.)

ELECTRICAL CONNECTION

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ELECTRICAL CONNECTION

ENGLISH

3 Use the screwdriver (+) to connect the EEV wires to the terminal block (E) according to the

displayed instructions.

Field Wiring Part

Note

BR : Brown

RD : Red

BL : Blue

OR : Orange

YL : Yellow

WH : White

WARNING

• Before installation, check the color on the label and connect it to the terminal block.

• It may result in malfunction.

• Use a ring type terminal (P4) to connect to the terminal block.

4 Close the cover of the EEV KIT terminal box (B).

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EEV CONTROLLER MODULE SPECIFICATION

ENGLISH

91(3.58)

54(2.13) 61(2.4)

Unit : mm(inch)

1. Open the door using the key.

(PAHCMS000)

2. Install the EEV controller module using screws

in the two holes.

CAUTION

• This model requires DC12 V ~ external power supply. (Select an insulating transformer

that complies with IEC61558-2-6 and NEC Class 2.)

• Please check the product operation range below.

Power supply DC 12 V

Product operation range

Ambient temperature -20 ~ 65 °C (-4 ~149 °F) DB

Humidity 0 ~ 98 % (Non-condensing)

Installation

Dimension

EEV CONTROLLER MODULE SPECIFICATION

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EEV CONTROLLER INSTALLATION

ENGLISH

EEV(1ch) EEV(2ch)

NTC

Circuit diagram

* Please refer to the circit diagram of PAHCMS000 for further details.

Electric wiring work (EEV Controller)

EEV CONTROLLER INSTALLATION

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EEV CONTROLLER INSTALLATION

ENGLISH

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 

6:

 

6:

DIP switch setting

• EEV Controller DIP switch 2 (SW02) is for setting modbus addresses, and it is common practice

to follow the table below.(SW01 is ‘reserved’)

SW02

1 2 3 4 Address

1 OFF OFF OFF

ON : Software Update

OFF : -

2 OFF OFF ON 1

3 OFF ON OFF 2

4 OFF ON ON 3

5 ON OFF OFF 4

6 ON OFF ON 5

7 ON ON OFF 6

8 ON ON ON 7

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LEAK TEST AND VACUUM

ENGLISH

Leak tests are carried out to standards identical with the MULTI-V leak test.

Leak tests are carried out by pressurizing nitrogen gas to 3.8MPa (38.7 kgf/cm

). Refer to the

following picture for test methods.

(The service valve should be closed when carrying out tests and pressurizing liquid and gas

pipes.)

After nitrogen gas has been pressurized, pressure must not drop during a 24 hour period.

Low

pressure

High

pressure

Ⓐ Nitrogen gas

Ⓑ Direction of indoor unit

Ⓓ Low-tension grip

Ⓔ High-tension grip

Ⓕ Service valve

Ⓖ Gas pipe

Ⓗ Liquid pipe

Ⓘ Outdoor unit

Ⓙ Service port

Vacuum testing is conducted to standards identical with the MULTI-V vacuum test.

As shown in the picture below, with the outdoor unit's service valve closed, use the vacuum

pump to perform vacuuming of the AHU and connector pipe from the stop valve's service port.

Vacuuming must always be conducted from the service port of liquid and gas pipes.

After maintaining a vacuum level of 5 Torr for one hour, there should be no change in the

vacuum level for another hour.

(If there is a change in the vacuum level, there could be a leak or moisture inside the pipe)

If there is a possibility of moisture inside the pipe, a vacuum must be maintained for 2 hours,

after which 0.05 Mpa (0.5 kgf/cm2) of nitrogen gas is injected.

After this, a vacuum is should be performed for at least one hour, maintained for an hour once 5

Torr is reached, and then the vacuum gauge is checked for changes.

※ Refrigerant should never be used for air purging.

※ Perform vacuuming using a vacuum pump with a vacuum gauge attached.

Vacuum

Leak test

LEAK TEST AND VACUUM

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LEAK TEST AND VACUUM

ENGLISH

Low

pressure

High

pressure

Ⓐ Manifold gauge

Ⓑ Low-tension handle

Ⓓ Service valve

Ⓔ Liquid pipe

Ⓕ Gas pipe

Ⓖ Service port

Ⓗ 3-direction joint

Ⓘ Valve

Ⓙ Valve

Ⓚ R410A cylinder

Ⓛ Scale: using a gravimeter

Use one that measures up to 0.1 kg

If a high-density scale is unavailable, a

charging cylinder can be used.

Ⓜ vacuum pump

- Perform a calculation to add a precise amount of refrigerant.

- Adding an imprecise amount of refrigerant could cause problems for the product.

- If the amount of added refrigerant goes beyond of ±10%, burning of the compressor and

poor performance of the indoor unit could occur.

WARNING

• Pipes that must be vacuumed: gas pipe, liquid pipe

• When installing or moving the product to another location, do not fill with any refrigerants

besides the regulated refrigerant (R410A).

• Mixing the original refrigerant with a different refrigerant can cause malfunctioning or

damage to the refrigerant cycle.

• If injecting gaseous R410A, you should change the refrigerant composition you use to a

liquid form.

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LEAK TEST AND VACUUM

ENGLISH

1 For the wired remote controller wire and outdoor unit communication wire, remove the

coating at the end of the wire to connect and use the pin type (JOBN153) to connect to the

terminal block.

Pin type (JOBN153)

Connection of the wires

Electrical work

CAUTION

• All field supplied parts and materials and electric works must be conform to local codes.

• Use copper wire only.

• All wiring must be performed by an authorized electrician.

• A main switch or other means for disconnection, having a contact separation in all poles,

must be incorporated in the fixed wiring in accordance to relevant local and national

legislation.

• Refer to the installation manual attached to the outdoor unit for the size of power supply

electric wire connected to the outdoor unit, the capacity of the circuit breaker and switch,

wiring and wiring instructions.

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LG PRLK594A0 Installation guide

LG PRLK594A0 Installation guide

LG PRLK594A0 Installation guide

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