LG Air-to-Water Heat Pump Monobloc Engineering Manual

Proprietary Data Notice

This document, as well as all reports, illustrations, data, information, and other materials are the property of LG Electronics U.S.A., Inc., and are disclosed by LG Electronics U.S.A., Inc. only in confidence. This document is for design purposes only.

For more technical materials such as submittals, catalogs, installation, owner's, and service manuals, visit www.lghvac.com.

A summary list of safety precautions is on page 4.

For continual product development, LG Electronics U.S.A., Inc., reserves the right to change specifications without notice. © LG Electronics U.S.A., Inc.

Table of Contents Overview

This manual covers various aspects of the LG Air-to-Water Heat Pump Monobloc units. Key sections include:

• Unit Nomenclature and Model Description
• LATS AWHP Program for system design
• Product Data: General Specifications, Accessories, Dimensions, Acoustic Data, Refrigerant Flow and Water Cycle Diagrams, Hydraulic Performance, Wiring Diagrams, Electrical Connections, Dip Switch Settings, and Operation Ranges.
• Performance Data: Detailed Cooling and Heating Capacity Tables.
• Placement Considerations, Transporting/Lifting, and Foundation Requirements.
• Water Control and Water Piping guidelines.

Table of Symbols

• ⚠️ DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• ❗ WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• ⚠️ CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
• ℹ️ Note: Indicates situations that may result in equipment or property damage accidents only.
• [Action Not Allowed Symbol]: Indicates an action that must not be performed.

Unit Nomenclature

The unit nomenclature follows a specific structure to identify product features:

LATS AWHP Program

The LATS (LG Air Conditioner Technical Solution) AWHP Program is a free software offered by LG for designing and selecting LG air conditioning systems. It provides detailed analysis for Air-to-Water Heat Pump (AWHP) applications, including monthly and annual heating energy consumption, system comparison, payback periods, and CO2 emission data. LG requires the use of this software for all projects to ensure proper system design and operation.

General Data / Specifications

Nominal Capacity Specifications (Table 1)

This table provides general data for the Monobloc units, detailing nominal capacity and input under various outdoor and leaving water temperatures. It lists Cooling (Btu/h) and Heating (Btu/h) capacities, along with Cooling (kW) and Heating (kW) power input, EER (Energy Efficiency Ratio), and COP (Coefficient of Performance).

Electrical Specifications (Table 2)

This table outlines the electrical data for the Monobloc units, including Power Supply (V/Ø/Hz), Peak Control Running Current (A), Rated Running Current (Cooling and Heating in A), Circuit Breaker rating (A), Power Supply Cable specifications (6.0 mm², 10 AWG x 3 cores, including Earth, H07RN-F), and Voltage Range (Min. to Max.).

Unit Data (Table 3)

This section details unit specifications such as Sound Power Levels (Daytime Max, Rated, Low Noise) and Sound Pressure Levels for heating. It also lists Net Dimensions (W x H x D in inches), Shipping Dimensions, Net Weight (lbs), Shipping Weight (lbs), Exterior Color (Warm Gray), and RAL Code (RAL 7044).

Water Specifications (Table 4)

Details on water-related specifications are provided, including Operation Range (Leaving Water Temp. for Cooling, Heating, DHW), Water Pump type (GRUNDFOS UPML 20-105 CHBL, BLDC motor, variable speed), Expansion Vessel capacity, Flow Sensor model, Water Pressure sensor model, Piping Connections (Male PT 1" tapered pipe threads), Strainer mesh size, and Relief Valve pressure limit.

Refrigerant Specifications (Table 5)

This table covers refrigerant-related data, including Operation Range (Outdoor Temp. for Cooling and Heating), Compressor type (Hermetic Sealed Scroll), Refrigerant type (R32), Global Warming Potential (GWP), Precharged Amount, Refrigerant Oil type, Heat Exchanger specifications, and Fan/Fan Motor details.

Accessories

Various accessories are available for the KPHTC411M, KPHTC481M, and KPHTC551M models, including sensors, control accessories, gateways, and interface modules, each with specific model numbers.

Dimensions

Detailed diagrams illustrate the unit dimensions and clearance requirements for installation. These diagrams show the overall size of the unit in millimeters and inches, including specific points for drain holes and recommended clearances for optimal operation and maintenance.

Acoustic Data

Sound Power Levels (Table 6)

This table presents Sound Power Levels in dB(A) for heating, categorized into Daytime Max, Rated, and Low Noise modes for each model.

Sound Power Graphs

Graphical representations show Sound Power Levels across different Octave Band Center Frequencies (Hz) for each model, illustrating the sound output characteristics under various operating modes.

Refrigerant Flow Diagram

A diagram illustrates the refrigerant flow path through the Monobloc unit, detailing components like the accumulator, compressor, expansion valves, heat exchangers, and sensors, along with their corresponding PCB connectors.

Water Cycle Diagram

Diagrams depict the water cycle for different system configurations, including connections for Solar Thermal Systems, DHW tanks, and basic installations. The legend explains various components and symbols used in the diagrams.

Hydraulic Performance

Information on the water pump's variable flow rate capability and recommendations for setting capacity are provided. Pressure Drop data (Table 7) details the head and pressure drop characteristics for different capacities. A Q-H chart illustrates the performance of the GRUNDFOS Water Pump (UPML 20 - 105 CHBL), showing the relationship between flow rate (Q) and head (H) at various operating percentages.

Wiring Diagram

A comprehensive wiring diagram is provided, illustrating the electrical connections for the Inverter PCB, Main PCB (Cycle), and Main PCB (Hydronic) for the unit models.

Electrical Connections

Electrical Data

This section presents electrical data for the outdoor units, including Hertz, Voltage, Voltage Range, MCA, MOP, Compressor Quantity, Compressor Motor RLA (Heating), and Other Motor specifications (Fan Motor, Water Pump).

General Power Wiring / Communications Cable Guidelines

Provides essential guidelines for power wiring and communication cable connections, emphasizing safety precautions, proper grounding, conduit usage, and compliance with local codes. It includes critical warnings regarding electric shock and fire hazards due to improper wiring.

Dip Switch Settings

Detailed instructions are provided for setting the dip switches on the control boards for various functions, including MODBUS communication, antifreeze agent settings, accessory installation, cycle modes, room air sensor integration, electric heater capacity, and thermostat configuration. Information on outdoor PCB dip switches for noise modes and peak control is also included, along with running current data.

Operation Range

Graphical representations illustrate the operational limits of the units under various conditions. These include Cooling Operation Ranges and Heating Operation Ranges, defining the boundaries for Continuous Operation and Operative states based on Outdoor Temperature and Water Temperature (Leaving or Entering).

Performance Data

Maximum Cooling Capacity Tables

Detailed tables provide Maximum Cooling Capacity and EER values for KPHTC411M and KPHTC481M models across various outdoor temperatures and leaving water temperatures, at specified water flow rates.

Maximum Heating Capacity Tables

Detailed tables provide Maximum Heating Capacity and COP values for KPHTC411M, KPHTC481M, and KPHTC551M models, including defrost effect. These tables cover various outdoor temperatures, leaving water temperatures, and water flow rates.

Placement Considerations

Selecting the Best Location for the Unit

Provides critical safety information (DANGER, WARNING, CAUTION) regarding unit placement, emphasizing avoiding areas with combustible gases, acidic solutions, oil, steam, or sulfuric gas. It also advises on selecting locations that ensure proper airflow, accessibility for maintenance, and suitable drainage. Specific "Don'ts" are listed, such as avoiding direct thermal radiation, high-frequency noise, and areas with strong winds. Notes on performance reduction in winter due to location are also included.

Installation

Condensate Drain Piping: Outdoor units require drain piping constructed with locally approved materials.

Planning for Snow and Ice: Measures for severe winter conditions are outlined, including positioning fans away from snowfall, clearing accumulated snow, using raised platforms, and installing snow protection hoods. Tie-down requirements for high winds are also mentioned.

Clearances

Diagrams illustrate required clearances around the unit for proper ventilation and access, including space for shut-off valves and strainers. Minimum distances are specified in inches.

Transporting / Lifting

Guidelines for safely transporting and lifting the unit are provided. This includes using appropriate lifting straps, ensuring proper angles, and employing suitable moving equipment. Warnings highlight the risks of physical injury or death due to improper handling, sharp edges, and the use of incorrect lifting materials. Recommendations for using forklifts and protecting painted surfaces are also included.

Diagrams show moving requirements, illustrating how to attach lifting straps and use forklifts.

Foundation For Installation

General Mounting

Requirements for the underlying structure and foundation are detailed, emphasizing the need to support the unit's weight and avoid low-lying areas. It advises referring to the installation manual and local codes for clearances, mounting, anchoring, and vibration attenuation. Checking the ground's strength and level is crucial. The process of removing the pallet (wood support) before installation and securing the unit with foundation bolts (M12) is described.

Diagrams illustrate bolting requirements and the foundation bolt executing method, showing dimensions in mm (inches) and the necessary components like spring washers, anti-vibration materials, and concrete base.

Water Control

Water Quality

Water quality must comply with EN 98/83 EC Directives. Recommendations include cleaning hydraulic pipes, installing sludge strainers, chemical treatment for rust prevention, and using additional filters for metallic particles. Water quality checks are essential before system installation. Specifications for pH, Conductivity, TDS, Alkalinity, Total Hardness, Iron, Sulphate, Nitrite, Free Chlorine, and Chlorides at different temperatures are detailed.

Frost Protection

For areas with entering water temperatures below 32°F, protection with an approved antifreeze solution is required. Recommended antifreeze types (Ethylene glycol, Propylene glycol, Methanol) and their mixing ratios for various temperatures are listed. Notes emphasize using only one type, adding corrosion inhibitors, checking concentration, and following local laws.

Capacity Correction Factor by Antifreeze

Diagrams show capacity correction factors for cooling and heating based on antifreeze type and concentration (% by wt).

Water Piping

Water Piping and Water Circuit Connection Guidelines

General considerations for water circuit connection include securing service space, cleaning pipes, providing space for external pumps, and avoiding connecting power during water charging. Water piping involves installing pipes for water flow, and water circuit connecting refers to making connections between unit and pipes. A buffer tank is recommended for load fluctuations. Installation considerations include closing pipe ends, ensuring pipe integrity after cutting/welding, and providing drain piping for safety valve discharge. Connection guidelines emphasize leak-proof fittings, proper sealing, using appropriate tools, and limiting flow control valve operation time.

Water Condensation

For underfloor cooling, maintaining leaving water temperature above 60.8°F is crucial to prevent dew condensation. In humid environments, the temperature should not drop below 64.4°F. For radiators, a 2-way valve is recommended to block cooling circuits if cold water is present to prevent dew generation.

Drainage

Condensed dew during cooling operation must be drained from the unit and dissipated frost-free.

Company Information

LG Electronics, U.S.A., Inc. Air Conditioning Technologies, located at 4300 North Point Parkway, Alpharetta, Georgia 30022. Website: www.lghvac.com.

Document supersedes previous versions: EM_AWHP_Monobloc_03_24, EM_AWHP_Monobloc_12_23.