ROOM AIR CONDITIONER SERVICE MANUAL
Contents
1. Figure 7 Figure 8 Figure 9 2 2 3 MOTOR A Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 Remove the air guide upper Refer to Section 2 2 1 Remove the compressor turbo fan fan and shroud Refer to Section 2 2 2 Remove 2 screws that secure the motor to the motor See Figure 10 Remove the motor Re install by referring to the procedures above 2 2 4 AIR GUIDE RwWhN 10 Disco2. 29 7 SERVICE PARTS LIST PART NO LOCATION NO DESCRIPTION GWHD6500R GWHD6500RY6 130410 BASE ASSEMBLY SINGLE 3041A10011E 130910 CABINET ASSEMBLY SINGLE 3091A30016C 132111 1 FRAME ASSEMBLY OO Fess GRLLEASSENEDFRONTSNGLE senao R 135313 GRILLE ASSEMBLY INLET 3530A10039A R 137215 GUIDE 5210AR3196C R 145200 LINK 4520AR3191A R 148000 BRACE 4800A30003A R 149980 SHROUD 4998A10008A R 152302 FILTER MECH A C 5231AR2148G R ewi SORROW 159900 2 VANE VERTICAL 5990AR3190D 238310 ESCUTCHEON 3831A10001F 249950 CONTROL BOX SINGLE 4994A20020A 263230 THERMISTOR ASSEMBLY 6323A20003D 267110 REMOTE CONTROLLER ASSEMBLY 6711A90019A 268712 PWB PCB ASSEMBLY DISPLAY 6871A20193B 268714 PWB PCB ASSEMBLY MAIN 6871A20188L 346811 MOTOR ASSEMBLY SINGLE 4681A10002U 352113 TUBE DISCHARGE 5910A21100A 352115 TUBE ASSEMBLY EVAPORATOR IN 5911A10063C 35211A TUBE ASSEMBLY SUCTION SINGLE 5211A10062C 5211A30874A 352390 2 AIR GUIDE Upper 5238A20004B 352901 AR GUDE Lower 354210 EVAPORATOR ASSEMBLY FIRST 5421A20016G 359012 FAN TURBO 5900A10005A 550140 ISOLATOR COMPRESSOR 5040AR4195A 552111 TUBE ASSEMBLY CAPILLARY 5211A30793C 5211A30793D COWENERASSEeN FAST E 554160 COMPRESSOR SET 2520UCEA
3. 346 13 5 6 5 0 8 3 32 AG 4 2 PIPING SYSTEM CONDENSER COILS FAN CAPILLARY TUBE MOTOR TURBO FAN EVAPORATOR COILS Following is a brief description of the important components and their function in what is called the refrigeration system Reference should be made to Figure 33 to follow the refrigerating cycle and the flow of the refrigerant in the cooling cycle ROOM AIR CONDITIONER CYCLE OF REFRIGERATION EVAPORATOR COILS CONDENSER COILS SUCTION LINE VAPOR INLET COMPLETE LIQUID COOL LOW PRESSURE VAPOR V SZ lt pr A gt OUTSIDE COOLING AIR FOR REFRIGERANT 7 PASS THROUGH 77 LIZZ DISCHARGE BASSAR NOT HIGH PRESSURE LIQUID 7 7 PRESSURE LIQUID OUTLET DROP LIQUID REFRIGERANT A D gt CT Cd Wii HIGH PRESSURE VAPOR CAPILLARY TUBE LIQUID REFRIGERANT LOW PRESSURE VAPOR Figure 33 17 4 3 TROUBLESHOOTING GUIDE In general possible trouble is classified in two kinds The one is called Starting Failure which is caused by an electrical defect The other is Ineffective Air Con ditioning caused by a defect in the refrigeration circuit and improper application Unit is runni
4. 3 ONAS ae ONAS AM 25S JWOD Aci cerere reer PEF 4 2 g g HLO yoz yoz 38 608 SdZ0u ak ch 0 3 4 as gt HZZ Hizey v 9 6 Fea AOL T E ge Oe 9eLZs age 5 L L Z0 OS7MNS 5 HL NWOO ZL 9 LHL NO 8 HLOH ES 10050 W CAS VLOU 97 5 3 COMPONENTS LOCATION 5 4 COMPONENTS LOCATION FOR MAIN P W B ASM FOR DISPLAY P W B ASM CHA l aes a i PCB 6870A90070B oD 2 lt 8 gt p Te lt gt e gt lt S amp S o oO o de O N a ma Qa 70r 5 o eor dW09 AY 8810ZVIL89 ASSY gMd 28 6 EXPLODED VIEW A r Qum r T 5 AS 5 9
5. Install the unit slanted slightly so the back is slight ly lower than the front about 1 4 This will force condensed water to the outside 5 Install the unit with the bottom about 30 60 above the floor level 3 2 HOW TO INSTALL 3 2 1 WINDOW REQUIREMENTS NOTE All supporting parts should be secured to firm wood masonry or metal 1 This unit is designed for installation in standard dou ble hung windows with actual opening widths of 22 to 36 The upper and lower sash must open sufficiently to allow a clear vertical opening of 13 from the bot tom of the sash to the window stool 2 storm window presents interference fasten a 2 wide wood strip to the inner window sill across the full width of the sill The wood strip should be thick enough to raise the height of the window sill so that the unit can be installed without interference by the storm window frame See Figure 23 Top of wood strip should be approximately 3 4 higher than the storm window frame STORM WINDOW FRAME or wood strip OUTDOORS to help condensation to drain properly to the outside 3 Install a second wood strip approximately 6 long by 11 2 wide and same thickness as first strip in the cen ter of the outer sill flush against the back off the inner sill This will raise the L bracket as shown Figure 23 4 If the distance between STORM WINDOW FRAME and WOOD STRIP MOUNTED ON TOP OF INNER SILL is more than 1 two of wood strip are not neces Sar
6. Check the wire connections if loose repair or replace the terminal If the wires are discon nected refer to wiring diagram for identification and replace the wires Check the wire connections If not according to the wiring diagram correct the connections Thermistor Check the TEMP control If not at the lowest number set TEMP control to this setting and restart the unit Check the continuity of the thermistor Replace the thermistor if the circuit is open Capacitor discharge Check the capacitor capacitor before Replace if not within 10 of manufacturer s servicing rating replace if shorted open or damaged Compressor Check the compressor for open circuit or ground If open or grounded replace the compressor Overload Check the compressor overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool and retest Compressor cycles on Voltage Check the voltage See the limits on the overload preceding page If voltage is not within these limits call an electrician Overload Check overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool and retest 94 COMPLAINT Compressor cycles on overload CAUSE Fan motor REMEDY If not running determine the cause Replace if required Condenser air flow restriction Remove the cabinet inspect the interior surface of
7. 004 2520AA1C71A 559010 FAN PROPELLER 5900A20017A 567502 O L P 6750U L058A 6750A90016A W0CZZ CAPACITOR DRAWING 0CZZA20001W 6120AR2359V W48602 CLAMP SPRING 3H02932B NOTE Please ensure GCSC since these parts may be changed depending upon the buyer s request GCSC WEBSITE http biz lgservice com GoidStar October 2005 P No 3828A20529B Printed inThailand
8. 2 SPECIFICATIONS MODELS ITEMS COOLING CAPACITY BTU h GWHD6500R GWHD6500RY6 6 900 POWER SUPPLY Phase V Hz 16 115V 0 INPUT W 670 OPERATING CURRENT AMP 6 1 REFRIGERANT CONTROL CAPILLARY TUBE REFRIGERANT CHARGE R 22 380g 13 4 Oz 350g 12 4 Oz INSIDE FAN TURBO OUTSIDE FAN AIR DISCHARGE CHASSIS PROPELLER FAN WITH SLINGER RING 2 WAY RIGHT AND LEFT TOP DOWN PROTECTOR OVERLOAD PROTECTOR FOR COMPRESSOR INTERNAL PROTECTOR FOR FAN MOTOR TEMPERATURE CONTROL THERMISTOR SWITCH 2 SPEED LOW FAN HIGH FAN FAN MOTOR 6 POLES 28W NOTE Specifications are subject to minor change without notice for further improvement 1 3 SAFETY PRECAUTIONS 1 When servicing set the POWER of CONTROL BOARD to Off and unplug the power cord 2 Observe the original lead dress If a short circuit is found replace all parts which have been overheated or damaged by the short cir cuit 3 After servicing make an insulation resistance test to prevent the customer s exposure to shock hazards 1 4 INSULATION RESISTANCE TEST 1 Unplug the power cord and connect a jumper between 2 pins black and white 2 The grounding conductor green or green and yel low is to be open 3 Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all Mode except POWER OFF 4 T
9. GoidStar ROOM AIR CONDITIONER SERVICE MANUAL CAUTION BEFORE SERVICING THE UNIT MODEL GWHD6500R GWHD6500RY6 CONTENTS Seen ane ee A E eee eee ree 3 3 Ste 3 ead et ea cat erecta ee let hh ah een 3 TAINSULATION RESIS ANCE TES tsetse sh oe aa hes a 3 te SOC PIT ONS CONTRO gece a ee 4 2 DISASSEMBLY INSTRUCTIONS 6 2 6 ee eee ee 6 eee 6 e a 6 aA Eaa o EAE 7 2 DA AUR GUDE UPPER narena e e a 7 2 2 2 ORIFICE TURBO 7 E 8 PNA GU 8 2 8 5 FOVERLOAD PROTEC TOR 8 ee Shoo 6 amp ee 9 9 9 23 S CONTROL PAINE estes a ed cme atest the 9 PONER ORD 10 2 A REFRIGERANT CY CUE Naveen ial cece tala eR oa 10 AC 10 2A D EVAPORATOR eR eee ee ee eee ee 10 2A eee ee ee eee eee 11
10. ICO1M DC 5V Exchange Is the voltage NO 13 or 16 of ICO1M OV Exchange e Check the RY Hi or RY Lo e Check the wiring diagram 21 Possible Trouble 5 e Romote controller does not operate Is the voltage of Battery about over 2 3V e Exchange the battery Is the voltage No 16 of CN DISP1 on Main P W B Ass y DC 5V N O e Check the P W B pattern YES NO e Connect connector to Is the connection of CN DISP1 all right CN DISP1 exactly YES e Exchange Receiver Ass y Possible Trouble 6 It displays abnormally on Display Ass y Exchange Is the all right Connect connector to CN DISP1 exactly Is the connection of CN DISP1 all right Does the Q01G Q02G Q03G Q04G operate normally e Exchange Q01G on main P W B Ass y Q02G Q03G Q04G e Exchange the display P W B 2299 ROOM AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM MAXIMUM 115V 10 COMPLAINT CAUSE REMEDY Fan motor will not run No power Check voltage at outlet Correct if none Power supply cord Check voltage to rotary switch If none check power supply cord Replace cord if circuit is open Rotary switch Check switch continuity Refer to wiring diagram for terminal identification Replace switch if defective Wire disconnected or Connect wir
11. K Pure gt a Cut the sash seal TYPE to the window width Stuff E the sash seal between the glass and the window to AJ SASH SEAL 15 prevent air and insects from getting into the room as shown in Figure 30 b Fasten the L bracket using a TYPE A screw as shown in Figure 30 6 a Remove the screws that secure the cabinet and base pan in the right side b Fasten the suport bracket TYPE G using a removed screw Attach the suport bracket TYPE G in the inner window sill with a screw TYPE B as shown Figure 7 Window installation of room air conditioner is now completed See ELECTRICAL DATA for attaching power cord to electrical outlet 3 2 4 HOW TO SECURE THE DRAIN PIPE In humid weather excess water may cause the BASE PAN to overflow To drain the water remove the DRAIN CAP and secure the DRAIN PIPE to the rear hole of the BASE PAN Figure 32 Press the drain pipe into the hole by pushing down and away from the fins to avoid injury D AN Figure 30 Support Bracket TYPE G KY Figure 31 Ohang push DRAIN CAP DRAIN PIPE Figure 32 15 REMOVAL FROM WINDOW Turn the air conditioner off disconnect the power cord remove the L bracket the screws and support bracket installed through the top and bottom of the guide panels and save for reinstallation later Close th
12. LER POWER turn the Set ON push the button To turn the Set OFF push the button again This button takes priority over any other buttons When you first turn it on the Set is on the High cool mode and the temp at 72 F 22 C TEMPERATURE SETTING This button can automatically control the temperature of the room The temperature can be set within a range of 60 F 16 C to 86 F 30 C by 1 F 1 C Select the lower number for lower temperature of the room FAN SPEED Everytime you push this button it is set as follows High F2 gt Low F1 gt High F2 or High F3 gt Mid F2 gt Low F1 gt High F3 TIMER STOPPING OPERATION Everytime you push this button when the set is operating Energy timer is set as follows Saver 1Hour 2Hours gt 3Hours gt 4Hours 5Hours gt 6Hours gt 7Hours 8Hours gt 9Hours 10Hours gt 11Hours 12Hours gt Cancel The Setting Temperature will be raised by 2 F 1 C 30min later and by 2 F 1 C after another 30 min ENERGY SAVER The fan stops when the compressor stops cooling Approximately every 3 minutes the fan will turn on and check the room air to determine if cooling is needed COOL FAN DRY or COOL FAN Everytime you push this button it will toggle between COOL FAN and DRY How to Insert Batteries 1 Remove the cover from the back of the remote controller Do not use recharge
13. OTECTOR a 296 9 2 ELECTRONIC CONTROL DEVICE 3 AOL nos A if Aak li Me vOOPNL ozz OND 100 77 L 0004 vo 7 0004 asoa azoa ES 1 awor fags aroo pI ae09 azoo 109 7 OWO Po 7 Es 7 O dSIG NO dSIG NO 34089 EA apog 5 j Aded Z OL GLool asoa 31078 As YIMOd NIV AZ SNVUL YIMOd wdLoAs SZ PLOUNZ aia ar cal TE 1 94091 ole CX l RD WD Hald Nd HIY 908 06 B ALA S Z rlou o lt Q ea E a O lt 6 gt YOM NO Lea 6 6 ovou I QOJ porte bo Reg 1souysad Roa A tare ate eae pe bs aloy 4100 4 0 3600 YOLIOVdVO a r r TE O O vl Pan O 5 mmm v 1M jo jo m U jm jm jm lt e e j IO 5 A S IS 5 g 5 vv Eb cv ly Ov 6 86 Ze 96 SE ve al gmo aqq 2 z Jezzng ONAS NO NMOd dn dWal fe 3 1 oe aK Net lt gt Lueos s aan Do 94 2 lt g g Do Sz 1 NLVHOLEd WL Nol Z or aana 2 WOOoIW z Do guess e161 o 9z ne a O nora eS 9 lt 2 AVM 2S gt
14. able batteries Such bat teries differ from standard dry cells in shape dimen sions and performance 2 Insert two batteries Be sure that the and directions are correct Be sure that both batteries are new Remove the batteries from the remote con troller if the air conditioner is not going to be used for an extended length of time 3 Re attach the cover 2 DISASSEMBLY INSTRUCTIONS 2 1 MECHANICAL PARTS 2 1 1 FRONT GRILLE Figure 1 Disconnect the unit from source of power 2 Using a screwdriver remove the screw that secures the front grille to control board See Figure 1 3 Push the front grille up from the bottom Pull the top of the front grille away from the cabinet as the top tabs lift out of their slots See Figure 2 4 Replace the grille by placing the tabs in the slots and push the grille until it snaps into place Figure 2 2 1 2 CABINET 1 Disconnect the unit from the power source 2 Remove the front grille Refer to section 2 1 1 3 Remove 9 screws that secure the cabinet to the base pan and condenser See Figure 3 4 Lift the cabinet from the unit 5 Re install by referring to the procedures above Figure 3 2 1 3 CONTROL BOARD 1 Disconnect the unit from the power source 2 Remove the front grille Refer to Section 2 1 1 3 Remove the cabinet Refer to Section 2 1 2 4 Remove 2 screws that secure the control board to base pan and air guide See F
15. al coy ee ee ee eee 13 JL SELECT IHE BEST LOCATON Soh tate cit ee ae aot 13 Ja HOW VO acer eta 13 ce al 09 5 eee ee ee ee eee eee 16 4 TROUBLESHOOTING GUIDE ete edeccocenc acta cee 16 TOUTS DE 16 17 4S TROUBLESHOOTING eee 18 5 SCHEMATIC DIAGRAM 26 2 6 0 DIAGRAM sen nee eee ee ere ee eee 26 52 ELECTRONIC CONTROL DEVIC E ache cht tah deca 27 5 3 COMPONENTS LOCATION FOR MAIN PW B ASI xcesscsacasscee setae tacts tae teetatss taste ue tidhcclh ea blieaecl haat 28 5 4 COMPONENTS LOCATION FOR DISPLAY PW B ASM sass ccssseccccses esazsarcea sceosassrsesscrescerusniesniesatueicemsenedeauisteeansaes 28 6 EXPLODED VIEW Seen eG en ee ee ee ere 29 net ee A 30 1 PREFACE This service manual provides various service information including the mechanical and electrical parts etc This room air conditioner was manufactured and assembled under a 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 FEATURES DESIGNED FOR COOLING ONLY POWERFUL AND INCREDIBLE COOLING WASHABLE ONE TOUCH FILTER TOP DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE COMPACT SIZE 1
16. binet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 5 Remove 2 screws that secure the brace to air guide upper and shroud See Figure 6 6 Remove 2 screws that secure the air guide upper to air guide lower See Figure 6 7 Lift air guide upper upward 8 Re install by referring to the procedures above UNa 2 2 2 ORIFICE TURBO FAN AND FAN Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 5 Remove the air guide upper Refer to Section 2 2 1 6 Remove 2 screws that secure the base pan to condenser See Figure 7 7 Remove 2 screws that secures the shroud to channel of condenser 8 Press the snap area of shroud with your thumbs This allows you to remove it from the condenser 9 Lift the compressor upward with the evaporator and condenser See Figure 7 Remove the orfice by pushing the snap area of the air guide blower See Figure 8 Remove the clamp springs which are clamped to the boss of fan and turbo fan by hand plier See Figure 9 Pull the fan and turbo fan outward Remove the shroud Re install by referring to the procedures above 10 12 13 14 Figure 6
17. e Refer to wiring diagram for connection loose terminal identification Repair or replace loose terminal Capacitor Discharge Test capacitor capacitor before testing Replace if not within 10 of manufacturer s rating Replace if shorted open or damaged Will not rotate Fan blade hitting shroud or blower wheel hitting scroll Re align assembly Units using slinger ring condenser fans must have 0 22 0 25 inch clearance to the base If necessary shim up the bottom of the fan motor with mounting screw s Check fan motor bearings if motor shaft will not rotate replace the motor Fan motor runs Revolves on overload Check voltage See limits on this page If not within limits call an electrician Test capacitor Check bearings Does the fan blade rotate freely If not replace fan motor Pay attention to any change from high speed to low speed If the speed does not change replace the motor COMPLAINT CAUSE REMEDY Fan motor noise Fan If cracked out of balance or partially missing replace it Blower If cracked out of balance or partially missing replace it Worn bearings lf Knocking sounds continue when running or loose replace the motor If the motor hums or noise appears to be internal while running replace motor Compressor will not run Voltage Check voltage See the limits on the preceding fan motor runs page If not within limits call an electrician Wiring
18. e guide panels Keeping a firm grip on the air conditioner raise the sash and carefully tilt the air conditioner backward draining any condensate Lift the air conditioner from the window and remove the sash seal from between the windows 3 3 ELECTRICAL DATA Line Cord Plug Use Wall Receptacle Power Supply Do not under any circumstances cut Use 15 AMP time or remove the l grounding prong delay fuse or circuit from the plug breaker Power supply cord with Standard 125V 3 wire grounding 3 prong grounding plug receptacle rated 15A 125V AC Power cord may include a current interrupter device A test and reset button is provided on the plug case The device should be tested on a periodic basis by first pressing the TEST button and the RESET button If the TEST button does not trip or if the RESET button will not stay engaged discontinue use of the air conditioner andcontact a qualified service technician USE OF EXTENSION CORDS Because of potential safety hazards we strongly discourage the use of an extension cord However if you wish to use an extension cord use a CSA certified UL listed 3 wire grounding extension cord rated 15A 125V 4 TROUBLESHOOTING GUIDE 4 1 OUTSIDE DIMENSIONS unit mm in 370 14 9 16 42 1 21 32 472 18 9 16 42 1 21 32 120 4 3 4 5 1 3 32 gt
19. e of bracket as shown Use the 2 screws TYPE A provided b The bracket helps to hold unit securely in place Be sure to place bracket edge flush against back of inner sill See Figure 27 oo oe re SS CAUTION a ROOM SIDE INNER SILL During the following step hold unit firmly until window sash is lowered to top channel behind INNER SILL side panel frames Personal injury or property damage may result if unit falls from window 3 INSTALL THE AIR CONDITIONER IN THE WINDOW a Carefully lift the air conditioner and slide it into the open window Make sure the bottom guide of the air conditioner drops into the notches of the L bracket See Figure 27 Figure 27 14 IMPORTANT When the air conditioner drops into the L bracket the air conditioner will be centered in window opening as shown in Figure 28 b While steadying the air conditioner carefully bring the window sash down behind the upper guide of the air conditioner as shown in Figure 29 Figure 28 CENTER LINE WINDOW FRAME 4 SECURE THE GUIDE PANELS UPPER GUIDE SEAL Extend the guide panels TYPE F to fill the window opening using 4 screws TYPE B to secure them as shown in Figure 30 BOTTOM GUIDE Figure 29 L BRACKET L BRACKET 5 INSTALL THE SASH SEAL AND SASH LOC
20. he value should be over 1 MQ 1 5 LOCATIONS OF CONTROLS 1 5 1 CONTROLS TEMPERATURE SETTING e This button can automatically control the temperature of the room The temperature can be set within a range of 60 F 16 C to 86 30 by 1 F 1 C Select the lower number for lower temperature of the room ENERGY SAVER The fan stops when the compressor stops cooling e Approximately every 3 minutes the fan will turn on and check the room air to determine if cooling is needed MODE e Everytime you push this button it will toggle between COOL FAN DRY or FAN COOL TIMER STOPPING OPERATION e Everytime you push this button when the unit is operating timer is set as follows 1Hour gt 2Hours gt 3Hours gt 4Hours 5Hours gt 6Hours gt 7Hours gt 8Hours gt 9Hours 10Hours 11Hours 12Hours gt Cancel e The Setting Temperature will be raised by 2 F 1 C 30min later and by 2 F 1 C after another 30 min DryO FanO Mode CoolO Timer On offO POWER turn the unit ON push the button To turn the unit OFF push the button again This button takes priority over any other buttons e When you first turn it on the unit is on the High cool mode and the temp 72 22 SPEED e Everytime you push this button it is set as follows High F2 gt Low F1 gt High F2 or High F3 Mid F2 Low F1 gt High F3 4 1 5 2 REMOTE CONTROL
21. igure 4 5 Pull the control board toward yourself Figure 4 Controls wires and capacitor are now accessible for servicing Discharge the capacitor before servicing See step 2 3 3 on page 9 for procedures 6 Disconnect one housing terminal and 3 wires for the fan motor and compressor See Figure 5 7 Re install components by referring to procedures above Refer to circuit diagram on page 26 in this manual or inside control board Figure 5 2 2 AIR HANDLING PARTS 2 2 1 AIR GUIDE UPPER Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the ca
22. ing a refrigerant recovery system Remove the air guide upper Refer to Section 2 2 1 After discharging the refrigerant completely unbraze the interconnecting tube of the capillary tube Remove the capillary tube Re install by referring to the procedures above NOTES Replacement of the refrigeration cycle When replacing the refrigerating cycle be sure to discharge the refrigerant by using a refrigerant recovery system After discharging the unit completely remove the desired components and unbraze the pinch off tubes Solder service valves into the pinch off tube ports leaving the valves open Solder the pinch off tubes with service valves After completing the above procedures the valve must be closed and left in place on the system for any subsequent procedures Evacuate as follows 6 1 Connect the vacuum pump as illustrated in figure 20A 6 2 Start the vacuum pump Slowly open manifold valves A and B with two full turns counter clockwise and leave the valves closed The vacuum pump is now pulling through valves A and B up to valve C by means of manifold and the entire system CAUTION If high vacuum equipment is used just crack valves A and B for a few minutes then open slowly with the two full turns counter clock wise This will keep oil from foaming and being drawn into the vacuum pump 6 3 Operate the vacuum pump for 20 to 30 min utes until 600 micron
23. n the compressor Remove the compressor Re install by referring to the removal procedure above See Figure 14 2 3 3 CAPACITOR 1 Remove the cabinet Refer to Section 2 1 2 Figure 15 2 Remove the control board Refer to Section 2 1 3 3 Discharge the capacitor by placing a 20 K resistor across the capacitor terminals 4 Pull the capacitor upward 5 Remove all the leads of capacitor terminals 6 Re install the components by referring to the removal procedure above See Figure 15 2 3 4 THERMISTOR 1 Remove the cabinet Refer to Section 2 1 2 2 Remove the control board Refer to Section 2 1 3 3 Disconnect the thermistor terminals from main PW B assembly 4 Remove the thermistor 5 Re install the components by referring to the removal procedure above See Figure 16 2 3 5 CONTROL PANEL Figure 17 1 2 3 Remove 2 lead wire terminals Re install the components by referring to the Bas Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 Pull the control panel forward and pull out it removal procedure above See Figure 17 2 3 6 POWER CORD Figure 18 Disconnect the unit from source of power Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove 2 screws that secure control board to base pan and air guide Refer to Section 2 1 3 Pulls the con
24. ng but cooling is ineffective Ineffective Cooling Check cold air Check outdoor coil Check heat load circulation for smooth heat exchanger and increase flow fan operation Dirty indoor coil Check gas leakage heat exchanger Not on separate circuit Repair gas leak Malfunction of fan Check inside gas Replacement of unit if pressure the unit is beyond repair Clogging of air filter Adjust refrigerant Obstruction at air outlet charge Remove obstruction Malfunction of compressor Check clogging in refrigera Replacement of tion circuit compressor Satisfactory operation Repair clogging in with temperature refrigeration circuit difference of inlet amp outlet air 44 50 F 7 10 C 18 Fails to Start Check of power source Check of circuit breaker and fuse Check control panel Check of control panel setting Compressor fails only to Fan only fails to start start Drop of power voltage Improper thermistor Improper wiring iai setting l Defect of fan motor Defect of compressor Loose terminal capacitor capacitor connection Irregular motor Capacitor check Improper wiring resistance Q Irregular motor insulation Q Replacement Replacement of fan motor Regular but fails to start Replacement of compressor Irregular motor resistance Q Irregular motor insulation Q Locking of pis
25. nnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 Remove the air guide upper Refer to Section 2 2 1 Remove the compressor turbo fan fan and shroud Refer to Section 2 2 2 Remove the motor Refer to Section 2 2 3 Remove 2 screws that secure the air guide to the base pan See Figure 11 Push the air guide backward and lift it upward See Figure 11 Re install by referring to the procedures above 2 3 ELECTRICAL PARTS 2 3 1 OVERLOAD PROTECTOR 1 DotA W NY Remove the front grille and cabinet Refer to Section 2 1 Remove the nut which fastens the terminal cover Remove the terminal cover Remove all the leads from the overload protector Remove the overload protector Re install the components by referring to the removal procedure above See Figure 12 and 13 Figure 10 Figure 11 Figure 12 Figure 13 N Ne 7 YV 2 3 2 COMPRESSOR 1 2 O Remove the front grille and cabinet Figure 14 Refer to Section 2 1 2 Discharge the refrigerant by using a refrigerant recovery system Remove the overload protector Refer to Section 2 3 1 After discharging the unit completely unbrace the suction and discharge pipes at the compressor connections Remove 3 nuts which faste
26. the condenser If restricted clean carefully with a vacuum cleaner do not damage fins or brush Clean the interior base before re assembling Condenser fins damaged Capacitor Wiring If the condenser fins are closed over a large area on the coil surface head pressures will increase causing the compressor to cycle Straighten the fins or replace the coil Test the capacitor Check the terminals If loose repair or replace Refrigeration system Check the system for a restriction Insufficient cooling Excessive noise Air filter If restricted clean or replace Unit undersized Blower or fan Determine if the unit is properly sized for the area to be cooled Check the set screw or clamp If loose or miss ing correct If the blower or fan is hitting scroll or barrier rearrange the air handling parts Copper tubing 25 Remove the cabinet and carefully rearrange the tubing not to contact the cabinet compressor shroud and barrier 5 SCHEMATIC DIAGRAM 5 1 CIRCUIT DIAGRAM BK BR Plain GN YL GN THERMISTOR DISPLAY P W B ASM CN WORK S MAIN P W B ASM FUSE 250V T2A 115V T2A 3854A20022K WIRING DIAGRAM LOCATION DESCRIPTION Q TY NO PER SET POWER CORD ASSEMBLY MOTOR COMPRESSOR DISPLAY PW B ASSEMBLY MAIN PW B ASSEMBLY THERMISTOR a ae CAPACITOR OVERLOAD PR
27. ton metal Replacement of compressor Motor damaged 19 ELECTRIC PARTS TROUBLESHOOTING GUIDE Possible Trouble 1 e The unit does not operate Is the Trans output power AC 115V e Check the Fuse 9 Check the wiring diagram e Check the Main P W B pattern Is the Trans output power about AC 14V Is shorted the Trans output e Exchange the Trans Is output Voltage of IC01D e Exchange D02D D0SD DC 12V e Exchange IC01D Is output Voltage of IC02D DC 5V Exchange IC02D Is the reset circuit all right The No 14 of Micom is 5V YES e Exchange Is the connection between Connect connector Main and Display exactly all right YES e Check the P W B pattern Exchange Main P W B Ass y 20 Possible Trouble 2 The compressor does not operate e Set the Temp setting to higher Temp setting set lower than Roo Is the voltage NO 7 of NO IC01M DC 5V Is the voltage No 10 Is the Unit for 3 minutes of IC01M YES e Check the RY COMP e Exchange IC01M e Wait 3 Minutes e Check the wiring e Exchange MAIN P W B Ass y e Connect LEAD Wire to RY COMP again Diagram Possible Trouble 3 The compressor always operate Is the wire connection of RY COMP all right YES e Check the RY COMP Possible Trouble 4 Fan does not operate Is the voltage NO 1 or 4 of
28. trol board toward you Remove the grounding screw 7 Remove a screw securing the clip with cord to the control board Pull the power cord 9 Re install by referring to procedures above RON Oo 2 4 REFRIGERANT CYCLE 2 4 1 CONDENSER Figure19 1 Remove the cabinet Refer to Section 2 1 2 2 Discharge the refrigerant by using a refrigerant recovery system 3 Remove 2 screws which fasten the condenser See Figure 19 4 After discharging the refrigerant completely unbraze the interconnecting tube at the condenser connections 5 Remove the condenser 6 Re install by referring to the procedures above 2 4 2 EVAPORATOR 1 Remove the cabinet Refer to Section 2 1 2 2 Discharge the refrigera by using a refrigerant recovery system 3 Remove the air guide upper Refer to Section 2 2 1 4 After discharging the refrigerant completely unbraze the interconnecting tube at the evaporator connections 5 Remove the evaporator 6 Re install by referring to the procedures above 10 2 4 3 CAPILLARY TUBE 1 2 5 6 Remove the cabinet Refer to Section 2 1 2 Discharge the refrigerant by us
29. ut ter cut the pinch off tube about 2 inches from the pinch off tool Use sil fos solder and solder the pinch off tube closed Turn off the unit allow setting for a while and then test the leak age of the pinch off connection O Equipment needed Vacuum pump charging cylinder manifold gauge brazing equipment pinch off tool capable of making a vapor proof seal leak detector tubing cutter hand tools to remove components and service valve COMPOUND GAUGE MANIFOLD GAUGE 3 CONDENSER HIGH PRESSURE SIDE i i y SEE INSETS EVAPORATOR LOW PRESSURE SIDE CAPILLARY TUBE HI CHARGING CYLINDER Figure 20A Pulling Vacuum Figure 20B Charging 3 INSTALLATION This air conditioner is designed with a button down chassis so it can be easily installed in a window 3 1 SELECT THE BEST LOCATION 1 To prevent vibration and noise make sure the unit is installed securely and firmly 2 Install the unit where the sun does not shine directly on the unit 3 The outside of the cabinet must extend outward for at least 10 and there should be no obstacles such as a fence or wall within 20 from the back of the cabinet because it will prevent heat radiation of the condenser Restriction of outside air will greatly reduce the cooling efficiency of the air conditioner CAUTION All side louvers of the cabinet must remain exposed on the outdside of the structure 4
30. vacuum is obtained Close valves A and B and observe vacuum gauge for a few minutes A rise in pressure would indicate a possible leak or moisture remaining in the system With valves A and B closed stop the vacuum pump 6 4 Remove the hose from the vacuum pump and place it on the charging cylinder See figure 20B Open valve C Discharge the line at the manifold connection 6 5 The system is now ready for final charging Recharge as follows 7 1 Rotary compressor systems are charged from the high side If the total charge cannot be put in the high side the balance will be put in the suction line through the access valve which is installed as the system is opened 7 2 Connect the charging cylinder as shown in fig ure 20B With valve C open discharge the hose at the manifold connection 7 3 Open valve A and allow the proper charge to enter the system Valve B is still closed 7 4 If more charge is required the high side will not take it Close valve A 7 5 With the unit running open valve B and add the balance of the charge a Do not add the liquid refrigerant to the low side b Watch the low side gauge allow pressure to rise to 30 lbs Turn off valve B and allow the pressure to drop Repeat steps B and C until the balance of the charge is in the system 7 6 When the unit is operating correctly use the pinch off tool with the unit still running and the clamp on the pinch off tube Using a tube c
31. y INSIDE _ OUTSIDE AWNING COOLED AIR HEAT RADIATION FENCE ai ABOUT 1 4 P Over 20 Figure 21 INNER SILL OUTER SILL INDOORS OUTDOORS Figure 22 WOOD STRIP MOUNTED 1 MAX ae ON TOP OF INNER SILL 4 CLEARANCE t STORM WINDOW INNER FRAME WOOD STRIP FOR L BRACKET X OUTER SILL INDOORS OUTDOORS Figure 23 13 Installation Kit Some models HARDWARE TYPE A 11EA TYPE B 5EA TYPE C 3EA SHORT SCREW WOOD SCREW L BACKET RAINE ft Tel e TYPE D 1EA TYPE E 1EA TYPE F 2EA TYPE G 1EA SEAL STRIP SASH SEAL GUIDE PANEL SUPPORT BACKET Adhesive backed Not adhesive backed 3 2 2 BEFORE INSTALLATION PB 1 Insert the guide panels into the guides of the air condi Na ZZ tioner Fasten the curtains to the unit with screws TYPE A as shown Figure 24 aes d 2 Cut the adhesive backed seal strip TYPE D to the window Ak P width A Remove the backing from the seal strip and attach the seal strip to the underside of the bottom window Figure 25 3 2 3 NOW START INSTALLATION 1 LOCATING UNIT IN WINDOW Open the window and mark center line on the center of arcane Ripe the inner sill as shown in Figure 26 TYPE D 2 ATTACH L BRACKET Figure 25 a Install the L brackets behind the inner window sill with the short sid
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