Heat Controller RADS-81B Air Conditioner User Manual
Contents
1. Replacement Parts List PART NO LOCATION NO DESCRIPTION Remark TUE 130410 BASE ASSEMBLY SINGLE 3041A30011D 3041A30005P 130910 CABINET ASSY SINGLE 3091A30005R E R P 135312 GRILLE ASST FRONT SINGLE uus 68 08 13500 COVER CONTROL CINDOOR 35504300308 R 1791 O Louver verten aaa 16 9 984100194 4998A10010 amp R 12 9 6 6 8 292200 Pavel cosmo 77 x50 1 3891420098 219950 _ CONTROL ASSEMBLY SINGLE 4995A20806C 4995 2080 R F 359012 FAN 5900A10008A 550140 TSOLATOR COMP 5040AR4195A 4830AR4335A 552102 TUBE CAPILLARY BEND 5211A30260B 8 R 352 TUBE ASSEMBLY SUCTION SINGLE AJR31679501 5211A20130M WOCZZ CAPACITOR 0CZZA20005B OCZZA20001N vice Manual 37 Specifications and performance data subject to change without notice HEAT CONTROLLER INC 1900 WELLWORTH AVENUE JACKSON MICHIGAN 49203 THE QUALITY LEADER IN CONDITIONING AIR Printed in China2. 0000000 LEDS LEDS J12 TIMER E SAVER D o UTO SWING 58 o t D03F f O Service Manual 27 Troubleshooting Guide E Troubleshooting Guide CONDENSER COIL m CAPILLARY TUBE MOTOR COMPRESSOR BLOWER EVAPORATOR COIL Figure 38 is a brief description of the important components and their function in what is called the refrigeration system This will help you to understand the refrigeration cycle and the flow of the refrigerant in the cooling cycle CYCLE OF REFRIGERATION EVAPORATOR COILS CONDENSER COILS VAPOR INLET COMPLETE LIQUID COOL LOW PRESSURE VAPOR HOT BOIL OFF POINT DISCHARGED COOLED Z AIR AIR ERE 6 gt ROOM AIR HEAT LOAD E 5 gt PO gt OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH i COMPRESSOR 600 7 LIQUID PRESSURE DROP LIQUID OUTLET D REFRIGERANT 18 PRESSURE VAPOR CAPILLARY TUBE lt LIQUID REFRIGERANT ESS LOW PRESSURE VAPOR lt lt Figure 34 28 Room Air Conditioner
3. OUTSIDE DIMENSION inch DB Dry Bulb WB Wet Bulb Installation Installation Select the 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 INSIDE _ OUTSIDE FENCE 3 The outside of the cabinet must extend outward for at least AWNING 11 and there should be no obstacles such as fence RO wall within 20 from the back of the cabinet because it will COOLED AIR EH HEAT prevent heat radiation of the condenser RADIATION Restriction of outside air will greatly reduce the cooling effi ciency of the air conditioner 222 CAUTION All side louvers of the cabinet must 2 ABOUT 1 4 A remain exposed on the outdside of the structure 2 Over 20 4 Install the unit slanted slightly so the back is slightly 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 Figure 1 The setting conditions must be checked prior to initial starting The following items are especially important checking points when the installation is finished 1 Grounding wire Green or Green and Yellow is provided in the power cord The green wire must be grounded 2 Connect to a single outlet 15A circuit or 20A ci
4. DC 5V ves Exchange Main P W B 5 Troubleshooting Guide Possible Trouble 2 The compressor does not operate setting set lower than Roo Set the Temp setting to lower Temp 15 the voltage No 10 of ICO1M OV Is the voltage NO 7 of Is the Unit for 3 minutes Ne IC01M DC 5V Check the RY COMP Exchange ICO1M Wait 3 Minutes Check the wiring Diagram Exchange MAIN P W B Ass y Possible Trouble 3 The compressor always operate Is the wire connection of NO Connect LEAD Wire to RY COMP all right RY COMP again Check Possible Trouble 4 Fan does not operate Is the voltage NO 1 or 4 of ICO1M DC 5V NO Exchange ICO1M Is the voltage NO 13 or 16 of ICO1M OV NO Exchange ICO1M Check the RY Hi or RY Lo Check the wiring diagram 32 Room Air Conditioner Troubleshooting Guide Exchange the battery Exchange IC01G Connect connector to CN DISP1 exactly Exchange Q01G 9026 Q03G Q04G Service Manual 33 Check the P W B pattern NO Connect connector to CN DISP1 exactly 8 Romote controller does not operate Possible
5. Remove the screw which fastens the front grille 3 Pull the front grille from the right side 4 Remove the front grille 5 Re install the component by referring to the removal procedure above See Figure 17 Figure 17 2 CABINET 1 After disassembling the FRONT GRILLE remove the 2 screws which fasten the cabinet at both sides 2 Remove the 2 screws which fasten the cabinet at back 3 Pull the base pan forward See Figure 18 4 Remove the cabinet 5 Re install the component by referring to the removal procedure above Figure 18 3 CONTROL BOX 1 Disconnect the unit from the power source 2 Remove the front grille 3 Remove the cabinet 4 Remove the screw which fastens the control box cover 5 Remove the housing which connects motor wire in the control box 6 Remove the 3 leads from the compressor 7 Discharge the capacitor by placing a 20 000 ohmresistor across the capacitor terminals 8 Remove the 2 screws which fasten the control box See Figure 19 9 Pull the control box forward completely 10 Re install the components by referring to the removal procedure above See Figure 19 2222222222 R N V 7 WH EHHH a a ee a Figure 19 Service Manual 17 KK 7 lt Figure 21 Figure 22 Disassembly 1 AIR GUIDE AND BLOWER 1 Remove the front grille 2
6. 6 3 THERMOSTAT 8 6 WIRING DIAGRAM 3854AR 3563A 7 S Service Parts N Non Service Parts LOCATION Q TY REMARKS NO DESCRIPTION PER SET POWER CORD ASSY 1 5 1 FAN MOTOR 1 S 2 COMPRESSOR 1 S 3 ROTARY SWITCH 1 S 4 THERMOSTAT 1 S 5 CAPACITOR 1 S 6 OVERLOAD PROTECTOR 1 S 7 P T C 1 S 8 24 Room Air Conditioner Schematic Diagram Circuit Diagram MODEL TOUCH amp REMOTE CONTROL TYPE MODEL POWER INPUT rs OR BR 0 BK 2775 121884 ry reuse So RY SYNC ZNR 2 5 FORMER 5 115 V T2A WIRING DIAGRAM EATON DESCRIPTION QTY NO PER SET POWER CORD ASSEMBLY 1 FAN MOTOR 1 COMPRESSOR 1 DISPLAY P W B ASSEMBLY 1 MAIN P W B ASSEMBLY 1 THERMISTOR 1 CAPACITOR 1 OWERLOAD PROTECTOR 1 4 AJOJN gt Service Manual 5 BABO ves 00 0800 0000 3 SAVE 5586 8 0001 E to o 2187 100 ao el Le oT 0900 0 66 gt O dSIG N9 dSIG NO 508 o 0252 lo 60 HIMOA ED vri auzos vrooeNm 8 1001 uiv Ll 1 5 2 4
7. OPERATING INDOOR CONDITION OUTDOOR REFRIGERANT R 22 CHARGE EVAPORATOR CONDENSER FAN INDOOR FAN OUTDOOR FAN SPEEDS FAN COOLING FAN MOTOR OPERATION CONTROL ROOM TEMP CONTROL AIR DIRECTION CONTROL CONSTRUCTION COMPRESSOR PROTECTOR FAN MOTOR POWER CORD DRAIN SYSTEM OUTSIDE DIMENSION inch DB Dry Bulb WB Wet Bulb Specfications M Product Specifications RADS 81B 12 115 60Hz 8 000 740 6 8 10 8 26 7 DB 19 4 WB 35 DB 23 9 WB 4909 17 3 oz 7 0 2ROW 14STACKS 05 0 2ROW 16STACKS TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 3 3 6 POLES REMOTE CONTROLLER THERMISTOR HORIZONTAL LOUVER UP amp DOWN VERTICAL LOUVER RIGHT amp LEFT SLIDE IN OUT CHASSIS OVERLOAD PROTECTOR INTERNAL THERMAL PROTECTOR 3 WIRE WITH GROUNDING ATTACHMENT PLUG CORD CONNECTED TYPE DRAIN PIPE OR SPLASHED BY FAN SLINGER 18 1 2 x 13 7 8 x 20 11 16 469 x 353 x 526 Service Manual 9 MODELS ITEMS POWER SUPPLY COOLING CAPACITY Btu h INPUT W RUNNING CURRENT A E E R BTU W h OPERATING INDOOR CONDITION OUTDOOR REFRIGERANT R 22 CHARGE EVAPORATOR CONDENSER FAN INDOOR FAN OUTDOOR FAN SPEEDS FAN COOLING FAN MOTOR OPERATION CONTROL ROOM TEMP CONTROL AIR DIRECTION CONTROL CONSTRUCTION COMPRESSOR PROTECTOR FAN MOTOR POWER CORD DRAIN SYSTEM
8. the control box 3 Disconnect the grounding screw from the control box Disconnect the 2 receptacles 5 Remove a screw which fastens the clip cord See Figure 30 Remove the power cord Re install the component by referring to the above removal procedure above Use only one ground marked hole for ground connection If the supply cord of this appliance is damaged it Figure 30 must be replaced by the special cord The special cord means the cord which has the same specification marked on the supply cord attached at the unit Refrigerating Cycle CAUTION Discharge the refrigerant system using a Freon Recovery System If there is no valve AR N to attach the recovery system install one such as 1 before venting the Freon Leave the valve in place after servicing the system 1 CONDENSER 1 Remove the cabinet 2 Remove the 3 screws which fasten the brace 3 Remove the 3 screws which fasten the condenser and shroud 4 After discharging the refrigerant completely unbraze the interconnecting tube at the condenser ci connections N 5 Remove the condenser carefully 6 Re install the component by referring to notes See Figure 31 N Q ue Figure 31 Service Manual 21 Disassembly Fig
9. 0 103 1 6 9 2 8 6 1HVIS3H V 1900 SNIMS V 0 1000 1000 26 103 5205 7009 0161q 4800 ams gt Jer Ter Tr Tor e es ze se e O MT NV 4900 ONAS AH 538 B1 22279 525257 H 255 9535 255 guess 25 Teueos i pueos DS Vas E vus T E ins T NMOG 1 ong 21 MT 440 N0 an anal z 5 E 1 6 aTe Te Te Te Ta Te Te Ts v Tz xL OS lm wv bon 0 2 206 HL 3dld A 205 Age Z0 052MNS LHL NO seus 25 HL NOOH KJ 26 Room Air Conditioner Schematic Diagram Schematic Diagram Components Location For Main PW B 6 d CN THI 305 05008 e BH E E PWB P NO 6870 90069 im PWB ASS Y 6871A10119 2 PWB ASS Y 6871A10123 K gt POWER TRANS P NO 6870A90070A ASM 43 10 022 901 4 581 FAN SPEED o 0 0 0 0 0 1 o s o DIGIT J02 0 o CN DISP o
10. HEAT CONTROLLER INC Room Air Conditioner MODELS RAD 101A RAD 81A RADS 81B Sewice ad Parts Manual CAUTION BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL ONLY FOR AUTHORIZED SERVICE PERSONNEL Air Conditioner Service Manual TABLE OF CONTENTS Safety uuu u uuu ee 3 ai AM 6 Outside Dimensions EA 6 Product Specifications ed 7 lUi 8 Select the Best 8 Installation 6411 5 sens n toot Uer pneter tenebat tei pe iced iue ee 8 How to Secure the Drain n n n nn 8 a I Ce 9 Operation ono sd tania M es Eo D 13 Location and Function of Controls ccce trench tae ca urine e 13 Remote Control Operations Hr 14 52 15 Mechanical PAINS a sh 15 Falls 16 Electrical PariS eee e a aA 17 Refrigerating PE 19 Schematic Diagram tesque a eta ice iu ee EEEE 22 Mana 22 Electronic Control DeVIg8 u u 24 Compon
11. Remove the cabinet 3 Remove the control box 4 Remove the 3 screws which fasten the brace 5 Remove the brace 6 Remove the 2 screws which fasten the evaporator 7 Move the evaporator forward and pulling it upward slightly See Figure 20 8 Move the evaporator to the left carefully 9 Pull out the hook of orifice by pushing the tabs and remove it See Figure 21 10 Remove the clamp with a hand plier which secures the blower 11 Remove the blower 12 Remove the 4 screws which fasten the air guide from the barrier 13 Move the air guide backward pulling out from the base pan 14 Re install the components by referring to the removal procedure above FAN AND SHROUD Remove the cabinet Remove the brace Remove the 3 screws which fasten the condenser Move the condenser to the left carefully Remove the clamp which secures the fan Remove the fan and then pull out the shroud See Figure 22 7 Re install by referring to the removal procedure 2 a M 18 Room Air Conditioner Disassembly 3 MOTOR 1 Remove the cabinet 2 Remove the evaporator 3 Remove the orifice 4 Remove the blower 5 6 Remove the fan Remove the control box cover and housing of the motor in the control box 7 Remove the 2 screws which fasten the motor from the mount motor See Figure 23 8 Remove the motor 9 Re install the components by referring to the removal procedu
12. TECTOR INTERNAL THERMAL PROTECTOR 3 WIRE WITH GROUNDING ATTACHMENT PLUG CORD CONNECTED TYPE DRAIN PIPE OR SPLASHED BY FAN SLINGER 18 1 2 x 13 7 8 x 20 11 16 469 x 353 x 526 Service Manual 7 MODELS ITEMS POWER SUPPLY COOLING CAPACITY Btu h INPUT W RUNNING CURRENT A E E R BTU W h OPERATING INDOOR CONDITION OUTDOOR REFRIGERANT R 22 CHARGE EVAPORATOR CONDENSER FAN INDOOR FAN OUTDOOR FAN SPEEDS FAN COOLING FAN MOTOR OPERATION CONTROL ROOM TEMP CONTROL AIR DIRECTION CONTROL CONSTRUCTION COMPRESSOR PROTECTOR FAN MOTOR POWER CORD DRAIN SYSTEM OUTSIDE DIMENSION inch DB Dry Bulb WB Wet Bulb Specfications M Product Specifications RAD 81A 12 115 60Hz 8 000 815 7 6 9 8 26 DB 19 4 WB 35 DB 23 9 WB 260 9 9 2 oz 1 0 2ROW 14STACKS 05 0 2ROW 16STACKS TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 3 3 6 POLES REMOTE CONTROLLER THERMISTOR HORIZONTAL LOUVER UP amp DOWN VERTICAL LOUVER RIGHT amp LEFT SLIDE IN OUT CHASSIS OVERLOAD PROTECTOR INTERNAL THERMAL PROTECTOR 3 WIRE WITH GROUNDING ATTACHMENT PLUG CORD CONNECTED TYPE DRAIN PIPE OR SPLASHED BY FAN SLINGER 18 1 2 x 13 7 8 x 20 11 16 469 x 353 x 526 Service Manual 8 MODELS ITEMS POWER SUPPLY COOLING CAPACITY Btu h INPUT W RUNNING CURRENT A E E R BTU W h
13. Trouble 5 P Is the voltage of Battery NO about over 2 3V ves ls the voltage No 16 of CN DISP1 on Main P W B Ass y DC 5V NO Is the connection of CN DISP1 all right Exchange Receiver Ass y Possible Trouble 6 It displays abnormally on Display P W B Ass y NO Is the ICO1G all right gt Is the connection of NO d j CN DISP1 all right yes Does the Q01G NO Q02G Q03G Q04G operate normally on main P W B Ass y Exchange the display P W B Ass y Troubleshooting Guide ROOM AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM MAXIMUM 115V 103 5V 126 5V 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 wire 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 shr
14. Troubleshooting Guide Check heat load increase Clean condenser Not on separate circuit Check inside gas pressure Adjust refrigerant charge Malfunction of compressor Replacement of compressor Service Manual 29 Troublesho In general possible trouble is classified in two kinds The one is called Starting Failure which is caused from an electrical defect and the other is ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application Ineffective Cooling Y Check outdoor coil heat exchanger and fan operation Check gas leakage Repair gas leak Replacement of unit if the unit is beyond repair Satisfactory operation with temperature difference of inlet amp outlet air 44 50 F 7 10 C Unit runs but poor cooling Check cold air circulation for smooth flow Dirty indoor coil heat exchanger Malfunction of fan EDAM Clogging of air filter Obstruction at air outlet Remove obstruction Check clogging in refrigera tion circuit Repair clogging in refrigeration circuit Troubleshooting Guide Check of power source Check of circuit breaker and fuse Check of control panel Check control panel setting Y Fan only fails to start Improper wiring Defect of fan motor capacitor Compressor fails only to start Do
15. at control to the desired temperature mark the mid point is a good starting position If the room temperature is not satisfactory after a reasonable time adjust the con trol to a cooler or warmer setting as appropriate FOR MAXIMUM COOLING 1 Turn the operation switch to the High Cool setting 2 Set the thermostat control to the largest temperature mark FOR QUIETER OPERATION 1 Turn the operation switch to the Low Cool setting 2 Set the thermostat control as needed Service Manual 15 CAUTION The Remote Controller will not function properly if strong light strikes the sensor window of the air conditioner or if there are obstacles between the Remote Controller and the air conditioner Power 1 3 Timer Saver Fan Speed 10 Hours gt 11 Hours 12 Hours CANCLE The set temperature will be raised by 2 F after 30 minutes and again after another 30 minutes Starting Operation Each press of the button cycles through the options in this order 1 Hour gt 2 Hours gt 3 Hours gt 4 Hours gt 5 Hours gt 6 Hours 7 Hours 8 Hours 9 Hours 10 Hours gt 11 Hours gt 12 Hours CANCLE 5 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 6 Cool Fan Dry Everytime you pus
16. block the inlet or outlet when removing the filter They are sharp and may cause injury It may cause failure of appliance or performance deteriorate Ensure that the outer caseis not damaged Be cautious not to touch the sharp edges by age orwear when installing Leaving it damaged couldresult in the air may cause injury conditioner falling out of the window creating a safety hazard Service Manual 5 Dimensions Dimensions This symbol alerts you to the risk of electric shock This symbol alerts you to hazards that could cause harm to the air conditioner This symbol indicates special notes 525 20 he 470 18 1 2 _ 353 13 7 8 6 Room Air Conditioner Specfications B Product Specifications RAD 101A 10 115 60Hz 9 800 1 000 9 3 9 8 26 7 DB 19 4 WB 35 DB 23 9 WB 4109 14 502 O 7 0 3ROW 14STACKS 07 0 2R 16STACKS L TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 3 3 6 POLES REMOTE CONTROLLER THERMISTOR HORIZONTAL LOUVER UP amp DOWN VERTICAL LOUVER RIGHT amp LEFT SLIDE IN OUT CHASSIS OVERLOAD PRO
17. ents Location For Main PW B s 25 Tro bleshooting ioi a nd olas al Duda aru sie i tege deua 26 PIPING eee eee E Anas nea 26 Troubleshooting Guide 27 Exploded View luyluy 35 Replacement Parts List 0 36 37 2 Room Air Conditioner Safety Precautions Safety Precautions To prevent injury to the user or other people and property damage the following instructions must be followed m incorrect operation due to ignoring instructions will cause harm or damage The seriousness is classified by the following indications WARNING This symbol indicates the possibility of death or serious injury CAUTION This symbol indicates the possibility of injury damage to property only m Meanings of symbols used in this manual are as shown below Be sure not to do 9 Be sure to follow the instruction J A WARNING Always install the expansion panel s Do not place the power cord near a heater Improper assembly or installation may cause It may cause fire and electric shock incorrect operation including injury fire and electric shock hazards J Do not use the power cord near flammable Do not disassemble or modify products gas or combustibles such as gasoline benzene thinner etc may cause explosion or fire It may cause failure and electric shoc
18. h this button it will toggle between COOL FAN and DRY Do not use rechargeable batteries Such batteries differ from standard dry cells in shape dimensions and perfor mance Remove the batteries from the remote controller if the air condi tioner is not going to be used for an extended length of time The controls look like this Controls 1 Power To 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 2 Temperature Setting This button controls the room temperature setting in a range between 60 F and 86 F in 1 incre ments 3 Fan Speed Pressing the Fan Speed button toggles between Low and High speeds 4 On Off Timer Stopping Operation Each press of the button cycles through the options in this order 1 Hour gt 2 Hours 3 Hours 4 Hours 5 Hours 6 Hours 7 Hours gt 8 Hours 9 Hours gt How to Insert Batteries 1 Remove the cover from the back of the remote con troller 2 Insert two batteries Be sure of the polarity when installing the batteries Be sure that both batteries are new 3 Re attach the cover 16 Room Air Conditioner Disassembly E Disassembly Before the following disassembly POWER SWITCH set to OFF and disconnect the power cord 1 FRONT GRILLE 1 Open the Inlet grille upward or downward 2
19. he selected position using 2 Type A screws in each support See Figure 8 Figure 8 6 The cabinet should be installed with a very slight Seren Type n pe tilt about 1 2 downward toward the outside See Figure 9 Adjust the bolt and the nut of Sill Support for balancing the cabinet About 1 2 Sill support Sash track 7 Attach the cabinet to the window stool by driving the screws Type B Length sixteen millimeters and below through the front angle into window stool 8 Pull each Frame Curtain fully to each window sash Screw Type track and repeat step 2 Sill support Figure 9 9 Attach each Frame Curtain the window sash using screws Type C See Figure 10 CAUTION DO NOT DRILL A HOLE IN THE BOTTOM PAN The unit is designed to operate with approximately 1 2 of water in bottom pan Figure 10 Service Manual 13 Power cord Screw Type A Figure 11 Foam Strip Figure 12 Window Locking Bracket Figure 13 Figure 16 Installation 10 Slide the unit into the cabinet See Figure 11 CAUTION For security purpose reinstall screws A Type A at cabinet s sides Screw Type A 11 Cut the Foam Strip to the proper length and insert between the upper window sash and the lower window sash See Figure 12 12 Attach the Window Locking Bracket with a Type C screw See Figure 13 13 Attach the front grille to the cabinet by inserting the tabs
20. his setting and restart the unit Check the continuity of the thermistor Replace the thermistor if the circuit is open Check for continuity refer to the wiring diagram for terminal identification Replace the switch if the circuit is open Check the position of knob If not at the coldest setting advance the knob to this setting and restart the unit Check the continuity of the thermostat Replace the thermostat if the circuit is open Check the capacitor Replace if not within 10 of manufacturer s rating replace if shorted open or damaged Check the compressor for open circuit or ground If open or grounded replace the compressor Check the compressor overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool and retest Service Manual 35 CAUSE Fan Blower Loose set screw Worn bearings Voltage Wiring Thermistor Rotary Thermostat Capacitor discharge capacitor before servicing Compressor Overload COMPLAINT Fan motor noise Compressor will not run fan motor runs REMEDY Check the voltage See the limits on the preceding page If voltage is not within these limits call an electrician Check overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool and retest If not running determ
21. ine the cause Replace if required Remove the cabinet inspect the interior surface of the condenser If restricted clean carefully with a vacuum cleaner do not damage fins or brush Clean the interior base before re assembling 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 Check the system for a restriction If restricted clean or replace 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 Remove the cabinet and carefully rearrange the tubing not to contact the cabinet compressor shroud and barrier CAUSE Voltage Overload Fan motor Condenser air flow restriction Condenser fins damaged Capacitor Wiring Refrigeration system Air filter Unit undersized Blower or fan Copper tubing Troubleshooting Guide COMPLAINT Compressor cycles on overload Compressor cycles on overload Insufficient cooling Excessive noise 36 Room Air Conditioner 88 Exploded View
22. k Service Manual 3 Safety Precautions Plug in the power plug Do not operate or stop the Do not damage or use an properly unit by inserting or pulling unspecified power cord out the power plug Otherwise it will cause e It will cause electric shock or It will cause electric shock or electric shock or fire fire fire 6 ADS LAK AN x NYC Do not modify power cord Use the air conditioner on a Always plug into a length single outlet circuit see page 7 grounded outlet Do not share the outlet with other appliances e It will cause electric shock or It will cause electric shock No grounding may cause fire fire electric shock Ventilate before operating air not use the socket if itis Do not operate with wet conditionerwhen gas goes loose or damaged hands or in damp out environment lt may cause explosion fire may cause fire and electric It will cause electric shock and burn shock 4 Room Air Conditioner Safety Precautions If water enters the product turn off the the Do not clean the air conditioner with water power switch of the main body of appliance Contact service center after taking the power plug out from the socket It will cause electric shock or failure of Water may enter the unit and degrade the machine insulation It may cause an electric shock CAUTION Never touch the metal parts of the unit Do not
23. on the grille into the tabs on the front of the cabinet Push the grille in until it snaps into place See Figure 14 14 Lift the inlet grille and secure it with a Type A screw through the front grille See Figure 15 15 Window installation of room air conditioner is now completed See ELECTRICAL DATA for attaching power cord to electrical outlet 14 Room Air Conditioner Operation g Operation DESIGNED FOR COOLING ONLY POWERFUL AND INCREDIBLE COOLING TOP DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE BUILT IN ADJUSTABLE THERMOSTAT WASHABLE ONE TOUCH FILTER COMPACT SIZE Location anc CAUTION If you turn off the air conditioner or switch from cooling to the fan wait at least 3 minutes before setting to cooling again e peration Off Turns air conditioner off Med Fan Med speed fan operation without cooling Low Fan Low speed fan operation without cooling High Cool Cooling with high speed fan operation Med Cool Cooling with med speed fan operation Low Cool Cooling with low speed fan operation This automatically controls the temperature of the indoor air Turn the knob so that arrow points to the larger marks for greater cooling Point the arrow to the smaller marks for more moderate cooling i e the higher the number the greater the cooling FOR NORMAL COOLING 1 Turn the operation switch to the High Cool or the Low Cool setting 2 Set the thermost
24. oud 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 34 Room Air Conditioner Troubleshooting Guide REMEDY If cracked out of balance or partially missing replace it If cracked out of balance or partially missing replace it Tighten it If knocking sounds continue when running or loose replace the motor If the motor hums or noise appears to be internal while running replace motor Check voltage See the limits on the preceding page If not within limits call an electrician 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 Check the TEMP control If not at the lowest number set TEMP control to t
25. rcuit for Electric Heater Model 3 To avoid vibration or noise make sure the air conditioner is installed securely 4 Avoid placing furniture or draperies in front of the air inlet and outlet How to Sec 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 2 Hang Push Drain Pipe Drain Cap Figure 2 10 Room Air Conditioner Installation INNER SILL OUTER SILL INDOORS OUTDOORS Figure 3 WOOD STRIP MOUNTED 1 MAX am N OF INNER SILL lt gt CLEARANCE STORM WINDOW INNER FRAME SIEL WOOD STRIP FOR L BRACKET y OUTER SILL INDOORS OUTDOORS Figure 4 Type FOAM PE Type K 2EA FRAME GUIDE 1 UPPER GUIDE Type H 1EA FOAM STRIP Type DRAIN WASHER Type DRAIN JOINT PIPE Type FOAM PE Type L 1EA Service Manual 11 WINDOW LOCKING BRACKET Window Requirements supporting parts should be secured to firm wood masonry or metal k This unit is designed for installation in standard double 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 15 from the bottom of the sash to the window stool 2 If storm window presen
26. re above See Figure 23 Figure 23 1 OVERLOAD PROTECTOR M 1 Remove the cabinet 9 ZI 2 Remove the nut which fastens the terminal cover cell D 3 Remove the terminal cover See Figure 24 amp 4 Remove all the leads from the overload protector 5 Remove the overload protector TV 6 Re install the component by referring to the 9 removal procedure above LS Figure 24 2 COMPRESSOR 1 Remove the cabinet 2 Discharge the refrigerant system using a Freon Recovery System If there is no valve to attach the recovery system install one such as a WATCO 1 before venting the Freon Leave the valve in place after servicing the system 3 Remove the overload protector 4 After purging the unit completely unbraze the suction and discharge tubes at the compressor connections 5 Remove the 3 nuts and the 3 washers which fasten the compressor 6 Remove the compressor See Figure 25 Figure 25 7 Re install the components by referring to the removal procedure above PDT V Service Manual 19 Disassembly 3 CAPACITOR MODEL ROTARY SWITCH TYPE MODEL 1 Remove the control box 2 Remove the knobs and the screw which fasten control panel from control box 3 Remove the screw which is located in the front Open the bottom side of control bo
27. s oi power Improper thermistor di setting Defect of compressor Loose terminal capacitor connection Irregular motor Capacitor check lt gt Improper wiring resistance Q Irregular motor insulation Replacement of fan motor Regular but fails to start Replacement of compressor Replacement Irregular motor resistance 0 Irregular motor insulation 2 Replacement of compressor Locking of piston metal Motor damaged 30 Room Air Conditioner Troubleshooting Guide 1 Check the Fuse Check the wiring diagram Check the Main P W B pattern Exchange the Trans Exchange 0020 005 Exchange ICO2D gt Exchange ICO1A 2 Connect connector exactly Check the P W B pattern Service Manual 31 Exchange IC01D MODEL BG8000ER WG8000RY4 WG1000RY4 ELECTRIC PARTS TROUBLESHOOTING GUIDE Possible Trouble 1 The unit does not operate Is the Trans input power AC 115V YES Is the Trans output power about AC 14V Is shorted the Trans output Is output Voltage of ICO1D DC 12V Is output Voltage of ICO2D NO DC 5V Is the reset circuit all right NO The No 14 of Micom is 5V YES Is the connection between Main and Display all right YES NO NO Is the voltage 18 of Micom
28. the proper length Peel off the backing and attach the Foam Pe to the underside of the window sash 4 Remove the backing from the top Upper Guide Foam Pe and attach the bottom of the Upper Guide 5 Attach the Upper Guide onto the top of the cabinet with 3 type screws 6 Insert the Frame Guides into the bottom of the cabinet 7 Insert the Frame Curtain into the Upper Guide and Frame Guides 8 Fasten the curtains to the unit with 4 Type screws CABINET INSTALLATION Open the window Mark a line on center of the window stool or desired air conditioner location Carefully place the cabinet on the window stool and align the center mark on the bottom front with the center line marked in the window stool 1 2 Pull the bottom window sash down behind the Upper Guide until it meets Do not pull the window sash down so tightly that the movement of Frame Curtain is restricted 2 Room Air Conditioner 1 Installation 3 Loosely assemble the Sill Support using the parts in Figure 7 INDOOR OUTDOOR Sill Support Nut Figure 7 4 Select the position that will place the Sill Support near the outer most point on sill See Figure 8 Be careful when you install the cabinet Frame Frame Guide Screw Type A Guides are broken so easily K 2 ex K ja T 0 gt Cabinet 5 Attach the Sill Support to the cabinet track hole in INDOOR OUTDOOR relation to t
29. ts 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 4 Top of wood strip should be approximately 3 4 higher than the storm window frame STORM WINDOW FRAME or wood strip OUT DOORS 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 center of the outer sill flush against the back off the inner sill This will raise the L bracket as shown Figure 4 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 necessary Installation HARDWARE Type A 16EA SCREW Type C 5EA SCREW Type 8 35 SCREW Type F 2EA Type G2EA SILL SUPPORT BOLT Type D 2EA Type E2EA NUT FRAME CURTAIN Installation Foam Pe Type A Upper Guide Screw Frame Guide Upper Guide Window stool Front Angle Figure 5 Figure 6 PREPARATION OF CHASSIS Remove the screws which fasten the cabinet at both sides and at the back 1 2 Slide the unit from the cabinet by gripping the base pan handle and pulling forward while bracing the cabinet 3 Cut the window sash seal to
30. ure 32 remaining in the system With valves A and B closed stop the vacuum pump 4 Remove the hose from the vacuum pump and place it on the charging cylinder See figure 37B Open valve C Discharge the line at the manifold connection 5 The system is now for final charging Recharge as follows 1 Refrigeration cycle 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 you installed as the system was opened 2 Connect the charging cylinder as shown in figure 33B With valve C open discharge the hose at the manifold connection 3 Open valve A and allow the proper charge to enter the system Valve B is still closed 4 If more charge is required the high side will not take it Close valve A 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 6 Turn off valve B and allow pressure to drop d Repeat steps b and c until the balance of the charge is in the system 6 When satisfied the unit is operating correctly use the pinch off tool with the unit still running and clamp on to the pinch off tube Using a tube cutter cut the pinch off tube about 2 inches from the pinch off tool Use sil fos braze and braze pinch off tube closed Turn off the unit allo
31. ve the valves open The vacuum pump is now pulling through valves A and B up to C by means of the manifold and entire system CAUTION If high vacuum equip ment is used just crack valves A and B for a few minutes then open slowly with the two full turns counter clockwise This will keep oil from foaming and being drawn into the vacuum pump 3 Operate the vacuum pump vaccum for 20 to 30 minutes until 600 microns of vaccum is obtained Close valves A and B and observe vacuum gauge for a few minutes A rise in pres sure would indicate a possible leak or moisture 22 Room Air Conditioner Disassembly Equipment needed Vacuum pump Charging cylinder Manifold gauge Brazing equipment Pin off tool capable of making a vapor proof seal Leak detector Tubing cutter Hand Tools to remove components Service valve COMPOUND GAUGE CONDENSER HIGH PRESSURE SIDE MANIFOLD 6 5 CAPILLARY TUBE SEE INSETS BELOW EVAPORATOR LOW PRESSURE SIDE COMPRESSOR EXTERNAL VACUUM PUMP CHARGING CYLINDER Figure 33A Pulling Vacuum Figure 33B Charging Service Manual 23 Schematic Diagram Schematic Diagram MODEL ROTARY SWITCH TYPE MODEL WRGD 0 Plain Ribbed ROTARY SWITCH GN GN YL 2 0 6 6
32. w it to set for a while and then test the leakage of the pinch off connection 2 EVAPORATOR Remove the cabinet Remove the 2 screws which fasten the evaporator Move the evaporator sideways carefully After discharging the refrigerant completely unbraze the interconnecting tube at the evaporator connections 5 Remove the evaporator carefully 6 Re install the component by referring to notes See Figure 32 3 CAPILLARY TUBE 1 Remove the cabinet 2 After discharging the refrigerant completely unbraze the interconnecting tube at the capillary tube 3 Remove the capillary tube 4 Re install the component by referring to notes N NOTICE Replacement of the refrigeration cycle 1 When replacing the refrigeration cycle be sure to Discharge the refrigerant system using a Freon recovery System If there is no valve to attach the recovery system install one such as WATCO 1 before venting the Freon Leave the valve in place after servicing the system 2 After discharging the unit completely remove the desired component and unbraze the pinch off tubes 3 Solder service valves into the pinch off tube ports leaving the valves open 4 Solder the pinch off tubes with Service valves 5 Evacuate as follows 1 Connect the vacuum pump as illustrated figure 33A 2 Start the vacuum pump slowly open manifold valves A and B with two full turns counterclock wise and lea
33. x Remove the screw and the clamp which fasten the capacitor Disconnect all the leads of capacitor terminals Re install the components by referring to the removal procedure above See Figure 26 Figure 6 N MODEL TOUCH 4 REMOTE CONTROL TYPE MODEL 1 Remove the control box 2 Remove the screw which fasten control panel from control box 3 Remove the screw which located in the front 4 Open the bottom side of control box 5 Remove the screw and the clamp which fastens the capacitor 6 Disconnect all the leads of capacitor terminals 7 Re install the components by referring to the removal procedure above See Figure 27 Figure 27 4 THERMOSTAT MODEL ROTARY SWITCH TYPE MODEL 1 Remove the control box 2 Open the control box 3 Remove the 2 screws which fasten the thermostat 4 Disconnect 2 leads of thermostat terminals 5 Remove the thermostat 6 Re install the components by refereing to the above removal procedure See Figure 28 Figure 28 20 Room Air Conditioner Disassembly 6 ROTARY SWITCH MODEL ROTARY SWITCH TYPE MODEL 1 Remove the control box 2 Open the control box 3 Remove the 2 screws which fasten the rotary switch 4 Disconnect all the leads of the rotary switch terminals 5 Remove the rotary switch 6 Re install the components by referring to the above removal procedure See Figure 29 7 POWER CORD Figure 29 1 Remove the control box 2 Open
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