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AD-101A
AD-81A
ADS-81B
CAU
• BEFOR
PRECA
• ONLY FOR AUTHORIZED SERVICE PERSONNEL.
Safety Precautions
Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions
must be followed.
Incorrect operation due to ignoring instructions will cause harm or damage. The seriousness
is classified by the following indications.
This symbol indicates the possibility of death or serious injury.
WARNING
This symbol indicates the possibility of injury or damage to property only.
CAUTION
Meanings of symbols used in this manual are as shown below.
Be sure not to do.
Be sure to follow the instruction.
WARNING
Always install the expansion panel(s).
Do not place the power cord near a heater.
• Improper assembly or installation may cause
incorrect operation, including injury, fire, and
electric shock hazards.
• It may cause fire and electric shock.
Do not use the power cord near flammable
gas or combustibles such as gasoline,
benzene, thinner, etc.
Do not disassemble or modify products.
• It may cause explosion or fire.
• It may cause failure and electric shock.
Service Manual 3
Safety Precautions
Plug in the power plug
properly.
Do not operate or stop the
unit by inserting or pulling
out the power plug.
Do not damage or use an
unspecified power cord.
• Otherwise, it will cause
electric shock or fire.
• It will cause electric shock or
fire.
• It will cause electric shock or
fire.
Do not modify power cord
length.
Use the air conditioner on a
single outlet circuit.(see page 7.)
Do not share the outlet with
other appliances.
Always plug into a
grounded outlet.
• It will cause electric shock or
fire.
•
It will cause electric shock or
fire.
• No grounding may cause
electric shock.
Ventilate before operating air Do not use the socket if it is
Do not operate with wet
hands or in damp
environment.
conditionerwhen gas goes
out.
loose or damaged.
It may cause explosion, fire,
and burn.
•
• It may cause fire and electric
shock.
• It will cause electric shock.
4 Room Air Conditioner
Safety Precautions
If water enters the product, turn off the the
power switch of the main body of appliance.
Contact service center after taking the power-
plug out from the socket.
Do not clean the air conditioner with water.
• It will cause electric shock or failure of
machine.
• Water may enter the unit and degrade the
insulation. It may cause an electric shock.
CAUTION
Never touch the metal parts of the unit
when removing the filter.
Do not block the inlet or outlet.
• They are sharp and may cause injury.
It may cause failure of appliance or
performance deteriorate.
•
Ensure that the outer caseis not damaged
by age orwear.
Be cautious not to touch the sharp edges
when installing.
• Leaving it damaged couldresult in the air
conditioner falling out of the window, creating
a safety hazard.
It may cause injury.
•
Sharp
edges
Service Manual 5
Dimensions
Dimensions
Symbols Used in this Manual
This symbol alerts you to the risk of electric shock.
This symbol alerts you to hazards that could cause harm to the
air conditioner.
NOTICE
This symbol indicates special notes.
Outside Dimensions
11
1
525(20 /16")
470(18 /2")
6 Room Air Conditioner
Specfications
rduct Specifications
MODELS
RAD-101A
ITEMS
1Ø, 115, 60Hz
POWER SUPPLY
COOLING CAPACITY
INPUT
(Btu/h)
(W)
9,800
1,000
9.3
RUNNING CURRENT
(A)
.
E.E.R
(BTU/W h)
9.8
OPERATING
26.7(DB)* 19.4(WB)**
INDOOR ( C)
OUTDOOR ( C)
CONDITION
35(DB)*
23.9(WB)**
410g(14.5oz)
REFRIGERANT (R-22) CHARGE
EVAPORATOR
Ø 7.0, 3ROW 14STACKS
Ø7.0 , 2R 16STACKS(L)
CONDENSER
TURBO FAN
FAN, INDOOR
PROPELLER TYPE FAN WITH SLINGER RING
FAN, OUTDOOR
3/3
FAN SPEEDS, FAN/COOLING
FAN MOTOR
6 POLES
REMOTE CONTROLLER
THERMISTOR
OPERATION CONTROL
ROOM TEMP. CONTROL
AIR DIRECTION CONTROL
CONSTRUCTION
HORIZONTAL LOUVER (UP & DOWN), VERTICAL LOUVER (RIGHT&LEFT)
SLIDE IN-OUT CHASSIS
OVERLOAD PROTECTOR
COMPRESSOR
PROTECTOR
INTERNAL THERMAL PROTECTOR
3 WIRE WITH GROUNDING
FAN MOTOR
POWER CORD
DRAIN SYSTEM
ATTACHMENT PLUG (CORD-CONNECTED TYPE)
DRAIN PIPE OR SPLASHED BY FAN SLINGER
18 1/2 x 13 7/8 x 20 11/16
OUTSIDE DIMENSION
(inch)
(W x H x D)
(mm)
469 x 353 x 526
* DB:Dry Bulb
**WB:Wet Bulb
Service Manual 7
Specfications
rduct Specifications
MODELS
RAD - 81A
ITEMS
1Ø, 115, 60Hz
POWER SUPPLY
COOLING CAPACITY
INPUT
(Btu/h)
(W)
8,000
815
RUNNING CURRENT
(A)
7.6
.
E.E.R
(BTU/W h)
9.8
OPERATING
26.7(DB)* 19.4(WB)**
INDOOR ( C)
OUTDOOR ( C)
CONDITION
35(DB)*
260
23.9(WB)**
g(9.2 oz)
REFRIGERANT (R-22) CHARGE
EVAPORATOR
Ø 7.0, 2ROW 14STACKS
CONDENSER
Ø5.0, 2ROW 16STACKS
TURBO FAN
FAN, INDOOR
PROPELLER TYPE FAN WITH SLINGER RING
FAN, OUTDOOR
3/3
FAN SPEEDS, FAN/COOLING
FAN MOTOR
6 POLES
REMOTE CONTROLLER
THERMISTOR
OPERATION CONTROL
ROOM TEMP. CONTROL
AIR DIRECTION CONTROL
CONSTRUCTION
HORIZONTAL LOUVER (UP & DOWN), VERTICAL LOUVER (RIGHT&LEFT)
SLIDE IN-OUT CHASSIS
OVERLOAD PROTECTOR
COMPRESSOR
PROTECTOR
INTERNAL THERMAL PROTECTOR
3 WIRE WITH GROUNDING
FAN MOTOR
POWER CORD
DRAIN SYSTEM
ATTACHMENT PLUG (CORD-CONNECTED TYPE)
DRAIN PIPE OR SPLASHED BY FAN SLINGER
18 1/2 x 13 7/8 x 20 11/16
OUTSIDE DIMENSION
(inch)
(W x H x D)
(mm)
469 x 353 x 526
* DB:Dry Bulb
**WB:Wet Bulb
Service Manual 8
Specfications
rduct Specifications
MODELS
RADS - 81B
ITEMS
1Ø, 115, 60Hz
POWER SUPPLY
COOLING CAPACITY
INPUT
(Btu/h)
(W)
8,000
740
RUNNING CURRENT
(A)
6.8
.
E.E.R
(BTU/W h)
10.8
OPERATING
26.7(DB)* 19.4(WB)**
INDOOR ( C)
OUTDOOR ( C)
CONDITION
35(DB)*
490
23.9(WB)**
g(17.3 oz)
REFRIGERANT (R-22) CHARGE
EVAPORATOR
Ø 7.0, 2ROW 14STACKS
CONDENSER
Ø5.0, 2ROW 16STACKS
TURBO FAN
FAN, INDOOR
PROPELLER TYPE FAN WITH SLINGER RING
FAN, OUTDOOR
3/3
FAN SPEEDS, FAN/COOLING
FAN MOTOR
6 POLES
REMOTE CONTROLLER
THERMISTOR
OPERATION CONTROL
ROOM TEMP. CONTROL
AIR DIRECTION CONTROL
CONSTRUCTION
HORIZONTAL LOUVER (UP & DOWN), VERTICAL LOUVER (RIGHT&LEFT)
SLIDE IN-OUT CHASSIS
OVERLOAD PROTECTOR
COMPRESSOR
PROTECTOR
INTERNAL THERMAL PROTECTOR
3 WIRE WITH GROUNDING
FAN MOTOR
POWER CORD
DRAIN SYSTEM
ATTACHMENT PLUG (CORD-CONNECTED TYPE)
DRAIN PIPE OR SPLASHED BY FAN SLINGER
18 1/2 x 13 7/8 x 20 11/16
OUTSIDE DIMENSION
(inch)
(W x H x D)
(mm)
469 x 353 x 526
* DB:Dry Bulb
**WB:Wet Bulb
Service Manual 9
Installation
Installation
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
11" 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.
INSIDE
OUTSIDE
AWNING
FENCE
COOLED AIR
HEAT
RADIATION
Restriction of outside air will greatly reduce the cooling effi-
ciency of the air conditioner.
ABOUT 1/4
"
CAUTION: All side louvers of the cabinet must
remain exposed on the outdside of the structure.
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.
Figure 1
5. Install the unit with the bottom about 30"~60" above the
floor level.
Installation Check
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 circuit 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 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. 2)
Drain Pipe
Drain Cap
Figure 2
10 Room Air Conditioner
Installation
How to Install
INNER
SILL
Window Requirements
NOTICE
All supporting parts should be secured to
firm wood, masonry, or metal.
1. 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.
OUTER
SILL
2. If 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. 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.
INDOORS
OUTDOORS
Figure 3
1" MAX.
WOOD STRIP MOUNTED
ON TOP OF INNER SILL
3/4"
CLEARANCE
STORM
WINDOW
FRAME
INNER
SILL
WOOD STRIP
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.
FOR
L
BRACKET
OUTER
SILL
INDOORS
OUTDOORS
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.
Figure 4
Installation
HARDWARE
Type A:16EA
(SCREW)
Type B:3EA
(SCREW)
Type C:5EA
(SCREW)
Type H:1EA
(FOAM-STRIP)
Type I:1EA
(UPPER GUIDE)
Type J:1EA
(FOAM-PE)
Type K:2EA
(FRAME-GUIDE)
Type L:1EA
(WINDOW LOCKING BRACKET)
Type M:1EA
(FOAM-PE)
Type N:1EA
(DRAIN JOINT PIPE)
Type O:1EA
(DRAIN WASHER)
Type D:2EA
(NUT)
Type E:2EA
(FRAME CURTAIN)
Type F:2EA
(SILL SUPPORT)
Type G:2EA
(BOLT)
10
Service Manual 11
Installation
PREPARATION OF CHASSIS
Shipping
Screws
1. Remove the screws which fasten the cabinet at both
sides and at the back.
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 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 it to the bottom of the Upper Guide.
5. Attach the Upper Guide onto the top of the cabinet with
3 type A screws.
Upper Guide
Foam-Pe
6. Insert the Frame Guides into the bottom of the cabinet.
Foam-Pe
7. Insert the Frame Curtain into the Upper Guide
and Frame Guides .
Upper Guide
(Type A)
8. Fasten the curtains to the unit with 4 Type A screws.
Screw
Frame-Guide
Screw
(Type A)
Screw
Frame-Guide
(Type A)
CABINET INSTALLATION
1. 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.
Upper Guide
Window stool
Front Angle
Figure 5
2. Pull the bottom window sash down behind the Upper
Guide until it meets.
Window Sash
Foam-pe
Upper guide
NOTICE
Do not pull the window sash down so tightly
that the movement of Frame Curtain is restricted.
Cabinet
Frame Curtain
Foam-pe
Figure 6
12 Room Air Conditioner
Installation
3. Loosely assemble the Sill Support using the parts in
Figure 7.
INDOOR
OUTDOOR
Sill Support
Nut
Bolt
Figure 7
4. Select the position that will place the Sill Support
near the outer most point on sill (See Figure 8)
Frame Guide
Screw(Type A)
NOTICE
Be careful when you install the cabinet (Frame
Guides are broken so easily).
Cabinet
INDOOR
OUTDOOR
5. Attach the Sill Support to the cabinet track hole in
relation to the selected position using 2 Type A
screws in each support(See Figure 8).
Figure 8
Screw(Type B)
Screw(Type A)
6. The cabinet should be installed with a very slight
tilt(about 1/2") downward toward the outside (See
Figure 9).
Adjust the bolt and the nut of Sill Support for
balancing the cabinet.
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.
Front Angle
Screw(Type B)
8. Pull each Frame Curtain fully to each window sash
Sill support
Figure 9
track, and repeat step 2.
9. Attach each Frame Curtain the window sash using
screws (Type C).(See Figure 10)
Type C
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
Installation
10. Slide the unit into the cabinet.(See Figure 11)
CAUTION: For security purpose, reinstall screws
(Type A) at cabinet's sides.
Power cord
Screw(Type A)
Screw(Type A)
Figure 11
11. Cut the Foam-Strip to the proper length and insert
between the upper window sash and the lower
window sash.
(See Figure 12)
Foam-Strip
Figure 12
12. Attach the Window Locking Bracket with a Type C
screw. (See Figure 13)
Window Locking Bracket
13. Attach the front grille to the cabinet by inserting the
tabs on the grille into the tabs on the front of the
cabinet. Push the grille in until it snaps into place.
(See Figure 14)
Figure 13
14. Lift the inlet grille and secure it with a Type A screw
through the front grille.
(See Figure 15)
Figure 14
Figure 15
15. Window installation of room air conditioner is now
completed. See ELECTRICAL DATA for attaching
power cord to electrical outlet.
Figure 16
14 Room Air Conditioner
Operation
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 and Function of Controls
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.
Operation
O ff
- Turns air conditioner off.
Me d Fa n - Med speed fan operation without cooling.
Low Fa n - Low speed fan operation without cooling.
High C ool - Cooling with high speed fan operation.
Me d C ool - Cooling with med speed fan operation.
Low C ool - Cooling with low speed fan operation.
Thermostat
5
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)
6
4
3
7
8
2
1
9
FOR NORMAL COOLING
1. Turn the operation switch to the High Cool or the Low Cool setting.
2. Set the thermostat 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
Operation
Remote Control Operations
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.
The controls look like this:
Controls
Power
1
7
Temp
3
2
Fan Speed
3
Timer
Mode
6
4
5
Energy
Saver
4
5
6
2
1
10 Hours ¡ 11 Hours ¡ 12 Hours ¡ CANCLE.
The set temperature will be raised by 2°F after 30
minutes and again after another 30 minutes.
1. Power
• To turn the Set ON, push the button. To turn the
Set OFF, push the button again.
- Starting Operation
• This button takes priority over any other buttons.
Each press of the button cycles through the options
in this order:
1 Hour ¡ 2 Hours ¡ 3 Hours ¡ 4 Hours ¡ 5 Hours
¡ 6 Hours ¡ 7 Hours ¡ 8 Hours ¡ 9 Hours ¡
10 Hours ¡ 11 Hours ¡ 12 Hours ¡ CANCLE.
• 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.
5. Energy Saver
The fan stops when the compressor stops cooling.
3. Fan Speed
• Approximately every 3 minutes the fan will turn on
and check the room air to determine if cooling is
needed.
• Pressing the Fan Speed button toggles between
Low and High speeds.
4. On/Off Timer
6. Cool/Fan/Dry
- Stopping Operation
• Everytime you push this button, it will toggle
between COOL, FAN, and DRY.
Each press of the button cycles through the options
in this order:
1 Hour ¡ 2 Hours ¡ 3 Hours ¡ 4 Hours ¡ 5 Hours
¡ 6 Hours ¡ 7 Hours ¡ 8 Hours ¡ 9 Hours ¡
How to Insert Batteries
• Do not use rechargeable batteries.
Such batteries
differ from standard dry cells in
shape, dimensions, and perfor-
mance.
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.
• Remove the batteries from the
remote controller if the air condi-
tioner is not going to be used for
an extended length of time.
3. Re-attach the cover.
16 Room Air Conditioner
Disassembly
Disassembly
— Before the following disassembly, POWER SWITCH set to OFF and disconnect the power cord.
Mechanical Parts
1. FRONT GRILLE
1. Open the lnlet grille upward or downward.
2. 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)
Figure 19
Service Manual 17
Disassembly
Air Handling Parts
1. AIR GUIDE AND BLOWER
1. Remove the front grille.
2. 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)
Figure 20
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.
Figure 21
2. FAN AND SHROUD
1. Remove the cabinet.
2. Remove the brace.
3. Remove the 3 screws which fasten the condenser.
4. Move the condenser to the left carefully.
5. Remove the clamp which secures the fan.
6. Remove the fan and then pull out the shroud.
(See Figure 22)
7. Re-install by referring to the removal procedure.
Figure
22
18 Room Air Conditioner
—7—
Disassembly
3. MOTOR
1. Remove the cabinet.
2. Remove the evaporator.
3. Remove the orifice.
4. Remove the blower.
5. Remove the fan.
6. 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 procedure, above.(See Figure 23)
Figure 23
Electrical Parts
1. OVERLOAD PROTECTOR
1. Remove the cabinet.
2. Remove the nut which fastens the terminal cover.
3. Remove the terminal cover. (See Figure 24)
4. Remove all the leads from the overload protector.
5. Remove the overload protector.
6. Re-install the component by referring to the
removal procedure, above.
Figure 24
2. COMPRESSOR
1. Remove the cabinet.
2. Discharge the refrigerant system using a FreonTM
Recovery System.
If there is no valve to attach the recovery system,
install one (such as a WATCO A-1) before venting
the FreonTM. 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)
7. Re-install the components by referring to the
removal procedure, above.
Figure 25
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.
4. Open the bottom side of control box.
5. Remove the screw and the clamp which fasten the
capacitor.
6. Disconnect all the leads of capacitor terminals.
7. Re-install the components by referring to the
removal procedure, above. (See Figure 26)
Figure 26
MODEL : TOUCH & 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
Figure 27
removal procedure, above. (See 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)
Figure 29
7. POWER CORD
1. Remove the control box.
2. Open the control box.
3. Disconnect the grounding screw from the control
box.
4. Disconnect the 2 receptacles.
5. Remove a screw which fastens the clip cord.
(See Figure 30)
6. Remove the power cord.
7. Re-install the component by referring to the above
removal procedure, above.
(Use only one ground-marked hole
connection.)
for ground
Figure 30
8. If the supply cord of this appliance is damaged, it
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
TM
CAUTION: 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 A-1) before venting the Freon . Leave
TM
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
connections.
5. Remove the condenser carefully.
6. Re-install the component by referring to notes.
(See Figure 31)
Figure 31
Service Manual 21
Disassembly
2. EVAPORATOR
1. Remove the cabinet.
2. Remove the 2 screws which fasten the evaporator.
3. Move the evaporator sideways carefully.
4. 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.
Figure 32
NOTICE
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 ready for final charging.
— Replacement of the refrigeration cycle.
1. When replacing the refrigeration cycle, be sure to
TM
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 A-1) before venting
the Freon . Leave the valve in place after
TM
6. Recharge as follows :
servicing the system.
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.
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 leave the valves open.
The vacuum pump is now pulling through valves
A and B up to valve C by means of the manifold
and entire system.
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.
c. 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.
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.
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, allow it to
set for a while, and then test the leakage of the
pinch-off connection.
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
GAUGE
A
B
CAPILLARY TUBE
SEE INSETS
BELOW
EVAPORATOR
(LOW PRESSURE SIDE)
COMPRESSOR
HI
LOW
A
A
B
B
EXTERNAL
VACUUM PUMP
CHARGING
CYLINDER
C
Figure 33B-Charging
Figure 33A-Pulling Vacuum
Service Manual 23
Schematic Diagram
Schematic Diagram
Wiring Diagram
MODEL : ROTARY SWITCH TYPE MODEL
P OWE R INP UT
1
BK(BR )
WH(BL)
(R ibbed)
(P lain)
R OTAR Y S WITC H
G N(G N/YL)
7
5
3
1
8
6
4
2
L
R D
BK
BL
R D
H
M
BK
2
4
BL
MOTOR
OR (BR )
YL
G N(G N/YL)
C AP AC ITOR
YL
F
6
OR (BR )
C
BK
BK
R D
BL
R
H
R D
S
C OMP .
3
5
BK
BR (YL) BL
C
OLP
THE R MOS TAT
R D
8
P .T.C
WIR ING DIAG R AM
3854AR 3563A
7
S: Service Parts
N: Non Service Parts
LOCATION
NO.
Q'TY
PER SET
REMARKS
DESCRIPTION
1
2
3
4
5
6
7
POWER CORD ASSY
S
S
S
S
S
S
S
1
1
1
1
1
1
1
FAN MOTOR
COMPRESSOR
ROTARY SWITCH
THERMOSTAT
CAPACITOR
OVERLOAD PROTECTOR
8
P.T.C
S
1
24 Room Air Conditioner
Schematic Diagram
Circuit Diagram
MODEL : TOUCH & REMOTE CONTROL TYPE MODEL
1
6
2
7
4
5
3
8
LOCATION
Q'TY
DESCRIPTION
NO.
PER SET
1
2
3
4
5
6
7
8
POWER CORD ASSEMBLY
FAN MOTOR
1
1
1
1
1
1
1
1
COMPRESSOR
DISPLAY P.W.B ASSEMBLY
MAIN P.W.B ASSEMBLY
THERMISTOR
CAPACITOR
OWERLOAD PROTECTOR
Service Manual 25
Schematic Diagram
Electronic Control Device
26 Room Air Conditioner
Schematic Diagram
Components Location(For Main P.W.B ASM)
Service Manual 27
Troubleshooting Guide
Troubleshooting Guide
Piping System
CONDENSER COIL
FAN
CAPILLARY TUBE
COMPRESSOR
MOTOR
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.
ROOM AIR CONITIONER
CYCLE OF REFRIGERATION
EVAPORATOR COILS
CONDENSER COILS
VAPOR INLET
SUCTION LINE
COOL LOW PRESSURE VAPOR
HOT
DISCHARGED
AIR
COMPLETE LIQUID
BOIL OFF POINT
COOLED
AIR
ROOM AIR HEAT LOAD
OUTSIDE COOLING
AIR FOR REFRIGERANT
PASS THROUGH
MOTOR
COMPRESSOR
OIL
LIQUID
PRESSURE
DROP
LIQUID OUTLET
HIGH PRESSURE VAPOR
(LIQUID REFRIGERANT)
LIQUID REFRIGERANT
LOW PRESSURE VAPOR
CAPILLARY TUBE
Figure 34
28 Room Air Conditioner
Troubleshooting Guide
Troubleshooting Guide
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.
Unit runs but poor cooling.
Ineffective Cooling
Check cold air
circulation for smooth
flow.
Check outdoor coil
(heat exchanger) and
fan operation.
Check heat load
increase.
Clean condenser.
Dirty indoor coil
(heat exchanger)
Check gas leakage.
Repair gas leak.
Not on separate circuit
Malfunction of fan.
Check inside gas
pressure.
Replacement of unit if
the unit is beyond repair.
Clogging of air filter.
Obstruction at air outlet.
Remove obstruction.
Adjust refrigerant
charge.
Malfunction of
compressor.
Check clogging in refrigera-
tion circuit.
Replacement of
compressor.
Satisfactory operation
with temperature
Repair clogging in
refrigeration circuit.
difference of inlet & outlet
air; 44~50°F (7~10°C)
Service Manual 29
Troubleshooting Guide
Fails to Start
Check of circuit breaker
and fuse.
Check of power source.
Check of control panel
setting.
Check control panel.
Compressor fails only to
start.
Fan only fails to start.
Improper wiring.
Improper thermistor
setting
Drop of power voltage.
Defect of fan motor
capacitor.
Defect of compressor
capacitor.
Loose terminal
connection
Irregular motor
resistance (Ω)
Irregular motor
insulation (Ω)
Capacitor check.
Replacement.
Improper wiring
Replacement of fan motor.
Regular but fails to start.
Irregular motor resistance (Ω)
Irregular motor insulation (Ω)
Replacement of compressor.
(Locking of piston, metal.)
Replacement of compressor
(Motor damaged).
30 Room Air Conditioner
Troubleshooting Guide
¡ MODEL : BG8000ER, WG8000RY4, WG1000RY4
ELECTRIC PARTS TROUBLESHOOTING GUIDE:
• The unit does not operate.
Possible Trouble 1
NO
•
•
Check the Fuse.
Check the wiring diagram.
Is the Trans input power
AC 115V?
YES
NO
NO
•
Check the Main
P.W.B pattern.
Is the Trans output power
about AC 14V?
Is shorted the Trans. output?
YES
YES
• Exchange the Trans.
Exchange D02D~D05D.
•
NO
NO
Is output Voltage of IC01D
DC 12V?
• Exchange IC01D.
YES
• Exchange IC02D.
Is output Voltage of IC02D
DC 5V?
YES
NO
NO
NO
Is the reset circuit all right?
(The No.14 of Micom
is 5V.)
• Exchange IC01A.
YES
Is the
• Connect connector
exactly.
connection between
Main and Display
all right?
YES
• Check the P.W.B
pattern.
Is the voltage No.18 of Micom
DC 5V?
YES
Exchange Main P.W.B Ass'y.
Service Manual 31
Troubleshooting Guide
• The compressor does not operate.
• Set the Temp. setting to lower Temp.
Possible Trouble 2
Is Temp.
setting set lower than Room
Temp.-0.5°C?
NO
NO
YES
NO
NO
Is the voltage No.10
of IC01M 0V?
Is the voltage N0.7 of
Is the Unit for 3 minutes
delay?
IC01M DC 5V?
YES
YES
YES
• Check the RY-COMP.
• Check the wiring
Diagram.
• Exchange IC01M.
• Wait 3 Minutes
• Exchange MAIN
P.W.B Ass'y.
• The compressor always operate.
Possible Trouble 3
• Connect LEAD Wire to
RY-COMP again.
NO
Is the wire connection of
RY-COMP all right?
YES
• Check the RY-COMP.
• Fan does not operate.
Possible Trouble 4
NO
Is the voltage NO.1 or 4
of IC01M DC 5V?
• Exchange IC01M.
• Exchange IC01M.
YES
NO
Is the voltage NO.13 or 16
of IC01M 0V?
YES
• Check the RY-Hi or
RY-Lo.
•
Check the wiring diagram.
32 Room Air Conditioner
Troubleshooting Guide
• Romote controller does not operate.
Possible Trouble 5
NO
NO
Is the voltage of Battery
about over 2.3V?
• Exchange the battery.
YES
Is the voltage No.16
of CN-DISP1 on Main P.W.B
Ass'y DC 5V?
•
Check the P.W.B pattern.
YES
• Connect connector to
CN-DISP1 exactly.
NO
Is the connection of
CN-DISP1 all right?
YES
•
Exchange Receiver Ass'y.
• It displays abnormally on Display P.W.B Ass'y.
Possible Trouble 6
NO
NO
NO
• Exchange IC01G.
Is the IC01G all right?
YES
NO
• Connect connector
to CN-DISP1 exactly.
Is the connection of
CN-DISP1 all right?
YES
Does the Q01G,
Q02G, Q03G Q04G operate normally
on main P.W.B Ass'y?
• Exchange Q01G,
Q02G, Q03G, Q04G
YES
• Exchange the display
P.W.B Ass'y.
Service Manual 33
Troubleshooting Guide
ROOM AIR CONDITIONER VOLTAGE LIMITS
NAME PLATE RATING
115V ± 10%
MINIMUM
103.5V
MAXIMUM
126.5V
COMPLAINT
CAUSE
REMEDY
Fan motor will not run.
No power
Check voltage at outlet. Correct if none.
Power supply cord
Rotary switch
Check voltage to rotary switch. If none, check
power supply cord. Replace cord if circuit is
open.
Check switch continuity. Refer to wiring diagram
for terminal identification. Replace switch if
defective.
Wire disconnected or
connection loose
Connect wire. Refer to wiring diagram for
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.
34 Room Air Conditioner
Troubleshooting Guide
REMEDY
COMPLAINT
CAUSE
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.
Loose set screw
Worn bearings
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.
Compressor will not run,
fan motor runs.
Voltage
Wiring
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.
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.
Rotary
Check for continuity, refer to the wiring diagram
for terminal identification. Replace the switch if
the circuit is open.
Thermostat
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.
Capacitor (discharge
capacitor before
servicing.)
Check the capacitor.
Replace if not within ±10% of manufacturer’s
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.)
Service Manual 35
Troubleshooting Guide
COMPLAINT
CAUSE
REMEDY
Compressor cycles on
overload.
Voltage
Check the voltage. See the limits on the
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.)
Compressor cycles on
overload.
Fan motor
If not running, determine the cause. Replace if
required.
Condenser air flow
restriction
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.
Condenser fins
(damaged)
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.
Capacitor
Test the capacitor.
Wiring
Check the terminals. If loose, repair or replace.
Check the system for a restriction.
If restricted, clean or replace.
Refrigeration system
Air filter
Insufficient cooling
Excessive noise
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
Remove the cabinet and carefully rearrange the
tubing not to contact the cabinet,
compressor, shroud, and barrier.
36 Room Air Conditioner
Exploded View
554030
554031
749740
731273
559010
267110
W52106-2
W52106-1
249950
238310
249950
263230
266003
W0CZZ
552102
552113
352115
W0CZZ
269310
137215
268712
352113
146812
264110
135500
135510
135500
149410
35211A
237200
268714
264110
Replacement Parts List
PART NO
LOCATION NO
DESCRIPTION
Remark
RAD-81A
RAD-101A
130410
130910
135312
BASE ASSEMBLY,SINGLE
CABINET ASSY,SINGLE
3041A30011D
3041A30005P
R
R
R
3091A30005R
GRILLE ASSY,FRONT(SINGLE)
3531A29018B
3530A10027A
3550A30036B
5210AR3196F
4758A20002A
4758A30008A
135313
135500
749740
147581
147582
149980
152302
237200
238310
249950
264110
263230
267110
268712
268714
GRILLE ASSY,INLET
COVER,CONTROL(INDOOR)
UPPER GUIDE CABINET
LOUVER,HORIZONTAL
LOUVER,VERTICAL
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
SHROUD
4998A10019A
4998A10010A
FILTER(MECH),A/C
5231A20004A
3720A20053A
3831A20015R
PANEL,CONTROL
ESCUTCHEON
CONTROL BOX ASSEMBLY,SINGLE
POWER CORD ASSEMBLY
THERMISTOR ASSEMBLY
REMOTE CONTROLLER
PWB(PCB) ASSEMBLY,DISPLAY
PWB(PCB) ASSEMBLY,MAIN
4995A20806C
6411A20056A
4995A20806D
6411A20056E
6323A20003S
6711A20066C
6871A20443B
EBR39266506
346811
349001
349480
349600
352113
352115
352390
354210
MOTOR ASSEMBLY,SINGLE
DAMPER,VENTILAYION
ORIFICE
4681A20073Z
4681A20027J
R
R
R
R
R
R
R
R
4901A30001A
4948A30007B
4960A20014A
MOUNT,MOTOR
TUBE ASSEMBLY,DISCHARGE SINGLE
TUBE ASSEMBLY,EVAPORATOR IN
AIR GUIDE ASSEMBLY
EVAPORATOR ASSEMBLY,FIRST
5211A20708D
5211AR2930Z
5211A20130R
5211A20130H
5239A30002S
5421A20061M
5421A20061K
359012
550140
FAN,TURBO
ISOLATOR,COMP
5900A10008A
R
R
5040AR4195A
4830AR4335A
552102
TUBE,CAPILLARY BEND
5211A30260B
5211A20598B
R
552113
554030
554160
559010
567502
731273
TUBE ASSEMBLY,CONDENSER OUT
CONDENSER ASSEMBLY,FIRST
COMPRESSOR
5211A10067G
5403A20092H
2520UCBA002 2520UCDK004
5900A20015A
6750UL048A
3127A20074D
5211A10067 P
5403A20043 S
R
R
R
R
R
R
FAN ASSEMBLY,AXIAL
O.L.P
INSTALL PARTS ASSEMBLY,SINGLE
A
6750U-L031
35211A
TUBE ASSEMBLY,SUCTION SINGLE
CAPACITOR
AJR31679501
0CZZA20005B
R
R
5211A20130M
0CZZA20001N
W0CZ
Z
vice Manual 37
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