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Shop Quality Grill Parts & Appliance Parts – Over 25,000 ModelsComfort-aire Air Conditioner Parts - Select From 599 Models
Instruction Manual for COMFORT-AIRE models including: REG-183A, REG-243A, REG-183A Cooling With Electric Heat, REG-183A, Cooling With Electric Heat, With Electric Heat, Electric Heat, Heat
Comfort-aire REG-183A Parts | Air Conditioners
This Owner's Manual is provided and hosted by Appliance Factory Parts. COMFORT-AIRE REG-183A ... REFRIGERANT (R-22) CHARGE. EVAPORATOR. CONDENSER. FAN, INDOOR.
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DocumentDocumentThis Owner's Manual is provided and hosted by Appliance Factory Parts. COMFORT-AIRE REG-183A Owner's Manual Shop genuine replacement parts for COMFORT-AIRE REG-183A Find Your COMFORT-AIRE Air Conditioner Parts - Select From 599 Models -------- Manual continues below -------- +($7&21752//(5,1& 5RRP$LU&RQGLWLRQHU REG-183A REG-243A 6HUYLFH$QG3DUWV0DQXDO CAUTION ·BEFORESERVICINGTHEUNIT,READTHESAFETY PRECAUTIONSINTHISMANUAL. ·ONLYFORAUTHORIZEDSERVICEPERSONNEL. Air Conditioner Service Manual TABLE OF CONTENTS Safety Precautions..........................................................................................................................................3 Dimensions......................................................................................................................................................5 Product Specifications ...................................................................................................................................6 Installation .......................................................................................................................................................8 How to Install the Unit ................................................................................................................................8 How to use the Reversible Inlet grille .........................................................................................................8 Window Requirements ...............................................................................................................................9 Installation Kits Contents (some models including installation kit) ...........................................................10 Suggested tool Requirements..................................................................................................................10 Cabinet Installation...................................................................................................................................11 Operation .......................................................................................................................................................13 Disassembly instructions.............................................................................................................................14 Mechanical parts ......................................................................................................................................14 Air Handling Parts ....................................................................................................................................15 Electrical Parts .........................................................................................................................................16 Refrigeration cycle ...................................................................................................................................19 Schematic Diagram.......................................................................................................................................22 Troubleshooting guide..................................................................................................................................23 Piping System ..........................................................................................................................................23 Troubleshooting guide ..............................................................................................................................24 Room Air Conditioner Voltage Limits........................................................................................................26 Exploded View...............................................................................................................................................28 Replacement Parts List ................................................................................................................................29 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. Incorrect operation due to ignoring instruction 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 or damage to property only. Meanings of symbols used in this manual are as shown below. Be sure not to do. Be sure to follow the instruction. Installation WARNING Do not use damaged power cord plugs, or a loose socket. Always use the power plug and socket with the ground terminal. · There is risk of fire or electric shock. · There is risk of electric shock. Service Manual 3 Safety Precautions Do not modify or extend the power cord. · There is risk or fire or electric shock. Do not install, remove, or re-install the unit by yourself(customer). · There is risk of fire, electric shock, explosion, or injury. Be cautious when unpacking and installing the product. Do not store or use flammable gas or combustibles near the air conditioner. · Sharp edges could cause injury. Be especially careful of the case edges and the fins on the condenser and evaporator. Sharp edges · There is risk of fire or failure of product. Gasolin Be sure the installation area does not deteriorate with age. · If the base collapses, the air conditioner could fall with it, causing property damage, product failure, and personal injury. 4 Room Air Conditioner 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 Dimensions D W H Dimension W H D Model mm(inch) mm(inch) mm(inch) REG-183A 660 (26) 428 (16 27/32) 770(30 5/16) REG-243A 660 (26) 428 (16 27/32) 770 (30 5/16) Service Manual 5 Specfications Product Specifications ITEMS MODELS POWER SUPPLY COOLING CAPACITY (Btu/h) INPUT (W) RUNNING CURRENT (A) E.E.R (BTU/W.h) HEATING CAPACITY (Btu/h) INPUT (W) RUNNING CURRENT (A) OPERATING CONDITION COOLING HEATING INDOOR(°C) OUTDOOR(°C) INDOOR(°C) OUTDOOR(°C) REFRIGERANT (R-22) CHARGE EVAPORATOR CONDENSER FAN, INDOOR FAN, OUTDOOR FAN SPEEDS, FAN/COOLING/HEATING FAN MOTOR OPERATION CONTROL ROOM TEMP. CONTROL AIR DIRECTION CONTROL CONSTRUCTION ELECTRIC HEATER PROTECTOR COMPRESSOR FAN MOTOR ELECTRIC HEATER POWER CORD DRAIN SYSTEM NET WEIGHT OUTSIDE DIMENSION (W x H x D) (lbs/kg) (inch) (mm) REG-183A REG-243A 1Ø, 208/230V, 60Hz 1Ø, 208/230V, 60Hz 17,500/17,000 23,00/23,500 1,800/1,750 2,700/2,760 8.2/8.8 13.2/12.2 9.7/9.7 8.5/8.5 11,600/9,400 9,400/11,600 3,100/3,670 3,750/3,770 15.0/16.0 15.0/16.0 26.7 (DB)* 19.4 (WB)** 35 (DB)* 23.9 (WB)** 21.1 (DB)* 15.6 (DB)** 8.3 (DB)* 6.1 (DB)** 810(28.6oz) 1040(36.7oz) 3ROW 18STACKS 3ROW 15STACKS 2ROW 19STACKS,L-BENDING TYPE 2ROW 16STACKS,L-BENDING TYPE BLOWER PROPELLER TYPE FAN WITH SLINGER-RING 1 / 2 / 2 1 / 2 / 2 6 POLES TOUCH PANEL THERMISTOR VERTICAL LOUVER(RIGHT&LEFT) HORIZONTAL LOUVER(UP&DOWN) SLIDE IN-OUT CHASSIS 3.5KW, 230V INTERNAL OVERLOAD PROTECTOR INTERNAL THERMAL PROTECTOR FUSE LINK, BIMETAL THERMOSTAT 1.6m(3 WIRE WITH GROUNDING) ATTACHMENT PLUG(CORD-CONNECTED TYPE) DRAIN PIPE OR SPLASHED BY FAN SLINGER 137/62 146/66 26 X 16 27/32 X 30 5/16 26 X 16 27/32 X 30 5/16 660 X 428 X 770 660 X 428 X 770 * DB:Dry Bulb ** WB:Wet Bulb NOTE: Please refer to Label Quality on the produst since this specification may be changed for improving performance. 6 Room Air Conditioner INSTALLATION How to Install the unit 1. To avoid vibration and noise, make sure the unit is installed securely and firmly. 2. Install the unit where the sunlight does not shine directly on the unit. If the unit receives direct sunlight, build an awning to shade the cabinet. 3. There should be no obstacle, like a fence, within 20" which might restrict heat radiation from the condenser. 4. To prevent reducing performance, install the unit so that louvers of the cabinet are not blocked. 5. Install the unit a little obliquely outward not to leak the condensed water into the room (about 1/2" or 1/4 bubble with level). 6. Install the unit with its bottom portion 30~60" above the floor level. 7. Stuff the foam between the top of the unit and the wall to prevent air and insects from getting into the room. 8. The power cord must be connected to an independent circuit. The green wire must be grounded. 9. Connect the drain tube to the base pan hole in the rear side if you need to drain (consult a dealer). Plastic hose or equivalent may be connected to the drain tube. FOAM COOLED AIR How to use the Reversible Inlet grille The grille is designed to clean the filter both upward and downward. A. BEFORE ATTACHING THE FRONT GRILLE TO THE CABINET, IF YOU WANT TO PULL OUT THE FILTER UPWARD; 1. Open the inlet grille slightly (a). 2. Turn inside out the front grille (a). 3. Disassemble the inlet grille from the front grille with separating the hinged part by inserting a straight type screw-driver tip (b). 4. Then, rotate the inlet grille 180 degrees and insert the hooks into bottom holes of the front grille. 5. Insert the filter and attach the front grille to the cabinet. B. IF YOU WANT TO PULL OUT THE FILTER DOWNWARD; THE GRILLE IS ALREADY DESIGNED FOR THAT WAY. 30-60" Installation 1/4 Bubble Level AWNING FENCE HEAT RADIATION About 1/2" Over 20" b (a) (b) (c) Service Manual 8 Installation Window Requirements NOTICE All supporting parts should be secured to firm wood, masonry, or metal. · WINDOW REQUIREMENTS 1. This unit is designed for installation in standard double hung windows with actual opening widths from 29" to 41". The top and bottom window sashes must open sufficiently to allow a clear vertical opening of 18" from the bottom of the upper sash to the window stool. 2. The stool offset (height between the stool and sill) must be less than 1 1/4". Installation Kits Contents (some models including installation kit) Top retainer bar Foam-PE (Adhesive-Backed) Foam strip Foam-PE (Plain-Back) (Adhesive-Backed) Left frame curtain Frame guide(2) Window locking bracket Sill bracket(2) Support bracket(2) Right frame curtain Type A (14) Type B (7) Type C (5) Type D (2) Carriage Bolt (2) Lock Nut (4) 9 Room Air Conditioner Suggested tool Requirements Installation SCREWDRIVER(+, -), RULER, KNIFE, HAMMER, PENCIL, LEVEL · PREPARATION OF CHASSIS 1. Remove the screws which fasten the cabinet at both sides and at the back. Keep these two screws which fasten the cabinet at both sides for later use. Shipping screws 2. Slide the unit out 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. Figure 1 4. Remove the backing from Foam-PE with 3 holes and attach it to the bottom of the Top retainer bar. 5. Attach the Top retainer bar onto the top of the cabinet with 3 screws (Type A). Figure 2 6. Insert the Frame guides into the bottom of the cabinet. 7. Insert the Frame Curtain into the Top retainer bar and Frame guides. Foam-PE Figure 3 Top retainer bar Top retainer bar Foam-PE 8. Fasten the curtains to the unit with 10 screws (Type A) at both sides. Screw (Type A) Figure 4 Frame guide Screw(Type A) Service Manual 10 Installation Cabinet Installation 1. Open the window. Mark a line on the center of the window stool between the side window stop moldings. Loosely attach the sill bracket to the support bracket using the carriage bolt and the lock nut. 2. Attach the sill bracket to the window sill using the screws (Type B). Carefully place the cabinet on the window stool and align the center mark on the bottom front with the center line marked window stool. 3. Using the M-screw and the lock nut, attach the support bracket to the cabinet track hole. Use the first track hole after the sill bracket on the outer edge of the window sill. Tighten the carriage bolt and the lock nut. Be sure the cabinet slants outward. 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. 4. Pull the bottom window sash down behind the Top retainer bar until they meet. NOTICE 1. Do not pull the window sash down so tightly that the movement of Frame curtain is restricted. Attach the cabinet to the window stool by driving the screws (Type B) through the cabinet into window stool. 2. The cabinet should be installed with a very slight tilt downward toward the outside. Sill Bracket Carriage Bolt (M-Screw) Figure 5 Cabinet Track hole Support Bracket Carriage bolt and lock nut Figure 6 Support Bracket Lock nut Machine screw (Type D) and lock nut Outer edge of window sill Screw(Type B) Sill bracket Top retainer bar Figure 7 Window stool Front angle Window sash Top retainer bar Foam-PE Cabinet Frame curtain Foam-PE Figure 8 Sash track 11 Room Air Conditioner Figure 9 Front Angle Screw(Type B) 5. Pull each Frame curtain fully to each window sash track, and pull the bottom window sash down behind the Top retainer bar until it meets. 6. Attach each Frame curtain the window sash by using screws (Type C). (See Fig. 10) Figure 10 7. Slide the unit into the cabinet. (See Fig. 11) CAUTION: For security purpose, reinstall screws (Type A) at cabinet's sides. 8. Cut the Foam-strip to the proper length and insert between the upper window sash and the lower window sash. (See Fig. 12) 9. Attach the Window locking bracket with a screw (Type C). (See Fig. 13) Screw Figure 11 Figure 12 Figure 13 10. 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 Fig.34) 11. Lift the inlet grille and secure it with a screw (Type A) through the front grille. (See Fig. 14) 12. Window installation of room air conditioner is now completed. Figure 14 Figure 15 Installation Screw(Type C) Power Cord Screw (Type A) Foam-Strip Window locking bracket Service Manual 12 Installation Operation · VENTILATION The ventilation lever must be in the CLOSE position in order to maintain the best cooling conditions. When a fresh air is necessary in the room, set the ventilation lever to the OPEN position. The damper is opened and room air is exhausted. CLOSE VENT OPEN REMOTE CONTROLLER Power 1 Temp 5 Fan Speed 4 Timer Mode 3 2 Energy Auto Saver Swing 7 6 1. POWER BUTTON To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again. This button takes priority over any other buttons. 2. OPERATION MODE SELECTION BUTTON Everytime you push this button, it will toggle COOL, FAN and HEAT. 3. ON/OFF TIMER BUTTON Everytime you push this button, timer is set as follows.(1Hour 2Hours 3Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel) 4. FAN SPEED SELECTOR Everytime you push this button, it is set as follows. (Hi[ ] Low[ ] Hi[ ]....) 5. ROOM TEMPERATURE SETTING BUTTON This button can automatically control the temperature of the room. The temperature can be set within a range of 60°F to 86°F by 1°F. 6. AUTO SWING This button can automatically control the air flow direction. 7. ENERGY SAVER The fan stops when the compressor stops cooling. Approximately every 3 munutes the fan will turn on and check the room air to determine if cooling is needed. 8. REMOCON SIGNAL RECEIVER CAUTION: A slight heat odor may come from the unit when first switching to HEAT after the cooling season is over. This odor, caused by fine dust particles on the heater, will disappear quickly. 13 Room Air Conditioner Disassembly Disassembly - Before the following disassembly, power switch is set to off and disconnected the power cord. Mechanical parts 1. Front grille 1. Open the inlet 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. (See Fig. 16) 5. Re-install the component by referring to the removal procedure. NOTICE Mark of inlet grille means opening direction. 2. Cabinet 1. After disassembling the front grille, remove the screws which fasten the cabinet at both sides. Keep these for later use. 2. Remove the two screws which fasten the cabinet at back. (See Fig. 17) 3. Pull the base pan forward. Figure 16 3. Control box 1. Remove the front grille. (Refer to section 1) 2. Pull the base pan forward so that you can remove the 2 screws which fasten the cover control at the right side. (See Fig. 18) 3. Remove the 3 screws which fasten the controlbox. (See Fig. 18) 4. Discharge the capacitor by placing a 20,000 ohm resistor across the capacitor terminals. 5. Disconnect two wire housings in the control box. 6. Pull the control box forward completely. 7. Re-install the components by referring to the removal procedure. (See Fig. 18) (Refer to the wiring diagram found on page 29~30 in this manual and on the control box.) Figure 17 Figure 18 Service Manual 14 Air handling parts 4. Cover (at the top) 1. Remove the front grille. (Refer to section 1) 2. Remove the cabinet. (Refer to section 2) 3. Remove 11 screws which fasten the brace and covers. 4. Remove the covers and the brace. (See Fig. 19) 5. Re-install the components by referring to the removal procedure, above. Figure 19 5. Blower 1. Remove the cover. (Refer to section 4) 2. Remove the 3 screws which fasten the evaporator at the left side and the top side.(See Fig. 19) 3. Move the evaporator sideward carefully. 4. Remove the 2 terminals carefully(See Fig. 20). 5. Remove the 3 screws which fasten the Heater Cover. (See Fig. 20) 6. Remove the Heater Cover.(See Fig. 20) 7. Remove the orifice from the air guide carefully. (See Fig. 21) 8. Remove the clamp which secures the blower with plier. (See Fig. 21) 9. Remove the blower with plier or your hand without touching blades. (See Fig. 22) 10. Re-install the components by referring to the removal procedure, above. Figure 20 Figure 21 Disassembly 15 Room Air Conditioner Figure 22 Disassembly 6. Fan 1. Remove the cabinet. (Refer to section 2) 2. Remove the brace and shroud cover. (Refer to section 4) 3. Remove the side cover with 2 screws.(See Fig. 23) 4. Remove the 5 or 6 screws which fasten the condenser. 5. Move the condenser sideways carefully. 6. Remove the clamp which secures the fan. 7. Remove the fan. (See Fig. 23) 8. Re-install the components by referring to the removal procedure, above. 7. Shroud 1. Remove the fan. (Refer to section 6) 2. Remove the 2 screws which fasten the shroud. 3. Remove the shroud. (See Fig. 24) 4. Re-install the component by referring to the removal procedure, above. Electrical parts 8. Motor 1. Remove the cabinet. (Refer to section 2) 2. Remove the cover control and disconnect a wire hous- ing in control box. (Refer to section 3) 3. Remove the blower. (Refer to section 5) 4. Remove the fan. (Refer to section 6) 5. Remove the 4 screws which fasten the motor. (See Fig. 25) 6. Remove the motor. 7. Re-install the components by referring to the removal procedure, above. 9. Compressor 1. Remove the cabinet. (Refer to section 2) 2. Discharge the refrigerant system using 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. Disconnect the 3 leads from the compressor. 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. (See Fig. 26) 6. Remove the compressor. 7. Re-instill the components by referring to the removal procedure, above. Figure 23 Figure 24 Figure 25 Figure 26 Service Manual 16 10. CAPACITOR 1. Remove the control box. (Refer to section 3) 2. Remove the screw and knobs which fasten the display panel. 3. Disconnect the 2 leads from the rocker switch and remove the panel. 4. Remove a screw and unfold the control box. (See Fig. 27) 5. Remove the screw and the clamp which fastens the capacitor. (See Fig. 27) 6. Disconnect all the leads of capacitor terminals. 7. Re-install the components by referring to the removal procedure, above. Figure 27 11. POWER CORD 1. Remove the control box. (Refer to section 3) 2. Unfold the control box. (Refer to section 10) 3. Disconnect the grounding screw from the control box. 4. Disconnect 2 receptacles. 5. Remove a screw which fastens the clip cord. 6. Pull the power cord. (See Fig. 28) 7. Re-install the component by referring to the removal procedure, above. (Use only one ground-marked hole for ground connection.) 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 fitted to the unit.) Figure 28 12. THERMISTOR 1. Remove the control box. (Refer to section 3) 2. Unfold the control box. (Refer to section 10) 3. Disconnect the thermistor terminals from main P.W.B assembly. 4. Remove the thermistor. 5. Re-install the components by referring to the removal procedure above. (See Figure 30) 17 Room Air Conditioner Figure 29 Disassembly Disassembly 13. SYNCHRONOUS MOTOR 1. Remove the control box. (Refer to section 3) 2. Unfold the control box. (Refer to section 10) 3. Remove the crankshaft. 4. Disconnect all the leads of the synchronous motor. 5. Remove the 2 screws which fasten the synchronous motor. (See Fig. 30) 6. Re-install the components by referring to the removal procedure, above. Figure 30 Service Manual 18 Disassembly Refrigeration cycle CAUTION: Discharge the refrigerant system using 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. 16. CONDENSER 1. Remove the cabinet. (Refer to section 2) 2. Remove the brace and the shroud cover. (Refer to section 4) 3. Remove 2 screws which fasten the side cover.(See Fig. 31) 4. Remove the 5 or 6 screws which fasten the condenser. 5. After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections. 6. Remove the condenser. 7. Re-install the components by referring to notes. (See Fig. 31) 17. EVAPORATOR 1. Remove the cabinet. (Refer to section 2) 2. Remove the top cover and the brace. (Refer to section 4) 3. Discharge the refrigerant completely. 4. Remove the 3 screws which fasten the evaporator at the left side and the top side. 5. Move the evaporator sideward carefully and then unbraze the interconnecting tube at the evaporator connectors. 6. Remove the evaporator. 7. Re-install the components by referring to notes. (See Fig. 32) Figure 31 18. CAPILLARY TUBE 1. Remove the cabinet. (Refer to section 2) 2. Remove the brace. (Refer to section 4) 3. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube. 4. Remove the capillary tube. 5. Re-install the components by referring to notes. Figure 32 19 Room Air Conditioner NOTICE - Replacement of the refrigeration cycle. 1. When replacing the refrigeration cycle, be sure to 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. 2. After discharging the unit completely, remove the desired component, and unbrace 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 Fig. 35A. 2) Start the vacuum pump, slowly open manifold valves A and B with two full turns counterclockwise and leave the valves closed. The vacuum pump is now pulling through valves A and B up to valve C by means of themanifold and 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 counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump. 3) Operate the vacuum pump for 20 to 30 minutes, until 600 microns of 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. 4) Remove the hose from the vacuum pump and place it on the charging cylinder. See Fig. 35B. Open valve C. Discharge the line at the manifold connection. 5) The system is now ready for final charging. 6. 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 Fig. 35B. 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 Lowside. 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. 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 solder and solder pinchoff tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection. Service Manual 20 Disassembly Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pin-off tool capable of making a leak-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve. CONDENSER (HIGH PRESSURE SIDE) COMPOUND GAUGE MANIFOLD GAUGE B A CAPILLARY TUBE SEE INSETS BELOW EVAPORATOR (LOW PRESSURE SIDE) COMPRESSOR A B EXTERNAL VACUUM PUMP Figure 31A-Pulling Vacuum 21 Room Air Conditioner LOW HI B A CHARGING CYLINDER C Figure 31B-Charging Schematic Diagram Wiring Diagram ELECTRIC HEATING MODEL Schematic Diagram Service Manual 22 Troubleshooting Guide Troubleshooting Guide Piping System CONDENSER COIL FAN MOTOR CAPILLARY TUBE COMPRESSOR BLOWER EVAPORATOR COIL Figure 32 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 COOLED AIR COMPLETE LIQUID BOIL OFF POINT SUCTION LINE COOL LOW PRESSURE VAPOR ROOM AIR HEAT LOAD CONDENSER COILS VAPOR INLET HOT DISCHARGED AIR LIQUID PRESSURE DROP 23 Room Air Conditioner MOTOR OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH COMPRESSOR OIL (LIQUID REFRIGERANT) CAPILLARY TUBE Figure 32 LIQUID OUTLET HIGH PRESSURE VAPOR LIQUID REFRIGERANT LOW PRESSURE VAPOR 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. Dirty indoor coil (Heat exchanger) Malfunction of fan Clogged of air filter. Obstruction at air outlet Correct above trouble Check outdoor coil (heat exchanger) & the fan operation. Check gas leakage. Repair gas leak. Replacement of unit if the unit is beyond repair. Check heat load increase. Clean condenser. Not on separate circuit. Check inside gas pressure. Adjusting of refrigerant charged. Malfunction of compressor. Check clogging in refrigeration circuit. Repair clogging in refrigeration circuit. Satisfactory operation with temperature difference of inlet & outlet air ; 44~50°F(7~10°C) Replacement of compressor. Service Manual 24 Troubleshooting Guide Fails to Start Check of power source. Check of control switch setting. Compressor only fails to start. Drop of power voltage. Defect of compressor capacitor. Capacitor check. Replacement Improper thermostat setting. Loose terminal connection. Improper wiring. Check circuit breaker and fuse. Gas leakage of feeler bulb of thermostat Check of control switch. Fan only fails to start. Improper wiring. Defect of fan motor capacitor. Irregular motor resistance ( ). Irregular motor insulation ( ). Replacement of fan motor. Irregular motor resistance ( ) Irregular motor insulation ( ) Replacement of compressor (Motor damaged) 25 Room Air Conditioner Regular but fails to start. Replacement of compressor (locking of rotor, metal). Troubleshooting Guide Room Air Conditioner Voltage Limits NAME PLATE RATING 208~230±10% 115±10% MINIMUM 187V 104V MAXIMUM 253V 126V COMPLAINT Fan motor will not run. Fan motor runs intermittently Fan motor noise. Compressor will not run, but fan motor runs. CAUSE No power Power supply cord Rotary switch Wire disconnected or connection loose Capacitor (Discharge capacitor before testing.) Will not rotate Revolves on overload. Fan Blower Loose clamper Worn bearings Voltage Wiring Rotary REMEDY Check voltage at outlet. Correct if necessary. 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. Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal. Test capacitor. Replace if not within ±10% of manufacturer's rating. Replace if shorted, open, or damaged. Fan blade hitting shroud or blower wheel hitting scroll. Realign assembly. Units using slinger ring for condenser fan must have 1/4 to 5/16 inch clearance to the base. If it hits the base, 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. Check voltage. 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. 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. If not within limits, call an electrician. Check the wire connections, if loose, repair or replace the terminal. If wires are off, refer to wiring diagram for identification, and replace. Check wire locations. If not per wiring diagram, correct. Check for continuity, refer to the wiring diagram for terminal identification. Replace the switch if circuit is open. Service Manual 26 Troubleshooting Guide COMPLAINT CAUSE REMEDY Compressor will not run, but fan motor runs. Compressor cycles on overload. Compressor cycles on overload. Compressor cycles on overload. Insufficient cooling or heating Excessive noise Auto air-swing fails. Thermostat Capacitor (Discharge capacitor before servicing.) Compressor Overload Voltage Overload Fan motor Condenser air flow restriction Condenser fins (damaged) Capacitor Wiring Refrigerating system Air filter Exhaust damper door Unit undersized Blower or fan Copper tubing Rotary switch. Wiring Synchronous motor. Check the position of knob If not at the coldest setting, advance the knob to this setting and restart unit. Check continuity of the thermostat. Replace thermostat if circuit is open. Check the capacitor. Replace if not within ±10% of manufacturers 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 it, and retest.) Check the voltage. If not within 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, determine 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 reassembling. If condenser fins are closed over a large area on the coil surface, head pressures will increase, causing the compressor to overload. Straighten the fins or replace the coil. Test capacitor. Check the terminals. If loose, repair or replace. Check the system for a restriction. If restricted, clean of replace. Close if open. Determine if the unit is properly sized for the area to be cooled. Check the set screw or clamp. If loose or missing, correct. If the blower or fan is hitting air guide, rearrange the air handling parts. Remove the cabinet carefully and rearrange tubing not to contact cabinet, compressor, shroud, and barrier. Set the knob to HIGH COOL or LOW COOL while rocker switch is ON. Check terminals. If loose, repair or replace. Check the synchronous motor for open circuit. 27 Room Air Conditioner Exploded View 130910 Exploded View 148000 135500 554031 749750 135515 749740 731273 346811 W48602 559011 149980 130410 354210 359012 349600 W48602 349001 147582 135312 135314 159830 264110 567480 268711-1 137215 238310 268711-2 554160 550140 249950 W0CZZ 552102 352115-2 352113 352115-1 352111 146812 35211A 753010 147581-2 147581-1 267110 135510 753000 Service Manual 28 LocNo 130410 130910 135312 135314 135510 137215 146812 147581-1 147581-2 147582 148000 149980 159830 238310 249950 264110 567480 268711-1 268711-2 267110 346811 349001 349600 352111 352113 35211A 749750 354210 359012 550140 552102 554031 554160 559011 753000 753010 W0CZZ W48602 352115-1 352115-2 135500 731273 749740 135515 P/NO 3041A23004F 3091AR6056Q AEB30969402 3530AR1604A 3551A30015A 3720AR6163A 2H01102J 4758AR7264C 4758AR7278C 4758AR6157B 4800AR7271A 4998AR1597B 5231AR6159A MDD37823802 4995A20186K 6411A20056Q 6323A20003S 6871A20611V EBR30851603 6711A20035A 4681A20081T 4900AR7265A 4960AR1596A 5211AR7059A 5211A25040C 5211A20204G 5239A20001N 5421A20059F 5834AR1599B 4H00982C 5210A24956Q 5403A20062F 2520UCBJ002 5900AR1508B 5300A20003A 5301A30001B 6120AR2194F 3H02932C 5211A20433C 5211A20433D 3550AR6167A 3127A10015M 2H00858D 3551A30001A Replacement Parts List REG-183A DESCRIPTION Base Assy Single Cabinet Assy Single Grille Assy Front Grille Assy Inlet COVER ASSEMBLY, CONTROL PANEL, CONTROL MOTOR ASSEMBLY, SYNC Louver ,HORIZONTAL LOUVER, HORIZONTAL LOUVER, VERTICAL BRACE SHROUD FILTER(MECH), A/C ESCUTCHEON CONTROL BOX ASSEMBLY, SINGLE POWER CORD ASSEMBLY THERMISTOR ASSEMBLY PWB(PCB) ASSEMBLY, DISPLAY PWB(PCB) ASSEMBLY, MAIN(AC) REMOTE CONTROLLER MOTOR ASSEMBLY, AC DAMPER, VENTILATION MOUNT, MOTOR TUBE ASSEMBLY, CONNECTOR TUBE ASSEMBLY, DISCHARGE SINGLE TUBE ASSEMBLY, SUCTION SINGLE AIR GUIDE ASSEMBLY EVAPORATOR ASSEMBLY, FIRST FAN ASSEMBLY, BLOWER ISOLATOR, COMP Tube,Bending CONDENSER ASSEMBLY, BENDING COMPRESSOR FAN ASSEMBLY, AXIAL HEATER, ELECTRIC HEATER ASSEMBLY, ELECTRIC CAPACITOR, DRAWING CLAMP, SPRING TUBE, EVAPORATOR TUBE, EVAPORATOR COVER Install Part Assembly,Single Guide Cover Assembly,Top(Indoor) REMARK R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R 28 LocNo 130410 130910 135312 135314 135510 137215 146812 147581-1 147581-2 147582 148000 149980 159830 238310 249950 264110 567480 268711-1 268711-2 267110 346811 349001 349600 352111 352113 35211A 749750 354210 359012 550140 552102 554031 554160 559011 753000 753010 W0CZZ W48602 352115-1 352115-2 135500 731273 749740 135515 Replacement Parts List REG-243A P/NO DESCRIPTION 3041A23004H Base Assy Single 3091AR6056Q Cabinet Assy Single AEB30969402 Grille Assy Front 3530AR1604A Grille Assy Inlet 3551A30015A COVER ASSEMBLY, CONTROL 3720AR6163A PANEL, CONTROL 2H01102J MOTOR ASSEMBLY, SYNC 4758AR7264C Louver ,HORIZONTAL 4758AR7278C LOUVER, HORIZONTAL 4758AR6157B LOUVER, VERTICAL 4800AR7271A BRACE 4998AR1597B SHROUD 5231AR6159A FILTER(MECH), A/C MDD37823802 ESCUTCHEON 4995A20186L CONTROL BOX ASSEMBLY, SINGLE 6411A20056Q POWER CORD ASSEMBLY 6323A20003S THERMISTOR ASSEMBLY 6871A20611V PWB(PCB) ASSEMBLY, DISPLAY EBR30851603 PWB(PCB) ASSEMBLY, MAIN(AC) 6711A20035A REMOTE CONTROLLER 4681A20130E MOTOR ASSEMBLY, AC 4900AR7265A DAMPER, VENTILATION 4960A10006A MOUNT, MOTOR 5211AR3399Z TUBE ASSEMBLY, CONNECTOR 5211A21526V TUBE ASSEMBLY, DISCHARGE SINGLE 5211A30250H TUBE ASSEMBLY, SUCTION SINGLE 5239A20001N AIR GUIDE ASSEMBLY 5421A20248E EVAPORATOR ASSEMBLY, FIRST 5834AR1599B FAN ASSEMBLY, BLOWER 4022UL005A ISOLATOR, COMP 5211A21444C Tube Assembly,Capillary 5403A20232G CONDENSER ASSEMBLY, BENDING 5416A20045B COMPRESSOR 5900AR1508B FAN ASSEMBLY, AXIAL 5300A20003A HEATER, ELECTRIC 5301A30001B HEATER ASSEMBLY, ELECTRIC 0CZZA20001X CAPACITOR, DRAWING 3H02932C CLAMP, SPRING 5210A22224W TUBE, EVAPORATOR 5210A22224U TUBE, EVAPORATOR 3550AR6173A COVER 3127A10015M Install Part Assembly,Single 2H00858D Guide 3551A30001A Cover Assembly,Top(Indoor) REMARK R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R 29 6SHFLILFDWLRQVDQGSHUIRUPDQFHGDWDVXEMHFWWRFKDQJHZLWKRXWQRWLFH +($7&21752//(5,1& :(//:257+$9(18(-$&.6210,&+,*$1 7+(48$/,7</($'(5,1&21',7,21,1*$,5 3ULQWHGLQ&KLQD