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RG-51-5

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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 Precautions..........................................................................................................................................3

Dimensions .....................................................................................................................................................7

Outside Dimensions ...................................................................................................................................7

Product Specifications ..................................................................................................................................8

Installation .......................................................................................................................................................9

Select the Best Location ............................................................................................................................9

How to Install ..............................................................................................................................................9

Operation ......................................................................................................................................................12

About the Controls of the Air Conditioner ................................................................................................13

Disassembly ..................................................................................................................................................14

Mechanical Parts......................................................................................................................................14

Air Handling Parts ....................................................................................................................................15

Electrical Parts .........................................................................................................................................16

Refrigerating Cycle...................................................................................................................................17

Schematic Diagram.......................................................................................................................................20

Circuit Diagram.........................................................................................................................................20

Electronic Control Device .........................................................................................................................21

Components Location(For Main P.W.B ASM)...........................................................................................22

Troubleshooting Guide .................................................................................................................................23

Piping System ........................................................................................................................................23

Troubleshooting Guide .............................................................................................................................24

Exploded View ..............................................................................................................................................32

Replacement Parts List ................................................................................................................................33

2 Room Air Conditioner

WARNING

This symbol indicates the possibility of death or serious injury.

CAUTION

WARNING

Do not use the power cord near flammable gas or combustibles such as gasoline, benzene, thinner, etc.

• It may cause explosion or fire.

Do not disassemble or modify products.

• It may cause electric shock and failure.

ON

Do not modify power cord length.

• It will cause electric shock or fire

Use the air conditioner on a single outlet circuit.(See page

7.) Do not share the outlet with other appliances.

• It will cause electric shock or fire.

Always plug into a grounded outlet.

• No grounding may cause electric shock.

Unplug the unit if strange sounds, odors, or smoke come from it.

• Otherwise it will cause fire and electric shock accident.

Do not use the socket if it is loose or damaged.

• It may cause fire and electric shock.

Do not operate with wet hands or in damp environment.

• It ma cause electric shock.

Close all doors, windows and other outside openings to the room.

• The air conditioner must be operated in a enclosed area to be most effective.

Ventilate before operating air conditioner when gas goes out.

• It may cause explosion, fire, and burn.

If water enters the product, turn off the power switch of the main body of appliance. Contact service center after taking the power plug ut from the socket.

• There is risk of fire or electric shock.

Do not clean the air conditioner with water.

• Water may enter the unit and degrage the insulation.

It may cause an electric shock.

CAUTION

Installation

Never touch the metal parts of the unit when removing the filter.

• They are sharp and may cause injury.

Do not block the inlet or outlet.

Ensure that the outer case is not damaged by age or wear.

• It may cause failure of appliance or performance deteriorate.

• If the outer case is damaged, it must be repaired or replaced immediately. Leaving it damaged could result in the air conditioner falling out of the window, creating a safety hazard.

Be cautious not to touch the sharp edges when installing

• It may cause injury.

Sharp edges

Hold the plug by the head when taking it out.

• It may cause electric shock and damage.

Unplug the air conditioner if it will not be used for a long period.

• It will waste power consumption in vain and it may cause accident.

Unplug the air conditioner before cleaning it.

Do not put a pet or nouse plant where it will be exposed to direct air flow

• Since the fan rotates at high speed during operation, it may cause injury.

• This could injury the pet or plant.

Do not use this appliance for special purposes such as pets, foods, precision machinery, or objucts of art.

• It is an air conditioner, not a precision refrigeration system.

Always insert the filter securely. Clean it every two weeks.

Use a soft cloth to clean. Do not use wax, thinner, or a strong detergent.

• Operation without filters will cause failure.

• The appearance of the air conditioner may deteriorate, change color, or develop surface flaws.

Do not drink water drained from air conditioner. Do not direct airflow at room occupants only.

• It is not sanitary and could cause illness or personal injury hazard.

W

ax Thinner

Dimensions

Symbols Used in this Manual

This symbol alerts you to the risk of electric shock.

NOTICE

This symbol alerts you to hazards that could cause harm to the air conditioner.

This symbol indicates special notes.

Outside Dimensions

D

W

Dimensions

Model

Dimension

W

H

D mm(inch) mm(inch) mm(inch)

All Model

439(17 5 /

16"

)

283(11 1 /

8"

)

326(12 13 /

16"

)

Service Manual 7

RG-51-5

COOLING CAPACITY (BTU/h)

POWER SUPPLY (Phase, V, Hz)

INPUT (W)

1ø, 115V, 60HZ

REFRIGERANT CONTROL

4.8

CAPILLARY TUBE

221g(7.8 Oz)

INSIDE FAN TURBO

OUTSIDE FAN ROPELLER FAN WITH SLINGER RING

AIR DISCHARGE 2-WAY (RIGHT AND LEFT)

CHASSIS TOP-DOWN

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

TEMPERATURE CONTROL THERMISTOR

NOTICE

Installation

Installation

This air conditioner is designed with a button-down chassis so it can be easily installed in a window.

Select the Best Location

1. To prevent vibration and noise, make sure the unit is installed securely and firmly.

2. Install the unit where the sun does not shine directly on the unit.

3. The outside of the cabinet must extend outward for at least 10" and there should be no obstacles, such as a fence or wall, within 20" from the back of the cabinet because it will prevent heat radiation of the condenser.

Restriction of outside air will greatly reduce the cooling efficiency of the air conditioner.

CAUTION: All side louvers of the cabinet must remain exposed on the outdside of the structure.

4. 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.

INSIDE

COOLED AIR

Figure 1

OUTSIDE

AWNING

HEAT

RADIATION

Over 20"

FENCE

How to Install

Window Requirements

INNER SILL

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 21" to 35".

The upper and lower sash must open sufficiently to allow a clear vertical opening of 12" from the bottom of the sash to the window stool.

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. 3. Top of wood strip should be approximately

3/4" higher than the storm window frame (STORM WIN-

DOW FRAME) or wood strip (OUTDOORS) to help condensation to drain properly to the outside.

3. Install a second wood strip (approximately 6" long by

11/2" wide and same thickness as first strip) in the center of the outer sill flush against the back off the inner sill.

This will raise the L bracket as shown Figure. 3.

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.

INDOORS

Figure 2

WOOD STRIP MOUNTED

ON TOP OF INNER SILL

INNER

SILL

INDOORS

Figure 3

1" MAX.

WOOD STRIP

FOR L BRACKET

OUTER

SILL

OUTDOORS

3

/

4

"

CLEARANCE

STORM

WINDOW

FRAME

OUTER

SILL

OUTDOORS

Service Manual 9

Installation

Installation Kits Contents(some Models)

HARDWARE

TYPE A: 14EA

(SHORT SCREW)

TYPE B: 2EA

(WOOD SCREW)

TYPE C: 2EA

(WOOD SCREW)

TYPE D: 3EA

(L BACKET)

TYPE E: 1EA

(SEAL STRIP)

(Adhesive backed)

TYPE F: 1EA

(SASH SEAL)

(Not adhesive backed)

TYPE G: 2EA

(GUIDE PANEL)

Before Installation (Some Models Including

Installation Kit)

1. Insert the guide panels into the guides of the air conditioner.

Fasten the curtains to the unit with screws (TYPE A), as shown

Figure. 4.

TYPE A

TYPE A

TYPE H: 1EA

(UPPER GUIDE)

Figure 4

TYPE A

2. Cut the adhesive-backed seal strip (TYPE E) to the window width.

Remove the backing from the seal strip and attach the seal strip to the underside of the bottom window. (Figure. 5)

SEAL STRIP

(TYPE E)

Figure 5

Start Installation (Some Models Including

Installation Kit)

1. Locating Unit in Window

Open the window and mark center line with pencil on the center of the inner sill, as shown in Figure. 6.

2. Attach L Bracket

a. Install the L brackets behind the inner window sill, with the short side of bracket as shown. Use the 2 screws (TYPE A) provided.

b. The bracket helps to hold unit securely in place. Be sure to place bracket edge flush against back of inner sill. See

Figure.7.

CENTER LINE

INNER SILL

ROOM SIDE

Figure 6

INNER SILL

OUTER SILL

TYPE A

INSIDE

CENTER LINE

7.5"

7.5"

OUTSIDE

Figure 7

L BRACKET

10 Room Air Conditioner

Installation

CAUTION: During the following step, hold unit firmly until window sash is lowered to top channel behind side panel frames.

Personal injury or property damage may result if unit falls from window.

3. Install the Air Conditioner in the Window

a. Carefully lift the air conditioner and slide it into the open window. Make sure the bottom guide of the air conditioner drops into the notches of the L bracket.

IMPORTANT :

When the air conditioner drops into the L bracket, the air conditioner will be centered in window opening as shown in

Figure. 8.

Figure 8

WINDOW FRAME

UPPER GUIDE b. While steadying the air conditioner, carefully bring the window sash down behind the upper guide of the air conditioner, as shown in Figure. 9.

BOTTOM

GUIDE

4. Secure the Guide Panels

Extend the guide panels (TYPE G) to fill the window opening using 2 screws (TYPE B), 2 screws(TYPE C) to secure them as shown in Figure. 10.

5. Install the Sash Seal and Sash Lock

a. Cut the sash seal (TYPE F) to the window width.

Stuff the sash seal between the glass and the window to prevent air and insects from getting into the room, as shown in Figure. 10.

b. Fasten the L bracket using a (TYPE A) screw, as shown in Figure. 10.

Figure 9

L BRACKET

L BRACKET

TYPE A

TYPE B

CENTER LINE

SEAL

ABOUT 1 /

4

"

FOAM SEAL

(TYPE F)

TYPE C

6. Window installation of room air conditioner is now completed. See ELECTRICAL DATA for attaching power cord to electrical outlet.

Figure 10

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. 11)

Press the drain pipe into the hole by pushing down and away from the fins to avoid injury.

DRAIN CAP

DRAIN PIPE

1 hang

2 push

Figure 11

Service Manual 11

Operation

Operation

Feature

• 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

Insulation Resistance Test

1. Unplug the power cord and connect a jumper between 2 pins (black and white).

2. The grounding conductor (green or green and yellow) is to be open.

3. Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all positions [except Off] of the ROCKER SWITCH.

4. The value should be over 1 M

Ω

.

About the Controls of the Air Conditioner

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.

12 Room Air Conditioner

POWER

FAN SPEED "Low"

-Turns air conditioner off.

Low speed fan operation with cooling or not.

FAN SPEED "High"

This automatically controls the temperature of indoor air. Turn the knob so that arrow points to the cooler marks for more moderate cooling.

Normal Fan

1. Turn the FAN speed mode switch to the "High" or the "Low" setting

2. Set the thermostat control to the temperature mark "Fan Only"

Normal cooling

1. Turn the FAN speed mode switch to the "High" or the "Low" setting

2. Set the thermostat control to the desire temperature (the mid-point is a good

starting position).

If the room temperature is not satisfactory after a reasonable time, adjust the

control to a warmer setting, as appropriate.

Maximum cooling

1. Turn the FAN speed mode switch to the "High" setting

2. Set the thermostat control to the cooler temperature mark.

Quieter operation

1. Turn the FAN speed mode switch to the "Low" setting

2. Set the thermostat control as needed.

NOTICE

Disassemblyly

Disassembly

Mechanical Parts

1. FRONT GRILLE

1. Disconnect the unit from source of power.

2. Using a screwdriver, remove the screw from the front grille. (See Figure 13)

3. Push the front grille up from the bottom.

Pull the top of the front grille away from the cabinet as the top tabs lift out of their slots. (See Figure 14)

4. Replace the grille by placing the tabs in the slots and push the grille until it snaps into place.

2. CABINET

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to section 1)

3. Remove 10 screws that secure the cabinet to the base pan and condenser. (See Figure 15)

4. Lift the cabinet from the unit.

5. Re-install by referring to the procedures above.

3. CONTROL PANEL

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove 2 screws that secure the control panel to control box and base pan. (See Figure 16)

5. Pull the control board toward yourself.

Controls, wires, and capacitor are now accessible for servicing. Discharge the capacitor before servicing.

6. Disconnect one housing terminal and 3 wires for the fan motor and compressor. (See Figure 17)

7. Re-install components by referring to procedures above.

(Refer to wiring diagram on page 19 in this manual or on control box.)

14 Room Air Conditioner

Air Handling Parts

4. AIR GUIDE UPPER

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove the control board. (Refer to Section 3)

5. Remove tape that attached the air guide upper and lower.

6. Lift air guide upper upward. (See Figure 18)

7. Re-install by referring to the procedures above.

Figure 18

5. ORIFICE, TURBO FAN AND FAN

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove the control panel. (Refer to Section 3)

5. Remove the air guide upper. (Refer to Section 4)

6. Remove 2 screws that secure the condenser to the base pan.

7. Remove the screw that secures the shroud to channel of condenser.

8. Press the snap area of shroud with your thumbs. This allows you to remove it from the condenser.

9. Remove 1 screw that secure the evaporator to the base pan. (See Figure 19)

10. Remove the orifice by pushing the snap area of the air guide blower. (See Figure 20)

11. Remove the clamp springs which are clamped to the boss of fan and turbo fan by hand plier.

(See Figure 21)

12. Pull the fan and turbo fan outward.

13. Re-install by referring to the procedures above.

Figure 19

Figure 20

Disassembly

Figure 21

Service Manual 15

Disassembly

6. MOTOR

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove the control panel. (Refer to Section 3)

5. Remove the air guide upper. (Refer to Section 4)

6. Remove the compressor, turbo fan, axial fan and shroud. (Refer to Section 5)

7. Remove 4 screws that secure the motor to the mount motor of shroud. (See Figure 22)

8. Remove the motor.

9. Re-install by referring to the procedures above.

7. AIR GUIDE LOWER AND SHROUD

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 1)

3. Remove the cabinet. (Refer to Section 2)

4. Remove the control panel. (Refer to Section 3)

5. Remove the air guide upper. (Refer to Section 4)

6. Remove the compressor, turbo fan, axial fan.

(Refer to Section 5)

7. Remove the motor. (Refer to Section 6)

8. Remove 2 screws that secure the shroud to the base pan. (See Figure 23)

9. Lift air guide lower and shroud upward.

(See Figure 23)

10. Re-install by referring to the procedures above.

Electrical Parts

8. OVERLOAD PROTECTOR

1. Remove the front grille and cabinet.

(Refer to Section 1, 2)

2. Remove the nut which fastens the terminal cover.

3. Remove the terminal cover.

4. Remove all the leads from the overload protector.

5. Remove the overload protector.

6. Re-install the components by referring to the removal procedure above. (See Figure 24)

9. COMPRESSOR

1. Remove the front grille and cabinet.

(Refer to Section 1, 2)

2. Discharge the refrigerant by using a refrigerant recovery system.

3. Remove the overload protector.

(Refer to Section 8)

4. After discharging the unit completely, unbrace the suction and discharge pipes at the compressor connections.

5. Remove 3 nuts which fasten the compressor.

6. Remove the compressor.

7. Re-install by referring to the removal procedure above. (See Figure 25)

16 Room Air Conditioner

Figure 22

Figure 23

Figure 24

Figure 25

3. Discharge the capacitor by placing a 20 K resistor

Figure 26

le

12. POWER CORD

4. Remove a screw that secures control panel to control

Figure 27

Figure 29

13. CONDENSER

Figure 30

Service Manual 17

Disassembly

15. EVAPORATOR

1. Remove the cabinet. (Refer to Section 2)

2. Discharge the refrigerant by using a refrigerant recovery system.

3. Remove the air guide upper.

(Refer to Section 4)

4. After discharging the refrigerant completely, unbraze the interconnecting tube at the evaporator connections.

5. Remove the evaporator.

6. Re-install by referring to the procedures above.

16. CAPILLARY TUBE

1. Remove the cabinet. (Refer to Section 2)

2. Discharge the refrigerant by using a refrigerant recovery system.

3. Remove the air guide upper.

(Refer to Section 4)

4. After discharging the refrigerant completely, unbraze the interconnecting tube of the capillary tube.

5. Remove the capillary tube.

6. Re-install by referring to the procedures above.

NOTICE

Replacement of the refrigeration cycle.

1. When replacing the refrigerating cycle, be sure to discharge the refrigerant by using a refrigerant recovery system.

2. After discharging the unit completely, remove the desired components, 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. After completing the above procedures, the valve must be closed and left in place on the system for any subsequent procedures.

6. Evacuate as follows:

6-1. Connect the vacuum pump, as illustrated in figure 31A.

6-2. 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 manifold and the entire system.

CAUTION: If high vacuum equipment is used, just crack valves A and B for a few minutes, then open

18 Room Air Conditioner

slowly with the two full turns counter-clockwise. This will keep oil from foaming and being drawn into the vacuum pump.

6-3. Operate the vacuum pump for 20 to 30 minutes, until 600 micron vacuum is obtained.

Close valves A and B and observe vacuum gauge for a few minutes.

A rise in pressure would indicate a possible leak or moisture remaining in the system.

With valves A and B closed, stop the vacuum pump.

6-4. Remove the hose from the vacuum pump and place it on the charging cylinder. See figure 20B.

Open valve C.

Discharge the line at the manifold connection.

6-5. The system is now ready for final charging.

7. Recharge as follows:

7-1. Rotary compressor systems are charged from the high-side. If the total charge cannot be put in the high-side, the balance will be put in the suction line through the access valve which is installed as the system is opened.

7-2. Connect the charging cylinder as shown in figure 31B. With valve C open, discharge the hose at the manifold connection.

7-3. Open valve A and allow the proper charge to enter the system. Valve B is still closed.

7-4. If more charge is required, the high-side will not take it. Close valve A.

7-5. With the unit running, open valve B and add the balance of the charge. a. Do not add the liquid refrigerant to the lowside. b. Watch the low-side gauge, allow pressure to rise to 30 lbs(0.2MP). c. Turn off valve B and allow the pressure to drop. d. Repeat steps B and C until the balance of the charge is in the system.

7-6. When the unit is operating correctly, use the pinch-off tool with the unit still running and the clamp on the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos solder and solder the pinch-off tube closed. Turn off the unit, allow setting for a while and then test the leakage of the pinch-off connection.

Disassembly

Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment, pinch-off tool capable of making a vapor proof seal, leak detector, tubing cutter, hand tools to remove components and service valve.

COMPOUND GAUGE

MANIFOLD

GAUGE

B A

CONDENSER

(HIGH PRESSURE SIDE)

COMPRESSOR

SEE INSETS

BELOW

EVAPORATOR

(LOW PRESSURE SIDE)

CAPILLARY TUBE

B

A

EXTERNAL VACUUM PUMP

B

LO HI CHARGING CYLINDER

A

Figure 31A-Pulling Vacuum

C

Figure 31B-Charging

Service Manual 19

Schematic Diagram

Schematic Diagram

Circuit Diagram

REF. NO

1

2

3

6

7

4

5

8

DESCRIPTION & NAME

FAN MOTOR

MAIN PCB

DISPLAY

TERMITOR

COMPRESSOR

POWER CORD ASSY

CAPACITOR

OVERLOAD PROTECTOR

Q'TY

1

1

1

1

1

1

1

1

20 Room Air Conditioner

Electronic Control Device

ENERGY SAVER

Osc in

/Reset

TEST

Osc out

VSS

VAref

Room TH

Option1

Option2

Pipe TH

KEY0

KEY1

SEG-g

VDD

SEG-f

SEG-e

SEG-d

SLIDE SW

LED out1

LED out2

LED out0

Schematic Diagram

Service Manual 21

Trouleshooting Glwide

Components Location (For Main P.W.B ASM)

22 Room Air Conditioner

Troubleshooting Guide

Troubleshooting Guide

Piping System

CONDENSER COILS

FAN

MOTOR CAPILLARY

TUBE

TURBO FAN

EVAPORATOR

COILS

Following is a brief description of the important components and their function in what is called the refrigeration system. Reference should be made to Figure 32 to follow the refrigerating cycle and the flow of the refrigerant in the cooling cycle.

ROOM AIR CONDITIONER

CYCLE OF REFRIGERATION

EVAPORATOR COILS

COMPLETE LIQUID

BOIL OFF POINT

COOLED

AIR

ROOM AIR HEAT LOAD

SUCTION LINE

COOL LOW PRESSURE VAPOR

VAPOR INLET

CONDENSER COILS

OUTSIDE COOLING

AIR FOR REFRIGERANT

PASS THROUGH

HOT

DISCHARGED

AIR

LIQUID

PRESSURE

DROP

MOTOR

COMPRESSOR

OIL

(LIQUID REFRIGERANT)

CAPILLARY TUBE

DISCHARGE

LINE

NOT HIGH PRESSURE

VAPOR

LIQUID OUTLET

HIGH PRESSURE VAPOR

LIQUID REFRIGERANT

LOW PRESSURE VAPOR

Figure 32

Service Manual 23

Troubleshooting Guide

Troubleshooting Guide

In general, possible trouble is classified in two kinds.

The one is called Starting Failure which is caused by an electrical defect. The other is Ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application.

Unit is running but cooling is ineffective.

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.

Not on separate circuit

Repair gas leak.

Malfunction of fan.

Clogging of air filter.

Replacement of unit if the unit is beyond repair.

Check inside gas pressure.

Obstruction at air outlet.

Adjust refrigerant charge.

Remove obstruction.

Malfunction of compressor.

Check clogging in refrigeration circuit.

Repair clogging in refrigeration circuit.

24 Room Air Conditioner

Satisfactory operation with temperature difference of inlet & outlet air; 44~50°F (7~10°C)

Replacement of compressor.

Check of power source.

Check of control switch setting.

Fails to Start

Compressor fails only to start.

Drop of power voltage.

Defect of compressor capacitor.

Capacitor check.

Replacement.

Irregular motor resistance (

Ω

)

Irregular motor insulation (

Ω

)

Replacement of compressor

(Motor damaged).

Improper thermostat setting

Loose terminal connection

Improper wiring

Troubleshooting Guide

Check of circuit breaker and fuse.

Gas leakage of feeler bulb of thermostat.

Check control switch.

Fan only fails to start.

Improper wiring.

Defect of fan motor capacitor.

Irregular motor resistance (

Ω

)

Irregular motor insulation (

Ω

)

Replacement of fan motor.

Regular but fails to start.

Replacement of compressor.

(Locking of piston, metal.)

Service Manual 25

Troubleshooting Guide

ELECTRIC PARTS TROUBLESHOOTING GUIDE:

Possible Trouble 1

• The unit does not operate.

NO

Is the Trans input power

AC 115V?

YES

Is the Trans output power about AC 14V?

YES

NO

Is output Voltage of IC01D

DC 12V?

YES

NO

Is output Voltage of IC02D

DC 5V?

YES

NO

NO

Is the reset circuit all right?

(The No.14 of Micom is 5V.)

YES

Is the connection between

Main and Display all right?

YES

NO

Is the voltage No.18 of Micom

DC 5V?

YES

Exchange Main P.W.B Ass'y.

NO

26 Room Air Conditioner

• Check the Fuse.

• Check the wiring diagram.

Is shorted the Trans. output?

NO

• Check the Main

P.W.B pattern.

YES

• Exchange the Trans.

•

Exchange D02D~D05D.

• Exchange IC01D.

• Exchange IC02D.

• Exchange IC01A.

• Connect connector

exactly.

• Check the P.W.B

pattern.

Troubleshooting Guide

Possible Trouble 2

• The compressor does not operate.

Is Temp.

setting set lower than Room

Temp.-0.5

°

C?

NO

YES

• Set the Temp. setting to lower Temp.

Is the voltage No.10

of IC01M 0V?

YES

• Check the RY-COMP.

• Check the wiring

Diagram.

NO

Is the voltage N0.7 of

IC01M DC 5V?

YES

• Exchange IC01M.

NO

Is the Unit for 3 minutes delay?

YES

NO

• Wait 3 Minutes

• Exchange MAIN

P.W.B Ass'y.

Possible Trouble 3

• The compressor always operate.

• Connect LEAD Wire to

RY-COMP again.

Is the wire connection of

RY-COMP all right?

YES

• Check the RY-COMP.

NO

Possible Trouble 4

• Fan does not operate.

Is the voltage NO.1 or 4 of IC01M DC 5V?

YES

NO

Is the voltage NO.13 or 16 of IC01M 0V?

YES

• Check the RY-Hi or

RY-Lo.

• Check the wiring diagram.

NO

• Exchange IC01M.

• Exchange IC01M.

Service Manual 27

Troubleshooting Guide

Possible Trouble 5

Is the voltage of Battery about over 2.3V?

YES

Is the voltage No.16 of CN-DISP1 on Main P.W.B

Ass'y DC 5V?

YES

NO

NO

Is the connection of

CN-DISP1 all right?

YES

• Exchange Receiver Ass'y.

NO

• Romote controller does not operate.

• Exchange the battery.

• Check the P.W.B pattern.

• Connect connector to

CN-DISP1 exactly.

Possible Trouble 6

NO

Is the IC01G all right?

YES

Is the connection of

CN-DISP1 all right?

NO

NO

YES

Does the Q01G,

Q02G, Q03G Q04G operate normally on main P.W.B Ass'y?

NO

YES

• Exchange the display

P.W.B Ass'y.

• It displays abnormally on Display P.W.B Ass'y.

• Exchange IC01G.

• Connect connector

to CN-DISP1 exactly.

• Exchange Q01G,

Q02G, Q03G, Q04G

28 Room Air Conditioner

Troubleshooting Guide

Room Air Conditioner Voltage Limits

NAME PLATE RATING

115V ± 10%

MINIMUM

103.5V

MAXIMUM

126.5V

COMPLAINT CAUSE

Fan motor will not run.

Fan motor runs.

No power

Power supply cord

Rocker switch

Wire disconnected or connection loose

Capacitor (Discharge capacitor before testing.)

Will not rotate

Revolves on overload

REMEDY

Check voltage at outlet. Correct if none.

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. 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.

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.

Service Manual 29

Troubleshooting Guide

COMPLAINT CAUSE

Fan motor noise. Tubo Fan

Compressor will not run, fan motor runs.

Axial Fan

Loose set screw

Worn bearings

Voltage

Wiring

Rocker Switch

Thermostat

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 disconnected, 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 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.

Compressor cycles on overload.

Capacitor (discharge capacitor before servicing.)

Compressor

Overload

Voltage

Overload

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.)

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.)

30 Room Air Conditioner

Troubleshooting Guide

COMPLAINT CAUSE REMEDY

Compressor cycles on Fan motor If not running, determine the cause. Replace if overload. 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)

Insufficient cooling

Capacitor

Wiring

Refrigeration system

Air filter

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.

Unit undersized

Excessive noise Turbo Fan or Axial Fan

Copper tubing

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 tubo fan or axial 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.

Service Manual 31

Exploded View

Exploded View

B

264110

A

149410

238310

266002-2

266002-1

269310

137215

1

59830

W0CZZ

148000

E

135312

1

47582-2

1

47582-1

359011

W48602

554030

352380-1

W48602

346811

352115

249950

354210

349480

359012

149980

352113

552113

C

352380-2

130910

749740

130410

567502

554160

D

550140

26

Room Air Conditioner

Replacement Parts List

Replacement Parts List

LocNo P/NO

130410 3041A10040P

352380-1 5238A10026A

352380-2 5238A10025A

349480 4948A20031B

148000 4800A30012A

149980 4998A10028B

359011 5900A20042A

346811 4681A20116N

359012 5900A20040A

Replacement Parts List

RG-51-5

DESCRIPTION

BASE ASSY SINGLE

GUIDE ,AIR

GUIDE ,AIR

ORIFICE

SUPPORTER

SHROUD

FAN,AXIAL

MOTOR ASSEMBLY, AC

FAN TURBO

W48602 3H02932B

354210 5421A20176B

554030 5403A20174A

352115 5211A25019B

CLAMP, SPRING

EVAPORATOR ASSEMBLY, FIRST

CONDENSER ASSEMBLY, FIRST

TUBE ASSEMBLY EVAPORATOR (IN)

552102 5210A31415B

552113 5211A21145A

TUBE,BENDING

TUBE ASSEMBLY,CONDENSER (OUT)

35211A 5211A21228B TUBE ASSEMBLY, SUCTION

352113 5211A21305A TUBE ASSEMBLY, DISCHARGE SINGLE

554

16

0 2520UC-AA011

550140 5040AR4195A

249950 4995A20343F

237200 3720A30090A

W0CZZ 0CZZA20005B

264110 6411A20056A

269310 2H01109X

238310 3831A20085A

COMPRESSOR SET,CHINA

DAMPER,COMPRESSOR

CASE ASSEMBLY,CONTROL

PANEL, CONTROL

CAPACITOR, FILM BOX

POWER CORD ASSEMBLY

THERMOSTAT ASSEMBLY

ESCUTCHEON

149410 4941A20003A

130910 3091A10055A

135312 3531A10243C

159830 5231A20029B

147582-1 4758A30041A

147582-2 4758A30041B

567502 6750UL-050A

266002-1 2H01319H

266002-2 2H01316J

KNOB ASSEMBLY

CABINET ASSY SINGLE

GRILLE ASSY FRONT

FILTER ASSEMBLY,AIR CLEANER

LOUVER, VERTICAL

LOUVER, VERTICAL

OVERLOAD PROTECT

SWITCH,ROCKER

SWITCH,ROCKER

749740 4974A30066B GUIDE

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

Service Manual 33

P/No.: 3828A20517B

February, 2007

Printed in China