Heat Controller Inc Air Conditioner REG 243A User Manual

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REG-183A  
REG-243A  
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CAUTION  
• BEFORE SERVICING THE UNIT, READ THE SAFETY  
PRECAUTIONS IN THIS MANUAL.  
• 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 instruction will cause harm or damage. The seriousness is  
classified by the following indications.  
This symbol indicates the possibility of death or serious injury.  
WARNING  
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.  
WARNING  
Installation  
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.  
Do not install, remove, or re-install the unit by  
yourself(customer).  
• There is risk or fire or electric shock.  
• 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 com-  
bustibles near the air conditioner.  
• Sharp edges could cause injury. Be especially careful  
of the case edges and the fins on the condenser and  
evaporator.  
• There is risk of fire or failure of product.  
Sharp edges  
Gasolin  
Be sure the installation area does not deterio-  
rate with age.  
• If the base collapses, the air conditioner could fall with  
it, causing property damage, product failure, and per-  
sonal injury.  
4 Room Air Conditioner  
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  
D
W
Model  
REG-183A  
REG-243A  
Dimension  
W
H
mm(inch)  
mm(inch)  
mm(inch)  
660 (26)  
660 (26)  
428 (16 27/32)  
428 (16 27/32)  
770 (30 5/16)  
5
D
770(30 /16)  
Service Manual 5  
Specfications  
Product Specifications  
MODELS  
REG-183A  
REG-243A  
ITEMS  
1Ø, 208/230V, 60Hz  
17,500/17,000  
1,800/1,750  
8.2/8.8  
1Ø, 208/230V, 60Hz  
23,00/23,500  
2,700/2,760  
13.2/12.2  
POWER SUPPLY  
COOLING CAPACITY  
INPUT  
(Btu/h)  
(W)  
RUNNING CURRENT  
E.E.R  
(A)  
9.7/9.7  
8.5/8.5  
(BTU/W.h)  
(Btu/h)  
11,600/9,400  
3,100/3,670  
15.0/16.0  
9,400/11,600  
3,750/3,770  
15.0/16.0  
HEATING CAPACITY  
INPUT  
(W)  
RUNNING CURRENT  
(A)  
26.7 (DB)* 19.4 (WB)**  
INDOOR(°C)  
OUTDOOR(°C)  
INDOOR(°C)  
OUTDOOR(°C)  
COOLING  
35 (DB)* 23.9 (WB)**  
21.1 (DB)* 15.6 (DB)**  
OPERATING  
CONDITION  
HEATING  
8.3 (DB)*  
6.1 (DB)**  
1040(36.7oz)  
810(28.6oz)  
REFRIGERANT (R-22) CHARGE  
EVAPORATOR  
3ROW 18STACKS  
3ROW 15STACKS  
2ROW 16STACKS,L-BENDING TYPE  
2ROW 19STACKS,L-BENDING TYPE  
CONDENSER  
BLOWER  
PROPELLER TYPE FAN WITH SLINGER-RING  
1 / 2 / 2 1 / 2 / 2  
FAN, INDOOR  
FAN, OUTDOOR  
FAN SPEEDS, FAN/COOLING/HEATING  
FAN MOTOR  
6 POLES  
TOUCH PANEL  
THERMISTOR  
OPERATION CONTROL  
ROOM TEMP. CONTROL  
VERTICAL LOUVER(RIGHT&LEFT)  
HORIZONTAL LOUVER(UP&DOWN)  
SLIDE IN-OUT CHASSIS  
AIR DIRECTION CONTROL  
CONSTRUCTION  
ELECTRIC HEATER  
COMPRESSOR  
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  
PROTECTOR  
FAN MOTOR  
ELECTRIC HEATER  
POWER CORD  
DRAIN SYSTEM  
NET WEIGHT  
137/62  
146/66  
(lbs/kg)  
26 X 16 27/32 X 30 5/16  
26 X 16 27/32 X 30 5/16  
OUTSIDE DIMENSION  
(W x H x D)  
(inch)  
(mm)  
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  
INSTALLATION  
How to Install the unit  
1. To avoid vibration and noise, make sure the unit is  
installed securely and firmly.  
1/4 Bubble  
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.  
Level  
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.  
FENCE  
AWNING  
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).  
FOAM  
HEAT  
RADIATION  
COOLED  
AIR  
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.  
About 1/2"  
Over 20"  
8. The power cord must be connected to an independent cir-  
cuit. 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.  
b
How to use the Reversible Inlet grille  
The grille is designed to clean the filter both upward and downward.  
(a)  
A. BEFORE ATTACHING THE FRONT GRILLE TO THE CAB-  
INET, 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.  
(b)  
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.  
(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 bot-  
tom of the upper sash to the window stool.  
1
4
2. The stool offset (height between the stool and sill) must be less than 1 / ".  
Installation Kits Contents (some models including installation kit)  
Foam strip  
(Plain-Back)  
Foam-PE  
(Adhesive-Backed)  
Top retainer bar  
Foam-PE  
(Adhesive-Backed)  
Left frame  
curtain  
Frame guide(2)  
Window locking  
bracket  
Right frame  
curtain  
Sill bracket(2)  
Type A (14)  
Support bracket(2)  
Type B (7)  
Type C (5)  
Type D (2)  
Carriage Bolt (2)  
Lock Nut (4)  
9 Room Air Conditioner  
Installation  
Suggested tool Requirements  
SCREWDRIVER(+, -), RULER, KNIFE, HAMMER, PENCIL, LEVEL  
• PREPARATION OF CHASSIS  
Shipping screws  
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.  
2. Slide the unit out from the cabinet by gripping the base pan  
handle and pulling forward while bracing the cabinet.  
Figure 1  
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 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  
Top retainer bar  
Foam-PE  
6. Insert the Frame guides into the bottom of the cabinet.  
Foam-PE  
Figure 3  
7. Insert the Frame Curtain into the Top retainer bar and  
Frame guides.  
Top retainer bar  
8. Fasten the curtains to the unit with 10 screws (Type A) at  
both sides.  
Screw  
(Type A)  
Screw(Type A)  
Frame guide  
Figure 4  
Service Manual 10  
Installation  
Cabinet Installation  
1. Open the window. Mark a line on the center of the win-  
dow stool between the side window stop moldings.  
Loosely attach the sill bracket to the support bracket  
using the carriage bolt and the lock nut.  
Sill  
Bracket  
Support  
Bracket  
Carriage  
Bolt  
(M-Screw)  
Lock nut  
Figure 5  
2. Attach the sill bracket to the window sill using the  
screws (Type B).  
Machine screw (Type D)  
and lock nut  
Cabinet  
Carefully place the cabinet on the window stool and  
align the center mark on the bottom front with the center  
line marked window stool.  
Track hole  
Outer edge  
of window  
sill  
Support  
Bracket  
Screw(Type B)  
Carriage bolt  
and lock nut  
Sill bracket  
Figure 6  
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.  
Top  
retainer  
bar  
Window stool  
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.  
Front angle  
Figure 7  
Window sash  
Top retainer bar  
Foam-PE  
4. Pull the bottom window sash down behind the Top  
retainer bar until they meet.  
Cabinet  
Frame curtain  
Foam-PE  
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.  
Figure 8  
Sash track  
2. The cabinet should be installed with a very slight tilt  
downward toward the outside.  
Front Angle  
Screw(Type B)  
Figure 9  
11 Room Air Conditioner  
Installation  
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.  
Screw(Type C)  
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, rein-  
stall screws (Type A) at cabinet's  
sides.  
Power Cord  
Screw (Type A)  
Screw  
Figure 11  
8. Cut the Foam-strip to the proper length and insert  
between the upper window sash and the lower window  
sash. (See Fig. 12)  
Foam-Strip  
Figure 12  
Window locking  
bracket  
9. Attach the Window locking bracket with a screw (Type  
C). (See Fig. 13)  
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 cabi-  
net. 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)  
Figure 14  
12. Window installation of room air conditioner is now  
completed.  
Figure 15  
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 ven-  
tilation 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
2
6
Timer  
Mode  
3
7
Energy  
Saver  
Auto  
Swing  
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.  
Figure 17  
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 18  
Service Manual 14  
Disassembly  
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).  
Figure 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 21  
Figure 22  
15 Room Air Conditioner  
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)  
Figure 23  
Figure 24  
Figure 25  
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)  
Figure 26  
6. Remove the compressor.  
7. Re-instill the components by referring to the removal  
procedure, above.  
Service Manual 16  
Disassembly  
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 connec-  
tion.)  
Figure 28  
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.)  
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)  
Figure 29  
17 Room Air Conditioner  
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)  
Figure 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)  
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.  
6. Recharge as follows :  
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.  
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. After discharging the unit completely, remove the  
desired component, and unbrace the pinch-off tubes.  
2) Connect the charging cylinder as shown in Fig.  
35B.  
3. Solder service valves into the pinch-off tube ports,  
leaving the valves open.  
With valve C open, discharge the hose at the  
manifold connection.  
4. Solder the pinch-off tubes with Service valves.  
5. Evacuate as follows.  
3) Open valve A and allow the proper charge to  
enter the system. Valve B is still closed.  
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 counterclock-  
wise and leave the valves 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.  
The vacuum pump is now pulling through valves A  
and B up to valve C by means of themanifold  
and entire system.  
a. Do not add the liquid refrigerant to the Low-  
side.  
b. Watch the Low-side gauge; allow pressure to  
rise to 30 lbs.  
CAUTION: If high vacuum equip-  
ment is used, just crack valves A  
and B for a few minutes, then  
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.  
open slowly with the two full turns coun-  
terclockwise. This will keep oil from  
foaming and being drawn into the vacu-  
um 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 cut-  
ter, cut the pinch-off tube about 2 inches from the  
pinch-off tool. Use sil-fos solder and solder 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 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 sys-  
tem. With valves A and B closed, stop the vacu-  
um 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.  
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.  
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 31B-Charging  
Figure 31A-Pulling Vacuum  
21 Room Air Conditioner  
Schematic Diagram  
Schematic Diagram  
Wiring Diagram  
ELECTRIC HEATING MODEL  
Service Manual 22  
Troubleshooting Guide  
Troubleshooting Guide  
Piping System  
CONDENSER COIL  
FAN  
CAPILLARY TUBE  
COMPRESSOR  
MOTOR  
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  
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 32  
23 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) & the 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  
Clogged of air filter.  
Check inside gas  
pressure.  
Replacement of unit if the  
unit is beyond repair.  
Obstruction at air outlet  
Correct above trouble  
Adjusting of refrigerant  
charged.  
Malfunction of compressor.  
Check clogging in refrigera-  
tion circuit.  
Replacement of  
compressor.  
Satisfactory operation with  
temperature difference of  
inlet & outlet air ;  
Repair clogging in refrigera-  
tion circuit.  
44~50°F(7~10°C)  
Service Manual 24  
Troubleshooting Guide  
Fails to Start  
Check of power source.  
Check circuit breaker  
and fuse.  
Check of control switch  
setting.  
Gas leakage of feeler bulb  
of thermostat  
Check of control switch.  
Compressor only fails to  
start.  
Fan only fails to start.  
Improper wiring.  
Drop of power voltage.  
Improper thermostat setting.  
Defect of fan motor  
capacitor.  
Defect of compressor  
capacitor.  
Loose terminal connection.  
Improper wiring.  
Irregular motor resistance  
(
).  
Irregular motor insulation  
).  
Capacitor check.  
Replacement  
(
Replacement of fan motor.  
Regular but fails to start.  
Irregular motor resistance (  
Irregular motor insulation (  
)
)
Replacement of compressor  
(locking of rotor, metal).  
Replacement of compressor  
(Motor damaged)  
25 Room Air Conditioner  
Troubleshooting Guide  
Room Air Conditioner Voltage Limits  
NAME PLATE RATING  
208~230±10%  
115±10%  
MINIMUM  
187V  
MAXIMUM  
253V  
104V  
126V  
COMPLAINT  
CAUSE  
REMEDY  
Fan motor will not run.  
No power  
Check voltage at outlet. Correct if necessary.  
Power supply cord  
Check voltage to rotary switch. If none, check power  
supply cord. Replace cord if circuit is open.  
Rotary switch  
Check switch continuity. Refer to wiring diagram for  
terminal identification. Replace switch if defective.  
Wire disconnected or con-  
nection loose  
Connect wire. Refer to wiring diagram for terminal  
identification. Repair or replace loose terminal.  
Capacitor (Discharge  
capacitor before testing.)  
Test capacitor.  
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. 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.  
Revolves on overload.  
Check voltage. If not within limits, call an electrician.  
Fan motor runs  
intermittently  
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.  
Fan  
If cracked, out of balance, or partially missing,  
replace it.  
Fan motor noise.  
Blower  
If cracked, out of balance, or partially missing,  
replace it.  
Loose clamper  
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.  
Check voltage.  
If not within limits, call an electrician.  
Compressor will not run,  
but fan motor runs.  
Voltage  
Wiring  
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.  
Rotary  
Service Manual 26  
Troubleshooting Guide  
COMPLAINT  
CAUSE  
Thermostat  
REMEDY  
Compressor will not run,  
but fan motor runs.  
Check the position of knob If not at the coldest set-  
ting, advance the knob to this setting and restart  
unit.  
Check continuity of the thermostat. Replace ther-  
mostat if circuit is open.  
Capacitor (Discharge  
Check the capacitor.  
capacitor before servicing.)  
Replace if not within ±10% of manufacturers rat-  
ing. Replace if shorted, open, or damaged.  
Compressor  
Overload  
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 tem-  
perature is high, remove the overload, cool it, and  
retest.)  
Voltage  
Compressor cycles on  
overload.  
Check the voltage.  
If not within 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.)  
Fan motor  
If not running, determine the cause. Replace if  
required.  
Compressor cycles on  
overload.  
Condenser air flow restric-  
tion  
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.  
Condenser fins (damaged)  
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.  
Capacitor  
Test capacitor.  
Compressor cycles on  
overload.  
Wiring  
Check the terminals. If loose, repair or replace.  
Check the system for a restriction.  
If restricted, clean of replace.  
Close if open.  
Refrigerating system  
Air filter  
Insufficient cooling or heat-  
ing  
Exhaust damper door  
Unit undersized  
Determine if the unit is properly sized for the area  
to be cooled.  
Blower or fan  
Copper tubing  
Excessive noise  
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.  
Auto air-swing fails.  
Rotary switch.  
Set the knob to HIGH COOL or LOW COOL while  
rocker switch is ON.  
Wiring  
Check terminals. If loose, repair or replace.  
Check the synchronous motor for open circuit.  
Synchronous motor.  
27 Room Air Conditioner  
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