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HEAT CONTROLLER, INC. Window-Type Air Conditioner MODELS: CD-121 CD-101-5 Service Manual CAUTION -Before servicing the unit, read the "safety precautions" in this manual. -Only for authorized service personnel. Air Conditioner Service Manual TABLE OF CONTENTS Safety Precautions..........................................................................................................................................3 Dimensions .....................................................................................................................................................5 Outside Dimensions ...................................................................................................................................5 Product Specifications ..................................................................................................................................6 Installation .......................................................................................................................................................7 Select the Best Location ...........................................................................................................................7 How to Install..............................................................................................................................................7 Installation Kits Content(Some Models) .....................................................................................................7 How to secure the Drain Pipe.....................................................................................................................9 Operation ......................................................................................................................................................10 Features ...................................................................................................................................................10 Insulation Resistance Test........................................................................................................................10 About the Controls on the Air conditioner ................................................................................................10 Disassembly ..................................................................................................................................................11 Mechanical Parts......................................................................................................................................11 Air Handling Parts ....................................................................................................................................12 Electrical Parts .........................................................................................................................................13 Refrigerating Cycle...................................................................................................................................14 Schematic Diagram.......................................................................................................................................17 Wiring Diagram.........................................................................................................................................17 Troubleshooting Guide .................................................................................................................................18 Piping System ..........................................................................................................................................18 Troubleshooting Guide .............................................................................................................................19 Room Air Conditioner Voltage Limits........................................................................................................21 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 properties 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 Always install the expansion panel(s). • No installation may cause fire and electric shock accident. 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 place the power cord near a heater. • It may cause fire and electric shock. Do not disassemble or modify products. • It may cause failure and electric shock. Gasolin Service Manual 3 Safety Precautions ■ Installation Never touch the metal parts of the unit when removing the filter. • They are sharp and may cause injury. Ensure that the outer case is not damaged by age or wear. • If leaving appliance damaged, there is concern of damage due to the falling of product. Hold the plug by the head when taking it out. • It may cause electric shock and damage. 4 Room Air Conditioner Do not block the inlet or outlet. • It may cause failure of appliance or accident. Be cautious not to touch the sharp edges when installing. • It may cause injury. Turn off the main power switch when not using it for a long time. • Prevent accidental startup and the possibility of injury. 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 W H D Model All Model Dimension W mm(inch) 368(14 1/2") H mm(inch) 521(20 1/2") D mm(inch) 584(23) Service Manual 5 Product Specifications Product Specifications MODELS ITEMS CD-101-5 CD-121 POWER SUPPLY 115V/60Hz COOLING CAPAC (Btu/H) 10,000 11,500 INPUT (W) 1,050 1,210 RUNNING CUR (A) 9.6 11.0 E.E.R (BTU/W·h) OPERATING CONDITION 9.5 INDOOR (℃) 26.7(DB)* 19.4(WB)** OUTDOOR (℃) 35(DB)* 23.9(WB)** REFRIGERANT(R-22)CHARGE 480g(16.9oz) 655g(23.1oz) EVAPORATOR 3 ROW CONDENSER 2 ROW 23STACKS, LOUVER FIN TYPE 16STACKS, SLIT FAN TYPE 3 ROW 16STACKS, SLIT FAN TYPE FAN,INDOOR TURBO FAN FAN,OUTDOOR AXIAL FAN FAN SPEEDS,FAN/COOLING 3/3 FAN MOTOR 6 POLES OPERATION CONTROL REMOTE CONTROLLER ROOM TEMP . CONTROL THERMOSTAT AIR DIRECTION CONTROL VERTICAL LOUVER (RIGHT&LEFT) CONSTRUCTION HORIZONTAL LOUVER (UP&DOWN) PROTECTOR COMPRESSOR OVERLOAD PROTECTOR FAN MOTOR INTERNAL THERMAL PROTECTOR 3 WIRE WITH GROUNDING POWER CORD ATTACHMENT PLUG(CORD-CONNECTED TYPE) DRAIN SYSTEM NET WEIGHT DRAIN PIPE SPLASHED BY FAN SLINGER (lbs/kg) OUTSIDE DIMENSION (W×H×D) NOTICE (inch) (mm) 77/35 79/36 141/2×201/2×23 368×521×584 SPECIFICATIONS ARE SUBJECT TO MINOR CHANGE WITHOUT NOTICE FOR FURTHER IMPROVEMENT. 6 Room Air Conditioner Installation Installation Installation Kits Contents 8 9 10 15 16 17 2 12 4 11 1 3 13 5 6 14 7 NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 NAME OF PARTS Curtain Curtain Frame Upper Guide Side Guide Support Bracket Bracket Leveling Bolt & Nut Bolt Nut Washer Side Guide seal Foam Seal Strip Window Track Seal Window Locking Bracket Screw (Type A) Screw (Type B) Screw (Type C) QTY 1 1 1 2 1 1 1 2 2 2 1 1 1 1 9 3 8 Window Requirements 1. These instructions are for a horizontal sliding or a casement window. 2. The electrical outlet must be within reach of the power cord. For installation in a casement window, the window frame assembly and the side of the building must be adequate to support the weight of the air conditioner. 21"1 min. 40 /2" max. 21 1/2" min. 15 1/2" min. Horizontal sliding window 15 1/2" min. 16 1/2" max. Casement window Service Manual 7 Installation How to Install the Unit 1. To prevent vibration and noise, make sure the unit is installed securely and firmly Awning 2. Install the unit where the sunlight does not shine directly on the unit. NOTICE All side louvers of the cabinet must remain exposed to the outside of the structure. 4. Install the unit at a slight incline so the back is slightly lower than the front(about 1/4"). This will force condensed water to flow to the outside. 5. Install the unit with the bottom about 30"~60" above the floor level. 8 Room Air Conditioner Cooled air 30"~60" 3. The outside of the cabinet must extend outward for at least 14" 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. Heat radiation About 1/4" Over 20" Fence Installation Horizontal Sliding Window Installation 1. Loosely attach the Support Bracket to the bottom of Bracket using Bolts, Washer, and Nuts. Attach the Leveling Bolt and Nut. (Fig. 1) Bolt Bracket Washer Nut 2. Remove protective backing from Window Track Seal and apply seal to window track. (Fig.2) Leveling Bolt & Nut Support Bracket Fig. 1 3. Measure and lightly mark a line 8-1/4 inches from window jamb. Center the Support Bracket assembly on the window track and fasten with 4 Type C screws.(Fig. 2) 4. Put the Support Bracket against the outside wall and tighten the Bolts on top of the Bracket. Adjust the Leveling Bolt so that the air conditioner will be installed with a very slight tilt (about 1/4") downward toward the outside for proper drainage. Tighten the nut. (Fig. 3) NOTICE Windo Jamb Window amb 1 8 /4 inches Windo Track Window Seal Windo Track Window Fig. 2 DO NOT drill a hole in the bottom of the base pan. The air conditioner is designed to operate with the bottom of the base pan approximately half-full of water. About 1/4" 5. Fasten Side Guides to the sides of the Air Conditioner using 3 Type A screws per Guide. Start with first screw at middle of Guide. (Fig. 4) Type C screw Ou tsi de Wa ll Fig. 3 Fastening Side Guides Upper Guide 6. Fasten Upper Guide on the top of the Air Conditioner using 3 Type A screws. (Fig. 4) Side Guide Fig. 4 Service Manual 9 7. Measure height of window opening from top of Bracket assembly as shown Fig. 5. Subtract 20-3/4 inches. Mark this measurement on Curtain and cut the Curtain. (Fig. 5) Fig. 5 8. Slide Curtain into Curtain Frame. Slide Curtain Frame assembly into side Guides of the Air Conditioner cabinet. Make sure Curtain is firmly enclosed on all sides by the Frame. (Fig. 6) Frame Curtain 9. Cut side Guide seal into 2 equal lengths. Remove protective backing and apply it to the rear side of cabinet Side Guides, starting just below Curtain Frame assembly. Pinch off excess length so seal is even with the bottom of side Guide. (Fig. 7) Curtain Fig. 6 10. Place Air Conditioner in window opening. It should sit on Bracket assembly so that Curtain Frame and cabinet Side Guides are against top and side window jambs. Mate front of Bracket with Base Guide attached to the bottom of base pan. Apply weather seal to side guides just below edge of Curtain Frame . 11. Drill 1/8 inch holes in window track through the existing holes on Base Guide. Screw 4 Type C screws through the holes. (Fig. 8) Fig. 7 12. If this is a casement window installation, proceed to Casement Window Installation. If not, slide inner window sash firmly against side of the cabinet. 13. Drill 1/8 inch hole in window jamb to align with the existing holes in the Curtain Frame. Attach Curtain Frame to window frame with 2 Type B screws. (Fig. 8) Base pan Base Guide Bracket Type B screw Window Track Type C screw Window Track 10 Room Air Conditioner Fig. 8 NOTICE Check all seals and plug any remaining air gaps with a suitable weatherproof caulk. Foam seal strip 14. If this is a casement window installation, proceed to Casement Window Installation. If not, stuff the Foam Seal Strip between the vertical sash and the window glass. (Fig. 9) 15. Attach the L Bracket with a Type B screw. (Fig. 9) Window locking bracket Fig. 9 Casement Window Installation 1. Installation procedure is the same as that described in steps 1 through 11 and step 13 of the Horizontal Sliding Window installation. 2. If the window opening is wider than 15-3/4 inches you will need to install a filler panel. Make this panel from 3/4 inch thick wood and run it the full length of the window. Attach it securely to the window frame and paint it to protect it from the weather. 3. Since styles and sizes of casement windows vary widely, it is advisable to have the air conditioner installed by someone skilled in this type of installation. Service Manual 11 Operation Operation Controls The remote control and control panel will look like those represented in the following pictures. 1 6 3 Power 1 Temp 2 Fan Speed 4 Timer Mode 5 4 2 3 5 Remote Control Operations 1. POWER • To turn the air conditioner ON, push this button. To turn the air conditioner OFF, push the button again. • This button takes priority over any other button. • When you first turn it on, the unit is in cool mode, high fan speed, temperature setting at 72˚F. 2. TEMPERATURE SETTING • Use this button to automatically control the temperature of the room. The temperature can be set within a range of 60°F to 86°F by increments of 1°F. 3. MODE - Every time you push this button, it will cycle through the following modes: COOL, ENERGY SAVER and FAN. - ENERGY SAVER • The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and the unit will check the room air to determine if cooling is needed. 4. FAN SPEED • Every time you push this button, it advances the setting as follows: {High(F3) → Low(F1) → Med(F2) → High(F3)} 5. TIMER - SHUT-OFF TIME • You will usually use shut-off time while you sleep. • With unit running, use Timer to set number of hours until shut-off. • For your sleeping comfort, once Time is set, the Temperature setting will raise 2°F after 30 min, and 2°F after another 30 min. • Every time you push Timer button, it advances the Timer setting as follows: 1 Hour → 2 Hours → etc. → 12 Hours maximum. - START TIME • With unit not running, use timer to set number of hours before unit starts. • Every time you push Timer button, it advances the Timer setting as follows: 1 Hour → 2 Hours → etc. → 12 Hours maximum. 6. REMOTE CONTROL SENSOR AUTO RESTART When power is restored after an electrical power failure, the unit will begin to run at its last setting. 12 Room Air Conditioner Disassembly Disassembly - Before the following disassembly, set POWER SWITCH to OFF and disconnect the power cord. Mechanical Parts 1. Front Grille D 1. Open the inlet grille downward and remove the air filter. 2. Remove the screws which fasten the front grille.(See Figure 1) 3. Pull the front grille from the right side. 4. Remove the front grille.(There are 4 hooks.) 5. Re-install the components by referring to the removal procedure, above. 2. Cabinet 1. After disassembling the FRONT GRILLE, remove the 6 screws which fasten the cabinet at both sides.(See Figure 2) 2. Remove the 4 screws which fasten the cabinet at back. 3. Remove the cabinet. 4. Re-install the components by referring to the removal procedure, above. Figure 1 3. Control Box 1. Remove the front grille. (Refer to section 1) 2. Remove the cabinet. (Refer to section 2) 3. Remove the 1 screw which fasten the power cord. (See Figure 3) 4. Disconnect the grounding screw from the evaporator channel. 5. Remove the 2 screws which fasten the control box.(See Figure 3) 6. Remove the housing which connects motor wire in the control box. 7. Remove three leads which connect compressor. 8. Discharge the capacitor by placing a 20,000 ohm resistor across the capacitor terminals. 9. Raise the control box upward completely. 10. Re-install the components by referring to the removal procedure, above. (Refer to the circuit diagram found on pages 21~22 in this manual and on the control box.) Figure 2 Figure 3 Service Manual 13 Disassembly Air Handling Parts 4. Air Guide and Turbo Fan 1. Remove the front grille. (Refer to section 1) 2. Remove the cabinet. (Refer to section 2) 3. Remove the control box. (Refer to section 3) 4. Remove the 4 screws which fasten the brace. 5. Remove the brace. 6. Remove the 2 screws which fasten the upper air guide. (See Figure 4) 7. Remove the upper air guide. 8. Remove the 2 screws which fasten the evaporator. 9. Move the evaporator forward and pulling it upward slightly. (See Figure 5) 10. Remove orifice by pulling two taps. 11. Remove the clamp with a hand plier which secures the turbo fan. 12. Remove the turbo fan. (See Figure 6) 13. Remove the motor. (Refer to section 11) 14. Remove the 2 screws which fasten the lower air guide from the base pan. 15. Remove the 2 screws which fasten the motor mount from the base pan. 16. Remove the 2 screws which fasten the lower air guide and motor mount. 17. Move the lower air guide backward and pull out from the base pan. (Move the lower air giude carefully.) 18. Re-install the components by referring to the removal procedure, above. Figure 4 Figure 5 5. FAN 1. Remove the cabinet. (Refer to section 2) 2. Remove the brace (Refer to section 4) 3. Remove 6 screws which fasten the condenser. 4. Move the condenser to the right carefully. 5. Remove the clamp with a hand plier which secures the fan. 6. Remove the fan. (See Figure 7) 7. Re-install by referring to the removal procedure. 14 Room Air Conditioner Figure 6 Disassembly 5. Shroud 1. Remove the fan. (Refer to section 2.5) 2. Remove the shroud. (See Figure 8) 3. Re-install the components by referring to the removal procedure, above. Electrical Parts Figure 8 6. Overload Protector 1. Remove the cabinet. (Refer to section 2) 2. Remove the nut which fastens the terminal cover. 3. Remove the terminal cover. (See Figure 9) 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. 7. Compressor 1. Remove the cabinet. (Refer to section 2) 2. Discharge the refrigerant system using a FreonTM Recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the FreonTM. Leave the valve in place after servicing the system. 3. Remove the overload protector. (Refer to section 6) 4. After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections. 5. Remove the 3 nuts and the 3 washers which fasten the compressor. 6. Remove the compressor. (See Figure 10) 7. Re-install the components by referring to the removal procedure, above. Figure 9 Figure 10 Service Manual 15 Disassembly 8. Capacitor 1. Remove the cabinet. (Refer to section 2) 2. Remove the screw and the clamp which fastens the capacitor. 3. Disconnect all the leads of capacitor terminals. 4. Re-install the components by referring to the removal procedure, above. (See Figure 11) Figure 11 9. Power Cord 1. Remove the cabinet. (Refer to section 2) 2. Disconnect the grounding screw from the control box. 3. Disconnect the 2 receptacles. 4. Remove a screw which fastens the clip cord. (See Figure 12) 5. Remove the power cord. 6. Re-install the component by referring to the above removal procedure, above. (Use only one ground-marked hole for ground connection.) 7. If the supply cord of this appliance is damaged, it must be replaced by the special cord. (The special cord means the cord which has the same specification marked on the supply cord attached at the unit.) Figure 12 10. Thermostat 1. Remove the cabinet. (Refer to section 2.1.2) 2. Remove the 2 screws which fasten the thermostat. 3. Disconnect 2 leads of thermostat terminals. 4. Remove the thermostat. 5. Re-install the components by refering to the above removal procedure. (See Figure 13) 16 Room Air Conditioner Figure 13 Disassembly 11. Motor 1. Remove the cabinet. (Refer to section 5) 2. Remove the turbo fan. (Refer to section 5) 3. Remove the fan. (Refer to section 6) 4. Remove the 4 screws which fasten the motor from the Motor Mount. (See Figure 14) 5. Remove the motor. 6. Re-install the components by referring to the removal procedure, above.(See Figure 14) Figure 14 Refrigerating Cycle 12. CONDENSER CAUTION 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. 1. Remove the cabinet. (Refer to section ) 2. Remove the 4 screws which fasten the brace. 3. Remove the 4 screws which fasten the condenser and shroud. (See Figure 15) 4. Remove the 2 screws which fasten the condenser and base pan. 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 Figure 15) Figure 15 13. Evaporator 1. Remove the cabinet. (Refer to section 2) 2. Remove the control box.(Refer to section 3) 3. Remove the upper air guide. (Refer to section 4) 4. Remove the 2 screws which fasten the evaporator from lower air guide. 5. Move the evaporator sideways carefully. (Refer to section 4) 6. After discharging the refrigerant completely, unbraze the interconnecting tube at the evaporator connections. 7. Remove the evaporator. 8. Re-install the components by referring to notes. (See Figure 16) Figure 16 Service Manual 17 14. Capillary Tube 1. Remove the cabinet. (Refer to section 2) 2. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(See caution above) 3. Remove the capillary tube. 4. Re-install the components by referring to notes. NOTES — Replacement of the refrigerant. 1. When replacing the refrigerant, 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 unbraze the pinch-off tubes. 3. Solder service valves into the pinch-off tube ports, leaving the valves open. 4. Solder the pinch-off tubes with Service valves. 5. Evacuate as follows. 1) Connect the vacuum pump, as illustrated figure 17A. 2) Start the vacuum pump, slowly open manifold valves A and B with two full turns counterclockwise and leave the valves open. The vacuum pump is now pulling through valves A and B up to valve C by means of the manifold and entire system. CAUTION If high vacuum equipment is used, adjust valves A and B so they are opened only slightly 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 vaccum 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 figure 17B. Open valve C. Discharge the line at the manifold connection. 5) The system is now ready for final charging. 18 Room Air Conditioner 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 figure 17B. 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 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. Disassembly Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pin-off tool capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve. COMPOUND GAUGE CONDENSER (HIGH PRESSURE SIDE) MANIFOLD GAUGE A B CAPILLARY TUBE SEE INSETS BELOW EVAPORATOR (LOW PRESSURE SIDE) COMPRESSOR LOW HI A B B A EXTERNAL VACUUM PUMP CHARGING CYLINDER C Figure 17A-Pulling Vacuum Figure 17B-Charging Service Manual 19 Schematic Diagram Wiring Diagram optional part S/V4WAY FAN MOTOR C FAN HERM 1 3 3 1 1 3 3 SMW250-04 CN-TH1 R03H 10K X CN-4WAY O O R03H X X RY-HI O RY-4WAY 12V RY-MED RY-4WAY 1 1 SMW250-04 CN-TH2 Heat Pump Cool Only Model CN-4WAY YW396-03AV 3 3 O X CN-TH2 RY-COMP RY-SYNC RY-4WAY RY-LOW RY-MED D02D~D05D 1N4004 D03D D02D RY-HI 4 7 POWER TRANS 2 1 12V 5V SYNC COMP OSC01B 8.00MG 25 37 18 5V 17 16 MICOM 38 R12F 20K 39 40 TMP87CH47U 19 1M 8 4WAY 20 R01B 7 36 5V J01F 0.01 50V C06D 5V 35 21 12.1K 1% R22H 6 26 27 28 29 30 31 32 22 R01H 23 6.2K 1% 12.1K 1% 9 5 MED HI Buzzer Receiver 33 34 1K R02E 20 R01L 220 10V C05D + O 680pF C01L 7805 IC02D LED out3 12V I 0.01 50V C04D 24 R02H 12.1K 1% R21H 10 HVB LOW 5V OR02H 11 4 OR01H 12 3 X O + ION 2 R01E 1K 13 1 IC01D 1000 16V C03D 7812 J01F 14 O 15 16 IC01M ULN2004AF DISPLAY 0.1 50V C02D I 88 SEGMENT TYPE LED TYPE D05D 1000 35V D04D + C01D VSS SLIDE SW ROOM-TH PIPE-TH 3 1 CN-MOTOR 1 RY-LOW YW396-09AV 3 5 1 5 9 7 14D271 14D561 ZNR01J 120 1/2W 0.1/275V C01J 9 1 3 FUSE 250V/T2A R01J 7 1 3 CN-PWR YW396-03AV 4 RY-COMP G4A-1A-E-LG 41 15 42 14 12 44 1 2 3 4 5 6 7 8 9 10 11 Tx C01A 0.01 R01A 1K 13 43 Rx 10uF 50V C02A 100 R03A 3 R02A 4.7K + SEG-a 1 2 3.6V IC01A 5V S7136 C01P 0.01 EEPROM(optional part) 24LC01BT 1 Vcc 8 A0 2 7 A1 WP 3 6 A2 SCL GND SDA 5 4 SDA SCL Digit4 (Scan4) Digit2 (Scan2) Digit3 (Scan3) Digit1 (Scan1) SEG-b R01F 10K R02F 10K Digit0 (Scan0) SEG-c C02F 0.001 C01F 0.001 20K 20K R03P 16 R02P R04P 1K 1 15 12 14 11 3 5 10 2 6 9 13 7 4 IC01G 8 ULN2004AF 5V Model Auto Restart Non Auto Restart X O O X EEPROM R04P 1-6 1-13 1-12 1-11 1-10 1-7 1-6 1-13 1-12 1-11 1-10 Vout Vcc GND RECEIVER + 5V C22L 220 10V 5V 5V Q04G A101S Q01G 1-5 A101S Q02G 1-5 A101S Q03G 1-4 A101S 1-4 a c e f Digit0 SW6 POWER 1-3 FAN SW1 MODE SW4 Digit1 f g d 88 SEGMENT 0.4 inch d g a 5 1-3 D01F D06F 1-2 TIMER SW2 TEMP DOWN SW5 8 9 3 e 10 1-2 D02F D05F D04F 1-1 SW7 TEMP UP D07F a b c 6 4 7 1 b 1-1 BZ01E PKM13EPY -4000-A0 COOL e DRY/HEAT f d FAN TIMER E/SAVER e g f d c b a CN-DISP1 1-7 1-8 2-2 1-9 2-3 1-8 2-2 g CN-DISP2 1-9 2-3 2-4 2-1 2-4 2-1 CN-MAIN1 150 150 150 R01G 150 150 R02G 150 R03G R05G R04G R06G 150 CN-MAIN2 R07G b c 5V 20 Room Air Conditioner CAPACITOR MAIN POWER COMP 3 SEG-d VAref KEY0 TEST SEG-e Room TH KEY1 /Reset SEG-f Pipe TH LED out0 Osc out VDD Option1 LED out1 Osc in SEG-g Option2 LED out2 Schematic Diagram Wiring Diagram CASEMENT_10K CASEMENT_12K WIRING DIAGRAM CN-MAIN2 CAPACITOR YL F C BK CN-PWR WH(BL) (Ribbed) DC12V ZNR01J RD H CN-TH1 POWER TRANS OR(BR) CN-DISP2 DISPLAY PCB ASSEMBLY SWITCH CN-12V FUSE 250V/T2A (115V/T2A) BK(BR) (Plain) CN-DISP1 THERMISTOR CN-MAIN1 RY-HI MOTOR CN-MOTOR RY-MED BK BL RD YL OR RY-LOW GN/YL CN-HVB H.V. ASSEMBLY 3 GN/YL R COMP. 4 S BL C OLP RY-COMP MAIN PCB ASSEMBLY BK RD AIR FILTER ASSEMBLY 3854AR3629N Service Manual 21 Components Location Main P.W.B Assembly C01J R01J LW1 CN_PWR CN_4WAY CN_MOTOR ZNR01J 3 1 RY_LOW RY_HI RY_MED RY_4WAY TRANS CN_MAIN2 4 4 D02D CN_MAIN1 IC01D D05D FUSE OSC01B C01A C02A PCB ASM: 6871A01001 J02 R02A J01 IC01A J04 C05D PCB: 6870A91001A IC02D C03D R03H RY_COMP 250V T3.15A 4 CN_TH2 3 250V T2A C01D CN_TH1 1 13 D03D D04D 7 1 J03 Display P.W.B Assembly 2003.08.22 SEGMENT 1 1 LED4 FAN MODE LED1 COOL J8 J7 J6 BZ01E J3 D06F SW4 CN_DISP2 CN_DISP1 C22L SW6 POWER SW5 SW7 TEMP DOWN TEMP UP D02F D04F D07F J1 D05F D01F J5 RECEIVER SW1 SW2 J2 PCB P/NO : 6870A90166A 22 Room Air Conditioner J4 LED3 TIMER F/SPEED TIMER PCB ASM P/NO : 6871A20442 LED2 DRY/HEAT LED5 E/SAVER Troubleshooting Guide Troubleshooting Guide Piping System CONDENSER COIL FAN CAPILLARY TUBE MOTOR COMPRESSOR TURBO FAN EVAPORATOR COIL Following is a brief description of the important components and their functions in the refrigeration system. Refer to Fig. 18 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle. ROOM AIR CONITIONER CYCLE OF REFRIGERATION EVAPORATOR COILS CONDENSER COILS COMPLETE LIQUID BOIL OFF POINT COOLED AIR SUCTION LINE COOL LOW PRESSURE VAPOR VAPOR INLET HOT DISCHARGED AIR ROOM AIR HEAT LOAD MOTOR OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH COMPRESSOR OIL LIQUID PRESSURE DROP LIQUID OUTLET (LIQUID REFRIGERANT) HIGH PRESSURE VAPOR LIQUID REFRIGERANT CAPILLARY TUBE LOW PRESSURE VAPOR Figure 18 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 from an electrical defect, and 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) & the fan operation. Dirty indoor coil (Heat exchanger) Check gas leakage. Check heat load increase. Clean condenser. Not on separate circuit. Malfunction of fan Clogged of air filter. Repair gas leak. Replace of unit if the unit is beyond repair. Obstruction at air outlet Check inside gas pressure. Adjusting of refrigerant charge. Correct above problem Malfunction of compressor. Check clogging in refrigeration system. Repair clogging in refrigeration system. 24 Room Air Conditioner Replacement of compressor. Satisfactory operation with temperature difference of inlet & outlet air ; 44~50°F(7~10°C) 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. Capacitor check. Irregular motor resistance ( ). Irregular motor insulation ( ). Improper wiring. Replacement Replacement of fan motor. Irregular motor resistance ( ) Irregular motor insulation ( ) Tests normal but fails to start. Replacement of compressor (locking of rotor, metal). Replacement of compressor (Motor damaged) Service Manual 25 Troubleshooting Guide Room Air Conditioner Voltage Limits NAME PLATE RATING MINIMUM MAXIMUM AC 115V ±10% AC 103.5V AC 126.5V COMPLAINT Fan motor will not run. CAUSE REMEDY No power Check voltage at outlet. Correct if none. Power supply cord Check voltage to rotary switch. If none, check power supply cord. Replace cord if circuit is open. Wire disconnected or connection 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. Fan motor runs intermittently Revolves on overload. 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. Fan motor noise. Compressor will not run, but fan motor runs. Fan If cracked, out of balance, or partially missing, replace it. Turbo If cracked, out of balance, or partially missing, replace it. Loose clamper Tighten it. Worn bearings 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. Voltage Check voltage. If not within limits, call an electrician. 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. 26 Room Air Conditioner Troubleshooting Guide COMPLAINT Compressor will not run, but fan motor runs. CAUSE Thermistor REMEDY Check the TEMP control. If not at the lowest number, set TEMP control to this setting and restart the unit. Check the continuity of the thermistor. Replace the thermistor if the circuit is open. Compressor cycles on overload. Compressor cycles on overload. Compressor cycles on overload. Insufficient cooling or heating Excessive noise Capacitor (Discharge capacitor before servicing.) Check the capacitor. Replace if not within ±10% of manufacturers rating. Replace if shorted, open, or damaged. Compressor Check the compressor for open circuit or ground. If open or grounded, replace the compressor. Overload Check the compressor overload, if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool it, and retest.) Voltage 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. 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 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. Wiring Check the terminals. If loose, repair or replace. Refrigerating system Check the system for a restriction. Air filter If restricted, clean or replace. Exhaust damper door Close if open. Unit undersized Determine if the unit is properly sized for the area to be cooled. Turbo or fan Check the set screw or clamp. If loose or missing, correct. If the turbo or fan is hitting air guide, rearrange the air handling parts. Copper tubing Remove the cabinet carefully and rearrange tubing not to contact cabinet, compressor, shroud, and barrier. Service Manual 27 Specifications and performance data subject to change without notice. HEAT CONTROLLER, INC. 1900 WELLWORTH AVENUE • JACKSON, MICHIGAN 49203 THE QUALITY LEADER IN CONDITIONING AIR 04/18/07 P/No.: MFL36458901