Goldstar M5203R Air Conditioner User Manual
Contents
1. We AGeD 1 2 3803 SNL GAGS ee Q u 0 9C2 V gt 1 08 2 1 AN Asa AQT 100 SS 0001 Wy 022 ONAS AM 5 0603 EET Side r ma MZ 1 OZL ASLE T0 riod rio T 0203 AS OM NO 1 C T m 9 MM __ a um Orma FEY 000M tS 68 82 2 5 E 18 MS IVMV M 2 D 2 5 4 00 9014 5228 8 01 n GIN s dwog E H uondo zuondo 5 puodo FR LHL NO HL WOOM 5 ce 3 2080 LV090 99080 55 5098 T 96090 70 FAV m XI 6809 1088 aa 9 00 1453 810350 27 5 3 COMPONENTS LOCATION FOR MAIN P W B ASM No 8 Oy 6 0 01 48 CN BK CN BL CN RD CN SYNC CN WORK ROW BUZZER gt a lt 0 3 IC IC a gt gt 5355 IS 81818 8 SN XN 5 8 lt 3 H oS zo 1 ee lt gt ax dH02 A8 12. 031 ZdSIQ NO 022958 0229208 can 22 9 508 RA son 0 5904 vam 0229 9602 mm 031 022990 16 0 022940 ES 940 M0 300M I dSIQ NO LdSIQ NO 93MV5 3 40 NO 1NVIS3H V 00 08 83 13338 510 510 C1982510IV9X LOOPNT 0500 0200 805538 03 09525 55555 2886 201 0 933 E 433 08 o 3 8298 5 933 lt 63 o ASZ 10 0 228 3 0 tT m og gt data s T avana 489 688 808333 M 2 30099 102 Teta Gig igogzaan WLIOIW ASZ 10 0 2102 25 I C9C C9C 6C 0 1 lz VI0 1 103 AVE 02 108 jno 5950 VI 550
3. S a website http www lgservice com e mail http www lgeservice com techsup html CAUTION BEFORE SERVICING THE UNIT READ THE SAFETY PRECAUTIONS IN THIS MANUAL MODEL M5403R M5203R M5203L M6003R WM 6011 LWJ0611PCG LWC061JGMK1 CONTENTS 1 PREFACE 2 2 4 REFRIGERANT CYCLE TARE ATURE S 2 2 4 1 CONDENSER see 1 2 SPECIFICATIONS sss 3 2 4 2 EVAPORATOR 1 3 SAFETY PRECAUTIONS 3 2 4 3 CAPILLARY TUBE 1 4 INSULATION RESISTANCE TEST 3 INSTALLATION 1 5 LOCATIONS OF CONTROLS 4 3 1 SELECT THE BEST LOCATION sss 2 DISASSEMBLY INSTRUCTIONS 6 3 2 HOW TO INSTALL uu uu au lanpa kawa 2 1 MECHANICAL PARTS aaa 6 4 TROUBLESHOOTING GUIDE 2 11 FRONT GRILLE wisi eine te 6 4 1 OUTSIDE DIMENSIONS sess 2 4 2 ttt the tet eise 6 42 PIPING SYSTEM eeee s 2 1 3 CONTROL BOARD see 6 4 8 TROUBLESHOOTING GUIDE sss 2 2 AIR HANDLING PARTS ee 7 2 2 1 AIR GUIDE
4. 7 5 SCHEMATIC DIAGRAM 2 22 ORIFICE TURBO FAN AND FAN 7 5 1 CIRCUIT 2 2 9 MOTOR ihnen atto erect rp need tesa 8 326666 TRONIC GONTROLDENIGE 2 2 4 AIR GUIDE E oa 8 FA COMPONENTS FOCGATIONIFORMAIN 2 3 ELECTRICAL PARTS iam 8 TA LOMP 2 3 1 OVERLOAD PROTECTOR 8 6 EXPLODED VIEW 2 3 2 9 7 SERVICE PARTS LIST 2 9 9 CAPACITOR edite hulu ananas 9 2 3 4 THERMISTOR seen 9 2 3 5 CONTROL PANEL eene 9 2 3 6 POWER CORD 10 1 PREFACE This service manual provides various service information including the mechanical and electrical parts etc This room air conditioner was manufactured and assembled under a strict quality control system The refrigerant is charged at the factory Be sure to read the safety precautions prior to servicing the unit 1 1 FEATURES DESIGNED FOR COOLING ONLY POWERFUL AND INCREDIBLE COOLING TOP DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE WASHABLE ONE TOUCH FILTER COMPACT SIZE 1 2 SPECIFICATIONS MODELS M6003R WM 6011 6 000 LWJ0611PCG LWC061JGMK1
5. 090 aw 0503 1 3 CE 2 510 M 28 5 4 COMPONENTS LOCATION FOR DISPLAY P W B ASM PWB P N0 6870490004C 1 2 9 gt OOo NO ac lt Te 1 gt 1113 t gt m GND Vcc JW2 E E 8 2 a N 5 3 SW4 D03 E DOSF B O O Sw 8 _ 7 505 2 lt 1 JW8 5 9 JW9 Do6F lt c JWi3 lt gt JWi4 x x 1 LEDIN SWG LED4 DoF BO mo ABE E YN 9 NT S Z 503 Vcc SW7 GND JW22 z 502 55 Av ROIF Swi 6 EXPLODED VIEW 7 SERVICE PARTS LIST LOCATION NO DESCRIPTION PARTOS REMARKS M5403R M5203R M5203L 130410 BASE ASSY SINGLE 3041A10011E R 130910 CABINET ASSY SINGLE 3091A10020A R 135312 GRILLE ASSY FRONT SINGLE 3531AR1644H 3531AR1644U R 135313 GRILLE ASSY INLET 3530A10039A R 137215 PANEL CONTROL 3720A20017A 3720A20111
6. 6 000 M5403R M5203R M5203L ITEMS COOLING CAPACITY BTU h POWER SUPPLY Phase V Hz INPUT W OPERATING CURRENT AMP REFRIGERANT CONTROL REFRIGERANT CHARGE R 22 INSIDE FAN OUTSIDE FAN AIR DISCHARGE CHASSIS 5 300 5 200 5 200 16 115V 60HZ 470 4 3 CAPILLARY TUBE 3300 11 6 Oz 335g 11 8 Oz TURBO PROPELLER FAN WITH SLINGER RING 230g 8 1 02 235g 8 3 Oz 2 WAY RIGHT AND LEFT TOP DOWN OVERLOAD PROTECTOR FOR COMPRESSOR PROTECTOR INTERNAL PROTECTOR FOR FAN MOTOR TEMPERATURE CONTROL THERMISTOR ROTARY SWITCH 5 POSITIONS LOW FAN HIGH FAN OFF HIGH COOL LOW COOL FAN MOTOR 6 POLES 16W 6 POLES 21 3W 6 POLES 24W 6 POLES 21 4W NOTE Specifications are subject to minor change without notice for further improvement 1 3 SAFETY PRECAUTIONS 1 2 When servicing set the POWER of CONTROL BOARD to Off and unplug the power cord Observe the original lead dress If a short circuit is found replace all parts which have been overheated or damaged by the short cir cuit After servicing make an insulation resistance test to prevent the customer s exposure to shock hazards 1 4 INSULATION RESISTANCE TEST 1 2 Unplug the power cord and connect a jumper between 2 pins black and white The grounding conductor green or green and yel low is to be open Measure the resistance value w
7. Check the system for a restriction Insufficient cooling Air filter If restricted clean or replace Unit undersized Determine if the unit is properly sized for the area to be cooled Excessive noise Blower or fan Check the set screw or clamp If loose or miss ing correct If the blower or fan is hitting scroll or barrier rearrange the air handling parts Copper tubing Remove the cabinet and carefully rearrange the tubing not to contact the cabinet compressor shroud and barrier 25 5 SCHEMATIC DIAGRAM 5 1 CIRCUIT DIAGRAM MODEL M5403R M5203R M5203L M6003R WM 6011 LWJ0611PCG LWC061JGMK1 POWER INPUT 1 WH BL Ribbed GN YL GN THERMISTOR z z 2 E s GO gt GN YL a gt GN 2 a 6 8 3 a 9 5 7 2 Sa beers 8 8 o Omio z z s 3 ZNR RY RY COMP 5 a 3 FUSE 250V T2A 8 115V T2A 3854AR2330K 3854A20022K WIRING DIAGRAM WIRING DIAGRAM 0610 DESCRIPTION QTY NO PER SET 1 POWER CORD ASSEMBLY 1 2 FAN MOTOR 1 3 COMPRESSOR 1 4 DISPLAY PW B ASSEMBLY 1 5 MAIN PW B ASSEMBLY 1 6 THERMISTOR 1 7 CAPACITOR 1 8 OWERLOAD PROTECTOR 1 26 5 2 ELECTRONIC CONTROL DEVICE 3 3 9031
8. Possible Trouble 2 The compressor does not operate setting set lower than Roo Set the Temp setting to higher Temp NO Is the Unit for 3 minutes delay 15 the voltage NO 6 of ICO1M DC 5V Is the voltage No 11 of ICO1M OV Check the RY COMP Exchange ICO1M e Wait 3 Minutes Check the wiring Diagram Exchange MAIN P W B Ass y Possible Trouble 3 The compressor always operate Connect LEAD Wire to Is the wire connection of RY COMP all right res Check the RY COMP Possible Trouble 4 Fan does not operate N ls or 4 O Exchange IC01M 0 f Es Is the voltage NO 13 or 15 of ICO1M OV NO e Exchange ICO1M Check the RY Hi or RY Lo Check the wiring diagram 21 Possible Trouble 5 5 the voltage of Battery NO Romote controller does not operate only for M 5400 M 6000 M 7000 about over 2 3V 85 the voltage No 10 of CN DISP2 on Main P W B Ass y DC 5V NO Is the connection of Exchange the battery Check the P W B pattern Connect connector to CN DISP2 all right Exchange Receiver Ass y Possible Trouble 6 NO CN DISP2 exactly It displays abnormal
9. Figure 31 INNER SILL Figure 28 CENTER LINE WINDOW FRAME UPPER GUIDE ABOUT 1 4 BOTTOM GUIDE Figure 29 L BRACKET L BRACKET SASH SEAL TYPE E Figure 31 DRAIN CAP DRAIN PIPE 15 REMOVAL FROM WINDOW Turn the air conditioner off disconnect the power cord remove the L bracket and the screws installed through the top and bot tom of the guide panels and save for reinstallation later Close the guide panels Keeping a firm grip on the air conditioner raise the sash and carefully tilt the air conditioner backward draining any condensate water Lift the air conditioner from the window and remove the sash seal from between the windows 3 3 ELECTRICAL DATA Line Cord Plug Use Wall Receptacle Power Supply Do not under any circumstances cut Use 15 AMP time or remove the grounding prong delay fuse or circuit from the plug breaker Power supply cord with Standard 125V 3 wire grounding 3 prong grounding plug receptacle rated 15A 125V AC USE OF EXTENSION CORDS Because of potential safety hazards we strongly discourage the use of an extension cord However if you wish to use an extension cord use a CSA certified UL listed 3 wire grounding extension cord rated 15A 125V 4 TROUBLESHOOTING GUIDE 4 1 OUTSIDE DIMENSIONS unit mm in 370 14 9 16 42 1 21 32 472 18 9ne 120 4
10. PRESSURE VAPOR CAPILLARY TUBE LIQUID REFRIGERANT 52224 Low PRESSURE VAPOR Figure 32 17 4 3 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 Con ditioning caused by a defect in the refrigeration circuit and improper application Unit is running but cooling is ineffective Ineffective Cooling Check cold air Check outdoor coil Check heat load circulation for smooth heat exchanger and increase flow fan operation Clean condenser Dirty indoor coil Check gas leakage heat exchanger Not on separate circuit Repair gas leak Malfunction of fan Replacement of unit if Check inside gas pressure the unit is beyond repair Clogging of air filter j Adjust refrigerant Obstruction at air outlet a charge Remove obstruction Malfunction of compressor Check clogging in refrigera Replacement of tion circuit compressor Satisfactory operation Repair clogging in with temperature refrigeration circuit difference of inlet amp outlet air 55 59 F 13 15 C 18 Fails to Start Check of circuit breaker and fuse Check of power source Check of control panel setting Check control panel Compressor fails only to start Fan only fails to start Improper wiring Defec
11. 11 Hours 12Hours Cancel ENERGY SAVER The fan stops when the compressor stops cooling Approximately every 3 minutes the fan will turn on and check the room air to determine if cooling is needed COOL FAN DRY How to Insert Batteries 1 Remove the cover from the back of the remote controller Do not use rechargeable batteries Such bat teries differ from standard dry cells in shape dimen sions and performance 2 Insert two batteries Be sure that the and directions are correct Be sure that both batteries are new Remove the batteries from the remote con troller if the air conditioner is not going to be used for an extended length of time 3 Re attach the cover 2 DISASSEMBLY INSTRUCTIONS 2 1 MECHANICAL PARTS 2 1 1 FRONT GRILLE 1 Disconnect the unit from source of power 2 Using a screwdriver remove the screw that secures the front grille to control board See Figure 1 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 2 4 Replace the grille by placing the tabs in the slots and push the grille until it snaps into place 2 1 2 CABINET 1 Disconnect the unit from the power source 2 Remove the front grille Refer to section 2 1 1 3 Remove 7 screws that secure the cabinet to the base pan and condenser See Figure 3 4 Lift the cabinet from the unit 5 Re install
12. Figure 22 WOOD STRIP MOUNTED 1 MAX ON TOP OF INNER SILL 3 4 5 CLEARANCE 4 STORM WINDOW INNER FRAME SILL WOOD STRIP FOR L BRACKET Y OUTER SILL INDOORS OUTDOORS Figure 23 13 Installation HARDWARE TYPE A 11EA SHORT SCREW TYPE D 1EA SEAL STRIP TYPE B 4EA WOOD SCREW TYPE E 1EA SASH SEAL TYPE C 3EA L BACKET TYPE F 2EA GUIDE PANEL DRAIN PIPE Not adhesive backed 3 2 2 BEFORE INSTALLATION Insert the guide panels into the guides of the air condi tioner Fasten the curtains to the unit with screws TYPE a A as shown Figure 24 DO 2 Cut the adhesive backed seal strip TYPE D to the window p width Remove the backing from the seal strip and attach the seal strip to the underside of the bottom window Figure 25 Figure 24 3 2 3 NOW START INSTALLATION 1 LOCATING UNIT IN WINDOW Open the window and mark center line on the center of the inner sill as shown in Figure 26 SEAL STRIP 2 ATTACH L BRACKET TYPE D a Install the L brackets behind the inner window sill with the short side of bracket as shown Figure 25 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 26 During the following step hold unit firmly until window sash is lowered to top
13. 34 _ 27 5 1 3 32 5 S O en ed Ss e SSS b e e a PE 22 5 0 8 3 32 1155 6 3 32 sr 370 14 9 16 M 1 m N N eo 1 16 4 2 PIPING SYSTEM CONDENSER COILS n FAN Q CAPILLARY MOTOR TUBE TURBO FAN EVAPORATOR cs 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 CONDENSER COILS SUCTION LINE VAPOR INLET HOT COM edu GCL LOW PRESSURE varon ass COOLED AIR ge ROOM AIR HEAT LOAD OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH TE MOTOR DISCHARGE gt LINE NOT HIGH PRESSURE COMPRESSOR VAPOR OL LIQUID PRESSURE DROP LIQUID OUTLET LIQUID REFRIGERANT EEA
14. by referring to the procedures above 2 1 3 CONTROL BOARD 1 Disconnect the unit from the power source 2 Remove the front grille Refer to Section 2 1 1 3 Remove the cabinet Refer to Section 2 1 2 4 Remove 2 screws that secure the control board to base pan and air guide See Figure 4 5 Pull the control board toward yourself NOTE Controls wires and capacitor are now accessible for servicing Discharge the capacitor before servicing See step 2 3 3 on page 8 for procedures 6 Disconnect one housing terminal and 3 wires for the fan motor and compressor See Figure 5 7 Re install components by referring to procedures above Refer to circuit diagram on page 26 in this manual or inside control board Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 2 2 AIR HANDLING PARTS 2 2 1 AIR GUIDE UPPER RON Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 Remove 2 screws that secure the air guide upper to air guide lower See Figure 6 Lift air guide upper upward Re install by referring to the procedures above 2 2 2 ORIFICE TURBO FAN AND FAN 1 2 3 4 5 12 13 14 Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remo
15. A R 149980 SHROUD 4998A10006A 4998A10008A R 152302 FILTER MECH A C 5231AR2148A R 238310 ESCUTCHEON 3831A10001F 3831A10013A R 249950 CONTROL BOX ASSY SINGLE 4995A20127D 4995A20127A 4995A20127G R 263230 THERMISTOR ASSY 6323A20003D R 264110 POWER CORD ASSY 2H00677P R 267110 REMOTE CONTROLLER ASSY 6711A20034A 6711A20034U R 268712 PWB PCB ASSY DISPLAY 6871A20115B 6871A20142A R 268714 PWB PCB ASSY MAIN 6871A10013M 6871A10013C 6871A10031B R 346811 MOTOR ASSY SINGLE 4681A10002A 4681A10002F 4681A10002H R 349480 ORIFICE 4948A10007A R 352113 TUBE DISCHARGE 5210A20252A 5210A20511A R 352115 TUBE ASSY EVPORATOR IN 5211A10063A 5211A10063C R 35211A TUBE ASSY SUCTION SINGLE 5211A10062A 5211A10062B R 352380 AIR GUIDE 5238A20004A 5238A20004B R 352390 AIR GUIDE ASSY 5239A30003A R 354210 EVAPORATOR ASSY FIRST 5421A10008B 5421A20016H R 359012 FAN TURBO 5900A20005A 5900A10005A R 550140 ISOLATOR COMP 5040AR4195A R 562111 TUBE ASSY CAPILLARY 5211A10065B 5211AR3332R R 554030 CONDENSER ASSY FIRST 5403A20038D 5403A20009E R 554160 COMPRESSOR 2520UABC2EA 5416A20013M R 559011 FAN PROPELLER 5900A20006A 5900A20017A R 567502 O L P 6750U L050A 6750A30001F R WO0CZZ CAPACITOR DRAWING 6120AR2359V R W48602 CLAMP SPRING 3H02932B R 30 Rd DESCRIPTION oe REMARK M6003R WM 6011 LWJ0611PCG LWC061JGMK1 130410 BASE ASSY SING
16. LE 3041A10011E 3041A10011E 3041A10011E 3041A10011E R 130910 CABINET ASSY SINGLE 3091A10020A 3091A10020A 3091A10020D 3091A10020D R 135312 GRILLE ASSY FRONT SINGLE 3531AR1644H 3531AR1644T 3531AR1644T 3531AR1644T R 135313 GRILLE ASSY INLET 3530A10039A 3530A10039A 3530A10039A 3530A10039A R 137215 PANEL CONTROL 3720A20017A 3720A20017A 3720A20017A 3720A20017A R 149980 SHROUD 4998A10008A 4998A10008A 4998A10006A 4998A10006A R 152302 FILTER MECH A C 5231AR2148A 5231AR2148A 5231AR2148G 5231AR2148G R 238310 ESCUTCHEON 3831A10001F 3831A10001G 3831410001G 3831A10001G R 249950 CONTROL BOX ASSY SINGLE 4995A20127D 4995A20127E 4995A20127E 4995A20127E R 263230 THERMISTOR ASSY 6323A20003D 6323A20003D 6323A20003D 6323A20003D R 264110 POWER CORD ASSY 2H00677P 2H00677P 2H00677P 2H00677P R 267110 REMOTE CONTROLLER ASSY 6711A20034A 6711A20034E 6711A20034E 6711A20034E R 268712 PWB PCB ASSY DISPLAY 6871A20115B 6871A20115B 6871A20193B 6871A20193B R 268714 PWB PCB ASSY MAIN 6871A10013M 6871A10013D 6871A20188Q 6871A20188Q R 346811 MOTOR ASSY SINGLE 4681A10002C 4681A10002C 4681A10012G 4681A10012G R 349480 ORIFICE 4948A10007A 4948A10007A 4948A10007A 4948A10007A R 352113 TUBE DISCHARGE 5210A20511A 5210A20511A 5210A20252A 5210A20252A R 352115 TUBE ASSY EVPORATOR IN 5211A10063C 5211A10063C 5211A10063E 5211A10063E R 35211A TUBE ASSY SUC
17. TION SINGLE 5211A10062B 5211A10062B 5211A10062D 5211A10062D R 352380 AIR GUIDE 5238A20004B 5238A20004B 5238A20005B 5238A20004B R 352390 AIR GUIDE ASSY 5239A30003B 5239A30003A 5239A30003A 5239A30003A R 354210 EVAPORATOR ASSY FIRST 5421A20016G 5421A20016G 54214200160 5421A20016G R 359012 FAN TURBO 5900A10005A 5900A10005A 5900A10005A 5900A10005A R 550140 ISOLATOR COMP 5040AR4195A 5040AR4195A 5040AR4195A 5040AR4195A R 552111 TUBE ASSY CAPILLARY 5211AR3332R 5211AR3332R R 552102 TUBE CAPILLARY BEND 5210A30018K 5210A30018K R 554030 CONDENSER ASSY FIRST 5403A20009E 5403A20009E 5403A20038D 5403A20038D R 554160 COMPRESSOR 2520UAMC2AA 2520UAMC2AA 25200 2 2520UAMC2AA R 559011 FAN PROPELLER 5900A20017A 5900A20017A 5900A20006A 5900A20006A R 567502 O L P 6750U L004A 6750U L004A 6750U L060A 6750U L060A R WOCZZ CAPACITOR DRAWING 6120AR2359V 6120AR2359V 6120AR2359V 6120AR2359V R W48602 CLAMP SPRING 3H02932B 3H02932B 3H02932B 3H02932B R 31 LG Electronics Inc February 2003 P No 3828A20038B Printed in Korea
18. channel behind side panel frames Personal injury or property damage may result if unit falls from window ROOM SIDE Figure 26 14 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 See Figure 27 IMPORTANT When the air conditioner drops into the L bracket the air conditioner will be centered in window opening as shown in Figure 28 b While steadying the air conditioner carefully bring the window sash down behind the upper guide of the air conditioner as shown in Figure 29 4 SECURE THE GUIDE PANELS Extend the guide panels TYPE F to fill the window opening using 4 screws TYPE B to secure them as shown in Figure 30 5 INSTALL THE SASH SEAL AND SASH LOCK a Cut the sash seal TYPE E 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 30 b Fasten the L bracket using a TYPE A screw as shown in Figure 30 6 Window installation of room air conditioner is now completed See ELECTRICAL DATA for attaching power cord to electrical outlet 3 2 4 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
19. discharge capacitor before Check the capacitor Replace if not within 10 of manufacturer s servicing rating replace if shorted open or damaged Compressor Check the compressor for open circuit or ground If open or grounded replace the compressor Overload Check the compressor overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool and retest Compressor cycles on Voltage Check the voltage See the limits on the overload preceding page If voltage is not within these limits call an electrician Overload Check overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool and retest 24 COMPLAINT CAUSE REMEDY Compressor cycles on overload Fan motor Condenser air flow restriction If not running determine the cause Replace if required Remove the cabinet inspect the interior surface of the condenser If restricted clean carefully with a vacuum cleaner do not damage fins or brush Clean the interior base before re assembling Condenser fins If the condenser fins are closed over a large damaged area on the coil surface head pressures will increase causing the compressor to cycle Straighten the fins or replace the coil Capacitor Test the capacitor Wiring Check the terminals If loose repair or replace Refrigeration system
20. e figure 23B Open valve C Discharge the line at the manifold connection 6 5 The system is now ready for final charging 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 Connect the charging cylinder as shown in fig ure 21B With valve C open discharge the hose at the manifold connection Open valve A and allow the proper charge to enter the system Valve B is still closed If more charge is required the high side will not take it Close valve A With the unit running open valve B and add the balance of the charge a Do not add the liquid refrigerant to the low side b Watch the low side gauge allow pressure to rise to 30 Ibs 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 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 cut ter 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 leak age of the pinch off connection 7 3 7 4 7 5 7 6 Equipment needed Vacuum pump charging cylinder manifold
21. emove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 Remove the air guide upper Refer to Section 2 2 1 Remove the compressor turbo fan fan and shroud Refer to Section 2 2 2 Remove the motor Refer to Section 2 2 3 Remove 2 screws that secure the air guide to the base pan See Figure 11 Push the air guide backward and lift it upward See Figure 11 Re install by referring to the procedures above 2 3 ELECTRICAL PARTS 2 3 1 OVERLOAD PROTECTOR 1 O O W N Remove the front grille and cabinet Refer to Section 2 1 Remove the nut which fastens the terminal cover Remove the terminal cover Remove all the leads from the overload protector Remove the overload protector Re install the components by referring to the removal procedure above See Figure 12 and 13 Figure 10 Figure 11 Figure 12 Figure 13 2 3 2 COMPRESSOR 1 2 o Remove the front grille and cabinet Refer to Section 2 1 2 Discharge the refrigerant by using a refrigerant recovery system Remove the overload protector Refer to Section 2 3 1 After discharging the unit completely unbrace the suction and discharge pipes at the compressor connections Remove 3 nuts which fasten the compressor Remove the compressor Re install by referring to the remo
22. emove the grounding screw Remove a screw securing the clip with cord to the control board Pull the power cord Re install by referring to procedures above 2 4 REFRIGERANT CYCLE 2 4 1 CONDENSER 1 2 3 Remove the cabinet Refer to Section 2 1 2 Discharge the refrigerant by using a refrigerant recovery system Remove the air guide Refer to Section 2 2 1 Remove 2 screws which fasten the condenser After discharging the refrigerant completely unbraze the interconnecting tube at the condenser connections Remove the condenser Re install by referring to the procedures above 2 4 2 EVAPORATOR 1 2 3 Remove the cabinet Discharge the refrigerant by using a refrigerant recovery system Remove the air guide upper Refer to Section 2 2 1 After discharging the refrigerant completely unbraze the interconnecting tube at the condenser connections Remove the evaporator Re install by referring to the procedures above Figure 18 Figure19 10 2 4 3 CAPILLARY TUBE 1 2 3 Remove the cabinet Discharge the refrigerant by using a refrigerant recovery system Remove the air guide upper Refer to Section 2 2 1 7 After discharging the refrigerant completely unbraze the interconnecting tube of the capillary tube Remove the capillary tube Re install by referring to the procedures above NOTES Replacement of the refri
23. ft will not rotate replace the motor Fan motor runs Revolves on overload Check voltage See limits on this page If not within limits call an electrician Test capacitor Check bearings Does the fan blade rotate freely If not replace fan motor Pay attention to any change from high speed to low speed If the speed does not change replace the motor 23 COMPLAINT Fan motor noise Compressor will not run fan motor runs CAUSE REMEDY Fan If cracked out of balance or partially missing replace it Blower If cracked out of balance or partially missing replace it Loose set screw Tighten it Worn bearings Voltage Wiring 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 discon nected refer to wiring diagram for identification and replace the wires Check the wire connections If not according to the wiring diagram correct the connections Thermistor Check the TEMP control If not at the lowest number set TEMP control to this setting and restart the unit Check the continuity of the thermistor Replace the thermistor if the circuit is open Capacitor
24. 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 00 MANIFOLD GAUGE CONDENSER HIGH PRESSURE SIDE SEE INSETS BELOW COMPRESSOR EVAPORATOR LOW PRESSURE SIDE CAPILLARY TUBE LO HI CHARGING CYLINDER O Q EXTERNAL VACUUM PUMP Figure 20A Pulling Vacuum Figure 20B Charging 12 3 INSTALLATION This air conditioner is designed with a button down chassis so it can be easily installed in a window 3 1 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 side louvers of the cabinet must remain exposed on the outdside of the structure 4 Install the unit slanted slightly so the back is slight ly lower than the front about 4 This will force condensed water to the outside 5 Install the unit with the bottom about 30 60 abo
25. geration cycle When replacing the refrigerating cycle be sure to discharge the refrigerant by using a refrigerant recovery system After discharging the unit completely remove the desired components and unbraze the pinch off tubes Solder service valves into the pinch off tube ports leaving the valves open Solder the pinch off tubes with service valves After completing the above procedures the valve must be closed and left in place on the system for any subsequent procedures Evacuate as follows 6 1 Connect the vacuum pump as illustrated in figure 20A Start the vacuum pump Slowly open manifold valves A and B with two full turns counter clockwise 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 6 2 CAUTION If high vacuum equipment is used just crack valves A and B for a few minutes then open slowly with the two full turns counter clock wise This will keep oil from foaming and being drawn into the vacuum pump 6 3 Operate the vacuum pump for 20 to 30 min utes 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 Se
26. ith an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all Mode except POWER OFF The value should be over 1 1 5 LOCATIONS OF CONTROLS 1 5 1 CONTROLS TEMPERATURE SETTING This button can automatically control the temperature of the room The temperature can be set within a range of 60 16 to 86 F 30 C by 1 1 F Select the lower number for lower temperature of the room ENERGY SAVER The fan stops when the compressor stops cooling Approximately every 3 minutes the fan will turn on and check the room air to determine if cooling is needed FAN COOL DRY Everytime you push this button it will toggle between COOL FAN and DRY ON OFF TIMER STOPPING OPERATION Everytime you push this button when the unit is operating timer is set as follows 1Hour 2Hours 3Hours 4Hours 5Hours gt 6Hours 7Hours 8Hours 9Hours 10Hours 11Hours 12Hours Cancel The Setting Temperature will be raised by 2 F 1 C 30min later and by 2 F 1 C after another 30 min STARTING OPERATION Everytime you push this button when the unit is not operating timer is set as follow Timer ovyorto 1Hour 2Hours 3Hours 4Hours 5Hours 6Hours THours 8Hours Hours 10Hours 11Hours 12Hours Cancel Fan Speed Power POWER pee To turn the unit ON push the button To turn the unit OFF push the button again This button
27. ly on Display P W B Ass y Is the ICO1G all right ves NO Is the connection of e Exchange IC01G Connect connector CN DISP2 all right Does the Q12G NO to CN DISP2 exactly Exchange Q12G Q13G Q14G operate normally on main P W B Ass y Exchange the display P W B Ass Q13G Q14G 22 ROOM AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM MAXIMUM 115V 10 103 5V 126 5V COMPLAINT CAUSE REMEDY Fan motor will not run 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 Rotary switch Check switch continuity Refer to wiring diagram for terminal identification Replace switch if defective Wire disconnected or Connect wire Refer to wiring diagram for connection loose terminal identification Repair or replace loose terminal Capacitor Discharge Test capacitor capacitor before testing Replace if not within 10 of manufacturer s rating Replace if shorted open or damaged Will not rotate Fan blade hitting shroud or blower wheel hitting scroll Re align assembly Units using slinger ring condenser fans must have 0 22 0 25 inch clearance to the base If necessary shim up the bottom of the fan motor with mounting screw s Check fan motor bearings if motor sha
28. t of fan motor capacitor Improper thermistor f 1 Drop of power voltage setting Defect of compressor Loose terminal capacitor connection Irregular motor Capacitor check a Improper wiring resistance Q Irregular motor insulation Q Replacement Replacement of fan motor Irregular motor resistance Q Regular but fails to start Replacement of compressor Irregular motor insulation Q Locking of piston metal Replacement of compressor Motor damaged 19 ELECTRIC PARTS TROUBLESHOOTING GUIDE Possible Trouble 1 The unit does not operate NO 15 the Trans output power AC 115V Check the Fuse Check the wiring diagram YES Is the Trans output power about AC 14V Is shorted the Trans output e Check the Main P W B pattern Exchange the Trans Is output Voltage of ICO1D NO DC 12V Exchange 0020 005 e Exchange ICO1D Is output Voltage of ICO2D NO Exchange ICO2D DC 5V Is the reset circuit all right The No 16 of Micom Exchange ICO1A is 5V YES Is the connection between Main and Display NO Connect connector exactly all right NO Check the P W B P pattern Exchange Main P W B Ass 20
29. takes priority over any other buttons When you first turn it on the unit is on the High cool mode and the temp at 72 F 22 C FAN SPEED Everytime you push this button it is set as follows High F2 Low F1 gt High F2 1 5 2 REMOTE CONTROLLER POWER To turn the Set ON push the button To turn the Set OFF push the button again This button takes priority over any other buttons e When you first turn it on the Set is on the High cool mode and the temp at 72 F 22 C TEMPERATURE SETTING This button can automatically control the temperature of the room The temperature can be set within a range of 60 F 16 C to 86 F 30 C by 1 F 1 C Select the lower number for lower temperature of the room FAN SPEED Everytime you push this button it is set as follows High F2 Low F1 gt High F2 ON OFF TIMER STOPPING OPERATION Everytime you push this button when the set is operating timer is set as follows 1Hour 2Hours 3Hours 4Hours 5Hours 6Hours gt 7Hours gt 8Hours gt 9Hours 10Hours 11Hours 12Hours Cancel Energy Saver The Setting Temperature will be raised by 2 F 1 C 30min later and by 2 F 1 C after another 30 min STARTING OPERATION Everytime you push this button when the set is not operating timer is set as follow 1Hour 2Hours gt 3Hours gt 4Hours gt 5Hours gt 6Hours 7Hours gt 8Hours 9Hours 10Hours
30. val procedure above See Figure 14 2 3 3 CAPACITOR 1 2 3 Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 Discharge the capacitor by placing a 20 resistor across the capacitor terminals Pull the capacitor upward Remove all the leads of capacitor terminals Re install the components by referring to the removal procedure above See Figure 15 2 3 4 THERMISTOR 1 2 3 Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 Disconnect the thermistor terminals from main P W B assembly Remove the thermistor Re install the components by referring to the removal procedure above See Figure 16 2 3 5 CONTROL PANEL 1 2 3 Remove 2 lead wire terminals Re install the components by referring to the Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 Pull the control panel forward and pull out it removal procedure above See Figure 17 Figure 14 Figure 15 Figure 16 Figure 17 2 3 6 POWER CORD Disconnect the unit from source of power Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove 2 screws that secure control board to base pan and orifice Pulls the control board toward you R
31. ve the control board Refer to Section 2 1 3 Remove the air guide upper Refer to Section 2 2 1 Remove 2 screws that secure the base pan to condenser See Figure 7 Remove screw that secures the shroud to channel of condenser Press the snap area of shroud with your thumbs This allows you to remove it from the condenser Lift the compressor upward with the evaporator and condenser See Figure 7 Remove the orfice by pushing the snap area of the air guide blower See Figure 8 Remove the clamp springs which are clamped to the boss of fan and turbo fan by hand plier See Figure 9 Pull the fan and turbo fan outward Remove the shroud Re install by referring to the procedures above Figure 9 Figure 6 Figure 7 Figure 8 2 2 3 N Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove the control board Refer to Section 2 1 3 Remove the air guide upper Refer to Section 2 2 1 Remove the compressor turbo fan fan and shroud Refer to Section 2 2 2 Remove 2 screws that secure the motor to the motor See Figure 10 Remove the motor Re install by referring to the procedures above 2 2 4 AIR GUIDE RON Disconnect the unit from the power source R
32. ve the floor level 3 2 HOW TO INSTALL 3 2 1 WINDOW REQUIREMENTS NOTE All supporting parts should be secured to firm wood masonry or metal 1 This unit is designed for installation in standard dou ble hung windows with actual opening widths of 22 to 36 The upper and lower sash must open sufficiently to allow a clear vertical opening of 13 from the bot tom 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 23 Top of wood strip should be approximately 3 4 higher than the storm window frame STORM WINDOW 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 cen ter of the outer sill flush against the back off the inner sill This will raise the L bracket as shown Figure 23 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 neces sary INSIDE OUTSIDE AWNING E HEAT RADIATION FENCE COOLED AIR p rude ABOUT 1 4 Over 20 Figure 21 INNER SILL OUTER SILL INDOORS OUTDOORS
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