Heat Controller CD-121, CD-101-5 Service Manual

Window-Type

Air Conditioner

Service Manual

CAUTION

-Before servicing the unit, read the "safety precautions" in this manual.

-Only for authorized service personnel.

HEAT CONTROLLER, INC.

MODELS: CD-121

CD-101-5

2 Room Air Conditioner

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

Service Manual 3

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.

■ Meanings of symbols used in this manual are as shown below.

WARNING

CAUTION

This symbol indicates the possibility of death or serious injury.
This symbol indicates the possibility of injury or damage to properties only.

WARNING

■ Installation

Be sure not to do.

Be sure to follow the instruction.

Always install the expansion panel(s).

• No installation may cause fire and electric shock acci-

dent.

Do not place the power cord near a heater.

• It may cause fire and electric shock.

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

• It may cause explosion or fire.

Do not disassemble or modify products.

• It may cause failure and electric shock.

Gasolin

4 Room Air Conditioner

Safety Precautions

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

• They are sharp and may cause injury.

Do not block the inlet or outlet.

• It may cause failure of appliance or accident.

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.

Be cautious not to touch the sharp edges when
installing.

• It may cause injury.

Hold the plug by the head when taking it out.

• It may cause electric shock and damage.

Turn off the main power switch when not using it
for a long time.

• Prevent accidental startup and the possibility of injury.

■ Installation

Dimensions

Dimensions

W

H

D

W mm(inch) 368(14 1/2")

H mm(inch) 521(20 1/2")

D mm(inch) 584(23)

Model

Dimension

All Model

Outside Dimensions

This symbol alerts you to the risk of electric shock.

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

This symbol indicates special notes.

NOTICE

Symbols Used in this Manual

Service Manual 5

6 Room Air Conditioner

Product Specifications

Product Specifications

SPECIFICATIONS ARE SUBJECT TO MINOR CHANGE WITHOUT NOTICE FOR FURTHER
IMPROVEMENT.

NOTICE

CD-101-5 CD-121

1１,５00

1,２１0

11.０

655g(23.1oz)

3 ROW 16STACKS,

SLIT FAN TYPE

79/36

（inch）

（mm）

77/35

14

1

/2×201/2×23

VERTICAL LOUVER （RIGHT&LEFT）

HORIZONTAL LOUVER （UP&DOWN）

OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

3/3

6 POLES

368×521×５８４

POWER CORD

DRAIN PIPE SPLASHED BY FAN SLINGER

3 WIRE WITH GROUNDING

ATTACHMENT PLUG（CORD-CONNECTED TYPE）

OPERATING
CONDITION

PROTECTOR

OUTSIDE DIMENSION

（W×H×D）

COMPRESSOR

FAN MOTOR

INDOOR （℃）

10,000

1,050

9.6

AIR DIRECTION CONTROL

3 ROW 16STACKS, SLIT FAN TYPE

2 ROW 23STACKS,

LOUVER FIN TYPE

REMOTE CONTROLLER

THERMOSTATROOM TEMP . CONTROL

OUTDOOR （℃）

DRAIN SYSTEM

NET WEIGHT （lbs/kg）

CONSTRUCTION

FAN SPEEDS，FAN/COOLING

FAN MOTOR

OPERATION CONTROL

115V/60Hz

9.5

26.7(DB)* 19.4(WB)**

480g(16.9oz)

E.E.R (BTU/W·h)

REFRIGERANT（R-22）CHARGE

TURBO FAN

AXIAL FAN

EVAPORATOR

CONDENSER

FAN，INDOOR

FAN，OUTDOOR

35(DB)* 23.9(WB)**

POWER SUPPLY

COOLING CAPAC (Btu/H)

INPUT (W)

RUNNING CUR (A)

ITEMS

MODELS

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.

Service Manual 7

Installation

Installation

Installation Kits Contents

Window Requirements

8

7

9 10

3

12

11

16

17

1

6

13

15

4

14

2

5

21" min.
40 1/2" max.

15 1/2"
min.

21 1/2" min.

15 1/2" min.
16 1/2" max.

Horizontal sliding window Casement window

NO. NAME OF PARTS QTY

1 Curtain 1
2 Curtain Frame 1
3 Upper Guide 1
4 Side Guide 2
5 Support Bracket 1
6 Bracket 1
7 Leveling Bolt & Nut 1
8 Bolt 2

9 Nut 2
10 Washer 2
11 Side Guide seal 1
12 Foam Seal Strip 1
13 Window Track Seal 1
14 Window Locking Bracket 1
15 Screw (Type A) 9
16 Screw (Type B) 3
17 Screw (Type C) 8

8 Room Air Conditioner

Installation

How to Install the Unit

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

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

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.

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.

NOTICE

About 1/4"

30"~60"

Awning

Cooled air

Fence

Over 20"

Heat

radiation

Service Manual 9

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)

2. Remove protective backing from Window Track Seal
and apply seal to window track. (Fig.2)

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)

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.

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)

6. Fasten Upper Guide on the top of the Air Conditioner
using 3 Type A screws. (Fig. 4)

NOTICE

81/4 inches inches81/4 inches

WindoWindow JambambWindow Jamb

WindoWindow TrackWindow Track

WindoWindow Track

Seal

Window Track

Seal

Bracket

Support Bracket

Nut

Washer

Leveling Bolt & Nut

Bolt

Type C screwType C screw

About

1/4"

Outside Wall

Fastening Side Guides

Upper Guide

Side Guide

Fig. 1

Fig. 2

Fig. 3

Fig. 4

10 Room Air Conditioner

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)

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)

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)

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.

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)

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)

Frame Curtain

Curtain

Apply weather seal
to side guides
just below edge of
Curtain Frame .

Type B screwType B screw

Base panBase pan

BracketBracket

Window Track

Base GuideBase Guide

Type C screw

Window Track

Fig. 5

Fig. 6

Fig. 7

Fig. 8

Check all seals and plug any remaining air
gaps with a suitable weatherproof caulk.

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)

NOTICE

Service Manual 11

Foam seal strip

Window

locking

bracket

Casement Window Installation

Fig. 9

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.

12 Room Air Conditioner

Operation

Controls

Remote Control Operations

Operation

The remote control and control panel will look like those represented in the following pictures.

Power

Temp

Fan Speed

Timer Mode

1

1
2

4
3

2

3

45

5

6

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.

Service Manual 13

Disassembly

Mechanical Parts

Disassembly

1. Front Grille

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.

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.)

- Before the following disassembly, set POWER SWITCH to OFF and disconnect the power cord.

D

Figure 1

Figure 3

Figure 2

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.

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

Disassembly

Air Handling Parts

Figure 4

Figure 5

Figure 6

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.

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 Freon

TM

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.

Service Manual 15

Disassembly

Electrical Parts

Figure 8

Figure 9

Figure 10

16 Room Air Conditioner

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)

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.)

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)

Figure 11

Figure 12

Figure 13

Service Manual 17

Disassembly

Refrigerating Cycle

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)

12. CONDENSER

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)

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 14

Figure 15

Figure 16

Discharge the refrigerant system using a
FreonTMRecovery 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.

CAUTION

18 Room Air Conditioner

— Replacement of the refrigerant.

1. When replacing the refrigerant, be sure to
Discharge the refrigerant system using a Freon

TM

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.

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.

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 Low-

side.

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.

NOTES

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.

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.

CAUTION

Service Manual 19

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.

A

COMPOUND GAUGE

EVAPORATOR
(LOW PRESSURE SIDE)

COMPRESSOR

CAPILLARY TUBE

CONDENSER
(HIGH PRESSURE SIDE)

SEE INSETS

BELOW

MANIFOLD

GAUGE

B

A

B

EXTERNAL
VACUUM PUMP

A

CHARGING
CYLINDER

LOW

HI

B

C

Figure 17A-Pulling Vacuum

Figure 17B-Charging

Schematic Diagram

Wiring Diagram

20 Room Air Conditioner

1-5

1-5

C03D

16V

1000

CAPACITOR

MAIN POWER

RY-HI

RY-MED

RY-LOW

0.1/275V

14D561

14D271

ZNR01J

120 1/2W

COMP

HERM

250V/T2A

RY-COMP

G4A-1A-E-LG

4

3

FUSE

135

7

9

1

3

CN-PWR

YW396-03AV

C

FAN

1

3

FAN

MOTOR

5

791

3

C01J

R01J

1N4004

D02D~D05D

POWER TRANS

1

2

D02D

4

D03D

7

50V

35V

+

D05D

D04D

C01D

1000

I

IC01D

C02D

0.1

7812

LED TYPE

88 SEGMENT TYPE

DISPLAY

4WAY

R03H

RY-4WAY

3

1

YW396-03AV

CN-MOTOR

CN-4WAY

YW396-09AV

S/V-

1

3

optional part

PIPE-TH

12V

Cool Only

Heat Pump

Model

CN-TH2

SMW250-04

RY-4WAY

X

O

15

RY-MED

RY-HI

IC01M

ULN2004AF

16

1

2

RY-COMP

RY-4WAY

RY-SYNC

RY-LOW

CN-4WAY

O

X

R03H

X

O

10K

X

CN-TH2

O

131214

12V

91011

64538

7

R21H

OR01H

5V

12.1K

1%

ROOM-TH

3

3

3

3

1

1

1

1

CN-TH1

SMW250-04

5V

1%

6.2K

R02H

SW6

D06F

SW4

D04FD05F

SW5SW7

D07F

GND

C22L

2-1

2-4

2-2

2-3

1-9

1-7

1-8

1-13

1-6

0.01

C06D

50V

50V

7805

IC02D

C04D

I

O

+

0.01

12V

O

C05D

220

10V

+

5V

5V

X

O

J01F

1K

R01E

R01L

C01L

680pF

1K

R12F

20K

J01F

ULN2004AF

IC01G

8 9

CN-MAIN2

R01F

C01F

0.001

10K

14

3

R04G

R06G

R07G

R05G

6

7

11

10

4

5

13

12

150

150

150

150

R02G

R01G

R03G

1

2

16

15

150

150

150

CN-DISP2

c

1-9

2-2

2-3

2-4

2-1

fgd

e

1-8

1-7

1-13

1-6

a

b

RECEIVER

BZ01E

PKM13EPY

-4000-A0

220

10V

0.4 inch

88 SEGMENT

3

9

8

6

7

1

c

DRY/HEAT

FAN

E/SAVER

TIMER

fgd

e

COOL

a

b

c

e

4

d

g

e

d

g

f

a

b

Digit1

10

a

f

Digit0

5

Auto Restart

1-10

1-11

Non Auto Restart

1-12

EEPROM(optional part)

8

9

10

11

7561234

TMP87CH47U

ION

36

R02E

20

LED out2
LED out1
LED out0

MED

Buzzer

Receiver

LED out3

313233

34 35

282930

HI

SEG-g

KEY0

KEY1

VDD

SLIDE SW

SEG-e

SEG-f

SEG-d

3837 4039 4241 43 44

20

Option1

Option2

Pipe TH

COMP

4WAY

SYNC

LOW

HVB

2425262723

22 21

OR02H

1%

R22H

12.1K

TEST

VAref
VSS

Osc in

Osc out

/Reset

Room TH

MICOM

1819 1617 1415

Tx

13 12

5V

Digit2 (Scan2)

R02F

0.001

C02F

10K

Digit0 (Scan0)

Digit1 (Scan1)

SEG-c

SEG-b

SEG-a

CN-MAIN1

Digit4 (Scan4)

Digit3 (Scan3)

SCL

SDA

Rx

Vcc

24LC01BT

SCL

SDA

WP

3

A2

4

GND

2

1

A0

A1

6

578

C01P

0.01

1K

R04P

5V

R02P

20K

R03P

20K

1K

0.01

C01A

12.1K

R01H

1%

OSC01B

8.00MG

R01B

1M

R01A

IC01A

S7136

5V

R03A

C02A

10uF

50V

+

100

3.6V

1

2

3

4.7K

R02A

Model

Q04G

A101S

TEMP UP

CN-DISP1

1-10

1-11

1-12

Vout

+

Vcc

5V

5V

5V

1-1

1-1

TEMP DOWN

TIMER

D02F

SW2

D01F

MODE

FAN

SW1

POWER

1-2

1-2

1-3

1-3

Q03G

A101S

1-4

1-4

A101S

Q02G

Q01G

A101S

EEPROM

O

X

R04P

X

O

c

b

5V

Service Manual 21

Schematic Diagram

Wiring Diagram

MOTOR

COMP.

CAPACITOR

DISPLAY PCB

ASSEMBLY

THERMISTOR

AIR FILTER
ASSEMBLY

MAIN PCB

ASSEMBLY

3854AR3629N

SWITCH

H.V.

ASSEMBLY

BK

CN-MOTOR

CN-PWR

DC12V

ZNR01J

CN-12V

CN-HVB

RY-COMP

3
4

FUSE

250V/T2A

(115V/T2A)

RY-LOW

RY-MED

RY-HI

CN-MAIN1
CN-MAIN2

POWER
TRANS

CN-DISP1
CN-DISP2

CN-TH1

BL
RD

RDBK

BL

R

S

C

OLP

YL
OR

YL

F

C

H

WH

(BL)

(

Ribbed

)

BK(BR

)

(

Plain

)

GN/YL

GN/YL

BK

RD

OR(BR

)

WIRING DIAGRAM

CASEMENT_10K
CASEMENT_12K

22 Room Air Conditioner

Components Location

Main P.W.B AssemblyMain P.W.B Assembly

J04

CN_TH1

250V T3.15A

4

CN_TH2

250V T2A

RY_COMP

FUSE

C01J

OSC01B

PCB ASM: 6871A01001

PCB: 6870A91001A

C05D

J01

IC01A

C02A

C01A

CN_4WAY

RY_4WAY

13

CN_MAIN2

3

C03D

IC02D

R02A

J02

R03H

C01D

7

D05D

4

D04D

D03D

D02D

CN_MAIN1

IC01D

TRANS

ZNR01J

CN_PWR

1 3

LW1

RY_MED

RY_LOW RY_HI

CN_MOTOR

1

J03

4

1

R01J

Display P.W.B Assembly

PCB P/NO : 6870A90166A

POWER

SW1

F/SPEED

D06F

J5

BZ01E

D01F

2003.08.22

SW6

PCB ASM P/NO : 6871A20442

J6

TEMP DOWN

D05F

SW5

J4

J2

RECEIVER

C22L

CN_DISP1

CN_DISP2

1 1

SW7

TEMP UP

J7

J1

D04F

D07F

J8

SEGMENT

E/SAVER

DRY/HEAT

TIMER

COOL

SW2

TIMER

MODE

D02F

J3

LED3

LED1

LED5

LED4
FAN

SW4

LED2

Service Manual 23

Troubleshooting Guide

Troubleshooting Guide

Piping System

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.

(LIQUID REFRIGERANT)

CAPILLARY TUBE

OUTSIDE COOLING
AIR FOR REFRIGERANT
PASS THROUGH

SUCTION LINE
COOL LOW PRESSURE VAPOR

COOLED
AIR

COMPLETE LIQUID
BOIL OFF POINT

LIQUID
PRESSURE
DROP

ROOM AIR HEAT LOAD

VAPOR INLET

HOT
DISCHARGED
AIR

LIQUID OUTLET

HIGH PRESSURE VAPOR
LIQUID REFRIGERANT
LOW PRESSURE VAPOR

ROOM AIR CONITIONER

EVAPORATOR COILS CONDENSER COILS

CYCLE OF REFRIGERATION

MOTOR

COMPRESSOR

OIL

CAPILLARY TUBE

COMPRESSOR

TURBO FAN

EVAPORATOR COIL

CONDENSER COIL

FAN
MOTOR

Figure 18

24 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 is running but cooling is ineffective.

Ineffective Cooling

Check outdoor coil
(heat exchanger) & the fan
operation.

Check gas leakage.

Repair gas leak.

Replace of unit if the
unit is beyond repair.

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

Check heat load
increase.

Clean condenser.

Not on separate circuit.

Check inside gas
pressure.

Adjusting of refrigerant
charge.

Malfunction of compressor.

Replacement of
compressor.

Check cold air circulation
for smooth flow.

Dirty indoor coil
(Heat exchanger)

Correct above problem

Check clogging in refrigera­tion system.

Repair clogging in refrigera­tion system.

Obstruction at air outlet

Clogged of air filter.

Malfunction of fan

Service Manual 25

Troubleshooting Guide

Fails to Start

Check circuit breaker
and fuse.

Gas leakage of feeler bulb
of thermostat

Check of control switch.

Fan only fails to start.

Improper wiring.

Defect of fan motor
capacitor.

Irregular motor resistance
(

).
Irregular motor insulation
(

).

Replacement of fan motor.

Tests normal but fails to start.

Replacement of compressor
(locking of rotor, metal).

Improper thermostat setting.

Loose terminal connection.

Improper wiring.

Irregular motor resistance ( )

Irregular motor insulation ( )

Replacement of compressor
(Motor damaged)

Drop of power voltage.

Capacitor check.

Replacement

Compressor only fails to
start.

Defect of compressor
capacitor.

Check of power source.

Check of control switch
setting.

26 Room Air Conditioner

Troubleshooting Guide

Room Air Conditioner Voltage Limits

COMPLAINT CAUSE REMEDY

Check voltage at outlet. Correct if none.
Check voltage to rotary switch. If none, check power

supply cord. Replace cord if circuit is open.
Connect wire. Refer to wiring diagram for terminal

identification. Repair or replace loose terminal.
Test capacitor.

Replace if not within ±10% of manufacturer's rating.
Replace if shorted, open, or damaged.

Fan blade hitting shroud or blower wheel hitting
scroll. Realign assembly.

Units using slinger ring for condenser fan must have

1

/4to 5/16inch clearance to the base. If it hits the
base, shim up the bottom of the fan motor with
mounting screw(s).

Check fan motor bearings; if motor shaft will not
rotate, replace the motor.

Check voltage. If not within limits, call an electrician.
Test capacitor.

Check bearings. Does the fan blade rotate freely?
If not, replace fan motor.

Pay attention to any change from high speed to
low speed. If the speed does not change, replace the
motor.

If cracked, out of balance, or partially missing,
replace it.

If cracked, out of balance, or partially missing,
replace it.

Tighten it.
If knocking sounds continue when running or loose,

replace the motor. If the motor hums or noise
appears to be internal while running, replace motor.

Check voltage.
If not within limits, call an electrician.

Check the wire connections, if loose, repair or
replace the terminal. If wires are off, refer to wiring
diagram for identification, and replace. Check wire
locations. If not per wiring diagram, correct.

No power
Power supply cord

Wire disconnected or con­nection loose

Capacitor (Discharge
capacitor before testing.)

Will not rotate

Revolves on overload.

Fan

Turbo

Loose clamper
Worn bearings

Voltage

Wiring

Fan motor will not run.

Fan motor runs
intermittently

Fan motor noise.

Compressor will not run,
but fan motor runs.

NAME PLATE RATING MINIMUM MAXIMUM

AC 115V ±10% AC 103.5V AC 126.5V

Service Manual 27

Troubleshooting Guide

COMPLAINT CAUSE 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.

Check the capacitor.
Replace if not within ±10% of manufacturers rating.
Replace if shorted, open, or damaged.

Check the compressor for open circuit or ground. If
open or grounded, replace the compressor.

Check the compressor overload, if externally mount­ed. Replace if open. (If the compressor temperature
is high, remove the overload, cool it, and retest.)

Check the voltage.
If not within limits, call an electrician.

Check overload, if externally mounted.
Replace if open. (If the compressor temperature is
high, remove the overload, cool, and retest.)

If not running, determine the cause. Replace if
required.

Remove the cabinet. inspect the interior surface of
the condenser; if restricted, clean carefully with a
vacuum cleaner (do not damage fins) or brush.
Clean the interior base before reassembling.

If condenser fins are closed over a large area on the
coil surface, head pressures will increase, causing
the compressor to overload. Straighten the fins or
replace the coil.

Test capacitor.
Check the terminals. If loose, repair or replace.
Check the system for a restriction.
If restricted, clean or replace.
Close if open.
Determine if the unit is properly sized for the area to

be cooled.
Check the set screw or clamp. If loose or missing,

correct. If the turbo 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.

Thermistor

Capacitor (Discharge
capacitor before servicing.)

Compressor

Overload

Voltage

Overload

Fan motor

Condenser air flow restric­tion

Condenser fins (damaged)

Capacitor
Wiring
Refrigerating system
Air filter
Exhaust damper door
Unit undersized

Turbo or fan

Copper tubing

Compressor will not run,
but fan motor runs.

Compressor cycles on
overload.

Compressor cycles on
overload.

Compressor cycles on
overload.

Insufficient cooling or heat­ing

Excessive noise

Specifications and performance data subject to change without notice.

HEAT CONTROLLER, INC.

1900 WELLWORTH AVENUE • JACKSON, MICHIGAN 49203

THE QUALITY LEADER IN CONDITIONING AIR

P/No.: MFL36458901

04/18/07