Heat Controller RAD-101A User Manual

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SERVICE MANUAL

AD-101A

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 .....................................................................................................................................................6

Outside Dimensions...................................................................................................................................6

Product Specifications ..................................................................................................................................7

Installation .......................................................................................................................................................8

Select the Best Location ............................................................................................................................8

Installation Check.......................................................................................................................................8

How to Secure the Drain Pipe....................................................................................................................8

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

Operation ......................................................................................................................................................13

Location and Function of Controls ...........................................................................................................13

Remote Control Operations ....................................................................................................................14

Disassembly ..................................................................................................................................................15

Mechanical Parts......................................................................................................................................15

Air Handling Parts ...................................................................................................................................16

Electrical Parts .........................................................................................................................................17

Refrigerating Cycle...................................................................................................................................19

Schematic Diagram.......................................................................................................................................22

Wiring Diagram.........................................................................................................................................22

Electronic Control Device.........................................................................................................................24

Components Location(For Main P.W.B ASM)...........................................................................................25

Troubleshooting Guide.................................................................................................................................26

Piping System ........................................................................................................................................26

Troubleshooting Guide .............................................................................................................................27

2 Room Air Conditioner

Safety Precautions

CAUTION

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 instructions will cause harm or damage. The seriousness

is classified by the following indications.

WARNING

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

This symbol indicates the possibility of death or serious injury.

This symbol indicates the possibility of injury or damage to property only.

Be sure not to do.

Be sure to follow the instruction.

WARNING



Always install the expansion panel(s).

• Improper assembly or installation may cause incorrect operation, including injury, fire, and

electric shock hazards.

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.

Service Manual 3

Safety Precautions

Plug in the power plug properly.

• Otherwise, it will cause electric shock or fire.

Do not modify power corDo not modify poDo not modify po dwer cor

Do not modify po length.

Do not operate or stop the unit by inserting or pulling out the power plug.

• It will cause electric shock or fire.

Use the air conditioner on a single outlet circuit.(see page 7.) Do not share the outlet with other appliances.

Do not damage or use an unspecified power cord.

• It will cause electric shock or fire.

Always plug into a grounded outlet.

• •• It will cause electr ic shoc• k or fire.

Ventilate before operating air conditionerwhen gas goes out.

It may cause explosion, fire, and burn.

•

It will cause electric shock or fire.

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

•• It may cause fire and electric shock.

• No •• grounding • may cause electric shock.

Do not operate with wet hands or in damp environment.

• It will cause electric shock.

4 Room Air Conditioner

Service Manual 5

Safety Precautions

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

• It will cause electric shock or failure of machine.

CAUTION

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

Do not clean the air conditioner with water.

• Water may enter the unit and degrade the insulation. It may cause an electric shock.

Do not block the inlet or outlet.

They are sharp and may cause injury.

••

Ensure that the outer caseis not damaged by age orwear.

Leaving it damaged couldresult in the air conditioner falling out of the window, creating a safety hazard.

It may cause failure of appliance or

• performance deteriorate.

Be cautious not to touch the sharp edges

•

when installing.

It may cause injury.

•

Sharp edges

6 Room Air Conditioner

Dimensions

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

470(18 1/2")525(20 11/16")

/8")

353(13

Product Specifications

SpecficationsSpecfications

MODELSMODELS

ITEMSITEMS

POWER SUPPLYPOWER SUPPLY

COOLING CAPACITYCOOLING CAPACITY (Btu/h)(Btu/h)

INPUT (W)

RUNNING CURRENT (A)

E.E.R (BTU/W(BTU/W.h)h)

OPERATING

CONDITION

REFRIGERANT (R-22) CHARGEREFRIGERANT (R-22) CHARGE

EVAPORATOREVAPORATOR

CONDENSERCONDENSER

FAN, INDOORFAN, INDOOR

FAN, OUTDOORFAN, OUTDOOR

FAN SPEEDS, FAN/COOLINGFAN SPEEDS, FAN/COOLING

FAN MOTORFAN MOTOR

OPERATION CONTROLOPERATION CONTROL

INDOOR ( C)

OUTDOOR ( C)

RAD-101A

11ØØ, 115, 60Hz, 115, 60Hz

9,800 1,000

9.3

9.9.88

26.7(DB)26.7(DB)** 19.4(WB) 19.4(WB)****

35(DB)35(DB)** 23.9(WB) 23.9(WB)****

410g(14.5oz)

Ø 7.0, 3ROW 14STACKS

Ø 7.0 , 2R 16STACKS(L)

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER RING

3/3

6 POLES

REMOTE CONTROLLER

ROOM TEMP. CONTROLROOM TEMP. CONTROL

AIR DIRECTION CONTROLAIR DIRECTION CONTROL

CONSTRUCTIONCONSTRUCTION

PROTECTORPROTECTOR

POWER CORD

DRAIN SYSTEM

OUTSIDE DIMENSION

(W x H x D)

* DB:Dry Bulb **

WB:Wet Bulb

COMPRESSORCOMPRESSOR

FAN MOTORFAN MOTOR

(inch)

(mm)

THERMISTOR

HORIZONTAL LOUVER (UP & DOWN), VERTICAL LOUVER (RIGHT&LEFT)

SLIDE IN-OUT CHASSIS

OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

3 WIRE WITH GROUNDING

ATTACHMENT PLUG (CORD-CONNECTED TYPE)

DRAIN PIPE OR SPLASHED BY FAN SLINGER

1/2

x 13

7/8

x 20

11/16

469 x 353 x 526

Service Manual7

SerSer

9 Room Air Conditioner

Installation

Select the Best Location

Installation Check

How to Secure the Drain Pipe

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 11" and there should be no obstacles, such as a fence or wall, within 20" from the back of the cabinet because it will prevent heat radiation of the condenser. Restriction of outside air will greatly reduce the cooling efficiency of the air conditioner.

CAUTION: All side louvers of the cabinet must

remain exposed on the outdside of the structure.

4. Install the unit slanted slightly so the back is slightly lower than the front (about 1/

4"). This will force condensed water

to the outside.

5. Install the unit with the bottom about 30"~60" above the floor level.

The setting conditions must be checked prior to initial starting. The following items are especially important checking points when the installation is finished.

1. Grounding wire (Green or Green and Yellow) is provided in the power cord. The green wire must be grounded.

2. Connect to a single-outlet 15A circuit. (or 20A circuit for Electric Heater Model)

3. To avoid vibration or noise, make sure the air conditioner is installed securely.

4 Avoid placing furniture or draperies in front of the air inlet and outlet.

In humid weather, excess water may cause the Base Pan to overflow. To drain the water, remove the Drain Cap and secure the Drain Pipe to the rear hole of the Base Pan. (Figure. 2)

ABOUT / "

Over 20"

HEAT

RADIATION

FENCE

AWNING

OUTSIDE

INSIDE

COOLED AIR

30"-60"

Drain Pipe

Drain Cap

Figure 1

Figure 2

Service Manual 10

Installation

How to Install

Window Requirements

All supporting parts should be secured to firm wood, masonry, or metal.

1. This unit is designed for installation in standard double hung windows with actual opening widths of 22" to 36". The upper and lower sash must open sufficiently to allow a clear vertical opening of 15" from the bottom of the sash to the window stool.

2. If storm window presents interference, fasten a 2" wide wood strip to the inner window sill across the full width of the sill. The wood strip should be thick enough to raise the height of the window sill so that the unit can be installed without interference by the storm window frame. See Figure. 4. 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.

Install a second wood strip (approximately 6" long by 11/2"

wide and same thickness as first strip) in the center of the outer sill flush against the back off the inner sill. This will raise the L bracket as shown Figure. 4.

4. If the distance between STORM WINDOW FRAME and

WOOD STRIP MOUNTED ON TOP OF INNER SILL is more than 1", two of wood strip are not necessary.

Installation

NOTICE

OUTDOORSINDOORS

INNER

SILL

OUTER

SILL

INNER

SILL

WOOD STRIP MOUNTED

ON TOP OF INNER SILL

WOOD STRIP

FOR

BRACKET

3/4"

CLEARANCE

1" MAX.

STORM

WINDOW

FRAME

OUTDOORSINDOORS

OUTER

SILL

Figure 3

Figure 4

HARDWARE

Type A:16EA

(SCREW)

10mm

Type D:2EA

(NUT)

Type E:2EA

(FRAME CURTAIN)

Type B:3EA

(SCREW)

16mm

Type F:2EA

(SILL SUPPORT)

Type C:5EA

(SCREW)

Type G:2EA

(BOLT)

16mm

Type H:1EA

(FOAM-STRIP)

Type L:1EA

(WINDOW LOCKING BRACKET)

Type I:1EA

(UPPER GUIDE)

Type M:1EA (FOAM-PE)

Type J:1EA (FOAM-PE)

Type N:1EA

(DRAIN JOINT PIPE)

Type K:2EA

(FRAME-GUIDE)

Type O:1EA

(DRAIN WASHER)

11 Room Air Conditioner

Installation

PREPARATION OF CHASSIS

1. Remove the screws which fasten the cabinet at both sides and at the back.

2. Slide the unit from the cabinet by gripping the base pan handle and pulling forward while bracing the cabinet.

3. Cut the window sash seal to the proper length. Peel off the backing and attach the Foam-Pe

to the

underside of the

window sash.

4. Remove the backing from the top Upper Guide FoamPe and attach it to the bottom of the Upper Guide.

5. Attach the Upper Guide onto the top of the cabinet with 3 type A screws.

6. Insert the Frame Guides into the bottom of the cabinet.

7. Insert the Frame Curtain

into the Upper Guide

and Frame Guides .

8. Fasten the curtains to the unit with 4 Type A screws.

CABINET INSTALLATION

1.Open the window. Mark a line on center of the window stool(or desired air conditioner location). Carefully place the cabinet on the window stool and align the center mark on the bottom front with the center line marked in the window stool.

2. Pull the bottom window sash down behind the Upper

Guide until it meets.

Upper Guide

Screw

Frame-Guide

(Type A)

Upper Guide

Window Sash

Window stool

Front Angle

Upper guide

Frame Curtain

Foam-pe

Cabinet

Foam-Pe

Shipping Screws

Figure 5

Figure 6

Foam-Pe

Frame-Guide

Screw

(Type A)

NOTICE

Do not pull the window sash down so tightly that the movement of Frame Curtain is restricted.

Service Manual 12

Installation

INDOOR OUTDOOR

Sill Support

Nut

Bolt

INDOOR OUTDOOR

Frame Guide

About 1/2"

Screw(Type A)

Cabinet

About 1/2"

Screw(Type B) Screw(Type A)

Sill support

Sash track

Front Angle

Type C

Screw(Type B)

Sill support

3. Loosely assemble the Sill Support using the parts in

Figure 7.

4. Select the position that will place the Sill Support

near the outer most point on sill (See Figure 8)

5. Attach the Sill Support to the cabinet track hole in

relation to the selected position using 2 Type A screws in each support(See Figure 8).

6. The cabinet should be installed with a very slight

tilt(about

/2") downward toward the outside (See

Figure 9). Adjust the bolt and the nut of Sill Support for balancing the cabinet.

7. Attach the cabinet to the window stool by driving the

screws (Type B: Length sixteen millimeters and below.) through the front angle into window stool.

8. Pull each Frame Curtain fully to each window sash

track, and repeat step 2.

9. Attach each Frame Curtain the window sash using

screws (Type C).(See Figure 10)

Figure 7

Figure 8

Figure 9

Figure 10

NOTICE

Be careful when you install the cabinet (Frame Guides are broken so easily).

CAUTION: DO NOT DRILL A HOLE IN THE

BOTTOM PAN.

The unit is designed to operate with approximately 1/2" of water in bottom pan.

Screw(Type A)

Power cord

Foam-Strip

Window Locking Bracket

10. Slide the unit into the cabinet.(See Figure 11)

11. Cut the Foam-Strip to the proper length and insert

between the upper window sash and the lower window sash. (See Figure 12)

12. Attach the Window Locking Bracket with a Type C

screw. (See Figure 13)

13. Attach the front grille to the cabinet by inserting the

tabs on the grille into the tabs on the front of the cabinet. Push the grille in until it snaps into place. (See Figure 14)

14. Lift the inlet grille and secure it with a Type A screw

through the front grille. (See Figure 15)

15. Window installation of room air conditioner is now

completed. See ELECTRICAL DATA for attaching power cord to electrical outlet.

Figure 11

Figure 12

Figure 13

Figure 16

Figure 15

Figure 14

13 Room Air Conditioner

Installation

CAUTION: For security purpose, reinstall screws (Type A) at cabinet's sides.

Operation

Location and Function of Controls

CAUTION: If you turn off the air conditioner or switch from cooling to the fan, wait

at least 3 minutes before setting to cooling again.

FOR NORMAL COOLING

1. Turn the operation switch to the High Cool or the Low Cool setting.

2. Set the thermostat control to the desired temperature mark (the mid-point is a good starting position). If the room temperature is not satisfactory after a reasonable time, adjust the control to a cooler or warmer setting, as appropriate.

FOR MAXIMUM COOLING

1. Turn the operation switch to the High Cool setting.

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

FOR QUIETER OPERATION

1. Turn the operation switch to the Low Cool setting.

2. Set the thermostat control as needed.

Service Manual 14

• DESIGNED FOR COOLING ONLY

• POWERFUL COOLING

• TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE

• BUILT-IN ADJUSTABLE THERMOSTAT

• WASHABLE ONE-TOUCH FILTER

• COMPACT SIZE

Operation

Operation  

O ff - Turns air conditioner off. Me d Fa n - Med speed fan operation without cooling. Low Fa n - Low speed fan operation without cooling. Hig h C oo l - Cooling with high speed fan operation. Me d C oo l - Cooling with med speed fan operation. Low C ool - Cooling with low speed fan operation.

Thermostat  

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

8

(i.e. the higher the number, the greater the cooling)

The controls look like this:

Controls

Auto

Swing

Power

Temp

Fan Speed

Timer Mode

Energy

Saver

Remote Control Operations

1. 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.

• When you first turn it on, the Set is on the High cool mode and the temp. at 72°F

2. Temperature Setting

• This button controls the room temperature setting in a range between 60°F and 86°F in 1° increments.

3. Fan Speed

• Pressing the Fan Speed button toggles between Low and High speeds.

4. On/Off Timer

- Stopping Operation Each press of the button cycles through the options in this order: 1 Hour → 2 Hours → 3 Hours → 4 Hours → 5 Hours

→ 6 Hours → 7 Hours → 8 Hours → 9 Hours →

10 Hours → 11 Hours → 12 Hours → CANCLE. The set temperature will be raised by 2°F after 30

minutes and again after another 30 minutes.

- Starting Operation Each press of the button cycles through the options in this order: 1 Hour → 2 Hours → 3 Hours → 4 Hours → 5 Hours

→ 6 Hours → 7 Hours → 8 Hours → 9 Hours → 10 Hours → 11 Hours → 12 Hours → CANCLE.

5. 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.

6. Cool/Fan/Dry

• Everytime you push this button, it will toggle

between COOL, FAN, and DRY.

How to Insert Batteries

1. Remove the cover from the back of the remote controller

2. Insert two batteries.

• Be sure of the polarity when installing the batteries.

• Be sure that both batteries are new.

3. Re-attach the cover.

• Do not use rechargeable batteries. Such batteries differ from standard dry cells in shape, dimensions, and performance.

• Remove the batteries from the remote controller if the air conditioner is not going to be used for an extended length of time.

CAUTION: The Remote Controller will not function properly if strong light strikes

the sensor window of the air conditioner or if there are obstacles between the

Remote Controller and the air conditioner.

15 Room Air Conditioner

Operation

4 5

6 ２１

７

Disassembly

Mechanical Parts

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

1. FRONT GRILLE

1. Open the lnlet grille upward or downward.

2. Remove the screw which fastens the front grille.

3. Pull the front grille from the right side.

4. Remove the front grille.

5. Re-install the component by referring to the removal procedure, above.(See Figure 17)

2. CABINET

1. After disassembling the FRONT GRILLE, remove the 2 screws which fasten the cabinet at both sides.

2. Remove the 2 screws which fasten the cabinet at back.

3. Pull the base pan forward. (See Figure 18)

4. Remove the cabinet.

5. Re-install the component by referring to the removal procedure, above.

3. CONTROL BOX

1. Disconnect the unit from the power source.

2. Remove the front grille.

3. Remove the cabinet.

4. Remove the screw which fastens the control box cover.

5. Remove the housing which connects motor wire in the control box.

6. Remove the 3 leads from the compressor.

7.Discharge the capacitor by placing a 20,000 ohmresistor across the capacitor terminals.

8. Remove the 2 screws which fasten the control

box.(See Figure 19)

9. Pull the control box forward completely.

10. Re-install the components by referring to the removal procedure, above. (See Figure 19)

Figure 17

Figure 19

Figure 18

Service Manual 16

17 Room Air Conditioner

Disassembly

Air Handling Parts

—7—

1. AIR GUIDE AND BLOWER

1. Remove the front grille.

2. Remove the cabinet.

3. Remove the control box.

4. Remove the 3 screws which fasten the brace.

5. Remove the brace.

6. Remove the 2 screws which fasten the evaporator.

7. Move the evaporator forward and pulling it upward

slightly. (See Figure 20)

8. Move the evaporator to the left carefully.

9. Pull out the hook of orifice by pushing the tabs and

remove it. (See Figure 21)

10. Remove the clamp with a hand plier which secures the blower.

11. Remove the blower.

12. Remove the 4 screws which fasten the air guide from the barrier.

13. Move the air guide backward, pulling out from the base pan.

14. Re-install the components by referring to the removal procedure, above.

2. FAN AND SHROUD

1. Remove the cabinet.

2. Remove the brace.

3. Remove the 3 screws which fasten the condenser.

4. Move the condenser to the left carefully.

5. Remove the clamp which secures the fan.

6. Remove the fan and then pull out the shroud. (See Figure 22)

7. Re-install by referring to the removal procedure.

Figure 20

Figure 21

Figure

Service Manual 18

Electrical Parts

Disassembly

3. MOTOR

1. Remove the cabinet.

2. Remove the evaporator.

3. Remove the orifice.

4. Remove the blower.

5. Remove the fan.

6. Remove the control box cover and housing of the motor in the control box.

7. Remove the 2 screws which fasten the motor from the mount motor. (See Figure 23)

8. Remove the motor.

9. Re-install the components by referring to the removal procedure, above.(See Figure 23)

1. OVERLOAD PROTECTOR

Figure 23

1. Remove the cabinet.

2. Remove the nut which fastens the terminal cover.

3. Remove the terminal cover. (See Figure 24)

4. Remove all the leads from the overload protector.

5. Remove the overload protector.

6. Re-install the component by referring to the removal procedure, above.

2. COMPRESSOR

1. Remove the cabinet.

2. Discharge the refrigerant system using a Freon 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.

4. After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections.

5. Remove the 3 nuts and the 3 w fasten the compressor.

6. Remove the compressor. (See Figure 25)

7. Re-install the components by referring to the removal procedure, above.

ashers

which

Figure 24

Figure 25

Disassembly

3. CAPACITOR

 MODEL : ROTARY SWITCH TYPE MODEL

1. Remove the control box.

2. Remove the knobs and the screw which fasten control panel from control box.

3. Remove the screw which is located in the front.

4. Open the bottom side of control box.

5. Remove the screw and the clamp which fasten the capacitor.

6. Disconnect all the leads of capacitor terminals.

7. Re-install the components by referring to the removal procedure, above. (See Figure 26)

Figure 26

 MODEL : TOUCH & REMOTE CONTROL TYPE MODEL

1. Remove the control box.

2. Remove the screw which fasten control panel from control box.

3. Remove the screw which located in the front.

4. Open the bottom side of control box.

5. Remove the screw and the clamp which fastens the capacitor.

6. Disconnect all the leads of capacitor terminals.

7. Re-install the components by referring to the removal procedure, above. (See Figure 27)

Figure 27

4. THERMOSTAT



MODEL : ROTARY SWITCH TYPE MODEL

1. Remove the control box.

2. Open the control box.

3. Remove the 2 screws which fasten the thermostat.

4. Disconnect 2 leads of thermostat terminals.

5. Remove the thermostat.

6. Re-install the components by refereing to the above

removal procedure. (See Figure 28)

Figure 28

19 Room Air Conditioner

6. ROTARY SWITCH

 MODEL : ROTARY SWITCH TYPE MODEL

1. Remove the control box.

2. Open the control box.

3. Remove the 2 screws which fasten the rotary switch.

4. Disconnect all the leads of the rotary switch terminals.

5. Remove the rotary switch.

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

removal procedure. (See Figure 29)

Disassembly

7. POWER CORD

1. Remove the control box.

2. Open the control box.

3. Disconnect the grounding screw from the control box.

4. Disconnect the 2 receptacles.

5. Remove a screw which fastens the clip cord. (See Figure 30)

6. Remove the power cord.

7. Re-install the component by referring to the above removal procedure, above. (Use only one ground-marked hole for ground connection.)

8. If the supply cord of this appliance is damaged, it must be replaced by the special cord. (The special cord means the cord which has the same specification marked on the supply cord attached at the unit.)

Refrigerating Cycle

Figure 29

Figure 30

CAUTION: Discharge the refrigerant system using a Freon

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.

CONDENSER

1. Remove the cabinet.

2. Remove the 3 screws which fasten the brace.

3. Remove the 3 screws which fasten the condenser and shroud.

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

5. Remove the condenser carefully.

6. Re-install the component by referring to notes. (See Figure 31)

Figure 31

Recovery System. If there is no valve

Service Manual 20

21 Room Air Conditioner

Disassembly

— Replacement of the refrigeration cycle.

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

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

33A.

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, just crack valves A

and B 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 vaccum 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 37B. 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 33B. 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.

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 braze and braze 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.

NOTICE

2. EVAPORATOR

1. Remove the cabinet.

2. Remove the 2 screws which fasten the evaporator.

3. Move the evaporator sideways carefully.

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

5. Remove the evaporator carefully.

6. Re-install the component by referring to notes. (See Figure 32)

3. CAPILLARY TUBE

1. Remove the cabinet.

2. After discharging the refrigerant completely,

unbraze the interconnecting tube at the capillary tube.

3. Remove the capillary tube.

4. Re-install the component by referring to notes.

Figure 32

Service Manual 22

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

EVAPORATOR (LOW PRESSURE SIDE)

COMPRESSOR

CAPILLARY TUBE

CONDENSER (HIGH PRESSURE SIDE)

SEE INSETS

BELOW

MANIFOLD

GAUGE

Figure 33A-Pulling Vacuum

Figure 33B-Charging

EXTERNAL VACUUM PUMP

CHARGING CYLINDER

LOW

Schematic Diagram

Wiring Diagram

 MODEL : ROTARY SWITCH TYPE MODEL

P OW E R IN PU T

B K( BR )

(P lain)

R OT AR Y S WIT C H

R D

C OMP .

B L

T HE R MOS T AT

B R (YL )

B K

B L

OR ( BR )

Y L

B K

R D

B L

OL P

MO T OR

Y L

OR ( BR )

B K

R D

B L

WH (B L)

(R ibbed)

G N(G N/YL )

C AP ACI TO R

B K

R D

P .T .C

WIR ING DIA G R AM 3854AR 3563A

LOCATION

NO.

POWER CORD ASSY

FAN MOTOR

COMPRESSOR

ROTARY SWITCH

THERMOSTAT

CAPACITOR

OVERLOAD PROTECTOR

P.T.C

23 Room Air Conditioner

DESCRIPTION

Q'TY

PER SET

S: Service Parts N: Non Service Parts

REMARKS

Service Manual 24

Schematic Diagram

Circuit Diagram

 MODEL : TOUCH & REMOTE CONTROL TYPE MODEL

LOCATION

NO.

Q'TY

PER SET

DESCRIPTION

POWER CORD ASSEMBLY

FAN MOTOR

COMPRESSOR

DISPLAY P.W.B ASSEMBLY

MAIN P.W.B ASSEMBLY

THERMISTOR

CAPACITOR

OWERLOAD PROTECTOR

25 Room Air Conditioner

Electronic Control Device

Schematic Diagram

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

Schematic Diagram

Service Manual 26

27 Room Air Conditioner

Troubleshooting Guide

Piping System

Figure 38 is a brief description of the important components and their function in what is called the refrigeration system. This will help you to understand the refrigeration cycle and the flow of the refrigerant in the cooling cycle.

MOTOR

COMPRESSOR

OIL

(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

Figure 34

CONDENSER COIL

FAN

CAPILLARY TUBE

MOTOR

COMPRESSOR

BLOWER

EVAPORATOR COIL

Service Manual 28

Troubleshooting Guide

In general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused from an electrical defect, and the other is ineffective Air

Conditioning caused by a defect in the refrigeration circuit and improper application.

Unit runs but poor cooling.

Ineffective Cooling

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

Replacement of unit if the unit is beyond repair.

Check outdoor coil (heat exchanger) and fan operation.

Check heat load increase.

Check cold air circulation for smooth flow.

Check gas leakage.

Clean condenser.

Not on separate circuit

Check inside gas pressure.

Adjust refrigerant charge.

Malfunction of compressor.

Replacement of compressor.

Check clogging in refrigeration circuit.

Repair clogging in refrigeration circuit.

Dirty indoor coil (heat exchanger)

Repair gas leak.

Malfunction of fan.

Clogging of air filter.

Obstruction at air outlet.

Remove obstruction.

29 Room Air Conditioner

Troubleshooting Guide

Fails to Start

Improper thermistor setting

Loose terminal connection

Improper wiring

Check of power source.

Drop of power voltage.

Capacitor check.

Replacement.

Check of control panel setting.

Compressor fails only to start.

Defect of compressor capacitor.

Replacement of compressor (Motor damaged).

Irregular motor insulation (Ω)

Irregular motor resistance (Ω)

Check of circuit breaker and fuse.

Check control panel.

Fan only fails to start.

Improper wiring.

Defect of fan motor capacitor.

Replacement of fan motor.

Regular but fails to start.

Replacement of compressor. (Locking of piston, metal.)

Irregular motor resistance (Ω) Irregular motor insulation (Ω)

Service Manual 30

Troubleshooting Guide

Is the Trans input power

AC 115V?

Is the Trans output power

about AC 14V?

Is shorted the Trans. output?

Is output Voltage of IC01D

DC 12V?

Is output Voltage of IC02D

DC 5V?

Is the voltage No.18 of Micom

DC 5V?

Exchange Main P.W.B Ass'y.

Is the

connection between

Main and Display

all right?

Is the reset circuit all right?

(The No.14 of Micom

is 5V.)

•

Check the Fuse.

•

Check the wiring diagram.

•

Check the Main

P.W.B pattern.

• Exchange the Trans.

•

Exchange D02D~D05D.

• Exchange IC01D.

• Exchange IC02D.

• Exchange IC01A.

• Connect connector

exactly.

• Check the

P.W.B

pattern.

YES

■ MODEL :

RAD-101A

ELECTRIC PARTS TROUBLESHOOTING GUIDE:

Possible Trouble 1

• The unit does not operate.

31 Room Air Conditioner

Troubleshooting Guide

Is Temp.

setting set lower than Room

Temp.-0.5°C?

Is the voltage No.10

of IC01M 0V?

• Exchange IC01M.

• Set the Temp. setting to lower Temp.

• Wait 3 Minutes

Is the Unit for 3 minutes

delay?

• Exchange MAIN P.W.B Ass'y.

Is the voltage N0.7 of

IC01M DC 5V?

• Check the RY-COMP.

• Check the wiring

Diagram.

NO NO

YES

Possible Trouble 2

• The compressor does not operate.

Is the wire connection of

RY-COMP all right?

• Check the RY-COMP.

• Connect LEAD Wire to

RY-COMP again.

YES

Possible Trouble 3

• The compressor always operate.

• Exchange IC01M.

Is the voltage NO.1 or 4

of IC01M DC 5V?

Is the voltage NO.13 or 16

of IC01M 0V?

• Check the RY-Hi or RY-Lo.

•

Check the wiring diagram.

YES

Possible Trouble 4

• Fan does not operate.

Service Manual 32

Troubleshooting Guide

Is the voltage of Battery

about over 2.3V?

•

Exchange Receiver Ass'y.

Is the connection of CN-DISP1 all right?

Is the voltage No.16

of CN-DISP1 on Main P.W.B

Ass'y DC 5V?

• Exchange the battery.

•

Check the P.W.B pattern.

• Connect connector to CN-DISP1 exactly.

YES

Possible Trouble 5

• Romote controller does not operate.

YES

Is the IC01G all right?

Is the connection of

CN-DISP1 all right?

• Exchange the display P.W.B Ass'y.

• Exchange IC01G.

• Exchange Q01G,

Q02G, Q03G, Q04G

• Connect connector to CN-DISP1 exactly.

Does the Q01G,

Q02G, Q03G Q04G operate normally

on main P.W.B Ass'y?

Possible Trouble 6

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

33 Room Air Conditioner

Troubleshooting Guide

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 shaft 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.

Service Manual 34

Troubleshooting Guide

COMPLAINT CAUSE REMEDY

Fan motor noise. 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 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.

Compressor will not run, Voltage Check voltage. See the limits on the preceding fan motor runs. page. If not within limits, call an electrician.

Wiring 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.

Rotary Check for continuity, refer to the wiring diagram

for terminal identification. Replace the switch if

the circuit is open. Thermostat Check the position of knob. If not at the coldest

setting, advance the knob to this setting and

restart the unit.

Check the continuity of the thermostat. Replace

the thermostat if the circuit is open.

Capacitor (discharge Check the capacitor. capacitor before 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.)

35 Room Air Conditioner

COMPLAINT CAUSE REMEDY

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.)

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

overload. required.

Condenser air flow Remove the cabinet, inspect the interior surface restriction 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 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.

Troubleshooting Guide

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04/18/07

Heat Controller RAD-101A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual