I
CONSUMER SERVICES TECHNICAL
EDUCATION GROUP PRESENTS
R-93
JOB AID
Part No. 4322657
SURROUND
COOL
AIR
CONDITIONERS
MODELS:
ACG052XJ
ACG072XJ
28
II
INTRODUCTION
This Job Aid,
“Surround Cool Air Conditioners
,” (Part No. 4322657), has been compiled to provide the
most recent information on design, features, troubleshooting, service and repair procedures of the
surround cool air conditioner.
Procedures for diagnosing and troubleshooting the sealed system can be found in Whirlpool Consumer Services publication
R-65, Basic Refrigeration Diagnosis
, Part No. 4314066, Rev. C.
Procedures for servicing the sealed system can be found in Whirlpool Consumer Services publication,
R-77, Sweep Charge Procedures for the 90’s
, Part Number 4321717 Rev. A. A companion VHS video
tape,
Sweep Charge Procedures for the 90’s
, Part Number 4321718V is also available.
GOALS AND OBJECTIVES
The goal of this Job Aid is to provide detailed information that will enable the service technician to
properly diagnose malfunctions and repair of the Surround Cool Air Conditioner.
The objectives of the Job Aid are:
The service technician will -
• Understand proper safety precautions.
• Successfully troubleshoot and diagnose malfunction.
• Successfully perform necessary repairs.
• Successfully return the air conditioner to proper operational status.
WHIRLPOOL CORPORATION ASSUMES NO RESPONSIBILITY
FOR ANY REPAIRS MADE ON OUR PRODUCTS BY ANYONE
OTHER THAN AUTHORIZED SERVICE TECHNICIANS.
© 1999 Whirlpool Corporation, Benton Harbor, MI 49022
27
III
TABLE OF CONTENTS
INTRODUCTION .......................................................................................... II
TABLE OF CONTENTS .................................................................................. III
SAFETY..... .................................................................................................. IV
SECTION ONE
INSTALLATION CONSIDERATIONS
Important Safety Instructions ...................................................................................... 1
Installation Instructions ............................................................................................... 1
SECTION TWO
THEORY OF OPERATION
Unique Operating Features.......................................................................................... 3
Sealed System .......................................................................................................... 3
Air Flow...................................................................................................................... 3
Electronic Controls .................................................................................................... 4
SECTION THREE
COMPONENT ACCESS
Component Location .................................................................................................... 7
Accessing Components at the Front of the Air Conditioner..................................... 8
Accessing the Electronic Control Assembly .............................................................. 8
Accessing Components Behind the Divider Wall .................................................... 10
Accessing the Component Compartment................................................................ 10
Removing the Fan Motor Assembly ........................................................................ 10
SECTION FOUR
TROUBLESHOOTING AND DIAGNOSIS
Component Testing .................................................................................................... 15
Troubleshooting.......................................................................................................... 16
Compressor Specifications ....................................................................................... 19
Fan Motor Specifications ........................................................................................... 19
Proper Location of Thermistor .................................................................................. 19
Servicing Information ................................................................................................. 20
SECTION FIVE
TECH TIPS
Wiring Diagram ........................................................................................................... 21
Strip Circuits ............................................................................................................... 22
Model and Serial Number Designators ..................................................................... 23
Warranty Information.................................................................................................. 24
26
CONFIRMATION OF LEARNING EXERCISE ANSWERS
1. C 6. C
2. D 7. B
3. C 8. A
4. B 9. B
5. C 10. B
IV
SAFETY
! WARNING
ELECTRICAL SHOCK HAZARD
Disconnect power before servicing the air conditioner.
Replace all panels before operating the air conditioner.
Failure to do so can result in death or electrical shock.
25
CONFIRMATION OF LEARNING EXCERCISE
1. How do you change the temperature setting from “F” (Fahrenheit) to “C” (Celsius)?
A. Press and hold the Temperature
Select “+” pad for 3 seconds?
B. Press and hold the Temperature
Select “-” pad for 3 seconds?
C. Press and hold the Mode pad for 3
seconds?
D. Press and hold the Time pad for 3
seconds?
2. When the Fan Speed is changed while the
unit is in AUTO COOL Mode:
A. The unit cycles off.
B. Only the fan cycles off.
C. Only the compressor cycles off.
D. Cooling Mode changes from AUTO
COOL to COOL.
3. During SLEEP Mode:
A. The fan runs at HI speed.
B. The display intensity decreases.
C. The fan runs at LOW speed.
D. B and C are correct.
4. When the preset temperature for any cool
ing mode is reached:
A. Only the fan cycles off.
B. Only the compressor cycle off.
C. Both the fan and compressor cycle off.
D. The unit cycles off.
5. If the thermistor fails::
A. Only the thermistor needs to be
replaced.
B. Only the control board assembly
needs to be replaced.
C. The thermistor and control board
assembly need to be replaced.
D. The compressor needs to be replaced.
6. During the AUTO COOL Mode::
A. Fan always runs at HI speed.
B. Fan always runs at LOW speed.
C. Fan speed automatically varies.
D. Fan always tuns at TURBO speed.
7. The sealed system is warranted for:
A. Full 1 year only.
B. Limited 5 years part only.
C. Limited 2 years parts and labor.
D. Limited 3 years part only.
8. Before replacing the Electronic Control
Board Assembly:
A. Follow all Troubleshooting procedures
and test all individual components.
B. Change the Thermistor and check for
proper operation.
C. Change the Touch Pad Board and
check for proper operation..
D. Change the Thermistor and Touch
Pad Board and check for proper
operation.
9. The preset temperature set range is:
A. 50°F to 95°F
B. 64°F to 86°F
C. 50°F to 86°F
D. 64°F to 95°F
10. During FAN ONLY Mode the fan runs
continuously to circulate the room air:
A. Runs at HI speed only
B. Is manually adjustable.
C. Automatically varies
D. Runs at TURBO speed only.
1
SECTION ONE
INSTALLATION CONSIDERATIONS
IMPORTANT SAFETY INSTRUCTIONS:
! WARNING
TO REDUCE THE RISK OF FIRE, ELECTRICAL SHOCK, INJURY OR SICKNESS WHEN USING THE AIR CONDITIONER, FOLLOW THESE BASIC PRECAUTIONS:
• Plug into a grounded 3-prong outlet.
• Do not remove ground prong.
• Do not use an adapter.
• Unplug the air conditioner before servicing.
• Do not drink the water collected inside the cabinet.
• Install the air conditioner in a window that will hold the weight, and secure the air conditioner according to the Installation Instructions.
• Connect the air conditioner to the proper kind of outlet with the correct electrical supply and ground.
(See Installation Instructions).
• Make sure the air conditioner is the correct size for the area to be cooled.
• Use the air conditioner only to do what a window air conditioner is designed to do.
• Make sure the air conditioner is not used by anyone unable to operate it properly.
• Maintain the air conditioner properly.
• Remove the Energy Label. Use a damp cloth to take off any glue residue. DO NOT use sharp
instruments, flammable fluids or abrasive cleaners. These can damage the air conditioner finish.
INSTALLATION INSTRUCTIONS
Follow the Installation Instructions provided with the air conditioner carefully.
24
LENGTH OF WARRANTY WHIRLPOOL WILL PAY FOR
FULL ONE-YEAR WARRANTY FROM
DATE OF PURCHASE
Replacement parts and repair labor to correct defects in materials or workmanship. Service must be provided by a designated
service company.
LIMITED FIVE-YEAR WARRANTY FROM
DATE OF PURCHASE
Replacement parts to correct defects in materials or workmanship in the sealed refrigeration system. These parts are:
1. Compressor 4. Strainer
2. Evaporator 5. Connecting Tubing
3. Condenser
Servicing must be provided by a designated service company.
WHIRLPOOL WILL NOT PAY FOR
A. Service calls to:
1.Correct the installation of your air conditioner.
2.Instruct you how to use your air conditioner.
3.Replace house fuses or correct house wiring.
4.Clean or replace the air filter.
5.Preventative Maintenance
B. Pickup and delivery. Your air conditioner is designed to be repaired in the home.
C. Damage to your air conditioner caused by accident, misuse, fir, flood, acts of God, or use of
products not mentioned in the Use and Care Guide.
D. the removal and reinstallation of your air conditioner it it is installed in an overhead or other
inaccessible location or is not installed in accordance with published installation instructions.
E. Repairs to parts or systems resulting from unauthorized modifications made to the appliance.
F. any labor costs during limited warranty.
G. Replacement parts or repair labor costs for units operated outside the United States or Canada.
WHIRLPOOL CORPORATION SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES. Some state or provinces do not allow the exclusion or limitation of incidental or consequential
damages, so this exclusion or limitation may not apply to you. The warranty gives you specific legal rights,
and you may also have other rights which vary from state to state or province or province.
Outside the United State and Canada a different warranty may apply. For details, please contact your
authorized dealer.
If you need service, first see the “Troubleshooting” section of the Use and Care Guide. After checking
“Troubleshooting,” additional help can be found by checking the “Requesting Assistance or Service” section, or
by calling the Manufacturer’s Consumer Assistance Center telephone number, 1-800-253-1301, from
anywhere in the U.S.A. For service in Canada, see “If you need assistance or service in Canada” for the
service branch in your area.
WHIRLPOOL WARRANTY
2
-- NOTES --
23
Serial Number Designator
SERIAL NUMBER
MANUFACTURING SITE
G = Manos, Brazil
Q = LaVergne, TN
YEAR OF MANUFACTURE
J = 1999
WEEK OF MANUFACTURE
PRODUCT SEQUENCE NUMBER
MODEL/SERIAL NUMBER DESIGNATORS
The Model/Serial Number plate is located behind the
front panel above the coil area.
Q J 36 50001
Model/Serial
Number Plate
Model Number Designator
MODEL NUMBER
INTERNATIONAL SALES or
MARKETING CHANNEL
PRODUCT GROUP
A = Air Conditioner
PRODUCT IDENTIFICATION
C = Warranty
MODEL TYPE
G = Surround Cool
APPROXIMATE CAPACITY: XX • 1,000 BTU’s
ELECTRICAL CODE
2 = 115VAC, 60 Hz, 1-Phase
FEATURE CODE
X = Features Not Defined
YEAR OF INTRODUCTION
J= 2000
ENGINEERING CHANGE
ACG 05 2 X j 0
3
UNIQUE OPERATING FEATURES
SEALED SYSTEM
• More Efficient Condenser - Higher heat exchange due to single row
condenser coil providing greater surface area to dissipate heat.
AIR FLOW
• Quieter Operation - Sound dampening material on the divider wall and
sealed system tubing isolates sound from entering the room.
• 270° Air Flow Out of The Air Conditioner - Provides cool air more space to
exit the Surround-Cool resulting in less air noise. This system evenly
distributes the air to all sections of the room without having to adjust the
louvers.
SIDE VIEW
TOP VIEW
TOP VIEW
SECTION TWO
THEORY OF OPERATION
22
STRIP CIRCUITS
1. Power Supply to Control Board
2. Compressor Run Circuit
3. 3-Speed Evaporator Fan Circuit
4
ELECTRONIC CONTROLS
• Thermistor Temperature Control - Solid-State electronic controls with
thermistor temperature sensing for more efficient and accurate cooling.
• Auto-Cool Cycle - Cools room to a preset temperature while automatically
controlling the fan speed.
• Fully Intrgrated Electronic Controls with Clock - Simple push button
operation with full LCD display allows for a wide variety of operations choices.
Clock provides for setting automatic on and off times. System is capable of
remote control. (Remote control sold separately.)
CONTROL PANEL
Press any control key to turn on the air conditioner.
TIMER
1. Press the TIMER key
to set the ON TIME.
The indicator light
and “--:--” will flash.
Press the “+” or “-” key to set the ON TIME.
2. Select MODE, FAN SPEED or SLEEP. If
an OFF time is desired, go to step 3. If
not, press the TIMER key twice to accept
the setting. The ON TIME indicator light
will stay on.
3. Press the TIMER key a second time to
set the OFF TIME. The ON TIME indicator light will stay on and the OFF TIME
indicator light and “--:--” will flash. Press
the “+” or “-” key to set OFF TIME.
4. Press the TIMER key a third time to accept settings. The indicator light or lights
stay on until each setting is reached.
To cancel ON TIME and/or OFF TIME, press
and hold TIMER key for 3 seconds.
To review settings, press once to view ON TIME, press a
second time to view OFF TIME, and press a thrid time to
exit.
CLOCK
1. If the air conditioner is in the FAN ONLY
mode or OFF:
• press the CLOCK key to set the time. The
colon will flash.
If the air conditioner is in the AUTO
COOL or COOL mode:
• press the CLOCK key one time to display
the time of day.
• Press the CLOCK key again to set the
time. The colon will flash.
2. Press the “+” or “-” keys to set the correct
time. After setting the time, press the
CLOCK key again to start the clock.
TEMPERATURE SELECTION
Press the “+” key to raise the temperature.
Each time the “+” key is pressed, the
temperature will go up 1° to a maximum of 86°F. Press the “-” key to
lower the temperature. Each time
the ”-” key is press the temperature
will go down 1° to a minimum of 64°F.
In the OFF mode, to view current preset temperature selection, press the “+” or “-” key.
NOTE: To change from “F” to :C: or from “C” to “F”, press
and hold the MODE key for 3 seconds.
21
SECTION FIVE
THEORY OF OPERATION
WIRING DIAGRAM
WIRING SCHEMATIC
5
• If a power failure occurs, all pre-set operating programs will be removed from the
electronic control board’s memory. They
must be reset before the unit will operate
properly.
• During Auto Cool, Cool and Sleep Modes,
once the preset temperature is reached,
only the compressor will cycle OFF. The
fan will remain running.
• Operating the air conditioner when the
outside air temperature is below 70°F will
result in the evaporator icing up.
CHECK FILTER
The CHECK FILTER indicator
light comes on every 720
hours of air conditioner operation indicating that the standard filter needs to be
cleaned. The 3M Filtrate filter must be replaced.
Press the FILTER RESET key to reset the CHECK
FILTER indicator light. The indicator light will turn
off.
OFF mode
Press the OFF key to turn the
air conditioner off. Once turned
off, the mode, fan speed and
temperature at the time the
air conditioner is turned off
are all stored in the electronic control and are returned to the display the next time the air conditioner is turned on.
MODE SELECTION
Press the MODE key until the
indicator light comes on for the
setting desired. Choose AUTO
COOL, COOL, or FAN.
AUTO COOL - Cools room to
a preset temperature while it
automatically controls the fan speeds. The preset temperature can be changed.
COOL - Cools the room to a preset temperature. Adjust the fan speed to LOW, HIGH or
TURBO.
FAN ONLY - Fan runs continuously to circulate
the air. No cooling takes place. Adjust the fan
speed to LOW, HIGH or TURBO.
FAN SPEED SELECTION
Press the FAN SPEED key until
the indicator light comes on for the
desired setting. Choose LOW,
HIGH or TURBO. When the fan
is operating at LOW, HIGH or
TURBO, the fan circulates air
continuously.
LOW - Sleeping comfort
HIGH - Normal cooling
TURBO - Maximum cooling
Select the FAN SPEED during the COOL or FAN
modes. If the fan speed is changed during AUTO
COOL mode, the mode will change to COOL
mode.
SLEEP MODE
Press the SLEEP key to select
the SLEEP mode. The SLEEP
indicator light will light up. Press
SLEEP again to turn it off, and
the indicator light will go off.
SLEEP mode operates the cooling mode at LOW
fan speed. This mode allows the room temperature in the first two hours to increase 3°F above
the preset temperature. It will remain this temperature until SLEEP mode is turned off. During
this mode the display’s light intensity will decrease.
SLEEP mode is available in COOL mode only,
not in AUTO COOL or FAN ONLY.
FILTER
RESET
! NOTE
REMOTE CONTROL (Optional)
A Remote Control is available for the Surround
Cool Air Conditioner and is sold separately. Both
the 5,000 BTU and 7,000 BTU models use the
same remote control. (P/N 8040252)
20
SERVICING INFORMATION
1. Refrigerant charge must be applied to the high side only.
2. This unit operates on 115 VAC core board and touch pad board.
3. The core board and touch pad board remain energized at all times when air conditioner is
plugged into an electrical supply.
4. The electronic control assembly does not contain serviceable parts. The entire electronic con-
trol assembly must be replaced if any part of it has failed.
BEFORE REPLACING ELECTRONIC CONTROL ASSEMBLY:
• Follow all troubleshooting procedures to determine if an individual component may be
defective first.
• Test individual components (compressor, fan motor, capacitor) before replacing electronic
control assembly.
IF ALL COMPONENTS TEST O.K., IT CAN SAFELY BE ASSUMED THE ELECTRONIC
CONTROL ASSEMBLY HAS FAILED AND SHOULD BE REPLACED.
! NOTE
SERVICEABLE ELECTRICAL COMPONENTS
SERVICEABLE PARTS
COMPRESSOR
(5,000btu)
Run Winding
Start Winding
COMPRESSOR (7,000btu)
Run Winding
Start Winding
OVERLOAD (5,000btu)
OVERLOAD (7,000btu)
3-SPEED EVAP FAN
Lo Speed
Hi Speed
Turbo Speed
ELECTRONIC
CONTROL ASSEMBLY
Includes:
Core Board
Touch Pad Board
Thermistor
Plastic Enclosure
Wire Assembly
Part No.
8040122
8040126
8011281
951779
8040173
8040023
Wattage
465
615
Resistance
1.469Ω
2.37Ω
1.13Ω
2.712Ω
40.4Ω
32.4Ω
20.4Ω
Amperage
1.2
1.5
1.1
1.6
2.8
3.5
5.6
6
-- NOTES --
19
PROBABLE CAUSE CORRECTIONPROBLEM
11. Moisture dripping
into room
12. Excess condensation running outside
11a. Extreme humidity
11b. Inadequate seal
11c. Improper level
12. Extreme humidity
11a. Advise customer of possible sweating formations under
abnormal conditions. Check and
improve all possible seals.
11b. Check and improve all
sealed areas.
11c. Check for proper side to
side level of unit. Check for (½”
rear slope (or 1 full bubble) on
level.
12. This condition is normal in
areas of extreme humidity.
TROUBLESHOOTING CHART
COMPRESSOR SPECIFICATIONS
Part Number
8040122
8040126
Capacity (Btu/hr)
5,160
6,745
Watts
465
615
Run Resistance
1.469
1.130
Start Resistance
2.373
2.712
Table 1
Table 2
PROPER LOCATION OF THERMISTOR
The thermistor must be properly mounted on
the front surface of the evaporator.
VERTICAL LOCATION: The plastic thermistor
mounting bracket should be located on the
fourth tube from the top as shown in the illustration.
HORIZONTAL LOCATION: The right end of
the plastic thermistor mounting bracket should
be located 6½” from the evaporator frame as
shown in the illustration. The end of the thermistor should be located 7½” from the evaporator frame.
7½”
6½”
FAN MOTOR SPECIFICATIONS
Part Number
8040173
Capacity (Btu/hr)
5,160 to 6,745
Turbo Speed
32.4Ω
Hi Speed
40.4Ω
Low Speed
20.4Ω
7
SECTION THREE
COMPONENT ACCESS
Component Location
Compressor
Dual
Capacitor
Condenser
Fan Blade
Control
Assembly
Control
Panel
Evaporator
Fan Blade
Fan
Motor
Evaporator
Condenser
Fig. 3-1
Strainer
(In bottom tube
behind return
bend)
18
PROBABLE CAUSE CORRECTIONPROBLEM
8. Noisy operation
9. Evaporator frosts
up
NOTE: 90% frosting of evaporator is normal under low-ambient, high humidity conditions
and 70% ice blockage is to be
considered normal.
NOTE: Initial start-up on rotary
compressor equipped units
may cause frosting on the first
2 or 3 evaporator passes (for
approximately 20 minutes) until refrigerant is driven out of the
oil by heating.
10. Remote control
does not oper-
ate unit.
8a. Loose parts
8b. “Ping” noticed as fan hits drops of
water in air stream
8c. Mounting area not firm
8d. Compressor could be overloaded
due to high ambient temperatures
or air flow restriction
8e. Fan motor
9a. Low outside air temperature
(below 65°F)
9b. Thermistor failed
9c. Improper air flow
9d. Fan motor slow
10a. Batteries dead
10b. Remote failed
8a. Check fan blades, cabinet,
washers, tubing contact or vibration, loose screws, etc.
8b. Normal operation
8c. Add support kit or improve
installation
8d. Loose internally, inadequate
lubrication, improper voltage
8e. Fan blades loose or hitting,
bad bearing or out of balance
9a. Instruct customer that operation at ambient temperatures
below 65°F is not considered a
normal requirement of the unit.
Adjust controls to warmer setting.
9b. Check thermistor location
(see pg. 19) and response to
temperature change by submerging it in ice water (compressor should cycle OFF) or holding it in your closed hand (compressor should START). If response is O.K., instruct customer.
9c. Clean or replace air filter.
Check for obstructed or restricted air passage. Check for
dirty evaporator or condenser
coil. Check for dirty blower
wheel, loose seals or missing
from back of front panel.
9d. Check for binding of fan
blade, blower wheel or motor
bearings. Using low fan speed,
instruct customer.
10.a. Check that unit operates
manually at control panel. If it
does, replace batteries in remote.
10b. Replace remote control.
TROUBLESHOOTING CHART
8
ACCESSING THE CONTROL BOX ASSEMBLY
ACCESSING COMPONENTS AT THE FRONT
OF THE AIR CONDITIONER
Components accessible from the front of the unit include:
• The Control Box Assembly: This assembly contains the electronic control board, the key
touch/display printed circuit board and the thermistor. If it is necessary to replace these components, the entire control box assembly must be replaced. The service replacement control
box assembly must be ordered by using the specific model number of the air conditioner being
serviced.
! WARNING
ELECTRICAL SHOCK HAZARD
Disconnect power before servicing the air conditioner.
Replace all panels before operating the air conditioner.
Failure to do so can result in death or electrical shock.
INSET
In most situations, access to the control box
assembly can be accomplished with the air
conditioner installed in the customer’s window.
! NOTE
1. Disconnect power from the air conditioner.
2. Remove the four (4) screws securing the front panel.
(Fig. 3-2)
3. Disconnect the wiring harness connectors from the control panel wiring plugs.
(Fig. 3-2, INSET)
These connectors are:
• WHITE Fan Motor Connector (3-wires:
black, blue and red)
• 2-Power Cord Connectors (black and
white)
• WHITE Compressor/Capacitor Connector
(2 Wires)
4. Remove the two (2) screws securing the
control box assembly to the front panel.
(Fig. 3-3)
Screws
Fig. 3-2
Fig. 3-3
17
PROBABLE CAUSE CORRECTIONPROBLEM
5. Insufficient cooling
- Compressor and
Fan run
(continued)
6. Compressor stops
and starts: too
short running time
7. House circuit
blowing
5d. Low voltage
5e. Improper seals
5f. Improper use
5g. Fan speed too slow
6a. Incorrect voltage
6b. Temp Controls set too warm
6c. Failed thermistor
6d. Failed compressor, controls
controlling compressor, incorrect
wiring
6e. Fan motor too slow
7a. Improper fuses
7b. Failed component or incorrect
wiring
5d. Check power supply. See
1b.
5e. Insulating seals out of place
or missing on unit. Doors or windows open.
5f. Excessive load. Advise customer if load is excessive or installation is incorrect or inadequate. Instruct on proper operation of controls.
5g. Check for wrong motor,
blower wheel or fan blade.
Check for binding of fan blade,
blower wheel or motor shaft.
Check for low voltage and correct capacitor.
6a. Check for proper voltage
6b. Instruct customer
6c. Check thermistor location
(see pg. 19) and response to
temperature change by submerging it in ice water (compressor should cycle OFF) or holding it in your closed hand (compressor should START).
6d. Check compressor windings, all wiring, overload and capacitor for shorts.
6e. Check for wrong motor,
blower wheel or fan blade.
Check for low voltage, binding of
fan blade, blower wheel or motor bearings.
7a. Check for correct size of
fuse or breaker. Check amp
draw.
7b. Check wiring and connections. Check operation of all
components.
TROUBLESHOOTING CHART
9
REPLACING THE CONTROL BOX ASSEMBLY
1. Place the thermistor wire in the locator slot
at the left bottom of the control box.
(Fig. 3-5, INSET)
1. Slide the new control box assembly into
place in the front half of the front panel.
(Fig. 3-5)
2. Tabs at each end of the control box
assembly will slide into the wide slots in
the front panel.
3. Locator pins on the bottom edge of the
con- trol box assembly fit into slots in
the front panel.
4. Replace the two (2) screws securing the
control box assembly to the front panel.
5. Reconnect the wiring harness connectors
to the control panel wiring plugs.
5. The control box assembly can now be removed from the front panel. Pull it straight up and away
from the front panel.
(Fig. 3-4)
When reconnecting the two power cord connectors:
• Be sure the RIBBED power cord wire is connected to the connector with the single WHITE
wire.
• Be sure the SMOOTH power cord wire is connected to the single BLACK wire.
Failure to do so will result in damage to the electronic control board
and the unit will not operate.
! NOTE
Fig. 3-4
Fig. 3-5
Locator
Slot
INSET
Wide Slot
at Each
End
16
PROBABLE CAUSE CORRECTIONPROBLEM
1. Unit does not run.
2. Fan runs - Compressor does not
run.
3. Compressor runs Fan does not run
4. No cooling - Compressor and Fan
running
5. Insufficient cooling
- Compressor and
Fan running.
1a. No power to unit.
1b. Low voltage
1c. Failed component or incorrect
wiring.
2a. Incorrect power supply.
2b. Failed components or incorrect
wiring.
3a. Blower wheel or fan blade binding
3b. Incorrect wiring.
3c. Motor windings shorted or motor
shaft stuck.
4a. Air flow restriction
4b. Compressor not pumping.
5a. Improper air flow
5b. Compressor not pumping at full
capacity.
5c. Operating 60 Hz unit on 50 Hz
current.
1a. Check for power at receptacle, good plug contact, fuses
of correct size and time delay
types. (Have customer contact
electrician if no power is available at receptacle.)
1b. Customer should contact a
qualified electrician to correct
this problem.
1c. Check all wiring and con-
nections, overload, compressor, fan motor, and
capacitor.
2a. Check for proper voltage.
2b. Check all wiring connec-
tions, overloads, compres-
sor, fan motor, capacitors,
etc.
3a. Check for proper clearance.
3b. Check wiring.
3c. Check for open or shorted
motor windings or check for
motor shaft rotation.
4a. Check air flow through condenser and evaporator.
4b. Check amp draw, restriction
in sealed system, loss of refrigerant.
5a. Clean or replace air filter.
Check for air passage restriction
or obstruction. Check for dirty
condenser, evaporator or fan
blades.
5b. Check amp draw, restriction
in sealed system or loss of refrigerant.
5c. Advise customer that the
unit should be operating on a 60
Hz electrical supply.
TROUBLESHOOTING CHART
10
ACCESSING COMPONENTS BEHIND THE DIVIDER WALL
Components accessible in the component compartment behind the divider wall include:
• Sealed Refrigeration System: This system includes the compressor, strainer, all sealed
system tubing, the condenser and the evaporator.
• Air Circulation System: This system includes the fan motor and the condenser and evapo-
rator fan blades.
• The Capacitor: The dual-electrolytic capacitor in this air conditioner contains the start capaci-
tor for the compressor motor and the start capacitor for the fan motor.
ACCESSING THE COMPONENT COMPARTMENT
1. Disconnect power from the air conditioners.
2. Remove the air conditioner from its installed position.
3. Remove the three (3) Phillips head screws securing the curtains to each side of the air conditioner.
(Fig. 3-6)
Slide the curtains from the channel rails at the top and bottom of the air condi-
tioner.
4. Remove the three (3) Phillips head screws securing the top channel rail to the top of the air
conditioner.
(Fig. 3-6)
5. Remove the four (4) Phillips head screws securing the top of the component compartment to the
air conditioner.
(Fig. 3-7)
6. Discharge the dual-capacitor with a 20,000 ohm resistor.
INSET
Removing the Fan Motor Assembly
1. Remove the four (4) screws securing the
front panel.
(Fig. 3-8)
2. Disconnect the wiring harness connectors
from the control panel wiring plugs.
(Fig. 3-8, INSET)
Fig. 3-6 Fig. 3-7
Fig. 3-8
15
Section Four
DIAGNOSIS and TROUBLESHOOTING
COMPONENT TESTING
! WARNING
ELECTRICAL SHOCK HAZARD
• Disconnect power before servicing the air conditioner.
• Replace all panels before operating the air conditioner.
Failure to do so can result in death or electrical shock.
TEST PROCEDURE RESULTSCOMPONENT
CAPACITOR
COMPRESSOR
FAN MOTOR
ELECTRONIC
CONTROL BOARD
Set a volt-ohmmeter to the Rx1 scale. Disconnect all wire leads. Discharge Capacitor.
1. Place probes on F and C terminals.
2. Place probes on H and C terminals.
Set volt-ohmmeter to Rx10 scale.
1. Place probes on each terminal and
outer case of capacitor.
Set a volt-ohmmeter to the Rx1 scale. Disconnect all wire leads.
1. Place the probes on the R and C
terminals.
2. Place the probes on the S and C
terminals.
Set a volt-ohmmeter to the Rx10 scale.
1. Place probes on each terminal and
outer case of compressor.
Set a volt-ohmmeter to the Rx1 scale.
Disconnect all wire leads.
1. Place probes on the BK and BR
motor terminals. (Phase Winding
and Overload)
2. Place probes on R and W.
3. Place probes on BK and W.
4. Place probes on BL and W.
Set volt-ohmmeter to Rx10 scale.
1. Place probes on each terminal
(except W) and motor housing.
There are no test points at the control board.
all soldered edge connections are covered with
a silicone sealant.
1. Meter should deflect momentarily and then show some minimal resistance.
2. Meter should deflect momentarily and then show some minimal resistance.
1. Meter should read infinity.
1. See Table 1 (page 19).
2. See Table 1 (page 19).
1. Meter should read infinity.
1. See Table 2 (page 19). If phase winding is shorted, meter will read no resistance. If overlaod is open, meter will read
infinity.
2. See Table 2 (page 19).
3. See Table 2 (page 19).
4.
See Table 2 (page 19).
1. Meter should read infinity.
The control board is powered by 115 VAC .
Output from the control board to the
compresor, condenser fan motor and capacitor is 115 VAC.
11
3. Remove the Hex head screw securing the
green ground wire to the evaporator frame.
(Fig. 3-9)
4. Remove the air director vanes from each
side of the evaporator shroud by first lifting
the large tab ( ). then slide the vane back
to release the end tabs from the slots in the
evaporator shroud ( ). Last, pull the
vane away from the air conditioner ( ).
(Fig. 3-10)
5. Remove the four (4) screws securing the
evaporator shroud to the evaporator frame.
(Fig. 3-11)
6. Carefully remove the styrofoam liner from
the back portion of the front panel assembly.
(Fig. 3-12)
If, during this step, the top edge of the tape
securing the styrofoam liner is damaged, remove the tape carefully, turn it upside down
and replace it during reassembly. The tape
is visible when the unit is assembled.
Failure to do this may result
in customer complaints.
! NOTE
7. Remove the five (5) screws securing the
back portion of the front panel assembly to
the divider wall. Then, slide the assembly
forward and off of the base plate.
(Fig. 3-13)
8. Remove the screen surrounding the component compartment by pulling it straight up
and away from the air conditioner.
(Fig. 3-14)
Back Portion
of Front Panel
Assembly
Fig. 3-9
Fig. 3-10
Fig. 3-11
Fig. 3-12
Fig. 3-13
Fig. 3-14
14
-- NOTES --
12
9. Remove the two (2) hex head screws securing the divider wall to the base plate of
the air conditioner.
(Fig. 3-15)
10. Remove the two (2) hex head screws securing the condenser shroud to the base
plate of the air conditioner.
(Fig. 3-15)
11. Remove the two (2) nuts securing the fan
motor mounting bracket to the bolts on the
base plate of the air conditioner.
(Fig.3-15)
12. Confirm that the capacitor is discharged.
13. Remove nut and washer securing the compressor terminals cover to the compressor.
(Fig. 3-16)
14. Disconnect the wiring harness connectors
from the compressor terminals.
15. The entire fan motor assembly, including the
fan motor, wiring harness, evaporator and
condenser fan blades,motor mounting
bracket and the unit support bracket can now
be lifted from the air conditioner. The capacitor will remain attached to the unit support bracket.
(Fig. 3-17)
When replacing the screen surrounding
the component compartment:
• Be sure the screen fits into the three (3) tabs
on each side of the divider wall.
• Be sure the screen seats flat on the base
plate of the air conditioner.
Failure to do so will result in damage to
the screen, undesirable noises during
operation and customer complaints.
! NOTE
1 of 2
Screws
Securing
Divider Wall
to Base Plate
1 of 2
Screws
Securing
Condenser Shroud
to Base Plate
1 of 2
Nuts Securing
Motor Bracket
to Base Plate
Fig. 3-15
Fig. 3-16
Fig. 3-17
13
When replacing the fan motor assembly:
• Be sure the fan motor mounting bracket is
properly located so that the base plate bolts
protrude through the holes in the motor
mounting bracket.
Failure to do so will result in damage to
the air conditioner, undesirable noises
during operation and customer com-
plaints.
! NOTE
Base Plate Bolt
protruding through Hole in
Fan Motor Mounting Bracket
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