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Room Air Conditioner
Service and Parts
Manual
CP05A10 CP06A10
CP05 / CP06 (06/05)
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CONTENTS 1. PREFACE ...................................................................................................................................................3 1.1 FEATURES.....................................................................................................................................................3 1.2 SPECIFICATIONS .........................................................................................................................................3 1.3 LOCA
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1. PREFACE This service manual provides various service information, including the mechanical and electrical parts, etc. This room air conditioner was manufactured and assembled under a strict quality control system. The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit. 1.1 FEATURES • DESIGNED FOR COOLING ONLY • POWERFUL AND INCREDIBLE COOLING • TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE • BUILT-IN ADJUSTABLE THERMOSTAT
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1.3 LOCATIONS OF CONTROLS 1 TEMPERATURE SETTING • These buttons control the temperature of the room. The temperature can be set within a range of 60°F to 86°F, in increments of 1°F. 2 MONEY SAVER The fan stops when the compressor stops cooling. 1 • Approximately every 3 minutes the fan will turn on and sample the room air to determine if more cooling is needed. 2 3 OPERATION MODE SELECTOR 3 • Everytime you push this button, it will rotate between the COOL, FAN and DRY modes. 4 ON/OFF TIMER 4
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2. DISASSEMBLY INSTRUCTIONS 2.1 MECHANICAL PARTS 2.1.1 FRONT GRILLE Figure 1 1. Pull the inlet grille forward. 2. Remove the screw securing the Front Grille. (Fig. 3) 3. Push the grille up from the bottom and pull the top of the grille away from the case to lift the top tabs out of their slots. (Fig. 4) 4. Carefully position the grille, bottom first, and snap back into place. 5. Reposition the screw that secures the front grille and replace the knobs. Figure 2 2.1.2 CABINET 1. Disconnect the u
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Figure 6 2.2 AIR HANDLING PARTS 2.2.1 AIR GUIDE UPPER 1. Disconnect the unit from the power source. 2. Remove the front grille. (Refer to Section 2.1.1) 3. Remove the cabinet. (Refer to Section 2.1.2) 4. Remove the control board. (Refer to Section 2.1.3) 5. Remove 2 screws that secure the air guide upper to air guide lower. (See Figure 6) 6. Lift air guide upper upward. 7. Re-install by referring to the procedures above. Figure 7 2.2.2 ORIFICE, TURBO FAN AND FAN 1. Disconnect the unit fro
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2.2.3 MOTOR Figure 10 1. Disconnect the unit from the power source. 2. Remove the front grille. (Refer to Section 2.1.1) 3. Remove the cabinet. (Refer to Section 2.1.2) 4. Remove the control board. (Refer to Section 2.1.3) 5. Remove the air guide upper. (Refer to Section 2.2.1) 6. Remove the compressor, turbo fan, fan and shroud. (Refer to Section 2.2.2) 7. Remove 2 screws that secure the motor to the motor. (See Figure 10) 8. Remove the motor. 9. Re-install by referring to the procedures ab
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2.3.2 COMPRESSOR Figure 14 1. Remove the front grille and cabinet. (Refer to Section 2.1) 2. Discharge the refrigerant by using a refrigerant recovery system. 3. Remove the overload protector. (Refer to Section 2.3.1) 4. After discharging the unit completely, unbraze the suction and discharge pipes at the compressor connections. 5. Remove 3 nuts which fasten the compressor. 6. Remove the compressor. 7. Re-install by referring to the removal procedure above. (See Figure 14) 2.3.3 CAPACITOR 1.
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Figure 18 2.3.6 POWER CORD 1. Disconnect the unit from source of power. 2. Remove the front grille. (Refer to Section 2.1.1) 3. Remove the cabinet. (Refer to Section 2.1.2) 4. Remove a screw that secures control board to base pan. (Refer to Section 2.1.3) 5. Pulls the control board toward you. 6. Disconnect the 2 receptacles and remove the grounding screw. 7. Remove a screw securing the clip with cord to the control board. 8. Pull the power cord. 9. Re-install by referring to procedures above.
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wise. This will keep oil from foaming and being 2.4.2 EVAPORATOR/CONDENSER drawn into the vacuum pump. 1. Remove the cabinet. 2. Discharge the refrigerant by using a refrigerant 6-3. Operate the vacuum pump for 20 to 30 min- recovery system. utes, until 600 micron vacuum is obtained. 3. Remove the air guide upper. (Refer to Section Close valves A and B and observe vacuum 2.2.1) gauge for a few minutes. 4. After discharging the refrigerant completely, A rise in pressure would indicate a possib
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Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment, pinch-off tool capable of making a vapor proof seal, leak detector, tubing cutter, hand tools to remove components and service valve. COMPOUND GAUGE MANIFOLD GAUGE B A CONDENSER SEE INSETS (HIGH PRESSURE SIDE) BELOW COMPRESSOR EVAPORATOR (LOW PRESSURE SIDE) CAPILLARY TUBE Figure 20 LO HI CHARGING CYLINDER A A B B EXTERNAL VACUUM PUMP C Figure 21A-Pulling Vacuum Figure 21B-Charging —11—
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3. TROUBLESHOOTING GUIDE 3.1 OUTSIDE DIMENSIONS (unit: mm [in]) 9 21 21 370 (14 /16") 42 (1 /32") 472 (18 9/16") 42 (1 /32") 3 120 (4 /4") 3 27.5 (1 /32") 22.5(0.8 3/32") 155(6 3/32") 9 370 (14 /16") 9 472 (18 /16") —12— 312 (12 1/4") 312 (12 1/4") 12 (0.4 1/16") 5 29 (1 /32") 5 346 (13 /8")
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3.2 PIPING SYSTEM CONDENSER COILS FAN MOTOR CAPILLARY TUBE TURBO FAN EVAPORATOR COILS Following is a brief description of the important components and their function in what is called the refrigeration system. Reference should be made to Figure 22 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle. ROOM AIR CONDITIONER CYCLE OF REFRIGERATION EVAPORATOR COILS CONDENSER COILS VAPOR INLET SUCTION LINE HOT COMPLETE LIQUID COOL LOW PRESSURE VAPOR DISCHARGED BOIL
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3.3 TROUBLESHOOTING GUIDE In general, possible trouble is classified in two categories. The one is called Starting Failure which is caused by an electrical defect. The other is Ineffective Air Con- ditioning caused by a defect in the refrigeration circuit and/or improper application. Unit is running but cooling is ineffective. Ineffective Cooling Check cold air Check outdoor coil Check heat load circulation for smooth (heat exchanger) and increase. flow. fan operation. Clean condenser.
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Fails to Start Check circuit breaker Check power source. and fuse. Check control switch Gas leakage of capillary setting. bulb on thermostat. Check control switch. Compressor fails to Fan only fails to start. start. Improper wiring. Improper thermostat Drop of power voltage. setting Defect of fan motor capacitor. Defect of compressor Loose terminal capacitor. connection Irregular motor resistance (Ω ) Capacitor check. Improper wiring Irregular motor insulation (Ω ) Repl
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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. Wire disconnected or Connect wire. Refer to wiring diagram for connection loose terminal identification. Repair or replace loose terminal. Capacitor (Discharge Test capacitor. capa
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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 limit
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COMPLAINT CAUSE REMEDY 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 co
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4. CIRCUIT DIAGRAM MODEL: CP05A10, CP06A10 POWER INPUT WH(BL) BK(BR) (Ribbed) (Plain) GN/YL(GN) THERMISTOR BK BK BL BL CN-TH1 RD RD MOTOR OR(BR) OR(BR) YL YL GN/YL (GN) CAPACITOR F C OR SYNC MOTOR BK WH RD H BK RY-SYNC BK ZNR R RD RY-COMP COMP. S 43 TRANS BL BL C FORMER FUSE 250V/T2A OLP (115V/T2A) 3854A20022K WIRING DIAGRAM S: Service Parts N: Non Service Parts RE- LOCATION Q'TY DESCRIPTION MARKS NO. PER SET 1 S 1 MOTOR ASSY 1 S 2 CAPACITOR 1 S 3 COMPRESSOR 1 S 4 OVERLOAD PROTECTOR 1 S 5 D
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5. EXPLODED VIEW 130910 559011 W48602 554030 149980 267110 349480 132111-1 132111-2 135312 352380 147581 147582-1 359012 346811 W48602 152302 352390 147582-2 354210 130410 135313 W0CZZ 264110 352111 352115 567502 352113 137215 554160 268714 263230 35211A 550140 238310 268712 249950 —20—
