SERVICE MANUAL CAUTION

Transcription

1 WEBSITE Room Air Conditioner SERVICE MANUAL CAUTION - BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS IN THIS MANUAL. - ONLY FOR AUTHORIZED SERVICE. MODEL: WR-800 WM-0 WM- HBLG800R R00M R00E WM-80 WR-0 WR-00 HBLG00R L04R

2 CONTENTS. PREFACE. SAFETY PRECAUTIONS.... INSULATION RESISTANCE TEST.... SPECIFICATIONS....4 FEATURES CONTROL LOCATIONS...4. DISASSEMBLY INSTRUCTIONS. MECHANICAL PARTS FRONT GRILLE CABINET CONTROL BOX...6. AIR HANDLING PARTS AIR GUIDE AND TURBO SHROUD...8. ELECTRICAL PARTS OVERLOAD PROTECTOR COMPRESSOR CAPACITOR POWER CORD MOTOR REFRIGERATION CYCLE CONDENSER EVAPORATOR CAPILLARY TUBE.... INSTALLATION. SELECT THE BEST LOCATION.... CHECK OF INSTALLATION.... HOW TO DRAIN....4 HOW TO INSTALL WHEN USING GASKET WHEN USING INSTALLATION KITS TROUBLESHOOTING GUIDE 4. OUTSIDE DIMENSIONS PIPING SYSTEM TROUBLESHOOTING GUIDE SCHEMATIC DIAGRAM 5. CIRCUIT DIAGRAM ELECTRONIC CONTROL DEVICE COMPONENTS LOCATION(FOR MAIN P.C.B ASM) COMPONENTS LOCATION(FOR DISPLAY P.C.B ASM) EXPLODED VIEW REPLACEMENT PARTS LIST.... 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.. SAFETY PRECAUTIONS. When servicing the unit, set the ROTARY SWITCH or POWER SWITCH to OFF and unplug the power cord.. Observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.. After servicing the unit, make an insulation resistance test to protect the customer from being exposed to shock hazards.. INSULATION RESISTANCE TEST. Unplug the power cord and connect a jumper between pins (black and white).. The grounding conductor (green) is to be open.. Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all the positions (except OFF) of the ROTARY SWITCH. 4. The value should be over MΩ.

3 . SPECIFICATIONS.. FOR WR-800, WM-80, WM-0, WR-0, WM-, HBLG800R, HBLG00R, WR-00, R00M, L04R, R00E MODELS ITEMS POWER SUPPLY COOLING CAPACITY (Btu/h) INPUT (W) RUNNING CURRENT (A) E.E.R (BTU/W.h) OPERATING INDOOR ( C) CONDITION OUTDOOR ( C) REFRIGERANT (R-) CHARGE EVAPORATOR CONDENSER, INDOOR, OUTDOOR SPEEDS, /COOLING MOTOR OPERATION CONTROL ROOM TEMP. CONTROL AIR DIRECTION CONTROL CONSTRUCTION COMPRESSOR PROTECTOR MOTOR POWER CORD DRAIN SYSTEM NET WEIGHT (lbs/kg) OUTSIDE DIMENSION (inch) (W xh xd) (mm) WR-800 WM-80 HBLG800R WM-0 HBLG00R ø, 5, 60Hz 8,000 0,000,000 0, ,00,0, (DB)* 9.4(WB)** 5(DB)*.9(WB)** 00g(0.6oz) 50g(8.oz) 470g(6.6oz) 50g(8.oz) ROW STACKS ROW STACKS ROW STACKS ROW STACKS ROW 6STACKS ROW 7STACKS ROW 6STACKS TURBO PROPELLER TYPE WITH SLINGER RING / / / / / 6 POLES ROTARY SWITCH REMOTE CONTROLLER ROTARY SWITCH REMOTE CONTROLLER ROTARY SWITCH THERMOSTAT THERMISTOR THERMOSTAT THERMISTOR THERMOSTAT VERTICAL LOUVER (RIGHT & LEFT) HORIZONTAL LOUVER (UP & DOWN) SLIDE IN-OUT CHASSIS OVERLOAD PROTECTOR INTERNAL THERMAL PROTECTOR ( WIRE WITH GROUDING) ATTACHMENT PLUG (CORD-CONNECTED TYPE) DRAIN PIPE OR SPLASHED BY SLINGER 6/8 WR-0 R-00M 0 / x 9 / x 9 /8 50 x 54 x 490 WM- L04R R00E WR00 * DB:Dry Bulb ** WB:Wet Bulb

4 .4 FEATURES Designed for COOLING ONLY. Powerful and whispering cooling. Slide-in and slide-out chassis for the simple installation and service. Low air-intake, top cooled-air discharge. Built-in adjustable Thermistor Washable one-touch filter Compact size Reliable and efficient rotary compressor is equipped..5 CONTROL LOCATIONS THERMOSTAT Thermostat will automatically control the temperature of the room. Select a higher number (the right side of arc) for a cooler temperature in the room. The temperature is selected by positioning the knob to the desired position. The 5 or 6 position is a normal setting for average conditions. OPERATION OFF : Turns the air conditioner to off. THERMOSTAT MED LOW OFF LOW COOL OPERATION HIGH COOL MED COOL MED LOW : Permits the medium fan speed operation without cooling. : Permits the low fan speed operation without cooling. HIGH COOL : Permits cooling with the high fan speed operation. MED COOL : Permits cooling with the medium fan speed operation. LOW COOL : Permits cooling with the low fan speed operation. DISPLAY REMOTE CONTROL Power Cool Energy Saver Fan Dry Timer F LOW F MED F HIGH TEMP C 6 AIR PURIFIER Air Purifier Temp Fan Speed Power Temp Fan Speed Timer Mode 4 MODE TIMER SPEED POWER 8 5 Sleep Timer Mode Auto Swing 5 4 4

5 Precaution: The Remote Control unit will not function properly if strong light strikes the sensor window of the air conditioner or if there are obstacles between the Remote Control unit and the air conditioner. POWER BUTTON To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again. This button takes priority over any other buttons. ROOM TEMPERATURE SETTING BUTTON This button can automatically control temperature of the room. The temperature can be set within a range of 6 C to 0 C by C Select the lower number for lower temperature of the room. OPERATION MODE SELECTION BUTTON Every time you push this button, it will shift among COOL, ENERGY SAVER, and DRY. - Energy Saver: If Energy Save mode is selected, the fan stops when the compressor stops cooling. Approximately every minutes the fan will turn on and check the room air to determine if cooling is needed. SPEED SELECTOR Every time you push this button, it is set as follows. (Hi Low Med Hi Low...) ON/OFF TIMER BUTTON You can set the time when the unit will turn on or turn off automatically by pressing the timer button. If the unit is operating, this button controls the time it will be turned off. If the unit is off state, this button controls the time it will start. Every time you push this button, the remaining time will be set as follows. - Stopping operation (Hour Hours Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 0Hours Hours Hours 0Hour Hour Hours... ) - Starting operation (Hour Hours Hours 4Hours 5Hours 6Hours 7Hours 8Hours 9Hours 0Hours Hours Hours off Hour Hours... ) REMOCON SIGNAL RECEIVER AIR PURIFIER Press the Air Purifier button. Operation will start when the button is pressed and stop when the button is pressed again. Set the fan speed with the remote control. You can select the fan speed in three steps high, low or medium. Each time the button is pressed, the fan speed mode is shifted. If you press the only Air Purifier button, only air purifying operates. Then, fan speed is low. You can select the fan speed in three steps high, low or medium. Each time the button is pressed, the fan speed mode is shifed. SLEEP MODE Press the sleep mode button to set the time you want the unit to turn off automatically. Every time you push this button, the remaining time will be set as follows. (Hour Hours Hours 4Hours 5Hours 6Hours 7Hours 0Hour Hour Hours... ) The temperature setting will be raised by F in 0 minutes and by 4 F in hour to prevent overcooling during sleep. 5

6 COOL ENERGY SAVER AIR PURYFIER AUTO RESTART COOL ENERGY SAVER AIR PURYFIER AUTO RESTART. DISASSEMBLY INSTRUCTIONS Before the following disassembly, POWER SWITCH set to OFF and disconnect the power cord.. MECHANICAL PARTS.. FRONT GRILLE. Open the lnlet grille downward and remove the air filter.. Remove the screw which fastens the front grille.(see Figure ). 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. TIME MODE TEMP POWER SPEED.. CABINET. After disassembling the FRONT GRILLE, remove the screws which fasten the cabinet at both sides.. Remove the screws which fasten the cabinet at back.. Pull the base pan forward. (See Figure ) 4. Remove the cabinet. 5. Re-install the components by referring to the removal procedure, above... CONTROL BOX. Remove the front grille. (Refer to section..). Remove the cabinet. (Refer to section..). Remove the screws which fasten the power cord. 4. Disconnect the grounding screw from the evaporator channel. 5. Remove the screw which fasten the control box cover. 6. Remove the housing which connects PCB and motor wire in the control box. 7. Disconnect the housing which connects Plazma Air Purifier.(Optional) 8. Remove the screw at left cover of filter case and open the cover to remove inner screw. (Optional) 9. Remove the nut which fastens the terminal cover. 0. Remove the terminal cover.. Remove all the leads from the overload protector.. Discharge the capacitor by placing a 0,000 ohmresistor across the capacitor terminals.. Raise the control box upward completely. (See Figure ) 4. Re-install the components by referring to the removal procedure, above. (Refer to the circuit diagram found on page 7 in this manual and on the control box.) 6 Figure Figure Figure INDOOR DESIRED DRY HEAT DEFROST TIME MODE TEMP POWER SPEED INDOOR DESIRED DRY HEAT DEFROST TIME MODE TEMP POWER SPEED

7 . AIR HANDLING PARTS.. AIR GUIDE AND TURBO. Remove the front grille. (Refer to section..). Remove the cabinet. (Refer to section..). Remove the control box. (Refer to section..) 4. Remove the 4 screws which fasten the brace. 5. Remove the brace. 6. Remove the screws which fasten the air guide upper. 7. Remove the air guide upper.(see figure 4) 8. Remove the screws which fasten the evaporator. 9. Move the evaporator forward and pulling it upward slightly. (See Figure 5) 0. Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 6). Remove the clamp with a hand plier which secures the turbo fan.. Remove the turbo fan.. Remove the screws which fasten the air guide from the base pan. 4. Move the air guide backward, and pull out from the base pan.(move the air giude lower carefully.) 5. Re-install the components by referring to the removal procedure, above. Figure 4 Figure 5... Remove the cabinet. (Refer to section..). Remove the brace (Refer to section..). Remove the 5 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. (See Figure 7) 7. Re-install by referring to the removal procedure. Figure 6 Figure 7 7

8 .. SHROUD. Remove the fan. (Refer to section..). Remove the shroud. (See Figure 8). Re-install the components by referring to the removal procedure, above. Figure 8. ELECTRICAL PARTS.. OVERLOAD PROTECTOR. Remove the cabinet. (Refer to section..). Remove the nut which fastens the terminal cover.. 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. Figure 9.. COMPRESSOR. Remove the cabinet. (Refer to section..). 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-) before venting the Freon TM. Leave the valve in place after servicing the system.. Remove the overload protector. (Refer to section..) 4. After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections. 5. Remove the nuts and the washers which fasten the compressor. 6. Remove the compressor. (See Figure 0) 7. Re-install the components by referring to the removal procedure, above. Figure 0 8

9 COOL AIR PURYFIER AUTO.. CAPACITOR. Remove the control box. (Refer to section..). Open the top cover from the control box. (See Figure ). Pull out the capacitor from the control box. 4. Disconnect all the leads of capacitor terminals. 5. Re-install the components by referring to the removal procedure, above. COOL DRY INDOOR DESIRED HEAT DEFROST ENERGY SAVER AIR PURYFIER AUTO RESTART Figure..4 POWER CORD. Remove the control box. (Refer to section..). Open the top cover from the control box. (Refer to section..). Disconnect the front panel from the control box. (See Figure ) 4. Disconnect two leads from the capacitor and relay. 5. Pull out 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.) INDOOR DESIRED DRY HEAT DEFROST ENERGY SAVER RESTART TIME MODE TEMP POWER SPEED Figure 9

10 ..5 MOTOR. Remove the cabinet. (Refer to section..). Remove the turbo fan. (Refer to section..). Remove the fan. (Refer to section..) 4. Remove the 4 screws which fasten the motor from the air guide. (See Figure ) 5. Remove the motor. 6. Re-install the components by referring to the removal procedure, above.(see Figure ).4 REFRIGERATING CYCLE.4. CONDENSER CAUTION 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-) before venting the Freon TM. Leave the valve in place after servicing the system. Figure. Remove the cabinet. (Refer to section..). Remove the 5 screws which fasten the brace.(refer to section..). Remove the 5 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. 6. Re-install the components by referring to notes. (See Figure 4).4. EVAPORATOR. Remove the control box.(refer to section..). Remove the air guide upper. (Refer to section..). Remove the screws which fasten the evaporator. 4. Move the evaporator sideways carefully. (Refer to section..) 5. After discharging the refrigerant completely, unbraze the interconnecting tube at the evaporator connections. 6. Remove the evaporator. 7. Re-install the components by referring to notes. (See Figure 5) Figure 4 Figure 5 0

11 .4. CAPILLARY TUBE. Remove the cabinet. (Refer to section..). After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(see caution above). Remove the capillary tube. 4. Re-install the components by referring to notes. TES Replacement of the refrigeration cycle.. When replacing the refrigeration cycle, 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-) before venting the Freon TM. Leave the valve in place after servicing the system.. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes.. 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. ) Connect the vacuum pump, as illustrated figure 6A. ) 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. ) Operate the vacuum pump for 0 to 0 minutes, until 600 microns of vacuum is obtained. Close valves A and B, and observe vacuum gauge for a few minutes. A rise in pressure would indicate a possible leak or moisture remaining in the system. With valves A and B closed, stop the vacuum pump. 4) Remove the hose from the vacuum pump and place it on the charging cylinder. See figure 6B. Open valve C. Discharge the line at the manifold connection. 5) The system is now ready for final charging. 6. Recharge as follows : ) 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. ) Connect the charging cylinder as shown in figure 6B. With valve C open, discharge the hose at the manifold connection. ) Open valve A and allow the proper charge to enter the system. Valve B is still closed. 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 Lowside. b. Watch the Low-side gauge; allow pressure to rise to 0 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 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.

12 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. CONDENSER (HIGH PRESSURE SIDE) COMPOUND GAUGE MANIFOLD GAUGE B A CAPILLARY TUBE SEE INSETS BELOW EVAPORATOR (LOW PRESSURE SIDE) COMPRESSOR LOW HI B A B A EXTERNAL VACUUM PUMP CHARGING CYLINDER C Figure 6A-Pulling Vacuum Figure 6B-Charging

13 . INSTALLATION. SELECT THE BEST LOCATION.To prevent vibration and noise, make sure the unit is installed securely and firmly..install the unit where the sunlight does not shine directly on the unit..the outside of the cabinet must extend outward for at least " and there should be no obstacles, such as a fence or wall, within 0" 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 to the outside of the structure. COOLED AIR 0"~60" Figure 7 AWNING HEAT RADIATION ABOUT /" Over 0" FENCE 4.Install the unit a little slanted so the back is slightly lower than the front (about /"). This will help force con-densed water to the outside. 5.Install the unit from the bottom about 0"~60" above the floor level.. CHECK OF INSTALLATION The setting conditions must be checked prior to initial starting. The undermentioned items are especially important checking points when the installation is finished.. Grounding wire (Green or Green and Yellow) is provided in the power cord. The green wire must be grounded.. Connect to a single-outlet 5A circuit. (or 0A circuit for Electric Heater Model). 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... HOW TO DRAIN (When using drain pipe) The air conditioner must be installed horizontally or tilted slightly to the outside for proper water drainage. On exceptionally hot and humid days the air conditioner may overflow condensed water. If the air conditioner is used in hot and a high humidity zone, exchange the HOLE RUBBER for the DRAIN PIPE.(See figure 8, figure 9.) BASE PAN Figure 8 BASE PAN Figure 9 BOTTOM HOLE RUBBER BOTTOM HOLE RUBBER

14 COOL INDOOR DRY HEAT DEFROST DESIRED ENERGY SAVER AIR PURYFIER AUTO RESTART COOL INDOOR DRY HEAT DEFROST DESIRED ENERGY SAVER AIR PURYFIER AUTO RESTART.4 HOW TO INSTALL.4. WHEN USING GASKET A A G B C B RIGHT SIDE J H HORIZONTAL LINE 4 D E F. WINDOW (WIDTH-A, HEIGHT-B). GASKET. WALL 4. DETAILS 5. x 0 ROUND HEAD WOOD SCREWS A B C D E F H J K 55mm 66mm 50mm 0mm 0~5mm OVER 40mm 5~0mm 0~5mm ( /") (4 7 /6") (0") ( /6") (0~") (OVER 6 7 /") ( /4") ( /6"~ /8") (0~ /6").4. WHEN USING INSTALLATION KITS A. WINDOW REQUIREMENTS This unit is designed for installation in standard double hung windows with actual opening widths from 5" to 6". The top and bottom window sash must open sufficiently to allow a clear vertical opening of 6" from the bottom of the upper sash to the window stool. B. INSTALLATION KITS CONTENTS 5" min 5" to 6" Stool Interior wall 0 /" min (Without frame curtain) Offset /" to /4" Sill Exterior NAME OF PARTS Q'TY FRAME CURTAIN SILL SUPPORT BOLT 4 NUT 5 SCREW(TYPE A) 6 6 SCREW(TYPE B) 7 SCREW(TYPE C) 5 8 FOAM-STRIP 9 FOAM-PE 0 UPPER GUIDE FOAM-PE FRAME GUIDE WINDOW LOCKING BRACKET 4

15 COOL ENERGY SAVER AIR PURYFIER AUTO RESTART COOL ENERGY SAVER AIR PURYFIER AUTO RESTART COOL ENERGY SAVER AIR PURYFIER AUTO RESTART SUGGESTED TOOL REQUIREMENTS SCREWDRIVER(+, -), RULER, KNIFE, HAMMER, PENCIL, LEVEL PREPARATION OF CHASSIS. Remove the screws which fasten the cabinet at both sides and at the back.. Slide the unit out from the cabinet by gripping the base pan handle and pulling forward while bracing the cabinet.. 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 Foam PE and attach it to the bottom of the Upper Guide. 5. Attach the upper guide onto the top of the cabinet with 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 at the both sides. INDOOR DESIRED DRY HEAT DEFROST TIME MODE TEMP POWER SPEED INDOOR DESIRED DRY HEAT DEFROST TIME MODE TEMP POWER SPEED INDOOR DESIRED DRY HEAT DEFROST TIME MODE TEMP POWER SPEED 9 Shipping Screws EPS Material 0 CABINET INSTALLATION. 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 front angle with the center line marked in the window stool. (Type A) Pull the bottom window sash down behind the upper guide until it meets. 5 (Type A) TE: Do not pull the window sash down so tightly that the movement of Frame Curtain is restricted. Upper Guide Window stool Front Angle Figure 0 Window Sash Upper guide 9 Foam-pe Cabinet Frame Curtain Foam-pe 0 Figure 5

16 . Loosely assemble the sill support using the parts in Figure. INDOOR Bolt OUTDOOR Sill Support Nut 4 Figure 4. Select the position that will place the sill support near the outer most point on sill (See Figure ) TE: Be careful when you install the cabinet (Frame Guides are broken easily). 5. Attach the sill support to the cabinet track hole in relation to the selected position using Type A screws in each support (See Figure ). Frame Guide INDOOR 5 Screw(Type A) Cabinet OUTDOOR About /" Figure 6. The cabinet should be installed with a very slight tilt (about /") downward toward the outside (See Figure 4). Adjust the bolt and the nut of Sill Support for balancing the cabinet. Screw(Type B) 6 Screw(Type A) 5 Sill support About /" 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 (5/8"). Sash track 8. Pull each Frame Curtain properly to each window sash track, and repeat step. Sill support Screw(Type B) 6 Front Angle Figure 4 9. Attach each Frame Curtain to the window sash by using screws (Type C). (See Figure 5) Type C 7 Figure 5 6

17 COOL DRY HEAT DEFROST INDOOR DESIRED COOL DRY HEAT DEFROST INDOOR ENERGY SAVER AIR PURYFIER AUTO RESTART TIME MODE TEMP POWER SPEED DESIRED ENERGY SAVER AIR PURYFIER AUTO RESTART COOL DRY HEAT DEFROST INDOOR DESIRED ENERGY SAVER AIR PURYFIER AUTO RESTART 0. Slide the unit into the cabinet.(see Fig. 6) CAUTION: For security purpose, reinstall screws (Type A) at the cabinet's sides. Power cord Screw(Type A) Screw(Type A) Figure 6. Cut the Foam-Strip to the proper length and insert between the upper and lower window sash. (See Fig. 7) Foam-Strip 8 Figure 7. Attach the window Locking Bracket with a type C screw. (See Fig. 8) Figure 8. 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 Fig. 9) TIME MODE TEMP POWER SPEED 4. Lift the inlet grille and secure it with a type A screw through the front grille.(see Fig. 0) Figure 9 Figure 0 Figure 4. TROUBLESHOOTING GUIDE 4. OUTSIDE DIMENSIONS unit: mm(inch) 490(9 / 8" ) 5 9( / " ) 6.5(4 / " ) ( / ") 8( / " ) 7

18 4. PIPING SYSTEM CONDENSER COIL MOTOR CAPILLARY TUBE COMPRESSOR TURBO EVAPORATOR COIL Figure 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. COOLED AIR EVAPORATOR COILS COMPLETE LIQUID BOIL OFF POINT ROOM AIR HEAT LOAD ROOM AIR CONITIONER CYCLE OF REFRIGERATION SUCTION LINE COOL LOW PRESSURE VAPOR VAPOR INLET CONDENSER COILS HOT DISCHARGED AIR MOTOR OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH COMPRESSOR LIQUID PRESSURE DROP OIL (LIQUID REFRIGERANT) CAPILLARY TUBE Figure LIQUID OUTLET HIGH PRESSURE VAPOR LIQUID REFRIGERANT LOW PRESSURE VAPOR 8

19 4. 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 Check cold air circulation for smooth flow. Check outdoor coil (heat exchanger) & the fan operation. Check heat load increase. Dirty indoor coil (Heat exchanger) Check gas leakage. Clean condenser. Malfunction of fan Repair gas leak. Not on separate circuit. Clogged of air filter. Replacement of unit if the unit is beyond repair. Check inside gas pressure. Obstruction at air outlet Adjusting of refrigerant charged. Correct above trouble Malfunction of compressor. Check clogging in refrigeration circuit. Replacement of compressor. Repair clogging in refrigeration circuit. Satisfactory operation with temperature difference of inlet & outlet air ; 44~50 F(7~0 C) 9

20 Fails to Start Check of power source. Check circuit breaker and fuse. Check of control switch setting. Gas leakage of feeler bulb of thermostat Check of control switch. Compressor only fails to start. Fan only fails to start. Drop of power voltage. Defect of compressor capacitor. Capacitor check. Replacement Improper thermostat setting. Loose terminal connection. Improper wiring. Improper wiring. Defect of fan motor capacitor. Irregular motor resistance ( ). Irregular motor insulation ( ). Replacement of fan motor. Irregular motor resistance ( ) Regular but fails to start. Irregular motor insulation ( ) Replacement of compressor (Motor damaged) Replacement of compressor (locking of rotor, metal). 0

21 ELECTRICAL PARTS TROUBLESHOOTING GUIDE: WM-80, WM-0 Possible Trouble The unit does not operate. Is the Trans input power AC 5V? Check the Fuse. Check the the wiring diagram. Is the Trans output power about AC 4V? Is shorted the Trans. output? Check the Main PCB pattern. Exchange the Trans. Is output Voltage of IC0D DC V? Exchange D0D~D05D. Exchange IC0D. Is output Voltage of IC0D DC 5V? Exchange IC0D. Is the reset circuit all right? (The No.4 of Micom is 5V.) Exchange IC0A, C0A. Is the connection between AC and DC all right? Connect connector exactly. Is the voltage No.8 of Micom DC 5V? Check the PCB pattern. Exchange AC PCB Ass'y.

22 Possible Trouble The compressor does not operate. Is setting Temp. set lower than Room Temp.-0.5 C? Select the setting Temp. to lower Number. Is the voltage No.0 of IC0M 0V? Is the voltage N0.9 of IC0M DC V? Is the Unit for minutes delay? Check the RY-COMP. Check the wiring Diagram. Exchange IC0M. Wait Minutes. Exchange MAIN PCB Ass'y. Possible Trouble The compressor always operate. Is the wire connection of RY-COMP all right? Connect LEAD Wire to RY-COMP again. Check the RY-COMP.

23 Possible Trouble 4 does not operate. Is the voltage. or or 4 of IC0M DC V? Exchange IC0M. Is the voltage.6 or 5 or of IC0M 0V? Exchange IC0M. Check the RY-Hi or RY-Med or RY-Lo. Check the wiring diagram. Possible Trouble 5 Remote controller does not operate. Is the voltage of Battery about over.v? Exchange the battery. Is the voltage No.0 of CN-AC/DC on DC PCB Ass'y DC 5V? Check the the PCB pattern. Is the connection of CN-AC/DC all right? Connect connector to CN-AC/DC exactly. Exchange Receiver Ass'y.

24 Possible Trouble 6 It displays abnormally on DC PCB Ass y. Is the IC0G all right? Exchange IC0G. Is the connection of CN-AC/DC all right? Connect connector to CN-AC/DC exactly. Does the IC0G (Q0G~Q04G for Delux Model) operate normally on DC PCB Ass'y? Exchange IC0G (Q0G~Q04G for Delux Model). Exchange the DC PCB Ass'y. 4

25 COMPLAINT CAUSE REMEDY Fan motor will not run. Fan motor runs intermittently Fan motor noise. Compressor will not run, but fan motor runs. No power Power supply cord Rotary switch Wire disconnected or connection loose Capacitor (Discharge capacitor before testing.) Will not rotate Revolves on overload. Fan Blower Loose clamper Worn bearings Voltage Wiring Rotary Check voltage at outlet. Correct if none. Check voltage to rotary switch. If none, check power supply cord. Replace cord if circuit is open. Check switch continuity. Refer to wiring diagram for terminal identification. Replace switch if defective. Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal. Test capacitor. Replace if not within ±0% 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 /4 to 5 /6 inch 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. Check for continuity, refer to the wiring diagram for terminal identification. Replace the switch if circuit is open. 5

26 COMPLAINT CAUSE REMEDY 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 Thermostat 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 Blower or fan Copper tubing Check the position of knob If not at the coldest setting, advance the knob to this setting and restart unit. Check continuity of the thermostat. Replace thermostat if circuit is open. Check the capacitor. Replace if not within ±0% 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 of 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 blower 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. 6

27 5. SCHEMATIC DIAGRAM 5. CIRCUIT DIAGRAM MODEL: WM-80, WM-0, WM-, HBLG800R, HBLG00R, L04R, R00E MODEL: WR-800, WR-0, WR-00, R00M 4 GN/YL (GN) GN/YL (GN) MOTOR CAPACITOR YL F C OR(BR) H WH(BL) (Ribbed) BK(BR) (Plain) R COMP. S C BK BL RD YL OR BK RD BL OLP WIRING DIAGRAM CN-MOTOR CN-PWR FUSE 50V/TA (5V/TA) 4 RY-LOW ZNR0J RY-COMP RY-MED POWER TRANS AC PCB ASSEMBLY 854AR56N CN-AC/DC RY-HI DCV CN-V CN-HVB CN-AC/DC DC PCB ASSEMBLY CN-TH THERMISTOR SWITCH H.V. ASSEMBLY BK RD AIR FILTER ASSEMBLY ROTARY SWITCH 7 8 L 6 H 4 M RD BK BL RD BK BL OR(BR) YL BL POWER INPUT BK(BR) WH(BL) (Plain) (Ribbed) GN(GN/YL) MOTOR CAPACITOR YL F OR(BR) C R BK BK COMP. S RD RD H C BR(YL) BL BL BK OLP THERMOSTAT RD P.T.C WIRING DIAGRAM 854AR56A 9 4 S: Service Parts N: Non Service Parts LOCATION. DESCRIPTION Q'TY PER SET RE- MARKS MOTOR ASSY CAPACITOR COMPRESSOR OVERLOAD PROTECTOR DC PCB ASSEMBLY AC PCB ASSEMBLY THERMISTOR PLASMA FILTER ASSY THERMOSTAT ROTARY SWITCH S S S S S S S S S S 7

28 5. ELECTRONIC CONTROL DEVICE MODEL : WM-80, WM-0, WM-,HBLG800R, HBLG00R, L04R, R00E HVB ROOM-TH CN-TH 5V SMAW00-0 R04H 6.K % R0H.K % OSC0B RT8.00MG R0B M 5V C0A V 4 0 R0A 0K C0A uf 0V Rx R05P 0K SDA SCL Digit4 (Scan4) Digit (Scan) Digit (Scan) Digit (Scan) Digit0 (Scan0) SEG-a SEG-b SEG-c.6V 5V IC0A S76 R06P 0K C0F R0F K C0F R0F K Model Auto Restart Non Auto Restart EEPROM CAT9C46 A0 Vcc A WP A SCL GND SDA EEPROM R04P O O R04P 5V R0P R0P 0K 0K R04P K Q0G A0S SW0G D0G TIMER SW04G D04G Q0G A0S Q0G A0S TEMP DOWN ON/OFF SW0G SW0G D0G D0G MODE TEMP UP SW05G SW06G D05G D06G 5V X X b c VAref VSS Osc out Osc in /Reset TEST 5V COMP SYNC 4WAY LOW Option Option Pipe TH Room TH MICOM TMP87CH47U VDD SEG-f SEG-e SEG-d KEY0 SLIDE SW SEG-g ION MED HI Receiver Buzzer LED out LED out LED out LED out0 KEY 5V RH RH.K.K % % ORH ORH V IC0M ULN004A 5V C0L 0 0V Vcc R0L K Vout GND RECEIVER R0E 0 R0P 0K C0L 680pF 50V HVB 0 Digit a Digit a b f 5 a b 9 c 8 d e f 7 f d c e 4 g e d 6 g g S/V- 4WAY MOTOR CAPACITOR C HERM MAIN POWER COMP PIPE-TH SW SW CN-TELE SMW00-0 5V (RD) C0T 0. 50V CN-TH SMW50-0 CN-HVB SMW00-0(BL) CN-CONT J5 SMW00-0(YL) CN-V SMW00-0(WH) CN-4WAY YW96-0AV(YL) CN-MOTOR YW96-09AV CN-PWR YW96-0AV RY-COMP G4A-A-E-LG FUSE 50V/TA 5V C0T Q0T R0T 0.00 C04M K Rx D0T C0T N448 Q04T 0.00 A04M 5V 5V Q0T C04M Tx Q0T A04M 0 J7 V RY-COMP RY-4WAY RY-LOW RY-MED RY-HI Model RY-4WAY J07 CN-4WAY CN-TH Cool Only O Heat Pump O O O RY-4WAY RY-HI RY-MED RY-LOW 5V V C0J 0./75V CN-AC/DC R0J /W STRAIGHT ZNR0J SVC7D-4A SVC7D-4A POWER TRANS D0D D0D D0D~D05D N4004 D05D IC0D O 78 D04D + C0D C0D C0D V 50V 6V BZ0E PKMEPY C05D C06D V 50V V CN-AC/DC 558-(YEONHO) (MOLEX) ANGLE V 5V IC0D O 7805 C04D C05D V 5V R0E K 5V 5V RF 0K 5V IC0G ULN004A 6 R0G R0G R0G 680 R04G 680 R05G 680 R06G R07G 680 V COOL DEFROST DRY/HEAT TIMER E/SAVER 88 SEGMENT X 7 4 X X X I + I

29 5. COMPONENTS LOCATION(FOR AC P.C.B ASM) MODEL : WM-80, WM-0, WM-, HBLG800R, HBLG00R, L04R, R00E CN-AC/DC J CN-V CN-CON D0D J5 CN-HVB C0T D0D D04D D05D HEAT SINK IC0D Q0T J4 C0D R0T Q0T Q0T J6 C0D D0T C0T J Q04T QIC0DT C04D CN-TELE J RY-4WAY RY-LOW RY-MED RY-HI J7 C05D CN-TH PCB:6870A90068A CN-PWR ZNR0J R0J E0J J8 CN-MOTOR E0J E0J CN-4WAY C0J RY-COMP ASSEMBLY:687A067 POWER TRANS FUSE 50V/TA E04J E05J 5.4 COMPONENTS LOCATION(FOR DC P.C.B ASM) MODEL : WM-80, WM-0, WM-, HBLG800R, HBLG00R, L04R, R00E 9

30 6. EXPLODED VIEW W W0CZZ W A W0CZZ

31 7. REPLACEMENT PARTS LIST R: Service Parts N: Non Service Parts LOCATION. DESCRIPTION PART. WR-800 WM-08 WM-0 WR-0 R00M WM- L04R 040 BASE ASSEMBLY,SINGLE 04A00V 04A00V 04A00N 04A000L 04A000L R 090 CABINET ASSEMBLY,SINGLE 09AR7K 09AR7K 09AR7K 09A00M 09A00M R 5 GRILLE ASSEMBLY,FRONT(SINGLE) 5A0097A 5A0097A 5A0097A 5A0098A 5A0098A R 50 GRILLE,INLET A007A 50A007A R 5 GRILLE ASSEMBLY,INLET 50A008A 50A008A 50A008A - - R 5500 COVER,CONTROL(INDOOR) 550A094A 550A04A 550A04A 550A094A 550A04A R 700 PANEL,CONTROL 70A0A 70A0A 70A0A 70A0A 70A0A R 4758 LOUVER,HORIZONTAL 4758A009A 4758A009A 4758A009A 4758A008A 4758A008A R LOUVER,VERTICAL 4758A0040A 4758A0040A 4758A0040A 4758A004A 4758A004A R LOUVER,VERTICAL 4758A0040B 4758A0040B 4758A0040B 4758A004B 4758A004B R BRACE 4800A000A 4800A000A 4800A000A 4800A000B 4800A000B R 4940 KBS ASSEMBLY 494A000A A000A - R SHROUD 4998A00A 4998A00A 4998A00A 4998A006A 4998A006A R 50 FILTER(MECH),A/C 5A0006A 5A0006A 5A0006A 5A0007A 5A0007A R 690 THERMOSTAT H009M - - H009M - R 80 ESCUTCHEON - 8A00J 8A00J - 8A00J R CONTROL BOX ASSEMBLY,SINGLE 4995A079A 4995A078A 4995A078B 4995A079C 4995A078C R 60 THERMISTOR - 6A0004D 6A0004D - 6A0004D R 640 POWER CORD ASSEMBLY 64A00T 64A00F 64A00R 64A00U 64A00H R 6600 SWITCH, ROTARY H00598E - - H00598E - R 670 REMOTE CONTROLLER - 67A004G 67A004G - 67A004G R 687 PWB(PCB) ASSEMBLY,DISPLAY - 687A04B 687A04B - 687A04B R 6874 PWB(PCB) ASSEMBLY,MAIN - 687A067C 687A067C - 687A067C R 468 MOTOR ASSEMBLY,SINGLE 468A0069M 468A0069G 468A0069H 468A0069P 468A0069J R 4900 DAMPER,VENTILATION 4900A000A 4900A000A 4900A000A 4900A000A 4900A000A R ORIFICE 4948A004A 4948A004A 4948A004A 4948A005A 4948A005A R 5 TUBE ASSEMBLY,DISCHARGE SINGLE 5A0708B 5A0708B 5A0074J 5A0074K 5A0074K R 55 TUBE ASSEMBLY,EVAPORATOR IN 5A0559K 5A0559K 5A0470F 5A0559N 5A0559N R 590- AIR GUIDE ASSEMBLY 59A00A 59A00A 59A00A 58A0008A 58A0008A R 590- AIR GUIDE ASSEMBLY 59A0005A 59A0005A 59A0005A 59A0004A 59A0004A R 540 EVAPORATOR ASSEMBLY,FIRST 54A006B 54A006B 54A006C 54A00A 54A00A R 5590,TURBO 5900A000A 5900A000A 5900A000A 5900A009C 5900A009C R ISOLATOR,COMP 480AR45A 480AR45A 480AR45A 480AR45A 480AR45A R 55 TUBE ASSEMBLY, CAPILLARY) 5A075N 5A075N 5A075M 5A075P 5A075P R CONDENSER ASSEMBLY,FIRST 540A009B 540A009B - 540AR9H 540AR9H R 5540 CONDENSER ASSEMBLY,BENT A004M - - R COMPRESSOR 546A004B 546A004B 50UKLCCA 50UKFCAA 50UKFCAA R ASSEMBLY,AXIAL 5900AR67B 5900AR67B 5900AR67B 5900A0009B 5900A0009B R O.L.P 6750A000N 6750A000N 6750U-L0A 6750U-L09A 6750U-L09A R 77 INSTALL PARTS ASSEMBLY,SINGLE 7A005B 7A005B 7A005B 7A005G 7A005G R 5A TUBE ASSEMBLY,SUCTION SINGLE 5A08R 5A08R 5A08S 5A044F 5A044F R W0CZZ CAPACITOR 60AR59V 60AR59V 0CZZA000N 0CZZA000N 0CZZA000N R W4860 CLAMP,SPRING H09B H09B H09B H09B H09B R TE) * Please ensure GCSC since these parts may be changed depending upon the buyer's request. (GCSC WEBSITE REMARK

32 LOCATION. DESCRIPTION PART. HBLG800R HBLG00R WR-00 R00E R: Service Parts N: Non Service Parts 040 BASE ASSEMBLY,SINGLE 04A00V 04A00N 04A00N 04A000L R 090 CABINET ASSEMBLY,SINGLE 09AR7K 09AR7K 09AR7K 09A00M R 5 GRILLE ASSEMBLY,FRONT(SINGLE) 5A060A 5A060A 5A0097A 5A06B R 50 GRILLE,INLET 50A0075A 50A0075A 50A008A 50A0076A R 5500 COVER 550A04A 550A04A 550A094A 550A04A R 4758 LOUVER,HORIZONTAL 4758A009A 4758A009A 4758A009A 4758A008A R LOUVER,VERTICAL 4758A0040B 4758A0040B 4758A0040A 4758A004A R LOUVER,VERTICAL 4758A0040A 4758A0040A 4758A0040B 4758A004B R BRACE 4800A000A 4800A000A 4800A000A 4800A000B R 4940 KB ASSEMBLY A000A - R SHROUD 4998A00A 4998A00A 4998A00A 4998A006A R 50 FILTER ASSEMBLY,AIR CLEANER 5A0006A 5A0006A 5A0006A 5A0007A R 700 PANEL, CONTROL 70A0A 70A0A 70A0A 70A0A R 80 ESCUTCHEON 8A00E 8A00E - 8A00J R 690 THERMOSTAT - - H009M - R CONTROL BOX ASSEMBLY,SINGLE 4995A094V 4995A094W 4995A079B 4995A078C R 60 THERMISTOR ASSEMBLY 6A0004D 6A0004D - 6A0004D R 640 POWER CORD ASSEMBLY 64A00F 64A00R 64A00V 64A00H R 6600 SWITCH, ROTARY - - H00598E - R 670 REMOTE CONTROLLER ASSEMBLY 67A9009C 67A9009C - 67A004C R 6874 PWB(PCB) ASSEMBLY,MAIN(AC) 687A067C 687A067C - 687A04B R 6874 PWB(PCB) ASSEMBLY,MAIN(DC) 687A04A 687A04A - 687A067C R 468 MOTOR ASSEMBLY,SINGLE 468A0069G 468A0069H 468A0069N 468A0069J R 4900 DAMPER,VENTILATION 4900A000A 4900A000A 4900A000A 4900A000A R ORIFICE 4948A004A 4948A004A 4948A004A 4948A005A R 5 TUBE ASSEMBLY,DISCHARGE SINGLE 5A0708B 5A0074J 5A0074J 5A0074K R 55 TUBE ASSEMBLY,EVAPORATOR IN 5A0559K 5A0470F 5A0470F 5A0559N R 5A TUBE ASSEMBLY,SUCTION SINGLE 5A08R 5A08S 5A08S 5A044F R 590- AIR GUIDE ASSEMBLY 59A0005A 59A0005A 59A0005A 58A0008A R 590- AIR GUIDE ASSEMBLY 59A00A 59A00A 59A00A 59A0004A R 540 EVAPORATOR ASSEMBLY,FIRST 54A006B 54A006C 54A006C - R 5590,TURBO 5900A000A 5900A000A 5900A000A 5900A009C R ISOLATOR,COMP 480AR45A 480AR45A 480AR45A 480AR45A R 55 TUBE ASSEMBLY, CAPILLARY 5A075N 5A075M 5A075M 544AR448G R CONDENSER ASSEMBLY,FIRST 540A009B AR9H R 5540 CONDENSER ASSEMBLY,BENT - 540A004M 540A004M - R COMPRESSOR 546A004B 50UCDK004 50UCDK004 50UKFCAA R ASSEMBLY,AXIAL 5900AR67B 5900AR67B 5900AR67B R O.L.P 6750A000N 6750U-L0A 6750U-L0A 6750U-L09A R 77 INSTALL PARTS ASSEMBLY, SINGLE 7A005B 7A005B 7A005B 7A005G R W0CZZ CAPACITOR,DRAWING 60AR59V 0CZZA000N 0CZZA000N 0CZZA000N R W4860 CLAMP,SPRING H09B H09B H09B H09B R TE) * Please ensure GCSC since these parts may be changed depending upon the buyer's request. (GCSC WEBSITE REMARK

33 MEMO

34 MEMO 4

35 P/No : 88A006A June, 004 Printed in Korea