ROOM AIR CONDITIONER INDOOR UNIT AQ09A5(6)MA AQ2A5(6)MC OUTDOOR UNIT UQ09A5(6)MA UQ2A5(6)MC SERVICE Manual AIR CONDITIONER CONTENTS. Installation 2. Disassembly and Reassembly. Troubleshooting 4. Exploded Views and Parts List 5. Refrigerating Cycle Block Diagrams 6. Wiring Diagrams 7. Schematic Diagrams E DB80086A(2)
. Installation Refrigerant Refill Procedure Refill an airconditioner with refrigerant when refrigerant has been leaked at installing or using. Purge air(for new installation only). 2. Turn the way valve clockwise to close, connect the pressure gauge(low pressure side) to the service valve, and open the way valve again. Suspension hook. Connect the tank to refill with Refrigerant 4. Set the unit to cool operation mode. 5. Check the pressure indicated by the pressure gauge(low pressure side). * Standard pressure is should be 64~78psi in a regular, high operation mode. Compound gauge For mounting other and of hose when not in use High pressure gauge Hand wheel Finger tight fittings Connected to high pressure side Charging line 6. Open the refrigerant tank and fill with refrigerant until the rated pressure is reached. * It is recommended not to pour the refrigerant in too quickly, but gradually while operating a pressure valve. R22 7. Stop operation of the air conditioner. 8. Close the way valve, disconnect the pressure gauge, and open the way valve again. 9. Close the cap of each valve.
2 Pump down Procedure Pump down' shall be carried out when an evaporator is replaced or when the unit is relocated in another area.. Remove the caps from the 2way valve and the way valve. 2. Turn the way valve clockwise to close and connect a pressure gauge(low pressure side) to the service valve, and open the way valve again.. Set the unit to cool operation mode. (Check if the compressor is operating.) 2Way Valve 4. Turn the 2way valve clockwise to close. 5. When the pressure gauge indicates "0" turn the way valve clockwise to close. Way Valve 6. Stop operation of the air conditioner. 7. Close the cap of each valve. Relocation of the air conditioner Refer to this procedure when the unit is relocated.. Carry out the pump down procedure (refer to the details of 'pump down'). 2. Remove the power cable.. Disconnect the assembly cable from the indoor and outdoor units. 4. Remove the flare nut connecting the indoor unit and the pipe. At this time, cover the pipe of the indoor unit and the other pipe using a cap or vinyl plug to avoid foreign material entering. 5. Disconnect the pipe connected to the outdoor unit. At this time, cover the valve of the outdoor unit and the other pipe using a cap or vinyl plug to avoid foreign material entering. 6. Make sure you do not bend the connection pipes in the middle and store together with the cables. 7. Move the indoor and outdoor units to a new locatioon. 8. Remove the mounting plate for the indoor unit and move it to a new location. 2
2. Disassembly and Reassembly Stop operation of the air conditioner and remove the power cord before repairing the unit. 2 Indoor Unit No Parts Procedure Remark Front Grille ) Stop the air conditioner operation and block the main power. 2) Separate tape of front panel upper. ) Contract the second finger to the left, and right handle and pull to open the inlet grille. 4) Take the left and right filter out. *Taking off the deodorizing filter. 5) Loosen one of the right fixing screw and separate the terminal cover. 6) Loosen three fixing screws of front grille. 7) Pull the upper left and right of discharge softly for the outside cover to be pulled out. 8) Pull softly the lower part of discharge and push it up. Caution; Assemble the front panel and fix the hooks of left and right.
No Parts Procedure Remark 2 Electrical Parts (Main PCB) Ass y Tray Drain. ) Do above 2) Take all the connector of PCB upper side out. (Inclusion Power cord) ) Separate the outdoor unit connection wire from the terminal block. 4) If pulling the Main PCB up. it will be taken out. ) Do, 2, above Separate the drain hose from the extension drain hose. 2) Pull tray drain out from the back body. 4 Heat Exchanger ) Do and 2,, above 2) Loosen two fixing earth screws of right side. ) Separate the connection pipe. 4) Separate the holder pipe at the rearside. 5) Loosen the three fixing screws of right and left side. 6) Lifting the heat exchanger up a little to push the up side for separation from the indoor unit. 5 Fan Motor and Cross Fan ) Do 2 4, above. 2) Loosen the fixing two screws and separate the motor holder. ) Loosen the fixing screw of fan motor. (By use of M wrench) 4) Separate the fan motor from the fan. 5) Separate the fan from the left holder bearing. 4
22 Outdoor Unit UQ09A5(6)MA No Parts Procedure Remark Common Work ) Loosen the fixing two screws and separate the cover Eparts. 2) Separate the connection wire from the terminal block. ) Loosen five fixing screws and separate the cabi Upper. 4) Loosen two fixing screws of Ass'y Epart. 5) Loosen nine fixing screws and separate the cabi side. 2 Fan and Motor ) Do, above. 2) Loosen four screws and seperaate Guard Fan from front cabinet 5
No Parts Procedure Remark 2) Remove the nut flange (Turn to the right to remove, as it is a left hand screw) ) Separate the fan. 4) Loosen four fixing screws to separate the motor. Heat Exchanger ) Do, 2 above. 2) Loosen two fixing screws of left and right side. ) Disassemble the inlet and outlet pipe by welding. 4) Separate the heat exchanger. 4 Compressor ) Do, above. 2) Loosen the nut on the terminal cover and open the terminal cover. ) Disassemble the inlet and outlet pipe of compressor by welding. 4) Disassemble the inlet and outlet pipe of condenser by welding 5) Loosen the three bolts of the lower part. 6) separate the compressor. 6
UQ2A5(6)MC No Parts Procedure Remark Common Work ) Loosen the fixing screw and separate the HandleCabi RH. 2) Separate the connection wire from the terminal block. ) Loosen 6 fixing screws and separate the upper cabinet. 4) Loosen the fixing screw of Ass'y Epart. 5) Loosen 5 fixing screws and separate the side cabinet. 7
No Parts Procedure Remark 2 FanMotor ) Loosen 4 fixing screw of the GuardFan. 2) Remove the nut flange (Turn to the right to remove, as it is a left hand screw) ) Separate the fan. 4) Loosen four fixing screws to separate the motor. 8
. Troubleshooting Items to be checked first ) The input voltage should be rating voltage ±0% range. The airconditioner may not operate properly if the voltage is out of this range. 2) Is the link cable linking the indoor unit and the outdoor unit linked properly? The indoor unit and the outdoor unit shall be linked by 5 cables. Check the terminals if the indoor unit and outdoor unit are properly linked by the same number of cables. Otherwise the airconditioner may not operate properly. ) When a problem occurs due to the contents illustrated in the table below it is a symptom not related to the malfunction of the airconditioner. Operation of air conditioner The STD operation indication LED blinks when a power plug of the indoor unit is plugged in for the first time. 2 In a COOL operation mode, the compressor does not operate at a room temperature higher than the setting temperature that the INDOOR FAN should operate. In a HEAT operation mode, the compressor does not operate at a room temperature lower than the setting temperature that indoor fan should operate. Fan speed setting is not allowed in AUTO or DRY mode. 4 Compressor stops operation intermittently in DRY mode. 5 Compressor of the outdoor unit is operating although it is turned off in a HEAT mode. 6 Timer LED only of the indoor unit lights up and the air conditioner does not operate. 7 The compressor and indoor fan stop intermittently in HEAT mode. 8 Indoor fan and outdoor fan stop operation intermittently in a HEAT mode. 9 The compressor stops intermittently in a COOL mode or DRY mode, and fan speed of the indoor unit decreases. Explanation It indicates power is on. The LED stops blinking if the operation ON/OFF button on the remote control unit is pushed. In happens after a delay of minutes when the compressor is reoperated. The same phenomenon occurs when a power is on. As a phenomenon that the compressor is reoperated after a delay of minutes, the indoor fan is adjusted automatically with reference to a temperature of the air blew The speed of the indoor fan is set to LL in DRY mode. Fan speed is 5 steps is selected automatically in AUTO mode. Compressor operation is controlled automatically in DRY mode depending on the room temperature and humidity. When the unit is turned off while deice is activated, the compressor continues operation for up to 9 minutes (maximum) until the deice is completed. Timer is being activated and the unit is in ready mode. The unit operates normally if the timer operation is cancelled. The compressor and indoor fan stop intermittently if room temperature exceeds a setting temperature in order to protect the compressor from overheated air in a HEAT mode. The compressor operates in a reverse cycle to remove exterior ice in a HEAT mode, and indoor fan and outdoor fan do not operate intermittently for within 20% of the total heater operation The compressor stops intermittently or the fan speed of the indoor unit decreases to prevent inside/outside air frozen depending on the inside/outside air temperature. 4) Indoor unit observes operation condition of the air conditioner, and displays self diagnosis details on the display panel. Display STD LED blinking (Hz) 2 TIMER LED blinking (Hz) STD and TIMER LED blinking (Hz) 4 NATURE LED blinking (Hz) Self Diagnosis Restore from power failure (input initial power) Indoor unit Room sensor Error (open or short) Indoor unit heat exchanger temperature sensor Error (open or short) Indoor fan malfunctioning (for spead is Below 450rpm) 9
2 Fault Diagnosis by Symptom 2 No Power(completely dead)initial diagnosis ) Checklist : () Is input voltage normal? (2) Is AC power linked correctly? () Is output voltage of DC regulator IC KA7805 (IC02) normal? (4.5VDC5.5VDC) 2) Troubleshooting procedure Remove power cord and plug in again in approx. 5 seconds Replace PCB display Is DC voltage of PCB display normal? Is rating voltage ±0% range applied to the primary side(~,~) of the BD7 Check linkage between power cord and terminal tap Check fuse Is 25VDC appear in the secondary side (+, ) of BD7 Is operation lamp blinking? Does operation start when ON/OFF button on the remote controller unit pushed? Is transmission display of the remote controller unit blinking? Is "beep"sound heard from the main unit? Is DC voltage of the PCB module normal? Are voltages of #8 (compressor), #7(4 way valve) and #6 (outdoor fan) of the micom normal? 5VDC Is voltage of #60 (indoor fan) of the micom normal? DC5V 0ms Normal Refer to remote control unit fault diagnosis Replace PCB module. Are voltages at RY7(Compressor) normal? DC2V Is voltage at SS7(indoor fan) Replace SMPS PARTS Is voltage at #50 terminal of the Micom normal? 0VDC Is voltage at #8 terminal of the Micom normal? 5VDC Is voltage at #52 terminal of the micom normal? Check connections compressor and indoor fan. Is output voltage of ICO2 normal? Replace RY7 and SS7 Replace resonator (X0) Is operation normal? 0ms Are voltage at #48 and #49 of the micom normal? Replace micom 250ns Check PCB pattern. Replace main PCB. Is voltage output terminal of TLP80(PC02) normal? OK Replace ICO2 Replace TLP80(pc02) OK 0
22 When the Indoor Unit Fan Does Not Operate. (Initial Diagnosis) ) Checklist : () Is the indoor unit fan motor properly connected with the connector (CN72)? (2) Is the AC voltage correct? () Is HALL IC in indoor fan motor properly connected with the connector (CN42)? (4) Is the running capacitor (CR7) properly connected with PCB board? 2) Troubleshooting procedure After unplugging out the power cord should be reconnected within five seconds. Does the STD lamp(green) blink? Check as in the procedure power parts Refer tp page 52. Does the Solid State Relay(SS7) work properly? Microcomputer is out of order. + Test rod location Normal Voltage SS7 SS7 2V Is the supply voltage of the fan motor sufficient? PCB is out of order. PCB should be replaced. PCB CN72 Test rod location Condition Normal voltage pin # and #5 Fan operate about AC 80V MFC is out of order Replace MFC Fan motor is out of order. Fan motor should be replaced.
2 When the Outdoor Unit Does Not Operate. (Initial Diagnosis) ) Checklist : () Is input voltage normal? (2) Is the set temperature of the remote control higher than room temperature in COOL mode? () Is the POWER IN connector (CN7) linked correctly? (4) Is the outdoor unit properly connected with the TERMINAL BLOCK connector((n), )? 2) Troubleshooting procedure After unplugging out the power cord should be reconnected within five seconds. Does the STD lamp blink Check as in the procedure "No Power parts" Refer to page 52. Does the timer lamp blink during operation? Room temperature sensor is out of order 2 PCB should be checked. Is the power relay RY7 operated by adjusting the room temperature? Microcomputer is out of order. Test rod location Normal + Condition Voltage IC4 Pin No.62 GND RY7 ON DC 4.8V PCB should be checked. Is rating voltage ±0% range applied relay between Terminal block (N) and No. Power relay is out of order Power relay should be replaced. 2 Outdoor unit is out of order. Is the room sensor normal register? 0 C 20 C 0 C 7.96k Ω 2.09k Ω 8.k Ω 2
24 When the UP/DOWN Louver Motor Does Not Operate. (Initial Diagnosis) ) Checklist : () Is input voltage normal? (2) Is the UP/DOWN louver motor properly connected with the connector (CN6)? 2) Troubleshooting procedure Remove power cord and plug in again in approx. 5 seconds. Is STD lamp blinking? Does operation start when swing button of the remote control unit pushed? Y N Y Check as in the procedure "No Power parts". Refer to page 52. Normal Voltage at pin ##4 of micom (ICO4) change?(squarewave) N N Micom (IC04) is faulty. Volatge at pin # ~ #6 of IC06 (KID6500) change?(squarewave) UP/DOWN louver motor is faulty. Y Y N Driver IC06 (KID6500) is faulty. 25 In the mode, When there is no warm air current. Check this first; () Is the set temperature of Remote Control lower than room temperature in Heat mode? (2) Is the Indoor PCB properly connected with the CN7 connector? After training on, the heating operation should start in five minutes. Is the number #8 of Micom (IC04) DC 5.0 V? Is the number checking # of IC06 (KID6500) LOW? Is the voltage between CN7 # and CN7 #5 rating voltage ±0% range Normal Abnormal Micom Abnormal IC06 Abnormal RY7 Abnormal 4way valve of Outdoor Unit. or connecting Cable 4 way valve should be replaced or connecting Cable Check. PCB should be replaced.
26 If Operation By Remote Control Unit Is Impossible. (Initial Diagnosis) ) Troubleshooting procedure Remove power cord and plug in again approx. 5 Seconds Is operation lamp blinking? sound heard from the indoor unit when ON/OFF button on the remote control unit pushed? Y N Y Check as in the procedure Power parts. Refer to page 52. Normal N Voltage of battery less than 2.5V (Remote Control Unit)? N LCD display status of REMOCON normal? Y Y N Replace battery. LCD is faulty. Transmission display lamp ( ) blinking when ON/OFF button on the remote control unit pushed? N Replace button. Y Voltage at PIN #0 of Remocon Micom change? Y Voltage at collecter of Q60 or Q602 change? Y N N Micom is faulty. Q60(C475Y) or Q602(C62Y) is faulty. IR LED(CLL5EU) is faulty. Voltage at pin #26 of micom (IC04) change (INDOOR UNIT)? Y Micom (IC04) is faulty. N Receiver module is faulty. 4
MEMO 5
4. Exploded Views and Parts List 4 Indoor Unit 8 86 8 86 84 85 6 24 8 82 7 2 4 4 5 0 2 8 20 25 22 9 9 2 6 5 7 4 2 2 6
Parts List No. CODE Description AQ2A5(6)MC Q TY AQ09A5(6)MA REMARK 2 4 5 6 7 8 9 0 2 2 4 5 2 2 4 4 5 6 7 8 8 82 8 84 85 86 86 9 20 2 22 2 24 25 DB6400085A DB600064A DB74000A DB600067A DB92000L DB670005A DB670002A DB60008A DB9400040E DB60200A DB0007A DB00072A DB200020A DB900255G DB900255H DB900267A DB900267D 00075 20008 500054 5020005 DB0900094A DB650000A DB900268E 2202000780 DB20007A DB90047A DB9400056A DB60062A DB60065A DB700006A DB9400058B DB940008A DB6600042A DB660028A DB660028B DB600082A DB95208A DB029A DB64025A DB676000A DB980494A DB7500020A DB944000A DB90025L DB70004A DB600226A GRILLE AIR INLET GUARDAIR FILTER FILTER CLEANER ASS Y COVER TEMINAL ASS Y PANEL SPACER EVAP LOW SPACER EVAP UP COVER U BEND ASS Y FAN CROSS(SF) BOLT SPECIAL MOTOR FAN IN THERMISTOR WIRE ASS Y ASS Y CONTROL IN ASS Y PCB MAIN IC EPROM IC PWM CONTROLLER RELAY MINIATURE SSR IC MCU TERMINAL BLOCK ASS Y ASS Y PCB DISPLAY C CERAMIC,MLCAXIAL MODULE REMOCON CONNECT WIRE PCB ASS Y BACK BODY(RIGHT SIDE) HOLDER MOTOR HOLDER PIPE PLATE HANGER ASS Y TRAY DRAIN(RIGHT SIDE) ASS Y DRAIN HOSE BLADE H BLADE V,A BLADE V,B SCREEN SAFETY WIRE ASS Y MOTOR STEPPING MOTOR STEPPING; GSP 24RW HOLDER SENSOR SPRING SENSOR EVAPORATOR ASS Y EVAPORATOR ASS Y ASS Y BEARING ASS Y REMOCON PLATEKCKOUT COVERTERMINAL BLOCK 2 6 2 6 7
42 Outdoor Unit UQ09A5(6)MA 2 22 7 9 20 8 6 9 82 8 85 8 5 4 0 6 8 84 8 82 7 7 4 2 5 2 8
Parts List No. CODE Description Specitication DB600086B GUARDFAN HSWR, IP2, 5&, SC9007T, NEW AP/J 70FAN Q TY UQ09A5(6)MA 2 DB600004A NUTFLALNGE 2C, M6, SM20C, NTR DB670006A FANPROPELLER AS+G/F20%, PI 75, BLK 4 DB0058G MOTORFAN OUT AMASS020ZREA, FAN OUT, 5V/60Hz 5 DB9000264A ASS Y FRAME (PAINT) SC9007T 6 DB9400078A ASS Y PARTITION ASS Y 620mm COND 7 DB9000077B ASS Y CABIUPPER ASS Y 8 DB900424A ASS Y CONTROL OUT ASS Y 8 2500020 COIL (COMP) 45µF, 70VAC 82 200079 COIL (MOTOR) 4.0µF, 450VAC 8 DB0042A ASS Y LEAD WIRE ASSY 84 DB2700004B SOLEID ASS Y RANCO, LB800 85 DB6540074A TERMINAL BLOCK 5P, N, L,, 2, 9 DB720045A CLOTHCOMP T8, 425, 225, 44F COMP 0 44B092HWEL ROTARY COMP Ph, 5V, 60Hz DB520066E PROTECTOR O/L MRA2092007 2 DB70004B GROMMETISOLATOR SILICON DB60008A NUTFLANGE PI0.8, M5, SM20C 4 DB620002A GASKET EPDM, TO.8 5 DB6065D COVERTERMINAL PBT 6 DB600028A NUTWASHER HEX, 2C, M8, ZPC 7 DB9600554A ASS Y TUBE CAPILLARY ID.5 x 00+/4 7 DB6200254B VALVESERVICE /4INCH 8 DB9900090D ASS Y VALVE 4WAY VK00B+/8 8 DB62008A TUBE4WAY VALVE BRASS, /8INCH, T.0, RANCO 82 DB624007B VALVESERVICE C77BD, 42L/H, /8, 0Kg/cm2G 9 DB7500029A ASS Y COND.5DFIN, COATTING 620mm 20 DB64607D CABINETSIDE SECCP, T 0.8, AP/J 2 DB6790024A HANDLECABI LF ABS 22 DB6044C COVERE, PARTS ASS Y SC9007R 9
UQ2A5(6)MC 9 20 8 7 0 7 6 5 85 4 8 6 8 82 2 86 84 86 88 85 87 8 2 5 9 22 4 2 20
Parts List (OUTDOOR UNIT) No. CODE Description Specitication DB60007A GUARD FAN HSER Q TY UQ2A5(6)MC 2 DB600004A NUT FLANGE 2C SM20C M6 NTR DB675006A PROPELLERFAN AS+G/F, Ø405 4 DB0058C MOTOR FAN OUT ASSO2OWTVA 5 DB9000272A ASS Y FRAME(PAINT) ASS Y 6 DB9450077A ASS Y PARTITION ASS Y 7 DB9000085B CABINET UPPER SECCP 8 DB900424E ASS Y CONTROL OUT ASS Y 8 25000226 CAPACITOR COMP 25µF 70VAC 82 200075 CAPACITOR MOTOR.5µF 450VAC 8 DB6540074A TERMINAL BLOCK 5P, N, L,, 2, 84 DB90042A ASS Y LEAD WIRE ASS Y 85 DB472000L O L P MRA20022008 86 DB6760020A O L P SPRING STS04 87 DB2700004B ASS Y SOLEIDE LB800 RANCO 88 DB200007A THERMOSTAT 250V, 7A 9 DB7250574D CLOTH COMP BOTTOM FELT 0 DB9900089A ASS Y 4WAY VALVE ASS Y 48A5IVEL COMPRESSOR 20820V 60Hz 2 DB70004B GROMMETISOLATOR SILICON DB600028A NUTWASHER HEX 2C MB ZPC 4 DB620002A GASKET EPDM 5 DB6065D COVER TERMINAL PBT 6 DB60008A NUTFLANGE M5, SM20C 7 DB96005A ASS YCAPILLARY ASS Y(.7 X00) 8 DB9600509A ASS Y COND ASS Y(SF) 9 DB64006C CABINET SIDE ASS Y(BENDING) 20 DB6790025A HANDLE CABI, RH ABS 2 DB72002A CLOTHCOMP SIDE FELT 22 DB950022A ASS YHEATER ASS Y 2
4 ASS Y CONTROL IN Parts List No Description Specification Remark HOLDER CONTROL ABS 2 ASS Y MAIN PCB AS09AME ASS Y TERMINAL BLOCK 4 ASS Y DISPLAY PCB AS09AME 5 CONNECTOR WIRE PCB U/D 6 BRACKET EARTH SGCCM 7 HOLDER WIRE CLAMP 8 CONNECTOR WIRE EARTH AWG#6 9 SCREW WP, TH + M4 L8, ZPC(WHT), T.C 0 SCREW PH, M L22 SCREW TH + M4 L6, ZPC(WHT), SWRCH 2 HOLDER CLAMP IN SEAL PANEL FRONT RH 4 SEAL H/CONTROL FRONT 22
5. Refrigerating Cycle Block Diagram INDOOR UNIT OUTDOOR UNIT Capillary tube T 2way valve Liquid side Heat exchanger (Evaporator) Cross fan Heat exchanger (Condenser) Propeller fan T2 Gas side way valve Compressor 4way valve Cooling Heating Gas leak check point Refrigerating cycle temperature and pressure STD Pressure Piping Temp.( F) Use Temp. Condition ( F) Operating Condition (psi) Indoor Outdoor WAY V/V T T2 DB WB DB WB Standard 70~74 48~5 48~5 80 67 95 75 Cooling Max over load 60~64 60~64 80 67 5 75 Low temp 4~9 4~9 67 57 67 57 Standard 248~287 99~0 4~55 70 60 47 4 Heating Max over load 00~09 40~60 80 75 65 Deice 85~95 07~20 70 60 5 2
6. Wiring Diagrams 6 Indoor Unit AQ09A5(6)MA AQ2A5(6)MC 24
62 Outdoor Unit UQ09A5(6)MA DIAGRAMOUTDOOR C : 4µF x 450VAC C2 : 45µF x 70VAC UQ2A5(6)MC DIAGRAMOUTDOOR C :.5µF x 450VAC C2 : 25µF x 70VAC 25
7. Schematic Diagrams 7 Indoor Unit AQ09A5(6)MA 26
AQ2A5(6)MC 27
ELECTRONICS Printed in Korea.