CONSUMER SERVICES TECHNICAL EDUCATION GROUP PRESENTS R-94 P MODEL AIR CONDITIONER JOB AID Part No. 8178039
FORWARD This Whirlpool Job Aid, P Model Air Conditioner (Part No. 8178039), provides the technician with information on the installation and service of the P Model Air Conditioner. It is to be used as a training Job Aid and Service Manual. For specific information on the model being serviced, refer to the Use and Care Guide, or Tech Sheet provided with the air conditioner. The Wiring Diagrams and Strip Circuits used in this Job Aid are typical and should be used for training purposes only. Always use the Wiring Diagram supplied with the product when servicing the unit. 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 the P Model Air Conditioner. The objectives of this Job Aid are to: Understand and follow proper safety precautions. Successfully troubleshoot and diagnose malfunctions. Successfully perform necessary repairs. Successfully return the air conditioner to its proper operational status. WHIRLPOOL CORPORATION assumes no responsibility for any repairs made on our products by anyone other than Authorized Service Technicians. Copyright 2001, Whirlpool Corporation, Benton Harbor, MI 49022 - ii -
TABLE OF CONTENTS Page GENERAL... 1-1 Safety First... 1-1 Electrical Power Supply & Grounding Requirements... 1-1 Weight Handling Requirements... 1-2 Electrostatic Discharge (ESD) Sensitive Electronics... 1-2 Whirlpool Model & Serial Number Designations... 1-3 Model & Serial Number Label Location... 1-4 Specifications... 1-5 Whirlpool Air Conditioner Warranty... 1-6 INSTALLATION INFORMATION... 2-1 COMPONENT ACCESS... 3-1 Component Locations... 3-1 Removing The Front Grille Assembly & Cabinet... 3-2 Removing The Control Panel & Display PCB... 3-4 Removing The Power Cord... 3-5 Removing The Thermistor, The Capacitor, & The Main PCB... 3-6 Removing The Fan Motor... 3-8 Removing The Overload Protector And The Compressor... 3-12 Removing The Evaporator... 3-14 Removing The Condenser... 3-16 COMPONENT TESTING... 4-1 Thermistor... 4-1 Line Fuse... 4-2 Capacitor... 4-2 Fan Motor... 4-3 Overload Protector... 4-4 Compressor... 4-4 WIRING DIAGRAMS... 5-1 Wiring Diagram (Models ACD052PK & ACM062PK)... 5-1 Wiring Diagram (Models ACQ052PK & ACQ062PK)... 5-2 - iii -
NOTES - iv -
GENERAL SAFETY FIRST Your safety and the safety of others is very important. We have provided many important safety messages in this Job Aid and on the appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word DANGER or WARNING. These words mean: You can be killed or seriously injured if you don t immediately follow instructions. You can be killed or seriously injured if you don t follow instructions. All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed. ELECTRICAL POWER SUPPLY & GROUNDING REQUIREMENTS Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. Electrical Shock Hazard Plug into a grounded 3-prong outlet. Do not remove ground prong. Do not use an adapter. Do not use an extension cord. Failure to follow these instructions can result in death, fire, or electrical shock. 1-1
Electrical Shock Hazard Connect green ground wire to ground screw. Failure to do so can result in death or electrical shock. WEIGHT HANDLING REQUIREMENTS Excessive Weight Hazard Use two or more people to move and install the air conditioner. Failure to do so can result in back, or other injury. ELECTROSTATIC DISCHARGE (ESD) SENSITIVE ELECTRONICS ESD problems are present everywhere. ESD may damage or weaken the electronic control assembly. The new control assembly may appear to work well after repair is finished, but failure may occur at a later date due to ESD stress. Use an antistatic wrist strap. Connect the wrist strap to a green ground connection point or unpainted metal in the appliance; or touch your finger repeatedly to a green ground connection point or unpainted metal in the appliance. Before removing the part from its package, touch the antistatic bag to a green ground connection point or unpainted metal in the appliance. Avoid touching electronic parts or terminal contacts. Handle the electronic control assembly by the edges only. When repackaging the failed electronic control assembly in an antistatic bag, observe the above instructions. 1-2
WHIRLPOOL MODEL & SERIAL NUMBER DESIGNATIONS MODEL NUMBER MODEL NUMBER A C Q 05 2 P K 0 PRODUCT GROUP: A = AIR CONDITIONER PRODUCT IDENTIFICATION: C = WARRANTY D = DEHUMIDIFIER O = ROOM A/C CABINETS MODEL TYPE: C = CASEMENT E = ELECTRIC PUMP H = HEAT PUMP M = VALUE SERIES P = PLUG-IN (7.5 AMPS OR LESS)(BEFORE 1999) P = PREMIUM / ELECTRONICS MODELS (AFTER 1998) Q = DESIGNER STYLE R = REVERSE CYCLE WITH ELECTRIC HEAT S = SLIDER U = THROUGH-WALL W = THROUGH-WALL (BUILT-IN) APPROXIMATE CAPACITY: (30,000 B.T.U. / HR. MAXIMUM) ELECTRICAL CODE: 2 = 115V, 60 HZ, 1 PHASE 3 = 230V, 60 HZ, 1 PHASE 4 = 230V-208V, 60 HZ, 1 PHASE 5 = 208V, 60 HZ, 2 PHASE FEATURE CODE: P MODEL YEAR OF INTRODUCTION: H = 1999. J = 2000, K = 2001 ENGINEERING CHANGE: 0, 1, 2, ETC. SERIAL NUMBER SERIAL NUMBER QL L 08 08012 MANUFACTURING RESPONSIBILITY YEAR OF PRODUCTION: K = 2000, L = 2001, M = 2002 WEEK OF PRODUCTION: 8th WEEK PRODUCT SEQUENCE NUMBER 1-3
MODEL & SERIAL NUMBER LABEL LOCATION The Model/Serial Number label location is shown below. Model & Serial Number Location 1-4
SPECIFICATIONS Model Number ACD052PK ACM062PK ACQ052PK ACQ062PK Ratings BTU - Cool 5000 6000 5200 6000 Energy Efficiency Rating # 9.7 9.7 9.7 9.7 Air Features Air Flow on Turbo (CFM) 140 140 140 140 Air Flow on Low (CFM) 115 115 115 115 Features Cooling Speed Selections 2 3 3 3 Timer-Clock (On/Off) No No Yes Yes Power Saver No No Yes Yes Fan Only Yes-1 Speed Yes-1 Speed Yes-3 Speed Yes-3 Speed Remote No No Yes Yes Electrical Volts 115 115 115 115 Frequency (Hz) 60 60 60 60 Amps (Cooling) 4.8 5.8 5.0 5.8 Fuse Size (Amps) 15 15 15 15 Power Cord Length (ft) - Cabinet to Wall 6 ft. 6 ft. 6 ft. 6 ft. Power Cord Length (m) - Cabinet to Wall 1.8 m. 1.8 m. 1.8 m. 1.8 m. Exterior Fan Control Rotary Rotary Electronic Electronic Thermostat Control Rotary Rotary Electronic Electronic Miscellaneous Warranty Full 1 Year 1 Year 1 Year 1 Year Full Sealed System 1 Year 5 Years 5 Years 5 Years 1-5
WHIRLPOOL AIR CONDITIONER WARRANTY LENGTH OF WARRANTY: FULL ONE-YEAR WARRANTY FROM DATE OF PURCHASE. FULL FIVE-YEAR WARRANTY FROM DATE OF PURCHASE. (THIS WARRANTY DOES NOT APPLY TO MODEL ACD052PK.) WHIRLPOOL WILL PAY FOR: Replacement parts and repair labor costs to correct defects in materials or workmanship. Service must be provided by a Whirlpool-designated service company. Replacement parts and repair labor costs to correct defects in materials or workmanship in the sealed refrigeration system. These parts are: 1. Compressor 2. Evaporator 3. Condenser 4. Accumulator 5. Conecting Tubing Service must be provided by a Whirlpool-designated service company. WHIRLPOOL WILL NOT PAY FOR: A. Service calls to: 1. Correct the installation of the air conditioner. 2. Instruct you how to use the air conditioner. 3. Replace house fuses or correct house wiring. 4. Clean or replace the air filter. B. Pickup and delivery. The air conditioner is designed to be repaired in the home. C. Damage to the air conditioner caused by accident, misuse, fire, flood, acts of God, or use of products not mentioned in the Use and Care Guide. D. The removal or reinstallation of the air conditioner if 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. Replacement parts or repair labor costs for units operated outside the United States or Canada. WHIRLPOOL CORPORATION SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUEN- TIAL DAMAGES. Some states or provinces do not allow the exclusion or limitation of incidental or consequential damages, so this exclusion or limitation may not apply to you. This warranty gives specific legal rights and you may also have other rights which vary from state-to-state or province-to-province. Outside the United States and Canada a different warranty may apply. For details, please contact your local Whirlpool dealer. If you need service, first see the Troubleshooting section of the Use & Care Guide. After checking Troublesooting, additional help can be found by checking the Requesting Assistance Or Service section, or by calling the Whirlpool 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 in the Use and Care Guide for the service branch in your area. 1-6
1. Open the window and mark the centerline of the inner sill. Inner Sill Room Centerline 2. Use two short screws, and attach the two L-brackets 8 from both sides of the centerline so they are flush against the back of the inner sill, with the short side of the bracket positioned vertically. Outer Sill Inner Sill INSTALLATION INFORMATION Short Screws INSIDE Centerline IMPORTANT NOTES: Make sure that you maintain a good grip on the air conditioner so that it does not fall out of the window opening during the installation. Make sure that you center the unit in the window so that the L-brackets mate with the bottom guides. If the unit is not centered properly, it could slide out of the opening. 3. Carefully lift the air conditioner, and center it in the window opening, then slide it into place so that the bottom guides drop into the two L-brackets you installed in step 2. 8 (20.3 cm) Window Frame 8 (20.3 cm) Upper Guide OUTSIDE L-Brackets Seal about 1/4 (6.3 mm) Excessive Weight Hazard Use two or more people to move and install the air conditioner. Failure to do so can result in back, or other injury. L-Bracket Bottom Guide 4. Lower the window sash so it is behind the upper guide of the air conditioner. NOTE: the back of the air conditioner should tilt down slightly, as shown above. 2-1
REMOVING THE AIR CONDITIONER FROM THE WINDOW Excessive Weight Hazard Use two or more people to move and install the air conditioner. Failure to do so can result in back, or other injury. 3. Close the guide panels. 4. Raise the window sash and carefully tilt the air conditioner backward to drain any condensate water in the base. 5. Lift the air conditioner from the window and remove the sash seal from between the windows. 1. Unplug the air conditioner or disconnect the power. 2. Remove the L brackets and screws that are installed through the top and bottom of the guide panels. L Bracket Short Screw Sash Seal Wood Screw 2-2
COMPONENT ACCESS This section instructs you on how to service each component inside the air conditioner. The components and their locations are shown below. COMPONENT LOCATIONS Capacitor Compressor Main PCB Overload Protector Condenser Control Panel & Display PCB Fan Motor Thermistor Evaporator 3-1
REMOVING THE FRONT GRILLE ASSEMBLY & CABINET b) Remove the screw from the grille assembly. Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. NOTE: Sharp edges may be present. 1. Unplug the air conditioner or disconnect the power. 2. Remove the air conditioner from the window (see page 2-2 for the procedure). 3. To remove the front grille: a) Pull out on the two indented areas on both sides of the grille to release the tabs from the clips, and open the grille as far as it will go. Screw Indent Clip & Tab c) Raise the grill and secure it. d) Pull out on both sides of the grille frame and unhook the tabs from the cabinet slots. Grille Frame Slot Pull Forward Pull Out Pull Grille Forward 3-2
e) Pull the bottom of the grille assembly out, unhook it at the top, and remove the assembly. c) Remove the five side screws and the four rear screws. Unhook Pull Out 2 Screws (3 On Other Side) 4 Screws 4. To remove the cabinet: a) Remove the four screws from both curtain frames. b) Slide the left and right curtain frame assemblies off the sides of the unit. d) Lift the cabinet off the unit. Slide Out 4 Curtain Frame Screws 3-3
REMOVING THE CONTROL PANEL & DISPLAY PCB 5. Push down on the top two clips of the control panel and unhook them from the chassis slots, then lift the panel assembly off the unit, and remove it. Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. Control Panel Clips NOTE: Sharp edges may be present. 1. Unplug the air conditioner or disconnect the power. 2. Remove the air conditioner from the window (see page 2-2 for the procedure). 3. Remove the grille assembly from the air conditioner (see page 3-2 for the procedure). 4. Press in on the locking arms and disconnect the two connectors from the display PCB. Connector (1 of 2) 6. Remove the two screws from the display PCB, unclip the board from the control panel, and remove the board. Screw Clips Screw Press In On Locking Arm Display PCB 3-4
REMOVING THE POWER CORD 7. Remove the top and bottom screws from the control panel brackets. Screw Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. NOTE: Sharp edges may be present. 1. Unplug the air conditioner or disconnect the power. 2. Remove the air conditioner from the window (see page 2-2 for the procedure). 3. Remove the grille assembly and cabinet from the air conditioner (see pages 3-2 and 3-3 for the procedures). 4. Remove the machine screw from the green ground wire. Wire Tie 8. Remove the screw from the power cord strain relief clamp and remove the clamp from the power cord. Strain Relief Screw Control Panel Screw Ground Wire Machine Screw Ribbed Power Cord Lead Smooth Power Cord Lead 5. Disconnect the ribbed power cord lead from the capacitor terminal and the smooth lead from the main PCB relay terminal. 6. Pull the two power cord leads and the green ground wire through the wire tie. NOTE: If the wire tie is too tight, you will have to cut it and install a new one around the wiring after you install the new cord. Electrical Shock Hazard Connect green ground wire to ground screw. Failure to do so can result in death or electrical shock. NOTE: Be sure to reinstall the ribbed power cord lead on the capacitor terminal, the smooth lead on the main PCB relay terminal, and the green ground wire to the ground screw. 3-5
REMOVING THE THERMISTOR, THE CAPACITOR, & THE MAIN PCB b) Disconnect the 4-wire connector from the main PCB at CN-TH1. NOTE: You may have to move some of the wire bundles out of the way to access the connector. Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. NOTE: Sharp edges may be present. 1. Unplug the air conditioner or disconnect the power. 2. Remove the air conditioner from the window (see page 2-2 for the procedure). 3. Remove the grille assembly and cabinet from the air conditioner (see pages 3-2 and 3-3 for the procedures). 4. To remove the thermistor: a) Unclip the thermistor from the front of the unit. Thermistor Connector CN-TH1 c) Pull the thermistor through the chassis hole and remove it. Unclip Thermistor 3-6
5. To remove the capacitor: a) Remove the two screws from the top and bottom of the control panel assembly. Screw (black) e) Disconnect the wires from the following capacitor terminals: Yellow wire to 2-lug terminal (FAN). Red wire to 3-lug terminal (HERM). Black, (2) orange, and ribbed power cord lead to 4-lug terminal (C). Control Panel 4-Lug Terminal (C) 2-Lug Terminal (FAN) 3-Lug Terminal (HERM) Screw b) Pull the housing out the unit and position it as shown below. Fan Motor Connector Strap Capacitor 6. To remove the main PCB: a) If not already done, remove the capacitor (see step 5). NOTE: It is not necessary to perform step 5e. b) Remove the three screws from the main PCB. 4-Wire Connector Screw (1 of 3) Blue Wire & Smooth Power Cord Lead c) Discharge the capacitor by touching one lead of a 20,000 Ω resistor to the common (C) terminal, and the other lead to each of the other two terminals (marked FAN & HERM next to the terminals). d) Slide the capacitor out of the mounting strap. 6- & 11-Wire Connectors c) Disconnect the following connectors from the main PCB: Fan motor connector (see the photo to the left for the location). 6- & 11-wire connectors (brown wires). 4-wire connector (from thermistor). Smooth power cord lead from lug 3 and blue wire from lug 4 of the relay. d) Unclip the PCB from the holder. 3-7
REMOVING THE FAN MOTOR 5. Remove the two screws from the top air guide cover and remove the cover. Screw Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. Top Air Guide Cover NOTE: Sharp edges may be present. 1. Unplug the air conditioner or disconnect the power. 2. Remove the air conditioner from the window (see page 2-2 for the procedure). 3. Remove the grille assembly and cabinet from the air conditioner (see pages 3-2 and 3-3 for the procedures). 4. Remove the top and bottom screws from the control panel brackets and unclip the thermistor from the front of the evaporator, then move the control panel assembly out of the chassis pan. Screw Control Panel Screw 6. Lift both ends of the evaporator out of the front air guide and pull the right side out so you can access the cover behind it. NOTE: Be careful not to bend the bottom of the fins on the evaporator when you handle it. Evaporator Front Air Guide Cover Screw Pull Out Unclip Thermistor Lift Evaporator Out Of Guide 3-8
7. Unhook the right side of the front air guide cover from the front air guide, then lift the cover out of the guides on both sides, push the left side out so that it unhooks, and remove the cover. 10. Remove the screw from the left side of the rear air guide, and unhook the two tabs from the condenser slots on the right side. Rear Air Guide Front Air Guide Unhook Unhook Front Air Guide Cover Screw Condenser Unhook Lift From Guide 8. Pull the blower off the front shaft of the fan motor. NOTE: It may be necessary to remove the ring clamp if the blower cannot easily be removed. If so, use a pair of pliers and squeeze the ring tabs together, and pull it off the hub. 11. Remove the two screws from the front air guide. Blower Pull Out Ring Clamp Front Air Guide Screws 12. Slide the front air guide assembly toward the back of the unit until the left and right side keys clear the slots in the chassis pan. Lift the air guide assembly, and pull it forward over the edge of the pan just enough to allow access to the fan motor mounting screws. 9. Carefully reposition the evaporator back inside the front air guide in its normal mounting position to protect it during the rest of the procedure (see step 6). Slide Back Lift Front Air Guide Assembly Key Chassis Pan Slot (Each Side) 3-9 Continued on the next page
13. Carefully push on the center hub and slide the fan off the rear shaft of the fan motor, then remove the fan and the rear air duct (the duct is removed in the photo below). Be careful not to damage the fins on the condenser assembly. 15. Disconnect the fan motor connector from the capacitor wire connector. Capacitor Connector Fan Motor Connector Slide Back 16. Remove the two black mounting screws from the fan motor brackets and remove the motor. 17. Remove the green ground wire from the fan motor bracket. Screw Condenser Fan 14. Remove the ring clip from the fan hub with a pair of pliers. Screw Green Ground Wire 3-10
FAN MOTOR REINSTALLATION NOTES: Electrical Shock Hazard Connect green ground wire to ground screw. Failure to do so can result in death or electrical shock. 3. Note that the fan hub hole has a key inside it. Position this key over the flat of the motor shaft, and slide the fan onto the shaft until the end is approximately 1/4 from the outside of the fan hub hole. 4. Squeeze the tabs on the ring clip and slide the clip over the fan hub. 5. Install the blower on the front fan motor shaft as far as the stop at the end of the hub opening, then install the ring clip over the hub. 1. Make sure that you reconnect the green ground wire to the same bracket location as before (next to the power cable). 2. Position the fan motor as shown in the photo at the bottom of the previous page, and mount the motor to the front air guide with two black screws. 3-11
REMOVING THE OVERLOAD PROTECTOR AND THE COMPRESSOR b) Disconnect the brown wire from the compressor terminal, and the blue wire from the overload protector terminal. Brown Wire Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. NOTE: Sharp edges may be present. 1. Unplug the air conditioner or disconnect the power. 2. Remove the air conditioner from the window (see page 2-2 for the procedure). 3. Remove the grille assembly and cabinet from the air conditioner (see pages 3-2 and 3-3 for the procedures). 4. To remove the overload protector: a) Remove the hex cap nut and the nylon flat washer from the terminal cover and remove the cover. Compressor Terminals Overload Protector Blue Wire REASSEMBLY NOTE: When you reinstall the terminal cover on the compressor, make sure that the overload protector is centered in the gasket hole, and does not sit on any portion of the gasket. 5. To remove the compressor: a) Remove the overload protector (see step 4). b) Disconnect the red wire from the S (V) terminal and the black wire from the R (U) terminal of the compressor. c) Remove the gasket. Hex Cap Nut & Nylon Flat Washer Terminal Cover Black Wire Red Wire Compressor Terminals Gasket 3-12
d) Braze on an access valve and discharge the sealed system refrigerant into a refrigerant recovery bag. e) Disconnect the high side line from the compressor, and the suction line from the accumulator. High Side Line To Compressor Suction Line To Accumulator g) Lift the compressor off the three rubber shock mounts. Rubber Shock Mount f) Remove the three 1/2 hex nuts and bracket washers. 1/2 Hex Nut Bracket Washer (1 of 3) 3-13
REMOVING THE EVAPORATOR 5. Pull the mounting clip off the evaporator tubing and reinstall it on the new evaporator at the same location. Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. Remove Clip NOTE: Sharp edges may be present. 1. Unplug the air conditioner or disconnect the power. 2. Remove the air conditioner from the window (see page 2-2 for the procedure). 3. Remove the grille assembly and cabinet from the air conditioner (see pages 3-2 and 3-3 for the procedures). 4. Remove the thermistor from the mounting clip. 6. Braze on an access valve and discharge the sealed system refrigerant into a refrigerant recovery bag. 7. Remove the foam insulation from around the evaporator tubing. Foam Insulation Unclip Thermistor 3-14
8. Measure the new evaporator inlet and outlet tubes, and cut the existing lines to the proper length. 9. Lift the evaporator out of the front air duct. NOTE: Make sure that when you install the new evaporator the small tabs seat properly in the air duct guides on both sides. Evaporator Pull Out Lift Evaporator Out Of Guide 3-15
REMOVING THE CONDENSER 5. Measure the new condenser inlet and outlet tubes, and cut the existing lines to the proper length. 6. Remove the screw from the left side of the rear air guide, and unhook the two tabs from the condenser slots on the right side. Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. NOTE: Sharp edges may be present. 1. Unplug the air conditioner or disconnect the power. 2. Remove the air conditioner from the window (see page 2-2 for the procedure). 3. Remove the grille assembly and cabinet from the air conditioner (see pages 3-2 and 3-3 for the procedures). 4. Braze on an access valve and discharge the sealed system refrigerant into a refrigerant recovery bag. Rear Air Guide Unhook Screw Condenser Unhook 7. Remove the two condenser mounting screws from the rear of the chassis pan. Screw Chassis Pan Screw 8. Remove the condenser from the unit. 3-16
Before testing any of the components, perform the following checks: The most common cause for control failure is corrosion on connectors. Therefore, disconnecting and reconnecting wires will be necessary throughout test procedures. All tests/checks should be made with a VOM or DVM having a sensitivity of 20,000 ohmsper-volt DC, or greater. Check all connections before replacing components, looking for broken or loose wires, failed terminals, or wires not pressed into connectors far enough. Resistance checks must be made with power cord unplugged from outlet, and with wiring harness or connectors disconnected. Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. COMPONENT TESTING THERMISTOR Thermistor Connector Test @ Pins 1 & 2 Refer to page 3-6 for the procedure for servicing the thermistor. 1. Unplug the air conditioner or disconnect the power. 2. Disconnect the thermistor 4-wire connector at CN-TH1. 3. Insert two small test wires into pins 1 and 2 of the thermistor connector. 4. Set the ohmmeter to the R x 1K scale. 5. Clip the ohmmeter test leads to the test wires. 6. The meter should indicate approximately 1100 Ω at approximately 70 F. 4-1
Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. LINE FUSE CAPACITOR Main PCB Line Fuse Refer to page 3-6 for the procedure for servicing the main PCB. 1. Unplug the air conditioner or disconnect the power. 2. Discharge the capacitor by touching one lead of a 20,000 Ω resistor to the common (C) terminal, and the other lead to each of the other two terminals (marked FAN & HERM next to the terminals). 3. Set the ohmmeter to the R x 1 scale. 4. To test the line fuse, touch the ohmmeter test leads to the fuse clips. 5. The meter should indicate continuity (0 Ω). NOTE: If the fuse is open, check the fan motor windings (refer to page 4-3) to see if the motor is defective. 6. Replace the main PCB if there is no output to the fan motor or compressor. Refer to page 3-6 for the procedure for servicing the capacitor. 1. Unplug the air conditioner or disconnect the power. 2. Discharge the capacitor by touching one lead of a 20,000 Ω resistor to the common (C) terminal, and the other lead to each of the other two terminals (marked FAN & HERM next to the terminals). 3. Disconnect the wires from the capacitor terminals. 4. Set the ohmmeter to the R x 1K scale. 5. Touch one of the ohmmeter test leads to the common (C) terminal and the other test lead to the FAN and HERM terminals. 6. The meter should indicate several ohms and gradually return to infinity at both the FAN & HERM terminals. 4-2
Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. FAN MOTOR 3. Set the ohmmeter to the R x 100 scale. 4. Clip one of the ohmmeter test leads to the orange wire terminal and leave it there. 5. Touch the free ohmmeter test lead to the yellow wire terminal. The meter should indicate approximately 205 Ω. Black Refer to page 3-8 for the procedure for servicing the fan motor. 1. Unplug the air conditioner or disconnect the power. 2. Disconnect the fan motor connector from the capacitor wiring. Red Orange Blue Yellow 6. Touch the free test lead to the following wire color terminals. The meter should indicate (approximate) as shown: Black wire (high) = 100 Ω Blue wire (medium) = 125 Ω Red wire (low) = 135 Ω Fan Motor Connector 4-3
Electrical Shock Hazard Disconnect power before servicing. Replace all panels before operating. Failure to do so can result in death or electrical shock. OVERLOAD PROTECTOR COMPRESSOR Compressor Terminals Refer to page 3-12 for the procedure for servicing the overload protector. 1. Unplug the air conditioner or disconnect the power. 2. Discharge the capacitor by touching one lead of a 20,000 Ω resistor to the common (C) terminal, and the other lead to each of the other two terminals (marked FAN & HERM next to the terminals). 3. Disconnect the overload protector wires. 4. Set the ohmmeter to the R x 1 scale. 5. Touch the ohmmeter test leads to the overload protector terminal and connector. 6. The meter should indicate continuity (0 Ω). Blue R (U) C (W) Black S (V) Red Refer to page 3-12 for the procedure for servicing the compressor. 1. Unplug the air conditioner or disconnect the power. 2. Disconnect the three wires from the compressor terminals. 3. Set the ohmmeter to the R x 1 scale. 4. Clip an ohmmeter test lead to the overload protector terminal C (W). 5. Touch the free test lead to the following compressor terminals. The meter should indicate as shown: Terminal R (U) = 2.5 Ω Terminal S (V) = 4.8 Ω 4-4
WIRING DIAGRAMS WIRING DIAGRAM (MODELS ACD052PK & ACM062PK) POWER INPUT BK (BR) (SMOOTH) WH (BU) (RIBBED) ROTARY SWITCH GND (GN/YL) 1 2 H BK BK 3 5 7 4 6 8 L M RD BU RD BU OR (BR) FAN MOTOR YL CAPACITOR YL F OR (BR) C BR COMP. R C S BK RD BK RD BR BU BU H OVERLOAD PROTECTOR THERMOSTAT 5-1
WIRING DIAGRAM (MODELS ACQ052PK & ACQ062PK) POWER INPUT R COMPRESS S C FAN MOTOR CAPACITOR C F H OR (BR) RD OR BK BK RD BK BU RD YL BR BU BU OVERLOAD PROTECTOR WH (BL) (RIBBED) BK BU RD OR (BR) YL BK RD BK (BR) (SMOOTH) GND (GN/YL) THERMISTOR CN-RD MAIN PCB ASM. CN-WOR CN-BL CN-BK RY-L RY-M RY-H ZNR01J RY-COMP CN-TH1 CN-SYNC CN-DISP1 CN-DISP2 TRANSFORMER LINE FUSE, 125V, 2A DISPLAY PCB ASM. 5-2
PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION SOURCES IN THE UNITED STATES: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL: FOR WHIRLPOOL PRODUCTS: 1-800-253-1301 FOR KITCHENAID PRODUCTS: 1-800-422-1230 FOR ROPER PRODUCTS: 1-800-447-6737 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-253-2870 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED SERVICER FOR LITERATURE ORDERS: PHONE: 1-800-851-4605 IN CANADA: FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL: 1-800-461-5681 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL: THE TECHNICAL ASSISTANCE LINE: 1-800-488-4791 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED SERVICER
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