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Room Air Conditioner
Service and Parts
Manual
KP Line
KP05A10 KP06A10
KP05 / KP06 (03/03)
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CONTENTS 1. PREFACE ...................................................................................................................................................3 1.1 FEATURES.....................................................................................................................................................3 1.2 SPECIFICATIONS .........................................................................................................................................3 1.3 LOCA
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1. PREFACE This service manual provides various service information, including the mechanical and electrical parts, etc. This room air conditioner was manufactured and assembled under a strict quality control system. The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit. 1.1 FEATURES • DESIGNED FOR COOLING ONLY • POWERFUL AND INCREDIBLE COOLING • TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE • BUILT-IN ADJUSTABLE THERMOSTAT
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1.3 LOCATIONS OF CONTROLS 1 TEMPERATURE SETTING • These buttons control the temperature of the room. The temperature can be set within a range of 60°F to 86°F, in increments of 1°F. 2 MONEY SAVER The fan stops when the compressor stops cooling. 1 • Approximately every 3 minutes the fan will turn on and sample the room air to determine if more cooling is needed. 2 3 OPERATION MODE SELECTOR 3 • Everytime you push this button, it will rotate between the COOL, FAN and DRY modes. 4 ON/OFF TIMER 4
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2. DISASSEMBLY INSTRUCTIONS 2.1 MECHANICAL PARTS 2.1.1 FRONT GRILLE Figure 1 1. Pull the inlet grille forward. 2. Remove the screw securing the Front Grille. (Fig. 3) 3. Push the grille up from the bottom and pull the top of the grille away from the case to lift the top tabs out of their slots. (Fig. 4) 4. Carefully position the grille, bottom first, and snap back into place. 5. Reposition the screw that secures the front grille and replace the knobs. Figure 2 2.1.2 CABINET 1. Disconnect the u
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Figure 6 2.2 AIR HANDLING PARTS 2.2.1 AIR GUIDE UPPER 1. Disconnect the unit from the power source. 2. Remove the front grille. (Refer to Section 2.1.1) 3. Remove the cabinet. (Refer to Section 2.1.2) 4. Remove the control board. (Refer to Section 2.1.3) 5. Remove 2 screws that secure the air guide upper to air guide lower. (See Figure 6) 6. Lift air guide upper upward. 7. Re-install by referring to the procedures above. Figure 7 2.2.2 ORIFICE, TURBO FAN AND FAN 1. Disconnect the unit fro
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2.2.3 MOTOR Figure 10 1. Disconnect the unit from the power source. 2. Remove the front grille. (Refer to Section 2.1.1) 3. Remove the cabinet. (Refer to Section 2.1.2) 4. Remove the control board. (Refer to Section 2.1.3) 5. Remove the air guide upper. (Refer to Section 2.2.1) 6. Remove the compressor, turbo fan, fan and shroud. (Refer to Section 2.2.2) 7. Remove 2 screws that secure the motor to the motor. (See Figure 10) 8. Remove the motor. 9. Re-install by referring to the procedures ab
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2.3.2 COMPRESSOR Figure 14 1. Remove the front grille and cabinet. (Refer to Section 2.1) 2. Discharge the refrigerant by using a refrigerant recovery system. 3. Remove the overload protector. (Refer to Section 2.3.1) 4. After discharging the unit completely, unbrace the suction and discharge pipes at the compressor connections. 5. Remove 3 nuts which fasten the compressor. 6. Remove the compressor. 7. Re-install by referring to the removal procedure above. (See Figure 14) 2.3.3 CAPACITOR 1.
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Figure 18 2.3.6 POWER CORD 1. Disconnect the unit from source of power. 2. Remove the front grille. (Refer to Section 2.1.1) 3. Remove the cabinet. (Refer to Section 2.1.2) 4. Remove a screw that secures control board to base pan. (Refer to Section 2.1.3) 5. Pulls the control board toward you. 6. Disconnect the 2 receptacles and remove the grounding screw. 7. Remove a screw securing the clip with cord to the control board. 8. Pull the power cord. 9. Re-install by referring to procedures above.
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wise. This will keep oil from foaming and being 2.4.2 EVAPORATOR drawn into the vacuum pump. 1. Remove the cabinet. 2. Discharge the refrigerant by using a refrigerant 6-3. Operate the vacuum pump for 20 to 30 min- recovery system. utes, until 600 micron vacuum is obtained. 3. Remove the air guide upper. (Refer to Section Close valves A and B and observe vacuum 2.2.1) gauge for a few minutes. 4. After discharging the refrigerant completely, A rise in pressure would indicate a possible unbraze
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Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment, pinch-off tool capable of making a vapor proof seal, leak detector, tubing cutter, hand tools to remove components and service valve. COMPOUND GAUGE MANIFOLD GAUGE B A CONDENSER SEE INSETS (HIGH PRESSURE SIDE) BELOW COMPRESSOR EVAPORATOR (LOW PRESSURE SIDE) CAPILLARY TUBE LO HI CHARGING CYLINDER A A B B EXTERNAL VACUUM PUMP C Figure 21A-Pulling Vacuum Figure 21B-Charging —11—
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3. INSTALLATION This air conditioner is designed with a button-down chassis so it can be easily installed in a window. 3.1 SELECT THE BEST LOCATION 1. To prevent vibration and noise, make sure the unit is installed securely and firmly. 2. Install the unit where the sun does not shine directly INSIDE OUTSIDE on the unit. FENCE AWNING 3. The outside of the cabinet must extend outward for at least 10" and there should be no obstacles, such as a COOLED AIR fence or wall, within 20" from the back
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CENTER LINE ROOM SIDE Installation HARDWARE TYPE A: 11EA TYPE B: 5EA TYPE C: 3EA (SHORT SCREW) (WOOD SCREW) (L BRACKET) TYPE D: 1EA TYPE E: 1EA TYPE F: 2EA TYPE G: 1EA (SEAL STRIP) (SASH SEAL) (GUIDE PANEL) (SUPPORT BRACKET) (Adhesive backed) (Not adhesive backed) 3.2.2 BEFORE INSTALLATION 1. Insert the guide panels into the guides of the air condi- tioner. Fasten the curtains to the unit with screws (TYPE TYPE A A) as shown Figure. 25. 2. Cut the adhesive-backed seal strip (TYPE D) to the windo
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3. INSTALL THE AIR CONDITIONER IN THE WINDOW INNER SILL a. Carefully lift the air conditioner and slide it into the TYPE A OUTER SILL INSIDE open window. Make sure the bottom guide of the air CENTER LINE conditioner drops into the notches of the L bracket. See Figure. 28. 8" SHORT SIDE 8" OUTSIDE Figure 28 L BRACKET IMPORTANT : When the air conditioner drops into the L bracket, the air conditioner will be centered in window opening as shown in Figure. 29. b. While steadying the air conditioner,
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REMOVAL FROM WINDOW Turn the air conditioner off, disconnect the power cord, remove the L bracket and the screws installed through the top and bot- tom of the guide panels, and save for reinstallation later. Close the guide panels. Keeping a firm grip on the air conditioner, raise the sash, and carefully tilt the air conditioner backward, draining any condensate water. Lift the air conditioner from the window and remove the sash seal from between the windows. 3.3 ELECTRICAL DATA Line Cord Plug U
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4.2 PIPING SYSTEM CONDENSER COILS FAN MOTOR CAPILLARY TUBE TURBO FAN EVAPORATOR COILS Following is a brief description of the important components and their function in what is called the refrigeration system. Reference should be made to Figure 32 to follow the refrigerating cycle and the flow of the refrigerant in the cooling cycle. ROOM AIR CONDITIONER CYCLE OF REFRIGERATION EVAPORATOR COILS CONDENSER COILS VAPOR INLET SUCTION LINE HOT COMPLETE LIQUID COOL LOW PRESSURE VAPOR DISCHARGED BOIL
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4.3 TROUBLESHOOTING GUIDE In general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused by an electrical defect. The other is Ineffective Air Con- ditioning caused by a defect in the refrigeration circuit and improper application. Unit is running but cooling is ineffective. Ineffective Cooling Check cold air Check outdoor coil Check heat load circulation for smooth (heat exchanger) and increase. flow. fan operation. Clean condenser. Dirty i
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Fails to Start Check of circuit breaker Check of power source. and fuse. Check of control switch Gas leakage of feeler setting. bulb of thermostat. Check control switch. Compressor fails only to Fan only fails to start. start. Improper wiring. Improper thermostat Drop of power voltage. setting Defect of fan motor capacitor. Defect of compressor Loose terminal capacitor. connection Irregular motor resistance (Ω ) Capacitor check. Improper wiring Irregular motor insulation (
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ROOM AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM MAXIMUM 115V ± 10% 103.5V 126.5V COMPLAINT CAUSE REMEDY Fan motor will not run. No power Check voltage at outlet. Correct if none. Power supply cord Check voltage to rotary switch. If none, check power supply cord. Replace cord if circuit is open. Wire disconnected or Connect wire. Refer to wiring diagram for connection loose terminal identification. Repair or replace loose terminal. Capacitor (Discharge Test capacitor. capa
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COMPLAINT CAUSE REMEDY Fan motor noise. Fan If cracked, out of balance, or partially missing, replace it. Blower If cracked, out of balance, or partially missing, replace it. Loose set screw Tighten it. Worn bearings If knocking sounds continue when running or loose, replace the motor. If the motor hums or noise appears to be internal while running, replace motor. Compressor will not run, Voltage Check voltage. See the limits on the preceding fan motor runs. page. If not within limit
