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Amana RS4100004, Service

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Amana RS4100004 Service Download Page 35

35

       RS4100004  Rev. 0

Disassembly Procedures

!

WARNING

To avoid risk of electrical shock, personal injury, or death, disconnect electrical power source to unit and
discharge capacitor through a 10,000 ohm resistor before attempting to service, unless test procedures require
power to be connected. Ensure all ground wires are connected before certifying unit as repaired and/or
operational.

Front Frame Removal

To remove front frame:

1. Remove horizontal insert and air filter (see paragraph

Horizontal Insert (Front Grille) and Air Filter
Removal).

2. Remove 

TEMPERATURE CONTROL and FAN

CONTROL knobs from control panel.

3. Remove four ¼-inch screws securing front frame to

air conditioner chassis.

4. Pull front frame out and away from air conditioner.

Front Frame Removal

Front
frame

Control
knobs

Outer Case Removal

To remove outer case:

1. Remove front frame (see paragraph 

Front Frame

Removal).

2. Remove ¼-inch screw securing retaining clamp to

chassis.

3 Slide (pull) air conditioner chassis out of outer case

assembly.

NOTE: New air conditioners are shipped with packing

material (rigid foam/plywood blocks) on inside of
unit to prevent damage during shipment.
Remove packing material before operating unit.

Outer Case Removal

Outer case

Retaining
clamp

Summary of Contents for RS4100004

Page 1: ...on on Compact Quiet Zone Room Air Conditioners Refer to individual technical sheets for information on specific models This manual to be used by qualified appliance technicians only Amana does not assume any responsibility for property damage or personal injury for improper service procedures done by an unqualified person ...

Page 2: ... Overload Protector Removal 39 Compressor Removal 40 Evaporator Indoor Coil Removal 41 Important Information Important Notices for Consumers and Servicers 3 Recognize Safety Symbols Words and Labels 3 Important Safety Information General Information 4 Related Publications 4 General Precautions and Warnings 4 Product Identification Design Information 5 Sizing Instructions Sizing Room Air Conditione...

Page 3: ... be responsible for any injury or property damage from improper service procedures If performing service on your own product assume responsibility for any personal injury or property damage which may result DANGER DANGER Immediate hazards which WILL result in severe personal injury or death WARNING WARNING Hazards or unsafe practices which COULD result in severe personal injury or death CAUTION CA...

Page 4: ...per servicing make sure you read and understand the descriptions and meaning of various safety symbols words and labels used in this manual before attempting any procedures described in the manual Failure to understand and comply with safety information may result in severe personal injury or death General Information This Service Manual describes the operation disassembly troubleshooting and repa...

Page 5: ...ed on polyester Acoustical and thermal insulation are used on the partition panel and in the air discharge plenum to reduce noise and increase efficiency Product Identification Large evaporator and condenser coils are designed to provide maximum heat transfer Coils are manufactured from rifled copper tubing and rippled edge aluminum fins to achieve maximum heat transfer Vibration loops in refriger...

Page 6: ...person If average is one person subtract 600 Btu hour Add 1200 Btu hour if area includes a kitchen If room is heavily shaded subtract 10 percent from capacity Increase capacity by 10 percent if area is very sunny Note For best results select a room air conditioner with cooling capacity Btu hour rating closest to but not exceeding estimated size Sizing Instructions Sizing Room Air Conditioners for ...

Page 7: ... or ground circuit A fuse in the neutral or ground circuit could result in an electrical shock DO NOT use an extension cord with this appliance Observe all local codes and ordinances Grounding Instructions For safety air conditioner must be grounded This air conditioner has a power supply cord with a three prong grounding plug To minimize possible electrical shock hazards the power cord must only ...

Page 8: ...coils Make sure air conditioner does not fall during installation Do not use condensate water for drinking or cooking It is not sanitary Tools Required The following tools are required for installation Flat head screwdriver Phillips head screwdriver Carpenter s level Tape measure Electric or hand drill 9 64 inch drill bit General Through Wall Installation for Slide Out Chassis Model Amana Room Air...

Page 9: ...e inside opening with decorative molding If molding is used mount case in opening so inside edge of case extends inch beyond molding Case should extend into room to compensate for thickness of molding When wall thickness exceeds 10 inches provisions must be made to allow air to enter the condenser side louvers See paragraph Installation in Walls Exceeding 10 inches 24 Appropriate grounded power ou...

Page 10: ...d by chamfering the vertical portions of the outside opening as shown Mortar Caulk Inside wall Outside wall Air intake louvers Wall stud or framing 1 2 4 101 2 4 Walls Exceeding 10 inches Top View Caulk all sides Lintel and flashing if required Wall stud or framing Optional molding not provided Outer case must project a minimum beyond inside wall or molding to attach front frame 10 Front of outer ...

Page 11: ...nditioner is cooling When control is in EXHAUST position damper is open When open room air is exhausted vented outside Use exhaust position to remove stale or smoky air from area NOTE To conserve energy air conditioner should not be in cooling mode when using exhaust feature Fan Control The FAN CONTROL operates the fan motor On touch control panels select desired setting by pressing appropriate to...

Page 12: ... an extended period of time Temperature Control The TEMPERATURE CONTROL is used to set and adjust level of cooling The higher control is set the cooler room or area being cooled becomes NOTE TEMPERATURE CONTROL setting does not affect how quickly a room is cooled it only determines how cool a room becomes Setting control to its maximum setting will not cool a room faster Control settings of 3 and ...

Page 13: ...roperly grounded wall receptacle in accordance with the National Electrical Code WARNING To avoid risk of personal injury or death due to electrical shock DO NOT under any circumstances alter the grounding plug Air conditioner must be grounded at all times Do not remove warning tag from power cord NOTE Unplug air conditioner if it is to be turned off for an extended period of time 4 Make sure VENT...

Page 14: ...connect electrical power to unit before attempting to service the unit Horizontal Insert The horizontal insert front grille is removable to access air filter To remove horizontal insert grasp bottom center of insert then lift up and pull out Clean insert and cabinet with a sponge and soapy water After cleaning thoroughly remove all cleaner residue and ensure unit is completely dry before reinstall...

Page 15: ...its and components and direct wiring of compressor Accurate leak detector to check for refrigerant leaks Vacuum pump capable of removing all non condensables in sealed system Charging manifold and related equipment to determine and replenish exact refrigerant charges Recovery cylinder and related equipment to recover and store refrigerant charge in sealed system Additional tools and equipment may ...

Page 16: ...acitor faulty Check capacitor for open short Replace if faulty NOTE Discharge capacitor before testing Fan motor faulty Check fan motor windings for shorts opens Replace if faulty Electronic control faulty Ensure all control connections are tight and secure Check control for proper operation Replace if faulty NOTE Eliminate all other possible causes before replacing electronic control Fan blade wi...

Page 17: ...r position Reposition if necessary Ensure hardware attaching fan blade blower wheel to motor shaft is tight Tighten if loose replace if stripped Worn fan motor bearings Check bearings for wear loss of lubricant Replace motor if either condition found Fan motor mounting hardware bracket Check mounting bolts bracket loose or grommets worn if applicable for tightness Tighten if necessary Inspect grom...

Page 18: ...ossible causes before replacing electronic control Compressor cycles on and off Wire s disconnected or loose Ensure all connections are tight and secure Correct as required Supply voltage out of specification Check input voltage for proper levels Take appropriate action if voltage levels out of specification Overload protector open Check protector for continuity If open replace NOTE Ensure compres...

Page 19: ...ion Ensure vent control in closed vent door stuck open position when unit is cooling consumer education Check vent door for proper operation Replace repair as required Unit undersized for area room Reduce area being cooled or replace unit with larger capacity model Excessive noise Outside coil fan blade or inside coil Check fan blade blower wheel blower wheel loose or improperly aligned for proper...

Page 20: ...ernal noise Inspect compressor for proper operation Replace as required Excessive condensate in base Unit operating under excessive humidity Remove condensate drain pan conditions plug in base pan NOTE Removal of plug may result in slight decrease in cooling efficiency Removal not recommended if excessive humidity is temporary and infrequent condition for area No cooling Low refrigerant charge or ...

Page 21: ...open shorts Check compressor seals Perform compressor direct wiring test Replace compressor if faulty Wattage continuously high Refrigerant overcharge Test sealed system for proper charge Repair as required Evaporator coil partially frosted System low on refrigerant Test sealed system for proper charge Ensure system is free of leaks Repair as required Restricted capillary tube Replace capillary tu...

Page 22: ... Frequent blown fuses or tripped circuit breakers Premature failure of compressor or fan motor Noticeable dimming of lights when unit is operating Evaporator icing caused by reduced fan speed Common causes for low voltage include inadequate supply circuit wiring use of extension cords and loose fuses or connections in fuse box circuit breaker or distribution panel NOTE A good indication of voltage...

Page 23: ... or dead short 0 ohms replace compressor NOTE Motor windings typically have very little resistance When checking windings for shorts ensure ohmmeter is set on lowest scale Good windings may indicate as little as 2 ohms of resistance Ground Test 1 Disconnect power to unit 2 Discharge capacitor by shorting capacitor terminals through a 10 000 ohm resistor 3 Remove leads from compressor terminals 4 S...

Page 24: ... securely 7 Plug test cord into outlet then press and release start cord switch CAUTION To avoid damage to compressor windings immediately disconnect unplug test cord from power source if compressor does not start Damage to compressor windings occurs if windings remain energized when compressor is not running If compressor runs when direct wired it is working properly Malfunction is elsewhere in s...

Page 25: ...istance or if any continuity is indicated between motor frame and windings When replacing fan motor Replacement fan motor must be installed with motor leads below level of motor shaft Drip loop in motor leads must be below wire openings in motor housing Coat exposed areas of shaft from blower wheel or fan blade to end of shaft with Cosmoline or equivalent to prevent corrosion Ensure evaporator blo...

Page 26: ... must be disassembled cleaned and rebrazed Capture refrigerant charge if system is charged unbraze joint clean all parts then rebraze If leak is detected in tubing replace tubing If leak is detected in either coil replace faulty coil Brazing CAUTION To reduce risk of personal injury or property damage take necessary precautions against high temperatures required for brazing Satisfactory results re...

Page 27: ...f temperature drop if restriction is severe frost may form at point of restriction and extend down in direction of refrigerant flow in system Go to step 4 3 Turn unit off and time how long it takes high and low pressure gauges to equalize If pressure equalization takes longer than 7 minutes a restriction exists in the capillary tube strainer Go to step 4 If pressure equalization takes less than 7 ...

Page 28: ...uple vacuum gauge and charging cylinder as shown in illustration 2 Connect low side line to compressor process tube 3 Connect high side line to process tube of liquid line strainer NOTE If a compression or flare fitting cannot be attached to process tube s and still leave room for a pinch off swage tube s and braze on an additional length of tubing Electric vacuum guage Dial A Charge charging cyli...

Page 29: ...wer to system and charge to specifi cation through low side Do not charge through low side in a liquid form 4 Close low side valve on manifold and pinch off both process tubes Remove manifold set crimp shut open ends of process tubes and braze 5 Recheck for refrigerant leaks Refrigerant Precautions WARNING To avoid personal injury do not allow refrigerant to contact eyes or skin CAUTION To avoid r...

Page 30: ...ainers Ensure temperature scale on thermometers are readable without having to touch or move thermometers to do so 1 2 Placement Down from top 1 inch In from side 2 inchs Placement Center of return air vent Thermometer Testing Locations Taking Sling Psychrometer Readings The sling psychrometer obtains wet bulb temperatures used to determine percent relative humidity To obtain wet and dry bulb temp...

Page 31: ... Bulb Range Chart graphic for additional directions 5 Under DRY BULB in ROOM TEMPERATURE column find temperature nearest to the temperature recorded in step 3A for example if temperature recorded in step 3A was 87 F the nearest temperature on chart would be 85 F Use associated wet bulb temperatures shown in next column on chart in following step 6 Using wet bulb temperatures associated with dry bu...

Page 32: ...ted with dry bulb temperature located in previous step find temperature on chart nearest to wet bulb sling psychrometer reading obtained in step 4 8 Note minimum MIN and maximum MAX values shown to right of associated dry bulb wet bulb temperatures Unit under test is within wattage specifications if wattmeter reading recorded in step 5 falls within minimum and maximum values noted in step 8 Unit i...

Page 33: ...st Results Possible Malfunctions Cooling wattage and cooling range both Refrigerant charge low below minimum requirement Starved indoor coil Sealed system leak Restricted capillary tube Weak inefficient compressor Cooling wattage and cooling range both Refrigerant over charged exceed maximum requirement Slow fan motor Cooling wattage below minimum requirement Restricted air flow dirty filter dirty...

Page 34: ...ttached to the electrical component and to another part of the air conditioner Ground wires should not be removed from individual components while servicing unless the component is to be removed and replaced It is extremely important to replace all removed ground wires before completing service Horizontal Insert Front Grille and Air Filter Removal To remove horizontal insert and air filter 1 Lift ...

Page 35: ...and Air Filter Removal 2 Remove TEMPERATURE CONTROL and FAN CONTROL knobs from control panel 3 Remove four inch screws securing front frame to air conditioner chassis 4 Pull front frame out and away from air conditioner Front Frame Removal Front frame Control knobs Outer Case Removal To remove outer case 1 Remove front frame see paragraph Front Frame Removal 2 Remove inch screw securing retaining ...

Page 36: ...hrough a 10 000 ohm resistor before attempting to service unless test procedures require power to be connected Ensure all ground wires are connected before certifying unit as repaired and or operational Electronic Control Removal To remove electronic control 1 Remove outer case see paragraph Outer Case Removal 2 Discharge capacitor through 10 000 ohm resistor 3 Disconnect connector plug between co...

Page 37: ...wires are connected before certifying unit as repaired and or operational Capacitor Capacitor strap Condenser Removal To remove condenser 1 Remove outer case see paragraph Outer Case Removal 2 Remove two inch screws securing side brace to partition panel and two inch screws securing side brace to condenser assembly 4 screws total Remove side brace 3 Remove two inch screws securing condenser shroud...

Page 38: ...enser fan blade off fan motor shaft taking care not to damage condenser 10 Disconnect fan motor leads NOTE Before disconnecting or removing wires always note position or location of wires Ensure all disconnected wires are reconnected to proper location 11 Pull fan motor leads through routing hole on partition panel 12 Loosen 5 32 inch hex screw securing O clamp to blower wheel fan motor shaft Slid...

Page 39: ...ads 4 Lift overload protector up and away from compressor Disassembly Procedures WARNING To avoid risk of electrical shock personal injury or death disconnect electrical power source to unit and discharge capacitor through a 10 000 ohm resistor before attempting to service unless test procedures require power to be connected Ensure all ground wires are connected before certifying unit as repaired ...

Page 40: ...Remove compressor overload protector see paragraph Compressor Overload Protector Removal 3 Disconnect compressor leads 4 Evacuate sealed system see paragraph Evacuation in Troubleshooting Information section NOTE Before opening any refrigeration system capture refrigerant in system for safe disposal CAUTION To reduce risk of personal injury or property damage take necessary precautions against hig...

Page 41: ...al injury or property damage take necessary precautions against high temperatures required for brazing 5 Unbraze evaporator connection to compressor 6 Unbraze evaporator connection to capillary tube 7 Remove two inch screws securing bottom front of evaporator to base pan 8 Lift evaporator up and away from chassis Disassembly Procedures WARNING To avoid risk of electrical shock personal injury or d...

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