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4-20

REMOVING THE OVERLOAD PROTECTOR

AND THE COMPRESSOR

1. Unplug air conditioner or disconnect power.
2. Remove the cabinet from the unit (see

page 4-2 for the procedure).

3. Remove the components cover (see

page 4-5 for the procedure).

Compressor

Overload

Protector

5.

To remove the overload protector:

a) Remove the 5/16˝ nut from the termi-

nal cover and remove the cover.

b) Disconnect the wire from the overload

protector  terminal,  and  the  overload
protector  wire  from  the  compressor
terminal  (C),  then  remove  the  over-
load protector and coil.

Terminal Cover

Nut

Connector C

Overload

Protector

& Coil

Overload Protector

& Coil

Electrical Shock Hazard

Disconnect power before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.

4.

CAUTION: Discharge the capacitor by

touching the leads of a 20,000 ohm
resistor to the motor capacitor termi-
nals.

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Summary of Contents for ACP102PR

Page 1: ...CONSUMER SERVICES TECHNICAL EDUCATION GROUP PRESENTS R 100 JOB AID Part No 8178485 10 000 BTU PORTABLE ROOM AIR CONDITIONER Model ACP102PR ...

Page 2: ...er The Wiring Diagram used in this Job Aid is 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 information that will enable the service technician to prop erly diagnose malfunctions and repair the 10 000 BTU Portable Room Air Conditioner The objectives of...

Page 3: ...emoving The Control Board 4 6 Removing A Fan Motor Capacitor Compressor Motor Capacitor Transformer 4 7 Removing The Evaporator Fan Motor 4 9 Removing The Room Temp And De Ice Thermistors 4 11 Wire Tie Locations 4 13 Removing The Water Pump Motor 4 14 Removing The High Low Water Level Switches 4 16 Removing The Condenser Fan Motor 4 18 Removing The Overload Protector And The Compressor 4 20 Removi...

Page 4: ... iv NOTES ...

Page 5: ...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 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 You can be killed or seriously injured if you don t immediately follow instructions You ...

Page 6: ...CE NUMBER MODEL NUMBER AC P 10 2 P R 0 AC North America MAC Mexico YAC Canada MODEL TYPE D Value model E Heat cool M Value model P Portable Q Designer S Sliding Window U Thru The Wall BTU CAPACITY 05 to 24 ie 10 10 000 BTU ELECTRICAL CODE 2 115 Volt Standard 4 230 Volt Standard 8 115 Volt Energy Star 9 230 Volt Energy Star MANUFACTURING LOCATION P Purchased YEAR OF INTRODUCTION R 2005 ENGINEERING ...

Page 7: ...1 3 MODEL SERIAL NUMBER LABEL LOCATION The Model Serial Number label location is shown below Model Serial Number Label Location ...

Page 8: ... Height 32 1 4ʺ 820 mm Width 17 3 4ʺ 450 mm Depth 16ʺ 405 mm Weight Net Indoor Unit 81 6 lbs 37 0 kg Electrical Voltage 115 VAC Frequency 60 Hz Refrigerant Type R22 Quantity 23 3 oz Cooling Capacity 10 000 BTU h Working Temperature Range Indoor 64 4 90 F 18 0 32 0 C ...

Page 9: ...r units operated outside the United States or Canada 5 Pickup and delivery Your air conditioner is designed to be repaired in the home 6 The removal and reinstallation of your air conditioner if it is installed in an overhead or other inacces sible location or is not installed in accordance with published installation instructions 7 Repairs to parts or systems resulting from unauthorized modiﬁcati...

Page 10: ...1 6 NOTES ...

Page 11: ...5 180 cm The portable air conditioner should be con nected to a 115 V 60 Hz 15 or 20 amp fused 3 prong grounded outlet The use of a time delay fuse or time delay circuit breaker is recommended All wiring must comply with local and na tional electrical codes and be installed by a qualified electrician If you have any ques tions contact a qualified electrician Power Supply Cord NOTE Your unit s devi...

Page 12: ... release RESET listen for click Reset button will latch and remain in The power supply cord is ready for operation NOTES The Reset button must be pushed in for proper operation The power supply cord must be replaced if it fails to trip when the test button is pressed or fails to reset Do not use the power supply cord as an off on switch The power supply cord is de signed as a protective device A d...

Page 13: ...curely locked into place A Flexible exhaust hose B Evaporator air intake C Power supply D Drain port B A C D A Flexible exhaust hose B Window exhaust adapter B A Window Installation The window slider kit has been designed to fit most standard vertical and horizontal window applications However it may be necessary for you to modify some aspects of the installa tion procedures for certain types of w...

Page 14: ...utdoors C Window slider kit D Window exhaust adapter E Flexible exhaust hose E A B D C 3 Close the window onto the window slider kit to secure 4 Insert the window exhaust adapter into the window slider kit Horizontal Slide Window ...

Page 15: ...r temperature at the thermistor The control creates a set point 3 F 1 5 C cooler than room temperature and then operates in the cooling mode with the evaporator fan operating at low speed This 3 F 1 5 C dif ferential is needed to allow the compressor to run long enough to chill the evaporator Set point temperature may be increased or decreased by 4 F 2 C Only the actual temperature will be display...

Page 16: ...and condenser fan motors stop and a buzzer sounds When the de ice thermistor senses higher than 41 F 5 C normal opera tion resumes FULL WATER WARNING When the high water level switch closes the Water Full LED will ﬂash and all operation will cease The consumer must manually drain the sump by pulling the drain plug over a drain THERMISTOR FAILURE DEFAULT To provide some cooling operation in the eve...

Page 17: ... this time the compressor will not restart for another 3 to 5 minutes In Cooling or Dry mode the compressor and fanwillstopwhenroomtemperaturereaches set temperature A RUN indicator light B WATER FULL indicator light C Display D TEMP TIME plus and minus buttons E TIMER OFF button F TIMER on button G POWER button H FAN SPEED button choose Auto High or Low I MODE button choose ComfortMode control Co...

Page 18: ...oom Temperature is set by user Fan runs on Low only NOTES Dry mode should not be used to cool the room Dry mode does not require hot air outlet hose 1 Press MODE to choose Dry 2 Choose temperature See Tempera ture 3 Press POWER to start the air conditioner The RUN indicator light will glow green 4 When WATER FULL indicator light glows red air conditioner will turn off automati cally See Portable A...

Page 19: ... press twice to increase set temperature by 4 F 2 C Fan Only Mode Serves only to move air Fan speed is set by user 1 Press MODE to choose Fan Only 2 Choose fan speed See Fan Speed 3 Press POWER to start the air conditioner The RUN indicator light will glow green Fan Speed 1 Press FAN to set the fan speed 2 Choose Auto High or Low Auto Fan speed set automatically High Maximum cooling Low Minimum co...

Page 20: ...e between 64ºF 18 C and 90 F 32 C 4 For Fan Only mode adjust fan speed to High or Low 5 ForComfortMode controlandDrymodes adjust temperature up or down by 4 F 2 2 C NOTE In Fan Only mode temperature cannot be set 6 Press TIMER Timer ON 12 00 indicator light will ﬂash 7 Press the plus or minus button to change delay time 1 to 24 hours 8 Press TIMER again Timer ON 12 00 indicator light will remain o...

Page 21: ...peedseachtimeFanSpeed is pressed RapidCool Mode Used for fast cooling Automatically sets fan speed to high and temperature to 64 F 18 C NOTE ComfortMode control button does not operate in RapidCool mode 1 PressRapidCool mode Thetemperature will automatically set to 64 F 18 C 2 To turn RapidCool mode off press either ComfortMode control COOLING DRY FAN the power button or the plus or minus buttons ...

Page 22: ...er keeping previous settings 1 Turn off air conditioner 2 Press TIMER ON Timer ON 12 00 indi cator light will ﬂash 3 Press the plus or minus button to change the delay time 1 to 24 hours 4 PressTIMER ON again Timer ON 12 00 indicator light will remain on To set the Timer to turn on the air condi tioner changing the previous settings 1 Turn off air conditioner 2 Adjust Mode to ComfortMode control C...

Page 23: ...plug air conditioner or disconnect power 3 Move the air conditioner to a drain location or outside 4 Remove the rubber drain plug and allow water to drain from the air conditioner 5 Reinstall the drain plug 6 Reposition air conditioner 7 Plug in air conditioner or reconnect power 8 Press POWER to start the air conditioner NOTE A drain hose may also be connected to drain port to drain water from ai...

Page 24: ...Reset button will pop out the power supply cord Press and release RESET listen for click Reset button will latch and remain in to resume operation TROUBLESHOOTING Anelectricaloverloading overheating pinch ing or aging can trip Reset button will pop out the power supply cord After correcting the problem press and release RESET listen for click Reset button will latch and remain in to resume operati...

Page 25: ...ly hot Allow extra time for the air conditioner to cool off a very hot room Windows or doors to the outside are open Close all windows and doors Temperature on display does not match room temperature When the compressor and fan motor turn off duringnormaloperations orafteryouturnoff theunit alowertemperaturereadingthanthe actualroomtemperaturemaybedisplayedfor a short period of time This lower tem...

Page 26: ...3 12 NOTES ...

Page 27: ...SS Receiver Board Evaporator Fan Motor Water Pump Motor High Water Level Switch Low Water Level Switch Overload Protector Compressor Condenser Evaporator Room Temp Thermistor Louver Motor Condenser Fan Motor Power Supply Cord Terminal Viewed From Front Of Unit Viewed From Rear Of Unit De Ice Thermistor Transformer Compressor Capacitor Fan Motor Capacitors Control Board Not Shown User Interface Boa...

Page 28: ...n result in death or electrical shock 1 Unplug air conditioner or disconnect power 2 Disconnect the vent duct from the air conditioner by turning it counterclockwise and lifting it off the vent opening 3 Remove the seven screws from the cabi net rear Screw 1 of 7 Cabinet Rear Vent Duct 4 Pull the rear of the cabinet off the unit Cabinet Rear Remove ...

Page 29: ...erface connector from the main harness 6 Unsnap the cabinet front tabs from the sides of the chassis then lift the cabinet to clear the vent opening and remove the cabinet from the unit User Interface Connector 3 Tabs Cabinet Front ...

Page 30: ...ide down so the user interface board is accessible 4 Remove the six screws from the user in terface board and remove the board from the cabinet front User Interface Board User Interface Board User Interface Board 6 Screws Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock ...

Page 31: ... ceiver board and remove the board Screws Screws Components Cover Louver Motor Receiver Board 4 Cut the wire tie for the louver motor or the two wire ties for the receiver board see the top right photo 5 To remove the louver motor a Disconnect the motor wire connector CN13 from the control board Receiver Board Ties CN13 CN20 Louver Motor Screws Louver Motor Tie Receiver Board Receiver Board Screws...

Page 32: ...e the cabinet from the unit see page 4 2 for the procedure 3 Remove the components cover see page 4 5 for the procedure 4 Disconnect the wires from the control board and its components Control Board 5 Cut the wire tie around the user interface board cable see the top right photo 6 Squeeze the tabs on the ends of the con trol board standoffs and lift the board off the standoffs Wire Tie Standoff 1 ...

Page 33: ...rom the termi nals of the evaporator or condenser fan motor capacitor c Remove the mounting screw from the capacitor and remove the capacitor from the unit 5 To remove the compressor motor ca pacitor a CAUTION Discharge the capacitor by touching the leads of a 20 000 ohm resistor to the motor capacitor terminals b Remove the capacitor clamp screw and remove the capacitor from the clamp c Disconnec...

Page 34: ...rmer wire con nectors CN12 red wires and CN14 white wires from the control board c Remove the two transformer screws and remove the transformer from the unit CN14 CN12 Control Board Transformer Screw Screw REASSEMBLY NOTE Be sure to replace the wire ties that you removed with new ties and secure the wires neatly together ...

Page 35: ...ol board connectors a White wire at CN10 b Black wire at CN6 c Yellow wire at CN4 6 Disconnect the two red wires from the evaporator fan motor capacitor terminals 7 Remove the louver motor from the louver see page 4 5 for the procedure 8 Unhook the right end pull the left end out of the housing hole and remove the lou ver from the top of the unit CN10 CN6 CN4 Motor Cap Wires Unhook Louver Continue...

Page 36: ...ews three on each side and one on top from the lou ver housing assembly and lift the assem bly off the top of the unit so that you can access the fan 3 Screws Evap Fan Motor Top Screw 3 of 6 Screws Louver Housing Assembly 10 mm Fan Nut Evaporator Fan Motor Fan REASSEMBLY NOTE Be sure to replace the wire tie that you removed with a new one and secure the wires neatly to the chassis ...

Page 37: ...e procedure 4 Cut the indicated wire tie from around the wires Cut Wire Tie 5 Disconnect the room temp and de ice thermistor connector from the control board at CN1 Room Temp Thermistor De Ice Thermistor Thermistor Connector Continued on the next page Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or elec...

Page 38: ...the de ice thermistor a Cut the wire tie from around the evap orator tubing b Pull the de ice thermistor out of the evaporator housing Cut Wire Tie Pull Thermistor Out Of Housing Pull Thermistor Off Clip REASSEMBLY NOTE Be sure to replace the wire ties that you removed with new ties and secure the wires neatly together ...

Page 39: ...in the rest of this section and are not called out in the procedures The wire ties will need to be replaced to secure the wiring for the com ponent being serviced Always route the wires as shown in the photos and keep them neat to avoid vibration noise Viewed From Front Of Unit Viewed From Right Side Of Unit ...

Page 40: ...cking tabs from the im peller cover and remove the cover from the pump Water Pump Motor 4 Remove the two screws from the water pump motor see the top right photo 5 Remove the three screws from the water pump mounting plate and lift the pump off the housing Water Pump Motor Screws Water Pump Mounting Plate Screws Water Tubing Impeller Cover Tab Electrical Shock Hazard Disconnect power before servic...

Page 41: ... impeller and housing 10 Cut the necessary wire ties to remove the blue and red motor wires from the chassis 11 Disconnect the motor wires from the con trol board terminals CN8 red and CN9 blue Impeller Nut Motor Shaft Impeller CN9 Blue CN8 Red Control Board REASSEMBLY NOTE Be sure to replace all of the wire ties that you removed with new ties see page 4 13 for the locations and secure the wires n...

Page 42: ...itches see the top right photo 5 Loosen the nut from the water level switch you are servicing and slide the switch off the plate IMPORTANT NOTE Make sure that you position the rubber seal on the switch so it is between the bottom of the nut and the top of the mounting plate when you install the switch 3 Screws Mounting Plate Nut Seal Nut High Water Level Switch Low Water Level Switch Electrical Sh...

Page 43: ... from the control board at CN17 red or the low water level switch at CN18 white 8 Pull the water level switch wire through the mounting plate and remove the switch CN18 Wht CN17 Red Water Level Switch REASSEMBLY NOTE Be sure to replace all of the wire ties that you removed with new ties see page 4 13 for the locations and secure the wires neatly together ...

Page 44: ... for the procedure Cond Fan Motor 4 Remove the 7 screws from the fan motor cover and remove the cover Fan Cover 5 Loosen the 5 16 hex head fan screw on the condenser fan motor and pull the fan off the motor shaft Fan Screw 7 Screws Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock ...

Page 45: ...e 3 wire con nector from the control board at CN21 10 Cut the remaining wire ties that are nec essary to remove the condenser fan mo tor wires from the chassis 6 Remove the four screws from the con denser fan motor Fan Motor Screws Standoff Motor Ground Wire Tie CN21 Cond Fan Motor Capacitor Wires 13 Pull the condenser fan motor wires through the cover REASSEMBLY NOTE Be sure to replace all of the...

Page 46: ...and remove the cover b Disconnect the wire from the overload protector terminal and the overload protector wire from the compressor terminal C then remove the over load protector and coil Terminal Cover Nut Connector C Overload Protector Coil Overload Protector Coil Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result i...

Page 47: ...e of the compressor see the small inset in the lower left photo j Lift the compressor off the unit and re move the three rubber shock mounts from the base Black Wire R Red Wire S Compressor Cover e Cut the wire ties from the accumulator covering and from the covering on the suction line to the accumulator see the top right photo f Carefully peel the adhesive covering off the accumulator and the su...

Page 48: ...lip off the evaporator tubing and reinstall it on the replacement evaporator at the same location 6 Remove the two screws from the louver motor and remove the motor Louver Motor Screws 7 Unhook the right end pull the left end out of the housing hole and remove the lou ver from the top of the unit Unhook Louver Pull Clip Off Evaporator Electrical Shock Hazard Disconnect power before servicing Repla...

Page 49: ... of 6 Screws Louver Housing Assembly 9 Cut the wire tie and pull the de ice therm istor out of the housing in the evaporator 10 Remove the wire ties and foam insula tion from around the evaporator inlet and outlet tubing 11 Braze on an access valve and discharge the sealed system refrigerant into an ap proved refrigerant recovery system Inlet Outlet Tubing Insulation 14 Lift the evaporator out of ...

Page 50: ...he two top drain nozzles and remove the tray from the top of the condenser 7 Braze on an access valve and discharge the sealed system refrigerant into an ap proved refrigerant recovery system 8 Measure the new condenser inlet and outlet tubes and cut the existing lines to the proper lengths Water Tray Water Tube Screw Inlet Tubing Outlet Tubing Condenser Behind Condenser Fan Motor Assy Electrical ...

Page 51: ...4 25 10 Remove the condenser from the unit 9 Remove the fourteen mounting screws seven on each side from the condenser 7 Condenser Screws ...

Page 52: ...s screwdriver remove the screw from the strain relief plate and remove the strain relief and power supply cord from the unit NOTE If you cannot remove the strain relief plate screw as described remove the eight screws from the condenser fan motor housing see the left photo and remove the housing to access the strain relief 7 Remove the screws inside the strain re lief and remove the power supply c...

Page 53: ...t wire into pin 1 of the louver motor connector 4 Insert a small test wire into each of the remaining pins 2 5 in sequence to test the motor windings 5 Set the ohmmeter to the R x 1 scale 6 Clip the ohmmeter test leads to the test wires The meter should indicate between 190 and 210 Ω for each of the windings LOUVER MOTOR 1 5 Check all connections before replacing components looking for broken or l...

Page 54: ... procedure for access ing the transformer 1 Unplug air conditioner or disconnect power 2 Disconnect the transformer wires from the control board terminals 3 Set the ohmmeter to the R x 1 scale 4 Touch the ohmmeter test leads to the plug terminals with the primary red transformer wires The meter should in dicate between 110 and 140 Ω 5 Touch the ohmmeter test leads to the plug terminals with the se...

Page 55: ...R FAN MOTOR Refer to page 4 18 for the procedure for ac cessing the condenser fan motor 1 Unplug air conditioner or disconnect power 2 Disconnect the fan motor wires from the control board and capacitor terminals 3 Set the ohmmeter to the R x 1 scale 4 Touch the ohmmeter test leads to the in dicated fan motor plug pins and wire con nectors The meter should indicate as fol lows Motor Wires Red red ...

Page 56: ...uld indicate the same resistance for either thermistor as shown in the following chart Refer to page 4 14 for the procedure for ac cessing the water pump motor 1 Unplug air conditioner or disconnect power 2 Disconnect the water pump motor wires from the control board terminals 3 Set the ohmmeter to the R x 1 scale 4 Touch the ohmmeter test leads to the wire terminals The meter should indicate betw...

Page 57: ...0 Ω with the float raised OVERLOAD PROTECTOR Refer to page 4 20 for the procedure for ac cessing the overload protector 1 Unplug air conditioner or disconnect power 2 Discharge the compressor motor ca pacitor by touching a 20 000 Ω resis tor to the capacitor 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 pro...

Page 58: ...ires from the com pressor terminals 4 Set the ohmmeter to the R x 1 scale 5 Clip an ohmmeter test lead to the over load protector terminal C 6 Touch the free test lead to the following compressor terminals The meter should indicate as shown Terminal R 2 5 Ω Terminal S 4 8 Ω Black C Red R White S Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating...

Page 59: ...CAPACITOR THERMISTOR ROOM TEMP TH1 TH2 THERMISTOR DE ICE LOUVER MOTOR LOW WATER LEVEL SW HIGH WATER LEVEL SW RD RD RD BU BU YL GN YL GN YL GN YL GN BU BU BN BN BU 120 VAC BU BN BK BU RD WH WH YL BK WH CN14 CN16 CN20 CN1 CN13 CN18 CN11 CN19 CN15 3 1 2 1 2 3 4 1 2 CN17 CN3 1 2 M M M M CM FAN MOTOR CAPACITOR COMPRESSOR MOTOR CAPACITOR COMPRESSOR MOTOR OVERLOAD PROTECTOR RD R S C WH RD BK 115 VAC 60 H...

Page 60: ...6 2 NOTES ...

Page 61: ...6 3 NOTES ...

Page 62: ...6 4 NOTES ...

Page 63: ...RIZED SERVICER IN CANADA FOR PRODUCT SPECIFICATIONS AND WARRANTY INFORMATION CALL 1 800 461 5681 FOR TECHNICAL ASSISTANCE WHILE AT THE CUSTOMER S HOME CALL THE TECHNICALASSISTANCE LINE 1 800 488 4791 HAVE YOUR STORE NUMBER READY TO IDENTIFY YOU AS AN AUTHORIZED SERVICER FOR WHIRLPOOL PRODUCTS 1 800 253 1301 FOR KITCHENAID PRODUCTS 1 800 422 1230 FOR ROPER PRODUCTS 1 800 447 6737 FOR LITERATURE ORD...

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