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Amana RS4100004 Service

Amana RS4100004 Service

Compact quiet zone
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Service
Compact Quiet Zone
Room Air Conditioners
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.
Base manual covers general
information on Compact Quiet
Zone Room Air Conditioners.
Refer to individual technical
sheets for information on
specific models.
RS4100004
Revision 0
September 1997

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Summary of Contents for Amana RS4100004

  • Page 1 Service Compact Quiet Zone Room Air Conditioners 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. RS4100004...

  • Page 2: Table Of Contents

    Fan Motor Removal ........38 Troubleshooting Information Compressor Overload Protector Removal .... 39 Tools and Equipment ..........15 Compressor Removal .......... 40 Troubleshooting Table .......... 15 Evaporator (Indoor Coil) Removal ......41 Low Voltage ............22 High Voltage ............22 RS4100004 Rev. 0...

  • Page 3: Important Information

    (such as exposure to electrical shock) may result. CAUTION Amana will not 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 To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product.

  • Page 4: Important Safety Information

    NOT to be used as current This Service Manual describes the operation, carrying conductors. The standard accepted color disassembly, troubleshooting, and repair of Amana coding for ground wires is green or green with a Room Air Conditioners. It is intended for use by yellow stripe.

  • Page 5: Product Identification

    Avoid using tools long enough to reach the condenser. Design Information Many design features are incorporated into all Amana NOTE: Drain grommet should only be punctured or Room Air Conditioners. Basic concepts of balance in...

  • Page 6: Sizing Instructions

    · 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. RS4100004 Rev. 0...

  • Page 7: Installation Instructions

    The following paragraphs provide general instructions the National Electrical Code (and any applicable local and information on installing an Amana Room Air codes and ordinances). If an appropriate grounding-type Conditioner. Detailed instructions, included with unit or...

  • Page 8: Preparing For Installation

    General Through-Wall Installation for Slide Out Chassis Model CAUTION Amana Room Air Conditioners with slide out chassis To avoid risk of personal injury or product damage type cases are designed to be installed through a wall or in a window. The following instructions describe general due to the weight of this device and sharp edges procedures for wall installations.

  • Page 9: Brick Veneer Or Frame Wall Construction

    NOTE: If securing case with concrete nails, predrill " holes in case before driving nails into wall. Appropriate grounded power outlet must be within 5 feet of this location. Typical Wall Opening RS4100004 Rev. 0...

  • Page 10: Installation In Walls Exceeding 10½-Inches

    Air intake Outside for condensate outer case to louvers wall drainage air intake 4" 4" louvers Walls Exceeding 10½-inches (Top View) Caulk all sides Wall stud or framing Optional molding (not provided) Walls Exceeding 10½-inches (Side View) RS4100004 Rev. 0...

  • Page 11: Operating Instructions

    SETTINGS and compressor cycles on and off depending upon room temperature. When on, compressor cools and dehumidifies air circulating through air conditioner. Select this setting for quiet operation. OFF— Turns air conditioner off. TEMPERATURE CONTROL Rotary Control RS4100004 Rev. 0...

  • Page 12: Compressor Lockout Feature

    When voltage returns to specified level, unit automatically resumes operation. NOTE: On units with rotary controls, a compressor lockout occurs when unit resumes operation after low voltage shut down. RS4100004 Rev. 0...

  • Page 13: Initial Start Up

    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. RS4100004 Rev. 0...

  • Page 14: Care And Maintenance

    The fan motor is permanently lubricated. Additional lubrication should never be applied. Contact an To avoid risk of personal injury or death due to authorized Amana Service Center if fan malfunctions in electrical shock, disconnect electrical power to unit any manner.

  • Page 15: Troubleshooting Information

    · 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 be required. RS4100004 Rev. 0...
  • Page 16 Fan motor operates intermittently. Unit in ENERGY SAVER mode. Fan only operates when compressor is on, or to sample room temperature when compressor is off. Wire(s) disconnected or loose. Ensure all connections are tight and secure. Correct as required. Cycling on motor protector. Replace motor. RS4100004 Rev. 0...
  • Page 17 Compressor motor capacitor faulty. Check capacitor for open/ short. Replace if faulty. NOTE: Discharge capacitor before testing. Compressor faulty. Check compressor motor windings for opens/shorts. Check compressor seals. Perform compressor direct wiring test. Replace compressor if faulty. RS4100004 Rev. 0...
  • Page 18 Compressor motor capacitor faulty. Check capacitor for open/ short. Replace if faulty. NOTE: Discharge capacitor before testing. Sealed refrigerant system fault. Test sealed system for proper charge, leaks, and restrictions. Repair as required. RS4100004 Rev. 0...
  • Page 19 Inspect unit for parts that may excessive vibration. have worked free, loose/ missing screws, other problems that may cause excessive vibration. Repair as required. Worn fan motor bearings. Check bearings for wear/loss of lubricant. Replace motor if either condition is found. RS4100004 Rev. 0...
  • Page 20 Perform compressor direct wiring test. Replace compressor 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. RS4100004 Rev. 0...
  • Page 21 Insufficient air flow. Inspect air filter, indoor/ outdoor coil for dirt. Clean as required. Check fins on coils for damage. Straighten fins if bent, attempt other repairs as necessary. Replace faulty coil if repairs cannot be made. RS4100004 Rev. 0...

  • Page 22: Low Voltage

    4. Reverse ohmmeter leads on capacitor and repeat step 3. High Voltage High voltage causes motors to overheat, cycle on their protectors, or break down electrically. This problem can only be solved by local electric utility. RS4100004 Rev. 0...

  • Page 23: Checking Overload Protectors

    (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. RS4100004 Rev. 0...

  • Page 24: Operational Test (Short Term Testing Only)

    Technical Sheet for unit under test. · Cool thermostat to 100°F ±4°. Thermostat should read closed (continuity). NOTE: Ensure test cord cables and fuses meet specifications for unit under test (see Technical Replace thermostat if faulty. Sheet for unit under test). RS4100004 Rev. 0...

  • Page 25: Compressor Burnout

    · Drip loop in motor leads must be below wire openings in motor housing. NOTE: Do not use captured or recycled refrigerant in Amana units. Captured or recycled refrigerant · Coat exposed areas of shaft from blower wheel or fan blade to end of shaft with Cosmoline or equivalent to voids all Amana and/or compressor prevent corrosion.

  • Page 26: Leak Testing

    Joint 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. RS4100004 Rev. 0...

  • Page 27: Restriction Testing

    · If temperature of condenser tubing drops at any NOTE: Do not use captured or recycled refrigerant in point, tubing is restricted at point of temperature Amana units. Captured or recycled refrigerant drop (if restriction is severe, frost may form at point voids all Amana and/or compressor of restriction and extend down in direction of manufacturer's warranties.

  • Page 28: Evacuation

    9. Evacuate system to at least 29 inches gauge. Open for a pinch-off, swage tube(s) and braze on an valve to thermocouple vacuum gauge. additional length of tubing. RS4100004 Rev. 0...

  • Page 29: Charging

    Charging NOTE: Do not use captured or recycled refrigerant in Using Line Piercing Valves Amana units. Captured or recycled refrigerant Line piercing valves can be used for diagnosis, but are voids all Amana and/or compressor not suitable for evacuating or charging due to holes manufacturer's warranties.

  • Page 30: Performance Tests

    4 feet above floor. Record results. 4. Remove wick from sling psychrometer. Take psychrometer reading at same location as reading taken in step 3. Record results (this is the sling psychrometer dry bulb temperature). RS4100004 Rev. 0...

  • Page 31: Cooling Performance Test

    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. RS4100004 Rev. 0...

  • Page 32: Cooling Wattage Consumption Test

    5 falls within minimum and maximum values noted in step 8. Unit is out of specifications if calculation from step 5 is greater or less than values from step 8. (See paragraph Performance Test Diagnosis Guide for additional information.) RS4100004 Rev. 0...

  • Page 33: Performance Test Diagnosis Guide

    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 evaporator coil, dirty cooling range exceeds maximum condenser coil). requirement. RS4100004 Rev. 0...

  • Page 34: Disassembly Procedures

    It is extremely important to replace all removed ground wires before completing service. Horizontal insert Horizontal Insert and Air Filter Removal RS4100004 Rev. 0...

  • Page 35: Front Frame Removal

    4. Pull front frame out and away from air conditioner. material (rigid foam/plywood blocks) on inside of unit to prevent damage during shipment. Remove packing material before operating unit. Front frame Outer case Retaining Control clamp knobs Outer Case Removal Front Frame Removal RS4100004 Rev. 0...

  • Page 36: Electronic Control Removal

    6. Carefully work electronic control and attached thermostat sensor out and away from control panel. Top cover Control panel Vent door Vent door slide Electronic control Vent Control Removal Electronic Control Removal RS4100004 Rev. 0...

  • Page 37: Capacitor Removal

    6. Unbraze condenser connection to capillary tube. 7. Remove two ¼-inch screws securing condenser to base pan. 8. Lift condenser up and away from chassis. Condenser Side brace Capacitor strap Capacitor Condenser shroud Capacitor Removal Condenser Removal RS4100004 Rev. 0...

  • Page 38: Condenser Fan Blade, Blower Wheel, And Fan Motor Removal

    Slide blower wheel as far as possible towards end of fan moter shaft. Fan motor must be removed to completely remove blower Condenser Fan Blade, Blower Wheel, and Fan Motor wheel from shaft. Removal RS4100004 Rev. 0...

  • Page 39: Compressor Overload Protector Removal

    2. Remove nut securing terminal cover to compressor, cover then lift terminal cover up and away from compressor. 3. Disconnect overload protector leads. 4. Lift overload protector up and away from compressor. Overload protector Compressor Overload Protector Removal RS4100004 Rev. 0...

  • Page 40: Compressor Removal

    5. Unbraze compressor discharge tube connection to condenser (outside coil). 6. Unbraze compressor suction tube connection to evaporator (indoor coil). 7. Remove three -inch screws securing compressor to base pan. 8. Lift compressor up and away from chassis. Compressor Removal RS4100004 Rev. 0...

  • Page 41: Evaporator (Indoor Coil) Removal

    5. Unbraze evaporator connection to compressor. 6. Unbraze evaporator connection to capillary tube. 7. Remove two ¼-inch screws securing bottom front of evaporator to base pan. 8. Lift evaporator up and away from chassis. Evaporator Evaporator Removal RS4100004 Rev. 0...

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