Whirlpool R-94, User Manual

Page 1: ...CONSUMER SERVICES TECHNICAL EDUCATION GROUP PRESENTS R 94 JOB AID Part No 8178039 P MODEL AIR CONDITIONER ...

Page 2: ...ner 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 ...

Page 3: ...ENT 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...

Page 4: ... iv NOTES ...

Page 5: ... 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 All safety messages will tell you what the potential hazard is tell you how to reduce the c...

Page 6: ...ed 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 as sembly by the edges only When repackaging the failed electronic con trol assembly in an antistatic bag observe the above instructions Electrical Shock...

Page 7: ...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 QL L 08 08012 ...

Page 8: ...1 4 MODEL SERIAL NUMBER LABEL LOCATION The Model Serial Number label location is shown below Model Serial Number Location ...

Page 9: ...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 Rota...

Page 10: ...D052PK FULL ONE YEAR WARRANTY FROM DATE OF PURCHASE Replacement parts and repair labor costs to correct defects in materials or workman ship Service must be provided by a Whirl pool designated service company Replacement parts and repair labor costs to correct defects in materials or workman ship in the sealed refrigeration system These parts are 1 Compressor 2 Evaporator 3 Condenser 4 Accumulator...

Page 11: ... 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 Inner Sill Short Screws Outer Sill L Brackets Centerline INSIDE OUTSIDE 8 20 3 cm 8 20 3 cm Window Frame Seal about 1 4 6 3 mm Upper Guide Botto...

Page 12: ...g 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 Wood Screw Sash Seal 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 th...

Page 13: ...you on how to service each component inside the air conditioner The components and their locations are shown below COMPONENT ACCESS Condenser Overload Protector Fan Motor Compressor Main PCB Capacitor Control Panel Display PCB Evaporator Thermistor ...

Page 14: ...abs from the clips and open the grille as far as it will go NOTE Sharp edges may be present Pull Grille Forward b Remove the screw from the grille as sembly 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 Slot Pull Out Pull Forward Grille Frame Screw Electrical Shock Hazard Disconnect power before servicing Rep...

Page 15: ... remove the cabinet a Remove the four screws from both cur tain frames b Slide the left and right curtain frame assemblies off the sides of the unit d Lift the cabinet off the unit 2 Screws 3 On Other Side 4 Screws c Remove the five side screws and the four rear screws Unhook Slide Out 4 Curtain Frame Screws ...

Page 16: ...play PCB NOTE Sharp edges may be present 5 Push down on the top two clips of the con trol panel and unhook them from the chas sis slots then lift the panel assembly off the unit and remove it Press In On Locking Arm Connector 1 of 2 6 Remove the two screws from the display PCB unclip the board from the control panel and remove the board Control Panel Clips Clips Screw Screw Display PCB Electrical ...

Page 17: ...ight you will have to cut it and install a new one around the wiring after you install the new cord Smooth Power Cord Lead Wire Tie 8 Remove the screw from the power cord strain relief clamp and remove the clamp from the power cord Strain Relief Screw Screw Control Panel Ribbed Power Cord Lead Ground Wire Machine Screw NOTE Be sure to reinstall the ribbed power cord lead on the capacitor terminal ...

Page 18: ...he thermistor a Unclip the thermistor from the front of the unit 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 c Pull the thermistor through the chassis hole and remove it Thermistor Connector CN TH1 Unclip Thermistor NOTE Sharp edges may be present Electrical Shock Hazard Disconnect power bef...

Page 19: ...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 c Dischargethecapacitorbytouching one lead of a 20 000 Ωresistor to the common C terminal and the other lead to each of the other two termi nals marked FAN HERM next to the terminals d Slide the capacitor out of the mounting strap Capacitor Strap e Disconnect the wires...

Page 20: ...the chassis pan Control Panel Screw Screw Screw Screw Top Air Guide Cover 5 Remove the two screws from the top air guide cover and remove the cover 6 Lift both ends of the evaporator out of the front air guide and pull the right side out so youcanaccessthecoverbehindit NOTE Be careful not to bend the bottom of the fins on the evaporator when you handle it Lift Evaporator Out Of Guide Pull Out Evap...

Page 21: ...nd squeeze the ring tabs together and pull it off the hub Unhook Front Air Guide Cover Lift From Guide Front Air Guide Pull Out Blower Ring Clamp 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 Rear Air Guide Unhook Unhook Screw Condenser Front Air Guide Screws 12 Slide the front air gui...

Page 22: ...f 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 14 Remove the ring clip from the fan hub with a pair of pliers 15 Disconnect the fan motor connector from the capacitor wire connector Slide Back Fan Condenser Fan Motor Connector Capacitor Connector Screw Screw Green Ground ...

Page 23: ...n motor shaft as far as the stop at the end of the hub opening then install the ring clip over the hub Electrical Shock Hazard Connect green ground wire to ground screw Failure to do so can result in death or electrical shock FAN MOTOR REINSTALLATION NOTES 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...

Page 24: ...terminal Terminal Cover Hex Cap Nut Nylon Flat Washer Overload Protector Blue Wire Brown Wire 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 Black Wire Red Wire Compressor Terminals Compressor Terminals Gasket REASSEMBLY NOTE When you reinstall the t...

Page 25: ... 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 g Lift the compressor off the three rubber shock mounts Rubber Shock Mount Suction Line To Accumulator 1 2 Hex Nut Bracket Washer 1 of 3 ...

Page 26: ...lip 6 Braze on an access valve and discharge the sealed system refrigerant into a refrig erant recovery bag 7 Remove the foam insulation from around the evaporator tubing 5 Pull the mounting clip off the evaporator tubing and reinstall it on the new evapora tor at the same location Remove Clip Foam Insulation Unclip Thermistor NOTE Sharp edges may be present Electrical Shock Hazard Disconnect powe...

Page 27: ...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 Pull Out Evaporator Lift Evaporator Out Of Guide ...

Page 28: ...uide Unhook Unhook Screw Condenser 7 Remove the two condenser mounting screws from the rear of the chassis pan 8 Remove the condenser from the unit Screw Screw Chassis Pan 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 NO...

Page 29: ...checksmustbemadewithpower cord unplugged from outlet and with wiring harness or connectors disconnected Thermistor Connector Test Pins 1 2 Refer to page 3 6 for the procedure for servic ing the thermistor 1 Unplug the air conditioner or disconnect the power 2 Disconnect the thermistor 4 wire connec tor at CN TH1 3 Insert two small test wires into pins 1 and 2 of the thermistor connector 4 Set the ...

Page 30: ...e fan motor or compressor Line Fuse Main PCB Refer to page 3 6 for the procedure for servic ing 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 termi nals 3 Disconnect the wires from the capacitor termina...

Page 31: ...ange 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 Red Orange Yellow Blue Black 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 Electrical Shock Hazard Disconnect power before...

Page 32: ... and connec tor 6 Themetershouldindicatecontinuity 0Ω COMPRESSOR Refer to page 3 12 for the procedure for servic ing the compressor 1 Unplug the air conditioner or disconnect the power 2 Disconnect the three wires from the com pressor 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 compr...

Page 33: ...1 2 4 6 8 3 5 7 F C H THERMOSTAT COMP CAPACITOR FAN MOTOR OVERLOAD PROTECTOR BR BU BU BU RD RD BK BR BK BK OR BR OR BR POWER INPUT YL RD BU BK RD YL WH BU BK BR SMOOTH RIBBED GND GN YL R S C H L M WIRING DIAGRAM MODELS ACD052PK ACM062PK ...

Page 34: ...E FUSE 125V 2A FAN MOTOR OVERLOAD PROTECTOR TRANSFORMER BR BU BU RD RD BK BK RD BK OR OR BR OR BR ZNR01J CN TH1 CN SYNC CN DISP1 CN DISP2 POWER INPUT YL BU BU RD BK RD BK YL WH BL BK BR SMOOTH RIBBED GND GN YL RY L CN RD CN BL CN BK RY M RY H R S C WIRING DIAGRAM MODELS ACQ052PK ACQ062PK ...

Page 35: ...R 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 FOR WHIRLPOOL PRODUCTS 1 800 253 1301 FOR KITCHENA...

Page 36: ...CORPORATION ...