Amana AAC081SRA Service User manual

Servi
This manual is to be used by qualified appliance
technicians only. Maytag does not assume any
responsibility for property damage or personal
injury for improper service procedures done by
an unqualified person.
Sli e
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|
Air C e
This Base Manual covers general information
Refer to individual Technical Sheet
for information on specific models
This manual includes, but is
not limited to the following:
Amana
AAC081SRA
AAC101SRA
AAC121SRA
AAC141SRA
AAC182SRA
AAC202SRA
AAC242SRA
16022061
May 2003

important information
important Notices for Servicers and Consumers
Maytag will not be responsible for personal injury or property damage from improper service procedures. Pride and
workmanship go into every product to provide our customers with quality products. It is possible, however, that
during its lifetime a product may require service. Products should be serviced only by a qualified service technician
who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts,
testing instruments and the appropriate service information. IT IS THE TECHNICIANS RESPONSIBLITY TO
REVIEWALL APPROPRIATE SERVICE INFORMATION BEFORE BEGINNING REPAIRS.
_lb WARNING I
To avoid risk of severe personal injury or death, disconnect power before working!servicing on appliance to avoid
electrical shock.
To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this
product. For further assistance, please contact:
Customer Service Support Center
CAIR Center
Web Site Telephone Number
WWW.AMANA.COM ............................................... 1-800-843-0304
WWW.JENNAIR.COM ............................................ 1-800-536-6247
WWW.MAYTAG.COM ............................................. 1-800-688-9900
CAIR Center in Canada .......................................... 1-800-688-2002
Amana Canada Product .......................................... 1-866-587-2002
Recognize Safety Symbols, Words, and Labels
I _, DANGER
DANGER--Immediate hazards which WILL result in severe personal injury or death.
I _ WARNING I
WARNING--Hazards or unsafepracticeswhich COULD resultinseverepersonalinjuryordeath.
I _ll CAUTION I
CAUTION--Hazards or unsafe practices which COULD result in minor personal injury, product or property
damage.
2 16022061 Rev. 0 ©2003 MaytagAppliancesCompany

important Safety information
General Information
This Service Manual describes the operation,
disassembly, troubleshooting, and repair of Amana
Room Air Conditioners. it is intended for use by
authorized servicers who troubleshoot and repair these
units.
NOTE: It is assumed that users of this manual are
familiar with the use of tools and equipment used
to troubleshoot and repair electrical, mechanical,
and refrigeration systems; and understand the
terminology used to describe and discuss them.
Maytag urges you read and follow all safety precautions
and warnings contained in this manual. Failure to comply
with safety information may result in severe personal
injury or death.
Related Publications
This is a base service manual, covering a range of
[ ill WARNING J
To avoidriskofpersonalinjuryordeathdue toelectrical
shock, grounding wires and wires colored like grounding
wires are NOT to be used as current carrying
conductors. The standard accepted color coding for
ground wires is green or green with a yellow stripe.
Electrical components such as the compressor and fan
motor are grounded through an individual wire attached
to the electrical component and to another part of the air
conditioner. Grounding 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 grounding
wires before completing service.
[WARNING J
To avoid risk of heat exposure, which may cause death
or severe illness, air conditioner must be monitored
similar models. It is intended to be used in conjunction when malfunctions or shuts down.
with the Parts Manual and Technical Sheet covering
specific model being serviced.
General Precautions and Warnings
WARNING ]
To avoid risk of personal injury or death due to electrical
shock, disconnect electrical power to unit before
attempting to service the unit.
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. If a
two-prong (non-grounding) wall receptacle is
encountered, contact a qualified electrician and have
the receptacle replaced with a properly grounded wall
receptacle in accordance with the National Electrical
Code.
©2003 Maytag Appliances Company 16022061 Rev. 0 3

Table of Contents
Important Information .................................................. 2
Important Safety Information ........................................ 3
Product Identification .................................................... 5
Troubleshooting Information ......................................... 6
Testing Procedures ..................................................... 13
Low Voltage ........................................................... 13
High Voltage ......................................................... 13
Testing Capacitors ................................................ 13
Checking Overload Protectors ............................. 13
Checking Compressor Windings .......................... 13
Ground Test ......................................................... 14
Compressor Burnout ............................................ 14
Fan Motor ............................................................. 14
Leak Testing ......................................................... 14
Brazing ................................................................. 15
Restriction Testing ................................................ 15
Evacuation ........................................................... 15
Charging .............................................................. 16
Refrigerant Precautions ....................................... 17
Using Line Piercing Valves ................................... 17
Open Lines ........................................................... 17
Disassembly Procedures ............................................ 18
Air Filter Removal ................................................. 18
Insert Removal ..................................................... 18
Front Frame Removal .......................................... 19
Front Frame Clips Removal ................................. 19
Chassis Removal ................................................. 19
Rotary Control Assembly Removal ....................... 20
Fan MotorAssembly and Disassembly ................ 21
Condenser Removal ............................................ 21
Compressor Overload Protector Removal ............ 22
Compressor Removal .......................................... 22
Evaporator (Indoor Coil) Removal ........................ 23
Appendix A
Owner's Manual .................................................... A-1
4 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Product identification
Every Amana ® Room Air Conditioner has an
identification plate showing the model number, P
(manufacturing part) number, serial number of unit.
Identification plate is located on side of unit. Use plate to
positively identify specific model of unit being serviced.
Design information
Many design features are incorporated into all Amana ®
model Room Air Conditioners. Basic concepts of balance
in refrigeration and air handling components are used in
all models.
The outer case of unit, regardless of style, is designed to
help circulate air across evaporator, condenser,
compressor and fan motor. It must be in place to ensure
maximum efficiency of unit, to prevent overheating of
components, and to maintain system balance and
capacity.
Structural components of room air conditioners are
heavy, zinc-coated steel that is further treated with zinc
phosphate. Exterior parts are hot-dipped galvanized steel
that is chemically pretreated, then primed with electro-
coated primer, and finished with a baked-on polyester top
coat.
Modular design allows easier and faster disassembly
and assembly.
Acoustical and thermal insulation, used on partition panel
and in side air discharge plenum, reduce noise and
increase efficiency.
Large evaporator and condenser coils are designed to
provide maximum heat transfer. Coils are manufactured
from rifled copper tubing and embossed aluminum fins to
achieve maximum heat transfer. Thermal mastic is
placed on refrigeration tubes to dampen and isolate
system vibrations.
Fan motors are sealed to prevent moisture and dirt
contamination of motor windings. Motor bearings are
permanently lubricated. Large blower wheels and
condenser fans reduce noise levels.
Condenser fans contain a slinger ring for condensate
removal. The slinger ring picks-up condensate and
sprays it against the condenser, increasing condenser
evaporative cooling. In extreme humidity conditions,
excess condensate drains from base pan.
The following diagram explains how to interpret Amana
Room Air model numbers. Model numbers contain
information about cooling capacity, configuration, chassis
type, power requirements and series index for unit.
Brand
Product Type
Configuration
Cooling Capacity
123456789
-_ Series Index
_Controt Type
Chassis Type
--Voltage
3 Configuration
C= Cooling
4-5 BTU cooling Capacity
05= 5,000 BTU
08= 8,000 BTU
10= 10,000 BTU
12= 12,000 BTU
20= 20,000 BTU
6 Voltage
1= 115 Volt
2= 230 Volt
7 Chassis Type
F= Fixed
S= Slide Out
8 Control Type
R= Rotary Knob
T= Electronic control
9 Series Index
@2003 Maytag Appliances Company 16022061 Rev. 0 5

Troubleshooting information
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.
CAUTION
Units covered in this manual are polarized. Reversing polarity of a unit or any of its components will cause
damage. To avoid reversing polarity, any wires disconnected or removed during service must be reconnected to
the same location. To ensure wires are reconnected to the proper location, tag or otherwise mark the wires
before disconnecting or removing.
Tools and Equipment
Accurate diagnosis and repair of malfunctioning air
conditioners requires proper tools and equipment. In
addition to standard hand tools (screw drivers, pliers,
sockets, etc.), the following equipment is required:
Multimeter (combination voltmeter, ammeter, and
ohmmeter) for reading current loads during start-up
and normal operation, verifying voltage levels, and
testing various components for continuity.
,, 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 be required.
Troubleshooting Table
Troubleshooting table on the following pages contains
symptoms that may be seen in a malfunctioning air
conditioner. Each group of symptoms is accompanied by
one or more possible causes. Each possible cause is
accompanied by a remedy, or a test to determine if
suspect component(s) are working properly.
6 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Troubleshooting information
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.
Corrective Action
Symptom
Fan motor will not operate.
Possible Causes
No power supplied to unit.
Wire(s) disconnected or loose.
Fan motor capacitor faulty.
Check fuse box/circuit
breaker for blown fuse or
tripped breaker. Replace/reset.
Check power cord for opens.
Replace cord if faulty.
Ensure all connections are
tight and secure.
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.
Fan hitting shroud or blower wheel hitting scroll.
Fan blade will not rotate.
Wire(s) disconnected or loose.Fan motor operates intermittently.
Cycling on motor protector.
Check fan blade!blower wheel
for proper alignment on motor
shaft. Reposition if necessary.
Check fan motor for proper
position, ensure mounting
nuts/bracket tight and secure.
Ensure all connections are
tight and secure.
Replace motor.
@2003 Maytag Appliances Company 16022061 Rev. 0 7

Troubleshooting information
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.
Corrective Action
Symptom
Fan motor noisy.
Compressor does not run,
fan motor operates normally.
Possible Causes
Outside coil fan blade or inside
coil blower wheel loose or improperly aligned.
Worn fan motor bearings.
Fan motor mounting hardware!bracket
loose.
Wire(s) disconnected or loose.
Compressor capacitor faulty.
Compressor faulty.
Check fan blade!blower wheel
for proper position. Reposition
if necessary.
Ensure hardware attaching
fan blade/blower wheel to
motor shaft is tight. Tighten if
loose, replace if stripped.
Replace motor.
Check mounting bolts/bracket
for tightness. Tighten if
necessary.
Ensure all connections are
tight and secure. Correct as
required.
Check capacitor for short.
Replace if faulty,
NOTE: Discharge capacitor
before testing.
Check compressor motor
windings for open /shorts.
Replace compressor if
faulty.
8 16022061 Rev. 0 @2003 MaytagAppliancesCompany

Troubleshooting information
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.
Corrective ActionPossible Causes
Overload protector open.
Rotary control faulty.
Wire(s) disconnected or loose.
Supply voltage out of specification.
Symptom
Compressor does not run,
fan motor operates normally.
Overload protector open.
Compressor cycles on and off.
Fan motor faulty.
Restricted air flow.
Compressor capacitor faulty.
Sealed refrigerant system fault.
Check protector for continuity.
If open, replace.
Ensure all control connections
are tight and secure. Check
control for proper operation
and installation. Replace if
faulty.
Ensure all connections are
tight and secure.
Check input voltage for proper
levels. Take appropriate
action if voltage levels out of
specification.
Check protector for continuity.
If open, replace.
Check fan motor for proper
operation. Replace if faulty.
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 coil if
repairs cannot be made.
Check capacitor for
short. Replace if faulty.
NOTE: Discharge capacitor
before testing.
Test sealed system for proper
charge, leaks, and restrictions.
@2003 Maytag Appliances Company 16022061 Rev. 0 9

Troubleshooting information
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.
Possible Causes Corrective Action
Symptom
Insufficient cooling.
Excessive noise.
Low refrigerant charge.
Restricted air flow.
Unit undersized for area/room.
Outside coil fan blade or inside coil
blower wheel loose or improperly aligned.
Compressor mounting hardware loose or
grommets worn.
Free parts, loose screws causing or allowing
excessive vibration.
Worn fan motor bearings.
Test sealed system for proper
charge. Ensure system is free
of leaks.
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 coil if
repairs cannot be made.
Reduce area being cooled or
replace unit with larger
capacity model.
Check fan blade!blower wheel
for proper position. Reposition
blade or bower wheel.
Ensure hardware attaching fan
blade/blower wheel to motor
shaft is tight.
Check mounting bolts for
tightness. Tighten if
necessary. Don't overtighten.
Inspect grommets for wear.
Inspect unit for parts that may
have worked free, loose/
missing screws, other
)roblems that
may cause excessive
vibration.
Replace motor
10 16022061 Rev. 0 @2003 MaytagAppliancesCompany