Goldstar BG8000ER User manual

ROOM AIR CONDITIONER
SERVICE MANUAL
CAUTION
• BEFORE SERVICING THE UNIT, READ THE SAFETY PRECAUTIONS
IN THIS MANUAL.
• ONLY FOR AUTHORIZED SERVICE PERSONNEL.
MODEL: BG8000ER, WG8005R,
WG1005R, WG1205R
website http://www.lgservice.com

2Room Air Conditioner
Air Conditioner Service Manual
TABLE OF CONTENTS
Safety Precautions..........................................................................................................................................3
Dimensions .....................................................................................................................................................6
Outside Dimensions...................................................................................................................................6
Product Specifications ..................................................................................................................................7
Installation.......................................................................................................................................................8
Select the Best Location ............................................................................................................................8
Installation Check.......................................................................................................................................8
How to Secure the Drain Pipe....................................................................................................................8
How to Install..............................................................................................................................................9
Operation ......................................................................................................................................................13
Location and Function of Controls ...........................................................................................................13
Remote Control Operations ....................................................................................................................14
Disassembly..................................................................................................................................................15
Mechanical Parts......................................................................................................................................15
Air Handling Parts...................................................................................................................................16
Electrical Parts.........................................................................................................................................17
Refrigerating Cycle...................................................................................................................................19
Schematic Diagram.......................................................................................................................................22
Wiring Diagram.........................................................................................................................................22
Electronic Control Device.........................................................................................................................24
Components Location(For Main P.W.B ASM)...........................................................................................25
Troubleshooting Guide.................................................................................................................................26
Piping System ........................................................................................................................................26
Troubleshooting Guide .............................................................................................................................27
Exploded View ..............................................................................................................................................35
Replacement Parts List ................................................................................................................................36

Service Manual 3
Safety Precautions
Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions
must be followed.
Incorrect operation due to ignoring instructions will cause harm or damage.The seriousness
is classified by the following indications.
Meanings of symbols used in this manual are as shown below.
WARNING
CAUTION
This symbol indicates the possibility of death or serious injury.
This symbol indicates the possibility of injury or damage to property only.
WARNING

Always install the expansion panel(s).
•Improper assembly or installation may cause
incorrect operation, including injury, fire, and
Do not place the power cord near a heater.
•It may cause fire and electric shock.
Do not use the power cord near flammable
gas or combustibles such as gasoline,
benzene, thinner, etc.
•It may cause explosion or fire.
Do not disassemble or modify products.
•It may cause failure and electric shock.
Be sure not to do.
Be sure to follow the instruction.
electric shock hazards.

4Room Air Conditioner
Safety Precautions
Plug in the power plug
properly.
•Otherwise, it will cause
electric shock or fire.
Do not operate or stop the
unit by inserting or pulling
out the power plug.
•It will cause electric shock or
fire.
Do not damage or use an
unspecified power cord.
•It will cause electric shock or
fire.
Do not use the socket if it is
loose or damaged.
•• It may cause fire and electric
shock.
Do not operate with wet
hands or in damp
environment.
•It will cause electric shock.
Use the air conditioner on a
single outlet circuit.(see page 7.)
Do not share the outlet with
other appliances.
• It will cause electric shock or
fire.
Do not modify power corDo not modify poDo not modify po dwer cor
length.
Do not modify po
••• It will cause electric shoc•k or
fire.
Always plug into a
grounded outlet.
•No•• grounding•may cause
electric shock.
Ventilate before operating air
conditionerwhen gas goes
out.
It may cause explosion, fire,
and burn.

Service Manual 5
Safety Precautions
CAUTION
•
•
•
•
•
If water enters the product, turn off the the
power switch of the main body of appliance.
Contact service center after taking the power-
plug out from the socket.
•It will cause electric shock or failure of
machine.
Do not clean the air conditioner with water.
•Water may enter the unit and degrade the
insulation. It may cause an electric shock.
Never touch the metal parts of the unit
when removing the filter.
Do not block the inlet or outlet.
They are sharp and may cause injury. It may cause failure of appliance or
performance deteriorate.
Ensure that the outer caseis not damaged
by age orwear.
Leaving it damaged couldresult in the air
conditioner falling out of the window, creating
a safety hazard.
Be cautious not to touch the sharp edges
when installing.
It may cause injury.
Sharp
edges

6Room Air Conditioner
Dimensions
Dimensions
Outside Dimensions
This symbol alerts you to the risk of electric shock.
This symbol alerts you to hazards that could cause harm to the
air conditioner.
This symbol indicates special notes.
NOTICE
Symbols Used in this Manual
353(13 7/8")
470(18 1/2")525(20 11/16")

Service Manual 7
Specfications
Product Specifications
POWER SUPPLY
COOLING CAPACITY (Btu/h)
INPUT (W)
RUNNING CURRENT (A)
E.E.R (BTU/W.h)
INDOOR ( C)
OUTDOOR ( C)
REFRIGERANT (R-22) CHARGE
EVAPORATOR
CONDENSER
FAN, INDOOR
FAN, OUTDOOR
FAN SPEEDS, FAN/COOLING
FAN MOTOR
OPERATION CONTROL
ROOM TEMP. CONTROL
AIR DIRECTION CONTROL
CONSTRUCTION
PROTECTOR COMPRESSOR
FAN MOTOR
POWER CORD
DRAIN SYSTEM
(W x H x D) (mm)
BG8000ER WG8005R WG1005R WG1205R
MODELS
ITEMS
OPERATING
CONDITION
* DB:Dry Bulb
** WB:Wet Bulb
1Ø, 115, 60Hz
8,000 10,000 12,000
740 1020 1220
6.8 9.2 11.0
10.8 9.8
26.7(DB)* 19.4(WB)**
35(DB)* 23.9(WB)**
385g(13.6oz) 260g(9.2oz) 440g(15.5oz) 380g(13.4oz)
Ø9.52, 2ROW 12STACKS Ø7.0, 2ROW 14STACKS
Ø7.0, 2ROW 16STACKS Ø5.0, 2ROW 16STACKS Ø7, 2R 16STACKS 5, 2R 18STACKS
Ø7, 3R 14STACKS .7, 2R 14STACKS
TURBO FAN
PROPELLER TYPE FAN WITH SLINGER RING
3/3
6 POLES
REMOTE CONTROLLER
THERMISTOR
HORIZONTAL LOUVER (UP & DOWN), VERTICAL LOUVER (RIGHT&LEFT)
SLIDE IN-OUT CHASSIS
OVERLOAD PROTECTOR
INTERNAL THERMAL PROTECTOR
3 WIRE WITH GROUNDING
ATTACHMENT PLUG (CORD-CONNECTED TYPE)
DRAIN PIPE OR SPLASHED BY FAN SLINGER
469 x 353 x 526 380 x 600 x 555
Ser 7
Product Specifications
.
C)
H x
.0 Ø
Ser 7
Product Specifications
.
.0
7
Product Specifications
.
OUTSIDE DIMENSION (inch)
820
7.6
9.8
.0
18 1/2 x 13 7/8 x 20 11/16 235/8x1431/32x225/16
Ø
Ø

8Room Air Conditioner
Installation
Installation
Select the Best Location
Installation Check
How to Secure the Drain Pipe
1. To prevent vibration and noise, make sure the unit is installed
securely and firmly.
2. Install the unit where the sun does not shine directly on the
unit.
3. The outside of the cabinet must extend outward for at least
11" and there should be no obstacles, such as a fence or
wall, within 20" from the back of the cabinet because it will
prevent heat radiation of the condenser.
Restriction of outside air will greatly reduce the cooling effi-
ciency of the air conditioner.
CAUTION: All side louvers of the cabinet must
remain exposed on the outdside of the structure.
4. Install the unit slanted slightly so the back is slightly lower
than the front (about 1/4"). This will force condensed water
to the outside.
5. Install the unit with the bottom about 30"~60" above the
floor level.
The setting conditions must be checked prior to initial starting.
The following items are especially important checking points when the installation is finished.
1. Grounding wire (Green or Green and Yellow) is provided in the power cord. The green wire must be grounded.
2. Connect to a single-outlet 15A circuit.
(or 20A circuit for Electric Heater Model)
3. To avoid vibration or noise, make sure the air conditioner is installed securely.
4 Avoid placing furniture or draperies in front of the air inlet and outlet.
In humid weather, excess water may cause the Base Pan to
overflow. To drain the water, remove the Drain Cap and secure
the Drain Pipe to the rear hole of the Base Pan. (Figure. 2)
ABOUT / "
Over 20"
HEAT
RADIATION
FENCE
AWNING
OUTSIDE
INSIDE
COOLED AIR
30"-60"
14
Drain Pipe Drain Cap
Figure 1
Figure 2

Service Manual 9
Installation
How to Install
Window Requirements
All supporting parts should be secured to
firm wood, masonry, or metal.
1. This unit is designed for installation in standard double
hung windows with actual opening widths of 22" to 36".
The upper and lower sash must open sufficiently to allow
a clear vertical opening of 15" from the bottom of the
sash to the window stool.
2. If storm window presents interference, fasten a 2" wide
wood strip to the inner window sill across the full width of
the sill. The wood strip should be thick enough to raise
the height of the window sill so that the unit can be
installed without interference by the storm window
frame. See Figure. 4. Top of wood strip should be
approximately 3/4" higher than the storm window frame
(STORM WINDOW FRAME) or wood strip (OUT-
DOORS) to help condensation to drain properly to the
outside.
3. Install a second wood strip (approximately 6" long by 11/2"
wide and same thickness as first strip) in the center of the
outer sill flush against the back off the inner sill. This will
raise the L bracket as shown Figure. 4.
4. If the distance between STORM WINDOW FRAME and
WOOD STRIP MOUNTED ON TOP OF INNER SILL is
more than 1", two of wood strip are not necessary.
Installation
NOTICE
OUTDOORSINDOORS
INNER
SILL
OUTER
SILL
INNER
SILL
WOOD STRIP MOUNTED
ON TOP OF INNER SILL
WOOD STRIP
FOR
L BRACKET
3/4"
CLEARANCE
1" MAX.
STORM
WINDOW
FRAME
OUTDOORSINDOORS
OUTER
SILL
Figure 3
Figure 4
Type F:2EA
(SILL SUPPORT)
Type G:2EA
(BOLT)
Type C:5EA
(SCREW)
Type A:16EA
(SCREW)
Type D:2EA
(NUT)
10
16mm
16mm
Type B:3EA
(SCREW)
Type E:2EA
(FRAME CURTAIN)
10mm
Type K:2EA
(FRAME-GUIDE)
Type J:1EA
(FOAM-PE)
Type I:1EA
(UPPER GUIDE)
Type H:1EA
(FOAM-STRIP)
Type O:1EA
(DRAIN WASHER)
Type N:1EA
(DRAIN JOINT PIPE)
Type M:1EA
(FOAM-PE)
Type L:1EA
(WINDOW LOCKING BRACKET)
HARDWARE

10 Room Air Conditioner
Installation
PREPARATION OF CHASSIS
1. Remove the screws which fasten the cabinet at both
sides and at the back.
2. Slide the unit from the cabinet by gripping the base
pan handle and pulling forward while bracing the
cabinet.
3. Cut the window sash seal to the proper length.
Peel off the backing and attach the Foam-Peto the
underside of the window sash.
4. Remove the backing from the top Upper Guide Foam-
Pe and attach it to the bottom of the Upper Guide.
5. Attach the Upper Guide onto the top of the cabinet with
3 type A screws.
6. Insert the Frame Guides into the bottom of the cabinet.
7. Insert the Frame Curtain into the Upper Guide
and Frame Guides .
8. Fasten the curtains to the unit with 4 Type A screws.
CABINET INSTALLATION
1. Open the window. Mark a line on center of the
window stool(or desired air conditioner location).
Carefully place the cabinet on the window stool and
align the center mark on the bottom front with the
center line marked in the window stool.
2. Pull the bottom window sash down behind the Upper
Guide until it meets.
Upper Guide
Upper Guide
Screw
Frame-Guide
(Type A)
Upper Guide
Window Sash
Window stool
Front Angle
Upper guide
Frame Curtain
Foam-pe
Foam-pe
Cabinet
Foam-Pe
Shipping
Screws
Figure 5
Figure 6
NOTICE
Do not pull the window sash down so tightly
that the movement of Frame Curtain is restricted.
Foam-Pe
Frame-Guide
Screw
Screw
(Type A)
(Type A)

Service Manual 11
Installation
INDOOR OUTDOOR
Sill Support
Nut
Bolt
INDOOR OUTDOOR
Frame Guide
About 1/2"
Screw(Type A)
Cabinet
About 1/2"
Screw(Type B) Screw(Type A)
Sill support
Sash track
Front Angle
Type C
Screw(Type B)
Sill support
3. Loosely assemble the Sill Support using the parts in
Figure 7.
4. Select the position that will place the Sill Support
near the outer most point on sill (See Figure 8)
5. Attach the Sill Support to the cabinet track hole in
relation to the selected position using 2 Type A
screws in each support(See Figure 8).
6. The cabinet should be installed with a very slight
tilt(about 1/2") downward toward the outside (See
Figure 9).
Adjust the bolt and the nut of Sill Support for
balancing the cabinet.
7. Attach the cabinet to the window stool by driving the
screws (Type B: Length sixteen millimeters and
below.) through the front angle into window stool.
8. Pull each Frame Curtain fully to each window sash
track, and repeat step 2.
9. Attach each Frame Curtain the window sash using
screws (Type C).(See Figure 10)
Figure 7
Figure 8
Figure 9
Figure 10
NOTICE
Be careful when you install the cabinet (Frame
Guides are broken so easily).
CAUTION: DO NOT DRILL A HOLE IN THE
BOTTOM PAN.
The unit is designed to operate with approximately
1/2" of water in bottom pan.

Screw(Type A)
Screw(Type A)
Power cord
Foam-Strip
Window Locking Bracket
10. Slide the unit into the cabinet.(See Figure 11)
11. Cut the Foam-Strip to the proper length and insert
between the upper window sash and the lower
window sash.
(See Figure 12)
12. Attach the Window Locking Bracket with aType C
screw. (See Figure 13)
13. Attach the front grille to the cabinet by inserting the
tabs on the grille into the tabs on the front of the
cabinet. Push the grille in until it snaps into place.
(See Figure 14)
14. Lift the inlet grille and secure it with aType Ascrew
through the front grille.
(See Figure 15)
15. Window installation of room air conditioner is now
completed. See ELECTRICAL DATA for attaching
power cord to electrical outlet.
Figure 11
Figure 12
Figure 13
Figure 16
Figure 15
Figure 14
12 Room Air Conditioner
CAUTION: For security purpose, reinstall screws
(Type A) at cabinet's sides.
Installation

Operation
Location and Function of Controls
CAUTION: If you turn off the air conditioner or switch from cooling to the fan, wait
at least 3 minutes before setting to cooling again.
FOR NORMAL COOLING
1. Turn the operation switch to the High Cool or the Low Cool setting.
2. Set the thermostat control to the desired temperature mark (the mid-point is a good starting
position). If the room temperature is not satisfactory after a reasonable time, adjust the con-
trol to a cooler or warmer setting, as appropriate.
FOR MAXIMUM COOLING
1. Turn the operation switch to the High Cool setting.
2. Set the thermostat control to the largest temperature mark.
FOR QUIETER OPERATION
1. Turn the operation switch to the Low Cool setting.
2. Set the thermostat control as needed.
•DESIGNED FOR COOLING ONLY
•POWERFUL AND INCREDIBLE COOLING
•TOP-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE
•BUILT-IN ADJUSTABLE THERMOSTAT
•WASHABLE ONE-TOUCH FILTER
•COMPACT SIZE
Service Manual 13
Operation
O ff - Turns air conditioner off.
Me d Fa n - Med speed fan operation without cooling.
Low Fa n - Low speed fan operation without cooling.
High C ool - Cooling with high speed fan operation.
Me d C ool - Cooling with med speed fan operation.
Low C ool - Cooling with low speed fan operation.
This automatically controls the temperature of the indoor air.
Turn the knob so that arrow points to the larger marks for greater cooling.
Point the arrow to the smaller marks for more moderate cooling.
(i.e. the higher the number, the greater the cooling)
4
3
2
1
6
7
9
5
Thermostat  
Operation  
8

The controls look like this:
Controls
Auto
Swing
Power
Temp
Fan Speed
Timer Mode
Energy
Saver
1
2
5
4
3
6
Remote Control Operations
1. Power
•To turn the Set ON, push the button. To turn the
Set OFF, push the button again.
•This button takes priority over any other buttons.
•When you first turn it on, the Set is on the High cool
mode and the temp. at 72°F
2. Temperature Setting
•This button controls the room temperature setting
in a range between 60°F and 86°F in 1°incre-
ments.
3. Fan Speed
•Pressing the Fan Speed button toggles between
Low and High speeds.
4. On/Off Timer
- Stopping Operation
Each press of the button cycles through the options
in this order:
1 Hour →2 Hours →3 Hours →4 Hours →5 Hours
→6 Hours →7 Hours →8 Hours →9 Hours →
10 Hours →11 Hours →12 Hours →CANCLE.
The set temperature will be raised by 2°F after 30
minutes and again after another 30 minutes.
- Starting Operation
Each press of the button cycles through the options
in this order:
1 Hour →2 Hours →3 Hours →4 Hours →5 Hours
→6 Hours →7 Hours →8 Hours →9 Hours →
10 Hours →11 Hours →12 Hours →CANCLE.
5. Energy Saver
The fan stops when the compressor stops cooling.
•Approximately every 3 minutes the fan will turn on
and check the room air to determine if cooling is
needed.
6. Cool/Fan/Dry
•Everytime you push this button, it will toggle
between COOL, FAN, and DRY.
How to Insert Batteries
1. Remove the cover from the back of the remote con-
troller
2. Insert two batteries.
•Be sure of the polarity when installing the batteries.
•Be sure that both batteries are new.
3. Re-attach the cover.
•Do not use rechargeable batteries.
Such batteries
differ from standard dry cells in
shape, dimensions, and perfor-
mance.
•Remove the batteries from the
remote controller if the air condi-
tioner is not going to be used for
an extended length of time.
CAUTION: The Remote Controller will not function properly if strong light strikes
the sensor window of the air conditioner or if there are obstacles between the
Remote Controller and the air conditioner.
3
4 5 6２ １
７
14Room Air Conditioner
Operation

Disassembly
Disassembly
Mechanical Parts
—Before the following disassembly, POWER SWITCH set to OFF and disconnect the power cord.
1. FRONT GRILLE
1. Open the lnlet grille upward or downward.
2. Remove the screw which fastens the front grille.
3. Pull the front grille from the right side.
4. Remove the front grille.
5. Re-install the component by referring to the
removal procedure, above.(See Figure 17)
2. CABINET
1. After disassembling the FRONT GRILLE, remove
the 2 screws which fasten the cabinet at both
sides.
2. Remove the 2 screws which fasten the cabinet at
back.
3. Pull the base pan forward. (See Figure 18)
4. Remove the cabinet.
5. Re-install the component by referring to the
removal procedure, above.
3. CONTROL BOX
1. Disconnect the unit from the power source.
2. Remove the front grille.
3. Remove the cabinet.
4. Remove the screw which fastens the control box
cover.
5. Remove the housing which connects motor wire
in the control box.
6. Remove the 3 leads from the compressor.
7.Discharge the capacitor by placing a 20,000
ohmresistor across the capacitor terminals.
8. Remove the 2 screws which fasten the control
box.(See Figure 19)
9. Pull the control box forward completely.
10. Re-install the components by referring to the
removal procedure, above. (See Figure 19)
Figure 17
Figure 19
Figure 18
Service Manual 15

16 Room Air Conditioner
Disassembly
Air Handling Parts
—7—
1.AIR GUIDE AND BLOWER
1. Remove the front grille.
2. Remove the cabinet.
3. Remove the control box.
4. Remove the 3 screws which fasten the brace.
5. Remove the brace.
6. Remove the 2 screws which fasten the evaporator.
7. Move the evaporator forward and pulling it upward
slightly. (See Figure 20)
8. Move the evaporator to the left carefully.
9. Pull out the hook of orifice by pushing the tabs and
remove it. (See Figure 21)
10.Remove the clamp with a hand plier which
secures the blower.
11. Remove the blower.
12. Remove the 4 screws which fasten the air guide
from the barrier.
13. Move the air guide backward, pulling out from the
base pan.
14. Re-install the components by referring to the
removal procedure, above.
2.FAN AND SHROUD
1. Remove the cabinet.
2. Remove the brace.
3. Remove the 3 screws which fasten the condenser.
4. Move the condenser to the left carefully.
5. Remove the clamp which secures the fan.
6. Remove the fan and then pull out the shroud.
(See Figure 22)
7. Re-install by referring to the removal procedure.
Figure 20
Figure 21
Figure
22

Service Manual 17
Electrical Parts
1. Remove the cabinet.
2. Remove the evaporator.
3. Remove the orifice.
4. Remove the blower.
5. Remove the fan.
6. Remove the control box cover and housing of the
motor in the control box.
7. Remove the 2 screws which fasten the motor from
the mount motor. (See Figure 23)
8. Remove the motor.
9. Re-install the components by referring to the
removal procedure, above.(See Figure 23)Figure 23
3. MOTOR
1. OVERLOAD PROTECTOR
1. Remove the cabinet.
2. Remove the nut which fastens the terminal cover.
3. Remove the terminal cover. (See Figure 24)
4. Remove all the leads from the overload protector.
5. Remove the overload protector.
6. Re-install the component by referring to the
removal procedure, above.
Figure 24
Disassembly
2. COMPRESSOR
1. Remove the cabinet.
2. Discharge the refrigerant system using a FreonTM
Recovery System.
If there is no valve to attach the recovery system,
install one (such as a WATCO A-1) before venting
the FreonTM. Leave the valve in place after
servicing the system.
3. Remove the overload protector.
4. After purging the unit completely, unbraze the
suction and discharge tubes at the compressor
connections.
5. Remove the 3 nuts and the 3 washers which
fasten the compressor.
6. Remove the compressor. (See Figure 25)
7. Re-install the components by referring to the
removal procedure, above.
Figure 25

3. CAPACITOR
MODEL : ROTARY SWITCH TYPE MODEL
MODEL : TOUCH & REMOTE CONTROL TYPE MODEL
4. THERMOSTAT
MODEL : ROTARY SWITCH TYPE MODEL
Disassembly
18 Room Air Conditioner
1. Remove the control box.
2. Remove the screw which fasten control panel from
control box.
3. Remove the screw which located in the front.
4. Open the bottom side of control box.
5. Remove the screw and the clamp which fastens
the capacitor.
6. Disconnect all the leads of capacitor terminals.
7. Re-install the components by referring to the
removal procedure, above. (See Figure 27)Figure 27
Figure 26
1. Remove the control box.
2. Remove the knobs and the screw which fasten
control panel from control box.
3. Remove the screw which is located in the front.
4. Open the bottom side of control box.
5. Remove the screw and the clamp which fasten the
capacitor.
6. Disconnect all the leads of capacitor terminals.
7. Re-install the components by referring to the
removal procedure, above. (See Figure 26)
1. Remove the control box.
2. Open the control box.
3. Remove the 2 screws which fasten the thermostat.
4. Disconnect 2 leads of thermostat terminals.
5. Remove the thermostat.
6. Re-install the components by refereing to the above
removal procedure. (See Figure 28)Figure 28

Service Manual 19
Disassembly
6. ROTARY SWITCH
MODEL : ROTARY SWITCH TYPE MODEL
7. POWER CORD
Refrigerating Cycle
CAUTION: Discharge the refrigerant system using a FreonTM Recovery System. If there is no valve
to attach the recovery system, install one (such as a WATCO A-1) before venting the FreonTM. Leave
the valve in place after servicing the system.
1. CONDENSER
1. Remove the control box.
2. Open the control box.
3. Remove the 2 screws which fasten the rotary switch.
4. Disconnect all the leads of the rotary switch terminals.
5. Remove the rotary switch.
6. Re-install the components by referring to the above
removal procedure. (See Figure 29)
Figure 29
Figure 30
1. Remove the control box.
2. Open the control box.
3. Disconnect the grounding screw from the control
box.
4. Disconnect the 2 receptacles.
5. Remove a screw which fastens the clip cord.
(See Figure 30)
6. Remove the power cord.
7. Re-install the component by referring to the above
removal procedure, above.
(Use only one ground-marked hole for ground
connection.)
8. If the supply cord of this appliance is damaged, it
must be replaced by the special cord. (The
special cord means the cord which has the same
specification marked on the supply cord attached at
the unit.)
Figure 31
1. Remove the cabinet.
2. Remove the 3 screws which fasten the
brace.
3. Remove the 3 screws which fasten the condenser
and shroud.
4. After discharging the refrigerant completely,
unbraze the interconnecting tube at the condenser
connections.
5. Remove the condenser carefully.
6. Re-install the component by referring to notes.
(See Figure 31)

20 Room Air Conditioner
Disassembly
—Replacement of the refrigeration cycle.
1. When replacing the refrigeration cycle, be sure to
Discharge the refrigerant system using a FreonTM
recovery System.
If there is no valve to attach the recovery system,
install one (such as a WATCO A-1) before venting
the FreonTM. Leave the valve in place after
servicing the system.
2. After discharging the unit completely, remove the
desired component, and unbraze the pinch-off
tubes.
3. Solder service valves into the pinch-off tube ports,
leaving the valves open.
4. Solder the pinch-off tubes with Service valves.
5. Evacuate as follows.
1) Connect the vacuum pump, as illustrated figure
33A.
2) Start the vacuum pump, slowly open manifold
valves A and B with two full turns counterclock-
wise and leave the valves open.
The vacuum pump is now pulling through valves
A and B up to valve C by means of the manifold
and entire system.
CAUTION: If high vacuum equip-
ment is used, just crack valves A
and B for a few minutes, then open
slowly with the two full turns counter-
clockwise. This will keep oil from foaming
and being drawn into the vacuum pump.
3) Operate the vacuum pump vaccum for 20 to 30
minutes, until 600 microns of vaccum is
obtained. Close valves A and B, and observe
vacuum gauge for a few minutes. A rise in pres-
sure would indicate a possible leak or moisture
remaining in the system. With valves A and B
closed, stop the vacuum pump.
4) Remove the hose from the vacuum pump and
place it on the charging cylinder. See figure
37B. Open valve C.
Discharge the line at the manifold connection.
5) The system is now ready for final charging.
6. Recharge as follows :
1) Refrigeration cycle systems are charged from
the High-side. If the total charge cannot be put
in the High-side, the balance will be put in the
suction line through the access valve which you
installed as the system was opened.
2) Connect the charging cylinder as shown in figure
33B.
With valve C open, discharge the hose at the
manifold connection.
3) Open valve A and allow the proper charge to
enter the system. Valve B is still closed.
4) If more charge is required, the high-side will not
take it. Close valve A.
5) With the unit running, open valve B and add the
balance of the charge.
a.
Do not add the liquid refrigerant to the Low-side.
b. Watch the Low-side gauge; allow pressure to
rise to 30 lbs.
c. Turn off valve B and allow pressure to drop.
d. Repeat steps b. and c. until the balance of the
charge is in the system.
6) When satisfied the unit is operating correctly,
use the pinch-off tool with the unit still running
and clamp on to the pinch-off tube. Using a tube
cutter, cut the pinch-off tube about 2 inches from
the pinch-off tool. Use sil-fos braze and braze
pinch-off tube closed. Turn off the unit, allow it to
set for a while, and then test the leakage of the
pinch-off connection.
NOTICE
2. EVAPORATOR
3. CAPILLARY TUBE
Figure 32
1. Remove the cabinet.
2. Remove the 2 screws which fasten the evaporator.
3. Move the evaporator sideways carefully.
4. After discharging the refrigerant completely,
unbraze the interconnecting tube at the evaporator
connections.
5. Remove the evaporator carefully.
6. Re-install the component by referring to notes.
(See Figure 32)
1. Remove the cabinet.
2. After discharging the refrigerant completely,
unbraze the interconnecting tube at the capillary
tube.
3. Remove the capillary tube.
4. Re-install the component by referring to notes.