Friedrich ZQ05B10 User Manual

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Room Air Conditioner

Service and Parts

Manual

ZStar ®

ZQ05B10 ZQ07B10

ZQ05/ZQ07 (06/05)

CONTENTS

 

1. PREFACE ...................................................................................................................................................

3

1.1 FEATURES.....................................................................................................................................................

3

1.2 SPECIFICATIONS .........................................................................................................................................

3

1.3 LOCATIONS OF CONTROLS .......................................................................................................................

4

1.4 SAFETY PRECAUTIONS ..............................................................................................................................

4

1.5 INSULATION RESISTANCE TEST ................................................................................................................

4

2. DISASSEMBLY INSTRUCTIONS ................................................................................................

5

2.1 MECHANICAL PARTS ..................................................................................................................................

5

2.1.1 FRONT GRILLE ....................................................................................................................................

5

2.1.2 CABINET................................................................................................................................................

5

2.1.3 CONTROL BOARD ................................................................................................................................

5

2.2 AIR HANDLING PARTS ................................................................................................................................

6

2.2.1 AIR GUIDE UPPER ..............................................................................................................................

6

2.2.2 ORIFICE, TURBO FAN AND FAN .........................................................................................................

6

2.2.3 MOTOR ..................................................................................................................................................

7

2.2.4 AIR GUIDE.............................................................................................................................................

7

2.3 ELECTRICAL PARTS ....................................................................................................................................

7

2.3.1 OVERLOAD PROTECTOR ...................................................................................................................

7

2.3.2 COMPRESSOR .....................................................................................................................................

8

2.3.3 CAPACITOR ..........................................................................................................................................

8

2.3.4 THERMOSTAT .......................................................................................................................................

8

2.3.5 ROTARY SWITCH ..................................................................................................................................

8

2.3.6 POWER CORD .....................................................................................................................................

9

2.4 REFRIGERANT CYCLE ................................................................................................................................

9

2.4.1 CONDENSER .......................................................................................................................................

9

2.4.2 EVAPORATOR ....................................................................................................................................

10

2.4.3 CAPILLARY TUBE ..............................................................................................................................

10

3. TROUBLESHOOTING GUIDE.................................... ..................................... ...........................

12

3.1 OUTSIDE DIMENSIONS... ............................................................................................................. ............

12

3.2 PIPING SYSTEM ...................................................................................................................... ..................

13

3.3 TROUBLESHOOTING GUIDE ..................................................................................................... ..............

14

4. CIRCUIT DIAGRAM ...........................................................................................................................

19

5. EXPLODED VIEW ..............................................................................................................................

20

6. SERVICE PARTS LIST ....................................................................................................................

21

—2—

1. PREFACE

This service manual provides various service information, including the mechanical and electrical parts, etc. This room air conditioner was manufactured and assembled under a strict quality control system.

The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

1.1 FEATURES

DESIGNED FOR COOLING ONLY

POWERFUL AND INCREDIBLE COOLING

TOP-DOWNCHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE

BUILT-INADJUSTABLE THERMOSTAT

WASHABLE ONE-TOUCHFILTER

COMPACT SIZE

1.2 SPECIFICATIONS

MODELS

ZQ05B10

 

ZQ07B10

ITEMS

 

 

 

 

COOLING CAPACITY (BTU/h)

5,100

 

6,500

 

 

 

 

POWER SUPPLY (Phase, V, Hz)

 

1ø, 115V, 60HZ

 

 

 

 

INPUT (W)

540

 

670

 

 

 

 

OPERATING CURRENT (AMP.)

5.0

 

6.1

 

 

 

 

REFRIGERANT CONTROL

 

CAPILLARY TUBE

 

 

 

 

REFRIGERANT CHARGE (R-22)

325g (7.9 oz)

 

335g (11.8 oz)

 

 

 

 

INSIDE FAN

 

TURBO FAN

 

 

 

OUTSIDE FAN

PROPELLER FAN WITH SLINGER RING

 

 

 

AIR DISCHARGE

2-WAY(RIGHT AND LEFT)

 

 

 

 

CHASSIS

 

TOP-DOWN

 

 

 

PROTECTOR

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

 

 

 

 

 

TEMPERATURE CONTROL

 

THERMISTOR

 

 

 

 

FAN MOTOR

6 POLES, 16W

 

6 POLES, 27W

 

 

 

 

—3—

1.3 LOCATIONS OF CONTROLS

 

Operation

Off

: Turns air conditioner off.

 

 

 

 

 

Off

Hi Fan

: High speed fan operation without

 

 

 

cooling.

 

Hi

Hi

 

 

 

 

 

Fan O

Cool

Lo Fan

: Low speed fan operation without

 

 

 

Lo

O

Lo

 

cooling.

Fan

Cool

 

 

 

 

 

Hi Cool

: Cooling with high speed fan

 

 

 

 

operation.

 

 

Mode

Lo Cool

: Cooling with low speed fan

 

 

 

 

 

 

 

operation.

 

 

 

 

 

Thermostat

 

 

 

 

 

This automatically controls the temperature of the

 

 

 

indoor air.

 

 

 

 

Turn the knob so that the 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

Warmer

Cooler

cooling)

 

 

Temperature

 

 

 

 

 

 

 

 

 

CAUTION : After switching the air conditioner from Cool to Off or Fan, wait at least 3 minutes before switching it back to Cool.

1.4 SAFETY PRECAUTIONS

1.When servicing, set the ROTARY SWITCH to Off and unplug the power cord.

2.Observe the original lead dress.

If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.

3.After servicing, make an insulation resistance test to prevent the customer from being exposed to shock hazards.

1.5 INSULATION RESISTANCE TEST

1.Unplug the power cord and connect a jumper between 2 pins (black and white).

2.The grounding conductor (green or green and yellow) is to be open.

3.Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all position [except Off] of the ROTARY SWITCH.

4.The value should be over 1 MΩ .

—4—

2. DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1.Disconnect the unit from source of power.

2.Remove the two knobs by pulling them off. Using a screwdriver, remove the screw that secures the front grille to control board.

(See Figure 1)

3.Push the front grille up from the bottom. Pull the top of the front grille away from the cabinet as the top tabs lift out of their slots. (See Figure 2)

4.Replace the grille by placing the tabs in the slots and push the grille until it snaps into place.

Figure 1

Figure 2

2.1.2 CABINET

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to section 2.1.1) 3. Remove 9 screws that secure the cabinet to the

base pan and condenser. (See Figure 3)

Figure 3

4. Lift the cabinet from the unit.

5. Re-installby referring to the procedures above.

2.1.3 CONTROL PANEL

1.Disconnect the unit from the power source.

2.Remove the front grille. (Refer to Section 2.1.1)

3.Remove the cabinet. (Refer to Section 2.1.2)

4.Remove 2 screws that secure the control board to base pan and air guide. (See Figure 4)

5.Pull the control board toward yourself.

NOTE : Controls, wires, and capacitor are now accessible for servicing. Discharge the capacitor before servicing. See step

2.3.3on page 8 for procedures.

6.Disconnect one housing terminal and 3 wires for the fan motor and compressor. (See Figure 5)

7.Re-installcomponents by referring to procedures above. (Refer to wiring diagram on page 23 in this manual or inside control board.)

Figure 4

Figure 5

— 5—

2.2 AIR HANDLING PARTS

2.2.1 AIR GUIDE UPPER

1.

Disconnect the unit from the power source.

2.

Remove the front grille. (Refer to Section 2.1.1)

3.Remove the cabinet. (Refer to Section 2.1.2)

4.Remove the control panel. (Refer to Section 2.1.3)

5.Remove 2 screws that secure the air guide upper to air guide lower. (See Figure 6)

6.Lift air guide upper upward.

7.Re-installby referring to the procedures above.

2.2.2 ORIFICE, TURBO FAN AND FAN

1.Disconnect the unit from the power source.

2.Remove the front grille. (Refer to Section 2.1.1)

3.Remove the cabinet. (Refer to Section 2.1.2)

4.Remove the control panel (Refer to Section 2.1.3)

5.Remove the air guide upper. (Refer to Section 2.2.1)

6.Remove 2 screws that secure the base pan to condenser. (See Figure 7)

7.Remove screw that secures the shroud to channel of condenser.

8.Press the snap area of shroud with your thumbs. This allows you to remove it from the condenser.

9.Lift the compressor upward with the evaporator and condenser. (See Figure 7)

10.Remove the orfice by pushing the snap area of the air guide blower. (See Figure 8)

11.Remove the clamp springs which are clamped to the base of fan and turbo fan by hand plier. (See Figure 9)

12.Pull the fan and turbo fan outward.

13.Remove the shroud.

14.Re-installby referring to the procedures above.

Figure 6

Figure 7

Figure 8

Figure 9

— 6—

2.2.3 MOTOR

1.Disconnect the unit from the power source.

2.Remove the front grille. (Refer to Section 2.1.1)

3.Remove the cabinet. (Refer to Section 2.1.2)

4.Remove the control panel. (Refer to Section 2.1.3)

5.Remove the air guide upper. (Refer to Section 2.2.1)

6.Remove the compressor, turbo fan, fan and shroud. (Refer to Section 2.2.2)

7.Remove 2 screws that secure the motor to the motor. (See Figure 10)

8.Remove the motor.

9.Re-installby referring to the procedures above.

2.2.4 AIR GUIDE

1.Disconnect the unit from the power source.

2.Remove the front grille. (Refer to Section 2.1.1)

3.Remove the cabinet. (Refer to Section 2.1.2)

4.Remove the control panel. (Refer to Section 2.1.3)

5.Remove the air guide upper. (Refer to Section 2.2.1)

6.Remove the compressor, turbo fan, fan and shroud. (Refer to Section 2.2.2)

7.Remove the motor. (Refer to Section 2.2.3)

8.Remove 2 screws that secure the air guide to the base pan. (See Figure 11)

9.Push the air guide backward and lift it upward. (See Figure 11)

10.Re-installby referring to the procedures above.

2.3ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

1.Remove the front grille and cabinet. (Refer to Section 2.1)

2.Remove the nut which fastens the terminal cover.

3.Remove the terminal cover.

4.Remove all the leads from the overload protector.

5.Remove the overload protector.

6.Re-installthe components by referring to the removal procedure above.

(See Figure 12 and 13)

Figure 10

Figure 11

Figure 12

Figure 13

 

— 7—

2.3.2 COMPRESSOR

1.Remove the front grille and cabinet. (Refer to Section 2.1)

2.Discharge the refrigerant by using a refrigerant recovery system.

3.Remove the overload protector. (Refer to Section 2.3.1)

4.After discharging the unit completely, unbraze the suction and discharge pipes at the compressor connections.

5.Remove 3 nuts which fasten the compressor.

6.Remove the compressor.

7.Re-installby referring to the removal procedure above. (See Figure 14)

2.3.3 CAPACITOR

1.Remove the cabinet. (Refer to Section 2.1.2)

2.Remove the control panel. (Refer to Section 2.1.3)

3.Discharge the capacitor by placing a 20 KΩ resistor across the capacitor terminals.

4.Remove the screw which fastens the capacitor clamp.

5.Remove all the leads of capacitor terminals.

6.Re-installthe components by referring to the removal procedure above. (See Figure 15)

Figure 14

Figure 15

2.3.4 THERMOSTAT

1. Remove the cabinet. (Refer to Section 2.1.2)

Figure 16

2. Remove the control panel. (Refer to Section 2.1.3)

3. Remove 2 screws which fasten the thermostat.

4. Remove all the leads of the thermostat terminals.

5. Remove the thermostat.

6. Re-installthe components by referring to the removal procedure above. (See Figure 16)

2.3.5 ROTARY SWITCH

Figure 17

1.Remove the cabinet. (Refer to Section 2.1.2)

2.Remove the control panel. (Refer to Section 2.1.3)

3.Remove 2 screws which fasten the rotary switch.

4.Remove all the leads of the rotary switch terminals.

5.Remove the rotary switch.

6.Re-installthe components by referring to the removal procedure above. (See Figure 17)

— 8—

2.3.6 POWER CORD

1.Disconnect the unit from source of power.

2.Remove the front grille. (Refer to Section 2.1.1)

3.Remove the cabinet. (Refer to Section 2.1.2)

4.Remove a screw that secures control panel to base pan. (Refer to Section 2.1.3)

5.Pulls the control panel toward you.

6.Disconnect the 2 receptacles and remove the grounding screw.

7.Remove a screw securing the clip with cord to the control board.

8.Pull the power cord.

9.Re-installby referring to procedures above.

2.4 REFRIGERANT CYCLE

2.4.1 CONDENSER

1.Remove the cabinet. (Refer to Section 2.1.2)

2.Discharge the refrigerant by using a refrigerant recovery system.

3.Remove the air guide. (Refer to Section 2.2.1)

4.Remove 2 screws which fasten the condenser.

5.After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections.

6.Remove the condenser.

7.Re-installby referring to the procedures above.

Figure 18

Figure19

— 9—

2.4.2 EVAPORATOR/CONDENSER

1.Remove the cabinet.

2.Discharge the refrigerant by using a refrigerant recovery system.

3.Remove the air guide upper. (Refer to Section 2.2.1)

4.After discharging the refrigerant completely, unbraze the interconnecting tube at the proper connections.

5.Remove the proper coil.

6.Re-installby referring to the procedures above.

2.4.3 CAPILLARY TUBE

1.Remove the cabinet.

2.Discharge the refrigerant by using a refrigerant recovery system.

3.Remove the air guide upper. (Refer to Section 2.2.1)

4.After discharging the refrigerant completely, unbraze the interconnecting tube of the capillary tube.

5.Remove the capillary tube.

6.Re-installby referring to the procedures above.

NOTES

Replacement of the refrigeration cycle.

1.When replacing the refrigeration cycle, be sure to discharge the refrigerant by using a refrigerant recovery system.

2.After discharging the unit completely, remove the desired components, and unbraze the pinch-offtubes.

3.Solder service valves into the pinch-offtube ports, leaving the valves open.

4.Solder the pinch-offtubes with service valves.

5.After completing the above procedures, the valve must be closed and left in place on the system for any subsequent procedures.

6.Evacuate as follows:

6-1.Connect the vacuum pump, as illustrated in figure 21A.

6-2.Start the vacuum pump. Slowly open manifold valves A and B with two full turns counterclockwise and leave the valves closed.

The vacuum pump is now pulling through valves A and B up to valve C by means of manifold and the entire system.

CAUTION : If high vacuum equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclock-

wise. This will keep oil from foaming and being drawn into the vacuum pump.

6-3.Operate the vacuum pump for 20 to 30 minutes, until 600 micron vacuum is obtained. Close valves A and B and observe vacuum gauge for a few minutes.

A rise in pressure would indicate a possible leak or moisture remaining in the system. With valves A and B closed, stop the vacuum pump.

6-4.Remove the hose from the vacuum pump and place it on the charging cylinder. See figure 21B. Open valve C.

Discharge the line at the manifold connection. 6-5.The system is now ready for final charging.

7.Recharge as follows:

7-1.Refrigeration cycle systems are charged from thehigh-side.If the total charge cannot be put in thehigh-side,the balance will be put in the suction line through the access valve which is installed as the system is opened.

7-2.Connect the charging cylinder as shown in figure 21B. With valve C open, discharge the hose at the manifold connection.

7-3.Open valve A and allow the proper charge to enter the system. Valve B is still closed.

7-4.If more charge is required, thehigh-sidewill not take it. Close valve A.

7-5.With the unit running, open valve B and add the balance of the charge.

a.Do not add the liquid refrigerant to the lowside.

b.Watch the low-sidegauge, allow pressure to rise to 30 lbs.

c.Turn off valve B and allow the pressure to drop.

d.Repeat steps b. and c. until the balance of the charge is in the system.

7-6.When the unit is operating correctly, use thepinch-offtool with the unit still running and clamp on thepinch-offtube. Using a tube cutter, cut thepinch-offtube about 2 inches from thepinch-off .Usesil-fossolder and solder thepinch-offtube closed. Turn off the unit, allow unit to sit for a while and then test the leakage of thepinch-offconnection.

— 10—