Friedrich ZQ10 A10B User Manual

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Room Air Conditioner

Service and Parts

Manual

ZStarTM

ZQ10 (03/01)

CONTENTS

1. PREFACE

 

1.1 SAFETY PRECAUTIONS................................

2

1.2 INSULATION RESISTANCE TEST .................

2

1.3 SPECIFICATIONS...........................................

3

1.4 FEATURES......................................................

4

1.5 CONTROL LOCATIONS .................................

4

2. DISASSEMBLY INSTRUCTIONS

 

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

5

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

5

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

5

2.1.3 CONTROL BOX .....................................

5

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

6

2.2.1 AIR GUIDE AND BLOWER ....................

6

2.2.2 FAN AND SHROUD ...............................

6

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

7

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

7

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

7

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

7

2.3.4 POWER CORD ......................................

8

2.3.5 THERMOSTAT.......................................

8

2.3.6 ROTARY SWITCH .................................

8

2.3.7 MOTOR ..................................................

8

2.4 REFRIGERATION CYCLE ...................................

9

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

9

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

9

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

9

3. INSTALLATION

 

3.1 INSTALLATION HARDWARE................................12

3.2 SELECT THE BEST LOCATION ...........................12

3.3 WINDOW REQUIREMENTS .................................13

3.4 STORM WINDOW REQUIREMENTS ...................13

3.5 PREPARING THE UNIT FOR INSTALLATION .....

14

3.6 BEFORE INSTALLATION......................................

14

3.7 INSTALL THE CASE IN THE WINDOW ................

15

3.8 INSTALL THE WINDOW LOCKING BRACKET

 

AND THE FOAM TOP WINDOW GASKET ...........

15

3.9 INSTALL THE AIR CONDITIONER IN THE CASE ...

16

3.10 TO REVERSE THE GRILLE OPENING ..............

16

4. TROUBLESHOOTING GUIDE

 

4.1 OUTSIDE DIMENSIONS ...............................

17

4.2 PIPING SYSTEM...........................................

18

4.3 TROUBLESHOOTING GUIDE ......................

19

5. SCHEMATIC DIAGRAM

 

• CIRCUIT DIAGRAM ..........................................

24

6. EXPLODED VIEW ..................................

25

7. REPLACEMENT PARTS LIST........

26

1. PREFACE

This SERVICE MANUAL provides various service information, 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 SAFETY PRECAUTIONS

1.2 INSULATION RESISTANCE TEST

1.When servicing the unit, set the ROTARY SWITCH or POWER 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 the unit, make an insulation resistance test to protect the customer from being exposed to shock hazards.

—2—

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

2.The grounding conductor (green or green & yellow) should 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 the positions (except OFF or O) of the ROTARY SWITCH.

4.The value should be over 1MΩ .

1.3 SPECIFICATIONS

 

MODELS

 

 

ZQ10A10B

ITEMS

 

 

 

 

 

 

 

 

POWER SUPPLY

 

 

1ø, 115V, 60Hz

COOLING CAPACITY

 

(Btu/h)

10,000

INPUT

 

 

(W)

 

1,020

RUNNING CURRENT

 

(A)

 

9.2

E.E.R

(Btu/W.h)

 

9.8

OPERATING

INDOOR

 

(°C)

26.7(DB)*

19.4(WB)**

 

 

TEMPERATURE

OUTDOOR

(°C)

35(DB)

23.9(WB)

REFRIGERANT (R-22)CHARGE

439g (15.5 oz)

EVAPORATOR

 

 

 

3 ROW 14 STACKS, S-FINTYPE

CONDENSER

 

 

 

2 ROW 16 STACKS, L-BENDEDTYPE

FAN, INDOOR

 

 

 

TURBO FAN

FAN, OUTDOOR

 

 

PROPELLER TYPE FAN WITH SLINGER-RING

FAN SPEEDS, FAN/COOLING

 

2/3

FAN MOTOR

 

 

 

6 POLES

OPERATION CONTROL

 

 

ROTARY SWITCH

ROOM TEMP. CONTROL

 

 

THERMOSTAT

AIR DIRECTION CONTROL

VERTICAL LOUVER (RIGHT & LEFT)

HORIZONTAL LOUVER (UP & DOWN)

 

 

 

 

CONSTRUCTION

 

 

SLIDE IN-OUTCHASSIS

PROTECTOR

COMPRESSOR

OVERLOAD PROTECTOR

FAN MOTOR

INTERNAL THERMAL PROTECTOR

 

POWER CORD

 

 

 

1.8m(7') (3 WIRE WITH GROUDING)

 

 

 

ATTACHMENT PLUG (CORD-CONNECTEDTYPE)

 

 

 

 

DRAIN SYSTEM

 

 

 

DRAIN PIPE OR SPLASHED BY FAN SLINGER

NET WEIGHT

 

(lbs/kg)

 

70/32

OUTSIDE DIMENSION

 

inch

181/2 x 137/8 x 2011/16

(W x H x D)

 

 

mm

470 x 353 x 525

*DB : dry bulb

**WB : wet bulb

—3—

1.4 FEATURES

Designed for cooling only.

Powerful and whisper cooling.

Slide-inandslide-outchassis for the simple installation and service.

Side air-intake,sidecooled-airdischarge.

Built in adjustable THERMOSTAT.

Washable one-touchfilter.

Compact size.

Reliable and efficient rotary compressor equipped.

1.5 CONTROL LOCATIONS

1.5.1 CONTROL ONLY MODEL

• VENTILATION

The ventilation lever must be in the CLOSE position in order to maintain the best cooling conditions. When fresh air is necessary in the room, set the ventilation lever to the OPEN position.

The damper is opened and room air is exhausted.

NOTE

Before using the ventilation feature, make a ventilation kit. First, pull down part to horziontal line with part.

FOR NORMAL COOLING

1.Turn the Mode switch to the High, Med orLow Cool setting.

2.Set the Temperature control to the desired temperature point (the mid-pointis a good starting position). If the room temperature is not satisfactory after a reasonable time, adjust the control to a cooler or warmer setting, as appropriate.

FOR MAXIMUM COOLING

1.Turn the Mode switch to the High Cool setting.

2.Set the temperature control to the highest temperature point (all the way to the right).

FOR QUIETER OPERATION

1.Turn the Mode switch to the Low Cool setting.

2.Set the Temperature control as needed.

Energy Saver Switch

This rocker switch can be depressed to either YES orNO. In theYES position, you will get the most economical operation. Both the fan and the compressor will cycle on and off together, maintaining the selected temperature at a more constant level and reducing the humidity more efficiently. This control will only operate when the unit is in a cooling mode. In theNO position, the fan will run constantly as long as the unit is in the cooling mode.

CLOSE VENTOPEN

Part B

Part A

—4—

2. DISASSEMBLY INSTRUCTIONS

— Before disassembling, turn the POWER SWITCH to OFF and disconnect the power cord.

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1.Open the INLET GRILLE downward and remove the air filter.

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-installthe component by referring to the above removal procedure. (See figure 1)

Figure 1

Shipping screws

2.1.2 CABINET

1. After disassembling the FRONT GRILLE, remove two screws which fasten the CABINET at both

sides. 2. Remove two screws which fasten the CABINET at

back. 3. Pull the BASE PAN forward. (See figure 2)

2.1.3 CONTROL BOX

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 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.

(Refer to section 2.3.1)

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 3)

9.Pull the control box forward completely.

10.Re-installthe components by referring to the removal procedure, above. (See Figure 3) (Refer to the circuit diagram found on page 24 in this manual or on the control box.)

Figure 2

Figure 3

— 5—

2.2 AIR HANDLING PARTS

2.2.1 AIR GUIDE AND BLOWER

1.Remove the front grille. (Refer to section 2.1.1)

2.Remove the cabinet. (Refer to section 2.1.2)

3.Remove the control box. (Refer to section 2.1.3)

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 4)

8.Move the evaporator to the left carefully.

9.Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 5)

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-installthe components by referring to the removal procedure, above.

Figure 4

Figure 5

2.2.2 FAN AND SHROUD

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

2. Remove the brace (Refer to section 2.2.1)

3. Remove the screw which fastens the cover cond.

4. Remove the 5 screws which fasten the condenser.

5. Move the condenser to the left carefully.

6. Remove the clamp with a hand plier which secures the fan.

7. Remove the fan and then pull out the shroud. (See Figure 6)

8. Re-installthe components by referring to the removal procedure.

Figure 6

— 6—

2.3 ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

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

2. Remove the nut which fastens the terminal cover.

3. Remove the terminal cover. (See Figure 7)

4. Remove all the leads from the overload protector.

5. Remove the overload protector.

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

Figure 7

2.3.2 COMPRESSOR

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

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. (Refer to section 2.3.1)

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 Figure 8 fasten the compressor.

6.Remove the compressor. (See Figure 8)

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

2.3.3 CAPACITOR

1. Remove the control box. (Refer to section 2.1.3)

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-installthe components by referring to the

removal procedure, above. (See Figure 9)

Figure 9

— 7—

2.3.4 POWER CORD

1.Remove the control box. (Refer to section 2.1.3)

2.Open the control box. (Refer to section 2.3.3)

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 10)

6.Remove the power cord.

7.Re-installthe component by referring to the above removal procedure, above.

(Use only one ground-markedhole

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.)

2.3.5 THERMOSTAT

1.Remove the control box. (Refer to section 2.1.3)

2.Open the control box. (Refer to section 2.3.3)

3.Remove the 2 screws which fasten the thermostat.

4.Disconnect 2 leads of thermostat terminals.

5.Remove the thermostat.

6.Re-installthe components by refereing to the above removal procedure. (See Figure 11)

2.3.6 ROTARY SWITCH

1.Remove the control box. (Refer to section 2.1.3)

2.Open the control box. (Refer to section 2.3.3)

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-installthe components by referring to the above removal procedure. (See Figure 12)

2.3.7 MOTOR

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

2.Remove the evaporator. (Refer to section 2.2.1)

3.Remove the orifice. (Refer to section 2.2.1)

4.Remove the blower. (Refer to section 2.2.1)

5.Remove the fan. (Refer to section 2.2.2)

6.Remove the control box cover and housing of the motor in the control box. (Refer to section 2.1.3)

7.Remove the 2 screws which fasten the motor from the mount motor. (See Figure 13)

8.Remove the motor.

9.Re-installthe components by referring to the removal procedure, above.(See Figure 13)

— 8—

Figure 10

Figure 11

Figure 12

Figure 13

2.4 REFRIGERATING CYCLE

CAUTION

system using a System.

to attach the recovery (such as a WATCO A-1)

FreonTM. Leave the valve in the system.

2.4.1 CONDENSER

1. Remove the cabinet. (Refer to section 2.1.2) 2. Remove the 3 screws which fasten the

brace.(Refer to section 2.2.1) 3. Remove the screw which fastens the cover cond. 4. Remove the 5 screws which fasten the condenser and shroud.

5. After discharging the refrigerant completely, Figure 14 unbraze the interconnecting tube at the condenser

connections.

6.Remove the condenser carefully.

7.Re-installthe components by referring to the removal procedure.

(See Figure 14)

2.4.2 EVAPORATOR

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

2. Remove the 2 screws which fasten the evaporator.

3. Move the evaporator sideways carefully. (Refer to section 2.2.1)

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

5. Remove the evaporator carefully.

6. Re-installthe component by referring to notes. (See Figure 15)

Figure 15

2.4.3 CAPILLARY TUBE

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

2.After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(See caution above)

3.Remove the capillary tube.

4.Re-installthe component by referring to notes.

— 9—

NOTES

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-offtubes.

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

4.Solder the pinch-offtubes with Service valves.

5.Evacuate as follows.

1)Connect the vacuum pump, as illustrated figure 16A.

2)Start the vacuum pump, slowly open manifold valves A and B with two full turns counterclockwise 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 equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump.

3)Operate the vacuum pump 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 pressure 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 16B.

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 theHigh-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 16B.

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-sidewill 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 Lowside.

b.Watch the Low-sidegauge; 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-offtool with the unit still running and clamp on to thepinch-offtube. Using a tube cutter, cut thepinch-offtube about 2 inches from thepinch-offtool. Usesil-fossolder and solderpinch-offtube closed. Turn off the unit, allow it to set for a while, and then test the leakage of thepinch-offconnection.

— 10—