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KP05A10
User Manual
27 pgs915.3 Kb0

Friedrich KP05A10, KP06A10 User Manual

Room Air Conditioner
Service and Parts
Manual
KP Line
KP05 / KP06 (03/03)
KP05A10 KP06A10
—2—
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. INSTALLATION ....................................................................................................................................12
3.1 SELECT THE BEST LOCATION .................................................................................................................12
3.2 HOW TO INSTALL .......................................................................................................................................12
3.3 ELECTRICAL DATA .....................................................................................................................................15
4. TROUBLESHOOTING GUIDE ....................................................................................................
15
4.1 OUTSIDE DIMENSIONS..............................................................................................................................15
4.2 PIPING SYSTEM ........................................................................................................................................16
4.3 TROUBLESHOOTING GUIDE ....................................................................................................................17
5. CIRCUIT DIAGRAM ...........................................................................................................................22
6. EXPLODED VIEW ..............................................................................................................................23
7. SERVICE PARTS LIST ....................................................................................................................24
—3—
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-DOWN CHASSIS FOR THE SIMPLE INSTALLATION AND SERVICE
• BUILT-IN ADJUSTABLE THERMOSTAT
• WASHABLE ONE-TOUCH FILTER
• COMPACT SIZE
1.2 SPECIFICATIONS
MODELS
ITEMS
COOLING CAPACITY (BTU/h) 5,100 5,700 POWER SUPPLY (Phase, V, Hz) 1ø, 115V, 60HZ INPUT (W) 470 530 OPERATING CURRENT (AMP.) 4.4 4.8 REFRIGERANT CONTROL CAPILLARY TUBE REFRIGERANT CHARGE (R-22) 330g (11.6 oz) 365g (12.9 oz) INSIDE FAN TURBO FAN OUTSIDE FAN PROPELLER FAN WITH SLINGER RING AIR DISCHARGE 2-WAY (RIGHT AND LEFT) CHASSIS TOP-DOWN
PROTECTOR
TEMPERATURE CONTROL THERMISTOR FAN MOTOR 6 POLES, 21W 6 POLES, 27W
• OVERLOAD PROTECTOR FOR COMPRESSOR
• INTERNAL PROTECTOR FOR FAN MOTOR
KP05A10 KP06A10
—4—
1.3 LOCATIONS OF CONTROLS
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.
1. Remove the cover from the back of the remote
controller
2. Insert two batteries.
• Be sure that the (+) and (-) directions are correct.
• 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 performance.
• Remove the batteries from the remote controller if the air conditioner is not going to be used for an extended length of time.
How to Insert Batteries
1
2
3
4
6
5
MONEY SAVER
2
The fan stops when the compressor stops cooling.
• Approximately every 3 minutes the fan will turn on and sample the room air to determine if more cooling is needed.
TEMPERATURE SETTING
1
• These buttons control the temperature of the room.
The temperature can be set within a range of 60°F to 86°F, in increments of 1°F.
ON/OFF TIMER
4
ON–When the air conditioner is off, it can be set to automatically
come on in 1 to 12 hours from its previous setting. Each touch will increase the timer by 1 hour. OFF–When the air conditioner is on, it can be set to automatically turn off in 1 to 12 hours. Each touch will increase the timer by 1 hour. After the timer has been on for 30 minutes, the temperature will automatically rise 2°F, and after another 30 minutes, it will automatically rise 2°F again. The temperature will then stay the same until the timer goes OFF.
To cancel the timer, press the TIMER pad until the display time disappears.
POWER
5
• To turn the unit ON, push the button. To turn the unit OFF, push the button again.
• This button takes priority over any other buttons.
• When you first turn it on, the unit is on the High cool mode and the temp. at 72°F
FAN SPEED
6
• Everytime you push this button it will rotate between the following fan speeds:
High (F3) → Low(F1) → Medium (F2) → High (F3)
Power
Temp
Fan Speed
Timer Mode
Money
Saver
5 1
6 34
2
OPERATION MODE SELECTOR
3
• Everytime you push this button, it will rotate between the COOL, FAN and DRY modes.
—5—
2. DISASSEMBLY INSTRUCTIONS
2.1 MECHANICAL PARTS
2.1.1 FRONT GRILLE
1. Pull the inlet grille forward.
2. Remove the screw securing the Front Grille. (Fig. 3)
3. Push the grille up from the bottom and pull the top of the grille away from the case to lift the top tabs out of their slots. (Fig. 4)
4. Carefully position the grille, bottom first, and snap back into place.
5. Reposition the screw that secures the front grille and replace the knobs.
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)
4. Lift the cabinet from the unit.
5. Re-install by referring to the procedures above.
2.1.3 CONTROL BOARD
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 1 screws that secure the control board to
base pan and air guide. (See Figure 4)
5. Pull the control board toward yourself.
6. Disconnect one housing terminal and 3 wires for
the fan motor and compressor. (See Figure 5)
7. Re-install components by referring to procedures
above. (Refer to wiring diagram on page 23 in this manual or inside control board.)
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
NOTE : Controls, wires, and capacitor are now
accessible for servicing. Discharge the capacitor before servicing. See step
2.3.3 on page 8 for procedures.
—6—
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 board.
(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-install by 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 board.
(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 boss 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-install by referring to the procedures above.
Figure 6
Figure 7
Figure 8
Figure 9
—7—
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 board. (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-install by 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 board. (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-install by referring to the procedures above.
2.3 ELECTRICAL 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-install the components by referring to the removal procedure above. (See Figure 12 and 13)
Figure 10
Figure 12
Figure 13
Figure 11
—8—
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, unbrace the suction and discharge pipes at the compressor connections.
5. Remove 3 nuts which fasten the compressor.
6. Remove the compressor.
7. Re-install by 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 board. (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-install the components by referring to the removal procedure above. (See Figure 15)
2.3.4 THERMISTOR
1. Remove the cabinet. (Refer to Section 2.1.2)
2. Remove the control board. (Refer to Section 2.1.3)
3. Disconnect the thermistor terminals from main P.W.B assembly.
4. Remove the thermistor.
5. Re-install the components by referring to the removal procedure above. (See Figure 16)
2.3.5 CONTROL PANEL
1. Remove the cabinet. (Refer to Section 2.1.2)
2. Remove the control board. (Refer to Section 2.1.3)
3. Pull the control panel forward and pull out it.
4. Remove 2 lead wire terminals.
5. Re-install the components by referring to the removal procedure above. (See Figure 17)
Figure 14
Figure 15
Figure 16
Figure 17
—9—
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 board to base pan. (Refer to Section 2.1.3)
5. Pulls the control board 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-install by 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-install by referring to the procedures above.
Figure 18
Figure19
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