Friedrich ZQ10 A10B User Manual

Room Air Conditioner

Service and Parts

Manual

ZStar

ZQ10 (03/01)

—2—

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

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

INSTALLATION

3.1 INSTALLATION HARDWARE

................................

3.2 SELECT THE BEST LOCATION

...........................

3.3 WINDOW REQUIREMENTS

.................................

3.4 STORM WINDOW REQUIREMENTS

...................

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 ...

3.10 TO REVERSE THE GRILLE OPENING ..............16

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. 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.

1.2

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 & 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.

CONTENTS

—3—

1.3 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 NET WEIGHT

(lbs/kg)

OUTSIDE DIMENSION inch

(W x H x D) mm

10,000

1,020

9.2

9.8

26.7(DB)*

19.4(WB)**

35(DB)

23.9(WB)

439g (15.5 oz)

3 ROW 14 STACKS, S-FIN TYPE

2 ROW 16 STACKS, L-BENDED TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

2/3

6 POLES

ROTARY SWITCH

THERMOSTAT

VERTICAL LOUVER (RIGHT & LEFT)

HORIZONTAL LOUVER (UP & DOWN)

SLIDE IN-OUT CHASSIS

OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

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

ATTACHMENT PLUG (CORD-CONNECTED TYPE)

DRAIN PIPE OR SPLASHED BY FAN SLINGER

70/32

181/2x 137/8 x 2011/16

470 x 353 x 525

1ø, 115V, 60Hz

ZQ10A10B

MODELS

ITEMS

OPERATING TEMPERATURE

* DB : dry bulb ** WB : wet bulb

1.4 FEATURES

• Designed for cooling only.

• Powerful and whisper cooling.

• Slide-in and slide-out chassis for the simple installation and service.

• Side air-intake, side cooled-air discharge.

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.

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 or Low Cool setting.

2. Set the Temperature control to the desired temperature point (the mid-point is 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 or NO. In the YES 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 the NO position, the fan will run constantly as long as the unit is in the cooling mode.

• Built in adjustable THERMOSTAT.

• Washable one-touch filter.

• Compact size.

• Reliable and efficient rotary compressor equipped.

—4—

CLOSE VENT OPEN

Part

NOTE

—5—

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

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-install the 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.)

2. DISASSEMBLY INSTRUCTIONS

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

Shipping screws

Figure 1

Figure 2

Figure 3

—6—

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-install the components by referring to the

removal procedure, above.

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-install the components by referring to the removal procedure.

Figure 4

Figure 5

Figure 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-install the component by referring to the removal procedure, above.

2.3.2 COMPRESSOR

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

2. Discharge the refrigerant system using a Freon

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 fasten the compressor.

6. Remove the compressor. (See Figure 8)

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

—7—

Figure 7

Figure 8

Figure 9

—8—

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-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.)

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

Figure 10

Figure 11

Figure 12

Figure 13

2.4 REFRIGERATING CYCLE

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, unbraze the interconnecting tube at the condenser connections.

6. Remove the condenser carefully.

7. Re-install the 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-install the component by referring to notes. (See 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-install the component by referring to notes.

—9—

Figure 14

Figure 15

Discharge the refrigerant system using a FreonTMRecovery 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.

CAUTION

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