Friedrich ZQ05B10 User's Manual
Contents
1. 5 3854 2330 WIRING DIAGRAM ROCKER SWITCH S Service Parts N Non Service Parts LOCATION QTY RE NO DESCRIRTION PER SET MARKS 1 POWER CORD ASSY 1 S 2 FAN MOTOR 1 5 3 COMPRESSOR 1 S 4 ROTARY SWITCH 1 S 5 THERMOSTAT 1 S 6 CAPACITOR 1 S 7 OVERLOAD PROTECTOR 1 S 19 5 EXPLODED VIEW Ser S NU _ S 6 SERVICE PARTS LIST ZQ05B10 ZQ07B10 2005810 Loc FILTER MECH A C 6730007 CORD ASSEMBLY 260310 67300400 THERMOSTAT ASSEMBLY 67302119 TUBEASSEMBLYCAPILARY 215 67302004 TUBE ASSEMBLY EVAPORATORIN 352380 67302728 ARGUDE aso 673277 ARGUIDE ASSEMBLY 354210 673023 EVAPORATOR ASSEMBLYFIRST 3mor 6702 FANTURBO 67301900 ISOLATORCOMP sso 67303321 CONDENSER ASSEMBLY 67301616 COMPRESSORSET 67302613 FAN ASSEMBLYAXIAL 21 2007810 Loc 670017 POWER CORD ASSEMBLY 260310 67300400 THERMOSTAT ASSEMBLY 7206 ARE 67302727 ARGUDEASSEMBLY 67302422 EVAPORATOR ASSEMBLY FIRST _ _ 550140 67301900 SOLATORCONP sam 673022. rriedrich Room Air Conditioner Service and Parts Manual ZStar 115Volts 2005810 2007810 2005 2007 06 05 CONTENTS nubes tutta 3 1 FEATURES utn tas ute 3 12 5PECIEICAHONS ba cae ig 3 L3 LOCATIONS OF CONTROLS cit 4 1 4 SAFETY PRECAUTIONS tetti qc DER RI abd 4 1 5 INSULATION RESISTANCE TEST DA dM ttd AN 4 2 DISASSEMBLY INSTRUCTIONS 5 2 1 MECHANICAL PARTS aont ef pedido a gt ads 5 2i T FRONT GRILLE Saga ms nendum dus 5 2 A2 CABINET A 5 2 CONTROL BOARD iie 5 HANDLING PARTS 6 POT AIFUGUIDE UPPER nascenti RO nd qr a 6 2 2 2 ORIFICE TURBO FAN AND FAN teach ks pl o e t aita rn 6 223 MOTOR M 7 7 2 3 ELEGTRICAL PARTS ated atat 7 23 1 OVERLOAD PROTECTOR onn cuin eai nie rain 7 23 2 COMPRESSOR tes aeta DD a Eu DUM 8
3. 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 Remove the orfice by pushing the snap area of the air guide blower See Figure 8 Remove the clamp springs which are clamped to the base of fan and turbo fan by hand plier See Figure 9 Pull the fan and turbo fan outward Remove the shroud Re install by referring to the procedures above 2 3 4 12 13 14 Figure 6 Figure 7 Figure 8 Figure 9 2 2 3 Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove the control panel Refer to Section 2 1 3 Remove the air guide upper Refer to Section 2 2 1 Remove the compressor turbo fan fan and shroud Refer to Section 2 2 2 Remove 2 screws that secure the motor to the motor See Figure 10 Remove the motor Re install by referring to the procedures above 2 2 4 AIR GUIDE Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 Remove the control panel Refer to Section 2 1 3 Remove
4. The system is now ready for final charging Recharge as follows 7 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 is installed as the system is opened Connect the charging cylinder as shown in fig ure 21B With valve C open discharge the hose at the manifold connection Open valve A and allow the proper charge to enter the system Valve B is still closed If more charge is required the high side will not take it Close valve A 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 30 106 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 When the unit is operating correctly use the pinch off tool with the unit still running and clamp on the pinch off tube Using a tube cut ter cut the pinch off tube about 2 inches from the pinch off Use sil fos solder and solder the pinch off tube closed Turn off the unit allow unit to sit for a while and then test the leakage of the pinch off connection 7 3 7 4 7 5 Equipment needed Vacuum pump charging cylinder manifold gauge brazing equipment pinch off tool capable of making a vapor proof seal leak dete
5. GAPACITOR MD m 8 2 34 THERMOSTAT Geka ata eens 8 2 3 5 ROTARY 8 2 3 6 POWER 9 24 REFRIGERANT CYCLE nca o a a 9 CONDENSER aisina ai A S 9 2 42 EVAPORATOR 10 DAS CAPILLARY TUBE uci 10 3 TROUBLESHOOTING GUIDE aue ende cett 12 JI OUTSIDE DIMENSIONS HI Rada RM eate E RN D see 12 PIPING SYSTEM 15 ta breue aca e 13 3 3 TROUBLESHOOTING GUIDE iic paste prod tinxit 14 4 CIRCUIT n 19 5 EXPLODED De b DU 20 6 SERVICE PARTS LIST 21 1 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 ZQ05B10 ZQ07B10 ITEMS COOLING CAPACITY BTU
6. If not within limits call an electrician Wiring Check the wire connections if loose repair or replace the terminal If the wires are discon nected refer to wiring diagram for identification and replace the wires Check the wire connections If not according to the wiring diagram correct the connections Rotary Swtich Check for continuity refer to tht for terminal identification Replace the switch if the circuit is open Thermostat Check the position of knob If not at the coldest setting advance the knob to this setting and restart the unit Check the continuity of the thermostat Replace the thermostat if the circuit is open Capacitor discharge capacitor before Check the capacitor Replace if not within 10 of manufacturer s servicing rating replace if shorted open or damaged Compressor Check the compressor for open circuit or ground If open or grounded replace the compressor Overload Check the compressor overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool and retest Compressor cycles on Voltage Check the voltage See the limits on the overload preceding page If voltage is not within these limits call an electrician Overload Check overload if externally mounted Replace if open If the compressor temperature is high remove the overload cool and retest 17 COMPLAINT CA
7. OFF POINT POOL PRESSURE VAPOR DISCHARGED COOLED AIR AIR ROOM HEAT LOAD gt OUTSIDE COOLING AIR FOR REFRIGERANT SS THROUGH TE MOTOR DISCHARGE LINE NOT HIGH PRESSURE gt VAPOR COMPRESSOR LIQUID PRESSURE DROP LIQUID OUTLET LIQUID REFRIGERANT 17771 HIGH PRESSURE VAPOR CAPILLARY TUBE ouo REFRIGERANT Low PRESSURE VAPOR Figure 22 13 3 3 TROUBLESHOOTING GUIDE In general possible trouble is classified in two categories The one is called Starting Failure which is caused by an electrical defect The other is Ineffective Air Con ditioning caused by a defect in the refrigeration circuit and or improper application Unit is running but cooling is ineffective Ineffective Cooling Check cold air Check outdoor coil Check heat load circulation for smooth heat exchanger and increase flow fan operation Clean condenser Dirty indoor coil Check gas leakage heat exchanger Not on separate circuit Repair gas leak Malfunction of fan Replacement of unit if Check inside gas pressure the unit is beyond repair Clogging of air filter Adjust refrigerant Obstruction at air outlet Remove obstruction Malfunction of compressor Check clogging in refrigera Replacement of tion circuit compressor Satisfactory operation Repair clogging in
8. h 5 100 6 500 POWER SUPPLY Phase V Hz 19 115V 60HZ INPUT W OPERATING CURRENT REFRIGERANT CONTROL CAPILLARY TUBE REFRIGERANT CHARGE R 22 325g 7 9 02 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 OVERLOAD PROTECTOR FOR COMPRESSOR PROTECTOR INTERNAL PROTECTOR FOR FAN MOTOR TEMPERATURE CONTROL THERMISTOR FAN MOTOR 6 POLES 16W 6 POLES 27W 1 3 LOCATIONS OF CONTROLS Operation Off Off Turns air conditioner off Hi Fan High speed fan operation without cooling Lo Fan Low speed fan operation without cooling Hi Cool Cooling with high speed fan operation Lo Cool Cooling with low speed fan operation Thermostat Warmer Cooler 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 cooling 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 overheate
9. to the control board 8 Pull the power cord 9 Re install by referring to procedures above RON 2 4 REFRIGERANT CYCLE Figure19 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 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 A 2 4 2 EVAPORATOR CONDENSER 1 2 3 Remove the cabinet Discharge the refrigerant by using a refrigerant recovery system Remove the air guide upper Refer to Section 2 2 1 After discharging the refrigerant completely unbraze the interconnecting tube at the proper connections Remove the proper coil Re install by referring to the procedures above 2 4 3 CAPILLARY TUBE 1 3 4 5 6 Remove the cabinet 2 Discharge the refrigerant by using a refrigerant recovery system Remove the air guide upper Refer to Section 2 2 1 After discharging the refrigerant completely unbraze the interconnecting tube of the capillary tube Remove the capillary tube Re install by referring to the procedures above NOTES Replacement of the refrigeration cycle When replacing the refrigeration cycle be sure to dischar
10. 118 TUBE ASSEWBLY CAPILLARY 55400 67303220 CONDENSER ASSEMBLYFIRST 55160 67500117 COMPRESSORSETCHNA ssson 673203 FANASSEMBLKAXAL 000 22 9999909090999 908009000 23 Use Factory Certified Parts rriedrich FRIEDRICH AIR CONDITIONING CO Visit our web site at www friedrich com Post Office Box 1540 4200 Pan Am Expressway San Antonio Texas 78295 1540 210 357 4400 FAX 210 357 4490
11. USE REMEDY Compressor cycles on overload Insufficient cooling Fan motor If not running determine the cause Replace if required Condenser air flow restriction Condenser fins Remove the cabinet inspect the interior surface of the condenser If restricted clean carefully with a vacuum cleaner do not damage fins or brush Clean the interior base before re assembling If the condenser fins are closed over a large damaged area on the coil surface head pressures will increase causing the compressor to cycle Straighten the fins or replace the coil Capacitor Test the capacitor Wiring Check the terminals If loose repair or replace Refrigeration system Air filter Unit undersized Check the system for a restriction If restricted clean or replace Determine if the unit is properly sized for the area to be cooled Excessive noise Blower or fan Check the set screw or clamp If loose or miss ing correct If the blower or fan is hitting scroll or barrier rearrange the air handling parts Copper tubing 18 Remove the cabinet and carefully rearrange the tubing not to contact the cabinet compressor shroud and barrier 4 CIRCUIT DIAGRAM MODEL 2005810 2007810 BRIDE S WEBS D Plain Ribbed ROTARY SWITCH S GNGN YL 9 6 3 7
12. arge the capacitor by placing a 20 KO resistor across the capacitor terminals Remove the screw which fastens the capacitor clamp Remove all the leads of capacitor terminals Re install the components by referring to the removal procedure above See Figure 15 3 2 3 4 THERMOSTAT 1 Remove the cabinet Refer to Section 2 1 2 2 Remove the control panel Refer to Section 2 1 3 Remove 2 screws which fasten the thermostat Remove all the leads of the thermostat terminals Remove the thermostat Re install the components by referring to the removal procedure above See Figure 16 2 3 5 ROTARY SWITCH 1 Remove the cabinet Refer to Section 2 1 2 2 Remove the control panel Refer to Section 2 1 3 Remove 2 screws which fasten the rotary switch Remove all the leads of the rotary switch terminals Remove the rotary switch Re install the components by referring to the removal procedure above See Figure 17 Figure 14 Figure 15 Figure 16 Figure 17 2 3 6 POWER CORD Figure 18 Disconnect the unit from source of power Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 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
13. ctor tubing cutter hand tools to remove components and service valve COMPOUND GAUGE 00 MANIFOLD GAUGE CONDENSER HIGH PRESSURE SIDE SEE INSETS R BELOW COMPRESSOR EVAPORATOR LOW PRESSURE SIDE CAPILLARY TUBE Figure 20 LO CHARGING CYLINDER 210 EXTERNAL VACUUM PUMP Figure 21A Pulling Vacuum Figure 21B Charging 11 3 TROUBLESHOOTING GUIDE 3 1 OUTSIDE DIMENSIONS unit mm in 1 42 1 21 32 472 18 9 16 370 14 9 16 42 1 21 32 120 4 3 4 _ 27 5 1 3 32 346 13 5 8 312 12 1 4 NE 229 0 8 3 32 155 6 3 32 370 14 9 16 12 3 2 PIPING SYSTEM CONDENSER COILS n FAN CAPILLARY MOTOR TUBE TURBO FAN EVAPORATOR CD c Figure 22 is a brief description of the important components and their function in what is called the refrigeration system This will help you to understand the refrigeration cycle and the flow of the refrigerant in the cooling cycle ROOM AIR CONDITIONER CYCLE OF REFRIGERATION EVAPORATOR COILS CONDENSER COILS VAPOR INLET SUCTION LINE COMPLETE LIQUID HOT BOIL
14. d or damaged by the short cir cuit 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 yel low 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 MO 2 DISASSEMBLY INSTRUCTIONS 2 1 MECHANICAL PARTS 2 1 1 FRONT GRILLE Figure 1 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 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 4 Lift the cabinet from the unit 5 Re install by referring to the procedures above Figure 3 2 1 3 CONTROL PANEL 1 Disconnect the unit from the p
15. ge the refrigerant by using a refrigerant recovery system After discharging the unit completely remove the desired components and unbraze the pinch off tubes Solder service valves into the pinch off tube ports leaving the valves open Solder the pinch off tubes with service valves After completing the above procedures the valve must be closed and left in place on the system for any subsequent procedures Evacuate as follows 6 1 Connect the vacuum pump as illustrated in figure 21A Start the vacuum pump Slowly open manifold valves A and B with two full turns counter clockwise 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 6 2 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 10 wise This will keep oil from foaming and being drawn into the vacuum pump 6 3 Operate the vacuum pump for 20 to 30 min utes 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 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
16. gram for connection loose terminal identification Repair or replace loose terminal Capacitor Discharge Test capacitor capacitor before testing Replace if not within 10 of manufacturer s rating Replace if shorted open or damaged Will not rotate Fan blade hitting shroud or blower wheel hitting scroll Re align assembly Units using slinger ring condenser fans must have 0 22 0 25 inch clearance to the base If necessary shim up the bottom of the fan motor with mounting screw s Check fan motor bearings if motor shaft will not rotate replace the motor Fan motor runs Revolves on overload Check voltage See limits on this page If not within limits call an electrician Test capacitor Check bearings Does the fan blade rotate freely If not replace fan motor Pay attention to any change from high speed to low speed If the speed does not change replace the motor 16 COMPLAINT CAUSE REMEDY Fan motor noise Fan If cracked out of balance or partially missing replace it Blower If cracked out of balance or partially missing replace it Loose set screw Tighten it Worn bearings If knocking sounds continue when running or loose replace the motor If the motor hums or noise appears to be internal while running replace motor Compressor will not run fan motor runs Voltage Check voltage See the limits on the preceding page
17. ower 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 Figure 4 NOTE Controls wires and capacitor are now accessible for servicing Discharge the capacitor before servicing See step 2 3 3 page 8 for procedures 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 5 2 2 AIR HANDLING PARTS 2 2 1 AIR GUIDE UPPER Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 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 install by referring to the procedures above RON mm 2 2 2 ORIFICE TURBO FAN AND FAN 1 Disconnect the unit from the power source Remove the front grille Refer to Section 2 1 1 Remove the cabinet Refer to Section 2 1 2 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
18. the air guide upper Refer to Section 2 2 1 Remove the compressor turbo fan fan and shroud Refer to Section 2 2 2 Remove the motor Refer to Section 2 2 3 Remove 2 screws that secure the air guide to the base pan See Figure 11 Push the air guide backward and lift it upward See Figure 11 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 Remove the nut which fastens the terminal cover Remove the terminal cover Remove all the leads from the overload protector Remove the overload protector Re install the components by referring to the removal procedure above See Figure 12 and 13 Figure 10 Figure 11 Figure 12 Figure 13 2 3 2 COMPRESSOR 1 Remove the front grille and cabinet Refer to Section 2 1 Discharge the refrigerant by using a refrigerant recovery system Remove the overload protector Refer to Section 2 3 1 After discharging the unit completely unbraze the suction and discharge pipes at the compressor connections Remove 3 nuts which fasten the compressor Remove the compressor Re install by referring to the removal procedure above See Figure 14 2 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 Disch
19. with temperature refrigeration circuit difference of inlet amp outlet air 55 59 F 13 15 C 14 Fails to Start Check circuit breaker and fuse Check power source Check control switch setting Gas leakage of capillary bulb on thermostat Check control switch Fan only fails to start Improper wiring Defect of fan motor capacitor Compressor fails to start Improper thermostat f 3 Drop of power voltage setting Defect of compressor Loose terminal capacitor connection Irregular motor Capacitor check lt gt Improper wiring resistance Q Irregular motor insulation 9 Replacement Replacement of fan motor Irregular motor resistance 0 Regular but fails to start Replacement of compressor Irregular motor insulation Locking of piston metal Replacement of compressor Motor damaged 15 ROOM AIR CONDITIONER VOLTAGE LIMITS NAME PLATE RATING MINIMUM MAXIMUM 115V 10 103 5V 126 5V COMPLAINT CAUSE REMEDY Fan motor will not run No power Check voltage at outlet Correct if none Power supply cord Check voltage to rotary switch If none check power supply cord Replace cord if circuit is open Rotary switch Check switch continuity Refer to wiring diagram for terminal identification Replace switch if defective Wire disconnected or Connect wire Refer to wiring dia
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