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Room Air Conditioner
Service and Parts
Manual
TM
ZStar
ZQ08 (4-04)
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CONTENTS 1. PREFACE 1.1 SAFETY PRECAUTIONS................................2 3. INSTALLATION 1.2 INSULATION RESISTANCE TEST.................2 ................................ 3.1 INSTALLATION HARDWARE 12 1.3 SPECIFICATIONS...........................................3 ........................... 3.2 SELECT THE BEST LOCATION 12 1.4 FEATURES......................................................4 ................................. 3.3 WINDOW REQUIREMENTS 13 1.5 CONTROL LOCATIONS .......................
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1.3 SPECIFICATIONS MODELS ZQ08A10C ITEMS 1ø, 115V, 60Hz POWER SUPPLY COOLING CAPACITY (Btu/h) 8,000 INPUT (W) 820 RUNNING CURRENT (A) 7.6 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 261g (9.2 oz) EVAPORATOR 2 ROW 14 STACKS, S-FIN(LG-SLIT) TYPE CONDENSER 2 ROW 16 STACKS, S-FIN(LG-LOUVER) TYPE FAN, INDOOR TURBO FAN FAN, OUTDOOR PROPELLER TYPE FAN WITH SLINGER-RING FAN SPEEDS, FAN/COOLING 2/3 FAN MOTOR 6 POLES OPE
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1.4 FEATURES • Designed for cooling only. • Built in adjustable THERMOSTAT. • Powerful and whisper cooling. • Washable one-touch filter. • Slide-in and slide-out chassis for the simple • Compact size. installation and service. • Reliable and efficient rotary compressor equipped. • 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 CLOSE VENT OPEN in order to maintain the best cooling conditi
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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-install the component by referring to the above removal procedure. (See figure 1) Figure 1 Shipping screws 2.1.2 CABINET 1. After disassembling the FRONT G
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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. Figure 4 9. Pull out the hook of orifice by pushing
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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. Figure 7 2.3.2 COMPRESSOR 1. Remove the cabinet. (Refer to section 2.1.2) TM 2. Discharge the refrigerant system using a Freon Recovery System. If
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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 Figure 10 connection.) 8. If the supply cord of this appliance is damage
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2.4 REFRIGERATING CYCLE CAUTION Discharge the refrigerant system using a TM Freon Recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) TM before venting the Freon . Leave the valve in place after servicing 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 3 screws which fasten the condenser and shroud. 4. After discharging the refrigera
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NOTES — Replacement of the refrigeration cycle. 6. Recharge as follows : 1. When replacing the refrigeration cycle, be sure to TM Discharge the refrigerant system using a Freon 1) Refrigeration cycle systems are charged from recovery System. the High-side. If the total charge cannot be put If there is no valve to attach the recovery system, in the High-side, the balance will be put in the install one (such as a WATCO A-1) before venting suction line through the access valve which you TM the F
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Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pin-off tool capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve. Figure 16B-Charging Figure 16A-Pulling Vacuum —11— COMPOUND GAUGE CONDENSER (HIGH PRESSURE SIDE) MANIFOLD GAUGE B A CAPILLARY TUBE SEE INSETS BELOW EVAPORATOR (LOW PRESSURE SIDE) COMPRESSOR LOW HI A B A B EXTERNAL VACUUM PUMP CHARGING CYLINDER C
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3. INSTALLATION 3.1 INSTALLATION HARDWARE Window sash seal Left frame curtain Type A (13) Foam top window gasket Type B (3) Type C (5) Frame guide(2) Right frame curtain Window locking bracket Nut (2) Sill support(2) Bolt (2) 3.2 SELECT THE BEST LOCATION Step 1. To prevent vibration and noise, make sure the unit is FENCE installed securely and firmly AWNING Step 2. If possible, install the unit where sunlight does not shine directly on the unit. HEAT RADIATION Step 3. The outside of the cabinet
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3.3 WINDOW REQUIREMENTS Step 1. These instructions are for a standard double hung window. You will need to modify them for other types of windows. 25" to 36" Step 2. The air conditioner can be installed without the (With accordion panels) frame curtain if needed to fit in a narrow window. 15" min Stool See the window opening dimensions to the right. (With frame curtain) Offset 1 1 Step 3. All supporting parts must be secured to firm wood, /2" to 1 /4" masonry, or metal. Sill Step 4. The electric
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3.5 PREPARING THE UNIT FOR INSTALLATION Shipping screws Remove the 2 shipping screws from the back of the case. Remove the 2 screws on each side of the case. Keep these for later use. Slide the air conditioner from the case by gripping the base pan handle and pulling forward while bracing the case. 3.6 BEFORE INSTALLATION... Cut the window sash seal to the proper length. Peel off the backing and attach the seal to the underside of the window sash. Window sash seal Carefully insert the
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3.7 INSTALL THE CASE IN THE WINDOW Window Sash Top mountaing rail Step 1. Open the window and mark the centerline of the window stool (or desired air conditioner location). Step 2. Carefully place the case on the window stool and align the center mark on the bottom front with the centerline of the stool Step 3. Pull the window down behind the top mounting rail INDOOR OUTDOOR NOTE: Do not shut the window so tightly that movement of the frame curtains is restricted. Sill Support Nut Bolt Step 4. L
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3.9 INSTALL THE AIR CONDITIONER IN THE CASE Step 1. Slide the air conditioner into the case. Reinstall the 2 screws removed earlier on each side of the case. Power Cord Screw Screw Step 2. Before installing the front grille, pull out the vent control lever located above the unit control knobs, as shown. Step 3. Attach the front grille to the case by inserting the tabs on the grille into the slots on the front of the case. Push the grille in until it snaps into place. When you detach the front g
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4. TROUBLESHOOTING GUIDE 4.1 OUTSIDE DIMENSIONS 11 1 525mm(20 /16") 470mm(18 /2") 250mm(10") —17— 7 353mm(13 /8")
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4.2 PIPING SYSTEM CONDENSER COIL FAN CAPILLARY TUBE MOTOR COMPRESSOR BLOWER EVAPORATOR COIL TM Discharge the refrigerant system using a Freon Recovery System. If there is no valve to attach the recovery system, : REFRIGERANT FLOW TM install one (such as a WATCO A-1) before venting the Freon . Leave the valve in place after servicing the system. Do not TM vent Freon into the atmosphere. The following is a brief description of the important components and their function in what is called the refri
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4.3 TROUBLESHOOTING GUIDE In general, possible trouble is classified in two kinds. The one is called Starting Failure which is caused from an electrical defect. The other is Ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application. Unit runs but poor cooling is ineffective. Ineffective Cooling Check of cold air circulation Check of outdoor coil Check heat load for smooth flow. (heat exchanger) & fan increase. operation. Clean condenser. Dirty indo
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Fails to Start Check of power source. Check of circuit breaker and fuse. Check of control switch Gas leakage of feeler bulb setting. of thermostat Check of control switch. Only compressor fails to Only fan fails to start. start. Improper wiring Drop of power voltage Improper thermostat setting Defect of fan motor capacitor Defect of compressor capacitor Loose terminal connection Resistance irregular motor ( ). Check capacitor. Insulation irregular motor ( ). Improper wiring Replacement
