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Room Air Conditioner
Service and Parts
Manual
®
ZStar
ZQ05B10 ZQ07B10
ZQ05/ZQ07 (06/05)
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CONTENTS 1. PREFACE ...................................................................................................................................................3 1.1 FEATURES.....................................................................................................................................................3 1.2 SPECIFICATIONS .........................................................................................................................................3 1.3 LOCA
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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 THE
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1.3 LOCATIONS OF CONTROLS Off : Turns air conditioner off. Operation Hi Fan : High speed fan operation without Off cooling. Hi Hi Fan Cool O Lo Fan : Low speed fan operation without Lo Lo cooling. O Fan Cool Hi Cool : Cooling with high speed fan operation. Mode Lo Cool : Cooling with low speed fan operation. Thermostat 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
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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 Figure 2 and pus
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Figure 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 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. Figure 7 2.2.2 ORIFICE, TURBO FAN AND FAN 1. Disconnect the unit fro
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2.2.3 MOTOR Figure 10 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 panel. (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 ab
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2.3.2 COMPRESSOR Figure 14 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, unbraze 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.
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Figure 18 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 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 to the control board. 8. Pull the power cord. 9. Re-install by referring to procedures above.
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wise. This will keep oil from foaming and being 2.4.2 EVAPORATOR/CONDENSER drawn into the vacuum pump. 1. Remove the cabinet. 2. Discharge the refrigerant by using a refrigerant 6-3. Operate the vacuum pump for 20 to 30 min- recovery system. utes, until 600 micron vacuum is obtained. 3. Remove the air guide upper. (Refer to Section Close valves A and B and observe vacuum 2.2.1) gauge for a few minutes. 4. After discharging the refrigerant completely, A rise in pressure would indicate a possib
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Equipment needed: Vacuum pump, charging cylinder, manifold gauge, brazing equipment, pinch-off tool capable of making a vapor proof seal, leak detector, tubing cutter, hand tools to remove components and service valve. COMPOUND GAUGE MANIFOLD GAUGE B A CONDENSER SEE INSETS (HIGH PRESSURE SIDE) BELOW COMPRESSOR EVAPORATOR (LOW PRESSURE SIDE) CAPILLARY TUBE Figure 20 LO HI CHARGING CYLINDER A A B B EXTERNAL VACUUM PUMP C Figure 21A-Pulling Vacuum Figure 21B-Charging —11—
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3. TROUBLESHOOTING GUIDE 3.1 OUTSIDE DIMENSIONS (unit: mm [in]) 9 21 21 370 (14 /16") 42 (1 /32") 472 (18 9/16") 42 (1 /32") 3 120 (4 /4") 3 27.5 (1 /32") 22.5(0.8 3/32") 155(6 3/32") 9 9 370 (14 /16") 472 (18 /16") —12— 312 (12 1/4") 312 (12 1/4") 12 (0.4 1/16") 5 29 (1 /32") 5 346 (13 /8")
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3.2 PIPING SYSTEM CONDENSER COILS FAN MOTOR CAPILLARY TUBE TURBO FAN EVAPORATOR COILS 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 HOT COMPLETE LIQUID COOL LOW PRESSURE VAPOR DISCHARGED BOIL OFF POINT AIR
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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.
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Fails to Start Check circuit breaker Check power source. and fuse. Check control switch Gas leakage of capillary setting. bulb on thermostat. Check control switch. Compressor fails to Fan only fails to start. start. Improper wiring. Improper thermostat Drop of power voltage. setting Defect of fan motor capacitor. Defect of compressor Loose terminal capacitor. connection Irregular motor resistance (Ω ) Capacitor check. Improper wiring Irregular motor insulation (Ω ) Re
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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 diagram
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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, Voltage Check voltage. See the limits on the preceding fan motor runs. page. If not within limit
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COMPLAINT CAUSE REMEDY Compressor cycles on Fan motor If not running, determine the cause. Replace if overload. required. Condenser air flow Remove the cabinet, inspect the interior surface restriction of the condenser. If restricted, clean carefully with a vacuum cleaner (do not damage fins) or brush. Clean the interior base before re-assembling. Condenser fins If the condenser fins are closed over a large (damaged) area on the coil surface, head pressures will increase, causing the co
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4. CIRCUIT DIAGRAM MODEL: ZQ05B10,ZQ07B10 POWER INPUT 1 BK(BR) WH(BL) (Plain) (Ribbed) ROTARY SWITCH GN(GN/YL) 1 2H BK BK L RD RD 3 4 4 M BL BL 5 6 2 MOTOR OR(BR) 7 8 CAPACITOR YL YL F OR(BR) C 6 BK BK R RD RD S H 3 COMP. BR BL BL BR C 7 OLP THERMOSTAT 5 SYNC. M. YL BR BR 3854AR2330A ROCKER SWITCH WIRING DIAGRAM S: Service Parts N: Non Service Parts RE- LOCATION Q'TY DESCRIPTION MARKS NO. PER SET 1 S 1 POWER CORD ASSY 1 S 2 FAN MOTOR 1 S 3 COMPRESSOR 1 S 4 ROTARY SWITCH 1 S 5 THERMOSTAT 1
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5. EXPLODED VIEW 130910 559011 W48602 554030 149980 349480 352380 135312 147581 149410 359012 346811 147582-1 W48602 352390 147582-2 354210 130410 152302 135313 249950 266003 135500 264110 352111 352115 567502 352113 269310 554160 35211A W0CZZ 550140 —20—
