Carrier 1995 User Manual

Electronic Control

1995 Room Air Conditioner

Start-Up and Service Instructions

CONTENTS

	Page
SAFETY REMINDERS	1
START-UP	1
SERVICE	1-3
General Notes	1
Compressor Replacement	3
PREVENTIVE MAINTENANCE	3
General	3
System Cleaning/Flushing	3
DISASSEMBLY INFORMATION	3 11
Filter Removal	4
Front Grille Removal	4
Chassis Removal	4
Control Box Removal	5
Electronic Control Board Removal	6
Capacitor Removal	7
Air Sweep Motor Removal	7
Air-Handling System Removal	7
Evaporator and Condenser Coils Removal	8
Exhaust Door Removal	8
Indoor Blower Wheel Adjustment
or Removal	9
Propeller Fan Adjustment or Removal	10
Fan Motor Removal	10
Compressor Removal	11
Strainer Removal and Replacement	11
SERVICE POINTS	11
TROUBLESHOOTING	12

SAFETY REMINDERS

1 Carry a fire extinguisher in your truck Keep it within reach when using a torch Check fire extinguisher peri­ odically to be sure it is fully loaded and functional

2Know how to handle oxyacetylene equipment safely Lock the equipment in an upright position in the truck and at the job site

3Use dry nitrogen or carbon dioxide to pressurize the sys­ tem for leak checking Always use a good regulator Be careful not to exceed 150 psig test pressure in the her­ metic compressor

4Wear safety goggles and gloves when recovering refrig­ erant from a system

5Attend shop safety meetings

START-UP

Refer to opeiating instructions in Owner’s Guide pro­ vided with room air conditioner

SERVICE

General Notes — These Start-Up and Seivice Instruc­ tions aie provided to assist the trained and qualified service technician in lepairing or replacing components of Carrier electronically conti oiled (EC) Room Air Conditionei Dis­ assembly photos are included for the unit Unit physical data is found in Tables 1-9

IMPORTANT Repairing and servicing air condition­ ers can be hazardous for untrained individuals The instructions printed in this publication are for propeily trained and qualified Carrier seivice technicians only

A WARNING

Before working on any air conditioner, be sure to first disconnect all electric power to the unit to avoid the possibility of electrical shock and personal injury

Before disconnecting, discharge capacitors by shorting capacitors across terminals

Shield coils with cardboard to protect hands against in­ jury from sharp metal edges when removing compressor and other components

When disassembling wiring, use numbered stickers to iden­ tify wire leads and terminals This aids in quick, accuiate reassembly

Check clearances around scroll and housing before in­ stalling fans Before securing fan(s) fasteners, rotate fan by hand to ensure ample clearance

Refer to Carrier Standard Service Techniques, Chap­ ters 1 and 2, for information on checking motors, removing refrigerant, adding oil, and evacuating, dehydrating, and charg­ ing system Pay particular attention to all safety warnings for these procedures

NOTE In Carrier Standard Service Techniques, refrigerant removal must always include recovering the refrigerant, not allowing it to escape to the atmosphere

Manutecturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations

Book|1 14	PC 131	Catalog No 537-323	Printed in USA	Form73XC-1SS	Pg 1	1-95	Replaces: New
Tab 8a 10a

Table 1 — Physical and Electrical Data (Single-Phase, 60 Hz)

SERVICE/

CASING

COOLING

R-22

WET

NAMEPLATE

DISCRETE NO

(See Table 5)

CAPACITY

CHG

BULB

Volts

Voltage

Amps

Watts

EER

PF

(Btuh)‘

(OZ. ± 05)

At F

Range

(DOE)

(%)

73XCB118301E

305

18,000/

37 0

135

230/208

253-187

8 3/8 8

1870/

96

99

17,000

1840

SERVICE

CAPACITOR

FAN MOTOR

COMPRESSOR

COMPRESSOR-START

CAPILLARY (See Tables 6 and 7)

DISCRETE NO.

(See Table 4)

Carrier

FLA

(See Table 2)

THERMISTOR

Data

Insertion

Number

Part Number

(See Table 3)

of Tubes

73XCB118301E

RC-2

25901051

1 24

D-5

Z-1

CD-3

CI-1

3

LEGEND

AHAM — Association of Home Appliance Manufacturers

ANSI — American National Standards Institute DOE — Department of Energy

EER — Energy Efficiency Ratio FLA — Full Load Amps

PF — Power Factor

At — Entering wet-bulb temperature minus leaving wet-buib temper­ ature based on 67 F room wet-bulb temperature and 95 F drybulb outside-air temperature If conditions vary, wet-bulb At will vary

*Based on AHAM Standard RAC-1 and ANSI Z234 1

Table 2 — Compressor

	KEY NUMBER	REPLACEMENT	OIL RECHARGE	VOLTS	LRA	FLA
	(See Table 1)	PART NUMBER	(OZ)	(Slngle-Ph, 60 Hz)
	D-5	P033-1822	80	230/208	44 0	128

LEGEND

FLA — Full Load Amps

LRA — Locked Rotor Amps

Table 3 -- Compressor-Start Thermistor

KEY NUMBER	CARRIER	VENDOR	RESISTANCE
(See Table 1)	NUMBER	NUMBER	(Ohms)
Z-1	42320001	CM305C20C	25

Table 4 — Capacitor

	KEY NUMBER	CARRIER	MFD	VOLTS
	(See Table 1)	NUMBER
	RC-2	05706030	30/5	370

Table 5 - Casing Dimensions (in.)

	KEY NUMBER	HEIGHT	WIDTH	DEPTH
	(See Table 1)				»
	305	163/4	253/16	233/4

Table 6 — Capillary Data

	KEY NUMBER	DIMENSIONS (in}
	(See Table 1)	Length (± 002)	ID(± 002)
	CD-3	1 Tube — 47 0	1 Tube - 054
		2 Tubes — 29 3	2 Tubes — 054

Table 7 — Capillary Insertion

	KEY NUMBER	DEPTH (In.)	DEPTH (in )
		Condenser Coil	Evaporator Coil
	(See Table 1)
		Connection Tube	Connection Tube
	CM	1	1

Table 8 — Receptacle, Fuse Type, Wire Size

UNIT NAMEPLATE VOLTAGE	230/208
MAXIMUM NAMEPLATE AMPS	12
OUTLET RATED VOLTS/AMPS	250/15
RECEPTACLE CONFIGURATION

MFR PART NO	5661
Hubbell
P &S	5661
GE	GE4069-1
Arrow-Hart	5661
TIME-DELAY FUSE OR CIRCUIT	15
BREAKER SIZE (AMPS)
FUSE TYPE	Cartridge
RECOMMENDED AWG	14
WIRE SIZE*

LEGEND

AWG — American Wire Gage

‘Based on copper wire at 60 C temperature rating

Table 9 - Electronic Control

	ITEM	CARRIER PART	INDOOR
		NO	THERMISTOR
	COOLING-ONLY	CEPL130015-01	912-710011-P2216
	CONTROL

□El

Compressor Replacement

A CAUTION

Stand clear of compressor terminals when working on compressors With system under pressure, terminals may blow causing personal injury

Observe the same safety procedures for rotary compres­ sors as for reciprocating compressors

When changing compressors

1 Follow all safety codes Reminder use protective goggles, work gloves, and water-soaked quenching cloth

2Shut off all electrical power to unit by removing power cord from outlet, then disconnect all wiring from the compressor

3Apply field-supplied tap-a-lines to the true (closest to compressor) suction and discharge connections of the compressor

4Recover the refrigerant charge from the unit After re­

covering, cut the discharge and suction line process tubes below Sie tube crimps If you choose a good tubing location for cutting the refrigerant lines initially, the location is easily accessible when making the final joints You can braze the oil piping stub into the new compiessor fittings more easily before the compiessor is put back into the unit

A CAUTION

Oil vapor in piping stubs can ignite from torch flame and cause serious injury Exeicise extreme care when brazing, and keep brazing cloth and fire extin­ guisher handy for emergency use

Connect a nitrogen supply to the unit at one of the tap- a-line connectors (5 psig maximum flow), leaving the other connector open to the atmosphere Braze angle valves with stubs to each process tube

Remove compressor from unit Refer to Compressor Removal, page 11

Remove tap-a-lines from suction and discharge lines Carefully braze the holes closed from where the tap-a- lines were removed

Clean system add or replace liquid line filter drier For proper cleaning and flushing, use the Carriei Totalclaim® recovery system or a comparable refriger­ ant recycling system

Install new compressor and braze into place with fieldsupplied copper slip couplings

10 Connect wiring replace wire terminals if necessary

UProceed with evacuation and charging Pinch off lines where angle valves were added Cut off angle valves above pinch-off, and braze tubes

12 Start up unit

PREVENTIVE MAINTENANCE

General

CLEANING — Clean cooling coil and condenser coil Hold flashlight behind coil to see if all spaces are clear Use a hooked wire to remove dirt Dust accumulation obstructs or reduces airflow and results in loss of capacity Coils may be vacuumed when dry Outdoors, unit can be brushed with a stiff brush and fins blown out with compiessed aii

Thoioughly clean basepan, motois, fan wheels, other com­ ponents, and all drain passages Vacuum insulation Clean all inside painted surfaces with mild detergent to remove grease

Clean cabinet and grille Mild detergents reduce electro­ static charges on plastic sections of the grille and are good cleaners Do not use carbon tetrachloride, solvents, or waxes containing solvents to clean plastic sections

PAINTING — Paint any parts that show evidence of rust with a good rust-resistant paint

WIRING — Check all wiring for deterioration and all elec­ trical contacts for tightness and lack of corrosion

MOUNTING — Make sure unit is secure in window, and level from left to right and from front to rear according to installation instructions provided

Check fans to ensure they are correctly positioned, cen­ tered in orifice, and tight on shaft

LEAKS — Check any connections that show evidence of oil oi leaks When unit is propeily installed, centered, and leveled (see Owners’ Guide), check gaskets and wing pan­ els for possible ail leakage

CONTROLS — Check unit to ensure all contiols are func­ tioning correctly and unit operation is normal

Vibrations can cause unwanted noise Check to be sure no piping is vibrating against any side of unit

System Cleaning/Flushing — For proper cleaning and flushing, use the Carrier Totalclaim recovery system, or a comparable refrigerant recycling system

DISASSEMBLY INFORMATION

A WARNING

Before working on any air conditioner, be sure to first disconnect all electric power to unit to avoid the pos­ sibility of electrical shock and personal injury

The Electronic Control Room Air Conditioner is cooling only and has casing key no 305

All units have a slide-out chassis Units can be serviced without removing casing

Filter Removal

1Place index fingers inside the openings on either side of the filter frame See Fig 1

2Apply pressure inward toward the center, while pulling filter down and out

3Vacuum filter, or wash in lukewarm water Shake off excess water and dry thoroughly

4Replace filter by sliding filter upward behind front grille until filter snaps in place

Front Grille Removal

1Remove 2 screws located on either side of front grille See Fig 2

NOTE Facing the front of unit, grille screw on the righthand side serves as a unit security screw

2Pull grille out and upward, removing it from chassis See Fig 3

3To replace grille, place grille top on unit top edge and firmly press grille back into position

4Replace screws

Fig. 1 — Removing Filter

SCREW (HIDDEN)

SCREW (SECURITY)

Fig. 2 — Removing 2 Screws from Front Grille

■■

Fig. 3 — Removing Front Grille

Chassis Removal

A CAUTIOH

Coil fins are sharp Use care when removing chassis from casing to avoid personal injury Do not use plas­ tic parts for lifting or pulling, they are not structural members of the chassis Lift using basepan only Chas­ sis is heavy Obtain assistance for lifting

Chassis can be serviced without removing unit casing from window or wall location

1 Remove front grille See Front Grille Removal instruc­ tions, this page

2If unit has not been installed, remove shipping screw See Fig 4

3Slide chassis out from casing See Fig 5

4Reverse above procedure to reinstall chassis in casing Be sure to replace and tighten left-hand screw and righthand security sciew on the front grille

Fig. 4 - Removing Shipping Screw

Fig. 5 - Sliding Chassis Out from Casing