Carrier 42KLE14-H, 42KLE28-H, 42KLE32-H, 42KLE14-C, 42KLE28-C Service Maintenance Manual

2005

SERVICE & MAINTENANCE MANUAL

1

TABLE OF CONTENTS

PAGE NO.

1.

Precautions for Service & Maintenance 2

2. Split System Description 3

3.

Unit Model Designation & Identification 4

4. Unit Models & Part Numbers

4

5. System Operating Limits 5

6. System Safety Protections 5

7.

Exploded View of Indoor Unit 6

8. Part List of Indoor Unit 7

9. Exploded View of Outdoor Unit 9

10. Part List of Outdoor Unit 10

11. Wiring Diagrams 11

12. Field Electrical Connections Matching 13

13. Refrigeration Cycle 14

14. Self Diagnostic Function 16

15. Replacing Batteries of Remote Control 17

16. Emergency Operation of Air-Conditioner 17

17. Air Filter Cleaning 18

18. Periodical Checks 19

19. Trouble Shooting 20

2

1. PRECAUTIONS FOR SERVICE AND MAINTENANCE

SAFETY CONSIDERATIONS

• Service and maintenance of air conditioning equipment can be hazardous due to system

pressures and electrical components. Only trained and qualified service personnel should
install, repair or service the air conditioning equipment.

• When working on air conditioning equipment, observe precautions in the literature, tags and

labels attached to the unit and other safety codes.

• Wear safety glasses and gloves. Use quenching cloth and have fire extinguisher available for all

brazing operations

WARNING

• This manual describes the service and maintenance of Carrier split room air conditioner

consisting of an outdoor unit and an indoor unit manufactured by Carrier.

What is not covered in Carrier warranty?

1- Failure due to Misuse: Abusing, overloading, careless handling and negligence.

2- Failure due to Accident / Weather: Natural catastrophe, accident due to bad weather (Hail Storm,

Sand Storm, lightning, Flooding, Acid Rain and Air Borne fallout, etc).

3- Failure due to Damages during transport.

4- Failure due to modification:Any modifications done on the unit without Carrier consent.

5- Failure due to Improper Installation: Installation should be performed according to standard.

The decision of Carrier in ascertaining the same will be final. Carrier or its approved dealer

should do installation.

6- Failure due to Improper Maintenance: Lack of professional maintenance, improper adjustments,

use of improper consumables, filters, spare parts other than specified in the Carrier manuals.

7- Failure due to use of non-genuine Carrier Parts, substitute other than Carrier parts.

8- Refrigerant normal noise, wear and tear of deterioration.

9- Inconvenience or commercial loss is not covered.

The decision of Carrier in ascertaining the same will be final. Any such repairs will be carried out

at the expense of the purchaser.

3

2. SPLIT SYSTEM DESCRIPTION

(a) INDOOR UNIT

• Mounted inside the space to be air-conditioned.

• In summer it filters, dehumidifies and cools air.

• In winter it filters and heats air.

(d) SUPPLY AIR FROM INDOOR UNIT

cool or warm air comes out of supply air outlet

(c) RETURN AIR TO INDOOR UNIT

The return air from the space to be air-

conditioned passes through the return grille

and then through the anti-bacteria filters to

clean the air from dust and foreign particles

(f) REFRIGERANT PIPING LINES

Insulated copper piping through which the

refrigerant R22 flow connects the indoor and

outdoor units.

(g) DRAIN HOSE

• Drains the water condensated in the indoor

unit during cooling operation to the outside.

Fig. (1)

CONSOLE & UNDERCEILING SPLIT SYSTEM
53KLE-H SERIES HEAT PUMP
53KLE-E SERIES COOL/ELECTRIC HEAT
53KLE-C SERIES COOL ONLY

(e) WIRELESS REMOTE CONTROL (LCD)

Controls power, mode, fan speed, temperature,

and timer, swing and sleep functions.

(b) OUTDOOR UNIT

• Mounted outside the space to be air-conditioned.

• It contains compressor, fan, motor, condenser coil

,

copper tubing and electrical components.

4

3. UNIT MODEL DESIGNATION & IDENTIFICATION

UNIT MODEL DESIGNATION IDENTIFICATION (ID)

4. UNIT MODELS & PART NUMBERS

INDOOR UNIT

HEAT PUMP COOL ONLY

Model P/N ID Model P/N ID

42KLE14-H 46302213 H 42KLE14-C 46302214 C
42KLE22-H 46302216 H 42KLE22-C 46302217 C
42KLE28-H 46302219 H 42KLE28-C 46302231 C
42KLE32-H 46302222 H 42KLE32-C 46302223 C

COOL/ELECTRIC HEAT 42KLE39-C 46302225 C

Model P/N ID

42KLE39-E 46302243 E

OUTDOOR UNIT

HEAT PUMP COOL ONLY

Unit

Model

P/N ID

Unit

Model

P/N ID

38KLE14-H 46303305 H 38KLE14-C 46303309 C
38KLE22-H 46303366 H 38KLE22-C 46303368 C
38KLE28-H 46303367 H 38KLE28-C 46303369 C
38KLE32-H 46303308 H 38KLE32-C 46303312 C

38KLE39-C 46303313 C

42

38

H
E
C

42 = Indoor Unit
38 = Outdoor Unit

28

Compressor

Cooling Capacity

in MBTU/HR

at ASHARE
Conditions

Unit Type

H = Heat Pump
E = Cool/Electric Heat
C = Cool Only

KLE

Unit Family

5

5. SYSTEM OPERATING LIMITS

COOLING HEATING

Difference

Dry Bulb
Temp. C°

Wet Bulb

Temp. C°

Difference

Dry Bulb

Temp. C°

Wet Bulb
Temp. C°

Indoor temperature
Maximum
Minimum

32
21

23
15

Indoor temperature
Maximum

27

-

Outdoor temperature
Maximum
Minimum

55
21

-

-

Outdoor temperature
Maximum

21

-

MAIN POWER SUPPLY

Nominal

Power Supply

V/1PH/50HZ

Minimum

Voltage

Maximum

Voltage

200-240 180 264

* When the system is operated above or below these limits for a long time, system diagnostics may detect a malfunction

and the unit will not operate properly.

6. SYSTEM SAFETY PROTECTION

6-1 FOR HEAT PUMP SYSTEM

PROTECTION TYPE PROTECTION EFFECT OPERATION MODE WHEN ON

Cold draft prevention Indoor fan off Heating mode During unit operation

Defrost cycle Indoor fan off Heating mode During unit operation

Indoor coil

Freeze protection

Compressor off Cooling mode During unit operation

Against frequent

Compressor cycling

Compressor

Time delay

Cooling or heating

modes

At unit start-up or change

of operating mode

6-2 FOR COOL ONLY SYSTEM

PROTECTION TYPE PROTECTION EFFECT OPERATION MODE WHEN ON

Indoor coil

Freeze protection

Compressor off Cooling mode During unit operation

Against frequent

Compressor cycling

Compressor

Time delay

Cooling mode

At unit start-up or change

of operating mode

WARNING:

During heat pump operation the system will undergo several defrost cycles to remove ice that might
collect on the outdoor unit in very low ambient temperature. In these cycles, the indoor fan will be
automatically off and cannot operate until defrost cycle is completed.

6

7. EXPLODED VIEW OF INDOOR UNIT

12/4

5/6

4

8

6

9

7

7

2

3/9

3/1

3/8

3/7

3/2

11 10

5/1

5/2

5/3 5/4

5/5

3/4

3/3

3/5

3/6

12/5

1

1/6

&

12/1

12/3

12/2

12

Pour 42KLE39

7

8. PART LIST OF INDOOR UNIT

QTY./UNIT

42KLE-H 42KLE-E 42KLE-C

SR. DESCRIPTION

PART

NUMBER

14 22 28 32 39 14 22 28 32 39

1 Chassis Subassy 363-13331 1 1 1 1

363-13332 1 1 1 1
363-13333 1 1

1.1 Chassis Side LH Subassy 363-13327 1 1 1 1 1 1 1 1 1 1

1.2 Chassis Back 063-01800 1 1 1 1
063-01801 1 1 1 1
063-01802 1 1

1.3 Fan Deck Support 028-02318 2 2 2 2 2 2 2 2 2 2

1.4 Plug 028-02319 1 1 1 1 1 1 1 1 1 1

1.5 Chassis Side RH Subassy 363-13329 1 1 1 1 1 1 1 1 1 1

1.6 Motor Capacitor

1.6.1 Capacitor 3MFD +/- 5 % , 450 VAC 024-00302 1 1 1 1

1.6.2 Capacitor 5MFD +/- 5 % , 450 VAC 024-00332 1 1 1 1 1 1

1.7 Capacitor Clamp 028-04077 1 1 1 1 1 1 1 1 1 1

1.8 Terminal Block

1.8.1 Terminal Block 6 Poles-30Amps 025-01433 1 1 1 1

1.8.2 Terminal Block 4 Poles-30Amps 025-01413 1 1 1 1 1

2 Evaporator Coil & Headers Subassy 026-00180 1 1

026-00181 1 1
026-00182 1 1
026-00119 1 1
026-00120 1 1

3 Blower Deck Subassy 363-13319 1 1 1 1

363-13320 1 1 1 1
363-13396 1 1

3.1 Blower Deck 063-01807 1 1 1 1

063-01808 1 1 1 1
063-01809 1 1

3.2 Blower

3.2.1 Blower 155 mm Diam x 177.8 mm Width 028-02324 2 2 2 2

3.2.2 Blower 155 mm Diam x 228.6 mm Width 028-02325 2 2 3 2 2 3

3.2.3 Socket Set Screw – Blower 021-00317 2 2 2 2 3 2 2 2 2 3

3.3 Thermistor Clip Nylon 021-00846 1 1 1 1 1 1 1 1 1 1

3.4 Rubber Ring For Housing 028-00685 8 8 8 8 12 8 8 8 8 12

3.5 Motor Support 063-01810 1 1 1 1

063-01625 1 1 1 1
063-07403 1 1

3.6 Motor Clamp Kit C/W Screw & Nut 021-00913 2 2 2 2 2 2 2 2 2 2

3.7 Evaporator Motor

3.7.1 Motor 1/15 HP – 1200/1100/950/800 RPM 024-00096 1 1 1 1

3.7.2 Motor 1/10 HP – 1200/1100/950/800 RPM 024-00097 1 1 1 1

3.7.3 Motor 1/8 HP – 1220/1100/950 RPM 024-00178 1 1

3/8 Blower Housing RH 028-02328 2 2 2 2

028-02329 2 2 3 2 2 3

3.9 Blower Housing LH 028-02326 2 2 2 2

028-02327 2 2 3 2 2 3

3.10 Complement – Motor Shaft 024-00203 1 1

3.11 Coupling Rubber/Metal – Motor 024-00204 1 1

3.12 Bearing & Support Assy – Motor 024-00205 1 1
4 Drain Pan Subassy 363-13334 1 1 1 1

363-13335 1 1 1 1
363-13336 1 1

8

PART LIST OF INDOOR UNIT (Cont.)

QTY./UNIT

42KLE-H 42KLE-E 42KLE-C

SR. DESCRIPTION

PART

NUMBER

14 22 28 32 39 14 22 28 32 39

5 Electrical Box Subassy 363-13338 1 1 1 1 1 1 1 1

363-13364 1 1

5.1 Main PCB 025-03019 1 1 1 1 1 1 1 1 1 1

5.2 Room Sensor 530 ± 30 mm 025-03102 1 1 1 1 1 1 1 1 1 1

5.3 Indoor Coil Sensor 530 ± 30 mm 025-03119 1 1 1 1 1 2 2 2 2 2

5.4 Cable Main PCB – Led PCB 025-01566 1 1 1 1 1 1 1 1 1 1

5.5 Cable Main PCB Step Motor 025-01567 1 1 1 1 1 1 1 1 1 1

5.6 Evap. Electrical Box 028-02334 1 1 1 1 1 1 1 1 1 1

5.7 Set of Cables 025-00883 1 1

025-00884 1 1 1 1

025-00885 1 1 1 1

6 Cabinet Subassy 363-13303 1 1 1 1

(See Details Pages 5 & 6) 363-13304 1 1 1 1

363-13305 1 1

7 Air Filter-Anti Bacteria 028-02303 3 3 4 4 5 3 3 4 4 5

8 Spring for Return Grille 063-01829 1 1 1 1 1 1 1 1 1 1

9 Return Grille Subassy 363-13300 1 1 1 1

363-13301 1 1 1 1

363-13302 1 1

10 Wireless Remote Control 025-03100 1 1 1 1 1 1 1 1 1 1

11 Battery 1.5 Volt Size AAA - Alkaline 025-01125 2 2 2 2 2 2 2 2 2 2

12 Electric Heater Subassy

(Only For 42KLE39-E) 363-19007 1

12.1 Electric Heater Aluminum 4.0 kW 025-00181 1

12.2 Heater Fuse – One Shot 025-01100 1

12.3 Heater Thermostat – Manual Reset 025-01101 1

12.4 Power Relay Heater G7L-2A-T 024-00451 1

12.5 Bracket For Relay 024-00456 1

12.6 Heater Support RH 063-01628 1

12.7 Heater Support LH 063-01627 1

12.8 Heater Support Cover 063-01629 1