Carrier 51CM User Manual

0 (0)
51
HEATING & COOLING
Start-Up and Service Instructions
International Series
51CM,GM,ZM.CV,GY

CONTENTS

Page
SERVICE . . 1 General Notes .. .1 Compressor Replacement 1
SAFETY REMINDERS............................................ 2-5
Preventive Maintenance 2
System Cleaning ... .2
System Flushing .... .2
Physical and Electrical Data Compressors ... 4 Run Capacitors. .
Thermistors ... 4
Casing Dimensions .. .4 Capillary Data . 5 Capillary Insertion 5
DISASSEMBLY INFORMATION .... 6-17
Model 104's Casing .... 6
Models 304's/404's Casing ... 13
TROUBLESHOOTING GUIDE ... 18

START-UP

Refer to operating instructions in Owner’s Handbook
provided with room air conditioner
General Notes — These Start-Up and Service Instiac
tions are provided to assist the trained and qualified service technician in repaii ing or replacing components of Carrier room aii conditioner models produced in 1988, specifically International Series models (51CM,GM,ZM Cooling Only, 51CV,GY Cooling and Electiic Heat) Other Carriei models for prior yeais have separate Start­Up and Service publications
IMPORTANT Repairing and servicing ah condi
tioners can be hazardous for untiained individuals
The insti actions printed in this publication are for
properly ttained and qualified Carrier service tech
nicians only

A WARNING

Befoi e working on any air conditioner, be sure to first disconnect all electric power to the unit to avoid the possibility of electiical shock and personal injury
...................................
.....................

SERVICE

3
4
1988 Room Air Conditioners
Discharge capacitors beiore disconnecting, by shorting
acioss terminals
Shield coils with cardboard to protect hands against injury from sharp metal edges when removing compres­soi and other components
When disassembling wiring, use numbered stickers to identify wiie leads and terminals This aids in quick, accurate reassembly
Check clearances around scroll and housing before installing fans Before securing fan setscrews, rotate fan by hand to ensure ample clearance
Refer to Carriei Standard Service Techniques, Chapters 1 and 2, for information on checking motors, removing refrigerant, adding oil, evacuating, dehydrating and charging system Pay particular attention to all saiety warnings for these procedures
Compressor Replacement Stand clem ofcom-
ptessoi tetminals when wotking on comptessors With
system imdef piesswe, terminals mar blow Observe the same safety procedures for rotary compressors as for reciprocating compressors
When changing compressors
1 Follow all safety codes Reminder use protective
goggles, work gloves and water-soaked quenching cloth
Shut off electric power and remove wiring irom compressor
Purge or remove all refrigerant and pressure from
system Cut suction and discharge lines Use tubing cutter at
convenient location on tubing, near compressor, to ease reassembly using copper slip couplings
Remove compressor from unit Protect compressor irom heat and carefully unbraze piping stubs

A CAUTION

Oil vapor in piping stubs can ignite irom torch flame and cause serious injury Exercise extreme care when brazing, and keep brazingcloth and fire extinguisher handy for emergency use
Install oil piping stubs on new compressor and care
fully braze into place
Clean system add or replace liquid line filter drier Reiei to System Cleaning, and System Flushing
Install new compressor and braze into place with field-supplied copper slip couplings
9
Connect wiring, replace wire terminals if necessary Proceed with evacuation, charging and start-up
10
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations
Book 1 4
8a
Tab
10a
PC131 Catalog No 535-134 PrintedinUSA Form51-20SS Pgl 7-88 Replaces:New
For replacement Items use Carrier Specified Parts
It is much easiei to unsweat a short piece of tubing from the compressor afte) you have removed the compressoi irom the unit It follows that you can soldei the oil piping stub into the new compressor fittings more easily befoie the eompiessor is put back into the unit
If you choose a good tubing location for cutting the refrigerant lines initially, the loeation is easily accessible when making the final joints

SAFETY REMINDERS

1 Cany a file extinguishei in youi tiuck Keep it within
reach when using a torch Check fiie extinguisher peiiodically to be suie it is fully loaded and iunctional.
2 Know how to handle oxyacetylene equipment safely
Lock the equipment in an upright position in the truck and at the job site
3 Use dry nitrogen oi carbon dioxide to pressuiize the
system for leak checking Always use a good regulatoi Be careful not to exceed 150 psig test pressure in the heimetic eompiessor
4 Weal your safety goggles and gloves when lemoving
refiigeiant from a system
5 Attend your shop safety meetings

Preventive Maintenance

CLEANING — Clean cooling coil and condensei coil
Hold flashlight behind coil to see if all spaces are clear
Use a hooked wire to lemove dirt Dust accumulation obstructs or reduces airflow and results in loss of capac­ity Coils may be vacuumed when diy Outdoois, unit can be brushed with a stiff brush and fins blown out with
compressed aii
Thoroughly clean basepan, motors, fan wheels, other
components and all drain passages Vacuum insulation
Clean all inside painted surfaces with mineral spirits to
remove grease
Clean cabinet and grille Mild detergents reduce elec trostatic charges on plastic sections of the grille and are good cleaners Do no! 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
electrical contacts for tightness and lack of corrosion
LEAKS — Check any connections that show evidence of oil or leaks When unit is property installed, centered and leveled (see MOUNTING), check gaskets and wing panels for possible air leakage
MOUNTING — Make sure unit is secure in window, level from left to right, and from front to rear according to installation instructions provided
If used, check compressor mounting springs and re place if necessary Spt ings tend to lose their tension with use This could lead to noisy operation
Check fans to ensure they are correctly positioned, centered in orifice and tight on shaft
CONTROLS — Check unit to ensure all controls ate functioning 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 — A motor burnout is recognized by the burnt odor of the refrigerant system When the motor of a hermetically sealed compressor but ns out, the
insulation of the stator winding forms carbon, water and acid After burnout, clean refrigerant circuit before a new motor-compressor is installed installation of a new capillary and strainer is also recommended when re
placing a compressor after burnout
The system is partially cleaned by back flushing with relrigerant vapor blown into the suction line and out the discharge just before connecting the new compressor If this method is chosen, install a Sporlan C052S (Carrier No KH41EZ246) lilter drier or equal in the liquid line, using a capillary tube adapter (Carrier Part No DEC3680001) An alternate and equally satisfactory method follows under System Flushing
NOTE Damage to a new compressor caused by failure
to clean the system as recommended is not covered by the product warranty
System Flushing — Flush with liquid R-22 refrig
erant before the suction line is connected to the new
compressor
1 Clean, flux and solder discharge line to new compressor
NOTE Compressor valves keep relrigerant from
backing out through compressor
2 Makeal/4-in connection to suction line Forexample
Use a 1/2-in x 1/4-in flare reducing coupling
and a/1/2-in. flare nut and tube (flared) and a
1/2-in sweat coupling||that connects to the system
1 /2-in. suction line. For other size suction lines use
proper size fittings to make the connection Connect
1 /4-in fitting to a refrigerant di urn by using chaiging
hose 01 1 /4-in tubing Cut off the end of the pigtail on the discharge line
Flaie and install a I /4-in stop valve or (preferably) a
charging manifold
Invert drum and charge liquid refrigerant
Open discharge valve and allow to purge slowly until liquid Freon comes, then close valve
6 Close valve on refrigerant drum and allow refrigerant
to remain in piping at least 15 minutes
7 Open valve on discharge stub and allow refrigerant to
blow out quickly Be careful not to stand in front of valve when purging Protect hands from refrigerant burns with cloth
8 Disconnect refrigerant drum and unsolder connection
to suction line
9 Proceed with remainder of installation
Table 2 — Physical and Electrical Data (Single Phase, 60 Hz) — 1988
MODEL 51
ZMA705101 ZMA705111 ZMA706101
ZMA706103 ZGA706103 ZMA007913 ZGAa07903 ZMA007703 ZMA008101 ZMA008103 ZGA008103 ZMA008703 ZMA009913 ZGA009903 ZMA009703 ZMA009303 ZMB009703
Table 1 — Unit Model Numbers (104, 304, 404)
CASING
104
MODEL 51
CMA109101 CMB112111 CMB112103 CMC012311 CMB012313 CMA012903 CMB012913 CGA012903 CMA012703 CVA212703 CMA115301 CMB115303 CMA118903 CGA118903 CMB118313 CMA118703 CMA115703
CASING
304
MODEL 51
GMA009101 G MA114101 GMA118301 GMA121301 GMA121311 GMA124301 GMA228301 G MA118703 GYA318703 GMA224703
CASING
404
Cool
5,200
7,600
8 800 12,000 12,000
9,000
Cool
12 000 18 000 18,000
CAPACITY
(Btuh)
‘Based on AHAM Standard RAC-1 and ANSI Z234 1 A t — Entering wet-bulb temperature minus leaving wet-bulb temperature based on 67 F room wet-bulb temperature and95F dry-bulb outside air temperature
CAPACITY
(Btuh)
MODEL
51
ZMA705101 5,200 ZMA705111
2MA706101 6,100 ZM,ZGA706103 6,100 ZMA008101 7,600 ZM,ZGA008103
ZMA009303
CMAiogioi
CMB112111
CMB,CGA112103
CMC012311
CMB012313
CMA115301
CGA.CMB115303 15,000/14,800
CMB118313
GMA009101
GMA114101 13,500 GMA118301 18 000/17 700
GMA121301 20,500/20 000
GMA121311 20,500/20,000
GMA124301 23,500/23,000
GMA228301 27,500/27,000
DOE — Department of Energy EER — Energy Efficiency Ratio FLA — Full Load Amps
Hp — Horsepower
PF — Power Factor
MODEL
51
ZMA007913 7,000 ZGA007903 7,000 ZMA007703 7,000/ 6,800 ZMA009913 9,000 ZGA009903 9,000 ZMA009703 9,000/ 8 750 ZMA008703 ZMB009703
CMA012903 12,000 CMA012703 12,000/11,900 CVA212703 12,000/11,900 CMA115703 15,000/14,800 CMA118703 18,000/17.800 CMA118903 18 000 CMB012913 12,000 CGA012903 CMB118913 CGA118903
G MA118703
GYA318703 GMA224703 24 000/23,500
9,000/ 8,900
11,800/11,700 11,800/11 700 15,000/14,800
18,000/17,800
8,000/ 7,775 8,500/ 8,250 --
18,000/17,500 18,000/17,500
R-22
CHG
Heat
— — — — —
----
-
— — — — — —
— —
If conditions vary, wet-bulb At will vary
•Heat
_ — — — — — —
_ — — — — — — — — —
_
11,300/9,500
(oz ± 5 - 0)
155
15 5
15 0 12 1
150 12 1 18 0 18 0 20,0
23 0 30 0 30 0 32 0 32 0 38 0 38 0 32 0
27 0 27 0 40 0 12 1 44 0 39 0 39 0 15 8 40 0
R-22 CHG
{oz ± 5 - 0)
18 5 18 5
160 149
170
170 18 0 18 0
180
29 0 123 32 0 10 6 32 0 29 0 34 0 34 0 22 0 107 22 0 10 7 29 0
29.0 11.1 28 0
28 0 125 36 0 150
WET
BULB
(AtF)
98 98
15 5
155
16.5/16.4 230/208 96
11 2 11 2 109
109 13 1 13 1
14.0
65
86
14 5 14 5
187
VOLTS
115 115 115 115 115 115
115 115 115
230/208 230/208 230/208 230/208 230/208
115 115
230/208 230/208 230/208 230/208 230/208
Table 3 — Physical and Electrical Data (Single Phase, 50 Hz) — 1988
WET
BULB
(AtF)
159 159
21 0
21 0 20 2/20 0 20 2/20 0 20 2/20,0
10 6 10 8 12 9 13 2
11 1
12 5
VOLTS
200 200
240/220
200
200 240/220 240/220 240/220
200 240/220 240/220 240/220 240/220
200
200
200
200
200 240/220
240/220 240/220
Cool
56 56 63 63
81
8 1
4.2/ 4.6 86
120
120 5 9/62 5 9/62 7 5/79 7 5/79
9.2/10.2 7 2
120
8 7/95 10 3/11 0 10 3/11 0 11 3/12 0 15 2/16 0
Cool
44 44
3 8/40
56
56 4 5/47 4 5/47 4 5/47
62 5 6/60 5 6/60 7 8/82 9 5/99
11 9
70
70
11 0
11.0
10 4/110 10 4/11 0 13 7/14 7
NAMEPLATE*
Amps
Heat Cool
_
_
_
_ _
_
_ _
_
_
--
_ _
_
_
Amps
NAMEPLATE*
Heat Cool
_
_
— _
_
— —
-
_
_
_
_ _ _ _
_
15 1/14 0 2250/2190
580 580 665 665 845 845
900/ 890
930 1335 1335 1285 1285
1630/1610 1630/1610 2140/2120
750
1320
1950/1920 2220/2165 2220/2165 2550/2500 3350/3290
780 780
780/ 755
1000
1000 950/ 920 995/ 965 995/ 965
1265
1265/1250 1265/1250 1750/1730 2220/2200
2195
1275
1275
2115
2115
2250/2190 3000/2940
Watts
Watts
Heat
_
_
_ _ _ _
_ _
_ _ _
___ _
_ _
_ _ _
Heat
_
_
_
­_
_ _ _ _ _ _ _
_
3590/3050
FAN
OH
MO
FLA
93 93
93
93 93 93 91
.61
1 40 1 40 1 40
70
70 90 90
.90
1 11
3 10 98
1 00 1 11 1 11 1 60 1 60 Vi 96
FLA
44
44 41 44 89 44 41 'A , 41
.41 'Ad
60 60 60 Vi;
1 00 1 00 1 60
60 60
1 60
1.60 1 10
1 10
1 50 Va
MO
FAN
TOR
Hp
'/l5 Vts
Vl5 Vl3
V,. 93
Vl2 Vl2
’/.2 V,2 ’/l2
% % 'A 98
V,0 ’/6
'A 'A %
Hp
V20 V20 V20
V.2 y,2
'A
%
'A
'/t2
'A 'A
'A 'A
PF
(%)
90 90 92 92
91
98 93 93
98 98 97 97
93 97
94 94 98
PF
(%)
89 89 86
89 88/89 92/93 92/93
92 96 96 95 97
97
82
82
96
96
90
90
91
EER
(DOE)
90 90 92
9 2
90 90
10.0 9 5 304
90 304 90
9 2/9 1 9 2/9 1 304 T-9 9 2/9 2 9 2/9 2 304 T-12
8.4/8.4 304 T-14 120
102
92 92 9 2 9 2
82
EER
(DOE)
90 Ml-1 90 Mt-1 90 T-4 90 90 80 80
8.0 95 T'11
95 T-10 96 T-10 80 T-13
8 1 304 T-15
82 94 94 85
8.5 80 T-5
80
80 T-9
CASING COMPR
104 104 104 104 104 104 104
304 304
304
404
CASING COMPR
104
404 T-5
___
T-1 T-1 T-2 T-2 T-3 T-3
T-5
T-7 T-8 T-8 T-9
T-12
T-17 H-1 MA-1 T-14 MA-2 T-22 T-23
MI-2 MI-2 T-6 T-6 T-6
T-16 MI-3 Ml-3 MI-4 MI-4
CAPILLARY
Data
C-1 C-1 C-2 C-2 CM C-3 C-3 C--4
__
C-8 C-9 C-9 C-19 C-19 C-7 C-7 C-11
C-10 C-13 C-14 C-15 C-15 C-20 C-16
Data Insertion
C-5 C-5 C-4 C-6 C-6 C-6 C-6
____
______ C-9 C-10 C-10 C-7 C-11 C-11
C-12
e-12 c-11 c-11
c-17 c-17 CI-3 c-18
Insertion
CI-2
CI-3
CI-1
CI-2
START
THERMISTOR
Z-1
Z-1
START
THERMISTOR
Z-1
Z-1
z-1
DOE ~ Department of Energy EER — Energy Efficiency Ratio FLA — Full Load Amps Hp — Horsepower PF — Power Factor
‘Based on AHAM Standard RAC-1 and ANSI Z234 1
A t — Entering wet-bulb temperature minus leaving wet-bulb temperature based on 67 F room wet-bulb temperature and95 Fdry-bulboutsideairtemperature
If conditions vary, wet-bulb At will vary
Table 4 — Compressors
KEY NO
Matsushita MA-1
MA-2 Mitsubishi MI-1
MI-2 MI-3 MI-4
Tecumseh
H-1 Toshiba T-1
T-2 T-3 T-4 T-5 T-6 T-7 T-8 T-9 T-10 T-11 T-12 T-13 T-14 T-15 T-16 T-17 T-18 T-19 T-20 T-21 T-22 T-23 T-24 T-25
VENDOR MODEL
NO
2K25S3R236A-6A 2K32S3R236A-6A
RH421SS RH427SS RH434SS NH455NB
RK5513E
ERH62XA3-1K ERH68XA3-1K EH88X1-1CU1 PRH94XA4-4K PRH88XA4-3K PH112X2-4KU
ERH88XA4-1K EH120X2-1KU PH120X2-3KU PH142X2-4KU PH142X2-9LU PH160X2-3LU1 PH180X2-4LU PH210X3-3LU PH250X3-4LU PH250X3-9LU EH80X1-1CUI PH200X33-3LTU PH230X3J-3LTU
PH230X3J-4LTU
PH230X3-4LU PH250X3-3LU PH310X3-3MU PH310X3J-4MTU
PH310X3-4MU
OiL CHARGE (02 ± 1)
Dry
14 5 14 5
10 1 19 2
180
28 7
Recharge
17 3 16 2 25 8
11 8
7 4 7 4 7 4
74 7 4
11 0
7 4
10 6
106 11 0 11 0 14 0
140 20 3 20 3 20 3
74 20 3 20 3 20 3 20 3 20 3 23 7 23 7 23 7
18 3 18 3 18 3
18 3 18 3
21 3 21 3 21 3
\ir\\ TC
125 125
9 1
9 1
67 67 67
6 7
67
9 9 240/220
67 95 95 99
99 126 126
67 183
18 3 183
230/208 230/208
200 200 200 200
115 11 4
115 115
115 240/220 230/208
115 7 7
115 230/208 240/220
200 230/208 240/220 230/208 240/220
200
115 230/208 230/208 240/220 240/220 230/208 230/208 240/220 240/220
RLA LRA
74 42 0 96 52 0
FLA
4 5
56 30 0 73 38 0 97
26 0
47 0
67 0
52 35 0
59 35 0 75
34 20 0 39 25 0 40 23 0
11 6
54 45 26 0 52 27 0 68 38 0 69 36 0
9 1
88
10 2 51 0
20 0 79 0
— —
-
41 0
43 0 63 0 33 0
49 0 46 0
41 0 65 0
58 0 46 0 63 0 79 0 83 0 72 0
RUN
CAPACITOR
RC-4 RC-6
RC-12 RC-8 RC-8 RC-7
RC-9
RC-3 RC-3 RC-3 RC-1 RC-1 RC-2 RC-2 RC-5 RC-2 RC-2 RC-2 RC-4 RC-4 RC-6 RC-6 RC-6 RC-9 RC-6 RC-6 RC-6 RC-6 RC-6 RC-6 RC-10 RC-11
FLA “ Full Load Amps LRA — Locked Rotor Amps RLA — Rated Load Amps
Table 5 — Run Capacitors
KEY NO
RC-1
RC-2
RC-3 RC-4 RC-5 RC-6 RC-7
RC-8 RC-9
RC-10
RC-11
RC-12
MFD — Microfarad
CARRIER NO
HC98CA016 HC98CA026 HC98CA027 HC98CA036
HC98CA031
HC98CA046 HC98CA050 HC98DA031 HC98CA028 HC98CA062 HC98CA047 HC98DA026
MFD
15/5 25/5
25/7 5 370
35/5 30/5 45/5
50/5
30/5 25/10 60/7 5 45/7 5
25/5
VOLTS
370 370
370
370; 370 370 440 370 370 370 440
Table 6 — Thermistor
KEY NO
Z-1
CARRIER NO
HC95XX006 3M305C20C
VENDOR NO
Table 7 — Casing Dimensions (in.)
CASING
104 304 404
HEIGHT
UVe 20 Vm 17'/e
15S/t6 24Vm
173/i6
WIDTH
26
RESISTANCE
(Ohms)
25
DEPTH
27¥^6
28Vi6
Table 8 — Capillary Data
Table 9 — Capillary Insertion
KEY NO
C-1
C-2 106 055 C-3 106 055 C-4 C-5
C-6(2)
C-7 125 070
C-8 C-9 125 064
C-10 125
C-11
C-12 125 C-13 C-14
C-15(2)
C-16
C-16(2) 106 054
C-16
C-17 (2)
(Injection)
C-18 (2)
(injection)
C-19
C-20 (2)
OD
(± 002)
106 049
106 054 106 106
125 054
125 070 125
125 070 125 054 106 054
106 054 125 080 031 125 070 080 031
125 064 125 064
DIMENSIONS (in.
ID
(± 0003)
049 049
064 064
070
070
Length
(± 25)
30 39 38 42 26 66 34 25 25 35 22 26 26 24
16 46 34 56 36 36 31 18
30 25
NOTE Capillary number follows key number Numbercapillaries from left to right, facing evaporator inlet, when more than one is used
KEY NO
CI-1
C1-2
CI-3
DEPTH (In.)
Cond Coil Evap Coil
Conn Tube
(Max) (Min)
Conn Tube
Va
1
Va
1 1
DISASSEMBLY INFORMATION
Model 104's Casing
Model 51ZM — The Model 5IZM Room Air Condi-
tioner is leieiied to as the 104 size casing International Series unit See Fig 1
Fig. 1 — Model 51ZM
1 Grille — Decorative iiont grille insert is removed by
giipping top of insert and pulling outward while lift ing insert from grille frame See Fig 2
Fig. 3 — Removing Filter
Fig. 2 — Removing Grille Insert
Filter — Filter can be removed without having to
remove grille insert Grasp bottom edge of filter (located behind grille insert) and gently pull filter down and slightly toward you See Fig 3 Filter may be vacuumed, or washed in warm water Shake filter to remove excess water, dry thoroughly and replace by sliding filter upward behind front grille until filter snaps in place
Grille Frame — Grille frame is removed by first removing 4 screws holding frame to chassis See Fig 4 Pull top of grille frame outward and lift frame
away from chassis
Fig 4 — Removing Grille Frame Screws
Chassis Security Lock Screw — To slide
chassis out of casing, security screw must first be loosened Loosen screw and slide screw to unlock position (forward) When reinstalling chassis in casing, reverse procedure and tighten screw in lock position See Fig 5
Chassis — The International Series models have
a slide-out chassis Servicing the chassis is possible without having to remove rrnit casing from window See Fig 6 Use the offset in the basepan as a finger­grip handle to slide chassis out of casing

A CAUTION

Coil fins are sharp Use care when removing chassis from casing to avoid personal injury Do not use plastic parts for lilting or pulling They are not structural members of the chassis Lift using basepan only Chassis is heavy Obtain assistance for lifting
EVAPORATOR COVER SCREWS (5)
Fig 5 — Unlocking Chassis Security Lock Screw
Fig 6 — Sliding Chassis Out of Casing
Fig. 7 — Evaporator Cover Screws
6 Evaporator Cover — Remove evaporator by
removing 5 sciews as shown in Fig 7
7 Control Box — Conti ol Box is secured with 2
sciews See Fig 8 a Remove sensing bulb from coil See Fig 9 b Remove service cord screw See Fig 9 c Remove control knobs by pulling off See Fig 10 d Remove escutcheon plate
8 Timer — See location of timer in Fig 11
a Remove 2 screws holding timer to control box
b Caiefully pull wires fiom timer terminals being
sure to label or mark each wire for accurate wire
replacement on timer
c To reinstall timei. reverse above procedure
Fig 8 — Control Box Screws
9 Cool-Heat Control — See Cool-Heat Control
location in Fig 11
a Remove 2 sciews holding Cool-Heat Control to
control box
b Carefully pull wires from Cool-Heat Control ter
minals being sure to label or mark each wire for accurate wire replacement
c Reverse above procedure to reinstall Cool-Heat
Control
10 Fan Cycle Switch — See Fan Cycle Switch loca
tion in Fig 11
a Remove fan cycle switch using screwdriver as
shown in Fig 11
Loading...
+ 14 hidden pages