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
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
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 CoilEvap 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
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