Carrier 51CM User Manual

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Page 1

HEATING & COOLING

Start-Up and Service Instructions

International Series

51CM,GM,ZM.CV,GY

Page

START-UP ................................................................ 1

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

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

Connect wiring, replace wire terminals if necessary Proceed with evacuation, charging and start-up

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

Book 1 4

Tab

10a

PC131 Catalog No 535-134 PrintedinUSA Form51-20SS Pgl 7-88 Replaces:New

For replacement Items use Carrier Specified Parts

Page 2

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

Page 3

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

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

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

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

200 240/220

240/220 240/220

Cool

56 56 63 63

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 4 5/47 4 5/47 4 5/47

62 5 6/60 5 6/60 7 8/82 9 5/99

11 9

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

2115

2250/2190 3000/2940

Watts

Heat

_ _ _ _

_ _

_ _ _

___ _

_ _

—

_ _ _

—

Heat

—

_ _ _ _ _ _ _

3590/3050

—

FAN

FLA

93 93

93 93 93 91

.61

1 40 1 40 1 40

70 90 90

.90

1 11

3 10 98

1 00 1 11 1 11 1 60 1 60 Vi 96

FLA

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

FAN

TOR

'/l5 Vts

Vl5 Vl3

V,. 93

Vl2 Vl2

’/.2 V,2 ’/l2

% % 'A 98

V,0 ’/6

'A 'A %

V20 V20 V20

V.2 y,2

'/t2

'A 'A

(%)

90 90 92 92

98 93 93

98 98 97 97

93 97

94 94 98

(%)

89 89 86

89 88/89 92/93 92/93

92 96 96 95 97

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

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 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

START

THERMISTOR

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

Page 4

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

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

67 67 67

6 7

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

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

RESISTANCE

(Ohms)

DEPTH

27¥^6

28Vi6

Page 5

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)

(± 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.

(± 0003)

049 049

064 064

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

1 1

Page 6

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

Page 7

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

Page 8

Fig 9 ~ Sensing Bulb and Service Cord Screws

TIMER REMOVAL SCREWS (2)

TIMER COOL-HEAT FAN

CONTROL AND CYCLE SCREWS (2) SWITCH

Fig. 11 — Control Locations

Run Capacitor — See Run Capacitor in Fig 12

a Discharge capacitor before disconnecting by

shorting across terminals with a screwdriver

b Remove screw fastening capacitor strap to parti

tion assembly and remove strap

c Carefully pull wires from run capacitor terminal

Mark or label wires for correct reassembly

d Reverse above procedure for reassembly

Fig. 10 — Removing Knobs

b Caieiully pull wires iiom teiminals of fan cycle

switch Label oi mark wires to aid in proper wire lepla cement

c Reverse above procedure for reinstalling fan cycle

switch

1 Thermostat — See Thermostat location in Fig 11

a Remove 2 screws holding thermostat to control

box

b Carefully pull wires from thermostat terminals

being sure to label or mark wires to aid in correct

wire replacement

c Remove insulating sleeves trom thermostat bulb

d Rerfiove thermostat and bracket itom control

box

e Remove thermostat from bracket by removing 2

screws

f Reverse above procedure to reinstall thermostat

RUN CAPACITOR

Fig. 12 — Run Capacitor

RUN CAPACITOR

13 Fan Motor — See Fan Motor in Fig 13

a Loosen set screw on blower wheel See Fig 14 b Remove clip from condenser ian See Fig 14 c Disconnect fan motor wires from control box and

capacitor

Page 9

Remove fan motot leads irorn wiie ties Identify wires foi coirect reassembly

Remove fan motoi ground wiie fiom partition assembly by lemoving one sciew

Remove 3 screws fastening fan motoi to partition assembly See Fig 13

Pull fan motor carelully towaid condenser coil and remove

A CAUTION

Be careful to avoid damaging condensei coil when pulling and lemoving fan motor

h Reverse above proceduie foi leassembly of fan

motoi

NOTE For proper orientation ol diain holes in re

placement motor, check to be suie motor label is

facing up Foi optimum perfoi mance, position blowei

wheel and propeller fan properly on motoi shaft

SET SCREW LOCATION FAN CLIP

Fig. 14 — Blower Set Screw and

Condenser Fan Clip

CONDENSER FAN

Fig. 13 — Fan Motor

FAN MOTOR LUBRICATION — Fan motor is factory lubiicated and requires no lubrication undei normal con ditions foi a period of 5 years The fan motor should be oiled at the beginning of each cooling season thereafter li the unit is subjected to heavy usage, dusty atmosphere, or other abnormal conditions, oil motor at the beginning of the first cooling season and each cooling season theieaftei

Fan motois have an oil port on each end ol the motoi

Remove the lubber dust plugs liom oil poits and add 4 diops of SAE 20 oil through each poit Be sure to replace plugs aftei oiling

14 Condenser Fan—See Condensei Fan in Fig 14

a To aid in leassembly, maik shaft at point wheie

hub and shaft meet

b Remove clip from condensei tan as shown in

Fig 14

c Remove condenser oiifice by lemoving 4 screws

holding condenser orifice to the tube sheet as shown in Fig 15 and 18

PARTITION ASSEMBLY SCREWS

Fig 15 — Partition and Orifice Assembly Screws

d Remove 2 sciews in back of unit as shown in

Fig 16 Carefully lift and pull condensei coil outwaid

e Reverse above procedure foi reassembly

15 Evaporator Blower — See Evaporatoi Blowei in

Fig 14

Remove 3 screws in fiont ol unit as shown in Fig 17 Remove one screw oncompressoi side (see Fig 16) which holds evaporator coil tube sheet to partition assembly Remove 2 side seiews lastening pai tition assembly

to basepan and paitition assembly to evapoiator coil tube sheet See Fig 15

Remove 2 back sciews which hold partition assembly to basepan See Fig 15

Page 10

COMPRESSOR

CONDENSER COIL REMQV SCREWS (2)

PARTITION ASSEMBLY REMOVAL SCREW

'condenser COIL

CONDENSER ORIFICE REMOVAL

ÍSCREWS (4)

Fig, 16 — Condenser CoM/Partition Assembly

Screws

PARTITION ASSEMBLY REMOVAL SCREWS [3Ì

Fig. 17 — Partition Assembly Screws

e Remove screw on compressor side which holds

partition assembly to basepan as shown in Fig 18

f Remove 4 sciews which fasten condensei oiifice

to tube sheet See Fig 15 and 18

g Lift paitition assembly out of unit See Fig 19

When lifting, caiefully grasp secure parts and lift gently Obtain assistance in lifting if necessary

h Mark shaft at point wheie blowei hub and shaft

meet, to aid in leassembly

i Remove screw which holds the evaporatoi scioll

to the paitition See Fig 20

j Remove control box See Fig 8 Refei to Conti ol

Box removal diiections

k Pull evaporatoi scroll outwaid

1 Reverse above pioceduie foi leassembly

16 Compressor — See compressoi in Fig 18 Before

lemoving compressoi refer to Service, General Notes in this publication, and Cariier Standard Service Techniques Manual, Chapters 1 and 2

PARTITION ASSEMBLY

compressor

REMOVAL SCREW

Fig 18 — Partition Assembly Removal Screws

Fig 19 — Partition Assembly

WARNING

Compìessor terminals may blow with system undei piessuie Stand cleai of teiminals when woiking on compiessoi

a Remove compressor teiminal cover See Fig 21

b Disconnect wiies fiom compiessor and oveiload

protectoi teiminals See Fig 22 Identify wires to ensure coiiect leassembly

Page 11

VENT AND EXHAUST LEVER

EXHAUST DOOR

TERMINALS AND WIRING

VENT DOOR

Fig 20 — Evaporator Scroll

SCROLL

Fig. 22 — Compressor and Overload Protector

Wires

Fig 23 — Removing Nut from Compressor

Spring Mount (not all models)

Fig 21 — Removing Compressor Terminal Cover

c Replace overload piotectoi if needed d Disconnect piping Refer to Seivice in this publi

cation being caieful to observe all CAUTIONS

e Remove compiessoi mounting nuts See Fig 23 f Check compiessor mounts It compressoi is

mounted on spn'ngs, remove nuts from mounting studs See Fig 23 Some mounts also have a washei Piy off with seiewdiiver Failure to remove hardware lesults in noisy operation Save hardware for possible futuie transport of unit It unit istianspoited, replace haidware on mounting

studs Neglecting this could result in damage to unit when transported

g Remove compressor carefully Obtain help in

lifting if necessary

h Reverse above procedure lor reassembly

17 Exhaust Door — See Exhaust Door in Fig 20

a Remove metal spring from behind the door b Pull exhaust door carefully out oi mounting slot c Reverse above procedure for reassembly

18 Vent Door — See Vent Door in Fig 20

a Remove evaporator scroll as described under

Evaporator Blower

b Remove spring from vent door c Lift vent door up and pull out d Reverse above procedure for reassembly

Page 12

19 Vent and Exhaust Lever — See Vent and

Exhaust Level in Fig 20 a Remove exhaust dooi as desci ibed under Exhaust

Door

b Rotate levei upward while pushing lever out oi

mounting slot

c Reveise above procedure for leassembly

20 Evaporator and Condenser Coils — See

Evaporatoi and Condenser Coils in Fig 24 These coils have copper tubing The interconnecting tubing is designed as an integral pait of the coils to make servicing easier

21 Strainer — The strainer is installed in the inter

connecting tubing between the condenser and the capillary tube To change the strainer

a Purge and remove all refi igei ant from the system b Cut tubing one in from capillary tube insertion

point

c Use a thin piece of wire to remove strainer from

tubing

d Insert new strainer into tubing Reassemble with a

field-supplied 1 /4-in copper coupling

22 Test Run Unit — Plug unit into proper power

supply outlet Reiei to operating instructions in Owner’s Handbook for Comfortable Living Check all controls for correct operation, then unplug unit If unit sounds noisy during test-run, it may be because compressor spring-mount nuts have not yet been removed See Compressor instructions (16 f)

A WARNING

Moving parts can cause personal injury Be care ful when test-running unit Do not operate unit

with Iront grille removed

CONDENSER

'COIL

EVAPORATOR COILi

Fig 24 — Evaporator and Condenser Coiis

Page 13

DISASSEMBLY INFORMATION

Models 304's, 404's Casings

Models 51 C,G — The Model 51C Room Air Condi

tions is referred to as the 304 size casing International

Series unit The Model 51G Room Air Conditioner is referred to as the 404 size International Series unit Both

are alike in construction and contain identical controls

Fig 25 — Model 51C,G

REMOVE GRILLE INSERT

23 Grille — Decorative front grille insert is removed by

gripping top of insert and pulling outward while lift

ing insert from grille frame See Fig 26

24 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 27 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

25 Grille Frame — Grille Frame is removed by first

removing 1 screw holding frame to chassis See Fig 26 Pull bottom

OÍ grille frame outward and lift

frame away from chassis

26 Control Box — It is not necessary to slide chassis

out of casing in order to service the control box, located on right side of unit behind grille irame

Refer to Fig 25 To remove control box a Remove grille frame Refer to grille and grille

trame instructions and Fig 26

b Carefully pull oii thermostat and cool-heat con

trol knobs

c Remove 2 screws securing escutcheon and remove

escutcheon

d Remove 2 screws securing control box to chassis e Remove sensing bulb from coil face See Fig 29

f Pull control box straight out of unit carefully

NOTE The control box ground wire interieres with complete removal of control box If ground wire is detached, be sure to replace and secure with wire tie inside control box when servicing is completed

REMOVE 1 SCREW

Fig. 26 — Removing Grille Insert

and Grille Frame

Page 14

Fig. 27 — Removing Filter

28 Cool-Heat Control — See location ot Cool-Heat

Control in Fig 28 a Slide control box out Refer to control box

instructions

b Remove 2 screws holding cool-heat control to

front of control box

c Carefully pull wires from cool-heat control ter

minals Mark or label wires to aid in reassembly

d Reverse above procedure for reassembly

29 Timer Assembly — See location of Timer

Assembly in Fig 28 a Slide control box out Reier to control box

instructions

b Remove timer cover by squeezing sides and pull

ing cover straight out

c Careiully remove wires from timet assembly

Mark or label wires to aid in reassembly

d Remove 2 screws securing timer and pull timer

through front of control box

e Reverse procedure for reassembly

30 Run Capacitor — See location of Run Capacitor

in Fig 28 a Slide control box out Refer to control box

instructions

b Remove screw fastening capacitor strap to contr ol

box and remove strap

c Carefully pull wires from run capacitor terminals,

marking or labeling wires to aid in reassembly

d Reverse above procedure for reassembly

TIMER ASSEMBLY

Fig. 28 — Control Box Components

27 Thermostat — Thermostat is a cioss ambient

device Be careful not to damage sensing element of theimostat when handling See Thermostat

location in Fig 28 To remove

a Slide control box out Refer to contiol box

insti actions

b Remove 2 screws fiom bottom of control box

which fasten thermostat bracket to control box Some units have a third screw located at front of box

c Carefully pull wires from thermostat terminals

Mark or label wires to aid in reassembly

d Remove thermostat and bracket from control box e Detach thermostat from bracket

f Reverse above procedure for reassembly

31 Indicator Light — See location of Indicator Light

in Fig 28 a Slide control box out Refer to control box

instructions

b Remove timer cover by squeezing sides and pull

ing straight out

c Disconnect wires horn indicator light terminal,

marking or labeling wires to aid in reassembly

d Remove light by pulling straight out through

front of control box

e Reverse above procedure lor reassembly

32 Fan Cycle and Air Sweep Switches — See

location of switches in Fig 28 a Slide control box out Refer to Control Box

instructions

b Disconnect wires from switches Mark or label

wires to aid in reassembly c Push switches out from rear d To replace switches, insert them through front oi

panel, push in until they snap in place

e Complete reassembly by reversing above

procedure

33 Chassis — The International Series models have

slide-out chassis Servicing the chassis is possible without having to remove unit casing from window

a Remove fr ont grille frame See Grille instr actions

and Fig 26

b Loosen security lock screw and slide screw to

unlock position (left) See unit installation instructions

Page 15

SENSING BULB

.'•‘•««»A

Fig. 29 — Sliding Chassis Out of Casing

EXHAUST DOOR FRAME

Fig. 31 — Vent Door/Wire Hood

CLICKER BAR

c Slide chassis out of casing See Fig 29 d Reverse above proceduie to reinstall chassis in

casing, being suie to retain security lock screw to lock position and tighten

34 Exhaust Door — See location of Exhaust Door

in Fig 30

a Remove chassis fiom casing See Chassis

instructions

b Pull exhaust door away from hinge until it is no

longer trapped by the dooi frame

c Return spring to propei position and lemove

door

d Reveise above proceduie for reassembly

AIR SWEEP MOTOR COVER LOCATION (COVER REMOVED)

UPPER CONTROL BOX

UPPER CONTROL BOX SCREWS

PARTITION

DISCHARGE. DECK SCREWS

PARTITION SCREWS

EXHAUST DOOR

WIRE HOOD

BASEPAN

Fig 30 — Exhaust Door

35 Vent Door — See location of Vent Dooi in Fig 31

a Remove chassis from casing See Chassis instruc

tions and Fig 29

b Remove conti ol box See Control Box instructions c Remove dischaige louvers See Air Sweep Mech

anism instructions NOTE Removal of air sweep motor is not

necessary

d Remove one sciew seeming scioll plate to

basepan

e Remove 3 screws (Fig 30) securing upper conti ol

box to partition

f Remove 2 screws (Fig 30) securing dischaige deck

to paitition

g Remove one screw (Fig 35) securing discharge

deck to scroll plate

h Remove 3 screws (Fig 30 and 33) securing parti

tion to basepan

i Lift partition side and place over basepan flange t Lift discharge deck assembly and remove from

chassis

k Remove vent dooi spring from deck assembly and

repail or leplace paits as necessaiy

1 Reveise above pioceduie foi leassembly, being

caieful not to damage wires on sheet metal edges

36 Fan Section — See Fan Section in Fig 32

a Remove chassis from casing See Chassis

instructions b Remove partition top covei by removing 4 screws c Remove wiie hood by lemoving 2 screws See

Fig 31

d Disconnect fan motor wiies fiom conti ol box

Remove fan motoi leads fiom retaineis Mark or label wiles to aid in reassembly

e Remove fan motor ground wiie fiom unit

paitition f Detach condenser orifice by removing 4 screws

which attach condenser orifice to tube sheet

g Remove top gusset by removing 2 sciews Slide

slot filler out h Remove 2 fan motor clips i Gently lift fan assembly out of chassis See Fig 32

Page 16

CONDENSER FAN

EVAPORATOR BLOWER WHEEL

EVAPORATOR TOP GUSSET C0|L\ DARTITinM

CONDENSER ORIFICE

Fig 32 “ Evaporator Fan Section

j Reverse above piocedure tor reassembly

NOTE When replacing fan motor, be sure motor oil ports are facing up

37 Evaporator Fan—SeeEvapoiatoi FaninFig 32

a Remove fan section Refer to Fan Section

instiuctions

b Mai k shaft at point where fan hub and shait meet,

to aid in reassembly

c Loosen Allen set-sciew which locks evaporator

fan on motor shaft Some units have a spring

metal clip which must be removed d Remove fan tiom motor shaft e Fot reassembly, leveise above pioceduie

38 Condenser Fan — See Condenser Fan in Fig 32

a Remove fan section Refei to Fan Section

instructions b Mark shaft at point where fan hub and shaft meet

toi leassembly c Remove fan fiom motoi shaft d Reverse above procedure for leassembly

39 Fan Motor — See Fan Motot in Fig 32

a Remove fan section Refer to Fan Section

instiuctions

b Remove both fans Refei to Evapoiatoi Fan and

Condensei Fan instructions

c Reverse above procedure for reassembly

40 Compressor — See Compressor in Fig 33 Before

removing compressor, refer to Service, General

Notes in this publication, and Carrier Standard Service Techniques Manual, Chapters 1 and 2

a Remove compressor terminal cover See Fig 21 b Disconnect wires from compressor and overload

protector terminals Mark wires to aid in

reassembly

c Replace overload protector if needed

AIR SWEEP MECHANISM

AIR SWEEP MOTOR BRACKET COMPRESSOR

Fig. 33 — Chassis Top View

Disconnect piping Refer to Service in this publL

cation being careful to observe all CAUTIONS

Remove compressor mounting nuts See Fig 23 Remove compressor carefully Obtain help when

lifting if necessary Reverse above procedure for reassembly

41 Air Sweep Mechanism — See Air Sweep Mech

anism in Fig 33

a Remove chassis from casing Refer to Chassis

instructions and Fig 29

b Remove partition top cover by temoving4 screws

c Remove motor cover by removing 2 screws See

Fig 30 d Remove link assembly by lifting straight up e Remove spring to disassemble link assembly

f Remove cam from motor shaft

g Remove motor and motor bracket from chassis

by removing 2 screws

h Remove motor from motor bracket by removing

2 screws

i Slide out control box and disconnect air sweep

motor leads Refer to Fan Cycle and Ait Sweep Switches instruction

j To remove discharge louveis, flex and remove pin

from bottom hole Turn louver and pivot bottom upwaid to remove from top hole See Fig 29 and 34

k Reverse above procedure for reassembly

42 Evaporator and Condenser Coils — See

Evaporator and Condenser Coils in Fig 32 and 33

These coils have copper tubing and the intei con

necting tubing has been manufactured as an integral part of the coil to aid in seivicing

a Purge all refrigerant from system Refer to Serv

ice in this publication

b Cut interconnecting tubing and remove evap

orator coil from unit by removing 4 screws

Page 17

c Cut interconnecting tubing and lemove 2 screws

securing condenser coil Remove condenser

orifice mounting screws (4) d Remove condenser coil e Reverse procedure for reassembly

43 Strainer — Strainer is installed in the interconnect

ing tubing between the condenser and the capillary tube To change strainer

a Purge and remove all refrigerant from system

b Cut tubing one in horn capillary tube insertion

point

c Use a thin piece of wire to remove strainer from

tubing

d Insert new strainer into tubing Reassemble with a

field-supplied 1/4-in copper coupling

44 Vent and Exhaust Linkage — See Vent and

Exhaust Linkage in Fig 31 a Remove decorative front grille Refer to Grille

instructions and Fig 26

b Remove control box Refer to Control Box in

structions and Fig 25

c Remove clicker lever Push up on lever handle

while holding mount down See Fig 34

d To reinstall, push clicker lever straight in through

mount, until it snaps in place

e To remove mount, remove 2 screws Irom mount

and remove from discharge deck

1 To remove push bars, remove screws and dis

assemble from discharge deck See Fig 31

g To reassemble, reverse above procedure

45 Electric Heater Assembly — See Electric

Heater in Fig 35 The electric heater is found only in the Models 5ICV and 51 GY

a Remove chassis from casing See Chassis instruc

tions and Fig 29

b Remove partition top cover by removing4 screws

c Remove 2 wires Itom heater assembly Mark wires

to aid in reassembly

d Repair or replace limit switches as needed

e Remove heater by removing 2 screws and lifting

straight up

f Reverse above procedure for reassembly

Fig 34 — Vent and Exhaust Linkage

LIMIT SWITCHES

ELECTRIC HEATER

Fig. 35 — Electric Heater Assembly

DISCHARGE LOUVER

DISCHARGE

DECK SCREW (NOT VISIBLE)

Page 18

TROUBLESHOOTING

NO COOLING OR INSUFFICIENT COOLING

Compressor Does Not Run

OPENING IN POWER CIRCUIT

Control off Blown fuse Defective wiring

Defective service cord Loose electrical connections Faulty switches, theimostat oi fan

COMPRESSOR POWER SUPPLY OPEN

Loose leads at compiessoi teiminals Detective motor overload switch

Defective capacitor Open compressoi windings Seized compressor

Compressor Runs But Cycles

FAN OPERATING ERRATICALLY

Loose lead at fan motoi

Motor defective or burned out

Outdooi air restricted or leciiculating

OVERCHARGE OR NONCONDENSABLES IN SYSTEM

RESTRICTED DISCHARGE LINE

CYCLES ON COMPRESSOR OVERLOAD

Defective lun capacitor

Defective compìessor beatings oi valves Gieatly restricted indoor ait (iced indoor coil) Low lefrigerant charge Indooi capillary restricted

Liquid line lestiicted Compressor hot

Compressor Runs But Insufficient Cooling

COOLING AIR NOT ADEQUATE

Dirty filter 01 coil

Iced evaporator coil (slightly low lefiigerant

chaige)

Defective fan motor

CONDENSER AIR NOT ADEQUATE

Outside air restricted

Dirty coil

Defective Ian motoi

UNIT UNDERSIZE AIR LEAKAGE LIQUID LINE SLIGHTLY RESTRICTED

Capillary restricted

COMPRESSOR FLOODING

Unit oveichaiged

SERVICE POINTS

(Check Annually)

1 Clean evaporator and condenser coils Indoois —

Use a hooked wire or bristle brush to lemove dirt from fins Outdoors — Use compressed air or a

vacuum cleanei 2 Clean basepan and othei painted surfaces 3 Clean all drain passages

4 Clean motor and fans 5 Vacuum clean the insulation

Paint paits that show evidence of lust with a good lust-resistant paint

Check relrigerant connections foi evidence of

leakage Repair if necessaiy Check wires lot deteiioiation

Check damper contiols

Fans should be tight on motoi shaft

Run the unit and eliminate any piping vibiation

Page 19

Page 20

Page 21

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

Book Tab

1_\4

8ajl0a

PC131 Catalog No 535-134 PrintedinUSA Form51-20SS Pg 21 7-88 ReplacesiNew

For replacement items use Carrier Specitied Parts

Carrier 51CM User Manual

CONTENTS

START-UP

A WARNING

SERVICE

A CAUTION

SAFETY REMINDERS

Preventive Maintenance

A CAUTION

A CAUTION

WARNING

20 Evaporator and Condenser Coils — See

A WARNING

32 Fan Cycle and Air Sweep Switches — See

.'•‘•««»A

42 Evaporator and Condenser Coils — See

TROUBLESHOOTING

NO COOLING OR INSUFFICIENT COOLING

Compressor Does Not Run

Compressor Runs But Cycles

Compressor Runs But Insufficient Cooling