Carrier 52C, 52P User Manual

52C,P

SERIES

SERVICE TECHNICIAN GUIDE

PACKAGED TERMINAL AIR CONDITIONERS

AND HEAT PUMPS

CONTENTS

INTRODUCTION

SUMMARY OF DANGERS, WARNINGS,

AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

UNIT DISASSEMBLY

TOOLS NEEDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

REMOVE FRONT P ANEL . . . . . . . . . . . . . . . . . . . . . . . 3

DISCONNECT POWER FOR

CORD-CONNECTED UNIT . . . . . . . . . . . . . . . . . . . . . 3

DISCONNECT POWER FOR PERMANE N TLY

CONNECTED (HARDWIRED) UNITS . . . . . . . . . . . . 3

OPEN THE CONTROL BOX. . . . . . . . . . . . . . . . . . . . . 4

REMOVE THE UNIT FROM THE W ALL SLEEVE . . 4

ACCESSING UNIT COMPONENTS

ACCESSING INDOOR-AIR SECTION

COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

ACCESSING OUTDOOR-AIR SECTION

COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

REINSTALL FRONT PANEL. . . . . . . . . . . . . . . . . . . . . 8

GENERAL CLEANING

CLEANING AND SAFETY . . . . . . . . . . . . . . . . . . . . . . 9

TOOLS NEEDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

MONTHLY CLEANING. . . . . . . . . . . . . . . . . . . . . . . . 10

SEASONAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . 11

COMPRESSOR

COMPRESSOR TROUBLESHOOTING. . . . . . . . . . . 14

BASIC HERMETIC COMPRESSOR

ELECTRICAL MEASUREMENTS . . . . . . . . . . . . . . . 14

COMPRESSOR REPLACEMENT. . . . . . . . . . . . . . . . 15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,3

. . . . . . . . . . . . . . . . . . . . . . . . . . .3,4

. . . . . . . . . . . . . .5-8

. . . . . . . . . . . . . . . . . . . . . . . . .9-12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-17

Page

HEATERS

COMMON CAUSES OF HEATER FAILURE. . . . . . .18

HEATER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . .18

OPERATING CONTROLS

UNIT-MOUNTED CONTROLS. . . . . . . . . . . . . . . . . .20

WALL-MOUNTED THERMOSTAT CONTROLS. . . 21 REMOTE THERMOSTAT

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .21

DESCRIPTION OF SELECTOR

SWITCH SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .23

NON-USER ADJUSTABLE CONTROLS . . . . . . . . . .23

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . .24

COMPONENT OPERATION AND

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .24

ELECTRICAL COMPONENTS REMOVAL

AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . .27

FAN MOTOR

FAN MOTOR TROUBLESHOOTING. . . . . . . . . . . . .29

BASIC FAN MOTOR ELECTRICAL TESTS. . . . . . . . 29

FAN MOTOR REPLACEMENT. . . . . . . . . . . . . . . . . .31

FIELD TEMPERATURE CHARTS WIRING DIAGRAMS MOST FREQUENT PTAC SERVICE

QUESTIONS ACCESSORIES 52C PERFORMANCE AND PHYSICAL DATA 52P PERFORMANCE AND PHYSICAL DATA

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,19

. . . . . . . . . . . . . . . . . . . . . 20-28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-31

. . . . . . . . . . . . . . 32-40

. . . . . . . . . . . . . . . . . . . . . . . . 41-45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

. . . . . .48

. . . . . .49

Page

PTAC Customer Support Center

1•800•894•6449

52C,P

CANADIAN INSTALLATION

SERIAL 3701X11520 DATE OF MFG. 09/12/2001 VOLT RANGE 187-253 VOLTS 230/208 PH 1

MODEL 52PQA312301AA

MIN CKT AMPACITY 19.3 R-22 OZ 34

DESIGN PSIG 350 HIGH SIDE, 150 LOW SIDE

COOLING

HEATING

BTU/HR 12,100/12,000 AMPS 4.8/5.3

WATTS 1090/1122 EER 11.1/10.7

MOTOR

FAN

COMP

FLA

RLA LRA

6.1 29

0.75 1/8

BTU/HR 11,000/11,000 AMPS 15.6/14.5 WATTS 3570/2997 COP 3.2/3.2

HEATER

BTU/HR

AMPS 14.8/13.7 WATTS 3400/2850 WATER

STEAM

USE

TIME DELAY FUSE

OR HACR TYPE

CIRCUIT BREAKER

AMP

AMP AMP

MAX FUSE

MAX BREAKER

SERIES

INTRODUCTION

The focus of this manual is to provide basic information on service procedures, safety, troubleshooting, cleaning, and component replacement for service technicians. It is intended for use only by HVAC service

technicians who have successfully completed instruction and received Type I Certification from the U.S. Environmental Protection Agency.

The instructions in this manual are general in nature and are not to be substituted for installation and service instructions shipped with the unit. No attempt to install, ope rate, adju st, re pair , or di smant le any equi pment should be made until the manufacturer’s i nstructions are read and thoroughly understood by the service technician. Even equipment that seems familiar may have specific model diffe rences from year to year. Always review manufacturer’s instructions.

Model 52C,P packaged terminal air conditioner (PTAC) and heat pump units are self-contained for installation through the wall for individual room heating and cooling. The Model 52C,P polymer and metal sleeves are permanently fastened to the wall; the unit chassis slides out of the sleeve to allow the service technician easy access. Many accessories are offered to complement the unit’s performance and comfort control.

Before beginning any service procedu res, it is important to check the unit model number. See Figure 1 and

2. Units that seem similar may have subtle differences that could affect service procedures. The following units are covered in this manual:

52CE — 60 Hz cooling with electric heat units 52CQ — 60 Hz heat pump with electric heat units 52PE — 60 Hz cooling with electric heat units 52PQ — 60 Hz heat pump with electric heat units 52PC — 60 Hz cooling only units

Knowing which model is being serviced will help determine if the unit is performing at optimum levels. The model number is located on the data informatio n plate beneath the front panel of the unit. See Figure 1. The data information plate also lis ts voltage ranges and other important electric al information about the unit.

SUMMARY OF DANGERS, WARNINGS, AND CAUTIONS

The terms DANGER, WARNING, and CAUTION have specific meanings that identify the degree of hazard. Typically in the HVAC industry, these specific meanings are:

There is an immediate hazard which WILL result in severe personal injury or death.

Potential hazards or unsafe practices which COULD result in minor personal injury or equipment damage.

FIGURE 1 — SAMPLE DATA INFORMATION

PLATE

Hazards or unsafe practices which COULD result in severe personal injury or death.

52 PQ A 3 12 3 0 1 AA

Series Designation

PTAC (Packaged Terminal Air Conditioner)

CE – Cooling with Electric Heat CQ – Heat Pump with Electric Heat PC – Cooling Only PE – Cooling with Electric Heat PQ – Heat Pump with Electric Heat

Latest Revision

A – Z

Electric Heater Size

0 – No Heating (Cooling Only Model) 2 – 2.3 kW 3 – 3.4 kW 5 – 5.0 kW

Cooling Capacity (nominal)

07 – 7,000 Btuh 09 – 9,000 Btuh 12 – 12,000 Btuh 15 – 15,000 Btuh

FIGURE 2 — MODEL NUMBER NOMENCLATURE

UNIT DISASSEMBLY

This section includes common procedures for disassembly and re-assembly of u nit.

IMPORTANT: Follow manufacturer’s instructions when disassembling and re-assembling a unit for cleaning, maintenance, or part replacement. When disassembling wiring, it is strongly recommended that numbered stickers be attached to identify leads and terminals to aid in the re-assembly process. Always review safety procedures prior to the start of a job.

Prior to servicing electrical equipment, disconnect all power to avoid electric shock! Tag all disconnects. Never alter cord or plug and do not use extension cords.

TOOLS NEEDED

The following field-supplied items are recommended for general disassembly of the unit:

• Flat head screw driver

•

/16-in. nut driver

• Safety glasses

• Needle nose pliers

REMOVE FRONT PANEL

NOTE: Before removing front panel, remove 2 locking screws (if installed) located behind the filter handles.

Chassis Options

Blank or AA – Standard

CP – Corrosion Protection RC – Wall Thermostat Control RP – Wall Thermostat Control with

Corrosion Protection

Packaging

1 – Domestic

Non-Performance

Changes 0-9

Electrical Data

3 – 230/208-v, 60 Hz 4 – 265-v, 60 Hz

See Figure 3. If a lateral duct accessory is installed, the plenum must be removed before removing the front panel. Refer to Remove Lateral Duct Extension section for removal instructions.

1. Grasp the front panel firmly at the center of the top and bottom of the panel.

2. Pull the panel upward at the bottom and forward at the top to release magnetic latches and partition hooks. See Figure 4.

DISCONNECT POWER FOR CORD-CONNECTED UNIT

1. Turn selector switch to OFF position.

2. Open the disconnect swi tch at main power supply. Use proper Lockout and Tag procedures.

3. Unplug the unit service cord.

DISCONNECT POWER FOR PERMANENTLY CONNECTED (HARDWIRED) UNITS

1. Turn selector switch to OFF position.

2. Open the disconnect swi tch at main power supply. Use proper Lockout and Tag procedures.

3. Remove screw from access cover and remove access cover.

4. Pull out the plug assembly and disconnect. See Figure 5.

52C,P

SERIES

OPEN THE CONTROL BOX

The control box is factory wired. To open the box, remove the 2 screws on the top of the control box and lower the front hinged panel. See Figure 6.

REMOVE THE UNIT FROM THE WALL SLEEVE

1. Remove the four moun tin g scr e ws tha t secu re th e PTAC unit to the wall sleeve (2 screws per side). See Figure 7.

2. Grasp the sides of the unit and slide it from the sleeve.

NOTE: The mounting screws ma y be in a differen t location depending on brand of wall sleeve attached.

REMOVABLE FILTER

LOCATION OF REMOVED FILTER

LOCKING SCREW (NOTE: 2nd LOCKING SCREW IS LOCATED BEHIND 2nd FILTER)

FIGURE 3 — LOCATION OF LOCKING SCREWS

BEHIND FILTERS

FIGURE 4 — REMOVING FRONT PANEL

eplacement Package Terminal Air Conditioner, LASSIFIED BY UNDERWRITERS LABORATOIES INC., AS TO ELECTRIC SHOCK, FIRE AND ASUALTY HAZARDS ONLY. FOR FIELD INSTALATION WITH EXISTING WALL SLEEVES, OUT-

OOR, LOUVERS, AND INDOOR PANELS AS

PECIFIED ON THE PRODUCT.

The chassis weighs between 110 and 150 lbs. Take proper safety precautions to avoid personal injury when lifting and moving the chassi s.

The unit basepan may have water in it. Tilt the unit back slightly whe n removing it fro m th e sl e eve to drain some of the water into the sleeve.

CONDUIT

ACCESS PANEL

MOLEX PLUGS

FIGURE 5 — PLUG ASSEMBLY ON

HARDWIRE UNITS

POWER

GE WALL SLEEVE HOLES

AMANA, TRANE (SLOTTED HOLES) WALL SLEEVE HOLES

VARIOUS ATTACHMENT

HOLE LOCATIONS

CARRIER, BRYANT WALL SLEEVE HOLES

CORD ACCESS COVER

POWER CORD

FIGURE 6 — CONTROL BOX COVER

CONTROL BOX SCREWS

FIGURE 7 — PTAC UNIT TO WALL

SLEEVE MOUNTING SCREWS

ACCESSING INDOOR-AIR SECTION COMPONENTS

REMOVE LATERAL DUCT EXTENSION

■

ACCESSORY FOR UNITS EQUIPPED WITH THE LATERAL DUCT

1. Remove the 2 top screws that secure the lateral

2. Locate and remove the 2 bottom bracket screws

3. Carefully lift the plenum up and away from front

REMOVE THE DISCHARGE DECK ASSEMBLY

■

1. Remove the front panel. Re fer to Remove Front

2. Remove discharge screen screw using a

3. Remove th e dischar ge deck assembly screws using

4. Gently pull the deck/grille up and away from the

5. Reassemble by reversing steps above.

ACCESSING UNIT COMPONENTS

duct plenum to the top of the lateral duct extension. See Figure 8.

(located opposite extension duct) that secure the lateral duct plenum to the bracket flange. See Figure 8.

panel and duct extension.

Panel section and Figure 4.

/16-in. nut

driver. See Figure 9.

/16-in. nut driver. See Fi gure 9.

unit.

ACCESSING THE HEATER ASSEMBLY

■

— Once the discharge deck assembly is removed, the Heater Assembly should now be accessible. See Figure 10.

1. Using pliers, carefully remove all wires connected to the heater assembl y. Label ea ch wire for ea se of re-assembly.

2. Gently pull the heater assembly up and away from scroll. See Figure 11.

3. Reassemble by reversing steps above.

ACCESSING OUTDOOR-AIR SECTION COMPONENTS

REMOVE THE GUSSETS (See Figure 12)

■

1. Remove the 2 screws on each side that secure the gussets to the partition.

2. Remove the 2 screws that secure the gussets to the plastic condenser orifice and remove the gussets.

52C,P

SERIES

END CAP

BRACKET SCREWS

PLENUM LATERAL DUCT

LEFT BRACKET

TOP SCREWS (2)

EXTENSION

RIGHT BRACKET

FIGURE 8 — PTAC UNIT WITH LATERAL

DUCT ACCESSORY INSTALLED

ATTACHMENT SCREWS

WALL

BRACKET SCREWS

DISCHARGE DECK

FIGURE 10 — ACCESSING HEAT ER

HEATER PLATE ASSEMBLY

PLATE ASSEMBLY

DISCHARGE SCREEN

DISCHARGE DECK

FIGURE 9 — LOCATION OF ATTACHMENT

SCREWS ON DISCHARGE DECK OF UNIT

DETACH THE CONDENSER ORIFICE FROM THE

■

CONDENSER COIL

1. Remove top half of condenser orifice. a. Unscrew the top half of the condens er orifi ce b y

backing off the 4 captive screws. See Figure 13.

b. Using a flat head screwdriver, gently pry the

top half of the orifice from the tube sheets. See Figure 14.

c. Remove top of condenser orifice. See Figure 15.

2. Remove bottom half of condenser orifice. a. Using a flat head screwdriver, gently pry the

bottom half of the orifice from the tube sheets. See Figure 14.

b. Remove 2 outdoor coil tube sheet screws using a

Phillips head screwdriver. See Figure 16.

c. Carefully lift condenser up and away from con-

denser fan. Rest con d e nse r on bas epan . Se e Figure 17.

FIGURE 11 — REMOVAL OF HEATER

PLATE ASSEMBLY

d. Using Needle Nose Pliers remove co ndenser fan

hub clamp. See Figure 18. e. Pull condenser fan off fan motor shaft. f. Remove bottom half of condenser orifice.

3. Reassemble by reversing steps above.

REMOVE THE AIR DISCHARGE GRILLE

■

1. Remove the front panel from the unit, reference Remove Front Panel section.

2. Flip the front panel over to the backside. Remove the 2 screws on each end of the air discharge grille and remove grille. See Figure 19.

The grille can be positioned to direct the discharge air up or out by simply rotating the grille 180 degrees.

GUSSET

GUSSET SCREWS

CONDENSER ORIFICE (PLASTIC)

PARTITION GUSSET

GUSSET SCREWS

FIGURE 12 — GUSS ET RE M O VAL

CONDENSER ORIFICE

CAPTIVE SCREWS (2)

FIGURE 13 — LOCATION OF CAPTIVE SCREWS

ON CONDENSER ORIFICE

FIGURE 14 — PRYING CONDENSER ORIFICE

AWAY FROM TUBE SHEET

FIGURE 15 — REMOVING TOP OF

CONDENSER ORIFICE

52C,P

SERIES

OUTDOOR COIL TUBE SHEET SCREWS

FIGURE 16 — LOCATION OF OUTDOOR

COIL TUBE SHEET SCREWS

CONDENSER FAN

HUB CLAMP

FIGURE 18 — REMOVING COND EN SER

FAN HUB CLAMP

FIGURE 17 — REMOVING OUTDOOR COIL

FROM CONDENSER FAN

CONTROL DOOR HINGE PINS

FRONT PANEL (BACK VIEW)

SCREW SCREW

DISCHARGE GRILLE

FIGURE 19 — LOCATION OF SCREWS ON

DISCHARGE GRILLE

REINSTALL FRONT PANEL

1. Grasp the front panel firmly at the center of the top and bottom of the panel, tilti ng it fo rwar d 5 to 10 degrees from the vertical. See Figure 4.

2. Place the top of the front panel onto the unit, making sure the top engagement posts have engaged the slots on the unit. The top edge of the front panel should be flat against the top of the unit.

3. Gently lower the front panel onto the chassis, ensuring the conduit/cord is routed through the panel notch. Magnetic latches at the bottom of the front panel will secure the front panel to the unit.

GENERAL CLEANING

Maintaining proper performance of 52C,P systems requires conscientious cleaning and care of components. See Figure 20. Specific components require periodic cleaning and/or replacement, including the following:

COMPONENT CLEANING SCHEDULE

Indoor Air Filter

Vent Air Filter

Indoor Coil Indoor Fan

Outdoor Coil

Monthly

Monthly Seasonally Seasonally Seasonally

CLEANING AND SAFETY

Before starting to clean a unit, read the instructions thoroughly and gather the necessary tools for the job. Review all safety information on unit and in literature.

Before cleaning, servicing, performing maintenance, or removing the chassis from the wall sleeve, disconnect all power to the unit to avoid the possibility of electrical shock and personal injury. Only trained and qualified service personnel should perform installation and service procedures on these units. Untrained personnel may perform basic maintenance tasks such as cleaning and replacing filters. Refer to General Disassembly section of this ma nual for proper procedures to disconnect power to 52C,P units.

Consider the following safety issues before beginning:

• New and unfamiliar tasks should be performed under the supervision of an experienced service technician.

• Personal protective equipment, such as safety glasses and work gloves, should be used.

• The floor around the work area shoul d be clea n and free of debris.

• The 52C,P unit weighs up to 150 pounds. Use a lifting device or ask for assistance if the unit must be moved.

• Make sure tools are the correct tools for the job, and that they are working properly and in good condition.

FRONT PANEL (STANDARD)

CHASSIS (STANDARD)

FIGURE 20 — STANDARD 52C UNIT

EXTERIOR GRILLE (ACCESSORY)

WALL SLEEVE (ACCESSORY)

52C,P

SERIES

TOOLS NEEDED

The following list includes the recommended tools, devices, and cleaning solutions for use in cleaning the 52C,P unit and components.

Vacuum Cleaner with Crevice Tool Attachment,

Lifting Device (or another person for assistance)

Trigger Spray Extension Tube (Part No. P9029000)

Vent Air Filter Replacement (Part No. 52CQ500144)

Condenser Coil Cleaning Solution (Part No. P9020501)

Evaporator Coil Cleaning Solution (Part No. P90221001)

3% Solution of Hydrogen Peroxide in Spray Bottle

MONTHLY CLEANING

AIR FILTERS

■

should be cleaned once per month. Filt ers tha t are not cleaned become clogged and will restrict airflow. This may lead to major component damage. If a filter becomes torn, has holes, or other damage, replace it with a new one. Replacement filters are available through Carrier Finished Goods and Carrier Replacement Component Division.

CLEANING THE INDOOR AIR FILTER

■

filters are located in the unit’s front panel. To remove each filter simply grasp each filter handle with both hands and gently pull the filter up and away from the unit. See Figure 21.

or Soft Plastic Bristle Brush

Mild Household Detergent Phillips Head Screwdriver

/16-in. Nut Driver

Flat Head Screw Driver

Needle Nose Pliers, 90° Bend

Tank Sprayer (Part No. P9021001) or

Compressed Air Tank

Clean Water Supply

Indoor Air Filter Replacement

(Part No. AIR-FILTER-10PK)

10-in. by 29-in. Piece of Clean Cardboard

Clean Cloth

Safety Glasses

Protective Gloves

— The indoor and vent air filters

— Two air

REPLACING THE INDOOR AIR FILT ER

■

— Remove the indoor air filter as detailed in Cleaning the Indoor Air Filter. If damaged, use a filter replacement with the Carrier Part No. AIR-FILTER-10PK, available through Carrier Finished Goods and Carrier Replacement Component Division.

NOTE: Both filters are completely interchangeable.

CLEANING THE OUTDOOR AIR VENT FILTER

■

1. Remove the unit chassis from wall sleeve as described in the General Disassembly section of this manual. Refer to Remove the Unit from the Wall Sleeve section.

2. Swing open vent door. The filter is located directly behind the vent door. See Figure 22.

3. Once the filter is accessed, it may be cleaned using either a vacuum cleaner, or a soft bristle brush and a small amount of mild dish detergent. If detergent is used, remove detergent residue with a gentle, clean water stream. Allow the filter to air dry.

REPLACING THE OUTDOOR AIR VENT FIL TER —

■

If vent filter requires replacement:

1. Open vent door to access vent filter.

2. Remove vent door from hinges.

3. Using a small flat head screwdriver, pry the filter from the partition.

4. Replace vent filter using Carrier Part No. 52CQ500144.

5. Reverse Steps 1-3 to reattach vent door.

■

CHASSIS

Occasional cleaning of the e xterior surfaces of the PTAC unit optimizes the unit’s appearance and removes particles that may enter the air system. See Figure 23. Mild detergents clean and reduce electrostatic charges on the plastic components of the PTAC unit.

Use a clean cloth or brush to gently wipe exterior s urfaces. Be careful not to push dirt or other fibers into the unit’s interior components. Accessible wall sleeve surfaces should also be wiped clean.

SEASONAL CLEANING

VENT DOOR

OUTDOOR AIR FILTER

The indoor and outdoor coils should be cleaned at least once during every season. Refer to ACCESSING UNIT COMPONENTS section to prepare unit.

CLEANING THE INDOOR AND OUTDOOR

■

COILS

Coil fins are sharp and may cut hands. Wear heavy protective gloves when cleaning coils.

Use only cleaning solutions that meet local codes.

1. Use a vacuum cleaner or soft bristle brush to remove surface fibers and dirt from the interior surface of evaporator coil and both surfaces of condenser coil. See Figure 24. It is important to apply the tool in the same direction of the fins, not against them. Applying the tool against the fins may cause damage (fin edges may bend over).

2. With a tank sprayer or a trigger spray extension tube, spray coil cleaning solution evenly across the coils, making sure coils are thoroughly saturated. See Figure 25. Refer to instructions on the cleaning solution containers for best results. Do

not use a high-pressure sprayer.

3. Rinse the coils thoroughly with low-velocity, clean warm water (less than 200 F).

4. Repeat steps 2 and 3 for each coil surface.

5. Drain water and cleaning solution that may have collected in the basepan during the cleaning process by carefully tilting the chassis. This allows excess water to flow out of the overflow notches.

Do not set unit on end to drain water from basepan, or at any other time. Oil will drain from the compressor sump, which could cause compressor failure.

6. Thoroughly clean t he base pan an d drain pa ssages by rinsing with clean water. Be sure all debris is removed from the drain valve. Se e Fig ure 26.

7. Thoroughly clean outdoor fan assembly and all other mechanical components located in outdoor coil area. Be sure to remove all dirt and debris.

8. Clean wall sleeve.

CLEANING THE INDOOR FAN AND FAN

■

SCROLL —

Dried debris and build-up on the blower wheel and fan scroll can reduce the efficiency of the unit.

1. ACCESS AND CLEAN INDOOR FAN AND

FAN SCROLL

a. Reach behind the indoor coil and vacuum any

loose debris from the condensat e drai n pan, fan and other areas accessible to the fan scroll, being careful to avoid damage to the coil fins.

b. Use mild detergent and a damp cl oth to remov e

stubborn debris from surfaces around scroll and fan blades.

2. CLEAN HEATER ASSEMBLY — Use compressed air to blow off any dirt or dust that has accumulated on the heater coils.

NOTE: Do not direct air at the bi-metal discs on the temperature limiter switches.

FIGURE 21 — LOCATION OF

TWO-PIECE INDOOR FILTER

FIGURE 22 — LOCATION OF OUTDOOR AIR

VENT FILTER

52C,P

SERIES

FIGURE 23 — PTAC EXTERIOR SURFACES

FIGURE 25 — CLEANING COILS

FIGURE 24 — VACUUMING EVAPORATOR

COIL

DRAIN VALVE

FIGURE 26 — BASEPAN SECTION

COMPRESSOR

A cutaway view of the rotary compressor with key components labeled is shown in Figure 27. The motor stator is rigidly attached to the compressor shell. The rotor is pressed onto the eccentric shaft, which is supported by 2 bearings. Both the discharge valve and discharge muffler are attached to the motor bearing. The

DISCHARGE TUBE

SUCTION INLET

pump bearing provides a thrust surface for the shaft and the rolling piston. Compressed gas is separated from the suction gas by the vane. Discharge gas pressure and the vane spring keep the vane in contact with the rolling piston.

SHELL

STAT OR

SUCTION MUFFLER/ ACCUMULATOR

PISTON

VANE

OIL TUBE

ECCENTRIC SHAFT

ROTOR

MOTOR BEARING

DISCHARGE MUFFLER

DISCHARGE VALVE CYLINDER

PUMP BEARING

MOUNTING PLATE

FIGURE 27 — ROTARY COMPRESSOR COMPONENTS

52C,P

SERIES

The rotary compression process (Figure 28), starts at top dead center as shown in (1). Suction gas flows through the suction inlet and into the cylinder area. As the shaft rotates through 90 degrees, the rolling piston moves to positio n A as shown in (2). The su ction volume is now the area defined by point A and the tip of the vane. Gas in the remaining volume has been compressed above suction pressure. After another 90 degrees of shaft rotation, the rolling piston has moved to position B as shown in (3 ). Both the compressed gas and suction gas volumes are now equal. Another 90 degrees of shaft rotation is shown in (4 ). Compressed gas has reached a pressure sufficient to open the discharge valve, and flows from the cylinder into the compressor shell. After another 90 degrees of shaft rotation, the entire process begins again. Continuous suction and discharge allows for a smooth compression process.

The rolling piston is not in actual contact with the cylinder wall, vane, or bearing faces. Hydrodynamic sealing prevents leakage from the compressed gas volume to the suction volume via these paths. Precise control of machining tolerances, surfaces, finishes, and assembly clearances is critical to achieve high efficiency performance. In addition, the line contact between the vane tip and the rolling piston requires careful selection and control of materials to provide wear resistance and reliable long-term operation.

BASIC HERMETIC COMPRESSOR ELECTRICAL MEASUREMENTS

There are 2 basic electrical te st s for herme tic compres sors that will determine the electrical state of the motor. The first test requires checking the electrical resistance of each of the electric al motor windin gs. The second test requires checking the electrical resistance of each of the electrical motor windings to ground. These tests may be accomplished by performing the following steps:

1. DISCONNECT ALL POWER TO THE UNIT.

2. Remove the unit chassis from the sleeve as detailed in the UNIT DISASSEMBLY section.

3. Open the control box as detailed in the UNIT DISASSEMBLY section, then locate, label, and remove the 3 compressor wires from the following locations: the RUN wire (BLACK) from the capacitor, the START wire (BLUE) from the capacitor. The third wi re, C OM M O N wire (YELLOW ) ma y be connected to one of the following locations: for

PC units the wire is on the indoor thermostat, for CE, PE Remote Control Units the wi r e is on the RC Control Board, for all other CE, PE Units the wire is located on the rotary selector

switch. For ALL CQ, PQ Units the wire is on the outdoor frost thermostat.

COMPRESSOR TROUBLESHOOTING

Refer to Figure 29 for a basic compressor troubleshooting chart.

FIGURE 28 — ROTARY COMPRESSOR

COMPRESSION PROCESS

For compressors that are known to be damaged: Remove refrigerant prior to disconnecting

compressor wires. Damaged hermetic compressor terminals may become loose a nd eject f rom the compressor. Wear safety glasses and keep your face away from the area above the terminals when removing compressor wires.

4. Perform a shorted/open windings test to measure the resistance between the windings of the compressor motor. Use a volt-ohmmeter set to the lowest ohm reading level then read and record the resistance between the RUN and START, START and COMMON, and RUN and COMMON wires. See Figure 30. The typical resistance readings will be about 4, 3, and 1 ohms respectively. The smaller values should add to equal the larger value. If this is not true then the compressor is likely shorted winding to winding.

NOTE: The rotary compressor has the compressor overload located under the terminal cover. If the overload is open it can show ohm readings that are infinite. The unit should be off for at least an hour to give this overload time to reset if it is open.

POSSIBLE CAUSE

COILS/FILTERS DIRTY OR PLUGGED AIR OR NONCONDENSABLE GASES

IN SYSTEM SYSTEM REFRIGERANT OVERCHARGED DISCHARGE LINE RESTRICTED CAPILLARY TUBE OR STRAINER

RESTRICTED OR PLUGGED FAN BLADE OR MOTOR DEFECTIVE FAN BLADE OR BLOWER WHEEL STUCK SYSTEM REFRIGERANT UNDERCHARGED EVAPORATOR AIRFLOW RECIRCULATION UNIT OVERSIZED FOR APPLICATION COMPRESSOR REQUIRES START ASSIST NO POWER TO UNIT LOW VOLTAGE TO UNIT OVERLOAD PROTECTOR OPEN OVERLOAD PROTECTOR INCORRECT

OR DEFECTIVE CAPACITOR INCORRECT OR DEFECTIVE THERMOSTAT CONTACTS ARE OPEN THERMOSTAT IS SET TOO HIGH OR LOW SELECTOR SWITCH IS OPEN

OR DEFECTIVE WIRING IS INCORRECT OR DEFECTIVE SYSTEM PRESSURES NOT EQUALIZED COMPRESSOR MOTOR OR

MECHANISM DEFECTIVE COMPRESSOR GROUNDED

SYMPTOM

Compressor

Starts and

Runs But

Cycles On the

Overload

X X XX

XX X

X X X X X X

XX X X

XXX

XX X X

XXXX

XX X XX

Compressor

Starts After Cycling the

Overload

Several Times

XX X

Compressor

Will Not

Start. It Hums

and Cycles On

the Overload

Compressor

Will Not Start

and Makes No

Noise

X X

Compressor

Cycles Off

(Not On

Overload)

X X

FIGURE 29 — BASIC COMPRESSOR TROUBLESHOOTING GUIDE

5. Next, perform a grounded windings test to test the resistance individually of each wire to the shell of the compressor. The paint on t he compres sor can prevent good contact between the probe and the metal. The paint should be removed from a small section of th e shell of the compressor to ensure good contact by the meter probe. The voltohmmeter should be set to at least the 100X ohm level. The measured resistance between each wire and ground should be infinite or O.L. on the readout. If there is measurable resistance one of the windings is likely shorted to ground. See Figure 31.

6. A compressor that has a winding to winding short or a winding to compressor shell short is electrically failed and needs to be replaced. See the Compressor Replacement section for details.

COMPRESSOR REPLACEMENT

Before working on the compressor, read the instructions thoroughly and gather t he necessar y tools fo r the job. Review all safety information on unit and in literature. Always turn off all power to unit to avoid the possibility of electrical shock.

Consider the following safety issues before beginning:

• New and unfamiliar tasks should be performed under the supervision of an experienced service technician.

• Personal protective equipment, such as work gloves and safety glasses, should be worn.

• The floor around the work area should be clean and free of debris.

• Make sure tools are th e cor r ect to ol s for the jo b a nd that they are working properly and in good condition.

• Never replace a blown fuse without correcting the cause of the original fail u re. If thermally operated circuit breakers or overloads are tripping, make sure the trip is not due to excessi vely high temperatures or loose connections.

• When brazing suction and discharge lines, cool the lines with a damp, clean cloth to prevent injury.

• Oil may be present in the compressor accumulator and interconnecting tubing. Use caution when removing tubing.

52C,P

SERIES

FIGURE 30 — SHORTED/OPEN WINDINGS TEST

FIGURE 31 — GROUNDED WINDINGS TEST

REMOVING THE COMPRESSOR

■

— Follow the

steps below to remove the compressor:

1. Disconnect all power to unit.

2. Remove unit from wall sleeve as detailed in the UNIT DISASSEMBLY section. The unit weighs up to 150 pounds. Seek assistance or use a lifting device when removing unit from wall sleeve.

3. If the unit is a heat pump: Disconnect the wire plug on the reversing valve solenoid and carefully remove the outdoor thermostat capillary from the outdoor coil. See Figure 32.

4. Attach the piercing va lve to the suction side process tube below the crimps. Attach Carrier TOTALTEST® kit (Part No. TT1-001), to the piercing valve to verify acidity of the s ystem. After verifying the system acidity, remove the refrigerant using a certified refrigerant recovery system.

5. When all the refrigerant has been recovered, remove the terminal cover from the compressor with a nut driver. Disconnect th e 3 wire s from the compressor and label the location of each. Once the wires are labeled, replace the terminal cover to protect the compressor terminals.

6. Remove the air system components by following the procedure detailed in the ACCESSING UNIT COMPONENTS section.

7. Remove the piercing valve and cut the crimped portion of both process tubes off with a small tubing cutter. Braze an access valve on each process tube. Using a torch, disconnect the suction and discharge tubes from the compressor connections.

8. Remove the compressor mounting bolts, and remove the compressor.

For compressors that are known to be damaged: Remove refrigerant prior to disconnecting

compressor wires. Damaged hermetic compressor terminals may become l oos e and eje ct f r om the compressor. Wear safety glasses and keep your face away from the area above the terminals when removing compressor wires.

TOOLS NEEDED

■

— The following list inclu des the recommended tools and devices for removing and replacing the compressor.

/2-in. and 3/8-in. Tube Benders

/2-in. Nut Driver

/16-in. Nut Driver Flat Head Screwdriver Piercing Valve 2 Parker Access Valves (Part No. AVUSE-5) Pinch Off Tool Filter Drier — All Units (Part No. P504-80845) Carrier TOTALTEST Kit (Part No. TT1-001) Totalclaim System Charging Cylinder or an Electronic Scale Refrigerant-22 Tubing Cutter To rch Nitrogen Cylinder with Regulator Strainers Capillary Tubes

The compressor may still be hot from the brazing process.

IMPORTANT: Any time the compressor is replaced, the strainer and capillary tubes must be removed and replaced also.

9. For all units: Remove and replace the strainer and capillary tubes from the system. See Figure 32 for strainer and capillary tube location.

10. For Heat/Cool Units: Use an in-line filter drier (P/N P504-80845). The filter drier can be installed in any location in suction line. See Figure 33A for general installation location.

For Heat Pump Units: Use an in-line filter drier (P/N P504-80845) and install between the

reversing valve and the compressor accumulator. There are several suction tube configura-

tions and the in-line filter drier will be field piped and brazed in to the su ction tube for your uni t. See Figure 33B for a general installation location.

11. Remove the grommets from the existing compressor and install them onto the new compressor.

+ 36 hidden pages