52C,P SERIES
SERVICE TECHNICIAN GUIDE
PACKAGED TERMINAL AIR CONDITIONERS
AND HEAT PUMPS
CONTENTS
Page
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,3
SUMMARY OF DANGERS, WARNINGS,
AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
UNIT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,4 TOOLS NEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVE FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . 3
DISCONNECT POWER FOR
CORD-CONNECTED UNIT . . . . . . . . . . . . . . . . . . . . . 3
DISCONNECT POWER FOR PERMANENTLY CONNECTED (HARDWIRED) UNITS . . . . . . . . . . . . 3
OPEN THE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . 4
REMOVE THE UNIT FROM THE WALL SLEEVE . . 4
ACCESSING UNIT COMPONENTS . . . . . . . . . . . . . .5-8
ACCESSING INDOOR-AIR SECTION COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ACCESSING OUTDOOR-AIR SECTION COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REINSTALL FRONT PANEL . . . . . . . . . . . . . . . . . . . . . 8
GENERAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . .9-12 CLEANING AND SAFETY . . . . . . . . . . . . . . . . . . . . . . 9 TOOLS NEEDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MONTHLY CLEANING. . . . . . . . . . . . . . . . . . . . . . . . 10 SEASONAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . 11
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-17
COMPRESSOR TROUBLESHOOTING . . . . . . . . . . . 14 BASIC HERMETIC COMPRESSOR
ELECTRICAL MEASUREMENTS . . . . . . . . . . . . . . . 14 COMPRESSOR REPLACEMENT . . . . . . . . . . . . . . . . 15
Page
HEATERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,19
COMMON CAUSES OF HEATER FAILURE. . . . . . . 18
HEATER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATING CONTROLS. . . . . . . . . . . . . . . . . . . . . 20-28
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-31
FAN MOTOR TROUBLESHOOTING. . . . . . . . . . . . . 29 BASIC FAN MOTOR ELECTRICAL TESTS . . . . . . . . 29
FAN MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . 31
FIELD TEMPERATURE CHARTS . . . . . . . . . . . . . . 32-40
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . 41-45
MOST FREQUENT PTAC SERVICE
QUESTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
52C PERFORMANCE AND PHYSICAL DATA. . . . . . 48 52P PERFORMANCE AND PHYSICAL DATA . . . . . . 49
PTAC Customer Support Center
1•800•894•6449
52C,P 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, operate, adjust, repair, or dismantle any equipment should be made until the manufacturer’s instructions are read and thoroughly understood by the service technician. Even equipment that seems familiar may have specific model differences 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 procedures, 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 information plate beneath the front panel of the unit. See Figure 1. The data information plate also lists voltage ranges and other important electrical 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.
MODEL |
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52PQA312301AA |
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SERIAL |
3701X11520 |
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DATE OF MFG. |
09/12/2001 |
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VOLT RANGE |
187-253 |
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VOLTS |
230/208 |
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PH |
1 |
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HZ |
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60 |
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MIN CKT AMPACITY |
19.3 |
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R-22 OZ |
34 |
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DESIGN PSIG 350 HIGH SIDE, 150 LOW SIDE |
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COOLING |
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BTU/HR |
12,100/12,000 |
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AMPS |
4.8/5.3 |
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WATTS |
1090/1122 |
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EER |
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11.1/10.7 |
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COMP |
RLA |
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6.1 |
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LRA |
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29 |
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FAN |
FLA |
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0.75 |
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MOTOR |
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HP |
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1/8 |
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HEATING |
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BTU/HR |
11,000/11,000 |
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AMPS |
15.6/14.5 |
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WATTS |
3570/2997 |
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COP |
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3.2/3.2 |
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HEATER |
AMPS |
14.8/13.7 |
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WATTS |
3400/2850 |
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BTU/HR |
WATER |
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STEAM |
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AMP |
CANADIAN INSTALLATION |
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USE |
20 |
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MAX FUSE |
MAX BREAKER |
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TIME DELAY FUSE |
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OR HACR TYPE |
20 |
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AMP |
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AMP |
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CIRCUIT BREAKER |
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FIGURE 1 — SAMPLE DATA INFORMATION
PLATE
Hazards or unsafe practices which COULD result in severe personal injury or death.
2
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
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
FIGURE 2 — MODEL NUMBER NOMENCLATURE
UNIT DISASSEMBLY
This section includes common procedures for disassembly and re-assembly of unit.
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
•5/16-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.
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 switch 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 switch 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.
3
52C,P SERIES
REMOVABLE |
LOCATION OF |
LOCKING SCREW |
FILTER |
REMOVED FILTER |
(NOTE: 2nd LOCKING SCREW |
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IS LOCATED BEHIND |
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2nd FILTER) |
FIGURE 3 — LOCATION OF LOCKING SCREWS
BEHIND FILTERS
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 mounting screws that secure the 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 may be in a different location depending on brand of wall sleeve attached.
The chassis weighs between 110 and 150 lbs. Take proper safety precautions to avoid personal injury when lifting and moving the chassis.
The unit basepan may have water in it. Tilt the unit back slightly when removing it from the sleeve to drain some of the water into the sleeve.
CONDUIT ACCESS MOLEX
PANEL PLUGS
FIGURE 5 — PLUG ASSEMBLY ON
HARDWIRE UNITS
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, OUTOOR, LOUVERS, AND INDOOR PANELS AS PECIFIED ON THE PRODUCT.
4
CONTROL |
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BOX |
VARIOUS ATTACHMENT |
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SCREWS |
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HOLE LOCATIONS |
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POWER
CORD
ACCESS
COVER
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GE WALL |
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POWER |
AMANA, TRANE |
SLEEVE |
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(SLOTTED |
HOLES |
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CORD |
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HOLES) WALL |
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SLEEVE HOLES |
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FIGURE 6 — CONTROL BOX COVER
CARRIER, BRYANT WALL SLEEVE HOLES
FIGURE 7 — PTAC UNIT TO WALL
SLEEVE MOUNTING SCREWS
ACCESSING UNIT COMPONENTS
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 duct plenum to the top of the lateral duct extension. See Figure 8.
2.Locate and remove the 2 bottom bracket screws (located opposite extension duct) that secure the lateral duct plenum to the bracket flange. See Figure 8.
3.Carefully lift the plenum up and away from front panel and duct extension.
■REMOVE THE DISCHARGE DECK ASSEMBLY
1.Remove the front panel. Refer to Remove Front Panel section and Figure 4.
2.Remove discharge screen screw using a 5/16-in. nut driver. See Figure 9.
3.Remove the discharge deck assembly screws using a 5/16-in. nut driver. See Figure 9.
4.Gently pull the deck/grille up and away from the unit.
5.Reassemble by reversing steps above.
■ 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 assembly. Label each wire for ease 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.
5
52C,P SERIES
END CAP |
PLENUM TOP |
LATERAL DUCT |
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SCREWS (2) |
EXTENSION |
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WALL |
BRACKET |
LEFT |
RIGHT |
BRACKET BRACKET |
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SCREWS |
BRACKET |
SCREWS |
FIGURE 8 — PTAC UNIT WITH LATERAL
DUCT ACCESSORY INSTALLED
DISCHARGE DECK
FIGURE 10 — ACCESSING HEATER
PLATE ASSEMBLY
ATTACHMENT
SCREWS
HEATER PLATE
ASSEMBLY
DISCHARGE |
DISCHARGE |
SCREEN |
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 condenser orifice by 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 condenser fan. Rest condenser on basepan. See Figure 17.
FIGURE 11 — REMOVAL OF HEATER
PLATE ASSEMBLY
d.Using Needle Nose Pliers remove condenser 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.
6
GUSSET |
GUSSET |
CONDENSER |
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SCREWS |
ORIFICE (PLASTIC) |
PARTITION |
GUSSET |
GUSSET |
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FIGURE 12 — GUSSET REMOVAL
CONDENSER
ORIFICE
CAPTIVE |
CAPTIVE |
SCREWS (2) |
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
7
52C,P SERIES
CONDENSER
FAN
OUTDOOR COIL TUBE
SHEET SCREWS
HUB CLAMP
FIGURE 16 — LOCATION OF OUTDOOR
COIL TUBE SHEET SCREWS FIGURE 18 — REMOVING CONDENSER FAN HUB CLAMP
CONTROL DOOR |
SCREW |
SCREW |
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FRONT PANEL |
DISCHARGE |
(BACK VIEW) |
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, tilting it forward 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.
FIGURE 17 — REMOVING OUTDOOR COIL
FROM CONDENSER FAN
8
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 |
Monthly |
Vent Air Filter |
Monthly |
Indoor Coil |
Seasonally |
Indoor Fan |
Seasonally |
Outdoor Coil |
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 manual 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 should be clean 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.
EXTERIOR GRILLE (ACCESSORY)
FRONT |
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PANEL |
CHASSIS |
WALL SLEEVE |
(STANDARD) |
(STANDARD) |
(ACCESSORY) |
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FIGURE 20 — STANDARD 52C UNIT |
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9
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, or Soft Plastic Bristle Brush
Mild Household Detergent
Phillips Head Screwdriver
5/16-in. Nut Driver
Flat Head Screw Driver
Needle Nose Pliers, 90° Bend
Lifting Device (or another person for assistance)
Tank Sprayer (Part No. P9021001) or Trigger Spray Extension Tube (Part No. P9029000)
Compressed Air Tank
Clean Water Supply
Indoor Air Filter Replacement
(Part No. AIR-FILTER-10PK)
Vent Air Filter Replacement (Part No. 52CQ500144)
Condenser Coil Cleaning Solution (Part No. P9020501)
Evaporator Coil Cleaning Solution (Part No. P90221001)
10-in. by 29-in. Piece of Clean Cardboard
3% Solution of Hydrogen Peroxide in Spray Bottle
Clean Cloth
Safety Glasses
Protective Gloves
MONTHLY CLEANING
■AIR FILTERS — The indoor and vent air filters should be cleaned once per month. Filters that 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 — Two air 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.
■ REPLACING THE INDOOR AIR FILTER —
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 FILTER —
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 exterior 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 surfaces. Be careful not to push dirt or other fibers into the unit’s interior components. Accessible wall sleeve surfaces should also be wiped clean.
10
SEASONAL CLEANING
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.
FIGURE 21 — LOCATION OF
TWO-PIECE INDOOR FILTER
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 the basepan and drain passages by rinsing with clean water. Be sure all debris is removed from the drain valve. See Figure 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 condensate drain 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 cloth to remove 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.
VENT DOOR
OUTDOOR
AIR FILTER
FIGURE 22 — LOCATION OF OUTDOOR AIR
VENT FILTER
11
52C,P SERIES
FIGURE 23 — PTAC EXTERIOR SURFACES
FIGURE 25 — CLEANING COILS
FIGURE 24 — VACUUMING EVAPORATOR
COIL
DRAIN VALVE
FIGURE 26 — BASEPAN SECTION
12
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
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.
DISCHARGE TUBE
SUCTION INLET
SUCTION MUFFLER/ ACCUMULATOR
PISTON
VANE
OIL TUBE
SHELL
STATOR
ECCENTRIC SHAFT
ROTOR
MOTOR BEARING |
DISCHARGE MUFFLER |
DISCHARGE VALVE |
CYLINDER |
PUMP BEARING
MOUNTING PLATE
FIGURE 27 — ROTARY COMPRESSOR COMPONENTS
13
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 position A as shown in (2). The suction 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.
COMPRESSOR TROUBLESHOOTING
Refer to Figure 29 for a basic compressor troubleshooting chart.
FIGURE 28 — ROTARY COMPRESSOR
COMPRESSION PROCESS
BASIC HERMETIC COMPRESSOR ELECTRICAL MEASUREMENTS
There are 2 basic electrical tests for hermetic compressors that will determine the electrical state of the motor. The first test requires checking the electrical resistance of each of the electrical motor windings. 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 wire, COMMON wire (YELLOW) may 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 wire 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.
For compressors that are known to be damaged: Remove refrigerant prior to disconnecting compressor wires. Damaged hermetic compressor terminals may become loose and eject from 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.
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SYMPTOM |
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Compressor |
Compressor |
Compressor |
Compressor |
Compressor |
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POSSIBLE CAUSE |
Starts and |
Starts After |
Will Not |
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Will Not Start |
Cycles Off |
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Runs But |
Cycling the |
Start. It Hums |
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and Makes No |
(Not On |
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Cycles On the |
Overload |
and Cycles On |
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Noise |
Overload) |
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Overload |
Several Times |
the Overload |
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COILS/FILTERS DIRTY OR PLUGGED |
X |
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AIR OR NONCONDENSABLE GASES |
X |
X |
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IN SYSTEM |
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SYSTEM REFRIGERANT OVERCHARGED |
X |
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X |
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DISCHARGE LINE RESTRICTED |
X |
X |
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CAPILLARY TUBE OR STRAINER |
X |
X |
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X |
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RESTRICTED OR PLUGGED |
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FAN BLADE OR MOTOR DEFECTIVE |
X |
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X |
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FAN BLADE OR BLOWER WHEEL STUCK |
X |
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X |
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SYSTEM REFRIGERANT UNDERCHARGED |
X |
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X |
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EVAPORATOR AIRFLOW RECIRCULATION |
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X |
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UNIT OVERSIZED FOR APPLICATION |
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X |
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COMPRESSOR REQUIRES START ASSIST |
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X |
X |
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NO POWER TO UNIT |
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X |
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LOW VOLTAGE TO UNIT |
X |
X |
X |
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X |
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OVERLOAD PROTECTOR OPEN |
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X |
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OVERLOAD PROTECTOR INCORRECT |
X |
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X |
X |
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OR DEFECTIVE |
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CAPACITOR INCORRECT OR DEFECTIVE |
X |
X |
X |
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X |
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THERMOSTAT CONTACTS ARE OPEN |
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X |
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THERMOSTAT IS SET TOO HIGH OR LOW |
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X |
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SELECTOR SWITCH IS OPEN |
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X |
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OR DEFECTIVE |
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WIRING IS INCORRECT OR DEFECTIVE |
X |
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X |
X |
X |
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SYSTEM PRESSURES NOT EQUALIZED |
|
X |
X |
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X |
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COMPRESSOR MOTOR OR |
X |
X |
X |
X |
X |
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MECHANISM DEFECTIVE |
||||||
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COMPRESSOR GROUNDED |
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X |
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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 the compressor can prevent good contact between the probe and the metal. The paint should be removed from a small section of the 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 the necessary tools for 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 the correct tools for the job and that they are working properly and in good condition.
•Never replace a blown fuse without correcting the cause of the original failure. If thermally operated circuit breakers or overloads are tripping, make sure the trip is not due to excessively 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.
15
52C,P SERIES
FIGURE 30 — SHORTED/OPEN WINDINGS TEST
FIGURE 31 — GROUNDED WINDINGS TEST
For compressors that are known to be damaged: Remove refrigerant prior to disconnecting compressor wires. Damaged hermetic compressor terminals may become loose and eject from 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 includes the recommended tools and devices for removing and replacing the compressor.
1/2-in. and 3/8-in. Tube Benders
1/2-in. Nut Driver
5/16-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
Torch
Nitrogen Cylinder with Regulator
Strainers
Capillary Tubes
■ 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 valve 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 system. 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 the 3 wires 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.
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 configurations and the in-line filter drier will be field piped and brazed into the suction tube for your unit. See Figure 33B for a general installation location.
11.Remove the grommets from the existing compressor and install them onto the new compressor.
16