SERVICE & MAINTENANCE MANUAL
2005
TABLE OF CONTENTS
Precautions for Service & Maintenance 2
1.
2. Split System Description 3
3.
Unit Model Designation & Identification 4
PAGE NO.
4. Unit Models & Part Numbers
4
5. System Operating Limits 5
6. System Safety Protections 5
Exploded View of Indoor Unit 6
7.
8. Part List of Indoor Unit 7
9. Exploded View of Outdoor Unit 9
10. Part List of Outdoor Unit 10
11. Wiring Diagrams 11
12. Field Electrical Connections Matching 13
13. Refrigeration Cycle 14
14. Self Diagnostic Function 16
15. Replacing Batteries of Remote Control 17
16. Emergency Operation of Air-Conditioner 17
17. Air Filter Cleaning 18
18. Periodical Checks 19
19. Trouble Shooting 20
1
1. PRECAUTIONS FOR SERVICE AND MAINTENANCE
SAFETY CONSIDERATIONS
• Service and maintenance of air conditioning equipment can be hazardous due to system
pressures and electrical components. Only trained and qualified service personnel should
install, repair or service the air conditioning equipment.
• When working on air conditioning equipment, observe precautions in the literature, tags and
labels attached to the unit and other safety codes.
• Wear safety glasses and gloves. Use quenching cloth and have fire extinguisher available for all
brazing operations
WARNING
• This manual describes the service and maintenance of Carrier split room air conditioner
consisting of an outdoor unit and an indoor unit manufactured by Carrier.
What is not covered in Carrier warranty?
1- Failure due to Misuse: Abusing, overloading, careless handling and negligence.
2- Failure due to Accident / Weather: Natural catastrophe, accident due to bad weather (Hail Storm,
Sand Storm, lightning, Flooding, Acid Rain and Air Borne fallout, etc).
3- Failure due to Damages during transport.
4- Failure due to modification:Any modifications done on the unit without Carrier consent.
5- Failure due to Improper Installation: Installation should be performed according to standard.
The decision of Carrier in ascertaining the same will be final. Carrier or its approved dealer
should do installation.
6- Failure due to Improper Maintenance: Lack of professional maintenance, improper adjustments,
use of improper consumables, filters, spare parts other than specified in the Carrier manuals.
7- Failure due to use of non-genuine Carrier Parts, substitute other than Carrier parts.
8- Refrigerant normal noise, wear and tear of deterioration.
9- Inconvenience or commercial loss is not covered.
The decision of Carrier in ascertaining the same will be final. Any such repairs will be carried out
at the expense of the purchaser.
2
,
2. SPLIT SYSTEM DESCRIPTION
(d) SUPPLY AIR FROM INDOOR UNIT
cool or warm air comes out of supply air outlet
(c) RETURN AIR TO INDOOR UNIT
The return air from the space to be air-
conditioned passes through the return grille
and then through the anti-bacteria filters to
clean the air from dust and foreign particles
(g) DRAIN HOSE
• Drains the water condensated in the indoor
unit during cooling operation to the outside.
Fig. (1)
CONSOLE & UNDERCEILING SPLIT SYSTEM
53KLE-H SERIES HEAT PUMP
53KLE-E SERIES COOL/ELECTRIC HEAT
53KLE-C SERIES COOL ONLY
(a) INDOOR UNIT
• Mounted inside the space to be air-conditioned.
• In summer it filters, dehumidifies and cools air.
• In winter it filters and heats air.
(e) WIRELESS REMOTE CONTROL (LCD)
Controls power, mode, fan speed, temperature,
and timer, swing and sleep functions.
(f) REFRIGERANT PIPING LINES
Insulated copper piping through which the
refrigerant R22 flow connects the indoor and
outdoor units.
(b) OUTDOOR UNIT
• Mounted outside the space to be air-conditioned.
• It contains compressor, fan, motor, condenser coil
copper tubing and electrical components.
3
3. UNIT MODEL DESIGNATION & IDENTIFICATION
42 = Indoor Unit
38 = Outdoor Unit
42
38
UNIT MODEL DESIGNATION IDENTIFICATION (ID)
KLE
Unit Family
28
Compressor
Cooling Capacity
in MBTU/HR
at ASHARE
Conditions
4. UNIT MODELS & PART NUMBERS
INDOOR UNIT
HEAT PUMP COOL ONLY
Model P/N ID Model P/N ID
42KLE14-H 46302213 H 42KLE14-C 46302214 C
42KLE22-H 46302216 H 42KLE22-C 46302217 C
42KLE28-H 46302219 H 42KLE28-C 46302231 C
42KLE32-H 46302222 H 42KLE32-C 46302223 C
COOL/ELECTRIC HEAT 42KLE39-C 46302225 C
Model P/N ID
42KLE39-E 46302243 E
OUTDOOR UNIT
HEAT PUMP COOL ONLY
Unit
Model
38KLE14-H 46303305 H 38KLE14-C 46303309 C
38KLE22-H 46303366 H 38KLE22-C 46303368 C
38KLE28-H 46303367 H 38KLE28-C 46303369 C
38KLE32-H 46303308 H 38KLE32-C 46303312 C
38KLE39-C 46303313 C
P/N ID
Unit
Model
H
E
C
Unit Type
H = Heat Pump
E = Cool/Electric Heat
C = Cool Only
P/N ID
4
5. SYSTEM OPERATING LIMITS
COOLING HEATING
Difference
Indoor temperature
Maximum
Minimum
Outdoor temperature
Maximum
Minimum
* When the system is operated above or below these limits for a long time, system diagnostics may detect a malfunction
and the unit will not operate properly.
Dry Bulb
Temp. C°
32
21
55
21
Wet Bulb
Temp. C°
23
15
-
-
MAIN POWER SUPPLY
Nominal
Power Supply
V/1PH/50HZ
200-240 180 264
Difference
Indoor temperature
Maximum
Outdoor temperature
Maximum
Minimum
Voltage
Maximum
Voltage
Dry Bulb
Temp. C°
27
21
Wet Bulb
Temp. C°
-
-
6. SYSTEM SAFETY PROTECTION
6-1 FOR HEAT PUMP SYSTEM
PROTECTION TYPE PROTECTION EFFECT OPERATION MODE WHEN ON
Cold draft prevention Indoor fan off Heating mode During unit operation
Defrost cycle Indoor fan off Heating mode During unit operation
Indoor coil
Freeze protection
Against frequent
Compressor cycling
6-2 FOR COOL ONLY SYSTEM
PROTECTION TYPE PROTECTION EFFECT OPERATION MODE WHEN ON
Indoor coil
Freeze protection
Against frequent
Compressor cycling
WARNING:
During heat pump operation the system will undergo several defrost cycles to remove ice that might
collect on the outdoor unit in very low ambient temperature. In these cycles, the indoor fan will be
automatically off and cannot operate until defrost cycle is completed.
Compressor off Cooling mode During unit operation
Compressor
Time delay
Cooling or heating
modes
At unit start-up or change
of operating mode
Compressor off Cooling mode During unit operation
Compressor
Time delay
Cooling mode
At unit start-up or change
of operating mode
5
7. EXPLODED VIEW OF INDOOR UNIT
12/1
2
3/9
7
7
12/2
3/8
3/7
12/4
12/3
Pour 42KLE39
3/5
3/6
&
3/4
12/5
12
3/3
9
1
1/6
11 10
3/1
3/2
5/6
4
5/1
6
5/3 5/4
8
5/2
5/5
6
8. PART LIST OF INDOOR UNIT
SR. DESCRIPTION
1 Chassis Subassy 363-13331 1 1 1 1
363-13332 1 1 1 1
363-13333 1 1
1.1 Chassis Side LH Subassy 363-13327 1 1 1 1 1 1 1 1 1 1
1.2 Chassis Back 063-01800 1 1 1 1
063-01801 1 1 1 1
063-01802 1 1
1.3 Fan Deck Support 028-02318 2 2 2 2 2 2 2 2 2 2
1.4 Plug 028-02319 1 1 1 1 1 1 1 1 1 1
1.5 Chassis Side RH Subassy 363-13329 1 1 1 1 1 1 1 1 1 1
1.6 Motor Capacitor
1.6.1 Capacitor 3MFD +/- 5 % , 450 VAC 024-00302 1 1 1 1
1.6.2 Capacitor 5MFD +/- 5 % , 450 VAC 024-00332 1 1 1 1 1 1
1.7 Capacitor Clamp 028-04077 1 1 1 1 1 1 1 1 1 1
1.8 Terminal Block
1.8.1 Terminal Block 6 Poles-30Amps 025-01433 1 1 1 1
1.8.2 Terminal Block 4 Poles-30Amps 025-01413 1 1 1 1 1
2 Evaporator Coil & Headers Subassy 026-00180 1 1
026-00181 1 1
026-00182 1 1
026-00119 1 1
026-00120 1 1
3 Blower Deck Subassy 363-13319 1 1 1 1
363-13320 1 1 1 1
363-13396 1 1
3.1 Blower Deck 063-01807 1 1 1 1
063-01808 1 1 1 1
063-01809 1 1
3.2 Blower
3.2.1 Blower 155 mm Diam x 177.8 mm Width 028-02324 2 2 2 2
3.2.2 Blower 155 mm Diam x 228.6 mm Width 028-02325 2 2 3 2 2 3
3.2.3 Socket Set Screw – Blower 021-00317 2 2 2 2 3 2 2 2 2 3
3.3 Thermistor Clip Nylon 021-00846 1 1 1 1 1 1 1 1 1 1
3.4 Rubber Ring For Housing 028-00685 8 8 8 8 12 8 8 8 8 12
3.5 Motor Support 063-01810 1 1 1 1
063-01625 1 1 1 1
063-07403 1 1
3.6 Motor Clamp Kit C/W Screw & Nut 021-00913 2 2 2 2 2 2 2 2 2 2
3.7 Evaporator Motor
3.7.1 Motor 1/15 HP – 1200/1100/950/800 RPM 024-00096 1 1 1 1
3.7.2 Motor 1/10 HP – 1200/1100/950/800 RPM 024-00097 1 1 1 1
3.7.3 Motor 1/8 HP – 1220/1100/950 RPM 024-00178 1 1
3/8 Blower Housing RH 028-02328 2 2 2 2
028-02329 2 2 3 2 2 3
3.9 Blower Housing LH 028-02326 2 2 2 2
028-02327 2 2 3 2 2 3
3.10 Complement – Motor Shaft 024-00203 1 1
3.11 Coupling Rubber/Metal – Motor 024-00204 1 1
3.12 Bearing & Support Assy – Motor 024-00205 1 1
4 Drain Pan Subassy 363-13334 1 1 1 1
363-13335 1 1 1 1
363-13336 1 1
PART
NUMBER
42KLE-H 42KLE-E 42KLE-C
14 22 28 32 39 14 22 28 32 39
QTY./UNIT
7
PART LIST OF INDOOR UNIT (Cont.)
SR. DESCRIPTION
PART
NUMBER
42KLE-H 42KLE-E 42KLE-C
14 22 28 32 39 14 22 28 32 39
5 Electrical Box Subassy 363-13338 1 1 1 1 1 1 1 1
363-13364 1 1
5.1 Main PCB 025-03019 1 1 1 1 1 1 1 1 1 1
5.2 Room Sensor 530 ± 30 mm 025-03102 1 1 1 1 1 1 1 1 1 1
5.3 Indoor Coil Sensor 530 ± 30 mm 025-03119 1 1 1 1 1 2 2 2 2 2
5.4 Cable Main PCB – Led PCB 025-01566 1 1 1 1 1 1 1 1 1 1
5.5 Cable Main PCB Step Motor 025-01567 1 1 1 1 1 1 1 1 1 1
5.6 Evap. Electrical Box 028-02334 1 1 1 1 1 1 1 1 1 1
5.7 Set of Cables 025-00883 1 1
025-00884 1 1 1 1
025-00885 1 1 1 1
6 Cabinet Subassy 363-13303 1 1 1 1
QTY./UNIT
(See Details Pages 5 & 6) 363-13304 1 1 1 1
363-13305 1 1
7 Air Filter-Anti Bacteria 028-02303 3 3 4 4 5 3 3 4 4 5
8 Spring for Return Grille 063-01829 1 1 1 1 1 1 1 1 1 1
9 Return Grille Subassy 363-13300 1 1 1 1
363-13301 1 1 1 1
363-13302 1 1
10 Wireless Remote Control 025-03100 1 1 1 1 1 1 1 1 1 1
11 Battery 1.5 Volt Size AAA - Alkaline 025-01125 2 2 2 2 2 2 2 2 2 2
12 Electric Heater Subassy
(Only For 42KLE39-E) 363-19007 1
12.1 Electric Heater Aluminum 4.0 kW 025-00181 1
12.2 Heater Fuse – One Shot 025-01100 1
12.3 Heater Thermostat – Manual Reset 025-01101 1
12.4 Power Relay Heater G7L-2A-T 024-00451 1
12.5 Bracket For Relay 024-00456 1
12.6 Heater Support RH 063-01628 1
12.7 Heater Support LH 063-01627 1
12.8 Heater Support Cover 063-01629 1
8
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