Carrier 52S manual

SER VICE TECHNICIAN GUIDE P ACKAGED TERMINAL AIR CONDITIONERS AND HEA T PUMPS CONTENTS Page INTRODUCTION ................................. 2,3 SUMMAR Y OF DANGERS, W ARNINGS, AND CAUTIONS ... 2 GENERAL DISASSEMBL Y ........................... 4-9 TO DISCONNECT POWER FOR CORD-CONNECTED UNIT .. 4 TO DISCONNECT POWER FOR PERMANENTL Y CONNECTED (HARDWI[...]

INTRODUCTION The focus of this manual is to provide basic information on service procedures, safety , troubleshooting, clean- ing, and component replacement for service technicians. It is intended for use only by HV AC service tech- nicians who have successfully completed instruc- tion and received T ype I Certification from the U.S. Environmental[...]

FIGURE 2 — MODEL NUMBER NOMENCLA TURE FIGURE 3 — SAMPLE DA T A INFORMA TION PLA TE 3[...]

GENERAL DISASSEMBL Y This section includes common procedures for disassem- bly and reassembly of 52S units. These instructions are general in nature and include procedures the tech- nician may be called upon to perform when accessing certain components of the 52S unit. It is important to carefully follow manufacturer ’ s instruc- tions when disas[...]

TO REMOVE THE LA TERAL DUCT EXTENSION, FOR UNITS EQUIPPED WITH THE LA TERAL DUCT ACCESSOR Y P ACKAGE 1. Remove the front panel as shown in Figure 1. 2. Remove the four 1 3 ⁄ 4 -in. screws that secure the chassis to the wall sleeve (see Figure 6). There are 2 screws on each side. 3. Remove the 2 screws that secure the lateral duct ex- tension to t[...]

TO ACCESS INDOOR-AIR SECTION COMPONENTS n DISASSEMBLING THE LA TERAL DUCT ADAPTER, FOR UNITS EQUIPPED WITH THE LA TERAL DUCT ACCESSOR Y P ACKAGE 1. Remove the lateral duct adapter end cap, shown in Figure 10, by removing the two 1 ⁄ 2 -in. screws 2. Remove the adapter top panel by removing one screw at each end of unit as shown in Figure 1 1. Rot[...]

n TO REMOVE THE AIR DISCHARGE GRILLE 1. Remove the 2 screws on each end of the air discharge grille as shown in Figure 14. 2. Lift and rotate back the bottom edge of the discharge grille and remove it. n TO REMOVE THE ALUMINUM TOP P ANEL — Remove one screw from each end of the aluminum top panel (located on the underside of the panel) as shown in[...]

n TO REMOVE THE DISCHARGE DECK 1. Remove the 2 discharge deck screws shown in Figure 17. Also remove the screw located at the top left corner of the outdoor coil tube sheet. 2. Gently pull the left side panel out and lift the end of the discharge deck that the screws were re- moved from, up and forward, to remove. TO ACCESS OUTDOOR-AIR SECTION COMP[...]

n TO REMOVE THE ST A TOR — After pulling the top of the condenser orifice away from the condenser coil, grasp the top of the stator and slide it up and out of the stator track. See Figure 20. S TAT O R CONDENSER ORIFICE CONDENSER COIL FIGURE 20 — REMOVING ST A TOR 9[...]

GENERAL CLEANING Maintaining proper performance of 52S systems (Figure 21) requires conscientious cleaning and care of components. Specific components require periodic clean- ing and/or replacement, including the following: COMPONENT CLEANING SCHEDULE Indoor Air Filter Monthly V ent Air Filter Monthly Indoor Coil Seasonally Indoor Fan Seasonally O[...]

TOOLS NEEDED The following list includes the recommended tools, de- vices, and cleaning solutions for use in cleaning the 52S unit components. V acuum Cleaner with Crevice T ool Attachment, or Soft Plastic Bristle Brush Mild Household Detergent Phillips Head Screwdriver 5 ⁄ 16 -in. Nut Driver Flat Head Screw Driver Lifting Device (or another pers[...]

n CLEANING THE VENT AIR FIL TER 1. Remove the unit chassis from wall sleeve as described in the General Disassembly section of this manual. See Figure 6. 2. Swing open vent door . The filter is located directly behind the vent door . See Figure 23. 3. Remove the vent air filter by gently pushing on the filter slot. Once the vent air filter is r[...]

SEASONAL CLEANING n ACCESSING THE INDOOR AND OUTDOOR COILS — The minimum cleaning recommendation for indoor and outdoor coils is once per season. T o access the coils for a thorough cleaning, it is necessary to remove the Air System. T o accomplish this task, per- form the following steps: 1. DISCONNECT ALL POWER TO UNIT! 2. Remove the unit chass[...]

n CLEANING THE INDOOR AND OUTDOOR COILS Coil fins are sharp and may cut hands. Wear heavy protective gloves when cleaning coils. 1. Use a vacuum cleaner or soft bristle brush to remove surface fibers and dirt from each of the faces of the coil. Both the inner and outer surfaces of the coils must be cleaned. It is important to apply the tool in th[...]

n CLEANING THE INDOOR F AN AND F AN SCROLL — Once the indoor fan wheel and the indoor fan scroll have been accessed, proceed with the cleaning instructions detailed below: 1. Insert a piece of 9.5-in. by 9.5-in. cardboard between the blower wheel and the opening in the blower scroll to prevent fungus and other debris from falling into the coil. 2[...]

COMPRESSOR A cutaway view of the rotary compressor with key com- ponents labeled is shown in Figure 32. The motor sta- tor 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 muf fler are attached to the motor bearing. The pump bearing p[...]

The rotary compression process (Figure 33), 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 pis- ton moves to position A as shown in (2). The suction vol- ume is now the area defined by point A and the tip of the vane. Gas in th[...]

SYMPTOM g POSSIBLE CAUSE f COMPRESSOR ST ARTS AND RUNS BUT CYCLES ON THE OVERLOAD COMPRESSOR ST ARTS AFTER CYCLING THE OVERLOAD SEVERAL TIMES COMPRESSOR WILL NOT ST ART . IT HUMS AND CYCLES ON THE OVERLOAD COMPRESSOR WILL NOT ST ART AND MAKES NO NOISE COMPRESSOR CYCLES OFF (NOT ON OVERLOAD) COILS/FIL TERS DIRTY OR PLUGGED X AIR OR NONCONDENSABLE GA[...]

5. Next, test the resistance individually of each wire to the shell of the compressor . The paint on the com- pressor 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 volt-ohmmeter should be set to at least the 100[...]

n 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 GENERAL DISASSEMBL Y 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 [...]

10. For Heat Pump Units remove the capillary tube only . 11 . For Heat/Cool Units the filter drier is installed in the liquid line, in place of the strainer . T rim the saved liquid line tube from Step 9, to be 1.5 in. long (saving the crimped portion), and braze it into the filter drier , Part No. KH43LG060. See Figure 39. For Heat Pump Units: A[...]

HEA TERS The heater in 52S units is located directly behind the evaporator coil. The heater assembly includes the heater (2.3 kW , 3.4 kW or 5 kW), a primary limit switch, and a secondary limit switch (Figure 41). The primary and secondary limit switches are safety switches that regulate heater operation. The primary limit switch dis- ables current[...]

3. Remove the unit from the sleeve as detailed in the GENERAL DISASSEMBL Y section. 4. Remove the discharge air grille and the discharge air deck as detailed in the GENERAL DISASSEMBL Y section. Save screws. 5. Once the air discharge deck is removed, the heater assembly is exposed. After noting positions of wires and labelling them, use a pair of n[...]

OPERA TING CONTROLS The controls and components used in the 52S cooling only or heat/cool units are as follows: the selector switch, the indoor thermostat, the dual capacitor , the temperature limiter , the vent lever , and the fan cycle switch (Figure 45). The selector switch is used to determine the mode of op- eration: heat, cool, fan, or of f. [...]

DESCRIPTION OF SWITCH SETTINGS n OFF BUTTON — The OFF button terminates unit operation. n F AN ONL Y BUTTON — Push button for air circula- tion without heating or cooling. n HIGH HEA T OR HIGH COOL — Push button and rotate temperature knob to desired comfort level. This function provides maximum heating or cooling, and is recommended to raise[...]

SEQUENCE OF OPERA TION n HEA T/COOL UNITS (Figure 50) Fan Mode — With the selector switch set to F AN and the fan switch set to fan cycle, contacts L1 to LO and FCS1 to LS are made. Cooling (Low) — With the selector switch set to low speed cooling and the fan switch set to fan cycle, contacts FCS2 to LO, COMP to FCS1, and COMP to IT3 are made. [...]

COMPONENT OPERA TION AND TROUBLESHOOTING n TOOLS NEEDED V olt-Ohmmeter Flat and Phillips Screw Drivers 5 ⁄ 16 -in. Nut Driver Side Cutting Pliers Before cleaning, servicing, performing maintenance or removing the chassis from the wall sleeve, discon- nect all power to the unit to avoid the possibility of electrical shock and personal injury. Only[...]

n INDOOR THERMOST A T (Heat Pump Units) (cont) (Figure 54) — T o verify operation of the heat pump in- door thermostat switch, a continuity test may be per- formed as follows: 1. T urn off unit power as described in GENERAL DISASSEMBL Y section. 2. Remove wire leads from thermostat. Note their loca- tions to ease re-assembly . 3. T o test stage A[...]

n CAP ACITOR — The 52S units use a dual capacitor . One part of the capacitor is used with the fan motor . The other part of the capacitor is used by the compressor . Run circuits on single-phase compressor motors use capacitors which dramatically af fect the motor opera- tion. Run capacitors are connected to the motor circuit at all times. T o e[...]

ELECTRICAL COMPONENTS REMOV AL AND REPLACEMENT n INDOOR THERMOST A T — T o remove the indoor thermostat, perform the following steps: 1. T urn of f unit power as described in GENERAL DISASSEMBL Y section. 2. Remove the thermostat knob. 3. Remove control box escutcheon (Figure 58) to expose 2 Phillips head mounting screws. Remove the tem- perature[...]

n CAP ACITOR — T o remove the capacitor , perform the following steps: 1. T urn of f unit power as described in GENERAL DISASSEMBL Y section. 2. Open the control box (Figure 61) as detailed in the GENERAL DISASSEMBL Y section of this manual. 3. Properly discharge the capacitor as described in the Capacitor section under Component Operation and T [...]

F AN MOTOR The fan motor is a permanent split capacitor (PSC) type motor . This motor is common in air-conditioning sys- tem applications. A PSC motor does not require the use of a relay and always has a run capacitor connected between the run and start windings of the motor . See Figure 62. The 52S series fan motor has a motor shaft extended throu[...]

SYMPTOM g POSSIBLE CAUSE f MOTOR HUMS BUT DOES NOT ST ART MAKES NO NOISE AND DOES NOT ST ART ST ARTS BUT STOPS AFTER SHORT TIME ST ARTS BUT RUNS SLOW RUNS ON ONE SPEED, NOT ON OTHERS DEFECTIVE BEARING XX X CAP ACITOR DEFECTIVE XX SWITCH DEFECTIVE XX LOW LINE VOL T AGE XX X SHORTED MOTOR WINDING XX X NO POWER TO UNIT X INTERNAL THERMOST A T OPEN X M[...]

F AN MOTOR REPLACEMENT Perform the following steps to remove and reinstall the fan motor: 1. DISCONNECT ALL POWER TO UNIT . 2. Remove the unit from the sleeve as detailed in the GENERAL DISASSEMBL Y section and place the unit on a large flat surface. 3. Remove the discharge air grille, the aluminum top panel, the top cover , and the discharge air [...]

FIELD TEMPERA TURE CHAR TS See Figures 67 - 82 for field temperature data. FIGURE 67 — 52S 7,000 BTU UNIT FIELD TEMPERA TURE CHAR T — LOW COOL — 50% RH 35[...]

FIGURE 68 — 52S 7,000 BTU UNIT FIELD TEMPERA TURE CHAR T — HIGH COOL — 50% RH 52S SERIES 36[...]

FIGURE 69 — 52S 7,000 BTU UNIT FIELD TEMPERA TURE CHAR T , LOW HEA T MODE (47 F OUTDOOR TEMPERA TURE) 37[...]

FIGURE 70 — 52S 7,000 BTU UNIT FIELD TEMPERA TURE CHAR T , HIGH HEA T MODE (47 F OUTDOOR TEMPERA TURE) 52S SERIES 38[...]

FIGURE 71 — 52S 9,000 BTU UNIT FIELD TEMPERA TURE CHAR T — LOW COOL — 50% RH 39[...]

FIGURE 72 — 52S 9,000 BTU UNIT FIELD TEMPERA TURE CHAR T — HIGH COOL — 50% RH 52S SERIES 40[...]

FIGURE 73 — 52S 9,000 BTU UNIT FIELD TEMPERA TURE CHAR T , LOW HEA T MODE (47 F OUTDOOR TEMPERA TURE) 41[...]

FIGURE 74 — 52S 9,000 BTU UNIT FIELD TEMPERA TURE CHAR T , HIGH HEA T MODE (47 F OUTDOOR TEMPERA TURE) 52S SERIES 42[...]

FIGURE 75 — 52S 12,000 BTU UNIT FIELD TEMPERA TURE CHAR T — LOW COOL — 50% RH 43[...]

FIGURE 76 — 52S 12,000 BTU UNIT FIELD TEMPERA TURE CHAR T — HIGH COOL — 50% RH 52S SERIES 44[...]

FIGURE 77 — 52S 12,000 BTU UNIT FIELD TEMPERA TURE CHAR T , LOW HEA T MODE (47 F OUTDOOR TEMPERA TURE) 45[...]

FIGURE 78 — 52S 12,000 BTU UNIT FIELD TEMPERA TURE CHAR T , HIGH HEA T MODE (47 F OUTDOOR TEMPERA TURE) 52S SERIES 46[...]

FIGURE 79 — 52S 14,000 BTU UNIT FIELD TEMPERA TURE CHAR T — LOW COOL — 50% RH 47[...]

FIGURE 80 — 52S 14,000 BTU UNIT FIELD TEMPERA TURE CHAR T — HIGH COOL — 50% RH 52S SERIES 48[...]

FIGURE 81 — 52S 14,000 BTU UNIT FIELD TEMPERA TURE CHAR T , LOW HEA T MODE (47 F OUTDOOR TEMPERA TURE) 49[...]

FIGURE 82 — 52S 14,000 BTU UNIT FIELD TEMPERA TURE CHAR T , HIGH HEA T MODE (47 F OUTDOOR TEMPERA TURE) 52S SERIES 50[...]

WIRING SCHEMA TICS Refer to Figures 83 - 87 for typical 52S unit wiring schematics. NOTE: Figures 83 - 87 should not be substituted for the schematic located next to the unit control box. LEGEND FCS — Fan Cycle Switch IT — Indoor Thermostat L— Power Supply Line Component Connections (Marked) Component Connection (Unmarked) Accessory or Option[...]

LEGEND CAP — Capacitor COMP — Compressor FCS — Fan Cycle Switch FM — Fan Motor HTR — Heater IT — Indoor Thermostat L— Power Supply Line OL — Overload PL — Plug PLS — Primary Limit Switch SLS — Secondary Limit Switch ST — Start Thermistor SW — Selector Switch Component Connection (Marked) Component Connection (Unmarked) Acc[...]

LEGEND CAP — Capacitor COMP — Compressor CR — Cooling Relay EQUIP GND — Equipment Ground FM — Fan Motor FR — Fan Relay HR — Heating Relay IFT — Indoor Frost Thermostat L— Power Supply Line OL — Overload PL — Plug PLS — Primary Limit Switch SLS — Secondary Limit Switch SSS — Speed Selector Switch ST — Start Thermistor T[...]

LEGEND CAP — Capacitor COMP — Compressor FCS — Fan Cycle Switch FM — Fan Motor HTR — Heater IT — Indoor Thermostat L— Power Supply Line OL — Overload PL — Plug PLS — Primary Limit Switch RVS — Reversing V alve Solenoid SLS — Secondary Limit Switch ST — Start Thermistor SW — Switch Component Connection (Marked) Component [...]

LEGEND CAP — Capacitor COMP — Compressor CR — Cooling Relay EQUIP GND — Equipment Ground FM — Fan Motor FR — Fan Relay HR — Heating Relay IFT — Indoor Frost Thermostat L— Power Supply Line OFT — Outdoor Frost Thermostat OL — Overload PL — Plug PLS — Primary Limit Switch RVR — Reversing V alve Relay RVS — Reversing V al[...]

MOST FREQUENT PT AC SER VICE QUESTIONS 1. Can remote thermostats be used on standard (AA) models? No, only for use on remote control (RC) models. 2. Which remote thermostats are acceptable for use on 52S products? HH01AD045 — Manual changeover thermostat TST A TCCP AC01 — Programmable AC thermostat TST A TCCPHP01 — Programmable HP thermostat [...]