Start-Up and Service Instructions

Transcription

1 73TC Room Air Conditioners Start-Up and Service Instructions CONTENTS Page SAFETY REMINDERS...1 START-UP...1 SERVICE...1, General Notes...1 Compressor Replacement... PREVENTIVE MAINTENANCE...-4 General... System Cleaning/Flushing...3 DISASSEMBLY INFORMATION Filter Removal...5 Front Grille Removal...5 Discharge Air Deck Removal...5 Accessing Control Box Components...5 Capacitor Removal...6 Thermostat Removal...6 Thermostat Bulb Heater Removal (008P Unit Only)...6 Mode Selector Switch Removal...6 Fan Cycle Switch (Energy Saver Switch) Removal (008P Unit Only)...6 Wing Panel(s) Removal...6 Accessing Compressor, Fan Motor, Outdoor Coil Sections...7 Exhaust Feature (008P Unit Only)...7 Fan Motor Removal...7 OUTDOOR FAN INDOOR BLOWER WHEEL SERVICE POINTS...9 TROUBLESHOOTING...10 SAFETY REMINDERS 1. Carry a fire extinguisher in your truck. Keep it within reach when using a torch. Check fire extinguisher periodically to be sure it is fully loaded and functional.. Know how to handle oxyacetylene equipment safely. Lock the equipment in an upright position in the truck and at the job site. 3. Use dry nitrogen or carbon dioxide to pressurize the system for leak checking. Always use a good regulator. Be careful not to exceed 150 psig test pressure in the hermetic compressor. 4. Wear safety goggles and gloves when recovering refrigerant from a system. 5. Attend shop safety meetings. START-UP Refer to operating instructions in Owner s Guide provided with room air conditioner. Refer to Table 1 for specific model number information to properly service, maintain, and disassemble the unit. SERVICE General Notes These Start-Up and Service Instructions are provided to assist the trained and qualified service technician in repairing or replacing components of Carrier room air conditioner model offerings for Room air-conditioning models are cooling-only units. These instructions contain disassembly photos for Model 73TC (Siesta I and Siesta II). A typical 73TC unit is shown in Fig. 1. Unit physical data is found in Tables -8. Fig. 1 Model 008P IMPORTANT: Repairing and servicing air conditioners can be hazardous for untrained individuals. The instructions printed in this publication are for properly trained and qualified Carrier service technicians only. Before working on any air conditioner, be sure to first disconnect all electric power to the unit to avoid the possibility of electrical shock and personal injury. Before disconnecting, discharge capacitors by shorting capacitors across terminals. Shield coils with cardboard to protect hands against injury from sharp metal edges when removing compressor and other components. When disassembling wiring, use numbered stickers to identify wire leads and terminals. This aids in quick, accurate reassembly. ER Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 PC 131 Catalog No Printed in U.S.A. Form 73TC-1SS Pg Replaces: New Tab 8a 10a

2 Table 1 Model Number Nomenclature Check clearances around scroll and housing before installing fans. Before securing fan(s) fasteners, rotate fan by hand to ensure ample clearance. Refer to Carrier Standard Service Techniques, Chapters 1 and, for information on checking motors; removing refrigerant; adding oil; and evacuating, dehydrating, and charging system. Pay particular attention to all safety warnings for these procedures. NOTE: In Carrier Standard Service Techniques, refrigerant removal must always include recovering the refrigerant, not allowing it to escape to the atmosphere. Compressor Replacement Stand clear of compressor terminals when working on compressors. With system under pressure, terminals may blow causing personal injury. Observe the same safety procedures for rotary compressors as for reciprocating compressors. When changing compressors: 1. Follow all safety codes. Reminder: use protective goggles, work gloves, and water-soaked quenching cloth.. Shut off all electrical power to unit by removing power cord from outlet, then disconnect all wiring from the compressor. 3. Apply field-supplied tap-a-lines to the true (closest to compressor) suction and discharge connections of the compressor. 4. Recover the refrigerant charge from the unit. After recovering, cut the discharge and suction line process tubes below the tube crimps. If you choose a good tubing location for cutting the refrigerant lines initially, the location is easily accessible when making the final joints. You can braze the oil piping stub into the new compressor fittings more easily before the compressor is put back into the unit. Oil vapor in piping stubs can ignite from torch flame and cause serious injury. Exercise extreme care when brazing, and keep brazing cloth and fire extinguisher handy for emergency use. 5. Connect a nitrogen supply to the unit at one of the tapa-line connectors (5 psig maximum flow), leaving the other connector open to the atmosphere. Braze angle valves with stubs to each process tube. 6. Remove compressor from unit. Refer to Accessing Compressor, Fan Motor, Outdoor Coil Sections, page Remove tap-a-lines from suction and discharge lines. Carefully braze the holes closed from where the tap-a-lines were removed. 8. For proper cleaning and flushing, use the Carrier Totalclaim recovery system or a comparable refrigerant recycling system. 9. Install new compressor and braze into place with fieldsupplied copper slip couplings. 10. Connect wiring: replace wire terminals if necessary. 11. Proceed with evacuation and charging. Pinch off lines where angle valves were added. Cut off angle valves above pinch-off, and braze tubes. 1. Start up unit. PREVENTIVE MAINTENANCE General CLEANING Clean cooling coil and condenser (outdoor) coil. Hold flashlight behind coil to see if all spaces are clear. Use a hooked wire to remove dirt. Dust accumulation obstructs or reduces airflow and results in loss of capacity. Coils may be vacuumed when dry. Outdoors, unit can be brushed with a stiff brush and fins blown out with compressed air. Thoroughly clean basepan, motors, fan wheels, other components, and all drain passages. Vacuum insulation. Clean all inside painted surfaces with mild detergent to remove grease. Clean cabinet and grille. Mild detergents reduce electrostatic charges on plastic sections of the grille and are good cleaners. Do not use carbon tetrachloride, solvents, or waxes containing solvents to clean plastic sections. PAINTING Paint any parts that show evidence of rust with a good rust-resistant paint. WIRING Check all wiring for deterioration and all electrical contacts for tightness and lack of corrosion. MOUNTING Make sure unit is secure in window, and level from left to right and from front to rear according to installation instructions provided. Check fans to ensure they are correctly positioned, centered in orifice, and tight on shaft.

3 LEAKS Check any connections that show evidence of oil or leaks. When unit is properly installed, centered, and leveled (see Owners Guide), check gaskets and wing panels for possible air leakage. CONTROLS Check unit to ensure all controls are functioning correctly and unit operation is normal. Vibrations can cause unwanted noise. Check to be sure no piping is vibrating against any side of unit. System Cleaning/Flushing For proper cleaning and flushing, use the Carrier Totalclaim recovery system, or a comparable refrigerant recycling system. SERVICE/ DISCRETE NO. Table Physical and Electrical Data Model Offerings CASING (See Table 6) V-PH-Hz VOLTAGE RANGE ING CAPACITY* (Btuh) R- CHARGE (OZ. ±.05) WET BULB t F AMPS WATTS 73TCA005101B S TCA005111B S TCA00511B S TCA005131B S TCA005141B S TCA005151B S TCA005171B S TCA005101D S TCA005101L S TCA005111L S TCA00511L S TCA006101D S TCA006111D S TCA00611D S TCA008101D S TCA008101P S TCA010101D S EER (DOE) SERVICE/ DISCRETE NO. PF (%) CAPACITOR (See Table 5) FAN MTR CARRIER P/N FAN MTR FLA COMPRESSOR (See Table 7) THERMISTOR (See Table 4) CAPILLARY DATA (See Table 3) 73TCA005101B 96 RC-1/FC-1 HC01CE D-1 Z-1 CD-1 73TCA005111B 96 RC-1/FC-1 HC01CE D- Z-1 CD- 73TCA00511B 96 RC-/FC-1 HC01CE M-1 Z-1 CD-3 73TCA005131B 96 RC-/FC-1 HC01CE M-1 Z-1 CD-3 73TCA005141B 96 RC-1/FC-1 HC01CE D-3 Z-1 CD-4 73TCA005151B 96 RC-/FC-1 HC01CE D-3 Z-1 CD-4 73TCA005171B 96 RC-/FC-1 HC01CE D-3 Z-1 CD-4 73TCA005101D 91 RC-/FC-1 HC01CE M-1 Z-1 CD-5 73TCA005101L 96 RC-1/FC-1 HC01CE D-1 Z-1 CD-1 73TCA005111L 96 RC-/FC-1 HC01CE D-3 Z-1 CD-4 73TCA00511L 96 RC-/FC-1 HC01CE D-3 Z-1 CD-4 73TCA006101D 9 RC-/FC-1 HC01CE M- Z-1 CD-6 73TCA006111D 91 RC-/FC-1 HC01CE D-4 Z-1 CD-7 73TCA00611D 91 RC-/FC-1 HC01CE D-4 Z-1 CD-7 73TCA008101D 99 RC-3 HC43CE T-1 Z-1 CD-8 73TCA008101P 99 RC-4 HC33CE T-1 Z-1 CD-9 73TCA010101D 98 RC-4 HC33CE T- Z-1 CD-10 LEGEND AHAM Association of Home Appliance Manufacturers ANSI American National Standards Institute DOE Department of Energy EER Energy Efficiency Ratio FLA Full Load Amps PF Power Factor t Entering wet-bulb temperature minus leaving wet-bulb temperature based on 67 F room wet-bulb temperature and 95 F dry-bulb outside-air temperature. If conditions vary, wet-bulb t will vary. *Based on AHAM Standard RAC-1 and ANSI Z

4 Table 3 Capillary Data KEY NUMBER (See Table ) DIMENSIONS (in.) LENGTH DIMENSIONS (in.) ID NO. OF CAPILLARIES CD CD CD CD CD CD CD CD CD CD Table 4 Thermistor KEY NO. CARRIER RESISTANCE (See Table ) P/N (Ohms) Z-1 HC95XX006 5 Table 5 Capacitors KEY NO. (See Table ) CARRIER P/N MFD VOLTS FC-1 HC91PD RC-1 HC91EA RC- HC91EA RC-3 HC93CA RC-4 HC93CA LEGEND MFD Microfarad Table 6 Casing Dimensions (in.) KEY NO. (See Table ) HEIGHT WIDTH DEPTH S S Table 8 Receptacles, Fuse Types, Wire Sizes UNIT NAMEPLATE VOLTAGE 115 MAXIMUM NAMEPLATE AMPS 1 16 OUTLET RATED VOLTS/ AMPS 15/15 15/0 RECEPTACLE CONFIGURATION MFR PART NO. Hubbell P&S GE GE561-1 GE410-1 Arrow-Hart TIME-DELAY FUSE OR CIRCUIT BREAKER SIZE (AMPS) 15 0* FUSE TYPE Plug RECOMMENDED AWG WIRE SIZE 14 1 AWG American Wire Gage *May be used for 15-amp applications if fused for 15-amp. Based on copper wire at 60 C temperature rating. KEY NO. (See Table ) Table 7 Compressors REPLACEMENT PART NO. VOLTS (Single-Phase, 60 Hz) LRA FLA D-1 P D- P D-3 P HE D-4 P M-1 P M- P T-1 P T- P LEGEND FLA Full Load Amps LRA Locked Rotor Amps 4

5 OPEN LOW TEMPERATURE OPEN ENERGY SAVER DISASSEMBLY INFORMATION 6 8 ER Before working on any air conditioner, be sure to first disconnect all electric power to unit to avoid the possibility of electrical shock and personal injury MED LOW MODE OFF FAN ON IMPORTANT: It is not necessary to totally disassemble all sections of this air conditioner for every servicing operation. Some of the disassembly steps may be necessary for your particular need. Disassemble as needed. Filter Removal 1. Grasp molded top edge of filter and pull filter straight up and out of unit. See Fig... Vacuum filter, or wash filter in lukewarm water. Remove excess water and let filter dry before replacing. 3. Replace filter by sliding filter straight down into filter slot. PULL FILTER STRAIGHT UP PULL GRILLE TOWARD YOU, THEN UPWARD Fig. 3 Removing Front Grille 3. Remove screw and set aside for later assembly. 4. Carefully lift discharge air deck upward and slide deck to the left. See Fig Replace discharge air deck by reversing the above procedure. 4 6 EXHAUST TEMPERATURE 8 ER 10 ENERGY SAVER MODE OFF ON LIFT DECK, SLIDE IT TO LEFT SCREWS 1 HIGH FAN 14 MED Fig. Removing Filter Front Grille Removal 1. Ensure unit carry-handle is fully extended. This will avoid obstruction when removing front grille (applies to Siesta I 005 and 006 units only).. Grasp front grille with both hands at lower sides of front grille. See Fig Pull front grille straight toward you. 4. Tilt front grille slightly upward, lifting front grille off unit. 5. To replace front grille, carry handle must be fully extended (applies to Siesta I 005 and 006 units only). 6. Place front grille onto unit top edge, rotate front grille downward and firmly push bottom of front grille into position. Discharge Air Deck Removal 1. Remove control knobs by pulling knobs straight up. (Set knobs aside for later replacement.). Locate single screw in temperature (thermostat) knob cavity. Fig. 4 Air Discharge Deck Removal Accessing Control Box Components 1. Remove screw (located between evaporator coil and control box) holding control box. NOTE: If unit is 008P unit, proceed to step no.. If unit is not 008P unit, proceed to step no. 3.. Carefully unsnap exhaust door lever plastic retainer and put aside for assembly. See Fig Swing control box to right to gain access to components. See Fig Lift control box sheet metal hooks from retaining slots to complete removal. See Fig Replace control box by reversing above procedure. 5

6 4 EXHAUST TEMPERATURE 6 10 OPEN 1 ENERGY SAVER MODE ON FAN RETAINER EXHAUST LEVER. Remove metal clip which connects bulb heater to thermostat sensing bulb. See Fig Carefully disconnect wires from thermostat terminals. Label wires to aid in reassembly. 4. Reverse above procedure for reassembly. Thermostat Bulb Heater Removal (008P Unit Only) Use care not to damage sensing bulb or capillary of thermostats when handling bulb heater. See Fig Carefully disconnect bulb heater wires from terminals inside the control box. Label wires to aid in reassembly.. Carefully remove metal clip which connects bulb heater to thermostat sensing bulb. See Fig Carefully remove bulb heater wires from braided sleeve. See Fig Reverse above procedure for reassembly. Fig. 5 Removing Exhaust Door Retainer METAL CLIP CONNECTS BULB HEATER TO THERMOSTAT SENSING BULB THERMOSTAT BULB HEATER BRAIDED SLEEVE RETAINING SLOTS CONTROL BOX HOOK () ER 14 HIGH MED LOW Fig. 7 Removing Thermostat CAPACITOR Fig. 6 Accessing Control Box CAPACITOR STRAP SWING CONTROL BOX GENTLY TO RIGHT TO GAIN ACCESS Capacitor Removal 1. Before disconnecting, discharge capacitor by shorting capacitor across terminals.. Remove screw fastening capacitor strap to control box. See Fig Carefully disconnect wires from capacitor terminals. Label wires to aid in reassembly. 4. Reverse above procedure for reassembly. Thermostat Removal Indoor thermostat is a vaporfilled device. The 008P unit employs a thermostat bulb heater. Use care not to bend or kink the thermostat sensing bulb or capillary. 1. Remove screws securing thermostat to control box. See Fig. 4. NOTE: If unit is 008P unit, proceed to step no.. If unit is 008P unit, proceed to step no Mode Selector Switch Removal 1. Remove screws holding selector switch to the control box. See Fig. 8.. Carefully disconnect wires from switch terminals. Label wires to aid in reassembly. 3. Reverse above procedure for reassembly. Fan Cycle Switch (Energy Saver Switch) Removal (008P Unit Only) 1. Disconnect wires from switch. Label wire to aid in reassembly.. Remove screws securing fan cycle switch and remove switch. See Fig Reverse above procedure for reassembly. Wing Panel(s) Removal NOTE: When wing panel(s) are being removed, the upper and lower frame parts will separate slightly from the curtain. Hold the upper and lower frame parts securely in place while performing steps no. 1 and. See Fig Pull wing panel open to its fully opening width. Wing panel frame will be completely out of unit tracks. See Fig. 8.. Carefully bend panel back slightly, and gently slide panel upward and off unit side. See Fig To replace wing panel, compress curtain in frame. Insert ends of top and bottom frame parts as far as possible into unit side. See Fig. 9.

7 MOTOR COMPRESSOR THERMALLY PROTECTED MADE IN MEXICO TIME DELAY FUSE OR CIRCUIT BREAKER DESIGN PLUG HI 350 LG 150 VOLT RANGE VOLTS PH MODEL/CATALOG SERVICE DISCRETE DATE OF MFG. SERIAL USE AMP HZ STU/NR AMPS WATTS/INPUT EER R--OZ. LISTED ROOM AIR CONDITIONER GL16 S1TH50015 Syracuse, New York Carrier Corporation CAUTION ATTENTION SELECTOR SWITCH SCREWS () WING PANEL CURTAIN COMPRESSED IN FRAME EXERT SLIGHT FORCE TO SECURE PANEL FRAME FAN CYCLE SWITCH (008P MODEL ONLY) SLIDE PANEL FRAME OUT OF UNIT TRACKS, THEN LIFT UPWARD FAN CYCLE SCREWS () Fig. 8 Removing Wing Panel 3. Remove unit rear outdoor grille. 4. Remove ground screw in control box section. See Fig Remove compressor terminal cover. See Fig Disconnect 3 compressor wire quick-connects. Label wires to aid in reassembly. 7. Carefully bend evaporator coil assembly tubing outward and away from indoor blower wheel to allow for removal of air-handling system. See Fig. 1 for major sections separated. 8. Carefully remove air-handling system by gently pulling straight up. See Fig Reverse above procedure to replace components after servicing. Exhaust Feature (008P Unit Only) See Fig. 5 and 14 for any servicing and/or adjustment pictorial description. Fan Motor Removal OUTDOOR FAN 1. Remove center nut securing outdoor fan to fan motor shaft. See Fig Remove outdoor fan. 3. Disconnect outdoor fan motor wiring. Label wires to aid in reassembly. 4. Remove 3 screws securing fan motor to unit partition. See Fig Remove fan motor. INDOOR BLOWER WHEEL 1. Remove clip securing blower wheel to fan motor shaft. See Fig. 1.. Reverse above procedures to replace components. TOP REAR COVER FILE LR334 Fig. 9 Replacing Wing Panel 4. When curtain frame will not slide inward any further, use hand to bump frame inward toward unit. The force of your hand will secure the curtain in position against the side of the unit. See Fig. 9. Accessing Compressor, Fan Motor, Outdoor Coil Sections 1. Remove 3 screws on each side of unit (save screws). See Fig Remove top rear cover. See Fig. 10. Fig. 10 Removing Rear Cover REAR SCREWS (6) 7

8 COMPRESSOR TERMINAL COVER Fig. 13 Removing Air Handling System FAN MOTOR FAN MOTOR SECURING SCREWS (3) EXHAUST DOOR LINKAGE GROUND SCREW GROUND WIRE Fig. 11 Accessing Compressor BLOWER WHEEL CLIP EVAPORATOR COIL ASSEMBLY OUTDOOR FAN CENTER NUT OUTDOOR FAN Fig. 14 Fan Motor Removal EXHAUST DOOR INDOOR BLOWER WHEEL Fig. 1 Accessing Air-Handling System 8

9 SERVICE POINTS (Check Annually) 1. Clean indoor and outdoor coils. Indoor Coil Use a hooked wire or bristle brush to remove dirt from fins. Outdoor Coil Use compressed air or a vacuum cleaner.. Clean basepan and other painted surfaces. 3. Clean all drain passages. 4. Clean motor and fans. 5. Vacuum clean the insulation. 6. Paint parts that show evidence of rust with a good rustresistance paint. 7. Check refrigerant connections for evidence of leakage. Repair if necessary. 8. Check wires for deterioration. 9. Fans should be tight on motor shaft. 10. Run the unit and eliminate any piping vibration. 11. Check thermostat capillaries for proximity to refrigerant tubing (should not be touching). Check to be sure protective sleeve is in place. 9

10 TROUBLESHOOTING SYMPTOM AND PROBABLE REMEDY PROBABLE CAUSE COMPRESSOR DOES NOT RUN Opening in Power Circuit 1. Control off 1. Reset control button.. Blown fuse. Replace fuse. 3. Defective wiring 3. Replace wiring. 4. Defective service cord 4. Replace service cord. 5. Loose electrical connections 5. Tighten connections. 6. Faulty switches, thermostat, or fan 6. Replace defective component. Compressor Power Supply Open 1. Loose leads at compressor terminals 1. Tighten leads.. Defective motor overload switch. Replace switch. 3. Defective capacitor 3. Replace capacitor. 4. Open compressor windings 4. Replace compressor. 5. Seized compressor 5. Replace compressor. COMPRESSOR RUNS BUT CYCLES Fan Operating Erratically 1. Loose lead at fan motor 1. Tighten lead.. Defective or burned out motor. Repair or replace motor. 3. Outdoor air restricted or recirculating 3. Check for dirty filter, proper clearances around unit remove any obstructions. 4. Overcharge or noncondensables in system 4. Reclaim refrigerant, evacuate and recharge system according to nameplate specifications. 5. Restricted discharge line 5. Check for obstruction in line; replace tubing if required. 6. Defective motor overload switch 6. Replace switch. 7. Outdoor thermostat capillary touching suction tube 7. Move thermostat capillary away from suction tube. 8. Outdoor coil freezing up due to low temperature 8. Set outdoor thermostat higher. (outdoor thermostat may be set too low) Cycles on Compressor Overload 1. Defective run capacitor 1. Replace capacitor.. Defective compressor bearings or valves. Replace compressor. 3. Greatly restricted indoor air (iced indoor coil) 3. Defrost indoor coil 4. Low refrigerant charge 4. Add charge according to approved method. 5. Indoor capilliary restricted 5. Replace capillary. 6. Liquid line restricted 6. Replace strainer. 7. Compressor hot 7. Verify refrigerant charge. 8. Weak or inconsistent line power 8. Check line voltage at time of compressor start-up. INSUFFICIENT ING Cooling Air Not Adequate 1. Dirty filter or coil 1. Clean as required.. Iced indoor coil (slightly low refrigerant charge). Recharge. 3. Defective fan motor 3. Replace fan motor. Condenser Air Not Adequate 1. Outside air restricted 1. Check for obstructions and dirty filter. Remedy as required.. Dirty coil. Clean coil. 3. Defective fan motor 3. Replace fan motor. Unit Undersized Re-evaluate unit for proper capacity. Capilliary Restricted Replace capillary. Compressor Flooding 1. Unit overcharged 1. Reclaim refrigerant, evacuate and recharge system according to nameplate specifications.. Defective electrical connections. Check connections per wiring diagrams. 10

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12 Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 PC 131 Catalog No Printed in U.S.A. Form 73TC-1SS Pg Replaces: New Tab 8a 10a