Carrier 52S Series Service Technician Manual
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Carrier 52S Series Service Technician Manual

Packaged terminal air conditioners and heat pumps
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SERVICE TECHNICIAN GUIDE
PACKAGED TERMINAL AIR CONDITIONERS
CONTENTS
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UNITS EQUIPPED WITH THE LATERIAL DUCT
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ACCESSORY PACKAGE
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52S
SERIES
AND HEAT PUMPS
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PTAC Customer Support Center
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  • Page 1: Table Of Contents

    SERVICE TECHNICIAN GUIDE PACKAGED TERMINAL AIR CONDITIONERS AND HEAT PUMPS CONTENTS ....... . . INTRODUCTION SUMMARY OF DANGERS, WARNINGS, AND CAUTIONS .

  • Page 2: Introduction

    Even units that seem similar may have subtle differences that could affect service procedures. The 52S units covered in this book are the 52SC (Cooling Only model); the 52SE (Cooling with Electric Heat model); and the 52SQ (Cooling, Elec- tric Heat, and Heat Pump model).
  • Page 3 FIGURE 2 — MODEL NUMBER NOMENCLATURE FIGURE 3 — SAMPLE DATA INFORMATION PLATE...

  • Page 4: General Disassembly

    SERIES GENERAL DISASSEMBLY 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.

  • Page 5: To Remove The Lateral Duct Extension, For

    TO REMOVE THE LATERAL DUCT EXTENSION, FOR UNITS EQUIPPED WITH THE LATERAL DUCT ACCESSORY PACKAGE Remove the front panel as shown in Figure 1. Remove the four 1 ⁄ -in. screws that secure the chassis to the wall sleeve (see Figure 6). There are 2 screws on each side.

  • Page 6: To Access Indoor-Air Section Components

    SERIES TO ACCESS INDOOR-AIR SECTION COMPONENTS DISASSEMBLING THE LATERAL DUCT ADAPTER, FOR UNITS EQUIPPED WITH THE LATERAL DUCT ACCESSORY PACKAGE Remove the lateral duct adapter end cap, shown in Figure 10, by removing the two Remove the adapter top panel by removing one screw at each end of unit as shown in Figure 11.
  • Page 7 TO REMOVE THE AIR DISCHARGE GRILLE Remove the 2 screws on each end of the air discharge grille as shown in Figure 14. Lift and rotate back the bottom edge of the discharge grille and remove it. TO REMOVE THE ALUMINUM TOP PANEL —...

  • Page 8: To Access Outdoor-Air Section Components

    SERIES TO REMOVE THE DISCHARGE DECK 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. 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.
  • Page 9 TO REMOVE THE STATOR — 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. FIGURE 20 — REMOVING STATOR STATOR CONDENSER ORIFICE...

  • Page 10: General Cleaning

    • The floor around the work area should be clean and free of debris. • The 52S 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.

  • Page 11: Tools Needed

    TOOLS NEEDED The following list includes the recommended tools, de- vices, and cleaning solutions for use in cleaning the 52S unit components. Vacuum Cleaner with Crevice Tool Attachment, or Soft Plastic Bristle Brush Mild Household Detergent Phillips Head Screwdriver ⁄...
  • Page 12 As-needed cleaning of the unit’s exterior surfaces (Figure 24) optimizes the unit’s appearance and removes particles that may enter the air system. The 52S units are built to resist corrosion. The indoor front panel and wall sleeve are created from non-metallic compounds that do not rust.

  • Page 13: Seasonal Cleaning

    SEASONAL CLEANING ACCESSING THE INDOOR AND OUTDOOR COILS — The minimum cleaning recommendation for indoor and outdoor coils is once per season. To access the coils for a thorough cleaning, it is necessary to remove the Air System. To accomplish this task, per- form the following steps: DISCONNECT ALL POWER TO UNIT! Remove the unit chassis from the sleeve as described...
  • Page 14 SERIES CLEANING THE INDOOR AND OUTDOOR COILS Coil fins are sharp and may cut hands. Wear heavy protective gloves when cleaning coils. Use a vacuum cleaner or soft bristle brush to remove surface fibers and dirt from each of the faces of the coil.
  • Page 15 CLEANING THE INDOOR FAN AND FAN SCROLL — Once the indoor fan wheel and the indoor fan scroll have been accessed, proceed with the cleaning instructions detailed below: 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.

  • Page 16: Compressor

    SERIES 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.

  • Page 17: Compressor Troubleshooting

    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.
  • Page 18 SERIES SYMPTOM 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...

  • Page 19: Compressor Replacement

    2 Parker Access Valves (Part No. AVUSE-5) Pinch Off Tool Filter Drier for 52SQ Units (Part No. Sporlan C-164S) Filter Drier for 52SC or SE Units (Part No. KH43LG060) Carrier TOTALTEST Kit (Part No. TT1-001) Totalclaim System Charging Cylinder or an Electronic Scale Refrigerant-22...
  • Page 20 Attach the piercing valve to the suction side pro- cess tube below the crimps. Attach Carrier TOTALTEST kit (Part No. TT1-001), to the pierc- ing valve to verify acidity of the system. After...
  • Page 21 Carrier RCD), into the unit. Leak check the unit with 150 psi of nitrogen pressure. For 52S units, the system should be evacuated from the high side to the low side to a minimum of 200 microns of mercury. This evacuation removes residual moisture from the system prior to charging.

  • Page 22: Heaters

    SERIES 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.

  • Page 23: Heaters

    Remove the unit from the sleeve as detailed in the GENERAL DISASSEMBLY section. Remove the discharge air grille and the discharge air deck as detailed in the GENERAL DISASSEMBLY section. Save screws. Once the air discharge deck is removed, the heater assembly is exposed.

  • Page 24: Operating Controls

    There are 2 styles of ther- mostats qualified for use with 52S series Remote Con- trol units. See Figures 46 and 47. For all other 52S units, room controls are located on the unit or unit control panel.

  • Page 25: Description Of Switch Settings

    15 to 30 minutes. If room is not comfortable, turn knob one number setting at a time. When room is comfortable, keep control knob at that position. A. 52S COOLING ONLY UNIT B. 52S COOLING/HEATING UNIT C. 52S COOLING/HEATING UNIT WITH REMOTE CONTROL (BLANK PLATE) FIGURE 48 —...

  • Page 26: Sequence Of Operation

    SERIES SEQUENCE OF OPERATION HEAT/COOL UNITS (Figure 50) Fan Mode — With the selector switch set to FAN 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.

  • Page 27: Component Operation And Troubleshooting

    • Make sure tools are the correct tools for job, and that they are working properly and in good condition. • The 52S unit may weigh up to 150 pounds. Use a lift- ing device or ask for assistance if the unit must be moved.
  • Page 28 SERIES INDOOR THERMOSTAT (Heat Pump Units) (cont) (Figure 54) — To verify operation of the heat pump in- door thermostat switch, a continuity test may be per- formed as follows: Turn off unit power as described in GENERAL DISASSEMBLY section. Remove wire leads from thermostat.
  • Page 29 CAPACITOR — 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 affect the motor opera- tion.

  • Page 30: Electrical Components Removal And Replacement

    SERIES ELECTRICAL COMPONENTS REMOVAL AND REPLACEMENT INDOOR THERMOSTAT — To remove the indoor thermostat, perform the following steps: Turn off unit power as described in GENERAL DISASSEMBLY section. Remove the thermostat knob. Remove control box escutcheon (Figure 58) to expose 2 Phillips head mounting screws.
  • Page 31 CAPACITOR — To remove the capacitor, perform the following steps: Turn off unit power as described in GENERAL DISASSEMBLY section. Open the control box (Figure 61) as detailed in the GENERAL DISASSEMBLY section of this manual. Properly discharge the capacitor as described in the Capacitor section under Component Operation and Troubleshooting.

  • Page 32: Fan Motor

    • Make sure tools are the correct tools for the job, and that they are working properly and in good condition. • The 52S unit may weigh up to 150 pounds. Use a lift- ing device or ask for assistance if the unit must be moved.
  • Page 33 208/230 208/230 ⁄ ⁄ N.A. TYPICAL 265 VOLT MOTORS HC29CE273 HC33CE267 5KCP39BGR199S ⁄ ⁄ N.A. FIGURE 64 — TYPICAL 52S FAN MOTORS STARTS BUT STARTS RUNS ON STOPS AFTER BUT RUNS ONE SPEED, SHORT TIME SLOW NOT ON OTHERS HC35CE234...

  • Page 34: Fan Motor Replacement

    SERIES FAN MOTOR REPLACEMENT Perform the following steps to remove and reinstall the fan motor: DISCONNECT ALL POWER TO UNIT. Remove the unit from the sleeve as detailed in the GENERAL DISASSEMBLY section and place the unit on a large flat surface. Remove the discharge air grille, the aluminum top panel, the top cover, and the discharge air deck as detailed in the GENERAL DISASSEMBLY sec-...

  • Page 35: Field Temperature Charts

    FIGURE 67 — 52S 7,000 BTU UNIT FIELD TEMPERATURE CHART — LOW COOL — 50% RH...
  • Page 36 FIGURE 68 — 52S 7,000 BTU UNIT FIELD TEMPERATURE CHART — HIGH COOL — 50% RH...
  • Page 37 FIGURE 69 — 52S 7,000 BTU UNIT FIELD TEMPERATURE CHART, LOW HEAT MODE (47 F OUTDOOR TEMPERATURE)
  • Page 38 FIGURE 70 — 52S 7,000 BTU UNIT FIELD TEMPERATURE CHART, HIGH HEAT MODE (47 F OUTDOOR TEMPERATURE)
  • Page 39 FIGURE 71 — 52S 9,000 BTU UNIT FIELD TEMPERATURE CHART — LOW COOL — 50% RH...
  • Page 40 FIGURE 72 — 52S 9,000 BTU UNIT FIELD TEMPERATURE CHART — HIGH COOL — 50% RH...
  • Page 41 FIGURE 73 — 52S 9,000 BTU UNIT FIELD TEMPERATURE CHART, LOW HEAT MODE (47 F OUTDOOR TEMPERATURE)
  • Page 42 FIGURE 74 — 52S 9,000 BTU UNIT FIELD TEMPERATURE CHART, HIGH HEAT MODE (47 F OUTDOOR TEMPERATURE)
  • Page 43 FIGURE 75 — 52S 12,000 BTU UNIT FIELD TEMPERATURE CHART — LOW COOL — 50% RH...
  • Page 44 FIGURE 76 — 52S 12,000 BTU UNIT FIELD TEMPERATURE CHART — HIGH COOL — 50% RH...
  • Page 45 FIGURE 77 — 52S 12,000 BTU UNIT FIELD TEMPERATURE CHART, LOW HEAT MODE (47 F OUTDOOR TEMPERATURE)
  • Page 46 FIGURE 78 — 52S 12,000 BTU UNIT FIELD TEMPERATURE CHART, HIGH HEAT MODE (47 F OUTDOOR TEMPERATURE)
  • Page 47 FIGURE 79 — 52S 14,000 BTU UNIT FIELD TEMPERATURE CHART — LOW COOL — 50% RH...
  • Page 48 FIGURE 80 — 52S 14,000 BTU UNIT FIELD TEMPERATURE CHART — HIGH COOL — 50% RH...
  • Page 49 FIGURE 81 — 52S 14,000 BTU UNIT FIELD TEMPERATURE CHART, LOW HEAT MODE (47 F OUTDOOR TEMPERATURE)

  • Page 50: Field Temperature Charts

    FIGURE 82 — 52S 14,000 BTU UNIT FIELD TEMPERATURE CHART, HIGH HEAT MODE (47 F OUTDOOR TEMPERATURE)

  • Page 51: Wiring Schematics

    Refer to Figures 83 - 87 for typical 52S unit wiring schematics. NOTE: Figures 83 - 87 should not be substituted for the schematic LEGEND FCS — Fan Cycle Switch — Indoor Thermostat — Power Supply Line Component Connections (Marked) NOTES: 1.
  • Page 52 SERIES LEGEND — Capacitor COMP — Compressor SW — Selector Switch — Fan Cycle Switch — Fan Motor — Heater — Indoor Thermostat — Power Supply Line — Overload — Plug — Primary Limit Switch — Secondary Limit Switch NOTES: 1.
  • Page 53 — Capacitor COMP — Compressor — Cooling Relay EQUIP GND — Equipment Ground — Fan Motor — Fan Relay — Heating Relay — Indoor Frost Thermostat — Power Supply Line — Overload NOTES: 1. Recommended for use on grounded power supply only. 2.
  • Page 54 SERIES LEGEND — Capacitor COMP — Compressor SW — Switch — Fan Cycle Switch — Fan Motor — Heater — Indoor Thermostat — Power Supply Line — Overload — Plug — Primary Limit Switch — Reversing Valve Solenoid — Secondary Limit Switch NOTES: 1.
  • Page 55 — Capacitor COMP — Compressor — Cooling Relay EQUIP GND — Equipment Ground — Fan Motor — Fan Relay — Heating Relay — Indoor Frost Thermostat — Power Supply Line — Outdoor Frost Thermostat NOTES: 1. Recommended for use on grounded power supply only. 2.

  • Page 56: Most Frequent Ptac Service Questions

    2. Which remote thermostats are acceptable for use on 52S products? 3. How many 52S series units can be controlled by one remote thermostat? 4. What is the vent capacity of the 52S products? 5. How do the 52S series models handle condensate removal? 6.

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