Carrier 53KLE User manual

2005
SERVICE & MAINTENANCE MANUAL

1
TABLE OF CONTENTS
PAGE NO.
1. Precautions for Service & Maintenance 2
2. Split System Description 3
3. Unit Model Designation & Identification 4
4. Unit Models & Part Numbers 4
5. System Operating Limits 5
6. System Safety Protections 5
7. Exploded View of Indoor Unit 6
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

2
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.
!

3
2. SPLIT SYSTEM DESCRIPTION
(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.
(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
(
f
) REFRIGERANT PIPING LINES
Insulated copper piping through which the
refrigerant R22 flow connects the indoor and
outdoor units.
(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
(e) WIRELESS REMOTE CONTROL (LCD)
Controls power, mode, fan speed, temperature,
and timer, swing and sleep functions.
(b) OUTDOOR UNIT
• Mounted outside the space to be air-conditioned.
• It contains compressor, fan, motor, condenser coil
,
copper tubing and electrical components.

4
3. UNIT MODEL DESIGNATION & IDENTIFICATION
UNIT MODEL DESIGNATION IDENTIFICATION (ID)
4. UNIT MODELS & PART NUMBERS
INDOOR UNIT
HEATPUMP COOLONLY
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
HEATPUMP COOLONLY
Unit
Model P/N ID Unit Model P/N ID
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
42
38
H
E
C
42 = Indoor Unit
38 = Outdoor Unit
28
Compressor
Cooling Capacity
in MBTU/HR
at ASHARE
Conditions
Unit Type
H= Heat Pump
E= Cool/Electric Heat
C= Cool Only
KLE
Unit Family

5
5. SYSTEM OPERATING LIMITS
COOLING HEATING
Difference Dry Bulb
Temp. C°
Wet Bulb
Temp. C° Difference Dry Bulb
Temp. C°
Wet Bulb
Temp. C°
Indoor temperature
Maximum
Minimum
32
21
23
15
Indoor temperature
Maximum 27 -
Outdoor temperature
Maximum
Minimum
55
21
-
-
Outdoor temperature
Maximum 21 -
MAIN POWER SUPPLY
Nominal
Power Supply
V/1PH/50HZ
Minimum
Voltage
Maximum
Voltage
200-240 180 264
* 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.
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 Compressor off Cooling mode During unit operation
Against frequent
Compressor cycling
Compressor
Time delay
Cooling or heating
modes
At unit start-up or change
of operating mode
6-2 FOR COOL ONLY SYSTEM
PROTECTION TYPE PROTECTION EFFECT OPERATION MODE WHEN ON
Indoor coil
Freeze protection Compressor off Cooling mode During unit operation
Against frequent
Compressor cycling
Compressor
Time delay Cooling mode At unit start-up or change of operating mode
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.

6
7. EXPLODED VIEW OF INDOOR UNIT
12/4
5/6
4
8
6
9
7
7
2
3/9
3/1
3/8
3/7
3/2
11 10
5/1
5/2
5/3 5/4
5/5
3/4 3/3
3/5
3/6
12/5
1
1/1
1/5
1/4
1/6
1/4
1/5
1/3
1/8
&
1/2
1/7
12/1
12/3
12/2
12
Pour 42KLE39

7
8. PART LIST OF INDOOR UNIT
QTY./UNIT
42KLE-H 42KLE-E 42KLE-C
SR. DESCRIPTION PART
NUMBER 14 22 28 32 39 14 22 28 32 39
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

8
PART LIST OF INDOOR UNIT (Cont.)
QTY./UNIT
42KLE-H 42KLE-E 42KLE-C
SR. DESCRIPTION PART
NUMBER 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
(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

9
EXPLODE VIEW AND PARTS LISTOF INDOOR UNIT (Cont.)
(A) EXPLODED VIEW
4 & 6
13
18.3
10
18.2
18.1
14
3
1
4
6
5
SEE DETAILS
DETAILS
9
10
8
2

10
EXPLODE VIEW AND PARTS LISTOF INDOOR UNIT (Cont.)
(B) PART LIST
QTY./UNIT
42KLE-H 42KLE-E 42KLE-C
SR. DESCRIPTION PART
NUMBER 14 22 28 32 39 14 22 28 32 39
1 Cabinet Front Subassy 363-13312 1 1 1 1
363-13313 1 1 1 1
363-13314 1 1
2 Cabinet Side RH 028-02305 1 1 1 1 1 1 1 1 1 1
3 Holder Support 028-02321 1 1 1 1 1 1 1 1 1 1
4 Display & Receiver PCB 025-01561 1 1 1 1 1 1 1 1 1 1
5 Cable Main PCB – Led PCB 025-01563 1 1 1 1 1 1 1 1 1 1
6 Receiver Cover 028-02323 1 1 1 1 1 1 1 1 1 1
7 Half Moon Nameplate 029-00108 1 1 1 1 1 1 1 1 1 1
8 Step Motor MP35EAM 024-00167 1 1 1 1 1 1 1 1 1 1
9 Motor Support 028-02314 1 1 1 1 1 1 1 1 1 1
10 Gear 028-02315 1 1 1 1 1 1 1 1 1 1
11 Spacer For Step Motor 063-01839 1 1 1 1 1 1 1 1 1 1
12 Support RH – Flap 028-02311 1 1 1 1 1 1 1 1 1 1
13 Carrier Logo 035-00092 1 1 1 1 1 1 1 1 1 1
14 Cabinet Side LH 028-02304 1 1 1 1 1 1 1 1 1 1
15 Holder Support 028-02321 1 1 1 1 1 1 1 1 1 1
16 Support LH – Flap 028-02309 1 1 1 1 1 1 1 1 1 1
17 Bearing LH – Flap 028-02316 1 1 1 1 1 1 1 1 1 1
18 Flap Subassy 363-11309 1 1 1 1
363-11310 1 1 1 1
363-11311 1 1
18.1 Flap 028-02306 1 1 1 1
028-02307 1 1 1 1
028-02308 1 1
18.2 Blade 028-02312 12 12 16 16 20 12 12 16 16 20
18.3 Blade Bar 028-02313 3 3 4 4 5 3 3 4 4 5

11
9. EXPLODED VIEW OF OUTDOOR UNIT
20 20
21
18
5
2
9
8
6
10
12
13
7
1
14
16
15
4
3
11
17
19/4
19/5
19/2
19/3
19/3
19/1
19/8

12
10. PART LIST OF OUTDOOR UNIT
QTY./UNIT
38KLE-H 38KLE-C
SR. DESCRIPTION PART
NUMBER 14 22 28 32 14 22 28 32 39
1 COMPRESSOR C/W GROMMETS & SPACERS
1.1 Mitsushita Comp. 2KS206DSBB04 01500235 1 1
1.2 Mitsushita Comp. 2JS324D3AB07 01500240 1 1
1.3 Mitsushita Comp. 2JS438D3FE02 01500241 1 1
1.4 Copeland Comp. CR37KQ-PFT 01500256 1 1
1.5 Copeland Comp. CR47KQ-PFZ 01500172 1
2 COND. BASE 08107402 1 1 1 1 1 1 1 1 1
3 SUPPORTING LEG ASSY 36314043 4 4 4 4 4 4 4 4 4
4 COND. PARTITION 06307407 1 1 1 1 1 1 1 1
06307436 1
5 CONDENSER COIL SUBASSY.
5.1 Cond. Coil 1 Row – 33.46” x 22” - 12FPI 02600227 1 1
5.2 Cond. Coil 1 Row – 33.46” x 22” - 15FPI 02600228 1 1
5.3 Cond. Coil 2 Row – 33.15” x 22” - 14FPI 02600229 1 1
5.4 Cond. Coil 2 Row – 33.15” x 22” - 15FPI 02600234 1 1
5.5 Cond. Coil 2 Row – 33.15” x 28” - 15FPI 02600231 1
6 CONDENSER MOTOR SUPPORT SUBASSY. 36318880 1 1 1 1 1 1 1 1 1
7 CONDENSER MOTOR
7.1 Motor 1/10 HP-880 RPM 02400154 1 1 1 1 1 1 1 1
7.2 Motor 1/5 HP-860 RPM 02400179 1
8 PROPELLER C/W SOCKET SCREW 8X8MM 02600441 1 1 1 1 1 1 1 1 1
9 ORIFICE PROPELLER 02803112 1 1 1 1 1 1 1 1 1
10 COND. SHROUD 08107406 1 1 1 1 1 1 1 1
06307435 1
21 CARRIER LOGO 02900615 1 1 1 1 1 1 1 1 1
12 HANDLE 02803110 1 1 1 1 1 1 1 1 1
13 GUARD PROPELLER 02803113 1 1 1 1 1 1 1 1 1
14 COND. BACK PANEL 06307409 1 1 1 1 1 1 1 1
06307434 1
15 COUPLING PANEL 06307410 1 1 1 1 1 1 1 1 1
16 SERVICE DOOR 02803106 1 1 1 1 1 1 1 1 1
17 COIL GUARD 02803114 1 1 1 1 1 1 1 1
02803115 1
18 COND. COVER 08107400 1 1 1 1 1 1 1 1 1

13
PART LIST OF OUTDOOR UNIT (Cont.)
QTY./UNIT
38KLE-H 38KLE-C
SR. DESCRIPTION PART NUMBER
14 22 28 32 14 22 28 32 39
19 ELECTRICAL BOX SUBASSY 36314064 1
36314019 1
36314020 1
36314045 1
36313908 1
36313904 1
36314021 1
36314022 1
36313907 1
19.1 DUAL CAPACITOR
19.1.1 Dual Capacitor 35 + 5 MFD/370 VAC 02400376 1 1
19.1.2 Dual Capacitor 45 + 5 MFD/370 VAC * 02400644 1 1
19.1.3 Dual Capacitor 50 + 5 MFD/440 VAC 02400379 1 1 1 1
19.1.4 Dual Capacitor 60 + 5 MFD/440 VAC 02400377 1
19.2 CONTACTOR FOR COMPRESSOR
19.2.1 Contactor 2 poles – 25 Amps 02400580 1 1 1 1 1 1 1 1
19.2.2 Contactor 2 poles – 30 Amps 02400572 1
19.3 TERMINAL BLOCKS
19.3.1 Terminal Block 6 Poles-30 Amps 02501433 1 1 1 1
19.3.2 Terminal Block 4 Poles-30 Amps 02501405 1 1 1 1 1
19.3.3 Terminal Block 3 Poles-30 Amps 02501315 1 1 1 1 1 1 1 1 1
19.4 COND. ELECTRICAL BOX 06307405 1 1 1 1 1 1 1 1 1
19.5 CAPACITOR CLAMP 06301283 1 1 1 1 1 1 1 1 1
19.6 SUPPORT - CABLES 02802523 1 1 1 1 1 1 1 1 1
19.7 ELECTRICAL WIRE HARNESS 02500886 1 1
02500887 1 1 1 1
02500888 1 1
02500873 1
19.8 STARTER FOR COMPRESSOR
19.8.1 PTC Starter Model SPP POW-R-PAK * 02501579 1 1
19.8.2 PTC Starter Model SPP5 02501578 1
20 REVERSING VALVE & ELECTRIC COIL
02200405 1 1 1
02200404 1
21 ACCUMULATOR 02301012 1
22 SENSOR – OUTDOOR COIL 02503121 1 1 1 1
23 TUBING
36319212 1
36319215 1
36319216 1
36319217 1
36319218 1
36319219 1
36319220 1
36319223 1
36319224 1
36319225 1
* Option for sizes 14,22 and 28

14
INDOOR UNIT 42KLE-H SERIES HEAT PUMP
WIRING DIAGRAM
INDOOR UNIT 42KLE-C SERIES COOL ONLY
WIRING DIAGRAM
11. WIRING DIAGRAM

15
INDOOR UNIT 42KLE39-E COOL/ELECTRIC HEAT
WIRING DIAGRAM
WIRING DIAGRAM (CONT.)

16
OUTDOOR UNIT 38KLE-H SERIES HEAT PUMP
WIRING DIAGRAM
OUTDOOR UNIT 38KLE-C SERIES COOL ONLY
WIRING DIAGRAM
WIRING DIAGRAM (CONT.)

17
12. FIELD ELECTRICAL CONNECTIONS MATCHING
HEAT PUMP SYSTEM COOL ONLY SYSTEM
LEGEND
Note: The mains supply must be connected to the outdoor unit.
Earth
LLive power supply.
NNeutral power supply.
RLive connection indoor/outdoor unit.
CNeutral connection indoor/outdoor unit.
YCompressor control.
O Reversing Valve Control (Only for heat pump system).
W2 Outdoor Unit Motor Control (Only for heat pump system).
S1 Outdoor Coil Sensor (Only for heat pump system).
S2 Outdoor Coil Sensor (Only for heat pump system).
➊Outdoor Unit
➋Indoor Unit
➌Main Switch
➍Time-delay fuse or circuit breaker
200-240V ~ 50Hz 200-240V ~ 50Hz

18
13. REFRIGERATION CYCLE
HEAT PUMP SYSTEM

19
REFRIGERATION CYCLE (Cont.)
COOL ONLY SYSTEM