Carrier 60 Service Manual

T--295Bus AirConditioningEquipmentModelsGR--45GR--60(N.A.O.)

1-2T--2951.2 GENERAL DESCRIPTION1.2.1 Apex UnitThe apex unit (see Figure 1-2) includes the condensingsection, evaporator section, Micromax electronics

1-3T--295The receiver collects and stores liquid refrigerant. Thereceiver is fitted with upper and lower liquid level sightglasses to enable determini

1-4T--2951234567891. Evaporator Coil With IntegratedHeating Coil (2)2. Protection Plate3. Expansion Valve4. Evaporator Motor Fastening Clamps(4-GR45,

1-5T--295In the cooling m ode the compressor is energized whilethe evaporator and condenser fans are operated toprovide refrigeration as required. The

1-6T--295Low Pressure Switch (LPS)The l ow pressure switch is installed in t he compressorand opens on a pressure drop to shut down the systemwhen a l

1-7T--295COMPRESSORDISCHARGESUCTIONMAIN ENGINERADIATORDISCHARGELIQUIDSUCTIONAAVIEW A-ARECEIVER12345678910111112131415161617181. Condenser Fan Assembly

1-8T--295COMPRESSORMAIN ENGINERADIATORSUPPLYRETURNHEATVALVEBOOSTPUMPFigure 1-7. Heating Cycle Flow Diagram(GR60 Shown)1.9 HEATING CYCLEHeating circuit

1-9T--2951.10 RELAY BOARD1.10.1 Permanent Magnet Motors with 2 speed switching from series to parallel connection (Option 1)JP2D2 D6CB 4K2CB 3CB 2K1CB

1-10T--295b. Thermal Circuit BreakersCB 1 Evaporator Fan #1. 15 Amp.CB 2 Evaporator Fan #2. 15 Amp.CB 3 Evaporator Fan #3. 15 Amp.CB 4 Evaporator Fan

1-11T--2951.10.2 Electronically Communtated DC Motors with 2--speed Evaporator Input Signal (Option 2)D30D2 D6K2K1D26D17D14EF3CB 4EF4EF HIGH SIGNALEF6

SERVICE MANUALOPERATION ANDModelsGR--45GR--60(N.A.O.)BUSAIR CONDITIONINGUNITCarrier Corporation 2000 D Printed in U. S. A. 0300Carrier Transicold Divi

1-12T--2951.11 LOGIC BOARDJ1 Logic board power in.J2 Display interface.J3 Manual control inputs.J4 Interlock Inputs(WTS, low side pressure switch etc.

1-13T--2951.12 CONTROL PANEL (Diagnostic Module)123 4 5 678910111. Display2. DOWN Button -- decrease selection3. UP Button -- increase selection4. VEN

2-1T--295SECTION 2OPERAT ION2.1 STARTING, STOPPING AND OPERATINGINSTRUCTIONS2.1.1 Power to Logic BoardBefore starting, electrical power must be availa

2-2T--295SETPOINTHEAT MODEVENTHEATAUTO MODE REHEATCOOLHIGH SPEEDLOADEDCOOLHIGH SPEED4 CYLINDERSCOOLLOW SPEED2 CYLINDERSREHEA T 100%DUTY CYCLELOW SPEED

2-3T--2952.3 MODES OF OPERATIONThe system is operated by a Carrier TransicoldMicromax microprocessor controller which consists ofa logic board (Figure

2-4T--295The unloaders are used to control suction pressure andthereby prevent coil frosting:1 C ompressor UnloaderUV1 Relay.When the suctionpressure

2-5T--2952.4.2 ControlNOTE1 This procedure should be performed by anHVAC technician who has been trained onCarrier Model GR system design. Controlconf

2-6T--295Table 2-3. Parameter CodesCODECODE NAME DESCRIPTIONP1 Return AirTemperatureThis value is the temperature measured by the return air sensor. I

2-7T--295Table 2 -3. Parameter Codes -- ContinuedCodeCode Name DescriptionP18 Maximum Setpoint This is the maximum value that the operator will be all

T -2953-1SECTION 3TROUBLESHOOTINGCAUTIONDonotunderanycircumstances attempt toservice themicroprocessor. shoulda problem develop withthe microprocessor

Safety-1T--295SAFETY SUMMARYGENERAL SAFETY NOTICESThe following general safety notices supplement the specific warnings and cautions appearing elsewhe

3-2T--295Table 3 -2 Alarm CodesALARMNO.TITLE CAUSE REMEDY CONTROLLERRESPONSEA11 Coil Freeze Coil temperature isless than 32F and thecompressor is ope

T -2953-3Table 3 -2 Alarm Codes -- ContinuedALARMNOTITLE CAUSE REMEDY CONTROLLERRESPONSEA22 Breaker Trip Alarm A breaker on the relayboard has tripped

3-4T--295Table 3 -3 General System Troubleshooting ProceduresINDICATION/TROUBLEPOSSIBLE CAUSESREFERENCESECTION3.3.1 System Will Not CoolCompressor wil

T -2953-5Table 3 -3 General System Troubleshooting Procedures -- ContinuedINDICATION/TROUBLEPOSSIBLE CAUSESREFERENCESECTION3.3.4 Abnormal Noise Or Vib

T -2954-1SECTION 4SERVICEWARNINGBE SURE TO OBSERVE WARNINGS LISTED IN THE SAFETY SUMMARY IN THE FRONT OFTHIS MANUAL BEFORE PERFORMING MAINTENANCE ON T

T -2954-2SERVICEPORTVALVE CAPVALVESTEMTO DISCHARGE ORFROM SUCTIONLINEPORT TOCOMPRESSORService ValveFrontseated(clockwise)Service ValveBackseated(count

T -2954-3DS161023457891. Filter-Drier I nletService Valve2. ThermostaticExpansion Valve3. Manifold GaugeSet4. Thermistor VacuumGauge5. Vacuum Pump6. R

T -2954-4DS812345671. Suction ServiceValve and Port2. Discharge LineService Port3 Check Valve4. Manifold GaugeSet5. Vacuum Pump6. Reclaimer7. Refriger

T -2954-5g. Remove refrigerant using a refrigerant recovery sys-tem.h. Start vacuum pump and open all valves. Dehydrateunit to 500 microns Hg vacuum.i

T -2954-66123451. Cylinder Valve and Gauge2. Pressure Regulator3. Nitrogen Cylinder4. Pressure Gauge (0 to 400 psig = 0 to 27.22 bar)5. Bleed-Off Valv

i T--295TABLE OF CONTENTSPARAGRAPH NUMBER PageSAFETY SUMMARY Safety-1...DESCRIPTION

T -2954-74.13 EVAPORATOR COIL REPLACEMENTa. If refrigerant remains in the system, perform a lowside pump down to remove refrigerant from the evap-orat

T -2954-84.15 SERVICING THE LIQUID LINE SOLENOIDVALVEThe Liquid line solenoid valve (Figure 4-10) is verysimilar to the heat valve. It requires no mai

T -2954-94.16.2 Inspection And Cleaninga. At regular maintenance periods, remove brush cov-ers, examine and clean motor interior.b. Placemain batteryd

T -2954-10e. Remove capscrews and lift off power head and cageassemblies and gaskets.f. Check, clean and remove any foreign material fromthe valve bod

T -2954-11NOTES1 Service replacement compressors are soldwithout se rvice valves. Valve pads areinstalled in their place. The optionalunloaders are no

T -2954-120.030 inch (0.41 to 0.76 mm). If required, removetheeight armature spacer nuts and spacer. Add or removeshims to adjust gap. Reinstall space

T -2954-13connect or. Pressure should decrease 3 to 5 psi (0.2 to0.4 bar) when the unloader i s unplugged and increasethe same amount as the plug is r

T -2954-14Table 4-2. PressureT ransducer Voltage“/hg Voltage Psig Voltage Psig Voltage20” 0.369 100 1.446 215 2.57310” 0.417 105 1.495 220 2.622Psig V

T -2954-15Table 4-4. R-134a Temperature - Pressure ChartTemperature VacuumF C“/hg cm/hg kg/cm@@@@ bar-- 4 0 -- 4 0 14.6 49.4 37.08 0.49.35 .37 12.3

5-1T--295SECTION 5ELECTRICAL5--1 INTRODUCTIONThis section includes electrical wiring schematics. The schematic shown in this section provides i nforma

iiT--295TABLE OF CONTENTS (Continued)PARAGRAPH NUMBER Page2.3.11 Alarm Description 2-4...2.3.1

5-2T--295FRESH AIR VALVELIQUID LINEWATER TEMPERATURE SWITCHAMBIENT TEMPERATURE SENSORLOGIC POWERON/TESTMOTOR OVERLOADRELAY BOARD INTERFACESENSORDIAGNO

5-3T--295J6DPT(--)(+)(--)SPTGROUND (--)(+)ATSFTSRASC2320213J11924W_ATSW_ATSBA22564321K223COND FAN LOW RELAYCOND FAN HIGH RELAY54K24K23EVAP FAN HIGH RE

5-4T--295D21-- 121 (NOVA)BW_CTRL2F(15A)D69K19D663W_CTRL23JP3JP3FLOOR HEATERS+24VDCBPM +W_COMPUV2UV1A/C FAILD54K18D63K17D51D57K13K15AW_CTRL2JP43JP53CAW

5-5T--295J6DPT(--)(+)(--)SPTGROUND (--)(+)ATSFTSRASC2320213J11924W_ATSW_ATSBA22564321K223COND FAN LOW RELAYCOND FAN HIGH RELAY54K24K23EVAP FAN HIGH RE

5-6T--295EF1CDBW_CTRL2F(15A)D69K19D6633JP3JP3FLOOR HEATERS+24VDCBPM +W_COMPUV2UV1A/C FAILD54K18D63K17D51D57K13K15JP43JP53AW_COMPJP421JP6ACTHFW_COMPK14

Index-1T--295INDEXAAir Filters, 4-9Alarm, 2-4, 3-1Alarm Clear, 3-1Alarm Codes, 3-1Alarm Queue, 3-1Ambient Lockout, 1-6Apex Unit, 1-2BBoost Pump, 2-3CC

Index-2T--295INDEX -- ContinuedPPre--Trip Inspection, 2-1Pressure T ransducer, 1-5, 4-13Pump Down, 4-2, 4-3RRefrigerant Charge, 1-5, 4-2, 4-4, 4-5Refr

iii T--295TABLE OF CONTENTS (Continued)PARAGRAPH NUMBER Page4.8 ADDING REFRIGERANT TO SYSTEM 4-5...4.8.1 Check

ivT--295LIST OF ILLUSTRATIONSFIGURE NUMBER PageFigure 1-1. A/C Component Identification 1-1...Figure 1-

v T--295LIST OF TABLESTABLE NUMBER PageTable 2-1. Evaporator Fan Speed Relay Operation 2-4....Table 2-2. Cont

1-1T--295SECTION 1DESCRIPTION1.1 INTRODUCTIONThis manual contains Operating Instructions, ServiceInstructions and Electrical Data for the Model GR Air