Carrier 40MAQ Series Service Manual
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Carrier 40MAQ Series Service Manual

High- wall ductless split system sizes 09 to 30
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See also: Owner's Manual , Instruction and Installation Manual
40MAQ / 38MAQ
High- Wall Ductless Split System
Sizes 09 to 30

TABLE OF CONTENTS

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SAFETY CONSIDERATIONS

Installing, starting up, and servicing air- conditioning equipment
can be hazardous due to system pressures, electrical components,
and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should
install, start- up, and service this equipment.
Untrained personnel can perform basic maintenance functions such
as cleaning coils. All other operations should be performed by
trained service personnel.
When working on the equipment, observe precautions in the
literature and on tags, stickers, and labels attached to the
equipment.
Follow all safety codes. Wear safety glasses and work gloves. Keep
quenching cloth and fire extinguisher nearby when brazing. Use
care in handling, rigging, and setting bulky equipment.
Read this manual thoroughly and follow all warnings or cautions
included in literature and attached to the unit. Consult local building
codes and National Electrical Code (NEC) for special requirements.
Recognize safety information. This is the safety- alert symbol
When you see this symbol on the unit and in instructions or manuals,
be alert to the potential for personal injury. Understand these signal
words: DANGER, WARNING, and CAUTION.
Service Manual
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These words are used with the safety- alert symbol. DANGER
identifies the most serious hazards which will result in severe
PAGE
personal injury or death. WARNING signifies hazards which could
1
result in personal injury or death. CAUTION is used to identify
1
unsafe practices which may result in minor personal injury or
2
product and property damage. NOTE is used to highlight
3
suggestions which will result in enhanced installation, reliability, or
operation.
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5
!
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9
ELECTRICAL SHOCK HAZARD
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Failure to follow this warning could result in personal
10
injury or death.
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Before installing, modifying, or servicing system, main
12
electrical disconnect switch must be in the OFF
17
position. There may be more than 1 disconnect switch.
17
Lock out and tag switch with a suitable warning label.
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EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Do not bury more than 36 in. (914 mm) of refrigerant pipe
in the ground. If any section of pipe is buried, there must be
a 6 in. (152 mm) vertical rise to the valve connections on
the outdoor units. If more than the recommended length is
buried, refrigerant may migrate to the cooler buried section
during extended periods of system shutdown. This causes
refrigerant slugging and could possibly damage the
compressor at start- up.

INTRODUCTION

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This Service Manual provides the necessary information to service,
repair, and maintain the 38- 40MA family of Puron air conditioners
and heat pumps. Section 2 of this manual has an appendix with data
required to perform troubleshooting. Use the Table of Contents to
locate a desired topic.
WARNING
WARNING
EXPLOSION HAZARD
Failure to follow this warning could
result in death, serious personal injury,
and/or property damage.
Never use air or gases containing
oxygen for leak testing or operating
refrigerant compressors. Pressurized
mixtures of air or gases containing
oxygen can lead to an explosion.
CAUTION

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  • Page 1: Table Of Contents

    40MAQ / 38MAQ High- Wall Ductless Split System Sizes 09 to 30 Service Manual TABLE OF CONTENTS These words are used with the safety- alert symbol. DANGER identifies the most serious hazards which will result in severe PAGE personal injury or death. WARNING signifies hazards which could SAFETY CONSIDERATIONS .

  • Page 2: Model / Serial Number Nomenclature

    MODEL / SERIAL NUMBER NOMENCLATURES Size Voltage Outdoor Model Indoor Model 38MAQB09---1 40MAQB09B--1 115/l/60 38MAQB12---1 40MAQB12B--1 38MAQB09---3 40MAQB09B--3 38MAQB12---3 40MAQB12B--3 208-230/l/60 38MAQB18---3 40MAQB18B--3 38MAQB24---3 40MAQB24B--3 38MAQB30---3 40MAQB30B--3 40 = INDOOR UNIT 1 = 115/I/60 38 = OUTDOOR UNIT 3 = 208 - 230 - 1 - 60Hz NOT USED MA =MODEL UNIT TYPE...

  • Page 3: Standard Features And Accessories

    STANDARD FEATURES AND ACCESSORIES INDOOR UNITS Ease Of Installation Mounting Brackets Low Voltage Controls Comfort Features Microprocessor Controls Wired Remote Control Wireless Remote Control Automatic Horizontal Air Sweep Air Direction Control Auto Restart Function Cold Blow Protection On Heat Pumps Freeze Protection Mode On Heat Pumps Turbo Mode Silence Mode...

  • Page 4: Specifications (Heat Pump Only Units) Maq

    SPECIFICATIONS - HEAT PUMP ONLY UNITS (MAQ SERIES) Size Outdoor Model 38MAQB09---1 38MAQB12---1 38MAQB09---3 38MAQB12---3 38MAQB18---3 38MAQB24---3 38MAQB30---3 System Indoor Model 40MAQB09B--1 40MAQB12B--1 40MAQB09B--3 40MAQB12B--3 40MAQB18B--3 40MAQB24B--3 40MAQB30B--3 Energy Star Cooling Rated Capacity Btu/h 9,000 12,000 9,000 12,000 17,500 23,000 30,000 Cooling Cap.

  • Page 5: Dimensions - Indoor

    DIMENSIONS - INDOOR Fig. 2 – Indoor units Unit Size W in (mm) D in (mm) H in (mm) Operating Weight lb (kg) 9K/12K 32.9 (835) 7.8 (198) 11.0 (280) 19.2 (8.7) 39.0 (990) 8.6 (218) 12.4 (315) 26.5 (12.0) 24K/30K 46.7 (1186) 10.2 (258)

  • Page 6: Dimensions - Outdoor

    DIMENSIONS - OUTDOOR Fig. 3 – Outdoor Unit Sizes 09 and 12 Operating Model W in (mm) D1 in (mm) H in (mm) W1 in (mm) D1 in (mm) Weight lb (kg) 9K/12K 32.0 (810) 12.2 (310) 22.0 (558) 20.9 (530) 11.4 (290) 82.5 (37.4) 33.2 (845)
  • Page 7 DIMENSIONS - OUTDOOR (CONTINUED) Fig. 4 – Outdoor Units Size 18...
  • Page 8 DIMENSIONS - OUTDOOR (CONTINUED) Fig. 5 – Outdoor Units Size 24 and 30...

  • Page 9: Clearances - Indoor

    CLEARANCES - INDOOR CEILING 6" (0.15m) min. 5" 5" (0.13m) (0.13m) min. min. (1.8m) FLOOR Fig. 6 – Indoor Unit Clearance CLEARANCES - OUTDOOR Air-inlet Air-outlet Fig. 7 – Outdoor Unit Clearance Minimum Value UNIT in. (mm) 24 (609) 24 (609) 24 (609) 4 (101) 4 (101)

  • Page 10: Wiring

    ELECTRICAL DATA COMPRESSOR OUTDOOR FAN INDOOR FAN UNIT OPER. VOLTAGE MAX FUSE SIZE MAX / MIN* CB AMP V/PH/HZ V/PH/HZ V/PH/HZ 127 / 104 115/1/60 115/1/60 0.14 0.053 115/1/60 0.17 0.027 0.42 0.053 0.07 0.027 5.70 0.42 0.053 0.07 0.027 253 / 187 208-230/1/60 208-230/1/60...

  • Page 11: Connection Diagrams

    CONNECTION DIAGRAMS Fig. 8 – 115V Fig. 9 – 208- 230V Notes: 1. Do not use thermostat wire for any connection between indoor and outdoor units. 2. All connections between indoor and outdoor units must be as shown. The connections are sensitive to polarity and will result in a fault code.
  • Page 16 CN55 CN19...

  • Page 17: Fan And Motor Specifications

    FAN AND MOTOR SPECIFICATIONS System size (115V) (115V) (208-230 V) (208-230 V) (208-230 V) (208-230 V) (208-230 V) material Type GL-98*655-N GL-98*655-N GL-98*655-N GL-98*655-N GL-107.5*760-IN GL-118*895-IN GL-118*895-IN Diameter inch 107.5 Height inch material Type ZL-421*117*8-3K ZL-421*117*8-3K ZL-421*117*8-3K ZL-421*117*8-3K ZL-460*180*10-3N ZL-560*139*12-3KN ZL-560*139*12-3KN Diameter inch...
  • Page 18 ENVIRONMENTAL SPECIFICATIONS System size (115V) (115V) (208-230V) (208-230V) (208-230V) (208-230V) (208-230V) Cooling Outdoor Min - °F 4-122 4-122 4-122 4-122 4-122 4-122 4-122 Max DB (°C) (-20-50) (-20-50) (-20-50) (-20-50) (-20-50) (-20-50) (-20-50) Indoor Min - °F 63-90 63-90 63-90 63-90 63-90 63-90...

  • Page 19: Cooling Performance Data

    COOLING PERFORMANCE DATA Cooling Outdoor conditions (DB) Model Indoor Conditions DB Indoor Conditions WB 77F(25C) 86F(30C) 95F(35C) 104F(40C) 113F(45C) 122F(50C) 7.43 7.83 9.74 8.38 6.11 5.11 69.8F(21C) 59F(15C) 6.68 6.69 8.18 7.37 4.36 3.74 Input 0.35 0.54 0.81 0.75 0.75 7.78 9.14 9.89...

  • Page 20: Heating Performance

    HEATING PERFORMANCE Heating Outdoor conditions (DB) Model Indoor Conditions DB 53.6F(12C) 44.6F(7C) 39.2F(4C) 32F(0C) 24.8F(-4C) 19.4F(-7C) 17F(-8C) 5F(-15C) 11.2 11.1 10.89 10.65 9.87 9.11 8.27 6.71 59F(15C) Input 0.73 0.79 1.04 1.01 0.96 0.84 11.1 10.8 10.65 10.54 9.63 8.84 8.01 5.46 64.4F(18C)

  • Page 21: Refrigeration Cycle Diagram

    REFRIGERATION CYCLE DIAGRAMS Fig. 15 – Heat Pumps REFRIGERANT LINES General refrigerant line sizing: 1 The outdoor units are shipped with a full charge of R410A refrigerant. All charges, line sizing, and capacities are based on runs of 25 ft (7.6 m). For runs over 25 ft (7.6 m), consult long- line section on this page for proper charge adjustments.

  • Page 22: System Evacuation And Charging

    IMPORTANT: Both refrigerant lines must be insulated separately. The following maximum lengths are allowed: REFIGERANT LINE LENGHTS ft. (m) System size (115V) (115V) (208-230 V) (208-230 V) (208-230 V) (208-230 V) (208-230 V) Min. Piping Length ft (m) 10 (3) 10 (3) 10 (3) 10 (3)
  • Page 23 Triple Evacuation Method Refrigerant Indoor Unit Outdoor Unit The triple evacuation method should be used. Refer to Fig. 19 and Low Side proceed as follows: 1 Pump system down to 500 MICRONS of mercury and High Side allow pump to continue operating for an additional 15 minutes.

  • Page 24: Control System

    CONTROL SYSTEM I3COOL, I2COOL, I1COOL mean different running current value. Off: Compressor stops. The unit is equipped with a microprocessor control to perform two Decrease: Decrease the running frequency to the lower functions: level. 1 Provide safety for the system Hold: Keep the current frequency.

  • Page 25: Sequence Of Operation

    Evaporator Temperature Protection The evaporator temperature protection function acts as follows: — If the evaporator coil temperature (T2) is lower than 32_F (0_C), the compressor will stop and restarts once T2 ≥ 41_F (5_C). — T2<32_F(0_C), the compressor will stop and restart when T2≥41_F (5_C).

  • Page 26: Heating Mode

    Compressor Operation in Cooling Mode: Compressor Operation in Heating Mode In heating mode, the maximum operation frequency (Fmax) of the In cooling mode, the maximum operation frequency (Fmax) of the compressor, after it starts running, depends on the outdoor ambient compressor, after it starts running, depends on the outdoor ambient temperature (T4).
  • Page 27 Defrost Condition of ending defrosting: Defrost on heat pump units is controlled by the microprocessor and If any one of the following items is satisfied, the defrosting will is initiated if either of the following conditions occur: finish and the machine will turn to normal heating mode. 1 If the outdoor temperature, T4>32_F 0_C): - - - - T3 rises to be higher than TCDE 1_F —...

  • Page 28: Auto Mode

    AUTO MODE Set point In the Auto mode, the temperature can be set to values between 62~86F (17~30 ). In this mode, the machine will choose ° F (1 ° cooling, heating or fan- only mode according to ΔT. NOTE: ΔT =T1- Ts, where T1 represents the indoor room °...

  • Page 29: Troubleshooting

    Follow me 46_F (8_C) Heating (heating setback) 1 If the indoor PCB receives the signal which results from In heating operation, the preset temperature of the air conditioner pressing the FOLLOW ME button on remote controller, the can be as low as 46_F, which keeps the room temperature steady at buzzer will emit a sound and this indicates the follow me 46_F and prevents household pipes from freezing when the house function is initiated.

  • Page 30: Diagnosis And Solution

    INDOOR UNIT DIAGNOSTIC GUIDES Operation lamp Timer lamp Display LED STATUS  Indoor unit EEPROM parameter error 1 time  Indoor / outdoor units communication error 2 times  Zero-crossing signal detection error 3 times  Indoor fan speed has been out of control 4 times ...
  • Page 31 Indoor / outdoor unit’s communication error - diagnosis and solution (E1) Error Code Malfunction decision conditions Indoor unit does not receive feedback from outdoor unit in 110 seconds and this condition occurs four times continuously. Supposed Causes Indoor and outdoor unit communications fault Troubleshooting:...
  • Page 32 Remark Use a multimeter to test the DC voltage between the L2 port and S ports of the outdoor unit. (Fig. 35) The red pin of multimeter connects with the L2 port while the black pin is for the S port. When the AC is running normally, the voltage will move alternatively between - 50V to 50V.
  • Page 33 Zero crossing detection error diagnosis and solution (E2) Error Code Malfunction When PCB does not receive zero crossing decision con- signal feedback for 4 minutes or the zero ditions crossing signal interval is abnormal Supposed Connection mistake Causes PCB faulty Troubleshooting:...
  • Page 34 Fan speed has been out of control diagnosis and solution (E3) Error Code When the indoor fan speed is too slow (300 RPM) for a certain time, the unit will stop and the LED Malfunction decision conditions will display the failure. Wiring mistake Fan assembly faulty Supposed Causes...
  • Page 35 Index 1: Indoor or outdoor DC fan motor (control chip is in fan motor) Measure the resistance value of each winding by using the tester. If any resistance value is zero, the fan motor must have problems and needs to be replaced. Fig.
  • Page 36 2 Outdoor DC Fan Motor (control chip is in the outdoor PCB) Fig. 39 – Outdoor DC Fan Motor Color Orange Grey White Pink Black Signal Color Blue Yellow Signal 1 Release the UVW connector. Measure the resistance of U- V, U- W, V- W. If the resistance is not equal to each other, the fan motor has an issue and needs to be replaced.
  • Page 37 Open circuit or short circuit of temperature sensor diagnosis and solution (E5) Error Code Malfunction decision conditions If the sampling voltage is lower than 0.06V or higher than 4.94V, the LED will display the failure. Supposed Causes Wiring mistake Sensor faulty Troubleshooting:...
  • Page 38 Fig. 40 – Test...
  • Page 39 Refrigerant Leakage Detection Diagnosis and Solution (EC) Error Code Malfunction decision conditions Define the evaporator coil temp.T2 of the compressor just starts running as Tcool. In the beginning 5 minutes after the compressor starts up, if T2 <Tcool-35.6°F(Tcool-2°C) does not keep continuous 4 seconds and this situation happens 3 times, the display area will show “EC”...
  • Page 40 IPM malfunction or IGBT over- strong current protection diagnosis and solution (PO) Error Code Malfunction decision conditions When the voltage signal that IPM sends to the compressor drive chip is abnormal, the LED display will show “PO” and the AC will turn off. Supposed causes Wiring mistake IPM malfunction...
  • Page 41 Fig. 41 – P- U Fig. 42 – P- V...
  • Page 42 Fig. 43 – P- W Fig. 44 – N- U...
  • Page 43 Fig. 45 – N- V Fig. 46 – N- W...
  • Page 44 Over voltage or too low voltage protection diagnosis and solution (P1) Error Code Malfunction decision conditions An abnormal voltage rise or drop is detected by checking the specified voltage detection circuit. Power supply problems Supposed causes System leakage or block PCB faulty Troubleshooting:...
  • Page 45 Fig. 47 – Test NOTE: Measure the DC voltage between the P and N ports. The normal value should be around 310V.
  • Page 46 High temperature protection of compressor top diagnosis and solution (P2) Error Code Malfunction decision conditions If the sampling voltage is not 5V, the LED will display the failure. Supposed causes Power supply problems System leakage or block PCB faulty Troubleshooting...
  • Page 47 Inverter compressor drive error diagnosis and solution(P4) Error Code Malfunction decision conditions An abnormal inverter compressor drive is detected by a special detection circuit, including communication signal detection, voltage detection, compressor rotation speed signal detection and so on. Supposed causes Wiring mistake IPM malfunction Outdoor fan assembly fault...
  • Page 48 Main parks check 1 Temperature sensor checking Disconnect the temperature sensor from PCB, measure the resistance value with a tester. Fig. 48 – Tester Temperature sensors. Room temp. (T1) sensor, Indoor coil temp. (T2) sensor, Outdoor coil temp. (T3) sensor, Outdoor ambient temp. (T4) sensor, Compressor discharge temp.

  • Page 49: Compressor Checking

    Compressor checking Measure the resistance value of each winding by using the tester. Fig. 49 – Tester Terminal Resistance Value Terminal one Terminal two Terminal three Blue - Red 0.8Ω 1.77Ω 0.55Ω Blue - Black (68°F/20°C) (68°F/20°C) (68°F/20°C) Red - Blue Fig.
  • Page 50 IPM continuity check Turn off the power, let the large capacity electrolytic capacitors discharge completely, and dismount the IPM. Use a digital tester to measure the resistance between P and UVWN; UVW and N. Normal resistance Normal resistance Digital tester Digital tester value value...

  • Page 51: Disassembly Instructions

    DISASSEMBLY INSTRUCTIONS NOTE: This part is for reference only and the photos may differ from your unit. Indoor unit Parts name Procedures Remarks Front panel How to remove the front Overview: panel. Pull the bottom side of One screw Panel the panel and release the fixing the cover clips.
  • Page 52 Electrical How to remove the Room temp. parts electrical parts. sensor Grounding screws After removing the front panel from Swing motor procedure 1, pull out the room temp. sensor and evaporator coil sensor. Remove the grounding screws. Pull out the clip toward the left side and open the cover.
  • Page 53 Evaporator remove evaporator. 1) After removing front panel ass’y and electrical parts following procedure 1 and procedure 2, remove the pipe holder at the rear side of the unit. 2) Remove the two screws on the evaporator at the base bearing side. 3) Remove two screws on the evaporator at the fixed plates and then lift...
  • Page 54 Fan and How to remove the fan motor and motor. After remove the evaporator ass’y following procedure 1, procedure 2 and procedure 3, remove the three screws fixing the cover Remove the screw fixing the motor and then pull out the motor. Three screws One screw...

  • Page 55: Outdoor Unit

    OUTDOOR UNIT Part name Procedures Remarks Panel plate How to remove the panel plate. Stop operation of the air conditioner and turn “OFF” the breaker. Refer to the photos on the right to locate screws on the panels. Screw of top panel Remove the screws of Screws of...
  • Page 56 Screw of the top Remove the screws of panel the front panel, including the fixing screws of motor holder and then remove the front panel. Screws of right rear plate Remove the screws of the right side plate and Screw of remove the right side top panel plate.
  • Page 57 How. to remove the fan Electronic control box Fan ass’y Fan ass’y assembly After removing the panel plate following procedure 1, remove the hex nut fixing the fan and then remove the fan. Reactor Compressor and liquid-gas separator Nut fixing the fan Unfix the hooks and then open the electronic control box cover.
  • Page 58 Fan motor connector Disconnect the connector for fan motor from the electronic control board. Remove the four fixing screws of the fan motor. Four 5) Then remove the fan screws motor. Electrical How to remove the parts electrical parts. After finish work of Reactor connector item 1 and item 2, remove the three connectors for...
  • Page 59 Pull out the two blue wires connected with the four way valve. Pull out connectors of the compressor top temp. sensor, condenser coil temp. sensor(T3),outdoor ambient temp. sensor(T4) and discharge temp. sensor(T5). Four connectors of temp. sensors. Remove the ground wires .
  • Page 60 Four-way How to remove the valve four-way valve. The picture of four-way valve may be different from Perform work of item the one on your side. 1,2,3. Recover refrigerant Four-way valve from the refrigerant circuit. Remove the screw of Welded the coil and then remove parts the coil.

  • Page 61: Appendix 1

    APPENDIX 1 Temperature Sensor Resistance Value Table for T1, T2, T3, T4 (°C--K) °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm 115.266 12.6431 2.35774 ‐20 0.62973 108.146 12.0561 2.27249 ‐19 0.61148 101.517 11.5 2.19073 ‐18...
  • Page 62 APPENDIX 2 Temperature Sensor Resistance Value Table for T5 (°C--K) °C °F K Ohm °C °F K Ohm °C °F K Ohm °C °F K Ohm 542.7 68.66 13.59 3.702 511.9 65.62 13.11 3.595 62.73 12.65 3.492 455.9 59.98 12.21 3.392 430.5 57.37...
  • Page 63 APPENDIX 3 °C °F °C °F °C °F °C °F °C °F 69.8 123.8 179.6 235.4 24.8 71.6 125.6 181.4 237.2 26.6 73.4 127.4 183.2 28.4 75.2 129.2 240.8 30.2 186.8 242.6 25.5 77.9 132.8 188.6 244.4 32.9 78.8 134.6 190.4 246.2 33.8...
  • Page 64 Catalog No.38- 40MAQ- 01SM Copyright 2015 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231 Edition Date: 04/15 Replaces: NEW Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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38maq series

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