Carrier 38MGQ Series Service Manual
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Carrier 38MGQ Series Service Manual

Multi-zone ductless split system
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See also: Instruction and Installation Manual
38MGQ / 40MAQ/40MBC/40MBD/40MBF
538TR / 619PB/619RC/619RD/619RF
Multi---Zone Ductless Split System
Sizes 18 to 48

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
4
suggestions which will result in enhanced installation, reliability, or
operation.
5
6
!
7
11
ELECTRICAL SHOCK HAZARD
12
Failure to follow this warning could result in personal
14
injury or death.
24
Before installing, modifying, or servicing system, main
28
electrical disconnect switch must be in the OFF
30
position. There may be more than 1 disconnect switch.
31
Lock out and tag switch with a suitable warning label.
32
66
!
!
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

This Service Manual provides the necessary information to service,
repair, and maintain the multi- -zone family of 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

    38MGQ / 40MAQ/40MBC/40MBD/40MBF 538TR / 619PB/619RC/619RD/619RF Multi---Zone Ductless Split System Sizes 18 to 48 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.

  • Page 2: Model Number Nomenclature

    MODEL NUMBER NOMENCLATURE INDOOR UNIT --- --- 40 = FAN COIL UNIT MA = HIGH WALL VOLTAGE MB = CASSETTE, DUCTED, FLOOR CONSOLE 3 = 208/230 ---1 ---60 SYSTEM TYPE Q = HEAT PUMP NOT USED B=ALL INDOOR FAN COIL TYPE NOMINAL CAPACITY B = HIGH WALL 09 --- 3/4 TON...
  • Page 3 INDOOR UNIT 619 = FAN COIL UNIT A = ALL MODELS P = HIGHWALL R = CASSETTE, DUCTED, FLOOR CONSOLE M = ALL VOLTAGE E = 208 ---230/I/60 SYSTEM TYPE B = ALL Q = HEAT PUMP INDOOR FAN COIL TYPE NOMINAL CAPACITY B= High Wall 009 --- 3/4TON...

  • Page 4: Standard Features And Accessories

    STANDARD FEATURES AND ACCESSORIES INDOOR UNITS Ease of Installation Mounting Bracket Low Voltage Controls Comfort Features Microprocessor Control Wired Remote Control for High Walls, Cassette and Floor Console Wired Remote Control for Ducted Wireless Remote Control Rapid Cooling and Heating Automatic Air Sweep Cold Blow Prevention Continuous Fan...

  • Page 5: Combination Table

    COMBINATION TABLE Table 1—Combinations Table Size 18 Outdoor Model Outdoor Model Indoor Unit Nominal Unit Btuh Indoor Model Number Indoor Model Number Number Number 9,000 40MAQB09B--3 619PEQ009BBMA High Wall 12,000 40MAQB12B--3 619PEQ012BBMA 9,000 40MBQB09C--3 619REQ009CBMA Cassette 12,000 40MBQB12C--3 619REQ012CBMA 38MGQC18---3 538TEQ018RCMA 9,000 40MBQB09D--3...

  • Page 6: Physical Data - - Outdooor

    PHYSICAL DATA - - OUTDOOR Table 4—Outdoor Size 38MGQC18- -- -- -3 38MGQD27- -- -- -3 38MGQF36- -- -- -3 38MGQF48- -- -- -3 Outdoor Model 538TEQ018RCMA 538TEQ027RDMA 538TEQ036RFMA 538TEQ048RFMA System Max Number of Zones Energy Star Cooling Rated Capacity Btu/h 18,000 25,000...

  • Page 7: Dimensions - - Outdoor

    DIMENSIONS - - OUTDOOR Table 5—Outdoor Unit Size Height in (mm) 27.56(700) 31.89(810) 31.89(810) 36.93(1369) Width in (mm) 33.27(845) 37.20(945) 37.20(945) 53.9(938) Depth in (mm) 12.60(320) 15.55(395) 15.55(395) 15.43(392) Weight - - Net lbs (kg) 114.63(52) 154.76(70.2) 169.75(77) 255.50(115.9) Fig. 2 – Outdoor Dimensions Size 18...
  • Page 8 DIMENSIONS - - OUTDOOR (CONTINUED) Fig. 3 – Outdoor Dimensions Size 27...
  • Page 9 DIMENSIONS - - OUTDOOR (CONTINUED) Fig. 4 – Outdoor Dimensions Size 36...
  • Page 10 DIMENSIONS - - OUTDOOR (CONTINUED) Fig. 5 – Outdoor Dimensions Size 48...

  • Page 11: Clearances - - Outdoor

    CLEARANCES - - OUTDOOR Air-inlet Air-outlet Fig. 6 – Outdoor Unit Clearance Table 6—Outdoor Minimum Value UNIT in. (mm) 24 (609) 24 (609) 24 (609) 4 (101) 4 (101)

  • Page 12: Electrical Data

    ELECTRICAL DATA Table 7—High Wall System Voltage OPERATING VOLTAGE INDOOR FAN UNIT SIZE VOLT / PHASE / HZ MAX / MIN V- -PH- -HZ 0.07 0.027 0.07 0.027 0.17 0.077 208- -230/1/60 253 / 187 208- -230/1/60 0.23 0.08 0.23 0.08 Table 8—Ducted System Voltage...
  • Page 13 WIRING CAUTION All wires must be sized per NEC (National Electrical Code) or CEC (Canadian Electrical Code) and local codes. Use Electrical EQUIPMENT DAMAGE HAZARD Data table MCA (minimum circuit amps) and MOCP (maximum over current protection) to correctly size the wires and the Failure to follow this caution may result in equipment disconnect fuse or breakers respectively.

  • Page 14: Connection Diagram

    CONNECTION DIAGRAMS Fig. 7 – Connection Diagram Size 18 Fig. 8 – Connection Diagram Size 27...
  • Page 15 CONNECTION DIAGRAMS CONTINUED Fig. 9 – Connection Diagram Size 36 Fig. 10 – Connection Diagram Size 48 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 Fig. 11 – PCB Board Size 18...
  • Page 17 Fig. 12 – IPM Board Size 18...
  • Page 18 Fig. 13 – PCB Board Size 27...
  • Page 19 Fig. 14 – IPM Board Size 27...
  • Page 20 Fig. 15 – PCB Board Size 36...
  • Page 21 Fig. 16 – IPM Board Size 36...
  • Page 22 Fig. 17 – PCB Board Size 48...
  • Page 23 Fig. 18 – IPM and PFC Board Size 48...

  • Page 24: Wiring Diagram

    WIRING DIAGRAMS Fig. 19 – Wiring Diagrams 18k Table 12—Outdoor Unit Control Board Size 18 CODE PART NAME CN18/CN19/CN22 Output:Pin5&6(12V) Pin1- - Pin4:Pulse waveform,(0- - 12V) CN17 Input:Pin3~4 (5V) Pin2(0V),Pin1,Pin5(0- - 5V) Input:Pin1 (0- - 5V) Pin2(5V) CN1~CN2，CN5~CN6 Output: CN1~CN2，CN5~CN6（230VAC High voltage） P1~P2 Output: Connection of the high voltage CN3~CN4...
  • Page 25 Fig. 20 – Wiring Diagrams 27k Table 13—Outdoor Unit Control Board Size 27 CODE PART NAME CN18/CN19/CN22 Output:Pin5&6(12V) Pin1- - Pin4:Pulse waveform,(0- - 12V) CN17 Input:Pin3~4 (5V) Pin2(0V),Pin1,Pin5(0- - 5V) Input:Pin1 (0- - 5V) Pin2(5V) CN1~CN2，CN5~CN6 Output: CN1~CN2，CN5~CN6（230VAC High voltage） P1~P2 Output: Connection of the high voltage CN3~CN4...
  • Page 26 Fig. 21 – Wiring Diagram 36k Table 14—Outdoor Unit Control Board Size 36 CODE PART NAME CN17/CN18/CN19/CN20/CN21 Output:Pin5&6(12V) Pin1- -Pin4:Pulse waveform,(0- -12V) Input:Pin3~4 (5V) Pin2(0V),Pin1,Pin5(0- -5V) CN33 Input:Pin1 (0- -5V) Pin2(5V) CN4~CN40，CN10~CN44 Output: CN4~CN40，CN10~CN44（230VAC High voltage） CN3~CN22 Output: High voltage for 4- -way control CN1~CN2 Input:230VAC High voltage Input：Pin1,Pin3(0V)，Pin2,Pin4（0~5V）...
  • Page 27 Fig. 22 – Wiring Diagrams 48K Table 15—Outdoor Unit Control Board Size 48 CODE PART NAME CN1,CN3、P- - 1 Power input: 230V AC CN2,CN4 Output: Power output for DRIVER BOARD (230V AC) Input: Communication Main board and IPM Board ,Pin1(5V DC ) Input: DC FAN motor1 and DC FAN motor2 control, (Pin7 5V DC) CN8,CN9 Input: Temperature sensor(5V DC)

  • Page 28: Refrigeration Cycle Diagrams

    REFRIGERATION CYCLE DIAGRAMS INDOOR OUTDOOR EXV A CAPILIARY A LIQUID VALVE A CHECK VALVE EXV B CAPILIARY B LIQUID VALVE B Condenser temp. sensor CAPILIARY TUBE HEAT HEAT EXCHANGE T4 Ambient T1 Room EXCHANGE (EVAPORATOR) temp. sensor temp. sensor (CONDENSER) T2B-A Evaporator T2 Evaporator...
  • Page 29 INDOOR OUTDOOR EXV A CAPILIARY A LIQUID VALVE A EXV B CAPILIARY B LIQUID VALVE B CHECK VALVE EXV C CAPILIARY C LIQUID VALVE C Condenser temp. sensor EXV D CAPILIARY D CAPILIARY TUBE LIQUID VALVE D HEAT HEAT EXCHANGE T4 Ambient T1 Room EXCHANGE...

  • Page 30: Refrigerant Lines

    REFRIGERANT LINES 3 Refrigerant lines should not be buried in the ground. If it is necessary to bury the lines, not more than 36- -in (914 mm) General refrigerant line sizing: should be buried. Provide a minimum 6- -in (152 mm) vertical 1 The outdoor units are shipped with a full charge of R410A rise to the service valves to prevent refrigerant migration.

  • Page 31: System Evacuation And Charging

    SYSTEM EVACUATION AND Deep Vacuum Method The deep vacuum method requires a vacuum pump capable of CHARGING pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth. The deep vacuum method CAUTION is the most positive way of assuring a system is free of air and liquid water (see Fig.

  • Page 32: Troubleshooting

    TROUBLESHOOTING Electronic Expansion Valve (EXV) Control 1 EXV will be fully closed when turning on the power. Then This section provides the required flow charts to troubleshoot EXV will be standby with 350P open and will open to problems that may arise. target angle after compressor starts.
  • Page 33 Indoor Unit Diagnostic Guides Table 18—Diagnostic Codes Display LED STATUS IDU Error IDU Error Outdoor EEPROM malfunction Communication malfunction between indoor and outdoor units Communication malfunction between IPM board and outdoor main board —— —— Open or short circuit of outdoor temperature sensor (T3、T4、T5、T2B) Voltage protection PFC module protection ——...
  • Page 34 Diagnosis and Solution EEPROM parameter error - - diagnosis and solution (E0/F4) Error Code E0/F4 Malfunction decision conditions Indoor or outdoor PCB main chip does not receive feedback from EEPROM chip. Installation mistake Supposed Causes PCB faulty Trouble shooting: Shut off the power supply and turn it on 5 seconds later.
  • Page 35 Remark Use a multimeter to test the DC voltage between the L2 port and S ports of the outdoor unit. (Fig. 31) 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 36 Zero crossing detection error diagnosis and solution (E2) Error Code When PCB does not receive zero crossing signal feedback for 4 minutes or the zero Malfunction decision conditions crossing signal interval is abnormal Connection mistake Supposed Causes PCB faulty Troubleshooting:...
  • Page 37 E1, E2 (Communication malfunction between indoor and outdoor units) error diagnosis and solution. Error Code Indoor unit does not receive the feedback from outdoor unit during 120 seconds or outdoor Malfunction decision conditions unit does not receive the feedback from any one indoor unit during 180 seconds. Wiring mistake Supposed Causes Indoor or outdoor PCB faulty...
  • Page 38 Pic 1:Use a multimeter to test the DC voltage between L2 port and S port of outdoor unit. The red pin of multimeter connects with L2 port while the black pin is for S port. When AC is normal running, the voltage will move alternately between positive value and negative value.
  • Page 39 Pic 2: :IPM (For qua-zone) Power, Self-Check Opera ng PIC3 :Main board LED when power on and unit standby. PIC 4: Check point bu on, press 1 me for check how many indoor units are connected.
  • Page 40 E3(Communication malfunction between IPM board and outdoor main board) error diagnosis Error Code Malfunction decision conditions PCB main chip does not receive feedback from IPM module during 60 seconds. Wiring mistake Supposed causes PCB faulty Troubleshooting Communication malfunction between IPM board and outdoor main board Is there at least one LED in the IPM board light? Check the signal wire between...
  • Page 41 Remark: Use a multimeter to test the DC voltage between black pin and white pin of signal wire The normal value should be around 5V. Use a multimeter to test the DC voltage between black pin and red pin of signal wire. The normal value should be around 12V.
  • Page 42 E4 (open or short circuit of outdoor temperature sensor) diagnosis and solution F1/F2/F3/F4/F5 (open or short circuit of indoor coil temperature sensor) diagnosis and solution. Error Code E4/F1/F2/F3/F4/F5 Malfunction decision conditions If the sampling voltage is lower than 0.06V or higher than 4.94V, the LED displays the failure. Wiring mistake Supposed causes Sensor faulty...
  • Page 43 E5(Voltage protection) error diagnosis and solution. 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 Voltage protection Check the voltage of outdoor unit power supply, whether the voltage...
  • Page 44 IPM (for dual/tri- zone) IPM (for qua- zone) P-N (for dual/tri-zone)
  • Page 45 P-N (for qua-zone)
  • Page 46 bridge rectifier (for dual/tri-zone) bridge rectifier (for qua-zone)
  • Page 47 Remark: Measure the DC voltage between + and - port. The normal value should be 190V~250V.
  • Page 48 E6(PFC module protection) error diagnosis and solution. Error Code When the voltage signal that PFC sends to main control board is abnormal, the display LED Malfunction decision conditions displays “E6” and the AC turns off. Wiring mistake Outdoor PCB faulty Supposed causes Inductance of PFC module faulty PFC module malfunction...
  • Page 49 Inductance Two ports of the inductance...
  • Page 51 E8(Outdoor fan speed has been out of control) diagnosis and solution Error Code When outdoor fan speed keeps too low (300RPM) or too high(2400RPM) for certain time, the unit stops Malfunction decision conditions and the LED displays the failure. Wiring mistake Fan ass'y faulty Supposed causes Fan motor faulty...
  • Page 52 Index 1: DC fan motor (control chip is inside fan motor) Power on and when the unit is in standby, measure the voltage of pin1- -pin3, pin4- -pin3 in fan motor connector. If the value of the voltage is not in the range showing in below table, the PCB must have problems and need to be replaced. DC motor voltage input and output Color Signal...
  • Page 53 P0(Temperature protection of compressor top) error diagnosis and solution. Error Code Malfunction decision conditions If the sampling voltage is not 5V, the LED displays the failure. Wiring mistake Over load protector faulty Supposed causes System block Outdoor PCB faulty Troubleshooting Temperature protection of compressor Temperature protection of compressor Check the air flow system...
  • Page 55 P1(High pressure protection) error diagnosis and solution. Error Code Malfunction decision conditions If the sampling voltage is not 5V, the LED displays the failure. Wiring mistake Over load protector faulty Supposed causes System block Outdoor PCB faulty Troubleshooting High pressure protec on Whether the wiring Whether the wiring between the high pressure...
  • Page 57 P2 (Low pressure protection) error diagnosis and solution Error Code Malfunction decision conditions If the sampling voltage is not 5V, the LED displays the failure. Wiring mistake Over load protector faulty Supposed causes System block Outdoor PCB faulty Low pressure protec on Low pressure protec on Whether the wiring Whether the wiring...
  • Page 59 P3 (Current protection of compressor) error diagnosis and solution. Error Code Malfunction decision conditions If the outdoor current exceeds the current limit value, the LED displays the failure. Wiring mistake Over load protector faulty Supposed causes System block Outdoor PCB faulty Troubleshooting f compressor Judge 1: Check whether the input...
  • Page 61 P4(Temperature protection of compressor discharge) error diagnosis and solution. Error Code When the compressor discharge temperature(T5) is more than 239 F for 10 seconds, the Malfunction decision conditions compressor stops and restarts when T5 is less than 194 Refrigerant leakage Wiring mistake Supposed causes The discharge temperature sensor faulty...
  • Page 62 P5 (High temperature protection of condenser) error diagnosis and solution Error Code Malfunction decision conditions When outdoor pipe temperature is more than 149°F, the unit stops, and unit runs again when the outdoor pipe temperature is less than 125°F. The condenser temperature sensor faulty Supposed causes Heat exchanger dirty System block...
  • Page 63 P6 (IPM module protection) error diagnosis and solution Error Code When the voltage signal that IPM send to compressor drive chip is abnormal, the display LED Malfunction decision conditions shows “P6” and the AC turns off. Wiring mistake IPM malfunction Supposed causes Outdoor fan ass’y faulty Compressor malfunction...
  • Page 64 The cooling operation or heating operation does not operate. Supposed causes 4- -way valve faulty Check the 4- -way valve. Refer to part 5 in 9.5. When cooling, heat exchanger of non- -operating indoor unit frosts. When heating, non- -operating indoor unit gets warm. Supposed causes: EXV faulty Wire and tubing connected in reverse...
  • Page 65 Temperature sensor checking Disconnect the temperature sensor from PCB, measure the resistance value with a 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.(T5) sensor. Measure the resistance value of each winding by using the multi- -meter.

  • Page 66: Appendix

    APPENDIX 1 TEMPERATURE SENSOR RESISTANCE VALUE TABLE ( C- -K) ℃ ℃ ℃ ℃ K Ohm K Ohm K Ohm K Ohm 115.266 12.6431 2.35774 0.62973 108.146 12.0561 2.27249 0.61148 101.517 11.5000 2.19073 0.59386 96.3423 10.9731 2.11241 0.57683 89.5865 10.4736 2.03732 0.56038 84.2190...
  • Page 67 APPENDIX 2 Unit: ℃-K - Discharge Temperature Sensor Table 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 11.79 3.296 406.7 54.89 11.38 3.203 384.3 52.53 10.99 3.113 363.3 50.28 10.61 3.025 343.6 48.14 10.25...
  • Page 68 Compressor Check Measure the resistance value of each winding by using the tester. Position Resistance Value Blue - Red 0.95Ω (20℃/68℉) 0.55Ω (20℃/68℉) 0.53Ω (20℃/68℉) 0.44Ω (20℃/68℉) IPM continuity check...
  • Page 69 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 (+)Red (-)Black...
  • Page 70 4- -Way Valve 1 Power on, use a digital tester to measure the voltage, when the unit operates in cooling, it is 0V. When the unit operates in heating, it is about 230VAC. If the value of the voltage is not in the range, the PCB must have problems and need to be replaced. 2 Turn off the power, use a digital tester to measure the resistance.
  • Page 71 EXV check Disconnect the connectors. Resistance to EXV coil Color of lead wire Normal Value Red- Blue Red - Yellow About 50Ω Brown-Orange Brown-White...
  • Page 72 Red- Blue Red - Yellow...
  • Page 73 Brown-Orange Brown-White...
  • Page 74 DISASSEMBLY INSTRUCTIONS How to remove the panel plate. Panel plate 1) Stop operation of the air conditioner and turn “OFF” the power breaker. 2) Remove the screws of top Screws of top cover cover, and remove the top cover. (9 screws) Screws of right- Screws of rear panel...
  • Page 75 5) Remove the screws of big handle, and remove the big Screws of handle.(4 screws) big handle 6) Remove two screws of terminal board, four screws of water collector and Screws of water collector fourteen screws of right- rear panel, and remove the Screws of right-rear panel.
  • Page 76 4) Remove the electrical control box cover. 5) Disconnect the fan motor connector CN37(5p,white) from the PCB board. Remove the fan motor after unfastening four fixing screws. How to remove the electrical Electrical parts. parts 1) Perform work of item 1,2. 2) Remove the ten screws fixing the IPM board.

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