Carrier 40MAHB Series Service Manual

Carrier 40MAHB Series Service Manual

High wall ductless system
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40MAHB
High Wall Ductless System
Sizes 06 to 36

TABLE of CONTENTS

INTRODUCTION............................................................................ 1
WIRING ........................................................................................... 3
CONNECTION DIAGRAMS ......................................................... 4
WIRING DIAGRAM....................................................................... 5
REFRIGERATION CYCLE DIAGRAM........................................ 6
REFRIGERANT LINES .................................................................. 6
FAN AND MOTOR SPECIFICATIONS ........................................ 7
SYSTEM EVACUATION AND CHARGING ............................... 8
INQUIRY MODE ............................................................................ 12
TROUBLESHOOTING................................................................... 13
INDOOR UNIT DIAGNOSTIC GUIDES....................................... 14
DIAGNOSIS AND SOLUTION...................................................... 15
APPENDICIES ................................................................................ 37
DISASSEMBLY INSTRUCTIONS ................................................ 40
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 coil cleaning. 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 a 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 the 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.
These words are used with the safety-alert symbol. DANGER
identifies the most serious hazards which will result in severe personal
injury or death. WARNING signifies hazards which could result in
personal injury or death. CAUTION is used to identify unsafe
practices which may result in minor personal injury or product and
property damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability, or operation.
Service Manual
PAGE
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Before installing, modifying, or servicing the system, the
main electrical disconnect switch must be in the OFF
position. There may be more than 1 disconnect switch. Lock
out and tag switch (es) with a suitable warning label.
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.
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 a 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 40MAHB family of heat pumps. This manual
has an appendix (see "APPENDICIES" on page 37) with data
required to perform troubleshooting. Use the "TABLE of
CONTENTS"on page 1 to locate a desired topic.
Specifications subject to change without notice.
WARNING
WARNING
CAUTION

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Summary of Contents for Carrier 40MAHB Series

  • Page 1: Table Of Contents

    40MAHB High Wall Ductless System Sizes 06 to 36 Service Manual TABLE of CONTENTS WARNING PAGE INTRODUCTION................1 MODEL / SERIAL NUMBER NOMENCLATURES ....2 ELECTRICAL SHOCK HAZARD WIRING ................... 3 Failure to follow this warning could result in personal injury CONNECTION DIAGRAMS ............
  • Page 2: Model / Serial Number Nomenclatures

    40MAHB: Service Manual MODEL / SERIAL NUMBER NOMENCLATURES Table 1 —Unit Sizes SYSTEM TONS VOLTAGE INDOOR MODEL 1.00 115-1-60 40MAHBQ12XA1 0.50 40MAHBQ06XA3 0.75 40MAHBQ09XA3 1.00 40MAHBQ12XA3 1.50 208/230-1 40MAHBQ18XA3 2.00 40MAHBQ24XA3 2.50 40MAHBQ30XA3 3.00 40MAHBQ36XA3 INDOOR UNIT 40 = INDOOR UNIT MA = MODEL VOLTAGE 1=115-1-60...
  • Page 3: Wiring

    40MAHB: Service Manual WIRING All wires must be sized per NEC (National Electrical Code) or CEC (Canadian Electrical Code) and local codes. Use the Electrical Data table CAUTION MCA (minimum circuit amps) and MOCP (maximum over current protection) to correctly size the wires and the disconnect fuse or breakers respectively.
  • Page 4: Connection Diagrams

    40MAHB: Service Manual CONNECTION DIAGRAMS Fig. 1 — Connection Diagram - 12K (115V) Fig. 2 — Connection Diagram - 6K - 18K (208/230-1-60) Fig. 3 — Connection Diagram - 24K - 36K (208/230-1-60) NOTES: 1. Do not use thermostat wire for any connection between indoor and outdoor units. 2.
  • Page 5: Wiring Diagram

    40MAHB: Service Manual WIRING DIAGRAM Fig. 4 —Wiring Diagram (All Sizes) 115 and 208/230)) Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 6: Refrigeration Cycle Diagram

    40MAHB: Service Manual REFRIGERATION CYCLE DIAGRAM T2 Evaporator temp. sensor Fig. 5 — Refrigeration Cycle Diagram REFRIGERANT LINES IMPORTANT: Both refrigerant lines must be insulated separately. Refer to the outdoor unit’s installation instructions for other allowed piping lengths and refrigerant information. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 7: Fan And Motor Specifications

    40MAHB: Service Manual FAN AND MOTOR SPECIFICATIONS Table 2 — Fan and Motor Specifications HIGH WALL UNIT SIZE (115 V) (208/230 V) (208/230 V) (208/230 V) (208/230 V) (208/230 V) (208/230 V) (208/230 V) Acrylontrile Acrylontrile Acrylontrile Acrylontrile Acrylontrile Acrylontrile Acrylontrile Acrylontrile Material...
  • Page 8: System Evacuation And Charging

    40MAHB: Service Manual SYSTEM EVACUATION AND Deep Vacuum Method CHARGING The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth. The deep vacuum method is the most CAUTION effective way of assuring a system is free of air and liquid water (see Fig.
  • Page 9 40MAHB: Service Manual Main Protection COOLING Mode Indoor Fan Running Rules: Fan speed is out of control In the COOLING mode, the indoor fan runs all the time and the speed When the indoor fan speed is too low (300RPM) or too high (1500RPM) can be selected as HIGH, MEDIUM, LOW and AUTO.
  • Page 10 40MAHB: Service Manual Evaporator Coil Temperature Protection HEATING Mode Indoor Fan Running Rules: When the compressor is on, the indoor fan can be set to HIGH, MEDIUM, LOW, AUTO, MUTE. When the indoor unit coil temperature is low, the anti-cold air function starts and the indoor fan motor runs at a low speed and the speed cannot be changed.
  • Page 11 40MAHB: Service Manual Evaporator Anti-Freezing Protection Refrigerant Leakage Detection The evaporator anti-freezing protection condenser high temperature With this new technology, the display area displays “EC” when the protection and outdoor unit frequency limit are active and the same as that outdoor unit detects a refrigerant leak.
  • Page 12: Inquiry Mode

    40MAHB: Service Manual INQUIRY MODE To enter the Inquiry Mode: Press and hold together the On/Off and Fan buttons for 8 seconds. The remote control remains in Inquiry Mode for 1 minute if no button is pressed. In the Inquiry Mode, the remote display cancels all icons except AUTO, COOL, DRY, HEAT and battery strength. The digital display defaults to “0”...
  • Page 13: Troubleshooting

    40MAHB: Service Manual TROUBLESHOOTING Safety Electricity power is kept in the capacitors even if the power supply is shut off. NOTE: Remember to discharge the electricity power in capacitor. Electrolytic Capacitors (HIGH VOLTAGE! CAUTION!) Fig. 18 —Electrolytic Capacitors For other models, please connect discharge resistance (approximately 100 40W) or a soldering iron (plug) between the +, - terminals of the electrolytic capacitor on the contrary side of the outdoor PCB.
  • Page 14: Indoor Unit Diagnostic Guides

    40MAHB: Service Manual INDOOR UNIT DIAGNOSTIC GUIDES For ease of service, the systems are equipped with diagnostic code display LEDs on the indoor unit. There may be a few error codes displayed in the indoor unit that might relate to the outdoor unit's problems. If possible, always check the diagnostic codes displayed on the indoor unit first. Table 4 —...
  • Page 15: Diagnosis And Solution

    40MAHB: Service Manual DIAGNOSIS AND SOLUTION Outdoor Unit Error Display After the power is on, LED1 (blue color) flashes slowly (once per second) when the unit is in standby. The LED flashes quickly (twice per second) if the unit has an issue. Table 6 —...
  • Page 16 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Outdoor EEPROM Parameter Error or Compressor Driven Chip EEPROM Parameter Error (EC51) Description: Outdoor PCB main chip does not receive feedback from the EEPROM chip or the compressor driven chip. Recommended parts to repair: •...
  • Page 17 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Indoor and Outdoor Unit Communication Error (EL01) Description: The indoor unit cannot communicate with the outdoor unit Recommended parts to repair: • Indoor PCB • Outdoor PCB • Short-circuited component Troubleshooting Power off, then restart the unit after 2 minutes.
  • Page 18 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Remarks: • Use a multimeter to test the DC voltage between the 2 port (or S or L2 port) and 3 port (or N or S port) of the outdoor unit. • The red pin of multimeter connects with 2 port (or S or L2 port) while the black pin is for 3 port (or N or S port) the unit is running normal, the voltage is moving alternately as positive values and negative values.
  • Page 19 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Zero Crossing Detection Error Diagnosis and Solution (EH02) Description: When the PCB does not receive a zero crossing signal feedback for 4 minutes or the zero crossing signal time interval is abnormal. Recommended parts to repair: •...
  • Page 20 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) The indoor fan speed is operating outside of the normal range (EH03) Description: When the indoor fan speed remains too slow or too fast for an extended period of time, the LED displays a failure code and the unit turns off.
  • Page 21 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) The Outdoor Fan Speed is Operating Outside of Normal Range (EC07) Description: When the outdoor fan speed remains too low or too high for a certain time, the LED displays the failure code and the AC turns off. Recommended parts to repair: •...
  • Page 22 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Outdoor DC Fan Motor (DC motor that controls the chip on the PCB) 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 is faulty and must be replaced.
  • Page 23 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Indoor Temperature Sensor Is an Open Circuit or a Short Circuit (T1, T2) (EH60) Description: If the sampling voltage is lower than 0.06V or higher than 4.94V, the LED displays the failure code. Recommended parts to repair: •...
  • Page 24 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Outdoor Temperature Sensor Is an Open Circuit or Short Circuited (T3, T4, TP, T2B, TH) (EC53) Description: If the sampling voltage is lower than 0.06V or higher than 4.94V, the LED displays the failure code. Recommended parts to repair: •...
  • Page 25 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Refrigerant Leakage Detection (EL0C) Description: Define the compressor’s evaporator coil temperature (T2) starts running as Tcool.   In the initial 5 minutes after the compressor starts, if T2<Tcool-1.8 F (1 C) is not maintained for 4 seconds and the compressor runs at a frequency is higher than 50Hz however it does not maintain for a minimum of three minutes and this issue occurs 3 times, the LED displays the failure code and the unit turns off.
  • Page 26 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Indoor PCB/Display Board Communication Error (EH06) Description: The indoor PCB does not receive feedback from the display board. Recommended parts to repair: • Communication wire • Indoor PCB • Display board Troubleshooting Power off. Wait 2 minutes then restart the unit.
  • Page 27 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Current Overload Protection (PC08) Description: An abnormal current rise is detected by checking the specified detection circuit. Recommended parts to repair: • Communication wires • Reactor • Outdoor fan • Outdoor PCB Troubleshooting Was the protection activated in standby mode? Restart the unit when the...
  • Page 28 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) IPM Malfunction or IGBT over-strong current protection (PC00) Description: If the IPM sends an abnormal voltage signal to the compressor drive chip, the LED displays the failure code and the unit turns off. Recommended parts to repair: •...
  • Page 29 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Index IPM Continuity Check WARNING Electricity remains in the capacitors even when the power supply is off. Ensure the capacitors are fully discharged before troubleshooting. 1. Turn off the outdoor unit and disconnect the power supply. 2.
  • Page 30 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Compressor Check Disconnect the compressor and check the resistance between U-V, V-W and U-W, and all 3 values should be equal. If not, the compressor is faulty and needs to be replaced. Fig. 24 — Compressor Checks NOTE: Figure 24 is for reference only.
  • Page 31 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Over voltage or low voltage protection (PC01) Description: Abnormal increases or decreases in voltage are detected by checking the specified voltage detection circuit. Recommended parts to repair: • Power supply wires • IPM module board •...
  • Page 32 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Top temperature protection for compressor or High temperature or High pressure protection of IPM module (PC02) Description: For some models with overload protection, if the sampling voltage is not 5V, the LED displays the failure. If the IPM module temperature is higher than a certain value, the LED displays the failure code.
  • Page 33 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Top temperature protection for compressor or High temperature or High pressure protection of IPM module (PC02) (cont.) High pressure protection Are the high pressure switch Connect the high pressure switch and main control board wired and main control board.
  • Page 34 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Low Pressure Protection (PC03) Description: The outdoor pressure switch shuts the unit down because the low pressure is lower than 0.13 MPa and the LED displays the failure code. Recommended parts to repair: •...
  • Page 35 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Inverter compressor Drive Error (PC04) Description: An abnormal inverter compressor drive is detected by a special detection circuit, including communication signal detection, voltage detection, compressor rotation and speed signal detection. Recommended parts to repair: •...
  • Page 36 40MAHB: Service Manual DIAGNOSIS AND SOLUTION (CONT) Indoor Units Mode Conflict (match with multi outdoor unit) Description: The indoor units cannot operate in the COOLING mode and HEATING mode simultaneously. The HEATING mode is the priority. Examples: • If indoor unit A is operating in the COOLING mode or the FAN mode, and indoor unit B is set to the HEATING mode, unit A will power off and unit B will continue to operate in the HEATING mode.
  • Page 37: Appendicies

    40MAHB: Service Manual APPENDICIES Appendix 1 Table 8 — Temperature Sensor Resistance Value Table for T1, T2, T3, T4 (C--K) °C °F °C °F °C °F °C °F K Ohm K Ohm K Ohm K Ohm 115.266 12.6431 2.35774 0.62973 108.146 12.0561 2.27249...
  • Page 38 40MAHB: Service Manual Appendix 2 Table 9 — Temperature Sensor Resistance Value Table for T5 (TP) (C--K) ° C ° F ° C ° F ° C ° F ° C ° F K Ohm K Ohm K Ohm K Ohm 542.7 68.66 13.59...
  • Page 39 40MAHB: Service Manual Appendix 3  Table 10 — T(XF)=9XT(XC)/5 ° 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...
  • Page 40: Disassembly Instructions

    40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS Front Panel NOTE: This part is for reference only and the photos may differ from your actual unit. Procedure Illustration 1) Place your hands along the filter’s sides, pull the filter gently along the vertical direction, and then remove it.
  • Page 41 40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS (CONT) Procedure Illustration 4) Open the panel assembly, move the slider to secure the panel. 5) Open the two stop blocks of the panel frame assembly. 6) Remove 1 screw in the panel frame. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 42 40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS (CONT) Procedure Illustration 7) Pull the two sides of the bottom panel along the direction shown in the image to the right to remove it. 8) Pull the panel’s support bar to remove it. 9) Remove the panel assembly. Caution: If you want to close the panel, you must bend the middle of the support bar, otherwise it will break.
  • Page 43 40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS (CONT) Procedure Illustration 10) Remove 1 screw from the display board. 11) Rotate the display board subassembly in the direction shown in the picture to the right. 12) Pull the four clips to remove the display board.
  • Page 44 40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS (CONT) Electrical parts (Anti-static gloves must be worn.) Procedure Illustration 1) Pull the two ends of the electronic control box cover with your thumbs to open. 2) Raise the support bar to secure the cover. 3) Pull the electrical control box holder to remove it.
  • Page 45 40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS (CONT) Procedure Illustration 4) Disconnect the wires. 5) Remove one screw used for the ground connection. 6) Pull two clips of the electronic control box along the direction shown in the picture to the right to remove the main control board.
  • Page 46 40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS (CONT) Procedure Illustration 7) Remove the other screw used for the ground connection. 8) Collapse the support bar. 9) Pull the electronic control box cover along the direction shown in the image to the right to remove it. Ground Screw 10) Remove one screw then pull out the electronic control box subassembly.
  • Page 47 40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS (CONT) Evaporator NOTE: Remove the front panel, electrical parts and the fan. Procedure Illustration 1) Remove the 2 screws and then remove the panel frame assembly. 2) Disassemble the pipe clamp board. Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 48 40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS (CONT) Procedure Illustration 3) Remove the screw (1) on the evaporator located at the left fixed plate. 4) Remove the screw (1) on the evaporator located on the right side. 5) Bend the piping carefully, separate the chassis assembly (above) and the evaporator, then remove the evaporator.
  • Page 49 40MAHB: Service Manual DISASSEMBLY INSTRUCTIONS (CONT) Fan Motor and Fan Procedure Illustration 1) Open the two stop blocks of the chassis assembly (see picture on the right). 2) Remove the chassis assembly (below) along the direction (see picture on the right). 3) Remove the two screws and remove the fan motor board.
  • Page 50 Illustration 4) Remove the bearing sleeve. 5) Remove the screw. 6) Pull out the fan motor and the fan assembly from the side. © 2021 Carrier. All rights reserved. Edition Date: 07/21 Catalog No: SG-40MAHB-02 A Carrier company Replaces: SG-40MAHB-01...

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