Carrier xpower blue II 42KCL109313G Service Manual
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Carrier xpower blue II 42KCL109313G Service Manual

C10 inverter series
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C10 INVERTER SERIES
Service Manual 2012
CSI-A1-1206

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Summary of Contents for Carrier xpower blue II 42KCL109313G

  • Page 1 C10 INVERTER SERIES Service Manual 2012 CSI-A1-1206...

  • Page 2: Table Of Contents

    CONTENTS 1. Precaution .............................. 1 1.1 Safety Precaution .......................... 1 1.2 Warning ............................1 2. Function ..............................5 3. Dimension .............................. 6 3.1 Indoor Unit ............................. 6 3.2 Outdoor Unit ..........................8 4. Refrigerant Cycle Diagram ........................9 5. Wiring Diagram ............................ 10 5.1 Indoor Unit ...........................

  • Page 3: Precaution

    1. Precaution 1.1 Safety Precaution  To prevent injury to the user or other people and property damage, the following instructions must be followed.  Incorrect operation due to ignoring instruction will cause harm or damage.  Before service the unit, be sure to read this service manual at first. 1.2 Warning ...
  • Page 4 condenser and evaporator.  For installation, always contact the dealer or an authorized service center.  Do not install the product on a defective installation stand.  Be sure the installation area does not deteriorate with age. If the base collapses, the air conditioner could fall with it, causing property damage, product failure, and personal injury.
  • Page 5 There is risk of property damage, failure of product, or electric shock.  Do not open the inlet grill of the product during operation. (Do not touch the electrostatic filter, if the unit is so equipped.) There is risk of physical injury, electric shock, or product failure. ...
  • Page 6 could cause product malfunction or inefficient operation.  Operational  Do not expose the skin directly to cool air for long time. (Do not sit in the draft).  Do not use the product for special purposes, such as preserving foods, works of art etc. It is a consumer air conditioner, not a precision refrigerant system.

  • Page 7: Function

    2. Function Model Names of Indoor/Outdoor Units Capacity Indoor units Outdoor units 42KCL109313G 38KCL109313G 42KCL112313G 38KCL112313G Inverter 42KCL118313G 38KCL118313G 42KCL124313G 38KCL124313G Filter killer of formaldehyde Ionizer(O) 8 degree heating(O) Silver Ico Filter(O) Heat compensation(O) Vitamin C Filter(O) Self-diag. function 3M HAM Filter(O) Hydrophilic aluminum fin Bio Filter(O) Anti-rust cabinet...

  • Page 8: Dimension

    3. Dimension 3.1 Indoor Unit Model 42KCL109313G 42KCL112313G 42KCL118313G 42KCL124313G 1080 Model R(mm) L(mm) H(mm) Dimension of installation hole(mm) 42KCL109313G Φ65 42KCL112313G...
  • Page 9 Dimension of installation Model R(mm) L(mm) H(mm) hole(mm) Φ65 42KCL118313G Model R(mm) L(mm) H(mm) Dimension of installation hole(mm) Φ65 42KCL124313G 106.5...

  • Page 10: Outdoor Unit

    3.2 Outdoor Unit More than 30cm More than 60cm (Service space) More than 30cm More than 60cm More than 70cm Model 38KCL109313G 38KCL112313G 38KCL118313G 38KCL124313G...

  • Page 11: Refrigerant Cycle Diagram

    4. Refrigerant Cycle Diagram INDOOR OUTDOOR CHECK VALVE LIQUID SIDE (Heating Model only) 2-WAY VALVE CAPILIARY TUBE HEAT HEAT EXCHANGE EXCHANGE (EVAPORATOR) (CONDENSER) GAS SIDE REVERSING VALVE 3-WAY VALVE (Heating Model only) ACCUMULATOR COOLING COMPRESSOR HEATING...

  • Page 12: Wiring Diagram

    5. Wiring Diagram 5.1 Indoor Unit 42KCL109313G /42KCL112313G 42KCL118313G...
  • Page 13 42KCL124313G...

  • Page 14: Outdoor Unit

    5.2 Outdoor Unit 38KCL109313G / 38KCL112313G 38KCL118313G...
  • Page 15 38KCL124313G...

  • Page 16: Installation Details

    6 Installation Details 6.1 Wrench torque sheet for installation Outside diameter Torque Additional tightening torque inch N.cm N.cm Ф6.35 1500(153kgf.cm) 1600(163kgf.cm) Ф9.52 2500(255kgf.cm) 2600(265kgf.cm) Ф12.7 3500(357kgf.cm) 3600(367kgf.cm) Ф15.9 4500(459kgf.cm) 4700(479kgf.cm) Ф19 6500(663kgf.cm) 6700(683kgf.cm) 6.2 Connecting the cables The power cord of connect should be selected according to the following specifications sheet. Rated current of appliance Nominal cross-sectional area (mm²) >3 and ≤6...

  • Page 17: Pipe Length And The Elevation

    6.3 Pipe length and the elevation The pipe length and refrigerant amount: Pipe size Standard Max. Max. Additional Capacity length Elevation Length refrigerant Btu/h Liquid B (m) A (m) (g/m) 3/8’’ 1/4’’ 38KCD109313G+ 38KCD109313G (Ф9.52) (Ф6.35) 42KCD112313G+ 38KCD112313G 1/2" 1/4’’ 42KCD118313G + 38KCD118313G (Ф12.7) (Ф6.35)

  • Page 18: Installation For The First Time

    6.4 Installation for the first time Air and moisture in the refrigerant system have undesirable effects as below: ● Pressure in the system rises. ● Operating current rises. ● Cooling efficiency drops. ● Moisture in the refrigerant circuit may freeze and block capillary tubing. ●...
  • Page 19 the meter does not indicate -0.1Mpa after pumping 30 minutes, it should be pumped 20 minutes more. If the pressure can’t achieve -0.1Mpa after pumping 50 minutes, please check if there are some leakage points. Fully close the handle Lo valve of the manifold valve and stop the operation of the vacuum pump. Confirm that the gauge needle does not move (approximately 5 minutes after turning off the vacuum pump).
  • Page 20 Close the valve on the charging cylinder and discharge the refrigerant by loosening the flare nut on the 2-way valve approximately 45’ until the gauge indicates 0.3 to 0.5 Mpa. 6). Disconnect the charge set and the charging cylinder, and set the 2-way and 3-way valves to the open position.

  • Page 21: Adding The Refrigerant After Running The System For Many Years

    6).When the electronic scale displays the proper weight (refer to the table), disconnect the charge hose from the 3-way valve’s service port immediately and turn off the air conditioner before disconnecting the hose. 7). Mount the valve stem caps and the service port Use torque wrench to tighten the service port cap to a torque of 18N.m.

  • Page 22: Re-Installation While The Indoor Unit Need To Be Repaired

    6).When the electronic scale displays the proper weight (refer to the gauge and the pressure of the low side), disconnect the charge hose from the 3-way valve’s service port immediately and turn off the air conditioner before disconnecting the hose. 7).
  • Page 23 5). Operate the air conditioner at the cooling cycle and stop it when the gauge indicates 0.1MPa. 6). Set the 3-way valve to the closed position immediately Do this quickly so that the gauge ends up indicating 0.3 to 0.5Mpa. Disconnect the charge set, and tighten the 2-way and 3-way valve’s stem nuts.

  • Page 24: Re-Installation While The Outdoor Unit Need To Be Repaired

    Close the valve on the charging cylinder and discharge the refrigerant by loosening the flare nut on the 2-way valve approximately 45’ until the gauge indicates 0.3 to 0.5 Mpa. 6). Disconnect the charge set and the charging cylinder, and set the 2-way and 3-way valves to the open position Be sure to use a hexagonal wrench to operate the valve stems.
  • Page 25 2. Refrigerant charging Electronic scale Procedure: 1). Connect the charge hose to the charging cylinder, open the 2-way valve and the 3-way valve Connect the charge hose which you disconnected from the vacuum pump to the valve at the bottom of the cylinder.
  • Page 26 Use torque wrench to tighten the service port cap to a torque of 18N.m. Be sure to check for gas leakage...

  • Page 27: Operation Characteristics

    7. Operation Characteristics Temperature Cooling operation Drying operation Mode ＞10℃ ≥17℃ Room temperature 0℃～50℃ -15℃～50℃ Outdoor temperature 0℃～50℃ (For the models with low temperature cooling system) CAUTION: 1. If the air conditioner is used beyond the above conditions, certain safety protection features may come into operation and cause the unit to operate abnormally.

  • Page 28: Electronic Function

    8. Electronic function 8.1 Abbreviation T1: Indoor room temperature T2: Coil temperature of evaporator T3: Coil temperature of condenser T4: Outdoor ambient temperature T5: Compressor discharge temperature 8.2 Display function 8.2.1 Icon explanation on indoor display board. ① Auto indicator This indicator illuminates when the air conditioner is in AUTO operation.

  • Page 29: Main Protection

    8.3 Main Protection 8.3.1 Three Minutes Delay at restart for compressor 1 minute delay for the 1 time start-up and 3 minutes delay for others. 8.3.2 Temperature protection of compressor top The unit will stop working when the compressor top temp. protector cut off, and will restart after the compressor top temp.

  • Page 30: Operation Modes And Functions

    8.3.8 Zero crossing detection error protection If AC detects time interval is not correct for continuous 240s, the unit will stop and the LED will display the failure. The correct zero crossing signal time interval should be between 6-13ms. 8.4 Operation Modes and Functions 8.4.1 Fan mode (1) Outdoor fan and compressor stop.
  • Page 31 minutes according to the outdoor ambient temp. During the 7 minutes, the frequency limitation is active. 7 minutes later, the compressor running frequency will be controlled as below: -0.5 -1.0 While the zones of A,B,C... are corresponding to different compressor running frequency. Note: When T1-Ts keeps in the same temp.
  • Page 32 Resume: No limitation for frequency. Note: When AC is in “hold” zone for 3 minutes, the compressor frequency will rise to the higher level.(frequency will increase twice at most) 8.4.2.2 Outdoor fan running rules High 8.4.2.3 Indoor fan running rules In cooling mode, indoor fan runs all the time and the speed can be selected as high, medium, low and auto.
  • Page 33 ℃ ℃ ---4 ≤T2≤7 , the compressor will keep the current frequency. ℃ ---T2>7 , the compressor frequency will not be limited. 8.4.3Auto-mode This mode can be chosen with remote controller and the setting temperature can be changed between ℃ 17~30 .
  • Page 34 frequency limit are active and the same as that in cooling mode. 8.4.4.5 The outdoor fan operates the same as in cooling mode. 8.4.5 Forced operation function 8.4.5.1 Enter forced operation function: When the machine is off, pressing the touch button will carry the machine to forced auto mode. If pressing the button once again within 5 seconds, the machine will turn into forced cooling mode.

  • Page 35: Troubleshooting

    setting temperature stops rising and indoor fan is fixed as low speed. 8.4.7.3 Timer setting is available 8.4.7.4 When user uses timer off function in sleep mode (or sleep function in timer off mode), if the timing is less than 7 hours, sleep function will be cancelled when reaching the setting time. If the timing is more than 7 hours, the machine will not stop until reaches the setting time in sleep mode.

  • Page 36: Diagnosis And Solution

    9.2 Diagnosis and Solution 9.2.1 EEPROM parameter error diagnosis and solution...
  • Page 37 9.2.2 Indoor unit and outdoor unit communication protection error diagnosis and solution...
  • Page 38 9.2.3 Indoor fan speed has been out of control diagnosis and solution 9.2.4 Open circuit or short circuit of temperature sensor diagnosis and solution...
  • Page 39 9.2.5 IPM malfunction or IGBT over-strong current protection diagnosis and solution Check if the wiring between module PCB and compressor Correct the connection. connected correctly. IPM continuity check. Check if the IPM Replace the module PCB. terminal resistance values are uniform. Correct the installation, tighten the Check if the IPM installed correctly.
  • Page 40 9.2.7 High temperature protection of compressor top diagnosis and solution...
  • Page 41 9.2.8 Inverter compressor drive error diagnosis and solution 9.2.9 Zero crossing detection error diagnosis and solution Check if the connections and Correct the connections. Turn on the power supply is normal? unit when the power supply is good. Indoor PCB is defective. Replace indoor PCB.
  • Page 42 Main parts check 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.

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