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38MBQ
Outdoor Unit Single Zone Ductless System
Sizes 36 to 48
TABLE OF CONTENTS
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DIAGNOSIS GUIDES
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DIAGNOSIS AND SOLUTION
DISASSEMBLY INSTRUCTIONS
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 personal
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injury or death. WARNING signifies hazards which could result in
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personal injury or death. CAUTION is used to identify unsafe
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practices which may result in minor personal injury or product and
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property damage. NOTE is used to highlight suggestions which will
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result in enhanced installation, reliability, or operation.
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ELECTRICAL SHOCK HAZARD
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Failure to follow this warning could result in personal
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injury or death.
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Before installing, modifying, or servicing system, main
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electrical disconnect switch must be in the OFF
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position. There may be more than 1 disconnect switch.
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Lock out and tag switch with a suitable warning label.
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36
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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
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compressor at start−up.
INTRODUCTION
This Service Manual provides the necessary information to service,
repair, and maintain the 38MBQ 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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Summary of Contents for Carrier 38MBQ Series
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Page 1: Table Of Contents
38MBQ Outdoor Unit Single Zone Ductless System Sizes 36 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 personal PAGE injury or death. WARNING signifies hazards which could result in SAFETY CONSIDERATIONS . -
Page 2: Model/Serial Number Nomenclature
MODEL/SERIAL NUMBER NOMENCLATURE Table 1—Unit Sizes SYSTEM TONS kBTUh VOLTAGE - PHASE OUTDOOR MODEL 3.00 208/230-1 38MBQB36---3 4.00 208/230-1 38MBQB48---3 OUTDOOR UNIT 38 = OUTDOOR UNIT VOLTAGE 3 = 208/230-1-60 MB = MODEL SYSTEM TYPE Q = HEAT PUMP MAXIMUM NUMBER OF FAN COIL UNITS THAT CAN BE CONNECTED TO THE OUTDOOR UNIT NOT USED B = 1:1... -
Page 3: Specifications
SPECIFICATIONS Table 2—Specifications SYSTEM SIZE Outdoor Model 38MBQB36---3 38MBQB48---3 Voltage, Phase, Cycle V/Ph/Hz 208/230-1-60 208/230-1-60 Electrical MOCP - Fuse Rating Cooling Outdoor DB Min - Max °F(°C) -4~122 (-20~50) -4~122 (-20~50) Operating Range Heating Outdoor DB Min - Max °F(°C) -4~86 (-20~30) -4~86 (-20~30) Total Piping Length... -
Page 4: Dimensions
DIMENSIONS Fig. 1 – Outdoor Unit Table 3—Outdoor Unit OPERATING UNIT SIZE W in (mm) D in (mm) H in (mm) L1 in (mm) L2 in (mm) WEIGHT lb (kg) 37.2 (945) 15.5 (395) 31.8 (810) 25.2 (640) 15.9 (405) 137.5 (62.4) 36.93 (938) 15.4 (392) - Page 5 DIMENSIONS − OUTDOOR (CONT) Fig. 3 – Sizes 48K...
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Page 6: Clearances
CLEARANCES − OUTDOOR Air-inlet Air-outlet A07894 Fig. 4 – Outdoor Unit Clearance Table 4—Outdoor Unit Clearance Dimensions MINIMUM VALUE UNIT in. (mm) 24 (610) 24 (610) 24 (610) 4 (101) 4 (101) NOTE: Outdoor Unit must be mounted at least 2in (50mm) above the maximum anticipated snow depth. -
Page 7: Electrical Data
ELECTRICAL DATA Table 5—Single Zone Outdoor Unit OUTDOOR UNIT SIZE Volts-PH-Hz 208/230-1-60 208/230-1-60 Max – Min* Oper. Voltage 253-187 253-187 Power Supply Max Fuse/CB AMP Volts-PH-Hz 208/230-1-60 208/230-1-60 Compressor 13.5 13.4 *Permissible limits of the voltage range at which the unit will operate satisfactorily. LEGEND FLA - Full Load Amps MCA - Minimum Circuit Amps... -
Page 8: Wiring Diagrams
WIRING DIAGRAMS Fig. 6 – Wiring Diagram Size 36K Table 6—Outdoor Unit Main Board PART NAME PART NAME CN1,CN2 Power input: 230V AC CN3,CN22 Output: High voltage for 4-way control (230V AC) CN4,CN40 Output: High voltage for HEAT_Y control(230V AC) CN5,CN6 Output: Power output to DRIVER BOARD (230V AC) Input: Communication Main board and IPM Board,Pin1(12V DC),Pin2(5V DC ) - Page 9 WIRING DIAGRAMS (CONTINUED) Fig. 7 – Wiring Diagram − Size 48K Table 7—Outdoor Unit Main Board CN1,CN3 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,CN12 Input: Temperature sensor (5V DC)
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Page 10: Fan And Motor Specifications
FAN AND MOTOR SPECIFICATIONS Table 8—Fan and Motor Specifications SYSTEM SIZE Material Type ZL-560*139*12-3KN ZL-525*135*12-3KFN Outdoor Fan Diameter inch Height inch Model WZDK120-38G-W WZDK85-38G Phase Type 1.21 0.33 Insulation Class Safe Class IPX0 IPX0 Input Outdoor Fan Motor Output Range of Current Amps 1.21±10% 0.33±10%... -
Page 11: Refrigeration Cycle Diagrams
REFRIGERATION CYCLE DIAGRAMS INDOOR OUTDOOR Electronic CAPILIARY TUBE expansion valve LIQUID SIDE 2-WAY VALVE T3 Condenser temp. sensor HEAT EXCHANGE (EVAPORATOR) HEAT T4 Ambient T1 Room temp. T2 Evaporator EXCHANGE temp. sensor sensor temp. sensor (CONDENSER) middle T2B Evaporator temp. sensor outlet GAS SIDE 4-WAY VALVE... -
Page 12: Refrigerant Lines
3 Refrigerant lines should not be buried in the ground. If it is REFRIGERANT LINES 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 13: System Evacuation And Charging
Deep Vacuum Method SYSTEM EVACUATION AND 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 14: Electronic Functions
Condenser High Temperature T3 Protection: SYSTEM OPERATING CONDITIONS F(55 )<T3<140 ), the compressor Table 11—System Operating Conditions ° ° C ° ° C frequency decreases to the lower level until to F1 and OPERATING RANGE MIN / MAX °F (°C) then runs at F1. - Page 15 Defrosting Mode Point Check Function If any one of the following conditions are met, the AC enters the Press the remote controller LED DISPLAY or LED or MUTE DEFROSTING mode. After the compressor starts and continues button three times, and then press the AIR DIRECTION or to run, mark the minimum value of T3 from the 10th minute to SWING button three times in ten seconds (the buzzer rings for two 15th minute as T30.
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Page 16: Troubleshooting
For problems requiring measurements at the control boards, note TROUBLESHOOTING the following: This section provides the required flow charts to troubleshoot 1 Always disconnect the main power. problems that may arise. 2 When possible check the outdoor board first. NOTE: Information required in the diagnoses can be found 3 Start by removing the outdoor unit top cover. - Page 17 DIAGNOSTIC GUIDES Table 14—Diagnostic Guides Indoor Units OPERATION LAMP TIMER LAMP DISPLAY LED STATUS ☆ 1 time Indoor unit EEPROM parameter error ☆ 2 times Communication malfunction between indoor and outdoor units ☆ 4 times Indoor fan speed malfunction ☆ 5 times Indoor room temperature sensor (T1 ) malfunction ☆...
- Page 18 DIAGNOSIS AND SOLUTION Outdoor Unit Error Display Table 15—Diagnostic Table Outdoor Units PROBLEMS ERROR CODE Communication malfunction between indoor and outdoor units Current overload protection Outdoor ambient temperature sensor (T4 ) malfunction Condenser coil temperature sensor (T3) malfunction Compressor discharge temperature sensor (T5) malfunction Outdoor unit EEPROM parameter error Outdoor fan speed malfunction Inverter module (IPM) malfunction...
- Page 19 DIAGNOSIS AND SOLUTION (CONT) Table 16—Outdoor Check Function DISPLAY REMARK Normal display Display running frequency, running state or malfunction code Actual data*HP*10 If the capacity demand code is higher than 99, the digital display tube displays a single digit and tens digit. (For example, the digital display tube Indoor unit capacity demand code displays “5.0”,it means the capacity demand is 15.
- Page 20 DIAGNOSIS AND SOLUTION (CONT) Table 17—EEPROM Parameter Error Diagnosis and Solution (E0/F4) Error Code E0/F4 Malfunction conditions Indoor or outdoor PCB main chip does not receive feedback from EEPROM chip. Installation mistake Potential causes Faulty PCB Troubleshooting Power off, then restart the unit 2 minutes later Replace the indoor/outdoor main PCB...
- Page 21 DIAGNOSIS AND SOLUTION (CONT) Table 18—Overload Current Protection Diagnosis and Solution (F0) Error Code Malfunction decision conditions An abnormal current rise is detected by checking the specified current detection circuit. Power supply problems System blockage Supposed causes PCB faulty Wiring mistake Compressor malfunction Check the power supply Stop the unit...
- Page 22 DIAGNOSIS AND SOLUTION (CONT) Table 19—Indoor/Outdoor Unit Communication Error − Diagnosis and Solution (E1) Error Code Indoor unit does not receive feedback from outdoor unit for 60 seconds, or the outdoor unit does Malfunction decision conditions not receive feedback from indoor unit for 120 seconds. Wiring mistakes Supposed causes Faulty indoor or outdoor PCB...
- Page 23 DIAGNOSIS AND SOLUTION (CONT) Fig. 17 – DC Voltage Test Remark Use a multimeter to test the DC voltage between the outdoor unit’s L2 port and S ports (Fig. 16). The red pin of the multimeter connects with the L2 port while the black pin is for the S port. When the AC is running normally, the voltage moves alternatively between −50V to 50V. If the outdoor unit has a malfunction, the voltage moves alternatively with a positive value.
- Page 24 DIAGNOSIS AND SOLUTION (CONT) Index 1 Indoor or Outdoor DC Fan Motor (control chip is in the fan motor). Power on and when the unit is in standby, measure the voltage of pin−1 − pin3, pin4 −pin3 in the fan motor connector. If the value of the voltage is not in the range showing in the table below, the PCB has an issue and needs to be replaced.
- Page 25 DIAGNOSIS AND SOLUTION (CONT) Table 21—Open Circuit or Short Circuit of Temperature Sensor Diagnosis and Solution (E4/E5/F1/F2/F3) Error Code E4/E5/F1/F2/F3 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 26 DIAGNOSIS AND SOLUTION (CONT) Table 22—Refrigerant Leakage Detection Diagnosis and Solution (EC) Error Code 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) Malfunction Decision Conditions does not keep continuous 4 seconds and this situation happens 3 times, the display area shows “EC”...
- Page 27 DIAGNOSIS AND SOLUTION (CONT) Table 23—IPM Malfunction or IGBT Over−strong Current Protection Diagnosis and Solution (PO) Error Code When the voltage signal that IPM sends to the compressor drive chip is abnormal, the LED Malfunction Decision Conditions displays “PO” and the AC turns off. Wiring mistake IPM malfunction Supposed Causes...
- Page 28 DIAGNOSIS AND SOLUTION (CONT) Fig. 21 – P−U Fig. 22 – P−V...
- Page 29 DIAGNOSIS AND SOLUTION (CONT) Fig. 23 – P−W Fig. 24 – P−N...
- Page 30 DIAGNOSIS AND SOLUTION (CONT) Table 24—Over Voltage or Too Low Voltage Protection Diagnosis and Solution (P1) Error Code Malfunction Decision Conditions An abnormal current rise is detected by checking the specified current detection circuit. Power supply problems Supposed Causes System leakage or blockage PCB faulty Troubleshooting Check the power supply.
- Page 31 DIAGNOSIS AND SOLUTION (CONT) Table 25—High Temperature Protection of Compressor Top Diagnosis and Solution (P2) Error Code Malfunction Decision Conditions If the sampling voltage is not 5V, the LED displays the failure. Power supply problems Supposed Causes System leakage or block PCB faulty Troubleshooting Check the air flow system...
- Page 32 DIAGNOSIS AND SOLUTION (CONT) Table 26—Inverter Compressor Drive Error Diagnosis and Solution (P4) Error Code An abnormal inverter compressor drive is detected by a special detection circuit, including Malfunction Decision Conditions communication signal detection, voltage detection, compressor rotation speed signal detection and so Wiring mistake IPM malfunction Supposed Causes...
- Page 33 DIAGNOSIS AND SOLUTION (CONT) Main Parts Check 1 Temperature sensor checking Disconnect the temperature sensor from PCB, measure the resistance value with a tester. Fig. 25 – Tester Temperature Sensors: Room temp. (T1) sensor, Indoor coil temp. (T2) sensor, Outdoor coil temp. (T3) sensor, Outdoor ambient temp.
- Page 34 Compressor Checking Measure the resistance value of each winding by using the tester. Fig. 26 – Tester Table 27—Resistance Value POSITION RESISTANCE VALUE DA110S1C-30FZ Blue - Red Blue - Black 0.8Ω Red - Blue Fig. 27 – Compressor Checking...
- Page 35 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. Table 28—IPM Continuity Check DIGITAL TESTER NORMAL RESISTANCE VALUE DIGITAL TESTER NORMAL RESISTANCE VALUE...
- Page 36 DISASSEMBLY INSTRUCTIONS SIZE 36 Part name Procedures Remarks Panel plate How to remove the panel Big handle screws (4) plate Top panel screws (3), 1 screw is under the big handle) 1) Stop the air conditioner and turn off the power breaker.
- Page 37 DISASSEMBLY INSTRUCTIONS SIZE 36 (CONT) Fan assembly How to remove the fan assembly Electronic control box 1) Use procedure 1 to remove the panel plate. compressor 2) Remove the nut securing the fan, then remove the fan. 3) Unfix the hooks and remove the screws.
- Page 38 DISASSEMBLY INSTRUCTIONS SIZE 36 (CONT) Compressor T3,T4,T5,sensor Pressure switch wire 4) Disconnect the fan motor connector from the electronic control board. Motor wire Electronic expansion 4 way valve 5) Remove the fan motor’s four screws (4) then remove the motor.
- Page 39 DISASSEMBLY INSTRUCTIONS SIZE 36 (CONT) Electrical How to remove the parts electrical parts. 1) After completing steps in sections 1 and 2, remove the compressor connector. 2) Pull out the two blue wires connected with the four-way valve. 3) Pull out the condenser coil temp.
- Page 40 DISASSEMBLY INSTRUCTIONS SIZE 36 (CONT) 4) Disconnect the pressure switch connector. 5) Disconnect the electronic expansion valve wire from the control board. 6) Remove the ground wires. 7) Remove the wires (1,2,3 or L1,L2, S). Next, remove the electronic control box.
- Page 41 DISASSEMBLY INSTRUCTIONS SIZE 36 (CONT) Four-way How to remove the four-way valve. valve The picture of the four-way valve may differ from your actual valve. 1) Complete the steps in sections 1 and 3. 2) Recover refrigerant from the refrigerant circuit. 3) Remove the coil screw and then remove the coil.
- Page 42 DISASSEMBLY INSTRUCTIONS SIZE 48 Part name Procedures Remarks Fan assembly How to remove the fan assembly. 1) Stop the air conditioner and turn off the power breaker. 2) Remove the air outlet grille screws (8). 3) Remove the hex nut securing the fan.
- Page 43 DISASSEMBLY INSTRUCTIONS SIZE 48 (CONT) 6) Remove the right front side screws and the right front side panel (1 screw). 7) Disconnect the fan motor connectors FAN (3p, white) and FAN2 (3p, white) from the DC motor driver board. 8) Remove the fan motor after unfastening the securing screws.
- Page 44 DISASSEMBLY INSTRUCTIONS SIZE 48 (CONT) Screws of right-rear panel Electrical How to remove the electrical parts. parts 1) Complete steps 5 - 6 in section 1 and section 2. DC Fan IPM board PCB board Driver board 2) Disconnect the fan motor connector (5p, white) from the IPM board.
- Page 45 DISASSEMBLY INSTRUCTIONS SIZE 48 (CONT) CN2(yellow) CN1(red) CN6(black) CN3(yellow) W(black) CN9(10p,white) 4) Remove the screws securing the IPM board and remove the IBM board. 5) Disconnect the connectors and wires connected from the PCB and other parts. Connectors: CN8: Discharge temperature sensor CN1/CN3 (2p,white) CN12...
- Page 46 DISASSEMBLY INSTRUCTIONS SIZE 48 (CONT) 6) Disconnect the grounding wire (yellow-green) after removal of the big handle. 7) Remove the PCB board. Compressor How to remove the compressor. 1) Complete steps 5 - 6 in section and section 2. 2) Extract the refrigerant gas. 3) Remove the sound insultation material and crankcase heating cable.
- Page 47 DISASSEMBLY INSTRUCTIONS SIZE 48 (CONT) The 4-way How to remove the 4-way valve valve 1) Complete steps 5 - 6 of section 1 and section 2. Coil 2) Extract the refrigerant gas. Welded parts 3) Remove the electrical parts in section 3. 4) Remove the coil screw and remove the coil.
- Page 48 Catalog No:38MBQ-01SM Copyright 2016 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 10/16 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces: NEW...
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