Carrier 38MPRAQ09AA3 Service Manual
Carrier 38MPRAQ09AA3 Service Manual

Carrier 38MPRAQ09AA3 Service Manual

Outdoor unit single zone ductless system. sizes 09 to 24
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38MPRA
Outdoor Unit Single Zone Ductless System
Sizes 09 to 24

TABLE OF CONTENTS

SAFETY CONSIDERATIONS ....................................................... 1
INTRODUCTION............................................................................ 1
MODEL NUMBER NOMENCLATURE ....................................... 2
SPECIFICATIONS .......................................................................... 3
DIMENSIONS ................................................................................. 4
CLEARANCES................................................................................ 6
ELECTRICAL DATA ..................................................................... 7
WIRING ........................................................................................... 7
CONNECTION DIAGRAM............................................................ 8
WIRING DIAGRAM....................................................................... 9
FAN AND MOTOR SPECIFICATIONS ........................................ 12
REFRIGERATION CYCLE DIAGRAM........................................ 12
REFRIGERANT LINES .................................................................. 13
SYSTEM EVACUATION AND CHARGING ............................... 14
OPERATION MODES AND FUNCTIONS ................................... 15
TROUBLESHOOTING ................................................................... 20
ERROR CODE................................................................................. 22
QUICK MAINTENANCE BY ERROR CODE .............................. 26
TROUBLESHOOTING BY ERROR CODE .................................. 27
DIAGNOSIS AND SOLUTION...................................................... 29
DISASSEMBLY INSTRUCTIONS ................................................ 45
APPENDICES.................................................................................. 65

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 the 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 the 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
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
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.
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 with a
suitable warning label.
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 indoor units. 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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Table of Contents
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Summarization of Contents

SAFETY CONSIDERATIONS
General Safety Precautions
Discusses hazards, trained personnel, safety codes, and the safety alert symbol.
Electrical Shock Hazard
Warns about electrical shock and the need to turn off the disconnect switch.
Explosion Hazard
Warns against using oxygen for leak testing, risking explosion.
Equipment Damage Hazard
Warns about burying refrigerant pipe too deep, potentially damaging the compressor.
INTRODUCTION
Service Manual Overview
Provides information for servicing, repair, and maintenance.
MODEL NUMBER NOMENCLATURE
Unit Size Table
Lists unit sizes, capacities, and outdoor models.
Model Number Breakdown
Explains the structure and meaning of the model number components.
SPECIFICATIONS
Heat Pump Specifications
Details electrical, operating range, piping, refrigerant, and component specs for heat pumps.
DIMENSIONS
Sizes 9K and 12K Dimensions
Provides dimensional drawings and specifications for 9K and 12K units.
DIMENSIONS (Continued)
Sizes 18K and 24K Dimensions
Provides dimensional drawings and specifications for 18K and 24K units.
CLEARANCES
Outdoor Unit Clearances
Specifies minimum clearance values for outdoor unit installation.
Clearances for Multiple Units
Illustrates and specifies clearances required for multiple unit arrangements.
ELECTRICAL DATA
Electrical Data Table
Lists electrical specifications like voltage, MCA, MOCP, RLA, and fan motor ratings.
WIRING
Power and Communication Wiring
Details recommended wiring methods for power and communication, including wire types and precautions.
Wiring Safety Cautions
Provides crucial cautions regarding wire sizing, connections, and routing to prevent hazards.
CONNECTION DIAGRAM
Indoor and Outdoor Unit Connections
Illustrates the wiring connections between indoor and outdoor units, including notes on polarity sensitivity.
WIRING DIAGRAM
Wiring Diagram for 09K and 12K
Presents the wiring diagram for the 09K and 12K models.
Wiring Diagram Abbreviations
Lists abbreviations used in the wiring diagrams and their paraphrased meanings.
WIRING DIAGRAM (Continued)
Wiring Diagram for 18K and 24K
Presents the wiring diagram for the 18K and 24K models.
WIRING DIAGRAM (Continued)
Wiring Diagram Components (18K-24K)
Lists components and their codes for the 18K and 24K wiring diagrams.
Outdoor Unit PFC & Main Board Wiring
Details wiring for the Outdoor Unit PFC and Main Board.
FAN AND MOTOR SPECIFICATIONS
Outdoor Fan Motor Specs
Lists material, dimensions, voltage, FLA, HP, and input for outdoor fan motors.
REFRIGERATION CYCLE DIAGRAM
Heat Pump Refrigeration Cycle
Illustrates the refrigeration cycle for heat pump operation, showing key components.
REFRIGERANT LINES
General Refrigerant Line Sizing
Provides guidelines for sizing refrigerant lines, including minimum length and insulation.
Piping and Refrigerant Information
Details piping specifications, refrigerant type, and charge amounts for various unit sizes.
Long Line Applications
Provides guidance on additional refrigerant charge for longer line sets.
SYSTEM EVACUATION AND CHARGING
Vacuum Pump Procedure
Steps for evacuating the system using a vacuum pump.
Deep Vacuum Method
Explains the deep vacuum method for ensuring a system is free of air and moisture.
Triple Vacuum Method
Details the triple evacuation method with specific micron and pressure steps.
Final Tubing Check
Emphasizes checking refrigerant tubing for proper securing and avoiding rubbing.
OPERATION MODES AND FUNCTIONS
Unit Element Abbreviations
Lists abbreviations for unit elements like temperature sensors.
Safety Features
Covers compressor delay, discharge temp shutoff, fan speed shutoff, and inverter protection.
Unit Display Functions
Shows how various functions are displayed on the unit.
FAN Mode
FAN Mode Operation
Explains operation, temperature control, and fan speed settings in FAN mode.
COOLING Mode
Compressor Control in Cooling
Details compressor control logic based on runtime, frequency, and temperature.
Indoor Fan Control in Cooling
Describes how indoor fan speed adjusts based on temperature differences.
Outdoor Fan Control
Explains how outdoor fan speed is determined by temperature and compressor frequency.
Condenser/Evaporator Protection
Covers protection mechanisms related to condenser and evaporator temperatures.
MODE OPERATIONS
HEATING Mode Details
Covers compressor control, indoor/outdoor fan, and protection in heating mode.
DEFROSTING Mode Operation
Explains defrosting triggers, conditions, and indicators.
Evaporator Temperature Protection Levels
Details actions taken based on evaporator temperature: Off, Decrease, Hold, Resume.
AUTO and DRY Mode Operation
Explains AUTO mode selection and DRY mode specifics including protection.
OPERATIONAL FEATURES
Forced Operation and Timer Functions
Details forced modes, timer on/off/on-off functions.
Sleep, Auto-Restart, and Low Temp Heating
Covers sleep mode, auto-restart, and 46°F heating protection.
Energy Saving and Cleaning Functions
Explains ECO function and Self Clean for efficiency and maintenance.
Follow Me Functionality
Explains the Follow Me feature where the unit adjusts temperature based on remote controller location.
Silence
Silence Function
Describes the Silence function for reducing noise by setting faint breeze fan speed.
Occupancy Sensor (Sizes 09K-12K)
Occupancy Sensor Operation
Explains how the occupancy sensor detects movement and adjusts compressor frequency for energy saving.
Information Inquiry
Information Inquiry Procedure
Details the procedure to access and view information codes using the remote controller.
Information Codes Table
Lists displayed codes, their explanations, and additional notes for troubleshooting.
TROUBLESHOOTING
Safety Warning: Capacitors
Warns about residual electricity in capacitors and the need for discharging before troubleshooting.
Electrolytic Capacitors
Identifies electrolytic capacitors and provides a caution regarding high voltage.
Discharge Position
Illustrates the correct position for discharging capacitors using a soldering iron or resistance.
Troubleshooting (continued)
Indoor Unit Error Codes
Lists error codes displayed by the indoor unit and their corresponding solutions.
Troubleshooting Display Issues
Provides steps for troubleshooting unresponsive displays or remote control issues.
ERROR DIAGNOSIS AND TROUBLESHOOTING WITHOUT ERROR CODE
Remote Maintenance Troubleshooting
Correlates causes with remote control and electrical/refrigerant circuit checks.
ERROR DIAGNOSIS AND TROUBLESHOOTING WITHOUT ERROR CODE (continued)
Field Maintenance Troubleshooting
Correlates causes with field maintenance checks for electrical circuits.
ERROR DIAGNOSIS AND TROUBLESHOOTING WITHOUT ERROR CODE (continued)
Other Troubleshooting Factors
Covers troubleshooting for load conditions, assembly, capacity, and piping contact.
QUICK MAINTENANCE BY ERROR CODE
Error Code Part Replacement (Table 22)
Guides part replacement based on error codes E0-F0.
Error Code Part Replacement (Table 23)
Guides part replacement based on error codes F1-P4.
TROUBLESHOOTING BY ERROR CODE
Temperature Sensor Check
Instructions for checking temperature sensor resistance using a tester.
Compressor Checking
Instructions for measuring compressor winding resistance with a multimeter.
TROUBLESHOOTING BY ERROR CODE (continued)
IPM Continuity Check
Details how to measure resistance between IPM terminals for continuity testing.
DIAGNOSIS AND SOLUTION
E0/F4/EA EEPROM Parameter Error
Diagnoses and provides solutions for EEPROM parameter errors, including PCB replacement.
EEPROM Chip Location
Shows the physical location of the EEPROM chip on indoor and outdoor PCBs.
E1 (Indoor and Outdoor Unit Communication Error)
E1 Communication Error Troubleshooting
Outlines steps to diagnose and resolve communication errors between indoor and outdoor units.
E1 (Indoor and Outdoor Unit Communication Error) (continued)
Voltage Measurement for E1
Explains how to measure DC voltage for communication error diagnosis.
Reactor Resistance Check
Guides testing reactor resistance for proper function in communication circuits.
E2 (Zero crossing detection error diagnosis and solution)
E2 Zero Crossing Error Troubleshooting
Provides steps to diagnose and resolve zero crossing detection errors, involving PCB checks.
E3/F5 (Fan speed is operating outside of the Normal Range)
E3/F5 Fan Speed Error Troubleshooting
Details troubleshooting for indoor/outdoor fan speed errors, including wiring and PCB checks.
Index
Indoor/Outdoor DC Fan Motor Voltage
Explains how to measure voltage for DC fan motors and diagnose PCB issues.
Outdoor DC Fan Motor Troubleshooting
Outlines checks for outdoor DC fan motor functionality and PCB issues.
Indoor AC Fan Motor Voltage
Details voltage measurement for indoor AC fan motors to diagnose PCB problems.
EF (Occupancy Sensor Module Error Diagnosis and Solution)
EF Occupancy Sensor Error Troubleshooting
Provides steps to diagnose and resolve occupancy sensor module errors, including wiring and replacement.
P1 (Over voltage or too low voltage protection diagnosis and solution)
P1 Voltage Protection Troubleshooting
Guides troubleshooting for over/under voltage protection, checking power supply, wiring, reactor, and PCB.
P2 (High temperature protection of IPM module diagnosis and solution)
P2 IPM High Temp Troubleshooting
Details troubleshooting for IPM module high-temperature protection, focusing on screws and grease.
P4 (Inverter compressor drive error diagnosis and solution)
P4 Inverter Compressor Error Troubleshooting
Outlines troubleshooting for inverter compressor drive errors, checking wiring, IPM, fan, and compressor resistance.
E4/E5/F1/F2/F3 (Open circuit or short circuit of temperature sensor diagnosis and solution)
Temperature Sensor Circuit Errors
Guides diagnosis and solution for temperature sensor open/short circuit issues, checking connections, resistance, and PCB.
Eb (Communication error between the Indoor PCB and Display Board)
Eb Indoor/Display Board Communication Error
Details troubleshooting for communication errors between indoor PCB and display board, checking wiring and boards.
F0 (Overload current protection diagnosis and solution)
F0 Overload Current Protection Troubleshooting
Outlines troubleshooting for overload current protection, checking power, blockages, compressor, reactor, and PCB.
P0 (IPM malfunction or IGBT over-strong current protection diagnosis and solution)
P0 IPM Malfunction Troubleshooting
Provides steps to diagnose and resolve IPM malfunction or over-strong current protection issues.
Pressure on Service Port
Cooling Chart (R410A)
Presents pressure-temperature data for R410A refrigerant in cooling mode.
Pressure on Service Port (continued)
Heating Chart (R410A)
Presents pressure-temperature data for R410A refrigerant in heating mode.
DISASSEMBLY INSTRUCTIONS
Outdoor Unit Panel Plate Removal (9K-12K)
Step-by-step guide to remove the panel plate from the 9K-12K outdoor unit.
Front Panel and Water Cover Removal (9K-12K)
Details removing the front panel and water collecting cover from the outdoor unit.
Right Panel Removal (9K-12K)
Provides instructions for removing the right panel of the outdoor unit.
Electrical Parts / PCB Board Disassembly (9K-12K)
Steps for disconnecting and removing electrical parts and the PCB board.
Fan Disassembly (9K-12K)
Instructions for removing the fan and fan motor from the outdoor unit.
Sound Blanket Removal (9K-12K)
Steps to remove the sound blanket from the outdoor unit.
Four-way Valve Disassembly (9K-12K)
Instructions for detaching and removing the four-way valve assembly.
Compressor Terminal Cover and Connectors (9K-12K)
Steps for removing the compressor terminal cover and disconnecting connectors.
Compressor Removal (9K-12K)
Instructions for removing the compressor, including pipes and mounting hardware.
Outdoor Unit Panel Plate Removal (18K-24K)
Step-by-step guide to remove the panel plate from the 18K-24K outdoor unit.
Front Panel Removal (18K-24K)
Details removing the front panel from the 18K-24K outdoor unit.
Water Collecting Cover Removal (18K-24K)
Instructions for removing the water collecting cover.
Right Panel Removal (18K-24K)
Provides instructions for removing the right panel of the 18K-24K outdoor unit.
Electrical Parts / PCB Board Disassembly (18K-24K)
Steps for disconnecting and removing electrical parts and the PCB board for 18K-24K.
Fan Disassembly (18K-24K)
Instructions for removing the fan and fan motor from the 18K-24K outdoor unit.
Sound Blanket Removal (18K-24K)
Steps to remove the sound blanket from the 18K-24K outdoor unit.
Four-way Valve Disassembly (18K-24K)
Instructions for detaching and removing the four-way valve assembly for 18K-24K.
Compressor Terminal Cover and Connectors (18K-24K)
Steps for removing the compressor terminal cover and disconnecting connectors for 18K-24K.
Compressor Removal (18K-24K)
Instructions for removing the compressor, including pipes and mounting hardware for 18K-24K.
APPENDICES
Appendix 1: Temperature Sensor Resistance Table (T1-T4)
Provides resistance values for temperature sensors T1, T2, T3, and T4 across various temperatures.
Appendix 2
Appendix 2: Temperature Sensor Resistance Table (TP)
Provides resistance values for the TP temperature sensor across various temperatures.
Appendix 3
Appendix 3: Celsius - Fahrenheit Conversion
A table for converting Celsius temperatures to Fahrenheit.

Table of Contents