Carrier 38NYV009E Service Manual Download

Page: 1 / 86

April, 2007

FILE NO. SVM-07018-1

NQV009E / 38NYV009E

42NQV012E / 38NYV012E

SERVICE MANUAL

AIR-CONDITIONER

SPLIT WALL TYPE

Summary of Contents for 38NYV009E

Page 1: ...April 2007 FILE NO SVM 07018 1 42NQV009E 38NYV009E 42NQV012E 38NYV012E SERVICE MANUAL AIR CONDITIONER SPLIT WALL TYPE...

Page 2: ...2 Outdoor Unit 38NYV009E 38NYV012E 5 SPECIFICATION OF ELECTRICAL PARTS 5 1 Indoor Unit 5 2 Outdoor Unit 38NYV009E 38NYV012E 6 REFRIGERANT CYCLE DIAGRAM 6 1 Refrigerant Cycle Diagram 42NQV009E 38NYV009...

Page 3: ...1C Miswiring in indoor outdoor units and 1E 10 7 How to Diagnose Trouble in Outdoor Unit 10 8 How to Check Simply the Main Parts 10 9 How to Simply Judge Whether Outdoor Fan Motor is Good or Bad 11 H...

Page 4: ...ary type with DC inverter variable speed control COP Cooling Heating DA89X1C 23FZ 20 1450 1450 Flare connection Operation noise 6 35 Indoor 9 52 6 35 9 52 10 10 8 Medium Cooling Heating R410A 0 63 3 W...

Page 5: ...eed control COP Cooling Heating DA89X1C 23FZ 30 1650 1650 Flare connection Operation noise 6 35 Indoor 9 52 6 35 9 52 15 15 10 Medium Cooling Heating R410A 0 82 3 Wires includes earth Outdoor 4 Wires...

Page 6: ...ndoor DB 20 C Indoor air flow High Pipe length 5m Capacity ratio 100 Nominal Capacity 105 100 95 90 85 80 75 70 65 60 55 50 32 34 36 38 40 42 33 35 37 39 41 43 Outdoor temp C Capacity ratio Conditions...

Page 7: ...in Table 2 2 1 Never use copper pipes thinner than 0 8 mm even when it is available on the market 2 REFRIGERANT R410A This air conditioner adopts the new refrigerant HFC R410A which does not damage t...

Page 8: ...at a clamp bar and copper pipe have been cleaned By means of the clamp bar perform the flare processing correctly Use either a flare tool for R410A or conventional flare tool Flare processing dimensio...

Page 9: ...to 2 0 5 8 15 88 1 0 0 to 0 5 0 5 to 1 0 1 0 to 2 0 Table 2 2 4 Dimensions related to flare processing for R22 Nominal diameter Outer diameter mm Thickness mm Flare tool for R410A clutch type Dimensi...

Page 10: ...nut may crack and may be made non removable When choosing the tightening torque comply with values designated by manufacturers Table 2 2 7 shows reference values Note When applying oil to the flare su...

Page 11: ...used with for R410A equipment can conventional refrigerant be used 1 Flare tool Pipe flaring Yes Note 1 2 Copper pipe gauge Flaring by for adjusting projection conventional flare Yes Note 1 Note 1 ma...

Page 12: ...er does not return Set the refrigerant cylinder to the electronic balance connect the connecting hose to the cylinder and the connecting port of the electronic balance and charge liquid refrigerant Fo...

Page 13: ...solderability 2 Phosphor bronze brazing filler Phosphor bronze brazing filler is generally used to join copper or copper alloy 3 Low temperature brazing filler Low temperature brazing filler is genera...

Page 14: ...cal knowledge it must be performed by a person qualified In order to prevent the oxide film from occurring in the pipe interior during brazing it is effective to proceed with brazing while letting dry...

Page 15: ...150 150 160 160 26 32 45 40 190 275 45 235 120 Hanger Hanger Hanger Hanger Hanger Drain hose 0 54m Connecting pipe 0 43m Flare 6 35 Connecting pipe 0 33m For stud bolt 8 10 For stud bolt 6 Installati...

Page 16: ...C L C L 3 2 Outdoor Unit FILE NO SVM 07018 15...

Page 17: ...former and the power supply circuit of the rated voltage 2 1 3 4 5 Check the voltage at the No 1 pin on CN10 connector and CN24 Check the F01 6 AC 220 240V 1 2 2 3 MCC 861 BLK HA JEM A CN21 TERMINAL B...

Page 18: ...4 2 Outdoor Unit 38NYV009E 38NYV012E FILE NO SVM 07018 17...

Page 19: ...04051 0 6mH 15A Noise filter L03 GET 04052 2 0mH 10A Primary side DC280V Secondary 2 DC DC transformer SWT 72 side 7 0 V x 1 12 V x 1 17V x 2 3 Reactor CH 51 Z T L 19mH 10A 4 Outside fan motor SKF 240...

Page 20: ...ort Vacuum pump connecting port P Sectional shape of heat insulator Outer dia 6 35mm Thickness 0 80mm Deoxidized copper pipe 4 way valve Outer dia 9 52mm Thickness 0 80mm INDOOR UNIT Cross flow fan Te...

Page 21: ...heat exchanger Cross flow fan Deoxidized copper pipe Outer dia 6 35 mm Thickness 0 8 mm Sectional shape of heat insulator Allowable height difference 10m Allowable pipe length Max 15 m P Pressure meas...

Page 22: ...door hang fan er mode Compressor re pipe temp v T1 olution rps C T2 Temperature C condition Indoor C fan mode Indoor Outdoor Outdoor fan mode 20 15 Compressor rev T olution emperature rps condition 7...

Page 23: ...s Signal Receiver Initiallizing Circuit Clock Frequency Oscillator Circuit Power Supply Circuit Noise Filter From Outdoor Unit M C U Functions Louver Control 3 minute Delay at Restart for Compressor M...

Page 24: ...r position detect circuit Relay Fan motor 4way Valve Relay High power factor correction circuit 1 PWM synthesis function 2 Input current release control 3 IGBT over current detect control 4 Outdoor fa...

Page 25: ...tion control Defrost control in heating operation Temp measurement by outdoor heat exchanger and control for 4 way valve and outdoor fan 8 OPERATION DESCRIPTION As the compressor adopts four pole brus...

Page 26: ...speed by changing AC 220 240 V power to DC once and controls capac ity by changing supply power status to the compressor with transistor module includes 6 transistors The outline of the control is as...

Page 27: ...an is operated by the stepless speed change motor 2 For air flow level speed of the indoor fan motor is controlled in three steps If AUTO mode isselected the fan motor speed is automatically controlle...

Page 28: ...l section which occupy most of air conditioner input is detected by the outdoor current sensor and compressor motor speed is gradually Normal control 4 7 6 3 Current value A Comp motor speed down Comp...

Page 29: ...r operating motor speed is down Zone Operation stop zone Normal down zone of motor speed Slow down of motor speed Keep zone Motor speed is not changed Slow up zone of motor speed Normal operation zone...

Page 30: ...motor operates as shown in Fig 8 2 4 Fan speed is AUTO only The outdoor fan motor operates as described in Table 8 1 3 and the compressor motor speed according to the operation command signal sent fro...

Page 31: ...the compressor motor The power coupler IC20 for 4 way valve is turned on and turned off in defrost operation 1 Heating capacity control Calculate the difference between temperature detected by room t...

Page 32: ...Louver control When the compressor is turned off by high temp release control the vertical air flow louvers close once and then return to the position of previous time 6 ECONO operation control When t...

Page 33: ...ARY button is pushed the Auto operation with set temperature fixed at 25 C starts Controlling is same as that of Auto opera tion by the remote controller When the TEMPORARY button is pushed again the...

Page 34: ...roceed as follows The power supply to the unit must be on the function will not set if the power is off Push the TEMPORARY button located in the center of the front panel continuously for three second...

Page 35: ...t beeps three times The lamp changes from and continues to operate orange to green If the unit is not required to operate at this time push TEMPORARY button once more or use the remote control to turn...

Page 36: ...INSTALLATION WORK IMMEDIATELY LET FRESH AIR INTO THE ROOM IF THE REFRIGERANT GAS IS HEATED BY FIRE OR SOMETHING ELSE IT CAUSES GENERATION OF POISONOUS GAS WARNING Never modify this unit by removing an...

Page 37: ...t rear left rear right right bottom right or bottom left Right Rear right Bottom right Left Rear left Bottom left Insulate the refrigerant pipes separately with insulation not together 6 mm thick heat...

Page 38: ...g wind Use 8 mm or 10 mm anchor bolts and nuts If it is necessary to drain the defrost water attach drain nipple bottom plate of the outdoor unit before installing it Parts name Refrigerant piping Liq...

Page 39: ...ers Name Owner s manual Installation manual 9 1 3 Accessory and installation parts The part marked with asterisk is packaged with the outdoor unit 3 1 x 16 x 2 l Pan head wood screw Drain nipple x 1 P...

Page 40: ...diameter has been changed In order to increase pressure resisting strength hose materials and port size have been changed to 1 2 UNF 20 threads per inch When purchasing a charge hose be sure to confi...

Page 41: ...exposed to direct sunlight or close to a heating source such as a stove Keep the remote control at least 1 m apart from the nearest TV set or stereo equipment This is necessary to prevent image distu...

Page 42: ...rete or similar type walls make 5 mm dia holes in the wall Insert clip anchors for appropriate mounting screws NOTE Secure four corners and lower parts of the installation plate with 4 to 6 mounting s...

Page 43: ...drain hose installation Piping and Drain Hose Forming Since dewing results in a machine trouble make sure to insulate both the connecting pipes Use polyethylene foam as insulating material 1 Die cutt...

Page 44: ...within a radius of 30 mm To connect the pipe after installation of the unit figure Fig 9 2 13 NOTE If the pipe is bent incorrectly the indoor unit may unstably be set on the wall After passing the co...

Page 45: ...in the wall and hook the indoor unit on the installation plate at the upper hooks 2 Swing the indoor unit to right and left to confirm that it is firmly hooked up on the installation plate 3 While pr...

Page 46: ...for 12k An allowable height level is up to 8 m for 09k 10 m for 12k A place shere the drain water does not raise any CAUTION 1 Install the outdoor unit without anything blocking the air discharging 2...

Page 47: ...e charging hose from the service port 8 Securely tighten the caps on the packed valves Fig 9 3 7 Tightening torque of flare pipe connections The operating pressure of R410A is higher than that of R22...

Page 48: ...Wire type More than H07RN F or 245 IEC66 1 0 mm2 or more Packed valve handling precautions Open the valve stem all the way out but do not try to open it beyond the stopper Securely tighten the valve...

Page 49: ...ferent size tools are also required Accordingly special tools are required for the new refrigerant R410A as shown below For connecting pipes use new and clean piping materials with high pressure withs...

Page 50: ...me operating mode as before the power failure Information The product was shipped with Auto Restart function in the off position Turn it on as required How to set the auto restart Press and hold down...

Page 51: ...mains and discharging takes a lot of time After turning off the power source if touching the charging section before discharging an electrical shock may be caused Discharge the electrolytic capacitor...

Page 52: ...ture No Operation of air conditioner Descriptions The OEPRATION lamp of the indoor unit flashes when power source is turned on If START STOP button is operated once flashing stops Flashes also in powe...

Page 53: ...ontroller for servicing Table 10 3 1 Lamps Self diagnosis A OPERATION lamp is blinking 1Hz B OPERATION lamp is blinking 5Hz C OPERATION lamp is blinking 5Hz D OPERATION lamp is blinking 5Hz E OPERATIO...

Page 54: ...nit blinks continuously 5 times per 1 sec 2 Press 8TEMP button If there is no fault with a code the indoor unit will beep once Pi and the display of the remote control will change as follows Check the...

Page 55: ...continues Displayed when error is detected Displayed when error is detected Displayed when error is detected Displayed when error is detected Flashes when trouble is detected on Return serial signal...

Page 56: ...serial signal and normal status when signal is reset Displayed when error is detected Displayed when error is detected Displayed when error is detected Even if trying operation again all operations s...

Page 57: ...e control Does transmission mark on remote control flash normally and is its signal transmitted properly Remote control is defective Refer to 4 Remote Control Is fuse F01 of indoor control board blown...

Page 58: ...C board is replaced Confirmation procedure YES YES NO NO To item of Power is not turned on Turn on power supply Does operation lamp flash Is wired correctly to white and black lead wires of terminal...

Page 59: ...event temperature rising cause of incompleted connecting Does the cross flow fan rotate normally Is the rotation signal DC 5 V 0 V output between 2 gray lead wire and 3 brown lead wire of the motor co...

Page 60: ...cated Does indoor unit start to operate by automatic restart function Does radio sound is affected by remote control when a signal is transmitted at distance of 5 cm from radio Does indoor unit beep a...

Page 61: ...utdoor unit stops 10 to 20 minutes after operation started and 10 minutes or more are required to restart the unit 2 If the unit stops once it dose not operate until the power is turned on again 3 The...

Page 62: ...the outdoor fan It takes approx 7 seconds for positioning of the valve and sound ticktack hitting sound to stopper is heard for approx 0 5 seconds at least of that period As the sound is low check so...

Page 63: ...n the control board assembly is blown or not F01 Turn on power breaker and operate the air conditioner in COOL mode by short circuit of the timer Measure terminal voltage of the electrolytic capacity...

Page 64: ...heck Simply the Main Parts 10 8 1 How to check the P C board Indoor unit 1 Operating precautions 1 When removing the front panel or the P C board be sure to shut off the power supply breaker 2 When re...

Page 65: ...indicate normally after approximate 3 sec 1 Compressor does not operate 2 OPERATION lamp blinks 1 Compressor does not operate 2 OPERATION lamp blinks 1 Motor does not rotate The key operation is acce...

Page 66: ...racteristic table TD Discharge temp sensor TC Heat exchanger temp sensor TO Outdoor temp sensor TE Outdoor heat exchanger temp sensor TD 100 90 80 70 60 50 40 30 20 10 0 TA TC TO TE 10 0 20 30 40 Temp...

Page 67: ...g the tester Under normal temp 25 C Since judgement of AC motor is difficult on the single motor refer to 10 5 1 3 1 Room temp TA sensor Heat exchanger TC sensor 2 Remote controller 3 Louver motor MP2...

Page 68: ...Under 20 C Measure the resistance value of winding by using the tester For details refer to Section 10 9 Check conduction by using the tester Disconnect the connector and measure resistance value with...

Page 69: ...ff 6 Check that the tester shows the normal charging characteristics in continuity test C12 C13 C14 500 F 400V 1 Turn OFF the power supply breaker 2 Discharge all four capacitors completely 3 Check th...

Page 70: ...r fan motor 3 Motor drive circuit error of the outdoor P C board 3 How to simply judge whether outdoor fan motor is good or bad NOTE However GND circuit error inside of the motor may be accepted in so...

Page 71: ...and the connector 5P for the louver motor from the P C board assembly 5 Pull out the TC sensor from the sensor holder 6 Remove each screw for the ground wire the electrical part box and the LED unit T...

Page 72: ...er side of the heat exchanger slowly 1 Remove the front panel and the electrical part with the procedure 2 2 Loosen the set screw of the cross flow fan 3 Remove 2 screws fixing the motor band R 4 Pull...

Page 73: ...he procedure 5 Fix the cross flow fan with the set screw at the position where the gap between the back body and the right surface of the cross flow fan is 4 5 mm 1 Remove the front panel electrical p...

Page 74: ...ner 2 Remove the front panel Remove the 4 fixing screws 3 Remove the electrical part base 1 Common procedure 11 2 Microcomputer Replace the thermal fuse terminal block microcomputer ass y and the P C...

Page 75: ...t 2 After connecting the power cord and connecting cable attach the cord clamp and wiring cover Insert the upper part into the upper cabinet and insert the claw which has been hooked to the lower part...

Page 76: ...us that a large spark generates if short circuiting between the e e e e e d d d d d polarity with screw driver etc for discharging 4 Remove screw ST1T 4 x 10s 2 pc fixing the main body and the inverte...

Page 77: ...2 Remove the claw of the board support fixed to the inverter board and remove upwards holding the heat sink 3 Remove the three screws fixing the heat sink and control board assemble 4 Attach the new c...

Page 78: ...d splice 1 Perform work of item 1 of 1 1 of 2 3 and 5 2 Extract refrigerant gas 3 Remove the partition board ST1T 4 x 10s 3 pcs 4 Remove the sound insulation material 5 Remove the terminal cover of th...

Page 79: ...uard side faces downwards 3 Remove the hooking claws by pushing a minus screwdriver according to the arrow mark in the right figure and remove the fan guard 2 Attachment 1 Insert the claws of the fan...

Page 80: ...d color tape round the both terminals of the protective tube when colored protective tube is used 10 Fix the sensor again NOTES 1 Store the joint part of the sensor and the connector in the electric p...

Page 81: ...Location Part Location Part No No No No 401 43T69319 TEMPERATURE SENSOR 405 43T69079 PC BOARD ASSY WRS LED 402 43T60002 TERMINAL BLOCK 3P 406 43T69585 PC BOARD 42NQV009E 403 43T69320 TEMPERATURE SENS...

Page 82: ...S FLOW FAN 206 43T08418 LED PANEL ASSY 222 43T39302 BAND MOTOR L 207 43T70310 DRAIN HOSE 223 43T21394 FAN MOTOR 208 43T79301 CAP DRAIN 224 43T39303 BAND MOTOR R 209 43T21372 MOTOR STEPPING 225 43T8231...

Page 83: ...0481 UPPER CABINET 6 43T19336 FIN GUARD 21 43T00448 FIXING PLATE VALVE 7 43T47308 CAPILLARY TUBE 1 0 DIA 22 43T42331 BASE PLATE ASSEMBLY 8 43T46331 VALVE PACKED 9 52 DIA 23 43T79305 DRAIN NIPPLE 9 43T...

Page 84: ...FIXING PLATE VALVE 6 43T19336 FIN GUARD 22 43T42331 BASE PLATE ASSEMBLY 7 43T47007 CAPILLARY TUBE 1 2 DIA 23 43T79305 DRAIN NIPPLE 8 43T46331 VALVE PACKED 9 52 DIA 24 43T46313 REACTOR 9 43T47332 BONN...

Page 85: ...1 43T62320 HEATSINK 704 43T60326 FUSE 702 43T69620 ASM PCB SERV 38NYV009E 705 43T60377 TEMPERATURE SENSOR 702 43T69664 ASM PCB SERV 38NYV012E 706 43T50304 SENSOR HEAT EXCHANGER 703 43T60352 TERMINAL B...

Page 86: ...FILE NO SVM 03008 87...

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