Carrier 38NYV025M Service Manual Download

Page: 1 / 91

March, 2007

FILE NO. SVM-07009

SERVICE MANUAL

AIR-CONDITIONER

SPLIT WALL TYPE

NQV025M

/ 38NYV025M

42NQV025M-A / 38NYV025M-A

Summary of Contents for 38NYV025M

Page 1: ...March 2007 FILE NO SVM 07009 SERVICE MANUAL AIR CONDITIONER SPLIT WALL TYPE 42NQV025M 38NYV025M 42NQV025M A 38NYV025M A...

Page 2: ...IEWS 15 5 WIRING DIAGRAM 18 6 SPECIFICATIONS OF ELECTRICAL PARTS 20 7 REFRIGERANT CYCLE DIAGRAM 21 8 CONTROL BLOCK DIAGRAM 25 9 OPERATION DESCRIPTION 28 10 INSTALLATION PROCEDURE 56 11 HOW TO DIAGNOSE...

Page 3: ...d installation tools are different from those used for the conventional refrigerant units Accordingly special tools are required for the new refrigerant R410A units For connecting pipes use new and cl...

Page 4: ...d electrician in accordance with the Installation Manual Make sure the air conditioner uses an exclusive circuit An insufficient circuit capacity or inappropriate installation may cause fire When wiri...

Page 5: ...NYV025M 38NYV025M A Dimension Height mm 530 Width mm 660 Depth mm 240 Net weight kg 29 Compressor Motor output W 750 Type Single rotary type with DC inverter variable speed control Model DA89X1C 23FZ...

Page 6: ...igh Pipe Length 5m Voltage 230V 50 55 60 65 70 75 80 85 90 95 100 105 32 33 34 35 36 37 38 39 40 41 42 43 Cooling Capacity ratio Outside Temperature o C 0 20 40 60 80 100 120 10 5 0 5 10 Heating Capac...

Page 7: ...in the refrig eration cycle may become abnormally high so that a rupture or personal injury may be caused 5 After completion of installation work check to make sure that there is no refrigeration gas...

Page 8: ...t joints Nominal diameter 1 4 3 8 1 2 5 8 Reference outer diameter of copper pipe jointed mm 6 35 9 52 12 70 15 88 Minimum joint thickness mm 0 50 0 60 0 70 0 80 3 2 2 Processing of Piping Materials W...

Page 9: ...to 0 5 0 to 0 5 0 to 0 5 0 to 0 5 Conventional flare tool Clutch type Wing nut type 1 0 to 1 5 1 5 to 2 0 1 0 to 1 5 1 5 to 2 0 1 0 to 1 5 2 0 to 2 5 1 0 to 1 5 2 0 to 2 5 Table 3 2 4 Dimensions relat...

Page 10: ...orque for R410A is the same as that for conventional R22 Incidentally when the torque is weak the gas leakage may occur When it is strong the flare nut may crack and may be made non removable When cho...

Page 11: ...ant charging Refrigerant cylinder Leakage detector Charging cylinder Usage Pipe flaring Flaring by conventional flare tool Connection of flare nut Evacuating refrigerant charge run check etc Vacuum ev...

Page 12: ...nnecting port of the electronic balance and charge liquid refrigerant Water heat exchanger unit Outdoor unit Opened Opened Refrigerant cylinder with siphon Check valve Open close valve for charging El...

Page 13: ...of silver and copper It is used to join iron copper or copper alloy and is relatively expensive though it excels in solderability 2 Phosphor bronze brazing filler Phosphor bronze brazing filler is gen...

Page 14: ...flux which does not contain chlorine 3 When adding water to the flux use water which does not contain chlorine e g distilled water or ion exchange water 4 Remove the flux after brazing 3 5 3 Brazing A...

Page 15: ...el Knock out system 8 60 Hanger Hanger 8 Hanger Installation plate outline Center line 10 For stud bold For stud bold 6 215 235 215 145 145 605 Air filter Heat exchanger Air inlet Air outlet 740 250 F...

Page 16: ...C L C L FILE NO SVM 07009 4 2 Outdoor Unit 16...

Page 17: ...5 WIRING DIAGRAM 5 1 Indoor Unit FILE NO SVM 07009 17...

Page 18: ...5 2 Outdoor Unit FILE NO SVM 07009 18...

Page 19: ...C Rectifier 14 Fan control relay D15XB60 4001 15A 600V 16 4 way valve coil AC220 240V 17 Running capacitor DS451155NPQB AC450V 1 5 F for fan motor IGBT GT15J321 15A 600 Compressor DA89X1C 23FZ 3 phase...

Page 20: ...hanger Cross flow fan Deoxidized copper pipe Outer dia 6 35mm Thickness 0 8mm Sectional shape of heat insulator Allowable height difference 10m Allowable pipe length P Pressure measurement Gauge attac...

Page 21: ...Heat exchanger pipe temp Model name Standard Indoor Outdoor Compressor pressure fan mode fan mode revolution Indoor Outdoor P MPa T1 C T2 C rps 20 7 6 42NQV025M 2 4 to 2 6 43 to 45 0 to 3 High High 68...

Page 22: ...Exchanger Sensor Temperature Sensor Infrared Rays Signal Receiver Initiallizing Circuit Clock Frequency Oscillator Circuit Power Supply Circuit Noise Filter From Outdoor Unit M C U Functions Louver Co...

Page 23: ...otor 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...

Page 24: ...ations followed to judgment of serial signal from indoor side Detection of inverter input current and current release operation Over current detection and prevention operation to IGBT module Compresso...

Page 25: ...ontrol 33 1 Louver position 33 2 Air direction adjustment 33 3 Swing 33 8 ECO operation 34 9 Temporary operation 35 10 Discharge temperature control 35 11 Remote A or B selection 36 12 Hi POWER Mode 3...

Page 26: ...ntroller ON OFF Air conditioner Operation select COOL HEAT AUTO DRY Temperature setup Air direction Swing Air volume select AUTO LOW LOW MED MED HIGH ECO ON timer setup OFF timer setup Hi POWER Indoor...

Page 27: ...eed is controlled by the previous operation mode 4 DRY operation DRY operation is performed according to the difference between room temperature and the setup temperature as shown below In DRY operati...

Page 28: ...wn in Fig 1 2 When setting the fan speed to AUTO on the remote controller revolution of the fan motor is controlled to the fan speed level shown in Fig 2 and Table 1 according to the setup tempera tur...

Page 29: ...c 1 0 d 1 5 e 2 0 f 2 5 g 5 0 5 5 L W9 M WD 1 2 3 H WE H WE Line approximate H and SUL with Tc SUL W2 Stop 46 46 Tc 34 45 45 33 33 33 21 32 32 20 A 4 A 4 A 4 A 4 A 4 A 4 Fan speed MANUAL in starting F...

Page 30: ...pressor speed so that electric power of the compressor drive circuit does not exceed the specified value 4 Current release control Set temp Ts Room temp Ta Correction of Hz signal Outdoor temp To Setu...

Page 31: ...ressor speed is kept Q zone When temperature of the indoor heat exchanger drops in the range from 46 C to under 55 C the compressor speed is kept Q zone 2 When temperature of the indoor heat exchanger...

Page 32: ...lower stop the indoor fan Finish of defrost operation Returning conditions from defrost operation to heating operation 1 Temperature of outdoor heat exchanger rises to 8 C or higher 2 Temperature of o...

Page 33: ...ther upper or lower limit position swing operation is performed in width 35 from the limit which the stop position exceeded 3 Swing 2 Louver position in heating operation 2 Air direction adjustment Th...

Page 34: ...in 30 minutes A B C A B C Time Compressor speed 0Hz A zone aHz B zone a to cHz C zone cHz 0 0 5 1 0 1 5 2 0 2 5 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 11 0 Room temp Set temp 3 5 3 0 2 5 1 5 1 0 TSC 1 0 2 0...

Page 35: ...er lamp ON Press RESET button Did you press RESET button for 3 seconds or more Did you press RESET button for 10 seconds or more Switch to AUTO RESTART control YES YES NO NO NO YES Temporary AUTO oper...

Page 36: ...controller selection is set to A on all the indoor units There is no A setting display Setting the remote controller To separate using of remote control for each indoor unit in case of 2 air condition...

Page 37: ...1 Automatic operation The indoor unit operates in according to the current operation 2 Cooling operation remote controller does not change The indoor unit s fan speed level increase 1 tap The preset t...

Page 38: ...Function This indoor unit is equipped with an automatic restarting function which allows the unit to restart operating with the set operating conditions in the event of a power supply being accidental...

Page 39: ...ed to operate at this time press RESET button once more or use the remote controller to turn it on 9 3 2 How to Cancel the Auto Restart Function To cancel auto restart function proceed as follows Repe...

Page 40: ...OFF 1 Start Stop button 2 Mode select button 3 Temperature button 4 Fan speed button 5 Swing louver button 6 Set louver button 7 On timer button 8 Off timer button 9 Sleep timer button 10 Setup butto...

Page 41: ...er Press Set the timer Press Set the timer Press Cancel the timer Press Press Set the ON timer Press Press Set the OFF timer Press button during the or mark flashing 1 1 2 3 2 3 3 4 Everyday timer all...

Page 42: ...e operation 3 beep sound and OPERATION lamp blink 5 time sec for 5 secpmds Do not operate ON timer and OFF timer 2 Press and hold the RESET button on the indoor unit for 3 seconds to cancel the Settin...

Page 43: ...ck time is indicated The current time is always indicated except during TIMER operation 7 Hi POWER indicator Indicates when the Hi POWER operation starts Press the Hi POWER button to start and press i...

Page 44: ...unit operates as follows 1 Automatic operation The indoor unit operates in according to the current operation 2 Cooling operation The preset temperature drops 1 C The value of the preset temperature o...

Page 45: ...Do not allow the drain hose to get slack Make sure to run the drain hose sloped downward Cut the piping hole sloped slightly For the rear left and left piping Insert the cushion between the indoor un...

Page 46: ...m or 10 mm anchor bolts and nuts If it is necessary to drain the defrost water attach drain nipple 9 to the bottom plate of the outdoor unit before installing it Parts name Refrigerant piping Liquid s...

Page 47: ...der x 1 Nano Silver Ginseng filter x 1 Nano Photo Copper Zinc filter x 1 Part No 4 5 6 Part No 7 8 9 Others Name Owner s manual Installation manual Part name Q ty Mounting screw 4 x 25 s x 6 Pan head...

Page 48: ...t 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 conf...

Page 49: ...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 disturbances or noise interference The location of the remote control...

Page 50: ...brick concrete or similar type walls make 5 mm dia holes in the wall Insert clip anchors for appropriate mounting screws 7 NOTE Secure four corners and lower parts of the installation plate with 4 to...

Page 51: ...n 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 cutting Front panel slit Cu...

Page 52: ...a radius of 30 mm 6 35 40 mm 9 52 To connect the pipe after installation of the unit figure Fig 10 2 12 NOTE If the pipe is bent incorrectly the indoor unit may unstably be set on the wall After passi...

Page 53: ...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 54: ...up 10 m An allowable height level is up to 8 m A place where the drain water does not raise any problem CAUTION 1 Install the outdoor unit without anything blocking the air discharging 2 When the out...

Page 55: ...arging hose from the service port 8 Securely tighten the caps on the packed valves Fig 10 3 7 Tightening torque of flare pipe connections The operating pressure of R410A is higher than that of R22 App...

Page 56: ...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 s...

Page 57: ...rating a unit two units may receive the remote control signal simultaneously and operate In this case the operation can be preserved by setting either one indoor unit or remote control to B setting Bo...

Page 58: ...scharging 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 completely b...

Page 59: ...mperature No Operation of air conditioner Descriptions The OEPRATION lamp of the indoor unit flashes when power source is turned on If button is operated once flashing stops Flashes also in power fail...

Page 60: ...ck codes can be confirmed on the remote controller for servicing OPERATION Green Flashing display 1 Hz OPERATION Green TIMER Yellow Flashing display 5 Hz OPERATION Green Flashing display 5 Hz OPERATIO...

Page 61: ...be indicated on the display All indicators on the indoor unit will flash 5 times per 1 sec Press button to release the service mode The display of the remote controller returns to as it was before se...

Page 62: ...nues 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 and no...

Page 63: ...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 64: ...ol Does transmission mark on remote control flash normally and is its signal transmitted properly Remote control is defective Refer to 5 Remote Control Is fuse F01 of indoor control board blown Is vol...

Page 65: ...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 66: ...ng module failure T101 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 connector CN11 when rotating the cro...

Page 67: ...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 and operate...

Page 68: ...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 69: ...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 70: ...heck Simply the Main Parts 11 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 71: ...e 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 accepted 2 T...

Page 72: ...and compressor Check whether 25A fuse on 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 termin...

Page 73: ...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 Temperature C Resistance value kW...

Page 74: ...osition Resistance value 1 to 4 1 to 6 380 40 2 to 3 2 to 5 11 8 4 Outdoor unit 38NYV025M 38NYV025M A 1 Compressor Model DA89X1C 23FZ 2 Outdoor fan motor Model SKF 240 20B 1 Disconnect the connector a...

Page 75: ...f 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 three capacitors completely 3 Check th...

Page 76: ...oor 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...

Page 77: ...e screw for the electrical part box Then remove the LED and the electrical part box from the main unit How to mount the electrical part 1 To put back the electrical part box lock it to the upper hook...

Page 78: ...assemble cross flow fan and fan motor to the unit please turn the fan motor unit the center of its terminal meets the top position of band motor R Fix the cross flow fan with the set screw at the posi...

Page 79: ...conditioner 2 Remove the front panel Remove the 4 fixing screws 3 Remove the electrical part base 1 Common procedure 12 2 Microcomputer Replace the thermal fuse terminal block microcomputer ass y and...

Page 80: ...FILE NO SVM 07009 80 P C board layout Solder side...

Page 81: ...et 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 par...

Page 82: ...arge and voltage remains depending on the malfunction state in some cases NOTE This capacitor has mass capacity Therefore it is dangerous that a large spark generates if short circuiting between the e...

Page 83: ...ote 1 As the connector has a stopper release the housing lock when removing Note 2 Hold the housing resin part with stopper and pull out to remove 2 Remove the control board assembly from the inver te...

Page 84: ...sed end splice 1 Perform work of item 1 of 1 1 of 2 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 the...

Page 85: ...guard 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 fa...

Page 86: ...ctive 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 parts box 2 Never joint them near the thermal senso...

Page 87: ...ts Assy Location Part Location Part No No No No 401 43T60365 TERMINAL BLOCK 3P 405 43T69612 PC BOARD ASSY WRS LED 403 43T69319 TEMPERATURE SENSOR 410 43T62003 CORD CLAMP 404 43T69320 TEMPERATURE SENSO...

Page 88: ...03 43T03357 BACK BODY ASSY 219 43T20323 ASSY CROSS FLOW FAN 204 43T80317 AIR FILTER 220 43T39324 MOTOR BAND LEFT 205 43T09392 HORIZONTAL LOUVER 221 43T39321 MOTOR BAND RIGHT 206 43T70313 DRAIN HOSE 22...

Page 89: ...0 43T00481 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...

Page 90: ...o No 701 43T62320 HEATSINK 705 43T60377 TEMPERATURE SENSOR 702 43T69620 ASM PCB SERV 706 43T50304 SENSOR HEAT EXCHANGER 703 43T60352 TERMINAL BLOCK 6P 707 43T62313 BASE PLATE PC 704 43T60326 FUSE 708...

Page 91: ...FILE NO SVM 03008 87...

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