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Carrier 538FEQ009RBGA, Service Manual

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Carrier 538FEQ009RBGA Service Manual Download Page 63

63

9.Remove motor support

motor support

Twist off the tapping screws fixingthe motor 
support, pull it upwardsand then remove the 
motor support.

Twist off the screws connecting isolation sheet 
and end plate of condenser and chassis, and 
then remove the isolation sheet.

11.Remove 4-way valve

10.Remove isolation sheet

isolation sheet

4-way valve

Unsolder the pipeline between compressor, 
condenser, gas and liquid valve, and then 
remove the 4-way valve. (note: release all 
refrigerant before unsoldering).

Summary of Contents for 538FEQ009RBGA

Page 1: ...CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result i...

Page 2: ...B 1 1 Q E R SYSTEM TYPE Q HEAT PUMP VOLTAGE E 208 230 1 60 OUTDOOR UNIT 538 F GA 009 538 OUTDOOR UNIT F MODEL GA ALL MODELS NOMINAL CAPACITY 009 3 4TON 012 1TON 018 1 1 2TONS UNIT TYPE R OUTDOOR UNIT...

Page 3: ...pressor S Indoor Coil Freeze Protection S Indoor Coil High Temp Protection in Heating Mode S Condenser High Temp Protection in Cooling Mode S Ease Of Service And Maintenance Cleanable Filters S Diagno...

Page 4: ...5 8 Refrigerant Type R410A Design Pressure PSIG 550 550 550 Metering Device Electronic Expansion Valve Charge Lb 3 1 3 1 4 4 Outdoor Coil Face Area Sq Ft 4 5 4 5 7 7 No Rows 2 5 2 5 2 Fins per inch 18...

Page 5: ...5 DIMENSIONS INDOOR Fig 2 Indoor unit Model W H D Q 09 12K 37 4 5 12 3 5 8 2 1 6 18K 37 4 5 12 3 5 8 2 3 4...

Page 6: ...6 DIMENSIONS OUTDOOR Fig 3 Dimensions Fig 4 Dimensions Fig 5 Dimensions Fig 6 Dimensions...

Page 7: ...OPERVOLTAGE MAX MIN COMPRESSOR OUTDOOR FAN INDOOR FAN MCA MAX FUSE CB AMP V PH HZ RLA LRA V PH HZ FLA HP W V PH HZ FLA HP W 9K 253 187 208 230 1 60 8 5 35 208 230 1 60 0 37 0 04 30 208 230 1 60 0 1 0...

Page 8: ...wer and one is a ground wire To minimize voltage drop the factory recommended wire size is 14 2 stranded with a ground Communication Wiring A separate shielded copper conductor only with a minimum 300...

Page 9: ...GN Green CAP Jumper Cap YE Yellow BN Brown COMP Compressor RD Red BU Blue Grounding wire YEGN Yellow Green BK Black VT Violet OG Orange NOTE Jumper cap is used to determine the fan speed and the swin...

Page 10: ...10 Outdoor Unit Fig 11 Sizes 09 12...

Page 11: ...be temperature sensor 11 Up and down swing 2 4 Interface of jumper cap 8 Ambient temperature sensor 12 Up and down swing 1 1 Input of live wire of power 4 Input of ground wire of power 7 Neutral wire...

Page 12: ...HANGE CONDENSER COMPRESSOR GAS SIDE 3 WAY VALVE LIQUID SIDE 2 WAY VALVE COOLING HEATING Accumlator Discharge Suction 4 Way valve Electron Strainer Strainer expansion valve Strainer Capillary D Straine...

Page 13: ...on 1 4 Flare connection Refrigerant Refrigerant Type R410A R410A R410A Charge Amount Lbs kg 3 1 1 4 3 1 1 4 4 4 2 ADDITIONAL REFRIGERANT CHARGE TABLE Unit Size Total Line Length ft Additional Charge o...

Page 14: ...indoor units have thermistors used to monitor the system operation to maintain the unit within acceptable parameters and control the operating mode SYSTEM SAFETIES 3 Minute Time Delay To protect the...

Page 15: ...reless remote control has the following characteristics S Capable of displaying _C and _F with _F being the default setting To change the default setting refer to the Owner s Manual S The remote contr...

Page 16: ...he anti cold wind function is disabled Auto Mode in Heating Mode In heating mode When the fan speed is set to Auto the fan will run at a speed determined by the microprocessor based on the difference...

Page 17: ...2 frequency and indoor fan runs as breeze After running for 30 minutes the machine turns to auto mode with a 75_F 24_C set temperature Forced auto mode The action of forced auto mode is the same as no...

Page 18: ...tems are equipped with diagnostic code display LED s on both the indoor and outdoor units The outdoor diagnostic display is on the outdoor unit board and is limited to very few errors The indoor diagn...

Page 19: ...rates During heating operation the complete unit stops Replace outdoor control panel AP1 9 Limit decrease frequency due to high temp of module EU All modes operate normally while operation frequency f...

Page 20: ...tic capacitor C on control panel AP1 if normal there is a malfunction on the circuit replace the control panel AP1 23 Compressor Min frequence in test state P0 Showing during min cooling or min heatin...

Page 21: ...s when detect high power 42 Indoor unit and outdoor unit does not match LP OFF 1S and blink 16 times Compressor and Outdoor fan motor can not work Indoor unit and outdoor unit does not match 43 Failur...

Page 22: ...ly contacted Insert the temperature sensor tightly Yes Is malfunction eliminated Is there a short circuit Make sure all parts fastened tight Is malfunction eliminated Replace the mainboard with the sa...

Page 23: ...insert the wiring terminal of indoor fan It s the malfunction of main board Replace a new main board that is of the same model It s the malfunction of main board Replace a new main board that is of th...

Page 24: ...Is the jumper cap inserted correctly and tightly Replace the jumper cap with the same model End Yes Yes Assemble the jumper cap with the same model No Is malfunction eliminated No Yes Insert the jump...

Page 25: ...anger too dirty or are the air inlet and outlet blocked Normal fluctuation is within 10 of the rated voltage on the nameplate Malfunction is eliminated No No No No No No No No Malfunction is eliminate...

Page 26: ...Main board of IDU matches with that of ODU Communication wire is damaged Replace IDU s main board Malfunction eliminated End Connect the line according to wiring diagram Match correctly according to...

Page 27: ...board AP1 Replace outdoor mainboard Measure the voltage input with AC voltmeter see fig 30 Voltage within 180VAC 260VAC Shut down the power and wait 20 minutes or use DC voltmeter to measure the volta...

Page 28: ...H7 or P5 is displayed after turning on the unit Measure if the voltage input is within 180 265V with AC voltmeter see fig 30 The compressor is connected with mainboard AP1 Heat exchanger is blocked wi...

Page 29: ...gher than 127 F Normal protection unit starts when ambient temperature lowers Unit restarts normally Unit restarts normally Is the unit clear of debris and the coil is clean Clean the heat exchanger a...

Page 30: ...you opened both liquid and suction valves Does the unit start Is the compressor wired correctly Check the connection of outdoor mainboard AP1 and compressor and then connect it according to wiring dia...

Page 31: ...rotector with ohmmeter resistance value should be 1000ohm Is the plug connecting the EEV to the control board connected securely Replace EEV coil of electronic expansion valve Check the refrigerant if...

Page 32: ...the connection wire between reactor mainboard and situation of connection If there is short circuit or the connection wire is loose Reconnect the wire or replace the connection wire according to the...

Page 33: ...all terminals If the wiring is damaged Replace the wire Check the malfunction type with communication malfunction detector Malfunction of outdoor communication circuit Replace outdoor mainboard AP1 R...

Page 34: ...ower DC 180V 380V Test 5 Two ends of diode D15 D15 IPM modular 15V power supply DC 14 5V 15 6V Test 6 Two ends of electrolytic capacitor C715 C715 12V power supply DC 12V 13V Test 7 Two ends of electr...

Page 35: ...ntrol panel AP1 Replace the control panel AP1 Measure the AC voltage between terminalL andN on wiring board XT power supply Voltage within 210VAC 250VAC Shut down the power and repair the power supply...

Page 36: ...iagram Then Restart the unit Stop the unit and disconnect the power supply Wait 20 minutes or use DC voltmeter to measure the voltage between the two ends of capacitor C2 until the voltage is lower th...

Page 37: ...agnosis process 1 Check if fan terminal OFAN is connected well 2 Test if resistance value of any two terminals is less than 1k with ohmic meter Do the indoor and outdoor fan work After the unit de ene...

Page 38: ...onnection sequence is correct Replace control board AP1 Replace the compressor Is the malfunction removed If the stop time of compressor is more than 3min No If the stop time is not enough and the hig...

Page 39: ...more than 3min Synchronism after energize the unit and start it Connect wire well Synchronism occurred during operation Replace control board AP1 If the radiating of unit is well Remove malfunction I...

Page 40: ...c expansion valve If the wiring terminal FA is well connected Remove malfunction The resistance value of first 4 l ead foot an d th e fifth lead foot is similar less than100 After the unit de energize...

Page 41: ...Re energize the unit and start it Cut the terminal of reactor test the resistance between two terminals of reactor with ohmic meter Replace the reactor Re energize the unit and start it Check the con...

Page 42: ...utdoor unit Problem with communication circuit Check built in wiring of indoor and outdoor unit Connection correct Malfunction of circuit is detected with control board AP1 voltage Check connection wi...

Page 43: ...n Test voltage value with Test 13 position in diagram with voltage meter Number jumping Test voltage value with Test 11 position in diagram with voltage meter Number jumping Test voltage value with Te...

Page 44: ...d outdoor units is improper Check whether the installation position is correct according to installation requirements for air conditioner Adjust the installation position and install the rainproof and...

Page 45: ...sor terminals and its 0 Repair or replace the compressor Cylinder of compressor is blocked Compressor can not operate Repair or replace the compressor 6 Air conditioner is leaking Possible Causes Disc...

Page 46: ...46 REMOVAL PROCEDURE IMPORTANT Discharge the refrigerant completely before removal Indoor Unit Removal Procedure...

Page 47: ...47 Shut off power hold both ends of horizontal...

Page 48: ...48...

Page 49: ...49...

Page 50: ...50 ziptie side cutters...

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Page 55: ...Remove top cover cable cross plate sub assy valve cover panel grille Remove the screws connecting top cover left and right side plate as well as panel to remove the top cover Remove the screws fixing...

Page 56: ...late and condenser support boa rd to remove the left side plate Remove the screws fixing right side plate and valve support to remove the right side plate Remove the screw nut fixing cross fan blade r...

Page 57: ...terminal lift to remove the electric box assy Remove the four tapping screws fixing motor pull out the contact tag of motor wiring to remove the motor Remove the two tapping screws fixing motor suppor...

Page 58: ...aporizer assy Remove the screws connecting mid isolation board chassis and condenser assy to remove the mid isolation Cut the spot weld of four way valve assy compressor air suction discharging valve...

Page 59: ...screwnuts fixing compressor to remove the compressor Remove screws connecting condenser assy and chassis to remove the chassis sub assy Remove screws connecting condenser assy and chassis to remove th...

Page 60: ...handle pull the handle up ward to remove it Remove the screws connecting the top panel with the front panel and left right side plate and then remove the top panel 3 Remove front side panel front side...

Page 61: ...the screws connecting the grille and panel and then remove the grille 5 Remove right side plate right side plate Twist off the screws connecting the right side plate and chassis valve support and con...

Page 62: ...iring terminal pull it upwards to remove the electric box electric box fireproofing Twist off the screws on electric box fireproofing with screwdriver and then remove the electric box fireproofing 8 R...

Page 63: ...t off the screws connecting isolation sheet and end plate of condenser and chassis and then remove the isolation sheet 11 Remove 4 way valve 10 Remove isolation sheet isolation sheet 4 way valve Unsol...

Page 64: ...valve with wet cloth completely to avoid the damage to valve and recover all refrigerant completely at first Unsolder the soldering joint between liquid valve and connection pipe of liquid valve and...

Page 65: ...side plate Twist off the screws connecting the left side plate and chassis with screwdriver and then remove the left side plate Pull it upwards to separate the chassis and condenser 16 Remove chassis...

Page 66: ...tal louver Remove the horizontal louver along the center axle NOTE During operation install the left end of the horizontal louver first then install the right end Once installed restart the unit until...

Page 67: ...67 6 7 8...

Page 68: ...68 9 Remove electric box 10 Remove evaporator...

Page 69: ...69...

Page 70: ...70 11 Remove swing blade...

Page 71: ...71 12 Remove cross flow blade and motor...

Page 72: ...72 13 Remove drive box...

Page 73: ...ht side plate as well as panel to remove the top cover Remove the screws fixing panel to remove the panel Remove the screws connecting panel grille and panel loosen the clamp to remove the panel grill...

Page 74: ...late and condenser support boa rd to remove the left side plate Remove the screws fixing right side plate and valve support to remove the right side plate Remove the screw nut fixing cross fan blade r...

Page 75: ...terminal lift to remove the electric box assy Remove the four tapping screws fixing motor pull out the contact tag of motor wiring to remove the motor Remove the two tapping screws fixing motor suppor...

Page 76: ...assy Remove the screws connecting mid isolation board chassis and condenser assy to remove the mid isolation Welding cut the spot weld of four way valve assy compressor air suction discharging valve...

Page 77: ...screwnuts fixing compressor to remove the compressor Remove screws connecting condenser assy and chassis to remove the chassis sub assy Remove screws connecting condenser assy and chassis to remove th...

Page 78: ...handle pull the handle up ward to remove it Remove the screws connecting the top panel with the front panel and left right side plate and then remove the top panel 3 Remove front side panel front side...

Page 79: ...the screws connecting the grille and panel and then remove the grille 5 Remove right side plate right side plate Twist off the screws connecting the right side plate and chassis valve support and con...

Page 80: ...iring terminal pull it upwards to remove the electric box electric box fireproofing Twist off the screws on electric box fireproofing with screwdriver and then remove the electric box fireproofing 8 R...

Page 81: ...t off the screws connecting isolation sheet and end plate of condenser and chassis and then remove the isolation sheet 11 Remove 4 way valve 10 Remove isolation sheet isolation sheet 4 way valve Unsol...

Page 82: ...valve with wet cloth completely to avoid the damage to valve and release all refrigerant completely at first Unsolder the soldering joint between liquid valve and connection pipe of liquid valve and...

Page 83: ...side plate Twist off the screws connecting the left side plate and chassis with screwdriver and then remove the left side plate Pull it upwards to separate the chassis and condenser 16 Remove chassis...

Page 84: ...84 APPENDIX Appendix 1 Reference Sheet of Celsius and Fahrenheit...

Page 85: ...5 The length is equal Improper expanding leaning damaged surface crack uneven thickness Smooth surface Downwards Pipe Shaper Union pipe Pipe Expander Hard mold Pipe Pipe Pipe cutter Leaning Uneven Bur...

Page 86: ...3 0 697 3 57 18 36 9 382 75 2 206 114 0 678 2 54 31 37 9 003 76 2 133 115 0 66 1 51 59 38 8 642 77 2 064 116 0 642 0 49 02 39 8 297 78 1 997 117 0 625 1 46 6 40 7 967 79 1 933 118 0 608 2 44 31 41 7 6...

Page 87: ...112 0 956 4 80 31 35 13 04 74 3 04 113 0 93 3 76 24 36 12 51 75 2 94 114 0 904 2 72 41 37 12 76 2 844 115 0 88 1 68 79 38 11 52 77 2 752 116 0 856 0 65 37 39 11 06 78 2 663 117 0 833 1 62 13 40 10 62...

Page 88: ...10 54 103 3 04 13 323 9 26 47 08 65 10 18 104 2 955 12 306 2 27 45 07 66 9 827 105 2 872 11 289 6 28 43 16 67 9 489 106 2 792 10 274 29 41 34 68 9 165 107 2 715 9 259 3 30 39 61 69 8 854 108 2 64 8 24...

Page 89: ...89 UNIT BREAKDOWNS a b c d e...

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Page 94: ...P S 7310 W Morris St S Indianapolis IN 46231 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No 619FB 538FR 01SM Replace...

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