Carrier 38MGQF36---3 - User Manual

Service Manual
38MGQ / 40MAQ/40MBC/40MBD/40MBF
538TR / 619PB/619RC/619RD/619RF
Multi---Zone Du ctless S plit S ystem
Sizes 18 to 48
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 1.........................
INTRODUCTION 1...................................
MODEL NUMBER NOMENCLATURE 2.................
STANDARD FEATURES AND ACCESSORIES 4...........
COMBINATION TABLE 5..............................
PHYSICAL DATA -- OUTDOOOR 6......................
DIMENSIONS -- OUTDOOR 7..........................
CLEARANCES -- OUTDOOR 11........................
ELECTRICAL DATA 12...............................
CONNECTION DIAGRAM 14..........................
WIRING DIAGRAM 24................................
REFRIGERATION CYCLE DIAGRAMS 28................
REFRIGERANT LINES 30.............................
SYSTEM EVACUATION AND CHARGING 31.............
TROUBLESHOOTING 32..............................
APPENDIX 66.......................................
SAFETY CONSIDERAT I ONS
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 ma nual thor oughly a nd follow all wa rnings or cautions
included in literature and attached to the unit. Consult local building
codes and National Ele ct r ic a l Code ( NEC) f or s pec i al requirem ents.
Recognize safety infor m ation. This is the safet y--al ert symbol
!
!
.
Whe n you see this symbol on the unit and in instruc t ions or manua ls,
be al ert to the pote ntial for per sona l i nj ury. Unders tand the se signal
words: DANGER, WARNING, and 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 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.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, 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.
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.
!
WARNING
CAUTION
!
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 Ser vi ce Manua l provides the nece ssar y inf orma tion to se rvi c e,
repair, and maintain the multi--zone family of heat pumps. Section 2
of thi s manua l has an appendi x wit h dat a required to perform
troubles hoot ing. Use the Table of Contents to locate a desire d topi c.

Carrier 38MGQF36---3 Specifications

General

Brand	Carrier
Model	38MGQF36---3
Category	Air Conditioner
Language	English

Summary

Safety Precautions and Manual Overview

Installation and Operation Safety Warnings

Model Number Decoding

Electrical Specifications

Wiring and Connection Procedures

Unit Connection Diagrams

Wiring Diagrams by Unit Size

Refrigeration Cycle Flow Diagrams

Refrigerant Line Management

Refrigerant Line Sizing Guidelines

Line Length and Height Limits

Additional Charge Calculation

System Evacuation and Charging Procedures

Unit Damage Hazard Caution

Vacuum Pump Operation Procedure

Deep Vacuum Method

Triple Evacuation Method

Final Tubing Inspection

Troubleshooting Guide

Essential Troubleshooting Tools

List of essential tools needed for diagnosing unit issues.

General Troubleshooting Steps

General procedures and guidance for troubleshooting unit problems.

Indoor Unit Error Code Diagnostics

Diagnostic Codes Reference

EEPROM Parameter Error (E0;F4)

Zero Crossing Detection Error (E2)

Communication Malfunction Troubleshooting (E1, E2)

Power Cycle and Initial Check

Steps for power cycling and initial checks for communication faults.

Wiring Verification

Procedure to check wiring connections for communication errors.

Indoor Unit Display Status

Checking indoor unit displays for communication status.

IPM Power and Status Indicators

Verifying IPM board power and operating LED indicators.

Main Board 88 Lamp Status

Checking the status of the main board '88' lamp.

Reactor Connection Verification

Verifying the connection status of the reactor.

Indoor Unit Number Verification

Confirming the correct number of indoor units is detected.

IPM Identification and Voltage Testing

Identifying IPM and testing voltage for communication issues.

IPM-Main Board Communication Error (E3)

IPM Communication Error Troubleshooting

Diagnosis and solution for IPM to main board communication faults.

Signal Wire and Connection Checks

Checking signal wires and connections for IPM communication issues.

Component Replacement for E3 Error

Guidance on replacing IPM, main board, or control box for E3 errors.

Temperature Sensor Circuit Errors (E4, F1-F5)

Sensor Circuit Error Troubleshooting

Diagnosis and solution for open/short circuits in temperature sensors.

Sensor Connection and Resistance Checks

Checking sensor connections and resistance values.

Voltage Protection Error (E5)

Voltage Protection Error Troubleshooting

Diagnosis and solution for voltage protection errors.

Outdoor Power Supply Voltage Check

Verifying the voltage of the outdoor unit power supply.

IPM Board P;N Voltage Check

Checking voltage between IPM board P and N terminals.

Component Replacement for E5 Error

Guidance on replacing rectifiers, IPM, or main board for voltage errors.

PFC Module Protection Error (E6)

PFC Module Protection Troubleshooting

Diagnosis and solution for PFC module protection errors.

PFC Connection and IPM P-N Voltage Check

Checking PFC module connections and IPM P-N voltage.

Inductance and PFC Module Check

Checking inductance and replacing PFC module if faulty.

Outdoor Fan Speed Control Error (E8)

Fan Speed Error Troubleshooting

Diagnosis and solution for outdoor fan speed control issues.

Fan Speed Troubleshooting Steps

Steps to diagnose and resolve outdoor fan speed malfunctions.

Fan Motor and PCB Checks

Checking fan motor, wiring, and main PCB for speed control issues.

Compressor Top Temperature Protection (P0)

Compressor Top Temp Protection Troubleshooting

Diagnosis and solution for compressor top temperature protection.

Air Flow and Temperature Checks

Checking air flow and compressor top temperature.

Overload Protector and Refrigerant Checks

Checking overload protector wiring and refrigerant charge.

High Pressure Protection (P1)

High Pressure Protection Troubleshooting

Diagnosis and solution for high pressure protection errors.

High Pressure Switch;Protector Checks

Checking high pressure switch wiring and protector.

Environmental and System Checks

Checking ambient temp, ventilation, fan, heat exchanger, and refrigerant.

Low Pressure Protection (P2)

Low Pressure Protection Troubleshooting

Diagnosis and solution for low pressure protection errors.

Low Pressure Protector Checks

Checking low pressure protector wiring and function.

Ambient, Valve, Fan, Refrigerant Checks

Checking ambient temp, valve core, fan, and refrigerant.

Compressor Current Protection (P3)

Compressor Current Protection Troubleshooting

Diagnosis and solution for compressor current protection.

Power Supply Current and System Checks

Checking power supply current and system conditions.

Compressor Discharge Temp Protection (P4)

Discharge Temp Protection Troubleshooting

Discharge Temp Sensor;Connection Checks

Refrigerant Leak Check

Condenser High Temp Protection (P5)

Condenser High Temp Protection Troubleshooting

Condenser Temp and Sensor Checks

Ventilation, Fan, Heat Exchanger Checks

IPM Module Protection Error (P6)

IPM Module Protection Troubleshooting

IPM Voltage and Connection Checks

Bridge Rectifier, Reactor, Fan Motor Checks

Common Operation Issues

No Cooling or Heating Operation

Indoor Unit Frosting;Warming Issues

Temperature Sensor Checks

Compressor and IPM Checks

4-Way Valve Testing Procedures

EXV Coil Resistance Testing

Unit Disassembly Instructions