Carrier 40GVM-009 User Manual

Service Manual
38GVM / 40GVM
Multi---Split High---Wall Ductless Split System
38GVM --- Size 18k, 24k, 30k, 36k and 42k
40GVM --- Size 9k, 12k, and 18k
This Service Manual provides the necessary information to service,
repair, and maintain the 38/40GVM.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 1.........................
MODEL / SERIAL NUMBER NOMENCLATURE 2.........
STANDARD FEATURES AND ACCESSORIES 3...........
PHYSICAL DATA 4...................................
AHRI CAPACITY RATINGS 6..........................
AIRTHROW DATA 6..................................
SOUND RATINGS 6..................................
DIMENSIONS -- INDOOR 7............................
DIMENSIONS -- OUTDOOR 8..........................
CLEARANCES 9.....................................
SYSTEM OPERATING ENVELOPE 11...................
ELECTRICAL DATA 12...............................
CONNECTION DIAGRAM 13..........................
WIRING DIAGRAMS 14...............................
REFRIGERATION SYSTEM DIAGRAMS 19..............
SYSTEM EVACUATION AND CHARGING 21.............
REMOTE CONTROL AND FUNCTIONS 22...............
TROUBLESHOOTING 28..............................
APPENDIX TABLES 44..............................
UNIT REMOVAL PROCEDURES 47.....................
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
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult 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. 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 one disconnect switch. Lock out
and tag switch with a suitable warning label.
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.

Carrier 40GVM-009 Specifications

General

Refrigerant	R-410A
Operating Temperature (Cooling)	5°F to 122°F
Operating Temperature (Heating)	-13°F to 75°F
Cooling Capacity	9, 000 BTU
Voltage	208/230V
Heating Capacity	9, 000 BTU
Power Supply	208/230V, 1Ph, 60Hz

Summary

Safety Considerations

Explosion Hazard Warning

Warning about explosion risks from oxygen mixtures and pressurized systems.

Electrical Shock Hazard Warning

Warning regarding electrical shock precautions and disconnect switch use.

Equipment Damage Hazard Caution

Caution regarding improper operation causing equipment damage.

Physical Data - Outdoor Unit 38GVM

Compressor and Fan Specifications

Physical Data - Indoor Unit 40GVM

Indoor Fan and Coil Specifications

AHRI* CAPACITY RATINGS

CLEARANCES - INDOOR

CLEARANCES - OUTDOOR

Clearances for 38GVM018, 024, 030

Clearances for 38GVM036, 042

SYSTEM OPERATING ENVELOPE

Cooling Ambient Operating Range

Specifies the acceptable outdoor temperatures for cooling operation.

Heating Ambient Operating Range

Specifies the acceptable outdoor temperatures for heating operation.

ELECTRICAL DATA

Outdoor Unit Electrical Specifications

Details voltage, current, and fuse/breaker ratings for outdoor units.

Indoor Unit Electrical Specifications

Details voltage and fan current ratings for indoor units.

Power Wiring Requirements

Control Wiring Requirements

CONNECTION DIAGRAM

Field Wiring Diagram

Shows how to connect power and control signals between units.

WIRING DIAGRAMS

WIRING DIAGRAMS CONTINUED

REFRIGERATION SYSTEM DIAGRAMS

Refrigerant Circuit Components

Identifies key components like heat exchangers and expansion valves.

REFRIGERATION SYSTEM DIAGRAMS CONTINUED

Refrigerant Flow Path

Illustrates the path of refrigerant through system components.

SYSTEM EVACUATION AND CHARGING

Deep Vacuum Method

Detailed steps for deep vacuum evacuation using a pump and gauge.

Triple Evacuation Method

Alternative method for evacuation using nitrogen and vacuum pump.

REMOTE CONTROL AND FUNCTIONS

Remote Control Display Overview

Remote Control Buttons

REMOTE CONTROL AND FUNCTIONS CONTINUED

FUNCTION AND CONTROLS CONTINUED

Cool & Heat Modes

Timer OFF Function

Timer ON Function

TROUBLESHOOTING

Static Maintenance

Dynamic Maintenance

Troubleshooting Diagnosis Procedure

Steps for diagnosing issues, including power supply confirmation.

TROUBLESHOOTING CONTINUED

38GVM Diagnostic Codes

List of error codes, their descriptions, and affected units.

Error Code Table

Detailed error codes for sensor issues and mode conflicts.

Malfunction Indicator LED Display

Explains the meaning of LED indicators for various malfunctions.

IPM Protection Malfunction Check

Steps to check and resolve IPM protection malfunctions.

Compressor Wiring and Resistance Check

Procedure to diagnose compressor issues via wiring and resistance.

PFC Protection Malfunction Diagnosis

Steps to diagnose and resolve PFC protection errors.

Capacity Charging Malfunction Diagnosis

Steps to diagnose and resolve capacity charging malfunctions.

Anti-High Temperature Overload Diagnosis

Steps to diagnose and resolve high temperature/overload issues.

Temperature Sensor Malfunction Diagnosis

Steps to diagnose and resolve temperature sensor issues.

Start Failure Malfunction Diagnosis

Steps to diagnose and resolve compressor start failure.

Communication Malfunction (Some Units)

Troubleshooting for communication issues affecting specific indoor units.

Communication Malfunction (All Units)

Troubleshooting for communication issues affecting all indoor units.

Compressor Overload/Discharge Protection Diagnosis

Steps to diagnose and resolve compressor overload/discharge protection issues.

Compressor Desynchronizing Malfunction Diagnosis

Steps to diagnose and resolve compressor desynchronizing issues.

Communication Failure Check

Troubleshooting steps for communication failures between units.

Unit/System Does Not Work

Steps to take when the unit or system fails to operate.

Cooling Not Working Properly

Troubleshooting steps for cooling performance issues.

REMOVAL PROCEDURE OF OUTDOOR UNIT - 18K

Remove Top Cover and Wiring Cover

Remove Front Grille and Front Panel

Remove Fan Blade, Motor, and Support

Remove Right and Left Side Panels

Remove Control Box Assembly

Remove Condenser

REMOVAL PROCEDURE OF OUTDOOR UNIT - 24K / 30K

Remove Wiring Connection Cover

Remove Conduit Connection Plate

REMOVAL PROCEDURE OF OUTDOOR UNIT - 36K

Remove Compressor

Remove Condenser Sub-Assy

REMOVAL PROCEDURE OF OUTDOOR UNIT - 42K

Disconnect Power Cord (Compressor)

Disassembly and Assembly of Compressor

Remove Bad Compressor

Steps to remove the faulty compressor.

Place New Compressor

Steps to install and connect a new compressor.

Disassembly and Assembly of 4-way Valve

Remove 4-Way Valve

Steps to remove the existing 4-way valve.

Replace the 4-way Valve

Steps to install and connect a new 4-way valve.

Disassembly and Assembly of Electronic Expansion Valve

Remove Electronic Expansion Valve

Steps to remove the existing electronic expansion valve.

Replace the Electronic Expansion Valve

Steps to install and connect a new electronic expansion valve.

Disassembly and Assembly of Vapor Liquid Separator

Remove Liquid Separator

Steps to remove the existing liquid separator.

Fix New Liquid Separator