Carrier 38mvc018 3 Service Manual
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21 REFRIGERANT LINES General refrigerant linesizing: 1. The 38MVC/MVQ units are shipped with a full charge of R410A refrigerant. All charges, line sizing, and capacities are based on runs of 25 ft (7.6 m). For runs over 25 ft (7.6 m), consult long--line section on this page for proper charge adjustments. 2. Minimum refrigerant line length between the indoor and outdoor units is 10 ft. (3 m). 3. Refrigerant lines should not be buried in the ground. If it is necessary to bury the lines, not more than 36--in (914 mm) should be buried. Provide a minimum 6--in (152 mm) vertical rise to the service valves to prevent refrigerant migration. 4. Both lines must be insulated. Use a minimum of 1/2-- in. (12.7 mm) thick insulation. Closed--cell insulation is recommended in all long--line applications. 5. Special consideration should be given to isolating interconnecting tubing from the building structure. Isolate the tubing so that vibration or noise is not transmitted into the structure. SThe following maximum lengths are allowed: REFRIGERANT LINE LENGTHS ft. (m) Unit SizeMax Line LengthMax Elevation (ID over OD)Max Elevation (OD over ID) 9K65 (20)35 (11)35 (11)12K65 (20)35 (11)35 (11)18K100 (30)50 (15)50 (15)24K100 (30)60 (18)60 (18) SThe following are the piping sizes. PIPE SIZESUnit SizeMix PhaseVapor9K1/4”3/8”12K1/4”1/2”18K1/4”1/2”24K3/8”5/8” RefrigerantCharge REFRIGERANT CHARGE lb. (kg)Unit SizeAir ConditionerHeat Pump 9K2.3 (1.0)2.4 (1.1)12K2.9 (1.3)3.0 (1.4)18K4.4 (2.0)TBD24KTBDTBD SAbove charge is for piping runs up to 25 ft. (7.6 m). SFor piping runs greater than 25 ft. (7.6 m), add 0.1 oz. of refrigerant per foot of extra piping up to the allowable length.Long Line Applications, 38MVC Units: 1. A crankcase heater should be added for line lengths longer than 25 ft (7.62 m) to prevent the migration of refrigerant to the compressor during the “OFF” cycle. 2. A field fabricated wind baffle is recommended. 3. No change in line sizing is required. 4. Add refrigerant per table below. ADDITIONAL CHARGE TABLE Unit Size To t a l Line Length, ftAdditional Charge, oz. Min.Max.10 --- 25 ft (3.05 --- 7.62m)> 2 5 --- 6 5 f t (7.62 --- 19.81m)> 6 5 --- 1 0 0 f t (19.81 --- 30.48m) 9K cool only 10 65 none0.1 oz per foot 9K hp 12K cool only 12K hp 18K cool only1000.1 oz. per foot 5. Reduction in capacity due to long lines can be calculated from the chart below. CAPACITY LOSS Capacity,%Loss Line Length, ft Cooling:254565100 9&12KBTU/Hmodels0%2%5% 18 & 24 KBTU/H models0%2%4%7% Heating: 9&12KBTU/Hmodels0%7%11% 18 & 24 KBTU/H models0%7%11%15% 38/40MVC, MVQ
22 SYSTEM EVACUATION AND CHARGING UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation. Never use the system compressor as a vacuum pump. CAUTION! Refrigerant tubes and indoor coil should be evacuated using the recommended deep vacuum method of 500 microns. The alternate triple evacuation method may be used if the procedure outlined below is followed. Always break a vacuum with dry nitrogen. SYSTEM VACUUM AND CHARGE Using VacuumPump 1. Completely tighten flare nuts A, B, C, D, connect manifold gage charge hose to a charge port of the low side service valve. (See Fig. 18.) 2. Connect charge hose to vacuum pump. 3. Fully open the low side of manifold gage. (See Fig. 19) 4. Start vacuum pump 5. Evacuate using either deep vacuum or triple evacuation method. 6. After evacuation is complete, fully close the low side of manifold gage and stop operation of vacuum pump. 7. The factory charge contained in the outdoor unit is good for up to 25 ft. (8 m) of line length. For refrigerant lines longer than 25 ft (8 m), add 0.1 oz. per foot of extra piping up to the maximum allowable length. 8. Disconnect charge hose from charge connection of the low side service valve. 9. Fully open service valves B and A. 10. Securely tighten caps of service valves. Outdoor UnitIndoor UnitRefrigerant Service Valve Low Side High Side A BC D A07360 Fig. 18 – Service Valve Manifold Gage 500 microns Low side valveHigh side valve Charge hoseCharge hose Vacuum pump Low side valve A07361 Fig. 19 – ManifoldDeep Vacuum Method The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth. The deep vacuum method is the most positive way of assuring a system is free of air and liquid water. (See Fig. 20) 500 MINUTES 01234567 1000 1500LEAK IN SYSTEM VACUUM TIGHT TOO WET TIGHT DRY SYSTEM 2000 MICRONS 2500 3000 3500 4000 4500 5000 A95424 Fig. 20 – Deep Vacuum Graph Triple Evacuation Method The triple evacuation method should only be used when vacuum pump is only capable of pumping down to 28 in. of mercury vacuum and system does not contain any liquid water. Refer to Fig. 21 and proceed as follows: 1. Pump system down to 28 in. of mercury and allow pump to continue operating for an additional 15 minutes. 2. Close service valves and shut off vacuum pump. 3. Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig. 4. Close service valve and allow system to stand for 1 hr. Dur- ing this time, dry nitrogen will be able to diffuse throughout the system absorbing moisture. 5. Repeat this procedure as indicated in Fig. 21. System will then be free of any contaminants and water vapor. CHECK FOR TIGHT, DRY SYSTEM (IF IT HOLDS DEEP VACUUM)EVACUATE BREAK VACUUM WITH DRY NITROGEN WAIT EVACUATE RELEASE CHARGE INTO SYSTEM BREAK VACUUM WITH DRY NITROGEN EVACUATE WAIT A95425 Fig. 21 – Triple Evacuation Method Final Tubing Check IMPORTANT: Check to be certain factory tubing on both indoor and outdoor unit has not shifted during shipment. Ensure tubes are not rubbing against each other or any sheet metal. Pay close attention to feeder tubes, making sure wire ties on feeder tubes are secure and tight. 38/40MVC, MVQ
23 CONTROL SYSTEM The 40MVC/MVQ unit is equipped with a microprocessor control to perform two functions: 1. Provide safety for the system 2. Control the system and provide optimum levels of comfort and efficiency The main microprocessor is located on the control board of the fan coil unit (outdoor units have a microprocessor too) with thermistors located in the fan coil air inlet and on the indoor coil. Heat pump units have a thermistor on the outdoor coil. These thermistors monitor the system operation to maintain the unit within acceptable parameters and control the operating mode. SYSTEM SAFETIES SafetyCooling OnlyHeat Pump9K012K018K024K09K012K018K024K3MinTimeDelayXXXXXXXXOver Current Protection On CompressorXXXXXXXXIndoor Coil Freeze ProtectionXXXXXXXXCondenser High Temperature ProtectionXXXXIndoor Evaporator High TemperatureXXXX 3MINUTETIMEDELAY In order to protect the compressor, there is a 3 minute delay on break even if the control is calling for heating or cooling. COMPRESSOR OVERCURRENT PROTECTION Overcurrent protection can result due to any of the following: SThe ambient temperature is to high SLocked rotor on the compressor SBlockage in refrigeration circuit (cap tubes, for example) SOutdoor air is blocked or restricted The compressor current is monitored continuously and protection is provided as shown below: 3 sec 5 min 1 sec Normal Indoor fan: On compressor: On outdoor fan: OnOutdoor fan off (heating) Indoor fan low speed (cooling)Compressor off (after 5 minutes)Compressor off (after 3 seconds)Current down Current up A08117 Fig. 22 – Compressor Overcurrent Protection If the compressor is stopped 4 times at the 5 minute limit or 1 time at the 3 second limit, the system will be locked off and the main power will have to be reset before the system can be restarted. Time LimitCompressor Current 38MVC(Q)009 --- 138MVC(Q)012 --- 138MVC(Q)012 --- 338MVC(Q)018 --- 338MVC(Q)024 --- 3 3SEC14 A18 A11 A14 A23 A 5MIN12 A16A9A12 A21 A ISEC10.5 A14 A7A11 A18 A NORMAL9A12.5 A6A10 A16 A 38/40MVC, MVQ
24 Indoor Coil Freeze Protection The indoor coil can freeze due to any of the following: SLow system charge SReduced indoor airflow SRestricted refrigerant flow SLow ambient temperature (outdoor) SLow load (indoor) In cooling mode, the thermistor located on a return bend of the indoor coil monitors the coil temperature continuously. Any time the coil temperature drops below the TE5 limit for five consecutive minutes, the compressor and outdoor fan will be switched off until the coil temperature rises above the TE6 as shown below: Compressor and outdoor fan off (after 5 mins)Compressor and outdorr fan on EVAP temp. downEVAP temp. up TE5 TE6T (Evap Temp.) A08118 Fig. 23 – Indoor Coil Freeze Protection Parame te rCoil Temperature ° F (° C)40MVC(Q) 009 --- 140MVC(Q) 012 --- 140MVC(Q) 018 --- 340MVC(Q) 024 --- 3 TE539 (4)41 (5)36 (2)36 (2)TE650 (10)54 (12)54 (12)54 (12) Condenser High TemperatureProtection Condenser high temperature can occur due to any of the following conditions: SHigh outdoor ambient SOutdoor fan blocked SOutdoor coil blocked The outdoor coil thermistor on a heat pump unit continuously monitors the temperature of the outdoor coil. Anytime the coil temperature exceeds the TE10 limit, the compressor is switched off and the outdoor fan continues running to reduce the coil temperature. When the coil temperature drops below the TE11 limit, the compressor is switched back on as shown below: Compressor on Outdoor fan on COND temp. down TE11 TE10 TCOND temp. up Compressor off Outdoor fan on A08119 Fig. 24 – Condenser High Temp Protection Parame te rCondenser Temp. °F (°C) 38MVQ018 --- 338MVQ024 --- 3TE10149 (63)158 (70)TE11131 (55)149 (65) Indoor High TemperatureProtection High indoor coil temperature (in heating mode) can occur due to any of the following: SHigh outdoor ambient temperature SIndoor fan blocked SIndoor coil blocked (including dirty filters) The indoor coil thermistor on a heat pump unit continuously monitors the temperature of the indoor coil during heating operation. Anytime the coil temperate exceeds the TE8 limit, the outdoor fan is switched off. If the coil temperature continues to climb and exceeds the TE7 limit, the compressor is switched off. When the coil temperature drops below the TE9 limit, the compressor and outdoor fan are switched back on as shown below: TE9 TE8 TE7 T T temp. up Compressor on Fan on T temp. down Compressor off Fan off Compressor on Fan off A08120 Fig. 25 – Indoor High Temperature Protection Parame te r Condenser Coil Temp. °F (°C) 40MVQ 009 --- 140MVQ 012 --- 140MVQ 018 --- 340MVQ 024 --- 3 TE7140 (60)140 (60)145 (63)145 (63)TE8129 (54)129 (54)129 (54)129 (54)TE9118 (48)118 (48)122 (50)122 (50) SEQUENCE OF OPERATION Interface A wireless remote control, supplied with the unit, is the interface between the fan coil and the user. The wireless remote control has the following characteristics: SCapable of displaying_Cand_F with_C being the default setting. To change the default setting, refer to the Owner’s Manual or push the recessed F/C button once using a paper clip or similar object*. SThe remote control setpoint range is from 62_F(17_C) to 88_F(30_C) in increments of 2_F(1_C). SThere is a dedicated cooling only and heat pump remote control. SThe wireless remote control has an operating range of 25 ft. (7.62 m). SThe same remote control can be used to control more than one unit. SIf the remote control is lost, damaged, or the batteries are exhausted, the system can be operated by using the manual button (forced Auto) located under the front panel. Manual button A07364 Fig. 26 – Manual Button Location on Unit * On units produced during week 12 (2008) and later. Units produced before week 12 have dedicated_Cor_F controls. 38/40MVC, MVQ
25 MODES OF OPERATION The units have 5 main operating modes: 1. Fan Only 2. Cooling 3. Heating (heat pumps only) 4. Auto 5. Dehumidification (Dry) The units have 2 other modes (manual operation) that are operated in unique situations: 1. Auto Forced Mode (Emergency) 2. Test Mode Fan Mode Only In this mode, the system circulates the room air without changing the room air temperature. Cooling Mode In this mode, the system cools and dries the room air with the fan running continuously, either at a selected fan speed or Auto fan speed. The fan runs even when the compressor cycles off. This feature enhances room comfort and efficiency of the system. When the unit is operating in cooling, two sub modes can also be selected: 1. Sleep Mode is an energy saving feature that changes the set point automatically. 2. Turbo Mode is a comfort feature on the 9k and 12k units where the set point is reached quickly by having the fan run on high speed regardless of the speed that has been selected. Compressor and Outdoor Fan Operation The compressor and outdoor fan motor cycle on and off based on the conditions of the set point and the room temperature as shown below. There is no minimum run time. T = Room Temperature Ts = Set Point TemperatureCompressor off fan off Compressor and outdoor fan on Room temp. down 0 1.8°FT-Ts Room temp. up A08106 Fig. 27 – Compressor and Outdoor Fan -- Cooling Mode Indoor Fan Operation When in cooling mode, the fan runs continuously either at the chosen set speed , or in Auto mode, where the speed is determined by the microprocessor based on the difference between the room temperature and the temperature set point as shown below: Room temp. upRoom temp. down T= Room Temperature Ts = Set Point Temperature 9.0 °F 7.2 °F 1.8 °F T-Ts Low fanHigh fan Med fan A08107 Fig. 28 – Auto Fan -- Cooling ModeSleep Mode When in cooling mode, additional energy savings can be realized by selecting the Sleep setting. When the Sleep setting is selected, the temperature set point is adjusted automatically as shown below: Set point Time (hour) 121.8 °F 1.8 °F A08108 Fig. 29 – Sleep Mode The unit will shut off 7 hours after the Sleep Mode is selected. Turbo Mode When in cooling mode, selecting Turbo will allow the indoor unit to satisfy the temperature set point as quickly as possible. In Turbo Mode, the indoor fan will shift to high speed and either run continuously for 20 minutes or until the user pushes the Turbo button again, at which point the fan speed will return to the original setting. Heating Mode In this mode, the system heats the room air with the indoor fan running at either the selected speed or on Auto. As in the cooling mode, the indoor fan will run continuously unless interrupted by the cold blow algorithm. This algorithm will not allow the fan to run if the indoor coil temperature drops below a preset value. The sleep function can be selected while the unit is running in the Heating Mode. Defrost is controlled by the on--board microprocessor. Compressor and Fan Operation The compressor and outdoor fan cycle on and off based on the actual room temperature versus the set point as shown below. When the compressor starts, it will run continuously for 7 minutes even if the set point condition is satisfied. The 4 -- way value is energized in heating and will stay energized for 2 minutes after the mode is changed into a non--heating mode. Compressor on outdoor fan off Room temp. upRoom temp. downCompressor off outdoor fan on Ts+5.4* Ts+3.6* Ts TT = Room Temperature TS = Set Point Temperature * For 9k & 12k Units Only. For 18k and 24k units, numbers will be 5.4 and 7.2 respectively. A08109 Fig. 30 – Compressor and Outdoor Fan -- Heating Mode 38/40MVC, MVQ
26 Auto Fan When the fan speed is set to Auto, the fan will run at either the medium or low speed based on the difference between the room temperature and the set point temperature as shown below: Room temp. upRoom temp. down T- Ts0 Med. SpeedLow. Speed 3.6°FT = Room Temperature Ts = Set Point Temperature A08112 Fig. 31 – Auto Fan -- Heating Mode Manual Indoor Fan The indoor fan will run continuously in heating at the set fan speed (even if the compressor cycles off) unless the indoor coil temperature begins to drop. When the coil temperature drops to the TE3 limit, the 18k and 24k unit indoor fan switches to low speed. On the 9k and 12k unit the indoor fan switches to ultra low speed. When the coil temperature drops to the TE4 limit, the indoor fan on all systems shuts off to prevent cold blow as shown below. The cold blow algorithm also applies to the auto fan setting. T temp. upT temp. down Fan o ff Low Speed / Ultra Low SpeedSet fan speed TE4 TE1 TE3 TE2 T (Coil temp.) A08111 Fig. 32 – Manual Indoor Fan -- Heating Mode Parame te rIndoor Coil Temperature ° F (° C)40MVQ 009 --- 140MVQ 012 --- 140MVQ 018 --- 340MVQ 024 --- 3 TE188 (31)88 (31)77 (25)82 (28)TE293 (34)91 (33)90 (32)93 (34)TE386 (30)81 (27)86 (30)90 (32)TE472 (22)68 (20)68 (20)75 (24) SleepMode When in heating mode additional energy savings can be realized by selecting the Sleep setting. When the Sleep setting is selected, the temperature set point is adjusted automatically as shown below: Set Point Time (hour) 121.8ºF 1.8ºF A08110 Fig. 33 – Sleep Mode -- Heating The unit will shut off 7 hours after the Sleep mode is selected. Defrost Defrost on heat pump units is controlled by the microprocessor and is initiated if either of the following conditions occur: 1. The outdoor coil temperature is lower than 32_F(0_C) for more than 40 minutes and during that period, the coil temperature is continuously lower than 26.6_F(--3_C) for 3 minutes. 2. If the first condition does not occur within 90 minutes of termination of the last defrost cycle. The defrost cycle will terminate 10 minutes after initiation or when the coil temperature reaches 68_F(20_C). At the end of the Defrost cycle the timer resets automatically. The cycles of defrost algorithm are shown below: Compressor 4-way valve Outdoor fan Indoor fanDefrost 10 or 6 minutes On Off 5s 10s25s 2s A08114 Fig. 34 – Defrost Cycle Auto Mode When the Auto setting is selected, the microprocessor looks at the difference between the room temperature (T) and the set point (TS). The algorithm determines which mode the unit will run in as shown below: Heating (fan only in cooling) Fan only Cooling -1.8 °F 3.6°F T-T S A08115 Fig.35–AutoMode When the unit shifts modes, it will remain in that mode for at least 15 minutes while the algorithm ignores the difference between T and TS. This ensures that the unit cannot change modes too frequently. 38/40MVC, MVQ
27 Dry (Dehumidification) Mode When more humidity control is desired, the Dry setting can be selected. Lower humidity is achieved when the microprocessor adjusts the indoor fan speed and compressor cycling by comparing the room temperature (T) and the set point temperature (TS). There are two different control algorithms: Size 9k and 12 k units: T = TS + 3.6 -- the compressor will run for 6 minutes and the indoor fan will run at low speed. The compressor will be off for 4 minutes and the indoor fan will run in ultra low speed. TS = T < TS + 3.6 -- The compressor will run for 5 minutes and the indoor fan will run at low speed. The compressor will be off for 5 minutes and the indoor fan will run in ultra low speed. T < TS -- The compressor will run for 4 minutes and the indoor fan will run at low speed. The compressor will be off for 6 minutes and the indoor fan will run in ultra low speed. Size 18k and 24k units: These units do not have ultra low speed. When set for dehumidification, the indoor fan runs at low speed and the compressor cycles based on the difference between T and TS. Manual Operation The unit can be set for Forced Auto or Forced Cooling manually by pushing the Manual button once or twice as shown below: Remote modeForced autoForced cooling Push 3 TimesPush Once Push Twice A08116 Fig. 36 – Manual OperationForced Auto (Emergency Operation) Forced Auto option allows operation of the unit if the remote control is lost or the batteries have expired. When the system is in Forced Auto, it will run with a default set point of 75.2_F. While in Forced Auto, the system will respond to signals from the remote control. Forced Cooling Operation This option is used for diagnostic purposes. The system is forced to run in cooling for 30 minutes. After 30 minutes, the 9k and 12k systems will switch to Dry mode with a default set point of 75.2_F. The 18k and 24k systems will switch to Forced Auto mode. When the system is in Forced Cooling mode, it will not respond to signals from the remote control. The only way to exit the Forced Cooling mode is to push the manual button once to switch the system to remote control mode. 38/40MVC, MVQ
28 TROUBLESHOOTING This section provides the required flow charts to troubleshoot problems that may arise. NOTE:Information required in the diagnoses can be found either on the wiring diagrams or in the appendix. Required Tools: The following tools are needed when diagnosing the units: SDigital multimeter SScrew drivers (Phillips and straight head) SNeedle-- nose pliers Recommended Steps 1. Refer to the diagnostic hierarchy chart below and determine the problem at hand. 2. Go to the chart listed in the diagnostic hierarchy and follow the steps in the chart for the selected problem. DIAGNOSTIC HIERARCHY Unit has a problem Unit displays a diagnostic codeUnit not running and no diagnostic codeUnit running but not optimally Refer to page --- appropriate diagnostic chart Go to chart # 7Go to chart # 8 & 9 * For EEROM error, replace the indoor microprocessor board Unit has a problem Unit displays a diagnostic codeUnit not running and no diagnostic codeUnit running but not optimally Refer to page A8 & A9 identify error code*and use Go to chart Go to chart # * For EEROM error, replace the indoor microprocessor board A08165 For the ease of service, the systems are equipped with diagnostic code display LED’s on both the indoor and outdoor units. The outdoor diagnostic display is an LED on the outdoor unit board and is limited to very few errors. However, it is useful in identifying special error codes like a failure of the outdoor coil sensor on heat pumps. The indoor diagnostic display is a combination of flashing LED’s on the display panel on the front of the unit. If possible always check the diagnostic codes displayed on the indoor unit first. The diagnostic codes for the indoor and outdoor units are listed in appendix A8 and A9. Problems may occur that are not covered by a diagnostic code, but are covered by the diagnostic flow charts starting with the diagnostic hierarchy. These problems will be typical air conditioning mechanical or electrical issues that can be corrected using standard air conditioning repair techniques.For problems requiring measurements at the control boards please note the following: 1. Always disconnect the main power. 2. When possible check the outdoor board first. 3. Start by removing the outdoor unit top cover. 4. Reconnect the main power 5. Probe the outdoor board inputs and outputs with a digital multi-- meter referring to the wiring diagrams and input/output charts found in the appendix. 6. Connect the red probe to hot signal and the black probe to the ground or negative. 7. Note that some of the DC voltage signals are pulse will give continuously variable readings. 8. If it is necessary to check the indoor unit board you must start by disconnecting the main power. 9. Next remove the front cover of the unit and then control box cover. 10. Carefully remove the indoor board from the control box, place it face up on a plastic surface (not metal). 11. Reconnect the main power and repeat steps 5,6, and 7. 12. Disconnect main power before reinstalling board to avoid shock hazard and board damage. 38/40MVC, MVQ
29 CHART 1 -- INDOOR FAN SPEED OUT OF CONTROL Reset main power and restart system using remote. Problem persists? Replace indoor fan motor No further action is requiredNo Yes Check IFM output and input on indoor board. Values good? Yes Check motor connection. Connection good? No Fix connection Yes No Replace indoor board Reset main power and restart system using remote. Problem persists? Replace indoor fan motor No further action is requiredNo Yes Yes Check motor connection. Connection good? No Fix connection Yes No Replace indoor board A08166 38/40MVC, MVQ
30 CHART 2 -- TEMPERATURE SENSOR Reset main power and restart system using remote. Problem persists? Appendix 6 No further action is requiredNo Yes Check input and output on indoor or outdoor board. Yes Check sensor connector at ID or OD board Connection good? No Fix connection Yes No Replace board Check sensor resistance. No Yes Yes No Yes No No Replace sensor No Double check connection, for corrosion or high resistance. YesYes A08167 38/40MVC, MVQ