SERVICE & MAINTENANCE MANUAL
2005
TABLE OF CONTENTS
PAGE NO.
1. Precautions for Service & Maintenance
2. Split System Description
3. Unit Model Designation & Identification
4. Unit Models & Part Numbers
5. System Operating Limits
6. System Safety Protections
7. Exploded View of Indoor Unit
8. Part List of Indoor Unit
9. Exploded View of Outdoor Unit
10. Part List of Outdoor Unit
10
11. Wiring Diagrams
11
12. Field Electrical Connections Matching
13
13. Refrigeration Cycle
14
14. Self Diagnostic Function
16
15. Replacing Batteries of Remote Control
17
16. Emergency Operation of Air-Conditioner
17
17. Air Filter Cleaning
18
18. Periodical Checks
19
19. Trouble Shooting
20
1. PRECAUTIONS BEFORE INSTALLATION
SAFETY CONSIDERATIONS
Service and maintenance of air conditioning equipment can be hazardous due to system pressures and
electrical components. Only trained and qualified service personnel should install, repair or service the air
conditioning equipment.
When working on air conditioning equipment, observe precautions in the literature, tags and labels attached
to the unit and other safety codes.
Wear safety glasses and gloves. Use quenching cloth and have fire extinguisher available for all brazing
operations
WARNING
This manual describes the service and maintenance of Carrier split room air conditioner consisting of an outdoor unit
and an indoor unit manufactured by Carrier.
What is not covered in Carrier warranty?
1- Failure due to Misuse: Abusing, overloading, careless handling and negligence.
2- Failure due to Accident / Weather: Natural catastrophe, accident due to bad weather (Hail Storm, Sand Storm,
lightning, Flooding, Acid Rain and Air Borne fallout, etc).
3- Failure due to Damages during transport.
4- Failure due to modification: Any modifications done on the unit without Carrier consent.
5- Failure due to Improper Installation: Installation should be performed according to standard.
The decision of Carrier in ascertaining the same will be final. Carrier or its approved dealer should do
installation.
6- Failure due to Improper Maintenance: Lack of professional maintenance, improper adjustments, use of
improper consumables, filters, spare parts other than specified in the Carrier manuals.
7- Failure due to use of non-genuine Carrier Parts, substitute other than Carrier parts.
8- Refrigerant normal noise, wear and tear of deterioration.
9- Inconvenience or commercial loss is not covered.
The decision of Carrier in ascertaining the same will be final. Any such repairs will be carried out at the
expense of the purchaser.
2. SPLIT SYSTEM DESCRIPTION
(c) RETURN AIR TO INDOOR UNIT
(a) INDOOR UNIT
The return air from the space to be air-conditioned passes
x
Mounted inside the space to be air-conditioned.
through the front return grille and top the through the anti-
x
In summer it filters, dehumidifies and cools air.
bacteria filters to clean the air from dust and foreign particles
In winter it filters and heats air.
(d) SUPPLY AIR FROM INDOOR UNIT
Cool or warm air comes out of supply
air outlet
(f) REFRIGERANT PIPING LINES
(e) WIRELESS REMOTE CONTROL (LCD)
Controls on/off, mode, and fan speed,
Insulated copper piping through which refrigerant
temperature, timer and swing, and sleep
R22 flow connects the indoor and outdoor units.
functions.
(g) DRAIN HOSE
x
Drain the water condensated in the indoor
unit during cooling operation to the outside.
(b) OUTDOOR UNIT
Fig. (1)
x
Mounted outside the space to be airconditioned.
HI WALL SPLIT SYSTEMS
53QH-H SERIES HEAT PUMP
53QH-C SERIES COOL ONLY
x
It contains compressor, fan, motor, condenser
coil, copper tubing and electrical components.
3. UNIT MODEL DESIGNATION & IDENTIFICATION
UNIT MODEL DESIGNATION
42
38
42 = Indoor Unit
38 = Outdoor Unit
IDENTIFICATION (ID)
H
C
QH
30
Unit Family
System
Cooling Capacity
At ARI Conditions
30 = 30,000 Btu/hr
36 = 36,000 Btu/hr
Unit Type
H = Heat Pump
C = Cool Only
4. UNIT MODELS & PART NUMBERS
INDOOR UNIT
Heat Pump
Model
42QH30-H
42QH36-H
Cool Only
P/N
46303188
46303189
ID
H
H
Model
42QH30-C
42QH36-C
P/N
46303186
46303187
ID
C
C
OUTDOOR UNIT
Heat Pump
Model
38QH30-H
38QH36-H
P/N
46302173
46302177
Cool Only
ID
H
H
Model
38QH30-C
38QH36-C
P/N
46302179
46302178
ID
C
C
5. SYSTEM OPERATING LIMITS
Difference
Indoor temperature
Maximum
Minimum
Outdoor temperature
Maximum
Minimum
COOLING
Dry Bulb
Temp. C
Wet Bulb
Temp. C
32
21
23
15
55
21**
System
Model
Difference
HEATING
Dry Bulb
Temp. C
Wet Bulb
Temp. C
Indoor temperature
Maximum
27
Outdoor temperature
Maximum
21
MAIN POWER SUPPLY
Nominal
Minimum
Power Supply
Voltage
V/1PH/50HZ
Maximum
Voltage
Min. Voltage
200-240
180
264
Max. Voltage
220-240
198
264
NOTES:
* When the unit is operated above or below these limits for a long time, system diagnostics may detect
a malfunction and the unit will not operate properly.
6. SYSTEM SAFETY PROTECTIONS
6-1 FOR HEAT PUMP SYSTEM
PROTECTION TYPE
PROTECTION EFFECT
OPERATION MODE
WHEN ON
Cold draft prevention
Indoor fan off
Heating mode
During unit operation
Defrost cycle
Indoor coil
Freeze protection
Against frequent
Compressor cycling
Indoor fan off
Heating mode
During unit operation
Compressor off
Cooling mode
During unit operation
Compressor
Time delay
Cooling or heating
modes
At unit start-up or change of
operating mode
PROTECTION EFFECT
OPERATION MODE
WHEN ON
Compressor off
Cooling mode
During unit operation
Compressor
Time delay
Cooling mode
At unit start-up or change of
operating mode
6-2 FOR COOL ONLY SYSTEM
PROTECTION TYPE
Indoor coil
Freeze protection
Against frequent
Compressor cycling
WARNING:
During heat pump operation the system will undergo several defrost cycles to remove ice that might collect on the outdoor
unit in very low ambient temperature. In these cycles, the indoor fan will be automatically off and cannot operate until
defrost cycle is completed.
7. EXPLODED VIEW OF INDOOR UNIT
23
22
22
20
21
19
18
17
16
14
13
10
4
11
24.3
6
7
12
3
2
24.2
15
24.7
24.1
9
7
5
24.4
8
24.5
24.6
25
8. PART LIST OF INDOOR UNIT
QUANTITY / UNIT
NO.
PART
NUMBER
PART NAME
42QH- C
30
36
30
36
Mounting Bracket
Base Pan
02802427
End Plate Support L
02802425
Blower L
02802434
Blower R
02802435
Bracket Motor
02802422
Center Bearing W/Bracket
02802423
Motor
02400017
Evap. Support-R
02802433
10
Evap. Support-L
02802432
11
Drain Hose Connector
02802399
12
Drain Hose
02802398
13
Horizontal Louver
02802424
14
Drain Pan
02802428
15
Step Motor MP35
02400015
16
Deflector
02802430
16
16
16
16
17
Bar Gang
02802431
18
Deflector with Arm
02802429
19
Evap. Coil-3R x 5C x 3/8
02600159
20
Frame Grille
02802436
21
Screw Cover
02802400
22
Air Filter
02802401
23
Decorative Panel
02802437
Main PCB Cool/Heat
02503154
Main PCB Cool Only
02503186
24
24.1
02802426
42QH- H
Control Box Assy
24.2 Return Air Sensor
02503149
24.3 Indoor Coil Sensor
02503150
24.4 Capacitor 2.5 MF/ 450VAC
02400016
24.5 Lamp PCB/IR Receiver
02503151
24.6 Control Box
02503156
24.7 Auxiliary Switch
02503163
24.8 Wire Harness Auxiliary Switch
02503162
24.9 Wire Harness Lamp PCB
02503164
02503153
Remote Control Cool / Heat
02503155
Remote Control Cool Only
02503178
Battery size AAA-15.V
02501125
24.10 Extension Wire 8M
25
26
9. EXPLODED VIEW OF OUTDOOR UNIT
18
17
4
5
6
12
8
10
2
13
3
1
7
19/1
19/2
19/5
15
11
19/6
19/3
19/3
16
14
20
20
10. PART LIST OF OUTDOOR UNIT
SR.
PART
NUMBER
DESCRIPTION
1
1.1
1.2
2
3
4
COMPRESSOR COMPLETE WITH GROMMETS & SPACERS
Copeland Comp. CR37KQ-PFT
Copeland Comp. CR47KQ-PFZ
COND. BASE
SUPPORTING LEG ASSY
COND. PARTITION
5
5.1
5.2
6
7
7.1
7.2
8
9
10
CONDENSER COIL SUBASSY.
Cond. Coil 2 Row 33.15 x 22 - 14FPI
Cond. Coil 2 Row 33.15 x 28 - 15FPI
CONDENSER MOTOR SUPPORT SUBASSY.
CONDENSER MOTOR
Motor 1/10 HP-880 RPM
Motor 1/5 HP-860 RPM
PROPELLER C/W SOCKET SET SCREW 8 X 8 MM
ORIFICE PROPELLER
COND. SHROUD
21
12
13
14
CARRIER LOGO
HANDLE
GUARD PROPELLER
COND. BACK PANEL
15
16
17
COUPLING PANEL
SERVICE DOOR
COIL GUARD
18
19
COND. COVER
ELECTRICAL BOX SUBASSY
19.1 DUAL CAPACITOR
19.1.1 Dual Capacitor 50 + 5 MFD/440 VAC
19.1.2 Dual Capacitor 60 + 5 MFD/440 VAC
19.2 CONTACTOR FOR COMPRESSOR
19.2.1 Contactor 2 poles 25 Amps
19.2.2 Contactor 2 poles 30 Amps
19.3 TERMINAL BLOCKS
19.3.1 Terminal Block 6 Poles-30 Amps
19.3.2 Terminal Block 4 Poles-30 Amps
19.3.3 Terminal Block 3 Poles-30 Amps
19.4 COND. ELECTRICAL BOX
19.5 CAPACITOR CLAMP
19.6 SUPPORT CABLE
19.7 WIRE HARNESS SET
19.8 PTC STARTER FOR COMPRESSOR
19.8.1 PTC Starter Model SPP POW-R-PAK
19.8.2 PTC Starter Model SPP5
19.9 LOW PRESSURE CONTROL
19.10 PILOT LIGHT FOR LOW PRESSURE CONTROL
20
REVERSING VALVE & ELECTRIC COIL
21
ACCUMULATOR
22
23
SENSOR OUTDOOR COIL
TUBING
01500256
01500172
08107402
36314043
06307407
06307436
1
1
4
1
1
1
1
4
02400154
02400179
02600441
02803112
08107406
06307435
02900615
02803110
02803113
06307409
06307434
06307410
02803106
02803114
02803115
08107400
36314125
36314097
36314223
36314222
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
02400379
02400377
02400580
02400572
02501433
02501405
02501315
06307405
02804078
02802523
02500879
02500872
1
1
1
1
1
1
1
1
1
02200404
02200406
02301012
02301013
02503015
36314124
36314096
36313934
36314193
1
4
1
02600234
02600231
36313880
02501579
02501578
02400638
02502315
QTY./UNIT
38QH-H
38QH-C
30
36
30
36
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
11. WIRING DIAGRAMS
INDOOR UNIT 42QH-H SERIES HEAT PUMP
WIRING DIAGRAM
INDOOR UNIT 42QH-C SERIES COOL ONLY
WIRING DIAGRAM
0350151
10
WIRING DIAGRAMS (CONT.)
OUTDOOR UNIT 38QH-H SERIES HEAT PUMP
WIRING DIAGRAM
OUTDOOR UNIT 38QH-C SERIES COOL ONLY
WIRING DIAGRAM
11
12. FIELD ELECTRICAL CONNECTIONS MATCHING
OUTDOOR
COIL
SENSOR
COOL ONLY SYSTEM
200-240V ~ 50Hz
200-240V ~ 50Hz
HEAT PUMP SYSTEM
LEGEND
Outdoor Unit
Indoor Unit
Main Switch
Time-delay fuse or circuit breaker
Earth
L
Live power supply.
Neutral power supply.
Live connection indoor/outdoor unit.
Neutral connection indoor/outdoor unit
Compressor control.
Reversing valve control (Only for heat pump system)
Outdoor fan motor control (Only for heat pump system)
Earth
Note: The mains supply must be connected to the outdoor unit.
12
13. REFRIGERATION CYCLE
HEAT PUMP SYSTEM
13
REFRIGERATION CYCLE (Cont.)
COOL ONLY SYSTEM
14
14. SELF DIAGNOSTIC FUNCTION
14-1 INTRODUCTION
- Self-diagnostic function is the key for success of heat pump system.
- The printed circuit boards existing inside the indoor unit are equipped with self-diagnostic function to detect
malfunction and automatically stops the operation at the air conditioner after blinking of power or timer led as per
malfunction.
14-2 SELF DIAGNOSTIC FUNCTION
The self-diagnostic function included in the control system detects malfunctions of the following
components:
(1) Return Air Sensor
(2) Indoor Coil Sensor
(3) Outdoor Coil Sensor
(4) Compressor Drive
(5) Anti-overheat
(6) Low ambient
Power led or
Timer led
Blinking
No.
1
2
3
4
5
6
Malfunction
Reason
Power
Led
Return Air Sensor
Indoor Coil Sensor
Outdoor Coil Sensor
Compressor Overload
Anti-overheat
Low ambient
15
Blinking
Blinking
Blinking
Timer
Led
Blinking
Blinking
Blinking
-
15. AIR FILTER CLEANING
- The air filters supplied with the unit are high-efficiency washable and recyclable filters.
- To establish, how frequently these should be cleaned, the operating conditions must be
taken in to account.
- REMOVAL OF AIR FILTERS FOR CLEANING:
Open the return grille without removing the two screws and
the central clamp from their position.
Remove acrylic-fiber filters for cleaning.
- CLEANING OF ACRYLIC-FIBRE STANDARD FILTERS:
First clean the filter with a vacuum cleaner
Rinse filter under running water, and dry it
every month.
Notes: (1) After cleaning, put the filters back in the correct positions.
(2) Before operating the air conditioner, check that air filters are in their places inside
unit.
16
16. PERIODICAL CHECKS
For a good operation of the air conditioner it is recommended to carry out checks and
maintenance as indicated.
Recommended maintenance intervals may very depending on the installation environment,
e.g. dusty zones, etc.
Indoor Unit
Every Month
(1)
Clean air filter
Clean drain pipe (2)
Change controller batteries
Outdoor Unit
Clean outdoor coil from outside (2)
Clean outdoor coil from inside
Blow air over electric parts (2)
Check electric connection tightening (2)
Clean fan wheel (2)
Check fan tightening (2)
Clean drain pan (2)
Every 4 Months
Every Year
Every Month
Every 4 Months
Every Year
(1) Increase frequency in dusty zones.
(2) Operations to be carried out by qualified service personnel.
17
17. TROUBLE SHOOTING
TROUBLE
Compressor and outdoor fan will not
start
Compressor will not start, but outdoor
fan runs
Compressor runs bur cycles on
internal overload (other than normally
satisfying thermostat)
Compressor operates continuously
Excessive head pressure
REASON
ACTION
Power failure
Call power company
Fuse blown or / and circuit breaker tripped Replace fuse or reset circuit breaker
Detective contactor
Replace
Low line voltage
Determine cause and eliminate
Incorrect or loose wiring
Check wiring diagram and rewire correctly
Temp. setting too low
Faulty wiring or loose connections in
compressor circuit
Reset temp. setting
Check wiring and repair or correct
Compressor motor burned out, stuck or
internal over-load open
Replace compressor and determine cause
Detective run capacitor
Refrigerant over or under charge
Replace
Blow refrigerant, evacuate system and
recharge
Air or non condensable refrigerant in
system
Blow refrigerant, evacuate system and
recharge
Detective compressor
Replace and determine cause
Low or too high line voltage
Determine cause and correct
Blocked outdoor coil
Determine cause and replace
Outdoor fan stopped
Determine cause and replace
Detective run capacitor
Replace
Faulty fan motor of outdoor section
Replace
Restriction in refrigerant system
Locate restriction and remove
Capillary or Accurate restricted or ice
clogged.
System undersized for load
Blow refrigerant, evacuate system and
recharge
Decrease load or increase system size
Temp. setting too low
Reset temp. setting
Defective outdoor fan
Check for source and replace
Air or non condensable refrigerant in
system
Blow refrigerant, evacuate system and
recharge
Air restricted or indoor section filter dirty
Dirty outdoor coil
Clean filter or remove restriction
Clean coil
Detective outdoor fan
Replace
Refrigerant over charged
Purge excess refrigerant
Air or non condensable refrigerant in
system
Blow refrigerant, evacuate system and
recharge
Outdoor section air restricted
Remove restriction
18
TROUBLE SHOOTING (Cont.)
TROUBLE
Head pressure too low
REASON
Low refrigerant charge
ACTION
Check for leaks, repair and recharge
Restriction in liquid tube
Remove restriction
Indoor section air filter dirty
Clear filter
Reversing valve hung up or internal leak
Replace
Internal pressure relief open
Check for source and eliminate
Refrigerant over charged
Purge excess refrigerant
Suction pressure too low
Low refrigerant charge
Check for leaks, repair and recharge
(Low pressure control cuts-out & pilot
Indoor unit frosted
See next trouble
Excessive section pressure
light for low pressure control lights off) Low indoor air or short cycling
Eliminate cause, check for fan working
Restriction in suction tube
Locate restriction and remove
Capillary or accurate restricted or ice clogged
Blow refrigerant, evacuate system and
recharge
Outdoor fan stopped or cycling on
Detective fan motor capacitor
Replace
overload
Loose leads at fan motor
Check for cause and eliminate
Fan motor burned out
Replace
Motor bearing sized
Check for cause and eliminate
Batteries are exhausted or have the wrong
Replace batteries or check polarity.
After batteries have been placed into
the remote control, the display is not lit. polarity.
When pressing the recessed lock
Recessed button has not been pressed
Press with a round point, avoid exerting
adjustment button, hour figures on
correctly.
strong pressure
display do not flash.
When pressing any button, all symbols
Recessed button for time setting is blocked due Check and repair.
appear on display.
to excessive pressure during use.
Remote control has been irreversibly damaged. Replace with a new one.
When pressing start button, unit does
Main switch is OFF.
Switch it to ON position.
not acknowledge signal with a beep.
Remote control batteries are exhausted.
Replace batteries.
Remote control has not been pointed correctly
Turn remote control OFF and repeat the
to the receiver of indoor unit.
operation in the correct direction.
There are obstacles (curtains, walls, etc.)
Repeat the operation after having
between the remote control and the indoor unit removed the obstacles.
Receiver on the indoor unit or the remote
Avoid direct sun on the unit, shut curtains
control is under intense sun radiation.
or shades.
Signal transmission is obstructed by severe
Avoid sending signals when computers or
interference from an electromagnetic field.
household appliances (Food processors,
coffee makers, etc.) are operating close
by cellular or cordless telephones may
also interfere with the control.
19
TROUBLE CHART (Cont.)
TROUBLE
When pressing stop button, unit does
REASON
Remote control batteries are exhausted.
Replace batteries.
ACTION
not acknowledge signal with a beep.
Remote control has not been pointed
Turn remote control OFF and repeat the
correctly to the receiver of indoor unit.
operation in the correct direction.
There are obstacles (curtains, walls, etc.)
between the remote control and the
indoor unit
Receiver on the indoor unit or the remote
control is under intense sun radiation.
Signal transmission is obstructed by
Repeat the operation after having removed
the obstacles.
severe interference from an
household appliances (Food processors,
electromagnetic field.
coffee makers, etc.) are operating close by
Avoid direct sun on the unit, shut curtains or
shades.
Avoid sending signals when computers or
cellular or cordless telephones may also
interfere with the control.
When pressing any function button,
Main switch is OFF.
Switch it to ON position.
the remote control shows the function
Remote control batteries are exhausted.
Replace batteries.
requested on the display, but unit
Remote control has not been pointed
Turn remote control OFF and repeat the
does not acknowledge signal receipt
correctly to the receiver of indoor unit.
operation in the correct direction.
with a beep and does not carry out the There are obstacles (curtains, walls, etc.)
Repeat the operation after having removed
function.
the obstacles.
between the remote control and the
indoor unit
Receiver on the indoor unit or the remote
control is under intense sum radiation.
Signal transmission is obstructed by
Avoid direct sun on the unit, shut curtains or
shades.
Avoid sending signals when computers or
severe interference from an
household appliances (Food processors,
electromagnetic field.
coffee makers, etc.) are operating close by
cellular or cordless telephones may also
interfere with the control.
Air conditioner will not start.
Main supply switch is OFF
Fuses or main switch are blown
Protection against frequent compressor
cycling is ON
Selected temperature is higher than the
Switch to ON
Replace fuses
Wait for 3 minutes.
Correct selected temperature.
room temperature in the cooling mode (or
lower in the heating mode).
Air conditioner is not supplying
enough cooling.
Air flow cannot circulate freely
Dirty filters reduce air quantity circulating.
Doors and/or windows are open.
Fan speed has been set to Low
Air flow direction is not correct
Selected temperature is higher than the
room temperature in the cooling mode.
20
Remove obstructions.
Clean air filters
Close doors and windows
Set fan speed at high speed.
Adjust airflow direction as per the mode
chosen.
Correct selected temperature.
TROUBLE CHART (Cont.)
TROUBLE
Air conditioner is not supplying enough
REASON
Air flow cannot circulate freely
ACTION
Remove obstructions.
heating.
Dirty filters reduce air quantity circulating. Clean air filters
Doors and/or windows are open.
Close doors and windows
Fan speed has been set to Low
Set fan speed at high speed.
Air flow direction is not correct
Adjust airflow direction as per the mode
chosen.
Correct selected temperature.
Selected temperature is Lower than the
room temperature in the heating mode.
A slight mist is emitted from the indoor
The cool air from the indoor unit is
Normal operation
unit during cooling
coming into contact with the room air.
A slight whistling noise is heard when is
This is due to the refrigerant beginning to Normal operation
heard when the air conditioner starts or
circulate or an adjustment of the
stops.
refrigerant pressures.
Water vapor (mist) emanating from the
It is normal in heat pump operation, when Normal operation
outdoor unit.
defrost is automatically activated.
Unpleasant smells coming from the indoor Unpleasant smells can be caused by
Switch the system OFF and contact an
unit.
authorized service center to have the filters
substances accumulated in the air filters
cleaned.
Restart unit in the ventilation (fan only) mode
and open windows to change room air.
Strange noises coming from the indoor
Occasionally the indoor unit can emit
unit.
some strange short noises during
Normal operation
operation or when it has stopped.
These are generally due to the of
temperature changes on the plastic parts.
Starting in heating mode for heat pump
systems
Timer Led is Blinking
Power led is blinking
If the system starts at low ambient
temperatures, it takes a little while to
reach a comfortable room temperature.
When the system is started by the
remote control, it emits a signal beep, but
the louvre does not swing and the fan
does not run until the operating
temperature has been reached.
Faulty return air sensor
Faulty return indoor coil sensor
Faulty return outdoor coil sensor
Compressor overheat
Anti overheat
Low ambient
21
Normal operation
Determine reason and replace
Determine reason and replace
Determine reason and replace
Determine reason and correct
Determine reason and correct
Determine reason and correct
