Carrier 38HDR Bedienungsanleitung

38HDR

Ducted Condensing Units

Installation Instructions

A07532

Fig. 1 --- 38HDR

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS 1........................

INSTALLATION 2--9................................

Step 1 -- Complete Pre--Installation Checks 2............

Step 2 -- Rig and Mount Unit 2......................

Step 3 -- Complete Refrigerant Piping Connections 4.....

Step 4 -- Make Electrical Connections 7................

START--UP 10.......................................

SERVICE 10........................................

MAINTENANCE 14..................................

TROUBLESHOOTING 14.............................

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 would 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.

INSTALLATION

!WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could result in personal injury

or equipment damage.

Puron refrigerant systems operate at higher pressures than

standard R--22 systems. Do not use R--22 service

equipment or components on Puron refrigerant equipment.

PERSONAL INJURY AND EQUIPMENT DAMAGE

HAZARD

Failure to follow this caution may result in personal injury

and / or equipment damage.

DO NOT operate the unit without a filter or with grille

removed.

CAUTION

Step 1 —Complete Pre--Installation Checks

Unpack Unit

Move the unit to final location. Remove unit from carton,

being careful not to damage service valves and grilles.

Inspect Shipment

File a claim with the shipping company if shipment is damaged or

incomplete. Check the unit nameplates to ensure units match job

requirements.

Consider System Requirements

Consult local building codes and NEC for special installation

requirements.

Allow sufficient space for airflow clearance, wiring, refrigerant

piping, and servicing unit. See Fig. 2.

Locate unit so that condenser airflow is unrestricted on both sides.

Refer to Fig. 2.

Unit may be mounted on a level pad directly on base legs or

mounted on raised pads at support points. See Fig. 2 for center of

gravity.

Matching the Condensing Unit to an Indoor Unit

The 38HDR018--060 ducted condensing units can be matched to

corresponding indoor units. The 38HDR unit can be matched with

under--ceiling and residential fan coils and evaporator coils. Refer

to separate indoor unit literature for more information.

Step 2 —RIG AND MOUNT UNIT

Mounting on Ground

Mount unit on a solid, level concrete pad. Position unit so water or

ice from roof does not fall directly onto unit. Accessory stacking

kits can be used when units are to be stacked. See installation

instructions provided with the accessory kit. Use field--provided

snow stand or ice rack where prolonged subfreezing temperatures

or heavy snow occurs.

If conditions or local codes require unit be fastened to a pad, 6

field--supplied tiedown bolts should be used and fastened through

slots provided in unit mounting feet.

Mounting on Roof

Mount unit on a level platform or frame at least 6 in. (152.4 mm)

above roof surface. Isolate unit and tubing from structure.

38HDR

(FIELD PROVIDED AND INSTALLED)

NOTE: Dimensions shown in feet--inches. Dimensions in ( ) are millimeters.

UNIT MODELS CHASSIS

SIZE

(Reference)

ABC D E FG H JKL NP

38HDR

Unit Size

018 02’--1

8”

3’--0

16”

1’--2

16”

1’--4” 1’--11

16”

1’--5

16”

1’--5

8”

1’--10” 1’--1” 0’--6

8”

0’--11

4”

0’--2

16”

0’--6”

(638.2) (938.2) (369.9) (406.4) (595.3) (436.6) (435) (559.1) (330.2) (168.3) (285.8) (75) (152.4)

024 0.6 2’--7

8”

3’--0

16”

1’--2

16”

1’--4” 1’--11

16”

1’--5

16”

1’--11

8”

2 ’ -- 4 ” 1 ’ -- 2 ” 0 ’ -- 6

4”

0’--11

8”

0’--2

16”

0’--6”

(790.6) (938.2) (369.9) (406.4) (595.3) (436.6) (587.4) (711.5) (355.6) (171.5) (295.3) (75) (152.4)

030, 036 1.0 3’--1

16”

1’--5

16”

1’--6

16”

2’--6

2”

1’--7

8”

2’--5

16”

2’--10

16”

1’--1

16”

0’--8

8”

1’--3

8”

0’--3

16”

0’--6

2”

(944.6) (1131.9) (433.4) (468.3) (774.7) (498.5) (741) (865.5) (347.7) (206.4) (403.2) (88) (165.4)

048, 060 1.6 3’--7

16”

1’--5

16”

1’--6

16”

2’--6

2”

1’--7

8”

2’--11 /

13/16”

3’--4

16”

1’--2

2”

0’--8

2”

1’--6

8”

0’--3

16”

0’--6

2”

(1097) (1131.9) (433.4) (468.3) (774.7) (498.5) (893.4) (1017.9) (354.2) (215.9) (479.4) (88) (165.4)

UNIT SIZE M OPERATING WT

in. mm lb kg

38HDR

018

15.88 166 75.8

024

15.88 176 79.8

030

19.05 187 84.8

036

19.05 250 113.4

048

22.22 278 126.1

060

22.22 306 138.8

NOTES:

1. Required clearances: with coil facing wall, allow 6 in. minimum clearance

on coil side and coil end, and 3 feet minimum clearance on compressor

end and fan side. With fan facing wall, allow 8 in. minimum clearance on

fan side and coil end, and 3 feet minimum clearance on compressor end

and coil side. With multi--unit application, arrange units so discharge of one

does not enter inlet of another.

2. Dimensions in parenthesis are in millimeters.

3. Center of Gravity .

UNIT SIZE

MINIMUM MOUNTING PAD

DIMENSIONS

Support Feet

ft--in. mm

CHASSIS SIZES 0 & .6 1 -- 11 x3 --6 584.2 x 1066.8

CHASSIS SIZES 1 & 1.6 2--0x4--2 609.6 x 1270

3’ -- 8

9/16”

3’ -- 8

9/16”

Fig. 2 --- 38HDR Unit Dimensions

38HDR

Rigging

PERSONAL INJURY AND/OR EQUIPMENT

DAMAGE HAZARD

Failure to follow this caution may result in personal injury

and/or equipment damage.

Be sure unit panels are securely in place prior to rigging.

CAUTION

Keep the unit upright and lift unit using a sling. Use cardboard or

padding under the sling, and spreader bars to prevent sling damage

to the unit. See Fig. 3. See Fig. 2 for center of gravity reference.

Install the unit so that the coil does not face into prevailing winds.

If this is not possible and constant winds above 25 mph are

expected, use accessory wind baffle. See installation instructions

provided with the accessory kit.

NOTE: Accessory wind baffles should be used on all units with

accessory low ambient temperature control.

Field--fabricated snow or ice stands may be used to raise unit when

operation will be required during winter months. Units may also be

wall mounted using the accessory wall mounting kit.

A07396

Fig. 3 --- Lifting Unit with Sling

Step 3 —COMPLETE REFRIGERANT PIPING CONNEC-

TIONS

Outdoor units may be connected to indoor units using

field--supplied tubing of refrigerant grade and condition. See Table

1 for correct line sizes. Do not use less than 10 ft (3.05 m) of

interconnecting tubing.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment

damage or improper operation.

If any section of pipe is buried, there must be a 6 in. (152.4

mm) vertical rise to the valve connections on the outdoor

unit. If more than the recommended length is buried,

refrigerant may migrate to cooler, buried section during

extended periods of system shutdown. This causes

refrigerant slugging and could possibly damage the

compressor at start--up.

When more than 80 ft (24.38 m) of interconnecting tubing and

more than 20 ft (6.10 m) of vertical lift is used, consult the

residential Long Line Application Guide for required accessories.

If either refrigerant tubing or indoor coil is exposed to the

atmosphere, the system must be evacuated following good

refrigeration practices.

Run refrigerant tubes as directly as possible, avoiding unnecessary

turns and bends. Suspend refrigerant tubes so they do not damage

insulation on vapor tube and do not transmit vibration to structure.

Also, when passing refrigerant tubes through a wall, seal the

opening so that vibration is not transmitted to structure. Leave

some slack in refrigerant tubes between structure and outdoor unit

to absorb vibration. Refer to separate indoor unit installation

instructions for additional information.

Expansion Device

A hard shutoff, thermostatic expansion valve (TXV) is required at

the indoor section of the system for proper operation of these

products. If the indoor section of the system is not equipped with a

hard shutoff TXV, refer to Spec Sheet for the correct TXV kit to be

installed. Follow the instructions in the kit for proper installation.

38HDR

Filter Drier

The filter drier must be replaced whenever the refrigeration system

is exposed to the atmosphere.

Refer to Fig. 4 and install filter drier as follows:

1. Braze 5--in. (127 mm) liquid tube to the indoor coil.

2. Wrap filter drier with damp cloth.

3. Braze filter drier to above 5--in. (127 mm) liquid tube.

Flow arrow must point towards indoor coil.

4. Connect and braze liquid refrigerant tube to the filter drier.

A05178

Fig. 4 --- Filter Drier Components

Only use factory specified liquid--line filter driers with rated

working pressures less than 600 psig.

NOTE: Do not install a suction--line filter drier in liquid line.

Make Piping Sweat Connections

Remove plastic caps from liquid and suction service valves. Use

refrigerant grade tubing. Service valves are closed from the factory

and are ready for brazing. After wrapping the service valve with a

wet cloth, the tubing set can be brazed to the service valve using

either silver bearing or non--silver bearing brazing material.

Consult local code requirements. Refrigerant tubing and the indoor

coil are now ready for leak testing.

NOTE: Unit is shipped with Puronrrefrigerant factory charge

indicated on nameplate.

Pass nitrogen or other inert gas through piping while brazing to

prevent formation of copper oxide.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment

damage or improper operation.

To prevent damage to unit or service valves observe the

following:

SUse a brazing shield.

SWrap service valves with wet cloth or use a heat sink

material.

Provide Safety Relief

A fusible plug is located in unit suction line; do not cap this plug.

If local code requires additional safety devices, install as directed.

38HDR

Table 1—38HDR018--060 Physical Data

UNIT 38HDR 018 024 030 036 048 060

NOMINAL CAPACITY Tons 1.5 2.0 2.5 3.0 4.0 5.0

OPERATING WEIGHT lb (kg) 166 (75.30) 176 (79.83) 250 (113.4) 250 (113.4) 278 (126.10) 306 (138.80)

REFRIGERANT TYPE Puronr(R---410A)

METERING DEVICE TXV

CHARGE lb (kg)* 6.3 (2.86) 6.5 (2.95) 10.0 (4.54) 10.0 (4.54) 12.0 (5.44) 12.0 (5.44)

COMPRESSOR

Type Scroll

O i l C h a r g e ( P O E --- o z ) 25.0 25.0 25.0 25.0 42.0 42.0

Crankcase Heater (watts) — — 40 40 40 40

OUTDOOR FAN

Rpm/Cfm 840/1720 840/1720 850/3900 850/3900 850/3900 850/3900

Diameter in. (mm) 18 (457.2) 24 (609.6)

No. Blades 3

Motor (hp) 1/8 1/4

OUTDOOR COIL

Face Area (sq ft) 5.8 7.3 12.1 12.1 14.1 14.1

No. Rows 2 3 2 2 3 3

FPI 20 20 20 20 20 20

HIGH PRESSURE SWITCH

C u t --- I n p s i g

Cutout psig

420 ±25

650 ±10

LOW PRESSURE SWITCH

Low Cutout psig

Low Cut---in psig

20 ±5

45 ±25

REFRIGERANT LINES

Connection Type Sweat

Liquid Line (in.) OD 3/8 3/8 3/8 3/8 3/8 3/8

Vapor Line (in.) OD 5/8 5/8 3/4 3/4 7/8 7/8†

Max Length ft. (m) 200 (60.96)

Max Lift ft. (m) 65 (19.81)

Max Drop ft. (m) 150 (45.72)

CONTROLS

Fusible Plug _F(_C) 210 (98.89)

Control Voltage}24 vac

System Voltage 208/230 v 208/230 v 208/230 v 208/230 v, Single and 3 Phase, 460 v, 3 Phase

FINISH Gray

* Unit shipped with full factory charge. See ARI (Air Conditioning and Refrigeration Institute) capacity table for proper charge and piston for each fan coil type.

{Valve connection size is 7/8 inch. Recommended line size is 1---1/8 inches.

}24 v and a minimum of 40 va is provided in the fan coil unit.

FPI --- Fins Per Inch

POE --- P o l y o l E s t e r

38HDR

Step 4 —Make Electrical connections

!WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

The unit cabinet must have an uninterrupted or unbroken

ground to minimize personal injury if an electrical fault

should occur. The ground may consist of electrical wire or

metal conduit when installed in accordance with existing

electrical codes.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment

damage or improper operation.

Unit failure as a result of operation on improper line voltage

or excessive phase imbalance constitutes abuse and may

cause damage to electrical components. Such operation

would void any applicable Carrier warranty.

!WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

Before performing service or maintenance, be sure indoor

unit main power switch is turned OFF and indoor blower

has stopped.

Control Circuit Wiring

Control voltage is 24 v (40 va minimum). See Fig. 5 and unit label

diagram for field--supplied wiring details. Route control wire

through opening in unit side panel to connection in unit control

box.

A07398

Fig. 5 --- 38HDR Typical Control Circuit Connections

NOTE: Use No. 18 AWG color----coded, insulated (35_C

minimum) wire. If thermostat is located more than 100 ft (30.48

m). from unit, as measured along the control voltage wires, use No.

16 AWG color--coded wire to avoid excessive voltage drop.

NOTE: All wiring must conform to NEC and local codes.

NOTE: Operating unit on improper line voltage constitutes abuse

and could affect Carrier warranty. See Table 2. Do not install unit

in a system where voltage may fluctuate above or below

permissible limits.

See Table 2 for recommended fuse sizes. When making electrical

connections, provide clearance at the unit for refrigerant piping

connections.

NOTE: The 38HDR units use the control transformer supplied

with the matched indoor unit.

Power Wiring

Unit is factory wired for voltage shown on nameplate. Provide

adequate, fused disconnect switch within sight from unit, readily

accessible, but out of reach of children. Provision for locking the

switch open (off) is advisable to prevent power from being turned

on while unit is being serviced.

Disconnect switch, fuses, and field wiring must comply with the

NEC and local code requirements. Use copper wire only between

the disconnect switch and unit. Use minimum 60 C wire for the

field power connection.

Route power wires through the opening in unit side panel and

connect in the unit control box as shown on the unit label diagram

and Fig. 6. Unit must be grounded.

Connections to Duct Free Fan Coil Units

The 38HDR units are designed for easy match--up to 40QA duct free

fan coils. This unit provides 24 v power for the outdoor unit from the

fan coil.Connectthe Y and C terminals of the indoor unit to the Yand

Cterminals.

38HDR

Table 2—38HDR Electrical Data

38HDR

UNIT

SIZE

V --- P H --- H z

VOLTAGE

RANGE*

COMPRESSOR OUTDOOR FAN MOTOR MIN

CKT

AMPS

FUSE/BKR

AMPS

RLA LRA FLA NEC

Out

Min Max

018 208/230---1---60 187 253 9.0 48.0 0.80 0.125 0.09 12.1 20

024 208/230---1---60 187 253 12.8 58.3 0.80 0.125 0.09 16.8 25

030 208/230---1---60 187 253 14.1 73.0 1.45 0.25 0.19 19.1 30

036

208/230---1---60 187 253 14.1 77.0 1.45 0.25 0.19 19.1 30

208/230---3---60 187 253 9.0 71.0 1.45 0.25 0.19 12.7 20

4 6 0 --- 3 --- 6 0 414 506 5.6 38.0 0.80 0.25 0.19 7.8 15

048

208/230---1---60 187 253 21.8 117.0 1.45 0.25 0.19 28.7 50

208/230---3---60 187 253 13.7 83.1 1.45 0.25 0.19 18.6 30

4 6 0 --- 3 --- 6 0 414 506 6.2 41.0 0.80 0.25 0.19 8.6 15

060

208/230---1---60 187 253 26.4 134.0 1.45 0.25 0.19 34.5 60

208/230---3---60 187 253 16.0 110.0 1.45 0.25 0.19 21.5 35

4 6 0 --- 3 --- 6 0 414 506 7.8 52.0 0.80 0.25 0.19 10.6 15

LEGEND:

FLA --- F u l l L o a d A m p s

LRA --- L o c k e d R o t o r A m p s

NEC --- National Electrical Code

RLA ---RatedLoadAmps(compressor)

* Permissible limits of the voltage range at which the unit will operate

satisfactorily

NOTES:

1. Control circuit is 24---V on all units and requires external power

source. Copper wire must be used from service disconnect to unit.

2. All motors/compressors contain internal overload protection.

3. In compliance with NEC (U.S.A. Standard) requirements for multi-

motor and combination load equipment (refer to NEC Articles 430

and 440), the overcurrent protective device for the unit shall be fuse

or breaker.

4. Motor RLA values are established in accordance with UL (Underwrit-

ers’ Laboratories) Standard 465 (U.S.A. Standard).

5. 38HDR018---030 units are only available in single---phase voltage.

6. Unbalanced 3---Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is

greater than 2%. Use the following formula to determine the percent-

age of voltage imbalance:

= 100 X max voltage deviation from average voltage

average

EXAMPLE: S u p p l y v o l t a g e i s 4 6 0 --- 3 --- 6 0

AB = 452v

BC = 464v

AC = 455v

Average Voltage = 452 + 464 + 455

=1371

=457

Determine maximum deviation from average voltage:

(AB) 457---452 = 5v

(BC) 464 ---457 = 7v

(AC) 457---455 = 2v

Maximum deviation is 7v.

Determinepercentageofvoltageimbalance

% of voltage imbalance = 100 x 7

=1.53%

This amount of phase imbalance is satisfactory as it is below the maximum

allowable of 2%.

IMPORTANT: Contact your local electric utility company immediately if the

supply voltage phase imbalance is more than 2%.

38HDR

LEGEND

NOTES:

1. Compressor and fan motors are thermally protected.

2. Wire in accordance with National Electrical Code (NEC) and local codes. Replace

any original wires with 90° C wire or its equivalent.

3. The CLO locks out the COMP to prevent short cycling on COMP overloads and

safety devices. Before replacing CLO check these devices.

4. If indoor section has a transformer with a grounded secondary, connect the

grounded side to “C” on the low voltage board.

5. Use minimum 60° C wire for field power wiring.

6. Crankcase heater and thermostat used on selected models only.

C—Contactor, Compressor

CAP — Capacitor

CCHT — Crankcase Heater Thermostat

CH — Crankcase Heater

COMP — Compressor Motor

EQUIP — Equipment

GND — Ground

HPS — High-Pressure Switch

LPS — Low-Pressure Switch

OFM — Outdoor-Fan Motor

OL — Overload

TB — Terminal Board

Splice (Field)

Terminal (Marked)

Terminal (Unmarked)

Terminal Block

Splice

Factory Wiring

Field Control Wiring

Field Power Wiring

38HDR OPERATION SEQUENCE

CALL FOR COOLING:

1. Control voltage from transformer to thermostat (24 v).

2. At thermostat 24 v is switched to “G” and “Y.”

3. 24 v from thermostat “G” energizes fan relay at indoor fan coil and indoor-fan motor runs.

4. 24 v from thermostat “Y” energizes the contactor coil at the outdoor unit.

Compressor and outdoor-fan motor run.

6. If the internal protector of the compressor, HPS, or LPS open, the 24 v to the contactor coil will be inter-

rupted, and compressor and outdoor fan motor will stop.

A07535

Fig. 6 --- 38HDR018--060 Typical Wiring Schematic

38HDR

START--UP

Step 1 —Preliminary Checks

1. Check that all internal wiring connections are tight and that

all barriers, covers, and panels are in place.

2. Field electrical power source must agree with unit name-

plate rating.

3. All service valves must be open.

4. Belly--band crankcase heater must be tight on compressor

crankcase for those units with belly--band heaters.

Step 2 —Leak Test

Field piping and fan coil must be leak tested by pressure method.

Use Puronrrefrigerant at approximately 25 psig backed up with an

inert gas to a total pressure not to exceed 245 psig.

Step 3 —Evacuate and Dehydrate

Field piping and fan coil must be evacuated and dehydrated.

Step 4 —Charge System

Release charge into system by opening (backseating) liquid and

suction line service valves.

Step 5 —To Start Unit

Be sure that the field disconnect is closed. Set room thermostat

below ambient temperature. Operate unit for 15 minutes, then

check system refrigerant charge. See Refrigerant Charging section

on page 12.

NOTE: When using in conjunction with 40QA fan coils, refer to

start--up instructions included with fan coil for correct start--up

procedures.

SERVICE

!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.

Outdoor Fan

A reinforced wire mount holds the outdoor fan assembly in

position. See Fig. 7 for proper mounting position.

38HDR Unit Size, in. (mm)

018,024 030,036 048,060

0.433 (11.00) 0 0

A07401

Fig. 7 --- Condenser Fan Mounting Positions

High--Pressure Relief Valve

The high--pressure relief valve is located in the compressor. The

relief valve opens at a pressure differential of approximately 550 to

625 ±50 psig between suction (low side) and discharge (high side)

to allow pressure equalization.

Internal Current and Temperature Sensitive Overload

The control resets automatically when internal compressor motor

temperature drops to a safe level (overloads may require up to 45

minutes to reset). When an internal overload is suspected of being

open, check by using an ohmmeter or continuity tester.

Pumpdown Procedure

The system may be pumped down in order to make repairs on the

low side without losing complete refrigerant charge.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment

damage or improper operation.

Never open system to atmosphere while it is under a

vacuum.

When system must be opened for service, recover refrigerant, break

vacuum with dry nitrogen before opening system.

1. Attach pressure gage to suction service valve gage port.

2. Frontseat the liquid/mixed phase line valve.

3. Start unit and run until suction pressure reaches 20 psig.

4. Shut unit off and frontseat suction valve.

5. De--pressurize low side of unit and recover refrigerant fol-

lowing accepted practices.

38HDR

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