Carrier Air Conditioner 38HDF018 036 User Manual

38HDF018-036  
Duct Free Condensing Units  
38HDR018-060  
Ducted Condensing Units  
Installation, Start-Up and  
Service Instructions  
CONTENTS  
Page  
Puron® (R-410A) refrigerant systems operate at higher  
pressures than standard R-22 systems. Do not use R-22 ser-  
vice equipment or components on Puron refrigerant equip-  
ment. If service equipment is not rated for Puron refrigerant,  
equipment damage or personal injury may result.  
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1  
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10  
Step 1 — Complete Pre-Installation Checks . . . . . . 1  
• UNPACK UNIT  
• INSPECT SHIPMENT  
• CONSIDER SYSTEM REQUIREMENTS  
• MATCHING THE CONDENSING UNIT TO AN  
INDOOR UNIT  
INSTALLATION  
Step 1 — Complete Pre-Installation Checks  
UNPACK UNIT (See Fig. 1) — Move the unit to final loca-  
tion. Remove unit from carton, being careful not to damage  
service valves and grilles.  
Step 2 — Rig and Mount Unit. . . . . . . . . . . . . . . . . . . . . 3  
• MOUNTING ON GROUND  
• MOUNTING ON ROOF  
• RIGGING  
Step 3 — Complete Refrigerant Piping  
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
• CHECK ACCURATER CONTROL  
• FILTER DRIER  
• MAKE PIPING SWEAT CONNECTORS  
• PROVIDE SAFETY RELIEF  
Step 4 — Make Electrical Connections . . . . . . . . . . . 6  
• CONTROL CIRCUIT WIRING  
• POWER WIRING  
• CONNECTIONS TO DUCT-FREE FAN COIL UNITS  
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14  
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . .14,15  
SAFETY CONSIDERATIONS  
Installing and servicing air conditioning equipment can be  
hazardous due to system pressure and electrical components.  
Only trained and qualified service personnel should install or  
service air conditioning equipment.  
Untrained personnel can perform basic maintenance, such  
as cleaning and replacing filters. All other operations should be  
performed by trained service personnel. When working on air  
conditioning equipment, observe safety precautions in litera-  
ture, tags, and labels attached to unit.  
Follow all safety codes. Wear safety glasses and work  
gloves. Use quenching cloth for brazing operations. Have fire  
extinguisher available. Read these instructions thoroughly.  
Consult local building codes and the National Electrical Code  
(NEC) for special installation requirements.  
Fig. 1 — 38HDF,HDR Unit  
INSPECT SHIPMENT — File a claim with the shipping  
company if shipment is damaged or incomplete. Check unit  
nameplate to ensure unit matches job requirements.  
CONSIDER SYSTEM REQUIREMENTS — Consult local  
building codes and NEC for special installation requirements.  
Allow sufficient space for airflow clearance, wiring, refrig-  
erant 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 38HDF,HDR units can be matched to  
a corresponding indoor unit. The 38HDF018-036 units can be  
matched with an in-ceiling cassette or high wall indoor unit.  
The 38HDR unit can be matched with under-ceiling and resi-  
dential fan coils. Refer to separate indoor unit literature for  
more information.  
Before installing or servicing system, always turn off main  
power to system. There may be more than one disconnect  
switch. Turn off accessory heater power if applicable. Elec-  
trical shock can cause serious personal injury.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Catalog No. 02-38HD0001-SI Printed in U.S.A. Form 38HD-4SI Pg 1 1-06 Replaces: 38HDC-3SI  
Book 1  
4
Tab 3e 2f  
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When more than 50 ft of interconnecting tubing and more  
than 30 ft of vertical lift is used, consult the residential long line  
application instruction guide. For long-line applications, inter-  
connecting lines over 100 ft must be installed with a liquid line  
solenoid. A liquid line solenoid may also be installed on some  
units to improve part-load efficiency. Refer to the ARI (Air  
Conditioning & Refrigeration Institute) Directory.  
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 transmit-  
ted 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.  
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. above roof surface. Isolate unit and tub-  
ing from structure.  
RIGGING  
CHECK ACCURATER CONTROL — The correct Accu-  
Rater (bypass type) refrigerant control is required for system  
capacity optimization. An AccuRater device with field-  
replaceable piston (see Fig. 4) is supplied with the outdoor unit.  
Refer to the AccuRater metering device table in separate  
indoor unit installation instructions to determine the correct  
AccuRater piston size required for the condenser/evaporator  
system being installed.  
Piston style as shown in Fig. 4 is shipped with the unit. Do  
not interchange components between the AccuRater device  
types. Matching of outdoor unit with indoor unit may require  
field replacement of piston. Replace piston, if required, before  
connecting refrigerant lines. See Fig. 4. Piston replacement  
instructions are included in the indoor unit installation instruc-  
tions. After system installation is complete, see the Refrigerant  
Charging section on page 12 to check and/or adjust refrigerant  
charge.  
Be sure unit panels are securely in place prior to rigging.  
Loose unit panels could result in equipment damage or per-  
sonal injury.  
Keep the unit upright and lift unit using a sling. Use card-  
board 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.  
FILTER DRIER — The filter drier must be replaced whenev-  
er the refrigeration system is exposed to the atmosphere. See  
Fig. 4 for filter drier installation.  
NOTE: Arrow on AccuRater body points in free flow direction, away from the  
indoor coil.  
Fig. 3 — Lifting Unit with Sling  
Step 3 — Complete Refrigerant Piping Con-  
nections — Outdoor units may be connected to indoor  
units using field-supplied tubing of refrigerant grade and condi-  
tion. See Tables 1A and 1B for correct line sizes. Do not use  
less than 10 ft of interconnecting tubing.  
38HDF018-036  
DO NOT BURY MORE THAN 36 IN. OF REFRIGER-  
ANT PIPE IN THE GROUND. If any section of pipe is  
buried, there must be a 6-in. 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.  
38HDR018-060  
Fig. 4 — AccuRater (Bypass Type) Metering  
Device Components  
3
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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.  
To avoid damage while brazing, service valves should be  
wrapped with a heat-sinking material such as a wet cloth.  
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 ei-  
ther silver bearing or non-silver bearing brazing material. Con-  
sult local code requirements. Refrigerant tubing and the indoor  
coil are now ready for leak testing.  
When brazing tubing sets to the service valves, a brazing  
shield MUST be used to prevent damage to the painted unit  
surface.  
NOTE: Unit is shipped with R-410A factory charge indicated  
on nameplate.  
Pass nitrogen or other inert gas through piping while braz-  
ing to prevent formation of copper oxide.  
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.  
Table 1A — 38HDF018-036 Physical Data  
UNIT 38HDF  
NOMINAL CAPACITY (Tons)  
OPERATING WEIGHT (lb)  
REFRIGERANT TYPE  
METERING DEVICE  
018  
1.5  
166  
024  
2.0  
176  
030  
2.50  
187  
036  
3.0  
250  
R-410A  
AccuRater (Located at Fan Coil)  
5.0  
CHARGE (lb)*  
4.8  
5.3  
7.1  
OUTDOOR FAN  
Rpm/Cfm  
Diameter (in.)  
No. Blades  
Motor (hp)  
840/1720  
840/1720  
840/1720  
850/1720  
18  
3
18  
3
18  
3
24  
3
1
/
1
/
1
/
1
/
8
8
8
4
OUTDOOR COIL  
Face Area (sq ft)  
No. Rows  
5.82  
2
20  
7.27  
3
20  
7.27  
3
20  
12.1  
2
20  
FPI  
HIGH PRESSURE SWITCH  
Cut-In (psig)  
Cutout (psig)  
420 25  
650 10  
420 25  
650 10  
420 25  
650 10  
420 25  
650 10  
LOW PRESSURE SWITCH  
Cut-In (psig)  
Cutout (psig)  
45 25  
45 25  
45 25  
45 25  
20  
5
20  
5
20  
5
20  
5
REFRIGERANT LINES  
Connection Type  
Liquid Line (in.) OD  
Vapor Line (in.) OD  
Max Length (ft)  
Sweat  
3
5
3
5
3
3
3
3
/
/
/
/
/
/
/
/
8
8
8
8
8
8
4
4
200  
65  
150  
200  
65  
150  
200  
65  
150  
200  
65  
150  
Max Lift (ft)  
Max Drop (ft)  
COMPRESSOR  
Type  
Scroll  
Model  
ZP16K5E-PFV  
25.0  
ZP21K5E-PFV  
25.0  
ZP25K5E-PFV  
ZP34K5P-PFV  
42.0  
Oil Charge (POE - oz)  
Accumulator  
25.0  
Yes  
CONTROLS  
Fusible Plug (F)  
Control Voltage†  
210  
24 vac  
208/230 v, Single and 3 Phase,  
460 v, 3 Phase  
System Voltage  
208/230 v  
208/230 v  
208/230 v  
FINISH  
Gray  
LEGEND  
FPI — Fins Per Inch  
POE — Polyol Ester  
*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.  
†24 v and a minimum of 40 va is provided in the fan coil unit.  
4
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Table 1B — 38HDR018-060 Physical Data  
UNIT 38HDR  
NOMINAL CAPACITY (Tons)  
OPERATING WEIGHT (lb)  
REFRIGERANT TYPE  
METERING DEVICE  
018  
1.5  
166  
024  
2.0  
176  
030  
2.50  
250  
036  
3.0  
250  
048  
4.0  
278  
060  
5.0  
306  
R-410A  
AccuRater (Located at Fan Coil)  
CHARGE (lb)*  
6.3  
6.5  
10.0  
8.9  
12.0  
12.2  
OUTDOOR FAN  
Rpm/Cfm  
Diameter (in.)  
No. Blades  
Motor (hp)  
840/1720  
840/1720  
850/3900  
850/3900  
850/3900  
850/3900  
18  
3
18  
3
24  
3
18  
3
24  
3
24  
3
1
/
1
/
1
/
1
/
1
/
1
/
8
8
4
4
4
4
OUTDOOR COIL  
Face Area (sq ft)  
No. Rows  
5.8  
2
20  
7.3  
3
20  
12.1  
2
20  
12.1  
2
20  
14.1  
3
20  
14.1  
3
20  
FPI  
HIGH PRESSURE SWITCH  
Cut-In (psig)  
Cutout (psig)  
420 25  
650 10  
420 25  
650 10  
420 25  
650 10  
420 25  
650 10  
420 25  
650 10  
420 25  
650 10  
LOW PRESSURE SWITCH  
Cut-In (psig)  
Cutout (psig)  
45 25  
45 25  
45 25  
45 25  
45 25  
45 25  
20  
5
20  
5
20  
5
20  
5
20  
5
20  
5
REFRIGERANT LINES  
Connection Type  
Liquid Line (in.) OD  
Vapor Line (in.) OD  
Max Length (ft)  
Sweat  
Scroll  
3
5
3
5
3
3
3
3
3
7
3
/
/
/
/
/
/
/
/
/
/
/
8
8
8
8
8
8
8
8
7/88†  
200  
65  
4
4
200  
200  
200  
65  
150  
200  
65  
150  
200  
Max Lift (ft)  
65  
65  
65  
Max Drop (ft)  
150  
150  
150  
150  
COMPRESSOR  
Type  
Model  
Oil Charge (POE - oz)  
Crankcase Heater (watts)  
Accumulator  
ZP16K5E-PFV ZP21K5E-PFV ZP25K5E-PFV ZPZ9K5E-PFV ZP42K5E-PFV ZP51K5E-PFV  
25.0  
25.0  
25.0  
40  
25.0  
40  
42.0  
40  
42.0  
40  
Yes  
CONTROLS  
Fusible Plug (F)  
Control Voltage**  
System Voltage  
210  
24 vac  
208/230 v  
208/230 v  
208/230 v  
208/230 v, Single and 3 Phase, 460 v, 3 Phase  
FINISH  
Gray  
LEGEND  
FPI — Fins Per Inch  
POE — Polyol Ester  
*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.  
7
†Valve connection size is  
/
inch. Recommended line size is  
8
11/8 inches.  
**24 v and a minimum of 40 va is provided in the fan coil unit.  
5
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NOTE: For wire runs up to 50 ft, use no. 18 AWG (American  
Wire Gage) insulated wire. For 50 to 75 ft, use no. 16 AWG  
insulated wire. For over 75 ft, use 14 AWG insulated wire.  
Step 4 — Make Electrical Connections  
NOTE: All wiring must conform to NEC and local codes.  
Unit cabinet must have an uninterrupted, unbroken electri-  
cal ground to minimize the possibility of personal injury if  
an electrical fault should occur. This ground may consist of  
electrical wire connected to unit ground lug in control com-  
partment, or conduit approved for electrical ground when  
installed in accordance with NEC, and local electrical  
codes. Failure to follow this warning could result in the  
installer being liable for the personal injury of others.  
NOTE: Operating unit on improper line voltage constitutes  
abuse and could affect Carrier warranty. See Tables 2 and 3.  
Do not install unit in a system where voltage may fluctuate  
above or below permissible limits.  
See Tables 2 and 3 for recommended fuse sizes. When mak-  
ing electrical connections, provide clearance at the unit for re-  
frigerant piping connections.  
NOTE: The 38HDF units are supplied with a 24-v control  
transformer. 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 advis-  
able 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.  
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 opera-  
tion would invalidate any applicable Carrier warranty.  
Before performing service or maintenance, be sure indoor  
unit main power switch is turned OFF and indoor blower  
has stopped. Failure to do so may result in electrical shock  
or injury from rotating fan blades.  
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 and 7. 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 out-  
door unit from the fan coil. Connect the Y and C terminals of  
the indoor unit to the Y and C terminals.  
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.  
38HDR UNITS  
38HDF UNITS  
NOTE: For more information see schematic inside unit.  
Fig. 5 — Typical Control Circuit Connections  
6
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Table 2 — 38HDF Electrical Data  
VOLTAGE RANGE*  
COMPRESSOR  
OUTDOOR FAN MOTOR  
38HDF  
MIN CKT  
AMPS  
FUSE/HACR  
BKR AMPS  
V-PH-Hz  
UNIT SIZE  
Min  
187  
187  
187  
187  
187  
414  
Max  
253  
253  
253  
253  
253  
506  
RLA  
10.0  
14.3  
15.7  
20.0  
14.7  
6.6  
LRA  
48.0  
58.3  
73.0  
112.0  
88.0  
44.0  
FLA  
0.80  
0.80  
0.80  
1.45  
1.45  
0.80  
NEC Hp  
0.125  
0.125  
0.125  
0.25  
kW Out  
0.09  
0.09  
0.09  
0.19  
018  
024  
030  
208/230-1-60  
208/230-1-60  
208/230-1-60  
208/230-1-60  
208/230-3-60  
460-3-60  
13.3  
18.7  
20.4  
26.5  
19.8  
9.1  
20  
30  
35  
45  
30  
15  
036  
0.25  
0.25  
0.19  
0.19  
LEGEND  
Determine maximum deviation from average voltage:  
(AB) 457 – 452 = 5 v  
(BC) 464 – 457 = 7 v  
(AC) 457 – 455 = 2 v  
FLA  
Full Load Amps  
HACR — Heating, Air Conditioning, Refrigeration  
LRA — Locked Rotor Amps  
NEC — National Electrical Code  
RLA — Rated Load Amps (Compressor)  
Maximum deviation is 7 v.  
Determine percentage of voltage imbalance:  
*Permissible limits of the voltage range at which unit will operate  
satisfactorily.  
7
% Voltage Imbalance = 100 x  
457  
NOTES:  
1. Control circuit is 24 v on all units and requires an external power  
source.  
= 1.53%  
2. All motors and compressors contain internal overload protection.  
3. In compliance with NEC (U.S.A. Standard) requirements for mul-  
timotor and combination load equipment (refer to NEC Articles  
430 and 440), the overcurrent protective device for the unit shall  
be fuse or HACR breaker.  
This amount of phase imbalance is satisfactory as it is below the  
maximum allowable of 2%.  
IMPORTANT: Contact your local electric utility company immedi-  
ately if the supply voltage phase imbalance is more than 2%.  
4. Motor RLA values are established in accordance with UL (Under-  
writers’ Laboratories) Standard 465 (U.S.A. Standard).  
5. 38HDF,HDR018-030 units are only available in single-phase  
voltage.  
6. Unbalanced 3-Phase Supply Voltage  
Never operate a motor where a phase imbalance in supply volt-  
age is greater than 2%. Use the following formula to determine  
the percentage of voltage imbalance:  
max voltage deviation from average voltage  
= 100 x  
average voltage  
EXAMPLE: Supply voltage is 460-3-60.  
AB = 452 v  
BC = 464 v  
AC = 455 v  
452 + 464 + 455  
Average Voltage =  
3
1371  
3
=
=
457  
7
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Table 3 — 38HDR Electrical Data  
VOLTAGE RANGE*  
COMPRESSOR  
OUTDOOR FAN MOTOR  
38HDR  
MIN CKT  
AMPS  
FUSE/HACR  
BKR AMPS  
V-PH-Hz  
UNIT SIZE  
Min  
187  
187  
187  
187  
187  
414  
187  
187  
414  
187  
187  
414  
Max  
253  
253  
253  
253  
253  
506  
253  
253  
506  
253  
253  
506  
RLA  
10.0  
14.3  
15.7  
15.7  
10.4  
6.3  
LRA  
48.0  
58.3  
64.0  
77.0  
88.0  
38.0  
117.0  
83.1  
41.0  
134.0  
110.0  
52.0  
FLA  
0.80  
0.80  
1.45  
1.45  
1.45  
0.80  
1.45  
1.45  
0.80  
1.45  
1.45  
0.80  
NEC Hp  
0.125  
0.125  
0.25  
0.25  
0.25  
0.25  
0.25  
0.25  
0.25  
kW Out  
0.09  
0.09  
0.19  
0.19  
0.19  
0.19  
0.19  
0.19  
0.19  
0.19  
0.19  
0.19  
018  
024  
030  
208/230-1-60  
208/230-1-60  
208/230-1-60  
208/230-1-60  
208/230-3-60  
460-3-60  
208/230-1-60  
208/230-3-60  
460-3-60  
13.3  
18.7  
21.1  
21.1  
14.5  
8.7  
31.8  
21.0  
9.4  
20  
30  
35  
35  
20  
15  
55  
35  
15  
65  
40  
20  
036  
048  
060  
24.3  
15.6  
6.9  
208/230-1-60  
208/230-3-60  
460-3-60  
29.4  
17.8  
8.6  
0.25  
0.25  
0.25  
38.2  
23.7  
11.6  
LEGEND  
Determine maximum deviation from average voltage:  
(AB) 457 – 452 = 5 v  
(BC) 464 – 457 = 7 v  
(AC) 457 – 455 = 2 v  
FLA  
Full Load Amps  
HACR — Heating, Air Conditioning, Refrigeration  
LRA — Locked Rotor Amps  
NEC — National Electrical Code  
RLA — Rated Load Amps (Compressor)  
Maximum deviation is 7 v.  
Determine percentage of voltage imbalance:  
*Permissible limits of the voltage range at which unit will operate  
satisfactorily.  
7
% Voltage Imbalance = 100 x  
457  
NOTES:  
1. Control circuit is 24 v on all units and requires an external power  
source.  
= 1.53%  
2. All motors and compressors contain internal overload protection.  
3. In compliance with NEC (U.S.A. Standard) requirements for mul-  
timotor and combination load equipment (refer to NEC Articles  
430 and 440), the overcurrent protective device for the unit shall  
be fuse or HACR breaker.  
This amount of phase imbalance is satisfactory as it is below the  
maximum allowable of 2%  
IMPORTANT: Contact your local electric utility company immedi-  
ately if the supply voltage phase imbalance is more than 2%.  
4. Motor RLA values are established in accordance with UL (Under-  
writers’ Laboratories) Standard 465 (U.S.A. Standard).  
5. 38HDF,HDR018-030 units are only available in single-phase  
voltage.  
6. Unbalanced 3-Phase Supply Voltage  
Never operate a motor where a phase imbalance in supply volt-  
age is greater than 2%. Use the following formula to determine  
the percentage of voltage imbalance:  
max voltage deviation from average voltage  
= 100 x  
average voltage  
EXAMPLE: Supply voltage is 460-3-60.  
AB = 452 v  
BC = 464 v  
AC = 455 v  
452 + 464 + 455  
Average Voltage =  
3
1371  
3
=
=
457  
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START-UP  
Preliminary Checks  
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.  
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.  
Pumpdown Procedure — The system may be pumped  
down in order to make repairs on the low side without losing  
complete refrigerant charge.  
Leak Test — Field piping and fan coil must be leak tested  
by pressure method. Use R-410A at approximately 25 psig  
backed up with an inert gas to a total pressure not to exceed  
245 psig.  
Never open system to atmosphere while it is under a vac-  
uum. Equipment damage may result.  
Leak detectors should be designed to detect HFC (hydro-  
fluorocarbon) refrigerant.  
When system must be opened for service, recover refriger-  
ant, break vacuum with dry nitrogen before opening system.  
Evacuate and Dehydrate — Field piping and fan coil  
1. Attach pressure gage to suction service valve gage port.  
2. Frontseat the liquid/mixed phase line valve.  
must be evacuated and dehydrated.  
Charge System — Release charge into system by open-  
ing (backseating) liquid and suction line service valves. Refer  
to separate indoor unit installation instructions for the required  
total system charge when connected to 25 ft of tubing.  
The 38HDC unit coils hold only the factory-designated  
amount of refrigerant. Additional refrigerant may cause  
units to relieve pressure through the compressor internal  
pressure relief valve (indicated by a sudden rise of suction  
pressure) before suction pressure reaches 5 psig. If this  
occurs, shut off unit immediately then frontseat the suction  
valve and remove and recover excess refrigerant following  
accepted practices. Equipment damage may result.  
To Start Unit — Be sure that the field disconnect is  
closed. Set room thermostat below ambient temperature. Oper-  
ate unit for 15 minutes, then check system refrigerant charge.  
See Refrigerant Charging section on page 12.  
NOTE: When using in conjunction with 40QA or 40QK fan  
coils, refer to start-up instructions included with fan coil for  
correct start-up procedures.  
3. Start unit and run until suction pressure reaches 20 psig.  
4. Shut unit off and frontseat suction valve.  
SERVICE  
5. Depressurize low side of unit and recover refrigerant  
following accepted practices.  
Before performing recommended maintenance, be sure  
unit main power switch is turned off. Failure to do so may  
result in electrical shock or injury from rotating fan blade.  
High-Pressure Switch — The high-pressure switch,  
located on discharge line, protects against high discharge  
pressures caused by such events as overcharge, condenser-fan  
motor failure, system restriction, etc. It opens on pressure rise at  
about 650 10 psig. If system pressures go above this setting  
during abnormal conditions, the switch opens.  
Outdoor Fan — A reinforced wire mount holds the out-  
door fan assembly in position. See Fig. 8 for proper mounting  
position.  
DO NOT attempt to simulate these system abnormalities  
— high pressures pose a serious safety hazard.  
The high-pressure switch is checked with an ohmmeter. If  
system pressure is below 625 psig switch shows continuity.  
Crankcase Heater — The crankcase heater prevents  
refrigerant migration and compressor oil dilution during  
shutdown when compressor is not operating. If the crankcase  
heater is deenergized for more than 6 hours, both compressor  
service valves must be closed.  
38HDF UNIT SIZE, in.  
018-030  
036  
NOTE: Crankcase heaters are only available on 38HDR030-  
060 units.  
The crankcase heater is powered by the high-voltage power  
of the unit. It is connected across the line side of the contactor  
and is thermostatically controlled.  
0.433  
0
38HDR UNIT SIZE, in.  
018,024  
0.433  
030,036  
048,060  
0
0
Fig. 8 — Condenser-Fan Mounting Positions  
Use extreme caution when troubleshooting this device, as  
line voltage is continually present. Serious personal injury  
could result.  
High-Pressure Relief Valve — The high-pressure re-  
lief valve is located in the compressor. The relief valve opens at  
a pressure differential of approximately 550 to 625 50 psid  
between suction (low side) and discharge (high side) to allow  
pressure equalization.  
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To troubleshoot:  
All units are shipped with the refrigerant charge listed on  
the nameplate. See indoor unit Installation Instructions for ad-  
ditional charge requirements.  
NOTE: For 38HDF units only, charge to nameplate. See the  
indoor unit owner’s manual for any additional charge  
requirements.  
Refer to Table 4 and consider the following when working  
with Puron® refrigerant:  
• Puron refrigerant cylinders are rose colored.  
1. Apply voltmeter across crankcase heater leads to see if  
heater voltage is on. Do not touch heater. Carefully feel  
area around crankcase heater; if warm, crankcase heater  
is functioning.  
2. With power off and heater leads disconnected, check  
across leads with ohmmeter. Do not look for a specific re-  
sistance reading. Check for resistance or an open circuit,  
and change heater if an open circuit is detected.  
• Recovery cylinder service pressure rating must be  
400 psig, DOT (Department of Transportation) 4BA400  
or DOT BW400.  
• Puron systems should be charged with liquid refrigerant.  
Use a commercial type metering device in the manifold  
hose when charging into suction line with compressor  
operating.  
• Manifold sets should be 700 psig high side and 180 psig  
low side with 550 psig low-side retard.  
• Use hoses with 700 psig service pressure rating.  
Service Valves — The service valves in the outdoor unit  
come from the factory frontseated. This means the refrigerant  
charge is isolated from the line-set connection ports. To prevent  
damage to the valve, use a wet cloth or other accepted heat sink  
material on the valve before brazing.  
The service valve cannot be field repaired, therefore, only a  
complete valve or valve stem seal and service port caps are  
available for replacement.  
Refrigerant Charging  
• Puron refrigerant, as with other HFCs, is only compatible  
with POE oils.  
Vacuum pumps will not remove moisture from oil.  
• Polyol Ester oils absorb moisture rapidly. Do not expose  
oil to atmosphere.  
To prevent personal injury, wear safety glasses and gloves  
when handling refrigerant. Do not overcharge system —  
this can cause compressor flooding.  
• Polyol Ester oils may cause damage to certain plastics  
and roofing materials.  
• Wrap all filter driers and service valves with wet cloth  
when brazing.  
• A factory approved, liquid-line filter drier is required on  
every unit.  
• Do not use a TXV (thermostatic expansion valve)  
designed for use with R-22 refrigerant. Refer to separate  
indoor unit installation instructions for more details.  
• If using a suction line drier, do not leave in place for  
more than 72 hours.  
Service valves must be fully backseated to close service  
port. There is no Schrader valve at the service port, and  
failure to backseat the valve could result in loss of system  
charge or personal injury.  
NOTE: Do not vent or depressurize unit refrigerant to atmo-  
sphere. Remove and recover refrigerant following accepted  
practices.  
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Table 4 — Pressure vs. Temperature Chart — Puron® Refrigerant (R-410A)  
PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE  
PSIG  
12  
14  
16  
18  
20  
22  
24  
26  
28  
30  
32  
34  
36  
38  
40  
42  
44  
46  
48  
50  
52  
54  
56  
58  
60  
62  
64  
66  
68  
70  
72  
74  
76  
78  
80  
82  
84  
86  
88  
90  
92  
94  
96  
98  
100  
102  
104  
106  
108  
110  
112  
°F  
–37.7  
PSIG  
114  
116  
118  
120  
122  
124  
126  
128  
130  
132  
134  
136  
138  
140  
142  
144  
146  
148  
150  
152  
154  
156  
158  
160  
162  
164  
166  
168  
170  
172  
174  
176  
178  
180  
182  
184  
186  
188  
190  
192  
194  
196  
198  
200  
202  
204  
206  
208  
210  
212  
214  
°F  
PSIG  
216  
218  
220  
222  
224  
226  
228  
230  
232  
234  
236  
238  
240  
242  
244  
246  
248  
250  
252  
254  
256  
258  
260  
262  
264  
266  
268  
270  
272  
274  
276  
278  
280  
282  
284  
286  
288  
290  
292  
294  
296  
298  
300  
302  
304  
306  
308  
310  
312  
314  
316  
°F  
PSIG  
318  
320  
322  
324  
326  
328  
330  
332  
334  
336  
338  
340  
342  
344  
346  
348  
350  
352  
354  
356  
358  
360  
362  
364  
366  
368  
370  
372  
374  
376  
378  
380  
382  
384  
386  
388  
390  
392  
394  
396  
398  
400  
402  
404  
406  
408  
410  
412  
414  
416  
418  
°F  
PSIG  
420  
422  
424  
426  
428  
430  
432  
434  
436  
438  
440  
442  
444  
446  
448  
450  
452  
454  
456  
458  
460  
462  
464  
466  
468  
470  
472  
474  
476  
478  
480  
482  
484  
486  
488  
490  
492  
494  
496  
498  
500  
502  
504  
506  
508  
510  
512  
514  
516  
518  
520  
°F  
PSIG  
522  
524  
526  
528  
530  
532  
534  
536  
538  
540  
544  
548  
552  
556  
560  
564  
568  
572  
576  
580  
584  
588  
592  
596  
600  
604  
608  
612  
616  
620  
624  
628  
632  
636  
640  
644  
648  
652  
656  
660  
664  
668  
672  
676  
680  
684  
688  
692  
696  
°F  
37.8  
38.7  
39.5  
40.5  
41.3  
42.2  
43.0  
43.8  
44.7  
45.5  
46.3  
47.1  
47.9  
48.7  
49.5  
50.3  
51.1  
51.8  
52.5  
53.3  
54.0  
54.8  
55.5  
56.2  
57.0  
57.7  
58.4  
59.0  
59.8  
60.5  
61.1  
61.8  
62.5  
63.1  
63.8  
64.5  
65.1  
65.8  
66.4  
67.0  
67.7  
68.3  
68.9  
69.5  
70.1  
70.7  
71.4  
72.0  
72.6  
73.2  
73.8  
74.3  
74.9  
75.5  
76.1  
76.7  
77.2  
77.8  
78.4  
78.9  
79.5  
80.0  
80.6  
81.1  
81.6  
82.2  
82.7  
83.3  
83.8  
84.3  
84.8  
85.4  
85.9  
86.4  
86.9  
87.4  
87.9  
88.4  
88.9  
89.4  
89.9  
90.4  
90.9  
91.4  
91.9  
92.4  
92.8  
93.3  
93.8  
94.3  
94.8  
95.2  
95.7  
96.2  
96.6  
97.1  
97.5  
98.0  
98.4  
98.9  
99.3  
99.7  
100.2  
100.7  
101.1  
101.6  
102.0  
102.4  
102.9  
103.3  
103.7  
104.2  
104.6  
105.1  
105.4  
105.8  
106.3  
106.6  
107.1  
107.5  
107.9  
108.3  
108.8  
109.2  
109.6  
110.0  
110.4  
110.8  
111.2  
111.6  
112.0  
112.4  
112.6  
113.1  
113.5  
113.9  
114.3  
114.7  
115.0  
115.5  
115.8  
116.2  
116.6  
117.0  
117.3  
117.7  
118.1  
118.5  
118.8  
119.2  
119.6  
119.9  
120.3  
120.7  
121.0  
121.4  
121.7  
122.1  
122.5  
122.8  
123.2  
123.5  
123.9  
124.2  
124.6  
124.9  
125.3  
125.6  
126.0  
126.3  
126.6  
127.0  
127.3  
127.7  
128.0  
128.3  
128.7  
129.0  
129.3  
129.7  
130.0  
130.3  
130.7  
131.0  
131.3  
131.6  
132.0  
132.3  
132.6  
132.9  
133.3  
133.6  
133.9  
134.0  
134.5  
134.8  
135.2  
135.5  
135.8  
136.1  
136.4  
136.7  
137.0  
137.3  
137.6  
137.9  
138.3  
138.6  
138.9  
139.2  
139.5  
139.8  
140.1  
140.4  
141.0  
141.6  
142.1  
142.7  
143.3  
143.9  
144.5  
145.0  
145.6  
146.2  
146.7  
147.3  
147.9  
148.4  
149.0  
149.5  
150.1  
150.6  
151.2  
151.7  
152.3  
152.8  
153.4  
153.9  
154.5  
155.0  
155.5  
156.1  
156.6  
157.1  
157.7  
158.2  
158.7  
159.2  
159.8  
160.3  
160.8  
161.3  
161.8  
–34.7  
–32.0  
–29.4  
–26.9  
–24.5  
–22.2  
–20.0  
–17.9  
–15.8  
–13.8  
–11.9  
–10.1  
–8.3  
–6.5  
–4.5  
–3.2  
–1.6  
0.0  
1.5  
3.0  
4.5  
5.9  
7.3  
8.6  
10.0  
11.3  
12.6  
13.8  
15.1  
16.3  
17.5  
18.7  
19.8  
21.0  
22.1  
23.2  
24.3  
25.4  
26.4  
27.4  
28.5  
29.5  
30.5  
31.2  
32.2  
33.2  
34.1  
35.1  
35.5  
36.9  
3. Refer to Table 5. Find the temperature point at which the  
required subcooling temperature intersects the measured  
liquid line pressure.  
Subcooling Method — For 38HDR units only, the sub-  
cooling method is used to check and adjust charge during the  
cooling season. Refer to Table 5 and the following procedure:  
4. If the measured liquid line temperature does not agree  
with the required liquid line temperature, ADD refriger-  
ant to lower the temperature, or REMOVE refrigerant to  
raise the temperature (allow a tolerance of 3° F).  
NOTE: For use with residential fan coils and the 40QA060  
under ceiling unit only.  
1. Operate unit a minimum of 15 minutes before checking  
charge.  
2. Measure liquid line temperature near liquid line service  
valve, and measure the liquid pressure at the liquid line  
service valve. Use a digital thermometer for all tempera-  
ture measurements. DO NOT use mercury or dial-type  
thermometers.  
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Table 5 — Subcooling Charging Table  
Compressor Lockout Switch — The 38HDR units  
are provided with a compressor lockout protective device. If  
the compressor shuts down due to any safety device, a current  
loop monitoring the compressor current senses no current flow.  
The unit will lock out until the control power is interrupted to  
reset the lockout. Determine the reason for the safety trip. To  
restart, turn the thermostat to the OFF position and then set the  
thermostat to an operating position.  
REQUIRED LIQUID LINE  
TEMPERATURE (F)  
Required Subcooling  
Temperature (F)  
LIQUID PRESSURE  
AT SERVICE VALVE  
(psig)  
8
58  
10  
56  
12  
54  
14  
52  
16  
50  
18  
48  
50  
52  
54  
56  
58  
60  
62  
64  
66  
68  
70  
72  
74  
76  
78  
80  
82  
84  
86  
88  
90  
92  
94  
189  
195  
202  
208  
215  
222  
229  
236  
243  
251  
259  
266  
274  
283  
291  
299  
308  
317  
326  
335  
345  
354  
364  
374  
384  
395  
406  
416  
427  
439  
450  
462  
474  
486  
499  
511  
60  
62  
64  
66  
68  
70  
72  
74  
76  
78  
80  
82  
84  
86  
88  
90  
58  
60  
62  
64  
66  
68  
70  
72  
74  
76  
78  
80  
82  
84  
86  
88  
56  
58  
60  
62  
64  
66  
68  
70  
72  
74  
76  
78  
80  
82  
84  
86  
88  
90  
92  
94  
96  
98  
100  
102  
104  
106  
108  
110  
112  
114  
116  
118  
120  
122  
124  
54  
56  
58  
60  
62  
64  
66  
68  
70  
72  
74  
76  
78  
80  
82  
84  
86  
88  
90  
92  
94  
96  
98  
100  
102  
104  
106  
108  
110  
112  
114  
116  
118  
120  
122  
52  
54  
56  
58  
60  
62  
64  
66  
68  
70  
72  
74  
76  
78  
80  
82  
84  
86  
88  
90  
92  
94  
96  
98  
100  
102  
104  
106  
108  
110  
112  
114  
116  
118  
120  
MAINTENANCE  
Before performing recommended maintenance, be sure  
unit main power switch is turned off. Failure to do so may  
result in electric shock or injury from rotating fan blade.  
Lubrication  
COMPRESSOR — Compressor contains factory oil charge;  
replace oil when lost. Use Mobile 3MA-POE oil.  
Cleaning Coils — Coil should be washed out with water  
or blown out with compressor air. Note that the blow-thru  
design causes dirt and debris to build up on the inside of the  
coils.  
Clean coil annually or as required by location and outdoor  
air conditions. Inspect coil monthly and clean as required. Fins  
are not continuous through coil sections. Dirt and debris may  
pass through first section, become trapped between the row of  
fins and restrict condenser airflow. Use a flashlight to deter-  
mine if dirt or debris has collected between coil sections. Clean  
coil as follows:  
92  
94  
96  
98  
90  
92  
94  
96  
100  
102  
104  
106  
108  
110  
112  
114  
116  
118  
120  
122  
124  
126  
128  
98  
100  
102  
104  
106  
108  
110  
112  
114  
116  
118  
120  
122  
124  
126  
96  
98  
1. Turn off unit power.  
2. Using a garden hose or other suitable equipment, flush  
coil from the outside to remove dirt. Be sure to flush all  
dirt and debris from drain holes in base of unit. Fan  
motors are waterproof.  
100  
102  
104  
106  
108  
110  
112  
114  
116  
118  
TROUBLESHOOTING  
See Fig. 9 for troubleshooting information.  
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Fig. 9 — Troubleshooting the Cooling Cycle  
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Copyright 2006 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Catalog No. 02-38HD0001-SI Printed in U.S.A. Form 38HD-4SI Pg 16 2-06A 1-06 Replaces: 38HDC-3SI  
Book 1  
4
Tab 3e 2f  
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