Installation, Start-Up and Service Instructions
Contents
1. SIM DMV vL SAM DMY cL plougjos SAH JoisiuJgeu HL 91 Aejes 1S 106 060 9086 IDEE HU 24 i be Eee 0 060 9207 Josseidwog HdWO2 810 eBer DMV STAAON 400pul STAAON NGS Q N3931 HO 5 vaasn 134 49 YOLOW NVA anid AHVIOH NO ess QVO1H3AO osreziley g Alddns T 01 HOLOVHINOO 5 eno ar y pl T T MED l TON HOLON nn Lu 221 su z ante vs W E ae us i n 8 a KEPT EN ia etn EI T I ec i Ie hu NOD HOLON 8 Taqe T3AJHO 134 89 du 8 HM 4 SNOO 5 9NOO e m 6 5100 F MD LHM anid 0 9 3m8 gt NO er ed HM 3 5 HM d 6 3118 9 5 02 gt Sr dau 5 s GEE vs nn ne uinoo ee UNES E zi y8 dL j zr Lanos ENO9 Se ER 097 071 SAY ANNA LHL LINN HOOGQGNI 12 Refrigerant Piping Connections To connect the refrigerant lines Use only L type sealed dehydrated copper refrigerant tubing No other type of tubing may be used Use of other types of tubing will void the manufacturer s warran2. Clean all drains and drain pans at the start of each cooling season Check the flow by pouring water into the drain TO CLEAN OR REPLACE DRAIN PAN 1 Place a plastic sheet on the floor to catch any water that may spill from drain pan 2 Remove the intake grille and distribution assembly 3 Remove the condensate water in the drain pan by letting water drain into a 3 gallon bucket TROUBLESHOOTING A WARNING Be sure to check for broken wires or loose cable lugs before troubleshooting system INDICATOR LAMPS TROUBLESHOOTING GUIDE LAMPS STATUS POWER flashes 10 seconds after A C start up with or without other signal lamps POWER COMPRES and PRESSURE lamps flash POWER COMPRES and IMPEDANCE lamps flash POWER lamp flashes and PRESSURE is lit AIR CON is Off POWER and PRESSURE lamps flash AIR CON is Off FILTER is lit POWER IMPEDANCE lamps flash COMPRES is lit POWER lamp flashes IMPEDANCE and COMPRES lamps lit AIR CON lamp flashes after A C start up POWER lamp flashes IMPEDANCE and COMPRES are lit before A C start up POWER lamp flashes IMPEDANCE and COMPRES are lit AIR CON is lit after A C start up INDICATION Communication problem Thermistor failure Thermistor failure Low Pressure High Pressure Filter cleaning I NN mue 16 CORRECTIVE ACTION Check connection between control TAC 444 and display
3. Anchor Screw S g in x 2 in Bracket Screw UNC 10 x 2 in Nut UNC 10 Metal Screw 410 1 2 in UNIT A B 8 74 in 24 in 39 4 in 40CG CS018 225 mm 610 mm 1000 mm 8 74 in 24 in 42 24 in 40CG CS024 030 255 mm 610 1200 mm Fig 3B 40CG CS Indoor Unit Dimensions DIMENSIONS in mm 018 024 12 59 320 25 18 640 35 43 900 030 12 59 320 25 18 640 43 31 1100 Fig 3A 38CG CS Outdoor Unit Dimensions UNIT 38CS GS 40CG CS UNIT 38CG CS OUTDOOR UNIT REFRIGERANT LINES Fig 5 40CG CS Unit Refrigerant Line Routing Options ADAPTER d Drill holes in wall as marked Insert field supplied wall plugs Fig 4 38CG CS Unit Drainage e Attach mounting bracket to wall with long screws Adapter Connection provided f Check bracket is level and is secured tightly to wall INSTALLATION g Hang unit on mounting bracket See Fig 8 40CG CS Indoor Unit Wall Installation h Mark 2 holes from bottom of unit for later attach 1 Determine route of refrigerant piping lines to unit See ment of long screws Hold down screws once Fig 5 Refer to Table 3 for refrigerant piping details installation of unit is complete See Fig 8 i Remove unit from wall and drill holes Install AN field supplied wall plugs and repla
4. Fig 10 h Reassemble the front panel using the 7 screws which appear in Fig 6 Attach the remote control rack Use the two screws sup plied to attach the remote controller rack to the wall in location selected by the customer See Fig 11 MOUNTING BRACKET LONG SCREWS et Fig 8 40CG CS Indoor Unit on Mounting Bracket OUTDOOR REFRIGERANT M9 SENSOR LINES CABLE OUTDOOR ELECTRICAL CABLE DRAINAGE WALL TUBE Fig 9 Suggested Tubing Diameter and Contents P S9 r E pispt2 EXPLODED VIEW TERMINAL BLOCK Fig 10 Wiring Connections 40CG CS Indoor Units REMOTE CONTROL REMOTE CONTROL RACK WIRELESS REMOTE CONTROLLER Fig 11 Remote Control and Rack 40CG CS Indoor Unit Ceiling Installation IMPORTANT When performing a ceiling installation make sure that Switch 1 on the Display Board is set to the ON position See Fig 12 The remaining switches are fac tory set and should not be changed NOTE The tubing connecting the indoor and outdoor units can be routed in one of two directions as shown in Fig 13 If the tubing is routed horizontally direction no 1 the pipe cover at the bottom of the air conditioner must be removed See Fig 14 If the tubing is routed vertically directio
5. See Tables 4 and 5 for electrical data and Fig 19 20C for system wiring diagrams Air Vacuum and Refrigerant Charge When all the fittings are connected air must be expelled Follow the steps below to create an air vacuum 1 Open the service port cap on the suction line valve large valve 2 Connect the vacuum pump to the service port via the pressure gauge and operate the pump for 15 minutes 3 Be sure that full vacuum is present Disconnect the vacuum pump 4 Open the liquid line valve small valve with an Allen wrench 5 Open the suction line valve large valve with an Allen wrench 6 The outdoor unit is supplied with sufficient R 22 refriger ant for 26 ft of tubing Add 0 9 oz of refrigerant and 0 35 oz of oil field supplied oil type 3GS or equivalent for each additional foot of tubing used If the tubing is shorter than 26 ft remove gas from the system through the service valve into a recycling device 7 Close the service port caps on the suction line and the liquid valves 8 Make sure that the valves are properly opened Be careful not to open them more than required as this may damage the thread 9 Replace the stem cap Oil the cap beam and hand tighten the cap until resistance is met Use a suitable wrench to tighten the cap by an additional 5 turn Table 4 Electrical Data 40CG CS Indoor Units 208 230 1 60 40CG MOCP der pee MOTOR HEATER s ELECTRIC ELECTR
6. age Do not expose filter to fire to avoid fire damage Do not expose filter to direct sunlight Clean filter more fre quently when air is extremely dirty A CAUTION Do not attempt to clean or service components in control box 15 LUBRICATION The indoor fan automatic air sweep and the outdoor fan motors are factory lubricated and require no oiling Air Filters A CAUTION Operating your system with dirty air filters may damage the indoor unit and in addition can cause reduced perfor mance intermittent system operation frost build up on the indoor coil and blown fuses Inspect and clean or replace the air filters monthly TO REMOVE AIR FILTERS Remove filters by pulling them straight out TO CLEAN OR REPLACE FILTERS Filters can be vac uumed or washed in warm water Shake filter to remove any excess water and replace by sliding filter behind grille until filter snaps in place If the filter has begun to break down or is torn replace it Replacement filters are available through your Carrier distributor TO CLEAN INDOOR UNIT BOTTOM FRONT PANEL If the bottom front panel of the unit becomes dirty or smudged wipe the outside of the panel with a soft dry cloth Use a mild liquid detergent and wipe off carefully with a dry cloth TO CLEAN INDOOR COIL To clean the coil remove indoor unit bottom front panel and vacuum the coil fins using care not to bend or damage fins TO CLEAN CONDENSATE DRAINS
7. and walls or ceilings Indoor and outdoor units should be installed as close as possible to each other Condensate can form in the condenser in outdoor units during heating mode A drainage hose can be installed to remove condensate See Fig 4 Do not install indoor units near a direct source of heat such as direct sunlight steam or flame Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 533 80051 Book 1 4 PC 111 Tab 21 Printed in U S A Form 38C 40C 2SI Pg 1 2 02 Replaces 38 40 151 40CG CS INDOOR UNIT Fig 1 Typical 40CG CS Indoor Unit Ceiling Application 40CG CS INDOOR UNIT Fig 2 Typical 40CG CS Indoor Unit Wall Console Application ITEM Mounting Bracket s Long Screws Nut Outdoor Sensor Connecting Cable Absorption Cushions Electric Terminals Remote Controller Rack Remote Controller and Batteries Insulation for Fittings Drain Hose Adapter Owner s Manual Table 1 Parts List Wall Console Units DIAGRAM o ES ai N 50 E Table 2 Parts List Under Ceiling Units ITEM o d lt DIAGRAM Upper and Lower Mounting Strips Right and Left Mounting Strips Left Side Strip Right Side Strip
8. remote controller buttons function properly 2 Do the display panel lights work properly 3 Does the air deflection louver function properly 4 Does the drainage work OUTDOOR UNIT 1 Are there unusual noises or vibrations during operation 2 Is noise drain water or airflow from the unit likely to disturb the neighbors 3 Are there any gas leaks EXPLAIN THE FOLLOWING ITEMS TO THE CUS TOMER WITH THE AID OF THE USER MANUAL 1 How to turn the air conditioner and off selecting cool ing heating and other operating modes setting a desired temperature setting the timer to automatically start and stop air conditioner operation and the other features of the remote controller and display panel 2 How to remove and clean the air filter How to set the air deflection louver 4 Present the Owner s Manual and this installation sheet to the customer WALL THICKNESS OUTLET GRILLE FRAME 6 8 173mm 4 4 112 5 12mm 4 5 m 134 177 221 264 mm 230 340 450 560 670 in 112 155 1985 242 285 See Fig 17 for location of adjacent room air outlet ports Fig 21 Dimensional Drawing Two Way Air Conditioner Frame REAR AIR UTLET EVAPORATOR ADJACENT ROOM AIR OUTLET PORTS AIR FEEDBACK PVC AIR SPONGY GRILLE TUBE FEEDBACK GASKET OPENING Fig 22 Two Wa
9. the wall using a sealing material 8 Install the grille into the wooden frame Attach grille to the frame using 2 wood screws 9 Refer to specific unit application to complete unit instal lation steps TWO WAY AIR CONDITIONER WITH AIR FEED BACK CONSOLE APPLICATIONS ONLY See Fig 22 The air feedback grille is installed when air from the adjacent room is to be sampled by the thermostat when installed as a console See Fig 22 1 Affix a field supplied gasket around the air feedback opening at the rear of the air conditioner approximately 12 in from the opening 2 Drilla hole in the shared wall to insert the return air tube Mount the indoor unit on mounting bracket 4 Insert the tube into the hole until tube reaches the opening at the rear of the unit 5 Insert the grille on the end of the tube 6 Complete the installation by attaching the plastic frame to the wall using screws 7 Refer to specific unit application to complete unit instal lation steps Oe START UP System Checks 1 Hide the tubing where possible 2 Make sure that the drainage tube slopes downward along its entire length Insulate tubing and connections Fasten tubes to the outside wall Seal the hole through which the cables and tubing pass t Connect the air conditioner to power source and turn it on 7 Check all air conditioner operating modes Refer to manual for operating details INDOOR UNIT 1 Doall the
10. IC HEATER Amps nnn ennen ee 00 os 15 06 06 o8 H5 20 89 06 200 024 70 9 13 06 300 oso vo 9 14 06 300 LEGEND NOTE Specifications and performance data are subject to change MCA Minimum Circuit Amps without notice MOCP Maximum Overcurrent Protection 40CS Table 5 Electrical Data 38CG CS Outdoor Units 208 230 1 60 LOCKED MOCP MOTOR ROTOR AMPS LEGEND NOTE Specifications and performance data are subject to change MCA Minimum Circuit Amps without notice MOCP Maximum Overcurrent Protection 13 Leak Test Leak test all fittings with appropriate test equipment Field Installed Accessories TWO WAY AIR CONDITIONER CONSOLE APPLI CATIONS ONLY See Fig 21 Allows simultaneous air conditioning of adjacent rooms when installed as a console 1 Prepare a wooden frame with the proper dimensions See Fig 21 2 Locate the indoor unit and install mounting bracket 3 Before mounting the indoor unit on the wall open a hole in the wall to install the wooden frame using the unit as a guide 4 Insert the frame in the wall and fill in any gaps between the frame and the wall hole with an appropriate fill material 5 Cutthe required number of openings in the insulation ma terial on the back of the unit 6 Mount the indoor unit on mounting bracket 7 Seal any gaps between the back of the unit and
11. PRESS ons 38CG CS018 024 030 40CG CS018 024 030 Wall Console and Underceiling Duct Free Systems Installation Start Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS 1 1 5 INSTALLATION 5 14 40CG CS Indoor Unit Wall Installation 5 40CG CS Indoor Unit Ceiling Installation 7 38CG CS Outdoor Unit Installation 10 Refrigerant Piping Connections 13 Power Supply 13 Air Vacuum and Refrigerant Charge 13 Leak TeSt nc setae cscs RIDERE Cb XS 14 Field Installed Accessories 14 14 System Checks 14 CARE AND MAINTENANCE 15 38CG CS Outdoor 15 40CG CS Indoor 15 Air Filters ook 15 TROUBLESHOOTING 15 17 SAFETY CONSIDERATIONS Installing starting up and servicing air conditioning equip ment can be hazardous due to system pressures electrical components and equipment location roofs elevated struc tures etc Only trained qualified installers and service mechanics should install start up and service this equipment Untrained personnel can perform basic maintenance
12. ans L ees H3MOd T 5 tro LaO ua1V3H F HOLOVINOO _ 1wisOWHSHL art 297 m Ivy HIDE gap T ue 9NOO mL 99v ez 2 2 t BE UG mE m m i Ig Xx re etl le TA k c o i 9 s Jm lw 1 9NOO zi Fle JU et s alg T HOLOVINOO a Lr HOLOW ES THAO 1 xg eg s 298 M nt ua HM LSNO9 pem r El HO WAS ama 52100 mi EE 9l ama HO AWHD vs Ho LHM l nn v SNO9 d Hoe VS 70 Take ot HO EHM 2 HM HM 9 SNOO 63078 9 9 5 vs HO 91 AAH ee v SNOO 34 2 2 HA HA LSNOD SAH St Hae E vL SNOO EHL C E SAW LINN HOOAGLNO LINN HOOQNI 11 stun 998 990p uiejBeiq 202 614 LINNA
13. assembly TAC 460 for control assembly TAC 404 Check thermostat TH 1 for correct resistance Check for proper connection between TH 1 and TAC 444 Replace TH 1 if necessary Check thermistor TH 2 for correct resistance Check for proper connection between TH 2 and control TAC 444 Replace TH 2 if necessary Check if the filters are clean Check TH 1 and TH 2 for correct resistance Check cooling system for normal operation In Heat mode Check if the evaporator is blocked Also be sure filters are clean Check TH 2 in Heating mode or TH 3 in Cool mode for correct resistance Check cooling system for normal operation Clean all filters Check power supply voltage Check electrical connections Replace control TAC 444 Check power supply voltage Check electrical connections Replace control TAC 444 Check power supply voltage Check electrical connections Replace control TAC 444 Check power supply voltage Check electrical connections Replace control TAC 444 GENERAL SYSTEM TROUBLESHOOTING GUIDE SYMPTOM CORRECTIVE ACTION fails to start a Power supply to unit not connected POWER Check for proper connection of power at disconnect LED Off b Fuse blown POWER LED Off Reset automatic circuit breaker or replace line fuse c ON SEND has not been pressed Press ON SEND button on remote control or use the AUTO 3 position slide switch for automatic constant 72 F 22 C set point whe
14. aterial 4 Make wiring connections a Route the electrical cable and the outdoor sensor cable toward the lower right corner of the indoor unit b Using a screw driver insert the stripped wire ends into the terminal block as shown in Fig 10 NOTE Be sure the wires are connected in accordance with the wiring diagram located on the drain pan c Attach the electrical cable with the cable clamp located on the unit d Connect the Outdoor Sensor terminal TH3 connec tor to TH3 on terminal block See Fig 10 5 Make drainage connections a Connect the unattached end of the drainage tube to the drainage hose outlet b Make sure there are kinks U bends or flat tened sections in the tube Seal the drainage connection to prevent leakage d Check that the drainage functions properly Fill the pan below the unit s coil with water and observe that it drains out freely MOUNTING BRACKET ML Fig 7 Mounting Holes on Wall LONG SCREWS f 40CG CS INDOOR UNIT 3 70mm e Connect the ends of the refrigerant lines to their appropriate fittings following the guidelines in the Refrigerant Piping Connections section f Make sure the drainage hose is at the bottom side of the wall hole See Fig 9 g Connect the display panel connector to the display panel printed circuit board See
15. ce unit on wall a Carefully remove air intake grille and retaining spring by removing screws on both sides of grille NOTE Hold down screws will be attached once See Fig 6 unit is completely assembled 2 Mount unit by performing the following steps b Remove and save 7 screws that attach front panel Table 3 Refrigerant Piping Detail MAXIMUM LENGTH nis T M LIQUID LINE to unit Remove front panel UNIT LIF CAUTION 38 40CG CS in ft m ft m Be sure stepper motor and display cable are disconnected from electronic control before proceeding 018 024 c Position mounting bracket level on wall and mark 030 7 holes as shown in Fig 7 RETAINING FRONT PANEL SPRING AIR INTAKE GRILLE Fig 6 Removing Air Intake Grille and Front Panel 40CG CS Unit 3 Drill hole in wall to connect indoor and outdoor units a Drill a 3 in hole from inside wall for the tubing that contains refrigerant lines drainage hose and electric cables as shown in Fig 9 Use unit as a template when determining hole location NOTE Be sure to drill outward and downward so the opening in the outside wall is at least l 5 in lower than the opening on the inside wall b Insert tubing through hole Be sure the drainage hose is at the bottom side of the hole See Fig 9 c Hill the remaining wall hole gap with an appropri ate sealant m
16. de of the strip is located at the bottom of the air conditioner 2 The strip angle faces inward c Mount the indoor unit on the bracket Slide the protruding parts of the side strips onto the ceiling bracket so that the 4 safety screw holes on the left and right strips align with those on the ceiling bracket d Make sure that the air conditioner is tilted slightly toward the drainage outlet on the right side Use water to test for proper drainage Correct the tilt by adjusting the height of the right strip relative to the left strip e Fasten the air conditioner to the ceiling bracket using the 4 side screws See Fig 17 REFRIGERANT LINES OUTDOOR SENSOR CABLE DRAINAGE ELECTRICAL TUBE CABLE Fig 13 Routing Options for Cables Refrigerant Lines and Drainage Tube 7 g NOTE Be sure to drill outward and downward so the opening in the outside wall is at least l 5 in lower than the opening on the inside wall Insert tubing through hole Be sure the drainage hose is at the bottom side of the hole See Fig 9 Fill the remaining wall hole gap with an appropri ate sealant material 6 Drainage connections a b Connect the unattached end of the drainage tube to the drainage hose outlet Make sure there no kinks U bends or flat tened sections in the tube Seal the drainage connection to prevent leakage g h Check that the drainage functions properly F
17. e 38CG CS Outdoor Units INDOOR OUTDOOR TIME DELAY i ike HIGH SPEED 1 HEAT PUMP 3 BROWN eae ce 7 SWITCH MEDIUM SPEED 4 YELLOW E LOW SPEED GRAY ORANGE COMPRESSOR 7 RED 5 HEATING ELEMENT 10 BLUE 6 WHITE E PHASE R NEUTRAL PHASE S ORANGE Lc PHASE T OUTDOOR SENSOR CABLE TH 3 Fig 20A Wiring Diagram 10 spun Ajuo Buroo s28g S20t goz 6 4 aM DMV DMV cL eA eA SAH JojsiuJgau HL 21 Asjes 1S Joyioedeg UBS d L0 00 S28 10 0 0 500 3 Josseidwog 106 720 5086 0 20 590 SMY 102 810 5082 102 810 5 007 STAAON 100pul STAAON qN3931 HOLOW Nv FER S ua ama fe 8 las Tis o 5 Ad
18. e hour outdoor fan motor are working out due to high temperature Bless M and or heating takes 5 Compressor run capacitor is burnt Replace compressor run capacitor c Compressor winding shorted Replace compressor No air supply at indoor unit a Indoor fan motor is blocked or turns slowly 1 Check voltage Repair wiring if necessary compressor operates 2 Check indoor fan wheel if tight on motor shaft Tighten if necessary b Indoor fan motor capacitor is burnt Replace indoor fan motor capacitor c Indoor fan motor winding is burnt Replace indoor fan motor d In Heat mode Delayed start for indoor fan Normal software delay max 20 sec motor e Clogged air filters Clean filters Low capacity a Lack of refrigerant will be accompanied by Unit must be charged according to the nameplate whistling noise Causes ice formation on the after localizing the gas leak evaporator coil in Cool mode b Clogged air filters Clean filters In Heat mode only compressor A C operates in de icing cycle Wait 10 minutes maximum until the unit resumes runs Outdoor and indoor fan normal operation motors are stopped AIR CON indicator flashes Water accumulates and Drain pan pipe or hose is clogged or the spout of Disassemble plastic drain pipe from spout of evapora overflows from evaporator drain pan is clogged tor drain pan Flush with clean water drain pan Water dripping from the Water drain outlet or the spout i
19. func tions such as cleaning coils All other operations should be performed by trained service personnel When working on the equipment observe precautions in the literature and on tags stickers and labels attached to the equipment Follow all safety codes Wear safety glasses and work gloves Keep quenching cloth and fire extinguisher nearby when brazing Use care in handling rigging and setting bulky equipment WARNING Before installing or servicing system always turn off main power to system and install lockout tag on disconnect There may be more than one disconnect switch Electrical shock can cause personal injury GENERAL These instructions cover the installation start up and servic ing of 38CG CS outdoor and 40CG CS indoor units cooling only and heat pump duct free systems Depending on the specific application the 40CG CS indoor units can be installed as either a wall console unit or under ceil ing unit See Fig 1 and 2 See Tables 1 and 2 for parts included with systems System Requirements Consult local building codes and National Electrical Code NEC U S A for special installation requirements Control wiring should be THHN 600V 18 gage Use only type G or fuses Use single length power cable without extension Allow sufficient space for airflow clearance wiring refrigerant piping and servicing unit See Fig 3A and 3B for minimum required distances between unit
20. ht to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 111 Catalog No 533 80051 Printed in U S A Form 38 40 251 Pg 20 2 02 Replaces 38 40 15 Tab 5 5
21. ill the pan below the unit s coil with water and observe that it drains out freely Connect the ends of the refrigerant lines to their appropriate fittings following the guidelines in the Refrigerant Piping Connections section Make sure the drainage hose is at the bottom side of the wall hole See Fig 9 Connect the display panel connector to the display panel printed circuit board See Fig 10 Reassemble the front panel using the 7 screws which appear in Fig 6 NOTE If the drainage is routed in direction no 1 as shown in Fig 13 cut out an oval opening in the air intake opening for the drainage tube and route the tube through the air intake grille See Fig 18 40CG CS UNIT Fig 14 Fastening Left and Right Sides to Air Conditioner 1 BRACKET SCREWS 2 SCREWS BRACKET SCREWS NUT CEILING lt BRACKET Fig 15 Assembling the Ceiling Bracket CEILING BRACKET ANCHOR SCREWS ANCHOR SCREWS PROTRUSION SIDE ud c NOTE BE SURE TO FASTEN THE 4 SAFETY SCREWS ON THE SIDES OF THE UNIT SIDE SCREWS ADJACENT ROOM AIR OUTLET PORTS Tess 40CG CS UNIT Fig 17 Mounting Indoor Unit Onto Ceiling Bracket AIR INTAKE GRILLE CUT OUT DRAINAGE TUBE 5e V 2 Fig 18 Drainage Tube Routing Option 38CG CS Outdoor Unit Ins
22. n no 2 a conden sate pump must be installed for drainage 1 To assemble the ceiling bracket use 4 mounting strips and 8 UNC 10 screws and nuts provided See Fig 15 2 Fasten the ceiling bracket to the ceiling using the 6 anchor screws as shown in Fig 16 NOTE The anchor screws provided are intended for use with concrete ceilings Use fasteners which are appropriate for the type of ceiling present at the installation site 2 VERTICAL ROUTING 4 10 cm Situ 40CG CS INDOOR UNIT HORIZONTAL ROUTING 40CG CS UNIT Fig 12 Switch 1 Factory Default ON Position 40CG CS Ceiling Installations Only SWITCHES 3 The location of the ceiling bracket should allow a mini mum gap between the indoor unit and nearby walls as shown in Fig 13 4 Drill hole in wall to connect indoor and outdoor units a Using unit as a template drill a 3 in hole from inside wall for the tubing that contains refrigerant lines drainage hose and electric cables as shown in Fig 9 5 Mount unit by performing the following steps a Carefully remove air intake grille and retaining spring by removing screws on both sides of grille See Fig 6 b Remove 7 screws that attach front panel to unit Remove front panel Fasten the left and right side strips on bracket to the air conditioner using 6 sheet metal screws field supplied as shown in Fig 14 Be sure of the following 1 The wide si
23. n remote control is not available d Indoor unit does not receive transmitted Make sure that nothing is blocking the remote control commands transmission to the unit display e AUTO OFF REMOTE switch is set to Off Slide the 3 position switch on the Display to REMOTE RMOT position Only indoor fan ventilator works a The selected mode is Fan Only or Cool when Check if the remote control is in the desired mode If when cooling or heating is heating is desired not select the correct mode refer to User manual desired Also note that every 15 minutes max the compres sor will be switched minimally on for 3 minutes b Temperature is set to a value which is too high Observe the temperature setting on the remote control in Cool mode Also note that each 15 minutes max the compressor will be switched on minimally for 3 minutes Only indoor fan motor and a In Heat mode Indoor fan motor blocked Remove obstruction compressor Working Outdoor b In Cool mode System runs while evaporator Wait up to 90 seconds until anti ice routine is an motor stopped anti ice routine takes place completed In Cool mode high pressure or Run capacitor of outdoor fan motor is burnt Replace outdoor fan motor run capacitor in Heat mode outdoor coil freeze Winding of outdoor fan motor is shorted Replace outdoor fan motor Only indoor fan motor and a Overload safety device on compressor is cut Switch off power and try again after on
24. s clogged Open condenser cover clean out water outlet clean condenser base in Heat mode the base inside thoroughly Unit does not operate in desired a The 3 position slide switch on the unit display is Change the slider position to REMOTE RMOT mode in AUTO or OFF position b Faulty remote control settings 1 If remote control symbols respond to the commands correctly check the unit ID Code Standard or Alter native Refer to Changing Unit ID Code and to Remote Control DIP switch 3 setting in Control Assembly manual 2 If Cool commands are but Heat symbol is skipped on LCD refer to Remote Control DIP switch 7 setting 3 Replace remote control c Remote control low battery Replace remote control batteries d IR detector Try shorter distance between remote control and unit If no response replace IR detector The unit receives interference Common IR Code Modify the Remote Control IR transmission code from other remote control or the Refer to Changing Unit ID Code and to Remote Con remote control interferes with trol DIP switch 3 setting in control assembly manual other instruments In Cool mode the unit a Faulty thermistor outdoor sensor Replace the thermistor 3 TH 3 sensor compressor does not start b Faulty thermistor extension cable between Replace TH 3 extension cable indoor and outdoor 17 Copyright 2002 Carrier Corporation Manufacturer reserves the rig
25. tallation e Connect the outdoor sensor cable TH3 making NOTE The outdoor unit must be installed on a solid surface sure the connector is properly inserted 1 Fasten the outdoor unit legs to the base as shown in f Secure the inter unit electric and sensor cable to Fig 19 the outdoor unit with the clamp shown in Fig 19 2 Place the rubber absorption cushions supplied with the g Reassemble the plastic side cover outdoor unit under the unit s legs to prevent vibrations NOTE A drainage tube can be connected to the outdoor 4 Be sure that the unit is level unit to remove condensation formed during heating mode operation 4 Make wiring connections a Remove the outdoor unit plastic side cover i CAUTION b Loosen the screws on the terminal block s c Attach the electrical terminals supplied to the inter bis sure that all i and wires w properly 1 unit control and power cable wires ose wires or connections can cause damage and presen a fire hazard d Connect the wires to the terminal block as shown in Fig 20A 20C ol lol 9 9 9 9 91 PLUG TO CONNECT TA WITH OUTDOOR SENSOR CABLE TH3 INTER UNIT ELECTRIC CABLE CLAMP 38CG CS ol TI OUTDOOR 7 lt UNIT e ABSORPTION CUSHION X4 Fig 19 Wiring Connections and Location of Legs on Bas
26. ty Do not open service valves or remove protective caps from tubing ends until all the connections are made Bend tubing with special bending tools to avoid the forma tion of sharp bends Take care to avoid kinks or flattening of the tubing Keep the tubing free of dirt sand moisture and other con taminants to avoid damaging the refrigerant system Avoid sags in the suction line to prevent the formation of oil traps Insulate each tube with 3 g in walled thermal pipe insula tion Inserting the tubing into the insulation before making the connections will save time and improve installation The suc tion and liquid lines should never come in direct contact FLARING AND CONNECTING REFRIGERANT LINES Remove the protective cap from the flare fitting 2 Remove the protective cap from the tubing and cut to the required length Be sure that the cut is perpendicular and clean without burrs 3 Slip the flare nut on the tubing and flare the tube end using standard flaring tools 4 Tighten the nut until resistance is met Mark the nut and the fitting Using a suitable wrench tighten an additional 1 4 turn Use the following specified torque according to connection size Suction line 1 5 in 36 ft Ib 5 g in 47 ft lb 3 4 in 72 ft lb Liquid line 1 4 in 12 3 ft Ib 3 g in 29 ft Ib NOTE The valves on the outdoor unit must remain closed until all 4 connections have been made Power Supply
27. y Air Conditioner 14 CARE AND MAINTENANCE 38CG CS Outdoor Units A WARNING 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 CLEANING COILS Coil should be washed out with water or blown out with compressed air 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 outdoor unit airflow Use a flashlight to determine if dirt or debris has collected between coil sections Clean coil as follows 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 40CG CS Indoor Units CAUTION avoid the possibility of electric shock before perform ing any cleaning and maintenance operations always turn off power to the system by pressing the mode button on the remote control until the display shows OFF and turn off the separate disconnect switch located near the unit If the indoor unit is on a separate switch be sure to turn this dis connect off as well CAUTION Do not wash filter in water over 120 F to avoid shrink
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