Installation, Start-Up and Service Instructions - HVAC-Talk
Contents
1. 3 WIRES 30 il ji GROUND VADOR E WEATHERPROOF SUPPLY AIR 6 za RETURN FUSED DISCONNECT ADJACENT DUCT SPACE OPTION 24 V CONTROL POWER VENTILATION PROVIDED 6 IN ACCESSORY t INSIDE UNIT DUGT POWER VENTILATION POWER NN 2 CONDENSATE DRAIN LINE FROM PUMP 2 WIRES GROUND 4 6 WIRES THERMOSTAT FUSED DISCONNECT PER NEC LEGEND Standard NOTES b Phase TAccessory item 1 All piping must follow standard refrigerant piping techniques Refer to Carrier An Field supplied System Design Manual NEC National Electrical Code All wiring must comply with the applicable local and national codes Piping Thermostat is required ma Line Voltage Wiring and piping shown are general points of connection guides only and are 024 not intended for a specific installation Insulate condensate line if run above a conditioned space Do not install AccuRater metering device Do not install filter drier Vapor supply and suction lines must be insulated CON O Cl BON Fig 9 Tvpical Piping and Wiring In Ceiling Cassette Svstems 10 Step 4 Complete Refrigerant Piping Table 1 Physical Data NOTE Complete all refrigerant tubing connections at the I Unit 38HDS 024 048 fan coil units first Then route the tubing sets back to the 52 Capacity Btuh 48 000 outdoor u2. II a p l eed d wa n CIRCUITS 3 amp 4 ON 048 SIZE ONLY ww ON 048 SIZE ONLV DMI pre m x CIRCUITS 3 amp 4 momp P d G M DIA VAPOR RETURN LINE CONN l FEMALE SWEAT CONN 0 5 7 8 2 11491 6 07 ryp NDIA g 154 VAPOR SUPPLY LINE CONN TYP 07 6 5 16 FEMALE 5 CONN A be pq 07 7 13 16 25 106 STAND cms us n a n 1 3 7 8 1 11 16 gt TU 52 525 FRONT VIEW snou stano STAND FIELD FABRICATED ee O 8 RIGHT SIDE VIEW 287 rtm mm ptm Dmm mm Erin mm Fc mm _ efa aor ro we oon oom ma ars orm 457 oom 16 o9 10 os 160 05 148 292 NOTES 1 Required clearances with coil facing wall allow 6 in minimum clear ance on coil side and coil end and 3 ft minimum clearance on com pressor end and fan side With fan facing wall allow 8 in minimum clearance on fan side and coil end and 3 ft 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 in millimeters 3 Center of gravity g MINIMUM MOUNTING PAD DIMENSIONS SUPPORT FEET SNOW STAND ICE STAND 1 11 x 3 6 584 x 1067 2 2
3. RELAV 5 AGING SHORT 112 GRN YEL DISPLAY PCB AS i ie WIRELESS REMOTE CN11 CN10 TEBAS 5I TIMER JEM A 11213141516 CN13 EN STEP 3 MOTOR L rium EIL ME s CN14 T STEP inl 8 MOTOR R 3 K 5 BRN eee 4 RED L TO UNIT DISCONNECT BARE COPPER USE CABLE PROVIDED TBI CN8 CN3 CN4LLI2I3 ORG 089 BLU ORG TB2 WHT COMMON 24VAC TO OUTDOOR B GRA COP __ TA FMC CZ COMP UNIT LEGEND Home Automation RA Th Return Air Thermistor e Splice fread Sensor Capacitor Indoor Coil Thermistor RCV Receiver Terminal Block Indoor Fan Motor TB Terminal Block al Japan Electric TP Thermal Protector Factorv Wiring Manufacturing TRAN Transformer Field Control Wiring a C Terminal Unmarked Field Power Wiring Printed Circuit Board Right If any of the original wire furnished must be replaced it must be replaced with type 90 C wire or its equivalent Wire in accordance with National Electrical Code NEC and local codes 2 3 Fan motor has internal thermal protection 4 Transformer has an internal 2 amp thermal fuse on the primary side Fig 20 Typical Wiring Schematic 40QNB High Wall Units 208 230 1 60 DISCONNECT PER E PUMP DELAY RELAY PUMP 30 5 RUN gt U n 3 TIN w
4. COMPRESSOR lo 100 sec BLACK DENOTES CLOSED CONTACTS LEGEND ASM Air Sweep Motor Freeze Protection RIDTS Remote Indoor SZ ASR Air Sweep Relay Thermostat Temperature Sensor ES Terminal eae B Board FR Fan Relay TB Terminal Block Factory Wiring Contactor FU Fuse TRAN Transformer Field Control Wiring Capacitor IFM Indoor Fan Motor ___ Fi iri CKT Circuit OL Overload yy Terminal Marked III Feld Power Wiring CR Control Relay PDR Pump Delay Relay 2 DR Defrost Relay PL Plug Terminal Unmarked Accessory or Optiona EQUIP Equipment Ground Pump Motor Wiring GND PSS Pump Shut Off Switch e Splice NOTES 1 If any of the original wire furnished must be replaced it must be replaced with type 90 C wire or its equivalent 2 Wire in accordance with National Electrical Code NEC and local codes 3 Transformer is thermallv protected and will reset automaticallv 4 IFM S has internal thermal protection Fig 21 Typical Wiring Schematic 40QAB Ceiling Suspended Units 26 400 COIL EQUIP GNO TO INDOOR UNIT PUMP DELAY RELAY TIMING SEQUENCE PUMP Y RUN TIME DISCONNECT PR 55 core ESSOR Lo 120 SEC BLACK DENOTES CLOSED CONTACTS PL2 3 PSS WHY WHT WHT WH Ta WHT PL4 14 PLE PL6 2 PL4 TO OUTDOOR UNIT TO
5. 38HDS024 048 Outdoor Condensing Unit Installation Start Up and Service Instructions CONTENTS Page GENERAL 1 3 System Description 1 Planning the System 3 SAFETY CONSIDERATIONS 3 INSTALLATION 3 13 Step1 Complete Pre Installation Checks 3 e UNPACK OUTDOOR UNIT INSPECT SHIPMENT e CONSIDER SYSTEM REQUIREMENTS Step 2 Install Outdoor Unit 3 e MOUNTING ON GROUND e MOUNTING ON ROOF e SURROUNDING FENCES AND WALLS RIGGING Step 3 Install Fan Coil Units 5 Step 4 Complete Refrigerant Piping Connections 11 MAKE PIPING SWEAT CONNECTIONS e PROVIDE SAFETY RELIEF LEAK TEST EVACUATE AND DEHYDRATE SYSTEM Step 5 Make Electrical Connections 12 e OUTDOOR CONDENSING UNIT e INSTALL BRANCH CIRCUIT DISCONNECT PER NEC ROUTE LINE POWER LEADS CONNECT GROUND LEAD AND POWER WIRING INDOOR UNIT CONNECT CONTROL CIRCUIT WIRING RECONFIGURE FOR ONE FAN COIL UNIT PER COMPRESSOR CIRCUIT IF NECESSARY STARTUP i 13 18 Preliminary Checks 13 2222295 Tp 13 Evacuate Dehydrate 13 Charge System 13 Unit Operation 17 FAN COIL
6. HPS 09 BLK OT BLK BLU C SEE NOTE 3 BRN Fig 18 Typical Wiring Schematic 38HDS024 Condensing Unit 29 YEL K22 YEL FIELD YEL 3 d um BLK BLK POWER CLO1 CT vei GRN YEL BLU SUPPLY CAP1 I KE BRN EQUIP GND YEL FR KD FCRI WHT FCR2 FCR3 KID WHT 7 FCR4 KID vEL BRN Y BLK TR2 a TA Og PESE ee HPS 1 DTS 1 LPS 1 UNIT 1 T BL CDP BLL 0 B k o T 6 B k e BLU O 0 BLU to f INDOOR FC2 SEE NOTE 3 UNIT 2 RE BRN BRN 5 BRN INDOO FC3 BRN UNIT 3 RE BRN Pu 5 2 DTS 2 LPS 2 mE a GOP 9 9 BLK e 80 01 9 Rope BLU TO B INDOO FC4 UNIT 4 c d Sova SEE NOTE 3 O JOOS A zu CONTROL BOX e 4 4 0D i es J 5 1 f O 4 2 0300509 C 20 10 BI REFER TO COMP JUNCTION BOX DISCONNECT FOR PROPER ORIENTATION OF PER N E C TERMINALS USE COPPER CONDUCTORS ONLY CD aeta vroe aci eee 2 YIFC3IC virc4ic i 1 I CD Cam ee ELS FIELD CONTROL WIRING CLASS 2 come TO INDOOR SECTION TB LEGEND Contactor Compressor TR Transducer NOTES Capacitor TRAN Transformer 1 Fan motor is thermally protected Compressor Lockout 2 Wire accordance with National Electrical Code and local codes Compresso
7. WEATHERPROOF FUSED DISCONNECT PER NEC ees a d P os 2 WIRES GROUND SEE NOTE 6 ill MOISTURE INDICATOR NEC LEGEND National Electrical Code Piping Line Voltage 24 M Standard TField supplied ATE All piping must follow standard re frigerant piping techniques Refer to Carrier System Design Manual All wiring must comply with the ap plicable local and national codes Wiring and piping shown are gen eral points of connection guides only NER SIGHT GLASST WJ 7 ee UNIT and are not intended for a specific installation Insulate condensate drain if in stalled in a conditioned space Vapor supply line and suction line must be insulated Do not install filter drier Do not install Accurater Metering Device INSULATED VAPOR SUPPLY LINE lt s NO VAPOR RETURN CONTROL CONNECTIONS 2 WIREST 2 WIRES 9 GROUND 24 V CONTROL POWER PROVIDED INSIDE UNIT CONDENSATE DRAIN LINET FUSED DISCONNECTT WIRELESS CONTROLLER TO OPEN SIGHT DRAIN DO NOT TRAP Fig 7 Typical Piping and Wiring High Wall Systems WEATHERPROOF FUSED DISCONNECT PER JI 2 WIRES 10 3 WIRES 30 GROUND Eo ali AIRFLOW MOISTURE INDICATOR SIGHT GLASS OnE INS
8. Line Power Connections RECONFIGURE FOR ONE FAN COIL UNIT PER COM PRESSOR CIRCUIT IF NECESSARY The control also provides the option of using either 1 or 2 fan coil units per compressor depending on the position of the jumpers on J3 and J4 on the control board See Fig 15 The control is pre set to 2 fan coil units per compressor at the factory If only one fan coil per compressor is to be used position a jumper between pins 1 and 2 on J3 and J4 one jumper for each set of pins Jumper J3 is associated with the compressor on the 38HDSO24 units and compressor number 1 on 38HDS048 units bottom compressor Jumper J4 is associated with com pressor number 2 on the 38HDS048 units 13 START UP Preliminary Checks Complete Start Up Checklist on page CL 1 and the following checks prior to starting up unit 1 Check condensate drainage system To do this add a small amount of water into each fan coil unit condensate pan and ensure that each pan drains freely Inspect drain pans and lines and inspect as required 2 Make sure that all wiring connections are correct and tight 3 Check all barriers covers and panels to ensure they are in place 4 Identify which fan coil unit valve sets have been connected IMPORTANT DO NOT open valves which do not have fan coil units connected to them 5 Unit is shipped with the valve stems frontseated and caps factory installed Remove caps from all valves to which fan coil unit
9. The CLO locks out the COMP to prevent short cycling on COMP overloads COMP Compressor Motor and safety devices Before replacing CLO check these devices CT Current Transformer 4 If indoor section has a transformer with a grounded secondary connect the DTS Discharge Temperature Switch grounded side to C on the low voltage board EQUIP Equipment 5 Use minimum 60 C wire for field power wiring FC Fan Coil 6 The multi split control has a 2 minute internal time delay on compressor op FCR Fan Coil Relay eration The pins on plug may be shorted to speed up this time delay for FR Fan Relay servicing GND Ground 7 Jumper J3 must be moved to pins 1 2 when only one fan coil will be used HPS High Pressure Switch for compressor Circuit 1 Jumper J4 must be moved to pins 1 2 when only LA Low Ambient one fan coil will be used for compressor Circuit 2 LPS Low Pressure Switch MCB Multi Split Control Board OFM Outdoor Fan Motor SV Solenoid Valve TB Terminal Block TH Thermistor TR Transducer TRAN Transformer Q Terminal Field 78 lt x gt Terminal Marked POWER 1 O Terminal Unmarked SUPPLY SEE NOTE EP 77 Terminal Block EQUIP GND Splice Factory Wiring Field Control Wiring Field Power Wiring FCR1 REO FCRI TO f BLK INDOOR4 UNIT 1 L FCR2 f Y BLK INDOOR 2 UNIT 2 DTS LPS
10. x 3 6 660 x 1067 2 2 x 3 6 2 0 x 4 2 610 1270 2 4 x 4 4 711 x 1270 2 2 x 4 2 UNIT 38HDS 660 x 1067 660 x 1270 Fig 2 Base Unit Dimensions 8 3 0 914 914 SERVICE CLEARANCE C SS A 3 0 914 B 0 8 203 NOTE Dimensions in are in mm A Minimum operating clearance required when this side faces a wall B Minimum operating clearance required when this side faces away from a wall Fig 3 Operating and Service Clearance NE Step 3 Install Fan Coil Units Refer to Instal SLING lation Start Up and Service Instructions provided with the fan coil units NOTE If this system is mixing 2 or more types of fan coil SLING PADDING units be sure to follow instructions provided with each type CENTER OF of fan coil unit closely GRAVITY COMPRESSOR Mount fan coil units in locations which will be easily ac END cessible when routing refrigerant tubing see Fig 6 9 and electrical wiring between the fan coil units and outdoor unit Fan coil unit locations must also provide adequate drainage capabilities If desired condensate pumps may be used with any type of fan coil unit Y L IMPORTANT DO NOT install filter driers or AccuRater refrigerant metering device body or pis tons Into this system Thermostatic expansion valves are located the outdoor condensing unit to control Fig 4 Lifting Unit With Sling ref
11. 113 108 103 98 93 264 121 116 111 106 101 96 274 124 119 114 109 104 99 285 127 122 117 112 107 102 297 130 125 120 115 110 105 309 133 128 123 118 113 108 321 136 131 126 121 116 11 331 139 134 129 124 119 114 346 142 137 132 127 122 117 359 145 140 135 130 125 120 Compressor Lockout Switch CLO Units are provided with 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 inter rupted to reset the lockout Determine reason for safety trip To restart turn the 38HDS main disconnect to OFF then to ON position Indoor Coil Temperature Thermistor Ther mistor is for use only with duct free split systems using a microprocessor control 40QN fan coil units only as part of the system diagnostics Refer to separate installation instruc tions for the 400NB indoor units Low Ambient Control Thermistor LAT The low ambient control thermistor is located on the outdoor fan support bracket See Unit Operation section on page 17 and Fig 15 for more information about the controls Pressure Transducer pressure transducer tivates the low ambient control when discharge pressure drops to either 250 psig or 200 psig based on the setting of control jumper J1 See Unit Operat
12. 48 unit has 2 compressors which are stacked vertically using a sheet metal stand to support the top compressor In the event of a compressor failure remove and replace the compressor s as follows 1 Attach refrigerant hose to suction service valve of the cir cuit related to the defective compressor 2 Recover refrigerant using accepted techniques 3 Remove discharge and suction piping from compressor by unsweating Pass either nitrogen or another inert gas through the compressor 4 Remove compressor mounting bolts Use a swivel socket to remove the bolt in the rear 5 Carefully pull compressor stand and piping away from the compressor to remove the compressor 6 Reverse Steps 1 5 to install the new compressor TIME DELAY DEVICE OVERRIDE The time delay de vice can be overridden for easier unit servicing by tempo rarily shorting the time delay device override connector P9 located in the control box see Fig 15 The short MUST be removed before the time delay device timer can be cleared SYSTEM STATUS LEDs AND FAULT CODES In nor mal operating mode the green LED located on the outdoor unit microprocessor board will flash on and off at a rate of once per second Whenever a fan coil unit compressor or outdoor fan is energized a red LED designated for each fan coil unit will be illuminated If there is an error condition a code will be displayed using the green and red system status LEDs The green LED will bl
13. G ON ROOF Mount unit on a level platform or frame at least 6 in 154 mm above roof surface Isolate unit and tubing from structure SURROUNDING FENCES AND WALLS Select and in stall surrounding fences and walls to allow for free entry of ambient air Avoid pits and solid walls as unit surroundings because recirculation of warm discharge air can occur RIGGING A CAUTION Be sure unit panels are securely in place prior to rigging Keep unit upright Lift unit using sling Use cardboard or padding under sling and use spreader bars to prevent sling damage to unit See Fig 4 See Fig 2 for center of gravity reference Install unit so that coil does not face into prevail ing winds If this is not possible and constant winds above 25 mph are expected field fabricate and install wind baffles In areas where outdoor ambient will be less than 40 F during cooling wind baffles are also required See Fig 5 WIND BAFFLE FIELD FABRICATED AND INSTALLED E 0 7 1 2 1911 DRA IN HOLES aoe TYP 4 AIR DISCHARGE 5 5 1491 F p 07 0 11 18 07 3 1 2 18 ind TOP VIEW FIELD POWER SUPPLY CONN 1 178 DIA 29 HOLE FOR 024 SIZE FIELD CONTROL SUPPLY CONN 1 3 8 DIA 35 HOLE 7 87 DIA 22 HOLE FOR 048 SIZE AND THERMISTOR CABLE CONNECTIONS B gt gt 0 4 5 87 118 SERVICE PORTS PROVIDED INSIDE COMPRESSOR ACCESS TA p ED
14. N Bes GEO MOTOR DEFECTIVE FAULTY POWER DIRTY AIR DEFECTIVE UNIT OVERCHARGED Co SUPPLY FILTERS COMPRESSOR VALVES NO TIPI LOOSE LEADS RESTRICTED DISCHARGE DEFECTIVE OUTDOOR i AT COMPRESSOR LINE FAN MOTOR CAPACITOR TRANSFORMER FROSTED RELIEF OPEN T Sm FAULTY START GEAR NONCONDENSABLES DISCHARGE GAS IN SYSTEM SLIGHTLY LOW BULB LOOSE 2 THERMOSTAT ON REFRIGERANT o EA LINE VOLTAGE INDOOR BLOWER MOTOR TOO HIGH OR LOW DEFECTIVE OR CYCLING ON OVERLOAD CONTACTOR OR COMPRESSOR STUCK COIL DEFECTIVE COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR ISc SQH8 W104 LOOSE ELECTRCAL CONNECTION d TIT DEFECTIVE RUN BERE seal CAPACITOR TIME DELAY FAULTY ENABLED PLUGGED OR RESTRICTED TXV OUTDOOR CONTROL TIME HPS High Pressure Switch LLSV Liquid Vapor Supply Line Solenoid Valve LPS Low Pressure Switch TXV Thermostatic Expansion Valve suo1jebijqo G ULLINJUI JINOUHM pue Aue ye enunuoosip 0 146 DU S A19S91 Fig 23 Cooling Cycle Troubleshooting Chart ISL SGH8E seoejdeu START UP CHECKLIST A Multi Split Installation Planning Worksheet 38 5024 OUTDOOR CONDENSING UNIT CIRCUIT CIRCUIT IDENTIFICATION NO IDENTIFICATION NUMBER Room or Occupied Space Loc
15. OUTDOOR UNIT LEGEND CAP Capacitor IFM Indoor Fan Motor TB Terminal Block Factory Wiring CR Control Relay OL Overload TRAN Transformer Field Control Wiring Soup Gouna BEY B bel Rey Terminal Urmare Fo Power Wig GND PM Pump Motor Splice Printed Circuit Board FPT Freeze Protection PSS Pump Shutoff Switch Thermostat RIDTS Remote Indoor Temperature Terminal Block FR Fan Relay Sensor NOTES 1 If any of the original wire furnished must be replaced it must be replaced with type 90 C wire or its equivalent 2 Wire in accordance with National Electrical Code NEC and local codes 3 Transformer is thermally protected and will reset automatically 4 IFM S has internal thermal protection Fig 22 Typical Wiring Schematic 40QKB In Ceiling Cassette Units 27 NO COOLING OR INSUFFICIENT COOLING 400q COMPRESSOR Ce NA COMPRESSOR RUNS BUT WILL NOT RUN OVERLOAD HPS OR LPS INSUFFICIENT COOLING HIGH SUCTION HIGH SUCTION LOW HEAD PRESSURE LOW SUPERHEAT LLL Od OUTDOOR STOPPED uoneJod402 766 1uUGuAdo9 LOOSE LEAD AT LOW SUCTION OPEN SHORTED OR GROUNDED COMPRESSOR LOW REFRIGERANT OPEN CONTROL MOTOR WINDINGS CHARGE CIRCUIT VAPOR SUPPLY LINE SLIGHTLY RESTRICTED 5 CLOSED OR CYCLING ON EMO sedil EM O 2 OUTDOOR AIR 5 COMPRESSOR POWER SUPPLY OPE
16. PEED Y N 400AB 400KB Fan Coil Units POSITION SELECTOR SWITCH AT SUBBASE IN EACH FAN SPEED SETTING IN SEQUENCE DOES EACH FAN COIL UNIT CHANGE SPEEDS PER SWITCH SETTING Y N START SYSTEM OPERATION AT ONE FAN COIL UNIT SELECT COOLING MODE AND ADJUST SET POINT TO BE BELOW CURRENT ROOM TEMPERATURE OBSERVE OPERATION OF OUTDOOR CONDENSING UNIT DOES COMPRESSOR START AFTER INITIAL TIME DELAY AND RUN Y N DOES OUTDOOR FAN RUN OR CYCLE ACCORDING TO SPACE REQUIREMENTS AND OUTDOOR AMBIENT TEMPERATURE Y N DESELECT COOLING MODE AT INDOOR FAN COIL UNIT REPEAT FOR REMAINING FAN COIL UNIT S AND RECORD ALL INFORMATION BELOW START SYSTEM OPERATION AT BOTH FAN COIL UNITS ON A SINGLE COMPRESSOR CIRCUIT FOR 40QAB QYB FAN COIL UNITS SELECT COOL MODE AND INITIATE TEST CYCLE AFTER AT LEAST 15 MINUTES RUNNING TIME RECORD THE MEASUREMENTS BELOW FOR SYSTEMS USING 38HDS048 UNITS REPEAT THIS PROCEDURE FOR THE SECOND COMPRESSOR CIRCUIT SYSTEMA SYSTEM B COMPRESSOR AMPS L1 L2 OIL PRESSURE SUCTION PRESSURE SUCTION LINE TEMP DISCHARGE PRESSURE DISCHARGE LINE TEMP ENTERING OUTDOOR AIR TEMP LEAVING OUTDOOR AIR TEMP FAN COIL NO 1 FAN COIL NO 2 FAN COIL NO 1 FAN COIL NO 2 INDOOR ENTERING AIR DB dry bulb TEMP INDOOR ENTERING AIR WB wet bulb TEMP INDOOR LEAVING AIR DB TEMP INDOOR LEAVING AIR WB TEMP VAPOR SUPPLY LINE TEMPERATURE AT VAPOR SUPPLY LINE SOLENOID VALVE COIL CL 3 Copyright 1997 Carrier Corporation Manufa
17. ULATED VAPOR za OUTDOOR RETURN LINE UNIT INSULATED VAPOR TI SUPPLY LINE ALTERNATE CONDENSATE DRAIN WITH ACCESSORY PUMP t LEGEND b Phase NEC National Electrical Code Piping m Line Voltage 24 V Standard TAccessory item Field supplied NOTES 1 All piping must follow standard re frigerant piping techniques Refer to Carrier System Design Manual 2 All wiring must comply with the ap plicable local and national codes Thermostat is required Wiring and piping shown are gen eral points of connection guides only and are not intended for a spe cific installation Insulate condensate line if run above a conditioned space Do not install AccuRater meter ing device Do not install filter drier Vapor supply and suction lines must be insulated CON CONTROL CONNECTIONS 2 WIRES SEE NOTE 6 24 V CONTROL POWER PROVIDED INSIDE UNIT AIRFLOW 2 WIRES 4 GROUND 6 WIRES CONDENSATE DRAIN LINE FUSED DISCONNECT THERMOSTAT Le TO OPEN SIGHT DRAIN TRAP REQUIRED sess k 2 E A a d UM Fig 8 Typical Piping and Wiring Ceiling Suspended Systems MOISTURE INDICATOR SIGHT GLASS mall 11 NI I T cae CONTROL CONNECTIONS AIRFLOW i l 2 WIRES 7 OUTDOOR
18. UNITS 38HDS OUTDOOR CONDENSING UNIT 38HDS MICROPROCESSOR CONTROL OF OUTDOOR FAN STATUS INDICATOR LIGHTS UNIT MALFUNCTION SERVICE be Rex dan ees 18 21 Outdoor Fan 18 Scroll Compressors 19 TIME DELAY DEVICE OVERRIDE SYSTEM STATUS LEDs AND FAULT CODES High Pressure Relief Valve 19 Internal Current and Temperature Sensitive Overload 19 High Pressure Switch 19 Low Pressure Switch 19 Service Valves 20 Refrigerant Charging 20 SUBCOOLING CHARGING METHOD Compressor Lockout Switch CLO 20 Indoor Coil Temperature Sensor 20 Low Ambient Control Thermistor LAT 20 Pressure Transducer 21 MAINTENANCE 21 Lubricallon oput eeu p aon Axe eS avs 21 FAN MOTOR BEARINGS COMPRESSOR Cleaning Coils 21 TROUBLESHOOTING 22 Checking Cooling Control Operation 22 START UP CHECKLIST CL 1 CL 4 GENERAL The TXV thermostatic expansion valve is located in the outdoor unit NOT the indoor fan coil units The 38HDS outdoor unit has a factory installed low ambient control BOTH refrigerant lines between the indoor and outdoor uni
19. aces 38HDS 1SI 40QNB HIGH WALL FAN COIL UNIT 40QKB IN CEILING CASSETTE FAN COIL UNIT 38HDS OUTDOOR CONDENSING UNIT 048 Unit Shown Fig 1 Multi Split System Components Planning the System This is complex system with up to 4 separate tubing systems and 8 different control cable sets Plan the installation carefully as instructed below Read these installation Instructions outdoor condensing unit and the installation instructions included with the fan coil units carefully and completely PRIOR to system installation 1 Maximum line length 15 50 ft equivalent any single line run and maximum elevation differential is 30 ft from highest to lowest system component 2 Verify that Carrier components received form a legiti mate multi split system as follows a Systems using one 38 05024 outdoor condensing unit may use any combination for a total of 2 of Carrier nominal 1 2 ton fan coil units and require 2 circuits per compressor b Systems using one 38 05048 outdoor condensing unit may use any of the following combinations any combination for a total of 2 of Carrier nominal 2 ton fan coil units 1 fan coil unit per compressor e any one Carrier nominal 2 ton fan coil unit on one circuit and any combination of 2 Carrier nominal 1 2 ton fan coil units for a system total of 3 on the other compressor any combination for a total of 4 of Carrier nomi nal 11 2 ton fan coi
20. ation 2 1 38HDS048 OUTDOOR CONDENSING UNIT INSTALLER S CIRCUIT CIRCUIT Fun it IDENTIFICATION NO IDENTIFICATION NUMBER Room or Occupied Space Location NOTE Circuits 1 and 2 are controlled by compressor no 1 and circuits 3 and 4 are controlled by compressor no 2 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 111 Catalog No 533 826 Printed in U S A Form 38HDS 2SI CL 1 8 97 Replaces 38HDS 1SI Tab ssl Pre Start Up OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE Y N IF SO WHERE WILL THIS DAMAGE PREVENT UNIT START UP _________ CHECK POWER SUPPLY DOES IT AGREE WITH UNIT DATAPLATE Y N HAS THE GROUND WIRE BEEN CONNECTED Y N HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY Y N ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY Y N ARE ALL TERMINALS TIGHT Y N Piping ARE REFRIGERANT LINES CONNECTED TO SERVICE VALVE SETS AS INDICATED IN MULTI SPLIT INSTALLA TION PLANNING WORKSHEET Y N ARE CONTROL POWER LINES CONNECTED TO CONTROL POWER TERMINAL BLOCK AS INDICATED IN MULTI SPLIT INSTALLATION PLANNING WORKSHEET Y N ARE TERMINALS SNUG IN THE HOUSINGS Y N ARE SERVICE VALVES OPENED AND BACKSEATED Y N ARE STEM VALVES INSTALLED AND SNUG Y N HAVE ALL REFRIGERANT CONNECTIONS AND PIPING JOINTS BEEN CHECKED FOR LEAKS Y N INDOOR FAN COIL UNIT Pip
21. buried Sec Vapor Return Quantity OD in 2 4 tion during extended periods of system shutdown This Vapor Supply Quantity OD 4 3 causes refrigerant slugging and could possiblv damage Valve Connection ODF compressor at start up Vapor Return Quantitv ODF in 2 4 DO NOT USE MORE THAN 50 of equivalent Vapor Supply Quantity ODF in 4 terconnecting tubing more than 30 ft of vertical lift Nes acut igh Pressure Switch Cutout psig Sa 10 between the lowest system component and High Pressure Switch Cut in psig 320 20 UE Be component Low Pressure Switch Cutout psig i When more than 50 ft of interconnecting tubing or more SUM res Ure eee ee Discharge Temperature than 30 ft of vertical lift is necessary contact your local Switch Cutoutt F 280 distributor Fusible Plug 210 F If either refrigerant tubing or indoor coil is exposed to at Line sizes are for runs up to 25 ft mospheric conditions for longer than 5 minutes it must be TSwitch will reset automatically when temperature drops below 280 F evacuated to 1000 microns to eliminate contamination and moisture in the system MAKE PIPING SWEAT CONNECTIONS Check tubing set identification against Mulu Split Installation Planning Work sheet on page CL 1 to ensure correct selection of service valve set on outdoor unit Run refrigerant tubes as directly as possible avoidi
22. cess from and through outdoor and indoor unit The service valve cannot be field repaired only a complete valve or valve stem seal and service port caps are available for replacement NOTE Do not open service valves which are not connected to a tubing set Be sure any inactive circuits are capped off Refrigerant Charging A WARNING To prevent personal injury wear safety glasses and gloves when handling refrigerant Do not overcharge system this can cause compressor flooding WARNING 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 sys tem charge or personal injury NOTE Do not vent or depressurize unit refrigerant to at mosphere Remove and recover refrigerant following ac cepted practices see GTAC2 Module 5 The 38HDS units are factory charged with a full operat ing charge Check the system for proper charge level using the subcooling method If a refrigerant system must be opened for major service work first recover refrigerant in system as described in GTAC2 Module 5 Evacuate and dehydrate the system when ready to recharge then weigh in the proper refrigerant quantity as marked on the unit data plate for each circuit SUBCOOLING CHARGING METHOD 1 Operate the unit a minimum of 15 minutes before check ing the charge Outdoor fan must be operating continu ously when checking subo
23. ck CLO Compressor Lock Out HPS High Pressure Switch TRAN Transformer COMP Motor LPS Low Pressure Switch p CT Current Transformer LA Low Ambient Q Terminal Field Factory Wiring DTS Discharge Temperature MCB Multi Split Control Board Field Power Wiring Switch National Electrical Code 4x Terminal Marked EQUIP Equipment OFM Outdoor Fan Motor FC Fan Coil Unit SV Solenoid Valve Terminal Unmarked FCR Fan Coil Relay Terminal Block 15 HEAD PRESSURE CONTROL OPTION RED LED FAN ON WHEN LIT RED LED 6 GREEN LED SYSTEM STATUS LOW AMBIENT RED LED THERMISTOR SYSTEM STATUS OUTDOOR UNIT CONTROL BOARD LEGEND C Compressor Fan Coil J Connectors LED Light Emitting Diode SW Switch Circuit No 1 Option TCircuit No 2 Option Fig 15 Outdoor Unit Microprocessor Control Board Table 2 Electrical Data UNIT 38HDS 5 lt 208 200 1 60 1 60 FLA Full Load Amps HACR Heating Air Conditioning Refrigeration LRA Locked Rotor Amps Minimum Circuit Amps per NEC Section 430 24 NEC National Electrical Code RLA Rated Load Amps Compressor Permissible limits of the voltage range at which unit will operate satisfactorily NOTES 1 The 38HDS units contain a 24 v transformer additional trans formers are not requ
24. cturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 111 Catalog No 533 826 Printed in U S A Form 38 05 25 CL 4 8 97 Replaces 38HDS 1SI Tab
25. enses outdoor ambient temperature using a thermistor and refrigerant pressure using a pressure transducer mounted on the compressor circuit discharge line The 38HDSO24 units have one transducer and the 048 units have two The factory set points for the head pressure control op eration are 55 F for outdoor ambient temperature and 250 psig for discharge pressure The current set points can be determined as follows see Fig 15 If pin numbers 2 and 3 on JI are jumpered the setting is 250 psig factory set ting if pin numbers 1 and 2 are jumpered the setting is 200 psig When switch SW 1 is set at the top setting ambient set point is 55 F When the switch is set to the bottom set ting ambient set point is 35 When the outdoor ambient temperature is above the out door ambient set point and both fan coils on a compressor circuit are calling for cooling operation the outdoor fan will run at full speed whenever compressor operation is permit ted When only one fan coil is calling for cooling fan cy cling is permitted at all ambient temperatures Fan motor will be cycled on and off to maintain set point discharge pressure When the outdoor ambient temperature is below the speci fied set point the fan motor will be cycled on and off to maintain a compressor discharge pressure at the specified pres sure set point On 38HDS048 units with 2 compressors run ning the compressor with the lower head pressure will con trol the fan opera
26. g abnormal conditions the switch opens WARNING DO NOT attempt to simulate these system abnormali ties high pressures pose a serious safety hazard High pressure switch 1s checked with an ohmmeter If sys tem pressure 15 below approximately 320 psig switch shows continuity The high pressure switch will reset automati cally after CLO compressor lockout switch has been reset and time delay device has completed its timing cycle Low Pressure Switch This switch mounted on the suction line has fixed non adjustable settings To check pres sure switch attach pressure gage to suction service valve gage port Slowly close liquid shutoff valve and allow compres sor to pump down Do not allow compressor to pump down below 2 psig Compressor should shut down when suction pressure drops to about 7 psig and should restart when pres sure builds up to about 22 psig after CLO has been reset and time delay device has completed its timing cycle Service Valves service valves in the outdoor unit are frontseated at the factory This means the refrigerant charge is isolated from the line set connection ports To prevent dam age to the valve use a wet cloth or other accepted heat sink material on the valve before brazing The service valves must be backseated turned counter clockwise until seated before the service port caps are re moved and the hoses of gage manifold connected In this position refrigerant has ac
27. ing CHECK TO BE SURE ACCURATER DEVICE IS NOT INSTALLED IN FAN COIL UNIT CHECK TO BE SURE FILTER DRIER IS NOT INSTALLED IN VAPOR SUPPLY LINE AT INDOOR UNIT IS VAPOR SUPPLY LINE INSULATED OVER ENTIRE LENGTH TO OUTDOOR UNIT Y N ARE REFRIGERANT LINES CONNECTED TO SAME SERVICE VALVES AS THE MATCHING CONTROL WIRES Y N HAVE REFRIGERANT CONNECTIONS BEEN CHECKED FOR LEAKS Y N IS CONDENSATE LINE CONNECTED Y N DOES CONDENSATE LINE DRAIN FREELY Y N IF ACCESSORY CONDENSATE PUMP IS INSTALLED IS MAXIMUM LIFT OF PUMP LESS THAN 20 INCHES Y N IF ACCESSORY CONDENSATE PUMP IS INSTALLED DOES PUMP START AND RUN ACCORDING TO CONTROLS SPECIFICATION Y N Controls ARE CONTROL POWER WIRES LABELLED ACCORDING TO INDIVIDUAL FAN COIL UNIT Y N ARE CONTROL WIRES CONNECTED TO THE SAME CIRCUIT AS ASSOCIATED REFRIGERANT LINES Y N CHECK ROUTING OF LEADS WITHIN SUBBASE ARE THERE PINCHED OR CUT LEADS Y N CHECK MOUNTING OF SUBBASE TO WALL IS IT TIGHT DO NOT APPLY EXCESSIVE FORCE TO MOUNTING SCREW Y N CL 2 Pre Start Up cont Fan System DOES THE FAN ROTATE FREELY Y N ARE AIR FILTERS IN PLACE Y N Power Supply DOES THE POWER SUPPLY MATCH THE FAN COIL UNIT DATAPLATE Y N IS GROUND WIRE CONNECTED Y N C Start Up CHECK INDOOR FAN OPERATION 40QNB Fan Coil Units SELECT FAN MODE THEN INITIATE TEST SEQUENCE DOES EACH FAN COIL UNIT START AT LOW SPEED THEN SHIFT TO MEDIUM SPEED AND THEN SHIFT TO HIGH S
28. ink its code first followed by the red LED The LEDs will flash at a rate of once every 2 seconds with a 2 second pause between the last red LED flash and the first green LED flash of the next code See Table 3 1 N B 19 System Ready Low Head Pressure Circuit 1 High Head Pressure Circuit 1 Low Head Pressure Circuit 2 High Head Pressure Circuit 2 Low Outdoor Ambient Temperature Outdoor Thermistor High Outdoor Ambient Temperature Outdoor Thermistor Hardware Error Time Guard Device Active Circuit 1 Time Guard Device Active Circuit 2 High Pressure Relief Valve Valve is located in compressor Relief valve opens at a pressure differential of approximately 450 50 psig between suction low side and discharge high side to allow pressure equalization Internal Current and Temperature Sensitive Over load Control resets automatically when internal com pressor 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 If necessary refer to GTAC2 Module 9 for complete information High Pressure Switch This switch located on dis charge 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 426 psig If system pressures go above this setting durin
29. ion section on page 17 for more information about the controls If transducer has to be removed for any reason first dis connect the snap lock plug The transducer can now be un screwed and removed without loss of refrigerant since there is a Schrader type core valve in the transducer port When reinserting the transducer reverse this procedure Be careful not to overtighten the transducer CIRCUIT NO 3 CIRCUIT NO 4 CIRCUIT NO 1 CIRCUIT NO 2 LEGEND SV Service Valve X Measurement Location Fig 17 Vapor Supply Line Measurement Locations 38HDS048 Unit Shown 21 MAINTENANCE 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 Lubrication FAN MOTOR BEARINGS Oiling holes are provided at each end of condenser fan motor Remove fan motor and lu bricate motor with 32 drops 16 drops per hole of SAE 10 Society of Automotive Engineers nondetergent oil at the following intervals e Annually when environment is very dirty ambient tem perature is higher than 105 F 40 C and average unit op erating time exceeds 15 hours a day or Every 3 years when environment is reasonably clean am bient temperature is less than 105 F 40 C and unit op erating time averages 8 to 15 hours a day or Every 5 years when environment is clean ambient tem peratu
30. ired Unit Operation NOTE AUTO fan mode is used as the unit operation ex ample for ALL fan coil units in this section Contact your local Carrier dealer for operation information in other fan modes FAN COIL UNITS Each fan coil unit has a self contained control system that determines the set point for fan coil op eration fan mode operation and heating mode operation if provided The fan coil units are equipped with either a wired or wireless remote controller set wireless remote controller is not available for 40QKB or 40QAB fan coil units Set points and fan modes may be determined separately for each fan coil unit Each fan coil unit may call for cooling operation inde pendently On a call for cooling operation by a single fan coil unit 24 v signal is sent to the 38HDS outdoor unit and energizes a control relay The indoor blower starts according to the normal fan coil unit sequence of operation The con trol relay in the outdoor unit initiates operation of a cool ing cycle for the respective indoor unit refrigerant circuit including opening a liquid line solenoid valve in the outdoor unit As the set point at each fan coil is satisfied its individual 24 v signal to the 38HDS unit stops and the respective so lenoid valve for each fan coil unit closes The indoor fan cycles off 38HDS OUTDOOR CONDENSING UNIT The outdoor unit 1s equipped with a control that will monitor the indoor fan coil unit cooling re
31. is fault but the control will continue to cycle the outdoor fan according to input from the other transducer If only one transducer is active and is determined to be out of the operating circuit range the head pressure control will be bypassed and the fan will run con tinuously See Table 3 for diagnostic codes SERVICE A WARNING Before performing recommended maintenance be sure unit main power switch is turned off and be sure all disconnects for indoor fan coil units are open These sys tems typically have one disconnect per fan coil unit Fail ure to turn off unit main power and open all disconnects may result in electrical shock or injury from rotating fan blade Outdoor Fan A reinforced wire mount holds the out door fan assembly in position See Fig 16 for proper mount ing positions p 1 mt 1 Tn a FAN BLADE 4 lt 1 ZER N DIMENSION FROM FAN a E OUTSIDE EDGE OF BLADE TO OUTSIDE EDGE OF FAN DECK SEE TABLE BELOW UNIT SIZE in mm 38HDS024 38HDS048 0 709 18 0 16 4 Fig 16 Condenser Fan Mounting Positions Table 3 System Status Red and Green LEDs Fault Codes UNIT STATUS GREEN LED RED LED Number of Number of Number of Number of Flashes On Flashes Flashes On Flashes 1 LED Light Emitting Diode Scroll Compressors The 38805 condensing units use scroll compressors The 38HDSO24 unit has one com pressor and the 38HDS0
32. l units 2 fan coil units per circuit and 2 circuits per compressor 3 Identify and record each fan coil section as it will be con nected to the 38HDS outdoor unit on the Multi Split In stallation Planning Worksheet included as part of the Start Up Checklist on page CL 1 4 Check all system components to ensure that all required materials are on hand before starting installation of this system 5 Re read Step 3 Install Fan Coil Units section on page 5 before installing indoor fan coil units SAFETY CONSIDERATIONS Installing and servicing air conditioning equipment can be hazardous due to system pressure and electrical compo nents 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 literature and tags and labels attached to unit Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for brazing operations Have fire ex tinguisher available Read these instructions thoroughly Con sult local building codes and National Electrical Code NEC Standard ANSI NFPA 70 American National Standards Institute National Fire Protection Association for special in stallation requirements WARNING Before installing
33. low this warning could result in the installer being liable for personal injury of others CAUTION Unit failure as a result of operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components Do not install units in system where voltage may fluctuate above or below permissible limits Such operation would in validate any applicable Carrier warranty 12 OUTDOOR CONDENSING UNIT Be sure field wiring complies with local and national fire safety and electrical codes and that voltage to the system is within limits shown in Table 2 Contact local power company for correction of improper line voltage See Table 2 for recommended fuse sizes When making electrical connections provide clearance at unit for refrig erant piping connections INSTALL BRANCH CIRCUIT DISCONNECT PER NEC Install a disconnect of adequate size to handle unit start ing current Locate disconnect within sight from and readily accessible from unit per Section 440 14 of NEC ROUTE LINE POWER LEADS Extend leads from dis connect through power wiring hole provided and into unit splice area Remove outdoor unit control box cover to gain access to unit wiring NOTE Power leads from disconnect into outdoor unit must be COPPER WIRE ONLY CONNECT GROUND LEAD AND POWER WIRING Connect ground lead to equipment ground connection in out door unit control box Then connect power wiri
34. ng to TB1 terminal block no 1 See Fig 11 Splice the line power leads to yellow and black leads provided INDOOR UNIT Refer to installation instructions in cluded with the fan coil units for fan coil unit installation and power supply piping CONNECT CONTROL CIRCUIT WIRING WARNING avoid personal injury be sure system main power switch is turned off before proceeding 1 Refer to Multi Split Installation Planning Worksheet com pleted prior to the start of this installation and verify the markings on each set of control wiring cable sets 2 Route 24 v control wiring through wiring hole on the out door unit See Fig 12 for typical connections for each type of fan coil See Fig 13 and 14 for 38HDS compo nent arrangement and unit wiring details See Fig 15 for 38HDS control board detail 3 Connect wiring to screw connections labeled FC2 FC3 and FC4 on terminal board for each corresponding fan coil unit See Fig 12 15 4 Route the other end of the control wiring back to the fan coil unit and connect to the fan coil terminal board according to the wiring schematic for the fan coil unit See fan coil unit installation instructions for wiring schematic GROUND LEAD HO GROUNDING LUG CONNECTION L l DISCONNECT PER NEC LEGEND NEC National Electrical Code Field Wiring TBI Terminal Board Factory Wiring TB Connections Fig 11
35. ng un necessary turns and bends Suspend refrigerant tubes so they do not damage insulation on vapor return tube and do not transmit vibration to structure Also when passing refriger ant tubes through wall seal opening so that vibration is not CAUTION transmitted to structure Leave some slack in refrigerant tubes To avoid damage while brazing service valves should between structure and outdoor unit to absorb vibration See be wrapped with a heat sinking material such as a wet Fig 6 for indoor to outdoor unit tubing connections and re cloth fer to separate indoor fan coil unit installation instructions for additional Ouo A CAUTION NOTE If only 2 fan coil units are used 38HDS048 sys tems be sure that one is used with each compressor refrig When brazing tubing sets to the service valves a braz erant circuit If 2 or 3 fan coils are used cap any unused ing shield MUST be used to prevent damage to the painted refrigerant lines at the service valves unit surface Remove plastic caps from liquid and suction service valves A WARNING Use refrigerant grade tubing Service valves are closed from DO NOT INSTALL A FIELD SUPPLIED FILTER the factory and are ready for brazing Pass nitrogen or other DRIER in this system Filter drier is factory installed inert gas through piping while brazing to prevent formation inside the outdoor unit Installing a filter drier in the liq of copper oxide uid line between the indoor and ou
36. nit Mark each tubing set carefully to identify its PESE 265 respective fan coil unit pe Ib Refrigerant H 22 Outdoor units may be connected to indoor units using field Quantity Ib supplied tubing of refrigerant grade and condition See 5 0 ds Table 1 for correct line sizes Do not use less than 10 ft 3 m of interconnecting tubing compressor Type IS UE NOTE It is not necessary to make any changes to line sizes Modei Copeland or any refrigerant system modifications when using recom ZR23K1 PFV ZR23K1 PFV mended refrigerant line lengths Oil oz Recharge 25 When installing tubing both the vapor return line and the Crankcase Heater Watts e vapor supply smaller line must be insulated between out Outdoor Fan bi Propeller Type irect Drive Horizontal door unit and indoor unit to avoid condensation on the lines Rpm 850 850 Use closed cell foam insulation and tape all seams and Joints Diameter in No of Blades 243 Fan Pitch Deg 24 DO NOT BURY MORE THAN 36 IN 922 mm OF Nominal Airflow cfm 3900 REFRIGERANT TUBING IN THE GROUND If any Outdoor Coil Copper uminum Plate Fin section of tubing 15 buried there must b e a Face Area sq ft No of Rows 6 1 2 12 3 2 154 mm vertical rise to the valve connections on the Fins i sin 15 outdoor unit If more than the recommended length is Fine SIZes buried refrigerant may migrate to cooler
37. oling 2 Measure discharge pressure by attaching an accurate gage to the discharge service port DO NOT use the external service valves for this pressure reading 3 Measure the vapor supply line temperature by attaching an accurate thermistor type or electronic thermometer to the vapor supply line near the outdoor coil See Fig 17 4 Refer to Table 4 to find the required subcooling tempera ture for the unit Find the point at which the required sub cooling temperature intersects the measured internal dis charge service port pressure in Table 5 5 To obtain the required subcooling temperature at a spe cific discharge pressure add refrigerant if vapor supply line temperature is higher than indicated or remove re frigerant if temperature is lower than indicated Allow a tolerance of 3 20 Table 4 Required Unit Subcooling SUBCOOLING AT TXV INLET F UNIT 38HDS WITH ALL FANS OPERATING 024 19 048 16 TXV Thermostatic Expansion Valve Table 5 Required Liquid Line Temperatures F PRESSURE REQUIRED SUBCOOLING TEMPERATURE F Psig AT SERVICE FITTING 134 76 71 66 61 56 51 141 79 74 69 64 59 54 148 82 77 72 67 62 57 156 85 80 75 70 65 60 163 88 83 78 73 68 63 171 91 86 81 76 71 66 179 94 89 84 79 74 69 187 97 92 87 82 77 72 196 100 95 90 85 80 75 205 103 98 93 88 83 78 214 106 101 96 91 86 81 223 109 104 99 94 89 84 233 112 107 102 97 92 87 243 115 110 105 100 95 90 253 118
38. on is controlled by the microprocessor as described in 38HDS Microproces sor Control of Outdoor Fan section below When a second fan coil unit signals a demand for cooling its associated solenoid valve is energized immediately allowing refrigerant to flow to both fan coil units simultaneously Decreased Demand for Cooling When a fan coil unit s demand for cooling ends the 24 v signal to the 38HDS unit stops and the appropriate solenoid valve closes If the other fan coil unit on this circuit still has a demand the appro priate compressor will continue to run as long as necessary for the second fan coil unit When the second fan coil unit s demand for cooling ends its solenoid valve closes and the appropriate compressor stops The compressor will not start for at least 2 minutes after the end of this cycle due to the time delay function On size 024 units when the compressor stops the out door fan also stops On size 048 units outdoor fan operation may continue under control of the 38HDS microprocessor if the other refrigerant circuit is still operating The outdoor fan will only stop when both compressors are off Refer to 38HDS Microprocessor Control of Outdoor Fan section be low for more details 38HDS MICROPROCESSOR CONTROL OF OUTDOOR FAN The microprocessor control has a built in head pres sure control system that will cycle the outdoor fan motor to maintain a selected discharge pressure The microprocessor s
39. quest The control will turn on sole noid valves for the appropriate indoor fan coil unit system The control will also combine the cooling requests to con trol up to 2 compressors OPERATIONAL VOLTAGE COMPRESSOR V PH Hz 17 POWER SUPPLY Max Fuse or HACR Type Circuit Breaker Amps 25 40 2 All motors and compressors contain internal overload protection 3 In compliance with NEC requirements for multimotor and combi nation load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be fuse or HACR breaker 4 Motor RLA values are established in accordance with UL Under writers Laboratories Standard 1995 U The head pressure for the 2 compressors will be moni tored to control the outdoor fan output The control reads an outdoor temperature thermistor to determine if the head pres sure should be used to control the fan output There are 3 jumpers and one slide switch used to determine if the head pressure should be used to control the fan output See 38HDS MICROPROCESSOR CONTROL OF OUTDOOR FAN sec tion on next page for more details 62 5 The 38HDS unit control also includes an integral head pres sure control function This function will maintain a mini mum head pressure by cycling the outdoor fan motor in re sponse to inputs from the thermistor for outdoor ambient temperature and the transducers for system discharge pres sures in each compressor circ
40. r Motor e Terminal Field Replace any original wires with 90 C wire or its equivalent Current Transformer 3 CLO locks out the COMP to prevent short cycling COMP overloads Discharge Temperature Switch 4x Terminal Marked and safety devices Before replacing CLO check these devices Equipment Terminal U ken 4 If indoor section has a transformer with a grounded secondary connect the Fan Coil Relay erminal Unmarked grounded side to on the low voltage board 5 6 Use minimum 60 C wire for field power wiring Fan Relay Ground Terminal Block High Pressure Switch pu ao Swich Splice for servicing ow Pressure Switc E l ae Multi Split Control Board Factory Wiring 7 2 to PINS 1 2 when only fan coil will be used ROT Field Control Wiring Jumper J4 must be moved to PINS 1 2 when only one fan coil will be used Terminal Block Field Power Wiring for compressor Circuit 2 Thermistor Option or Accessory Wire Fig 19 Typical Wiring Schematic 38 05048 Condensing Unit 24 The multisplit control has a 2 minute internal time delay on compressor eration The PINS on PLUG P9 may be shorted to speed up this time delay SC 40QNB FAN COIL AGING For Burn In Test short terminals AS Assembly C Contactor CN Connector COMP Compressor EMI Electromagnetic Interference FMC Fan Motor Capacitor G GND Ground NOTES
41. re is less than 105 F 40 C and unit operating time averages less than 8 hours a day COMPRESSOR Compressor contains factory oil charge replace oil when lost See Table 1 for oil recharge and refer to Carrier Refrigerant Service Techniques training book for oil recharging procedure NOTE Use only Cryol 150A oil in these units Cleaning Coils Coil should be washed out with wa ter or blown out with compressed 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 be tween the rows of fins and restrict condenser airflow Use a flashlight to determine if dirt or debris has collected between coil sections Clean coil as follows 1 Turn off unit power 2 Using a garden hose or other suitable equipment flush coll from the outside to remove dirt Be sure to flush all dirt and debris from drain holes in base of unit Fan mo tors are waterproof TROUBLESHOOTING Refer to Figs 18 23 when troubleshooting these systems Checking Cooling Control Operation Check the system for proper control operation as follows refer to Fig 23 for more details 1 Check status LED at the 38HDS control board A green LED will flash on and off at one second Inte
42. rigerant flow END END I 1 3 33 AE 33 FRONT 38HDS024 38HDS048 NOTE Dimensions in are millimeters Fig 5 Wind Baffle Dimensions a ER cc ae Ray coll M cC RC EE ECC a L HEAT EXCHANGER pk v 8 1 ic a 5 9 2 w I O c TI n gt 7 im C In QJ 1 PROPELLER i5 pa e 1 EQUALIZER LINE VAPOR RETURN CONDITIONED SPACE a meu H H 44 MULTISPLIT FAN CONTROL l PRESSURE TRANSDUCER 1 l FAN A d A CONDITIONED SPACE ka x COMPRESSOR 1 1 OUTDOOR UNIT TXV BULBS COMPRESSOR 2 ZA i PAN A M LB 2 LEGEND M Motor SV Solenoid Valve Thermostatic Expansion Valve Field Supplied Tubing NOTE Insulate ALL lines between outdoor condensing unit and indoor fan coil units Fig 6 Refrigerant Tubing Schematic 38HDS048 Shown SOLENOID i VALVES SEEREERENE E gre VAPOR SUPPLY E E E E ERIE E s SV D Q a IN HB DE S RUN DR HER aaa BE l E epp AN 3 8 LINE INSULATED sees E e paie tea ge rase x
43. rvals when the unit is ready to run If a time delay function is active 3 green LED flashes followed by 2 or 3 red LED flashes wait 2 minutes for time delay to clear 2 Ata fan coil unit remote controller select AUTO fan mode COOL system mode and adjust set point down until ther mometer segment is fully displayed Notice the snow flake display on the handset system mode is COOL and the compressor run display demand signal is being sent to the outdoor unit Note that the indoor fan starts at low speed 22 3 At the outdoor unit check that the LED signal lamp for the indoor fan coil unit is illuminated that the compres sor and the outdoor fan motor start and run that the so lenoid valve for the indoor fan coil is energized and that refrigerant is flowing to the correct indoor unit Observe that cooling operation shuts down when control setting at the fan coil unit is satisfied compressor stops outdoor fan stops solenoid valve closes and LED for fan coil demand is off Observe operation of indoor fan during the off period The fan will be off for 3 minutes then turn on for 1 minute at low speed for occupied space air temperature sampling NOTES LEGEND 1 Fan motor is thermally protected 2 Wire accordance with National Electrical Code local codes __ Split Compressor Replace any original wires with 90 C wire or its equivalent CLO Compressor Lockout 3
44. s have been connected Replace caps and tighten until finger tight 6 Fully backseat open the vapor supply and vapor return tube service valves 7 Turn on main disconnect switch es to indoor fan coil units and outdoor condensing unit 8 Using the remote controller or thermostat for each indoor fan coil unit turn on each fan coil unit and operate each unit in each mode i e electric heat if provided and fan cooling for 15 minutes to test for proper operation 9 Test for proper refrigerant charge in each circuit using the subcooling method Leak Test Field piping and all tubing connections must be leak tested by the pressure method described in the Car rier General Training for Air Conditioning Manual GTAC2 Module 5 Use R 22 at approximately 25 psig backed up with an inert gas to reach a total system pressure not to ex ceed 245 psig Evacuate and Dehydrate Field piping and fan coil must be evacuated and dehydrated by either of the methods described in GTAC2 Module 5 WARNING 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 sys tem charge or personal injury Charge System Release charge into system by open ing backseating vapor supply and vapor return line service valves Open ONLY those service valve sets which have fan coil unit sections connected to them DO NOT open
45. servicing system always turn off main power to system There may be more than one dis connect switch since each fan coil unit will normally have its own disconnect Turn off accessory heater power if applicable Electrical shock can cause personal injury INSTALLATION Step 1 Complete Pre Installation Checks UNPACK OUTDOOR UNIT see Fig 1 Move 38HDS unit to final location Remove carton from unit being care ful not to damage service valves and grilles INSPECT SHIPMENT File claim with shipping com pany if shipment is damaged or incomplete Check unit name plate to be sure unit matches job requirements CONSIDER SYSTEM REQUIREMENTS Consult local building codes and NEC for special installation requirements Allow sufficient space for airflow wiring refrigerant pip ing and servicing unit See Fig 2 and 3 Locate unit so that condenser coil airflow 1s unrestricted on both sides Refer to Fig 2 and 3 Unit may be mounted on a level pad directly on base legs or mounted on raised pads at support points See Fig 2 and 4 for center of gravity Step 2 Install Outdoor 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 If conditions or local codes re quire unit be fastened to pad 6 field supplied tiedown bolts should be used and fastened through slots provided in unit mounting feet See Fig 2 MOUNTIN
46. tdoor units will cause After wrapping the service valve with a wet cloth the tub a high pressure drop and will result in abnormal sys ing set can be brazed to the service valve using either silver tem operation bearing or non silver bearing brazing material Consult local code requirements Refrigerant tubing and indoor coil are now ready for leak testing NOTE Unit is shipped from the factory with a full system charge of R 22 exact amount is indicated on unit nameplate 11 38HD5 The maximum system elevation is 30 ft from lowest point in the system to highest point in the system 40Q__ tal 30 0 9 1 1 MAXIMUM E 40Q_ ET Fig 10 Maximum Elevation Differential 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 LEAK TEST EVACUATE AND DEHYDRATE SYSTEM Refer to Leak Test section and Evacuate and Dehydrate section on page 13 for details Step 5 Make Electrical Connections WARNING Unit cabinet must have uninterrupted unbroken elec trical ground to minimize the possibility of personal in jury if an electrical fault should occur This ground may consist of electrical wire connected to unit ground lug in control compartment or conduit approved for elec trical ground when installed in accordance with NEC ANSI NFPA 70 and local electrical codes Failure to fol
47. tion If only one compressor is running that compressor will control the fan operation 18 If the discharge pressure on either circuit exceeds 370 psig the outdoor fan motor will run continuously and the fan cling function will be bypassed until the discharge pressure decreases to 365 psig STATUS INDICATOR LIGHTS See Table 3 and Fig 15 38HDS control board is equipped with LED light emitting diode indicators to aid evaluating the status of the control system including time delay function status fan coil unit demand status head pressure control status current unit malfunctions UNIT MALFUNCTION Each compressor circuit is equipped with a high pressure switch HPS a low pressure switch LPS and a discharge temperature switch DTS These safety devices are located in a Cycle LOC circuit that pre vents compressor operation if any of these safety devices is activated The lockout can be reset by turning the main power to the 38HDS unit off then on again Compressor overcurrent protection is achieved by an in ternal linebreak overload which will automatically reset when the motor temperature cools to a satisfactory level Manual reset of Cycle LOC circuit may also be required Pressure transducers and the outdoor ambient thermistor are monitored by the 38HDS controller If a pressure trans ducer is found to be out of the operating circuit range the LEDs will flash a code for th
48. ts MUST BE insulated because the TXV 15 in the out door unit DO NOT install a filter drier in the line set to the fan coil units A filter drier has already been factory installed on the outdoor unit The 38HDS unit has been pre charged at the factory with sufficient refrigerant for the entire system assuming 50 ft of tubing and the use of one of the system combinations listed in Planning the System section on page 3 System Description The 38HDS multi split air con ditioning system requires 3 major components see Fig 1 A 38HDS outdoor condensing unit Either 2 3 or 4 duct free split fan coil units for distribu tion of air to a maximum of 4 independent zones see Plan ning the System section on page 3 A wireless infrared remote controller to control each fan coil unit independently one remote controller is neces sary for each fan coil unit NOTE The wireless infrared remote controller is not avail able for 40QKB in ceiling cassette fan coil units IMPORTANT The 38HDS outdoor units may only be used with the indoor fan coil unit sizes listed 1n Plan ning the System section on page 3 DO NOT try to substitute or add more fan coils to these systems Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 533 826 Book 1 4 PC 111 Tab 3e 2f Printed in U S A Form 38HDS 2SI Pg 1 8 97 Repl
49. uit Operation The 38HDS unit receives a 24 v control signal from each fan coil unit as each fan coil unit initiates a de mand for cooling The 24 v signal energizes a control relay in the 38HDS unit one relay per fan coil unit The refrig erant flow to each fan coil unit is controlled through a so lenoid valve one valve per fan coil unit The solenoid valve s will not open until compressor operation is initiated by the controller The microprocessor control in the 38HDS unit includes 2 minute anti short cycle time delay function This func tion provides a minimum off delay between compressor run stages 2 minutes each from the end of the last on period to the beginning of the next on period If more than 2 minutes have passed since the end of the last on period the com pressor will be ready to restart with initiation of demand from any fan coil unit on its circuit Increased Demand for Cooling NOTE There are 2 separate compressor circuits the 38 05048 units circuit and circuit Each circuit erates independently and will operate as follows as will the single circuit 024 units upon receiving the first 24 v cool ing demand signal from a fan coil unit 1 After the 2 minute time delay function is satisfied the appropriate compressor starts 2 The solenoid valve connected to the fan coil sending the demand signal is energized at the 38HDS units 3 The outdoor fan starts and its operati
50. valves where no field tubing has been connected TO DISCONNECT FC1 2 38HDS FC3 FC4 HE BBJBB J TO DISCONNECT TO DISCONNECT EQUIPMENT GROUND LEGEND FC Fan Coil Unit TB Terminal Block Fig 12 Control Line Connections Typical Connections for Each Type of Fan Coil Illustrated 14 IREFER TO COMP JUNCTION BOX FOR PROPER ORIENTATION OF TERMINALS gl 3c 1 9 p2 er A n OUTDOOR LOW AMBIENT CONTROL ep DISCONNECT PER USE COPPER CONDUCTORS ONLY yleci c YIFCOC Y C Y FCAC v ittm nina TERMINALS NOT USED v u u U u etate FIELD CONTROL WIRING CLASS 2 TO INDOOR SECTION TB Fig 13 Component Arrangement 38HDS024 LA o TH CONTROL BOX opoo CLOI ide dle CD 2 CD CO MES pe de Din 122 TR2 1 sv QuIP i CAP2 1 1 1 E OOG KOOOOOOQLONOOMOO 2 20000 02 i PS P4 P3 d 16 bg LPSI 19 FE 1 gt 8 f PA OUTDOOR TRI LOW AMBIENT 43 4 CONTROL 5 REFER COMP JUNCTION BOX FOR PROPER ORIENTATION OF PER NEC 015 FIELD CONTROL WIRING NEC CLASS 2 CS COMP TO INDOOR SECTION Fig 14 Component Arrangement 38HDS048 LEGEND FOR FIG 13 AND 14 Contactor Compressor FR Fan Relay TH Themistor CAP Capacitor GND Ground TR Transducer Terminal Blo
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