38HDF018-036
Duct Free Condensing Units
38HDR018-060
Ducted Condensing Units
Installation, Start-Up and
Service Instructions
CONTENTS
Page
Puron® (R-410A) refrigerant systems operate at higher
pressures than standard R-22 systems. Do not use R-22 ser-
vice equipment or components on Puron refrigerant equip-
ment. If service equipment is not rated for Puron refrigerant,
equipment damage or personal injury may result.
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Step 1 — Complete Pre-Installation Checks . . . . . . 1
• UNPACK UNIT
• INSPECT SHIPMENT
• CONSIDER SYSTEM REQUIREMENTS
• MATCHING THE CONDENSING UNIT TO AN
INDOOR UNIT
INSTALLATION
Step 1 — Complete Pre-Installation Checks
UNPACK UNIT (See Fig. 1) — Move the unit to final loca-
tion. Remove unit from carton, being careful not to damage
service valves and grilles.
Step 2 — Rig and Mount Unit. . . . . . . . . . . . . . . . . . . . . 3
• MOUNTING ON GROUND
• MOUNTING ON ROOF
• RIGGING
Step 3 — Complete Refrigerant Piping
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
• CHECK ACCURATER CONTROL
• FILTER DRIER
• MAKE PIPING SWEAT CONNECTORS
• PROVIDE SAFETY RELIEF
Step 4 — Make Electrical Connections . . . . . . . . . . . 6
• CONTROL CIRCUIT WIRING
• POWER WIRING
• CONNECTIONS TO DUCT-FREE FAN COIL UNITS
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . .14,15
SAFETY CONSIDERATIONS
Installing and servicing air conditioning equipment can be
hazardous due to system pressure and electrical components.
Only trained and qualified service personnel should install or
service air conditioning equipment.
Untrained personnel can perform basic maintenance, such
as cleaning and replacing filters. All other operations should be
performed by trained service personnel. When working on air
conditioning equipment, observe safety precautions in litera-
ture, tags, and labels attached to unit.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for brazing operations. Have fire
extinguisher available. Read these instructions thoroughly.
Consult local building codes and the National Electrical Code
(NEC) for special installation requirements.
Fig. 1 — 38HDF,HDR Unit
INSPECT SHIPMENT — File a claim with the shipping
company if shipment is damaged or incomplete. Check unit
nameplate to ensure unit matches job requirements.
CONSIDER SYSTEM REQUIREMENTS — Consult local
building codes and NEC for special installation requirements.
Allow sufficient space for airflow clearance, wiring, refrig-
erant piping, and servicing unit. See Fig. 2.
Locate unit so that condenser airflow is unrestricted on both
sides. Refer to Fig. 2.
Unit may be mounted on a level pad directly on base legs or
mounted on raised pads at support points. See Fig. 2 for center
of gravity.
MATCHING THE CONDENSING UNIT TO AN
INDOOR UNIT — The 38HDF,HDR units can be matched to
a corresponding indoor unit. The 38HDF018-036 units can be
matched with an in-ceiling cassette or high wall indoor unit.
The 38HDR unit can be matched with under-ceiling and resi-
dential fan coils. Refer to separate indoor unit literature for
more information.
Before installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch. Turn off accessory heater power if applicable. Elec-
trical shock can cause serious personal injury.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 02-38HD0001-SI Printed in U.S.A. Form 38HD-4SI Pg 1 1-06 Replaces: 38HDC-3SI
Book 1
4
Tab 3e 2f
When more than 50 ft of interconnecting tubing and more
than 30 ft of vertical lift is used, consult the residential long line
application instruction guide. For long-line applications, inter-
connecting lines over 100 ft must be installed with a liquid line
solenoid. A liquid line solenoid may also be installed on some
units to improve part-load efficiency. Refer to the ARI (Air
Conditioning & Refrigeration Institute) Directory.
If either refrigerant tubing or indoor coil is exposed to
the atmosphere, the system must be evacuated following good
refrigeration practices.
Run refrigerant tubes as directly as possible, avoiding
unnecessary turns and bends. Suspend refrigerant tubes so they
do not damage insulation on vapor tube and do not transmit
vibration to structure. Also, when passing refrigerant tubes
through a wall, seal the opening so that vibration is not transmit-
ted to structure. Leave some slack in refrigerant tubes between
structure and outdoor unit to absorb vibration. Refer to separate
indoor unit installation instructions for additional information.
Step 2 — Rig and Mount Unit
MOUNTING ON GROUND — Mount unit on a solid, level
concrete pad. Position unit so water or ice from roof does not
fall directly onto unit. Accessory stacking kits can be used
when units are to be stacked. See installation instructions
provided with the accessory kit. Use field-provided snow stand
or ice rack where prolonged subfreezing temperatures or heavy
snow occurs.
If conditions or local codes require unit be fastened to a pad,
6 field-supplied tiedown bolts should be used and fastened
through slots provided in unit mounting feet.
MOUNTING ON ROOF — Mount unit on a level platform
or frame at least 6 in. above roof surface. Isolate unit and tub-
ing from structure.
RIGGING
CHECK ACCURATER CONTROL — The correct Accu-
Rater (bypass type) refrigerant control is required for system
capacity optimization. An AccuRater device with field-
replaceable piston (see Fig. 4) is supplied with the outdoor unit.
Refer to the AccuRater metering device table in separate
indoor unit installation instructions to determine the correct
AccuRater piston size required for the condenser/evaporator
system being installed.
Piston style as shown in Fig. 4 is shipped with the unit. Do
not interchange components between the AccuRater device
types. Matching of outdoor unit with indoor unit may require
field replacement of piston. Replace piston, if required, before
connecting refrigerant lines. See Fig. 4. Piston replacement
instructions are included in the indoor unit installation instruc-
tions. After system installation is complete, see the Refrigerant
Charging section on page 12 to check and/or adjust refrigerant
charge.
Be sure unit panels are securely in place prior to rigging.
Loose unit panels could result in equipment damage or per-
sonal injury.
Keep the unit upright and lift unit using a sling. Use card-
board or padding under the sling, and spreader bars to prevent
sling damage to the unit. See Fig. 3. See Fig. 2 for center of
gravity reference. Install the unit so that the coil does not face
into prevailing winds. If this is not possible and constant winds
above 25 mph are expected, use accessory wind baffle. See
installation instructions provided with the accessory kit.
NOTE: Accessory wind baffles should be used on all units
with accessory low ambient temperature control.
Field-fabricated snow or ice stands may be used to raise unit
when operation will be required during winter months. Units
may also be wall mounted using the accessory wall-mounting
kit.
FILTER DRIER — The filter drier must be replaced whenev-
er the refrigeration system is exposed to the atmosphere. See
Fig. 4 for filter drier installation.
NOTE: Arrow on AccuRater body points in free flow direction, away from the
indoor coil.
Fig. 3 — Lifting Unit with Sling
Step 3 — Complete Refrigerant Piping Con-
nections — Outdoor units may be connected to indoor
units using field-supplied tubing of refrigerant grade and condi-
tion. See Tables 1A and 1B for correct line sizes. Do not use
less than 10 ft of interconnecting tubing.
38HDF018-036
DO NOT BURY MORE THAN 36 IN. OF REFRIGER-
ANT PIPE IN THE GROUND. If any section of pipe is
buried, there must be a 6-in. vertical rise to the valve
connections on the outdoor unit. If more than the
recommended length is buried refrigerant may migrate to
cooler, buried section during extended periods of system
shutdown. This causes refrigerant slugging and could
possibly damage the compressor at start-up.
38HDR018-060
Fig. 4 — AccuRater (Bypass Type) Metering
Device Components
3
Only use factory specified liquid-line filter driers with rated
working pressures less than 600 psig.
NOTE: Do not install a suction-line filter drier in liquid line.
To avoid damage while brazing, service valves should be
wrapped with a heat-sinking material such as a wet cloth.
MAKE PIPING SWEAT CONNECTIONS — Remove plastic
caps from liquid and suction service valves. Use refrigerant
grade tubing. Service valves are closed from the factory and are
ready for brazing. After wrapping the service valve with a wet
cloth, the tubing set can be brazed to the service valve using ei-
ther silver bearing or non-silver bearing brazing material. Con-
sult local code requirements. Refrigerant tubing and the indoor
coil are now ready for leak testing.
When brazing tubing sets to the service valves, a brazing
shield MUST be used to prevent damage to the painted unit
surface.
NOTE: Unit is shipped with R-410A factory charge indicated
on nameplate.
Pass nitrogen or other inert gas through piping while braz-
ing to prevent formation of copper oxide.
PROVIDE SAFETY RELIEF — A fusible plug is located in
unit suction line; do not cap this plug. If local code requires
additional safety devices, install as directed.
Table 1A — 38HDF018-036 Physical Data
UNIT 38HDF
NOMINAL CAPACITY (Tons)
OPERATING WEIGHT (lb)
REFRIGERANT TYPE
METERING DEVICE
018
1.5
166
024
2.0
176
030
2.50
187
036
3.0
250
R-410A
AccuRater (Located at Fan Coil)
5.0
CHARGE (lb)*
4.8
5.3
7.1
OUTDOOR FAN
Rpm/Cfm
Diameter (in.)
No. Blades
Motor (hp)
840/1720
840/1720
840/1720
850/1720
18
3
18
3
18
3
24
3
1
/
1
/
1
/
1
/
8
8
8
4
OUTDOOR COIL
Face Area (sq ft)
No. Rows
5.82
2
20
7.27
3
20
7.27
3
20
12.1
2
20
FPI
HIGH PRESSURE SWITCH
Cut-In (psig)
Cutout (psig)
420 25
650 10
420 25
650 10
420 25
650 10
420 25
650 10
LOW PRESSURE SWITCH
Cut-In (psig)
Cutout (psig)
45 25
45 25
45 25
45 25
20
5
20
5
20
5
20
5
REFRIGERANT LINES
Connection Type
Liquid Line (in.) OD
Vapor Line (in.) OD
Max Length (ft)
Sweat
3
5
3
5
3
3
3
3
/
/
/
/
/
/
/
/
8
8
8
8
8
8
4
4
200
65
150
200
65
150
200
65
150
200
65
150
Max Lift (ft)
Max Drop (ft)
COMPRESSOR
Type
Scroll
Model
ZP16K5E-PFV
25.0
ZP21K5E-PFV
25.0
ZP25K5E-PFV
ZP34K5P-PFV
42.0
Oil Charge (POE - oz)
Accumulator
25.0
Yes
CONTROLS
Fusible Plug (F)
Control Voltage†
210
24 vac
208/230 v, Single and 3 Phase,
460 v, 3 Phase
System Voltage
208/230 v
208/230 v
208/230 v
FINISH
Gray
LEGEND
FPI — Fins Per Inch
POE — Polyol Ester
*Unit shipped with full factory charge. See ARI (Air Conditioning and
Refrigeration Institute) capacity table for proper charge and piston
for each fan coil type.
†24 v and a minimum of 40 va is provided in the fan coil unit.
4
Table 1B — 38HDR018-060 Physical Data
UNIT 38HDR
NOMINAL CAPACITY (Tons)
OPERATING WEIGHT (lb)
REFRIGERANT TYPE
METERING DEVICE
018
1.5
166
024
2.0
176
030
2.50
250
036
3.0
250
048
4.0
278
060
5.0
306
R-410A
AccuRater (Located at Fan Coil)
CHARGE (lb)*
6.3
6.5
10.0
8.9
12.0
12.2
OUTDOOR FAN
Rpm/Cfm
Diameter (in.)
No. Blades
Motor (hp)
840/1720
840/1720
850/3900
850/3900
850/3900
850/3900
18
3
18
3
24
3
18
3
24
3
24
3
1
/
1
/
1
/
1
/
1
/
1
/
8
8
4
4
4
4
OUTDOOR COIL
Face Area (sq ft)
No. Rows
5.8
2
20
7.3
3
20
12.1
2
20
12.1
2
20
14.1
3
20
14.1
3
20
FPI
HIGH PRESSURE SWITCH
Cut-In (psig)
Cutout (psig)
420 25
650 10
420 25
650 10
420 25
650 10
420 25
650 10
420 25
650 10
420 25
650 10
LOW PRESSURE SWITCH
Cut-In (psig)
Cutout (psig)
45 25
45 25
45 25
45 25
45 25
45 25
20
5
20
5
20
5
20
5
20
5
20
5
REFRIGERANT LINES
Connection Type
Liquid Line (in.) OD
Vapor Line (in.) OD
Max Length (ft)
Sweat
Scroll
3
5
3
5
3
3
3
3
3
7
3
/
/
/
/
/
/
/
/
/
/
/
8
8
8
8
8
8
8
8
7/88†
200
65
4
4
200
200
200
65
150
200
65
150
200
Max Lift (ft)
65
65
65
Max Drop (ft)
150
150
150
150
COMPRESSOR
Type
Model
Oil Charge (POE - oz)
Crankcase Heater (watts)
Accumulator
ZP16K5E-PFV ZP21K5E-PFV ZP25K5E-PFV ZPZ9K5E-PFV ZP42K5E-PFV ZP51K5E-PFV
25.0
—
25.0
—
25.0
40
25.0
40
42.0
40
42.0
40
Yes
CONTROLS
Fusible Plug (F)
Control Voltage**
System Voltage
210
24 vac
208/230 v
208/230 v
208/230 v
208/230 v, Single and 3 Phase, 460 v, 3 Phase
FINISH
Gray
LEGEND
FPI — Fins Per Inch
POE — Polyol Ester
*Unit shipped with full factory charge. See ARI (Air Conditioning
and Refrigeration Institute) capacity table for proper charge and
piston for each fan coil type.
7
†Valve connection size is
/
inch. Recommended line size is
8
11/8 inches.
**24 v and a minimum of 40 va is provided in the fan coil unit.
5
NOTE: For wire runs up to 50 ft, use no. 18 AWG (American
Wire Gage) insulated wire. For 50 to 75 ft, use no. 16 AWG
insulated wire. For over 75 ft, use 14 AWG insulated wire.
Step 4 — Make Electrical Connections
NOTE: All wiring must conform to NEC and local codes.
Unit cabinet must have an uninterrupted, unbroken electri-
cal ground to minimize the possibility of personal injury if
an electrical fault should occur. This ground may consist of
electrical wire connected to unit ground lug in control com-
partment, or conduit approved for electrical ground when
installed in accordance with NEC, and local electrical
codes. Failure to follow this warning could result in the
installer being liable for the personal injury of others.
NOTE: Operating unit on improper line voltage constitutes
abuse and could affect Carrier warranty. See Tables 2 and 3.
Do not install unit in a system where voltage may fluctuate
above or below permissible limits.
See Tables 2 and 3 for recommended fuse sizes. When mak-
ing electrical connections, provide clearance at the unit for re-
frigerant piping connections.
NOTE: The 38HDF units are supplied with a 24-v control
transformer. The 38HDR units use the control transformer
supplied with the matched indoor unit.
POWER WIRING — Unit is factory wired for voltage shown
on nameplate. Provide adequate, fused disconnect switch
within sight from unit, readily accessible, but out of reach of
children. Provision for locking the switch open (off) is advis-
able to prevent power from being turned on while unit is being
serviced. Disconnect switch, fuses, and field wiring must
comply with the NEC and local code requirements. Use copper
wire only between the disconnect switch and unit. Use
minimum 60 C wire for the field power connection.
Unit failure as a result of operation on improper line
voltage or excessive phase imbalance constitutes abuse and
may cause damage to electrical components. Such opera-
tion would invalidate any applicable Carrier warranty.
Before performing service or maintenance, be sure indoor
unit main power switch is turned OFF and indoor blower
has stopped. Failure to do so may result in electrical shock
or injury from rotating fan blades.
Route power wires through the opening in unit side panel
and connect in the unit control box as shown on the unit label
diagram and Fig. 6 and 7. Unit must be grounded.
CONNECTIONS TO DUCT-FREE FAN COIL UNITS —
The 38HDR units are designed for easy match-up to 40QA
duct free fan coils. This unit provides 24 v power for the out-
door unit from the fan coil. Connect the Y and C terminals of
the indoor unit to the Y and C terminals.
CONTROL CIRCUIT WIRING — Control voltage is 24 v
(40 va minimum). See Fig. 5 and unit label diagram for field-
supplied wiring details. Route control wire through opening in
unit side panel to connection in unit control box.
38HDR UNITS
38HDF UNITS
NOTE: For more information see schematic inside unit.
Fig. 5 — Typical Control Circuit Connections
6
Table 2 — 38HDF Electrical Data
VOLTAGE RANGE*
COMPRESSOR
OUTDOOR FAN MOTOR
38HDF
MIN CKT
AMPS
FUSE/HACR
BKR AMPS
V-PH-Hz
UNIT SIZE
Min
187
187
187
187
187
414
Max
253
253
253
253
253
506
RLA
10.0
14.3
15.7
20.0
14.7
6.6
LRA
48.0
58.3
73.0
112.0
88.0
44.0
FLA
0.80
0.80
0.80
1.45
1.45
0.80
NEC Hp
0.125
0.125
0.125
0.25
kW Out
0.09
0.09
0.09
0.19
018
024
030
208/230-1-60
208/230-1-60
208/230-1-60
208/230-1-60
208/230-3-60
460-3-60
13.3
18.7
20.4
26.5
19.8
9.1
20
30
35
45
30
15
036
0.25
0.25
0.19
0.19
LEGEND
Determine maximum deviation from average voltage:
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
FLA
— Full Load Amps
HACR — Heating, Air Conditioning, Refrigeration
LRA — Locked Rotor Amps
NEC — National Electrical Code
RLA — Rated Load Amps (Compressor)
Maximum deviation is 7 v.
Determine percentage of voltage imbalance:
*Permissible limits of the voltage range at which unit will operate
satisfactorily.
7
% Voltage Imbalance = 100 x
457
NOTES:
1. Control circuit is 24 v on all units and requires an external power
source.
= 1.53%
2. All motors and compressors contain internal overload protection.
3. In compliance with NEC (U.S.A. Standard) requirements for mul-
timotor and combination load equipment (refer to NEC Articles
430 and 440), the overcurrent protective device for the unit shall
be fuse or HACR breaker.
This amount of phase imbalance is satisfactory as it is below the
maximum allowable of 2%.
IMPORTANT: Contact your local electric utility company immedi-
ately if the supply voltage phase imbalance is more than 2%.
4. Motor RLA values are established in accordance with UL (Under-
writers’ Laboratories) Standard 465 (U.S.A. Standard).
5. 38HDF,HDR018-030 units are only available in single-phase
voltage.
6. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply volt-
age is greater than 2%. Use the following formula to determine
the percentage of voltage imbalance:
max voltage deviation from average voltage
= 100 x
average voltage
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
452 + 464 + 455
Average Voltage =
3
1371
3
=
=
457
7
Table 3 — 38HDR Electrical Data
VOLTAGE RANGE*
COMPRESSOR
OUTDOOR FAN MOTOR
38HDR
MIN CKT
AMPS
FUSE/HACR
BKR AMPS
V-PH-Hz
UNIT SIZE
Min
187
187
187
187
187
414
187
187
414
187
187
414
Max
253
253
253
253
253
506
253
253
506
253
253
506
RLA
10.0
14.3
15.7
15.7
10.4
6.3
LRA
48.0
58.3
64.0
77.0
88.0
38.0
117.0
83.1
41.0
134.0
110.0
52.0
FLA
0.80
0.80
1.45
1.45
1.45
0.80
1.45
1.45
0.80
1.45
1.45
0.80
NEC Hp
0.125
0.125
0.25
0.25
0.25
0.25
0.25
0.25
0.25
kW Out
0.09
0.09
0.19
0.19
0.19
0.19
0.19
0.19
0.19
0.19
0.19
0.19
018
024
030
208/230-1-60
208/230-1-60
208/230-1-60
208/230-1-60
208/230-3-60
460-3-60
208/230-1-60
208/230-3-60
460-3-60
13.3
18.7
21.1
21.1
14.5
8.7
31.8
21.0
9.4
20
30
35
35
20
15
55
35
15
65
40
20
036
048
060
24.3
15.6
6.9
208/230-1-60
208/230-3-60
460-3-60
29.4
17.8
8.6
0.25
0.25
0.25
38.2
23.7
11.6
LEGEND
Determine maximum deviation from average voltage:
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
FLA
— Full Load Amps
HACR — Heating, Air Conditioning, Refrigeration
LRA — Locked Rotor Amps
NEC — National Electrical Code
RLA — Rated Load Amps (Compressor)
Maximum deviation is 7 v.
Determine percentage of voltage imbalance:
*Permissible limits of the voltage range at which unit will operate
satisfactorily.
7
% Voltage Imbalance = 100 x
457
NOTES:
1. Control circuit is 24 v on all units and requires an external power
source.
= 1.53%
2. All motors and compressors contain internal overload protection.
3. In compliance with NEC (U.S.A. Standard) requirements for mul-
timotor and combination load equipment (refer to NEC Articles
430 and 440), the overcurrent protective device for the unit shall
be fuse or HACR breaker.
This amount of phase imbalance is satisfactory as it is below the
maximum allowable of 2%
IMPORTANT: Contact your local electric utility company immedi-
ately if the supply voltage phase imbalance is more than 2%.
4. Motor RLA values are established in accordance with UL (Under-
writers’ Laboratories) Standard 465 (U.S.A. Standard).
5. 38HDF,HDR018-030 units are only available in single-phase
voltage.
6. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply volt-
age is greater than 2%. Use the following formula to determine
the percentage of voltage imbalance:
max voltage deviation from average voltage
= 100 x
average voltage
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v
BC = 464 v
AC = 455 v
452 + 464 + 455
Average Voltage =
3
1371
3
=
=
457
8
9
10
START-UP
Preliminary Checks
Internal Current and Temperature Sensitive
Overload — The control resets automatically when
internal compressor motor temperature drops to a safe level
(overloads may require up to 45 minutes to reset). When an
internal overload is suspected of being open, check by using an
ohmmeter or continuity tester.
1. Check that all internal wiring connections are tight and
that all barriers, covers, and panels are in place.
2. Field electrical power source must agree with unit name-
plate rating.
3. All service valves must be open.
4. Belly-band crankcase heater must be tight on compressor
crankcase for those units with belly-band heaters.
Pumpdown Procedure — The system may be pumped
down in order to make repairs on the low side without losing
complete refrigerant charge.
Leak Test — Field piping and fan coil must be leak tested
by pressure method. Use R-410A at approximately 25 psig
backed up with an inert gas to a total pressure not to exceed
245 psig.
Never open system to atmosphere while it is under a vac-
uum. Equipment damage may result.
Leak detectors should be designed to detect HFC (hydro-
fluorocarbon) refrigerant.
When system must be opened for service, recover refriger-
ant, break vacuum with dry nitrogen before opening system.
Evacuate and Dehydrate — Field piping and fan coil
1. Attach pressure gage to suction service valve gage port.
2. Frontseat the liquid/mixed phase line valve.
must be evacuated and dehydrated.
Charge System — Release charge into system by open-
ing (backseating) liquid and suction line service valves. Refer
to separate indoor unit installation instructions for the required
total system charge when connected to 25 ft of tubing.
The 38HDC unit coils hold only the factory-designated
amount of refrigerant. Additional refrigerant may cause
units to relieve pressure through the compressor internal
pressure relief valve (indicated by a sudden rise of suction
pressure) before suction pressure reaches 5 psig. If this
occurs, shut off unit immediately then frontseat the suction
valve and remove and recover excess refrigerant following
accepted practices. Equipment damage may result.
To Start Unit — Be sure that the field disconnect is
closed. Set room thermostat below ambient temperature. Oper-
ate unit for 15 minutes, then check system refrigerant charge.
See Refrigerant Charging section on page 12.
NOTE: When using in conjunction with 40QA or 40QK fan
coils, refer to start-up instructions included with fan coil for
correct start-up procedures.
3. Start unit and run until suction pressure reaches 20 psig.
4. Shut unit off and frontseat suction valve.
SERVICE
5. Depressurize low side of unit and recover refrigerant
following accepted practices.
Before performing recommended maintenance, be sure
unit main power switch is turned off. Failure to do so may
result in electrical shock or injury from rotating fan blade.
High-Pressure Switch — The high-pressure switch,
located on discharge line, protects against high discharge
pressures caused by such events as overcharge, condenser-fan
motor failure, system restriction, etc. It opens on pressure rise at
about 650 10 psig. If system pressures go above this setting
during abnormal conditions, the switch opens.
Outdoor Fan — A reinforced wire mount holds the out-
door fan assembly in position. See Fig. 8 for proper mounting
position.
DO NOT attempt to simulate these system abnormalities
— high pressures pose a serious safety hazard.
The high-pressure switch is checked with an ohmmeter. If
system pressure is below 625 psig switch shows continuity.
Crankcase Heater — The crankcase heater prevents
refrigerant migration and compressor oil dilution during
shutdown when compressor is not operating. If the crankcase
heater is deenergized for more than 6 hours, both compressor
service valves must be closed.
38HDF UNIT SIZE, in.
018-030
036
NOTE: Crankcase heaters are only available on 38HDR030-
060 units.
The crankcase heater is powered by the high-voltage power
of the unit. It is connected across the line side of the contactor
and is thermostatically controlled.
0.433
0
38HDR UNIT SIZE, in.
018,024
0.433
030,036
048,060
0
0
Fig. 8 — Condenser-Fan Mounting Positions
Use extreme caution when troubleshooting this device, as
line voltage is continually present. Serious personal injury
could result.
High-Pressure Relief Valve — The high-pressure re-
lief valve is located in the compressor. The relief valve opens at
a pressure differential of approximately 550 to 625 50 psid
between suction (low side) and discharge (high side) to allow
pressure equalization.
11
To troubleshoot:
All units are shipped with the refrigerant charge listed on
the nameplate. See indoor unit Installation Instructions for ad-
ditional charge requirements.
NOTE: For 38HDF units only, charge to nameplate. See the
indoor unit owner’s manual for any additional charge
requirements.
Refer to Table 4 and consider the following when working
with Puron® refrigerant:
• Puron refrigerant cylinders are rose colored.
1. Apply voltmeter across crankcase heater leads to see if
heater voltage is on. Do not touch heater. Carefully feel
area around crankcase heater; if warm, crankcase heater
is functioning.
2. With power off and heater leads disconnected, check
across leads with ohmmeter. Do not look for a specific re-
sistance reading. Check for resistance or an open circuit,
and change heater if an open circuit is detected.
• Recovery cylinder service pressure rating must be
400 psig, DOT (Department of Transportation) 4BA400
or DOT BW400.
• Puron systems should be charged with liquid refrigerant.
Use a commercial type metering device in the manifold
hose when charging into suction line with compressor
operating.
• Manifold sets should be 700 psig high side and 180 psig
low side with 550 psig low-side retard.
• Use hoses with 700 psig service pressure rating.
Service Valves — The service valves in the outdoor unit
come from the factory frontseated. This means the refrigerant
charge is isolated from the line-set connection ports. To prevent
damage to the valve, use a wet cloth or other accepted heat sink
material on the valve before brazing.
The service valve cannot be field repaired, therefore, only a
complete valve or valve stem seal and service port caps are
available for replacement.
Refrigerant Charging
• Puron refrigerant, as with other HFCs, is only compatible
with POE oils.
• Vacuum pumps will not remove moisture from oil.
• Polyol Ester oils absorb moisture rapidly. Do not expose
oil to atmosphere.
To prevent personal injury, wear safety glasses and gloves
when handling refrigerant. Do not overcharge system —
this can cause compressor flooding.
• Polyol Ester oils may cause damage to certain plastics
and roofing materials.
• Wrap all filter driers and service valves with wet cloth
when brazing.
• A factory approved, liquid-line filter drier is required on
every unit.
• Do not use a TXV (thermostatic expansion valve)
designed for use with R-22 refrigerant. Refer to separate
indoor unit installation instructions for more details.
• If using a suction line drier, do not leave in place for
more than 72 hours.
Service valves must be fully backseated to close service
port. There is no Schrader valve at the service port, and
failure to backseat the valve could result in loss of system
charge or personal injury.
NOTE: Do not vent or depressurize unit refrigerant to atmo-
sphere. Remove and recover refrigerant following accepted
practices.
12
Table 4 — Pressure vs. Temperature Chart — Puron® Refrigerant (R-410A)
PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE PRESSURE TEMPERATURE
PSIG
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
°F
–37.7
PSIG
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
152
154
156
158
160
162
164
166
168
170
172
174
176
178
180
182
184
186
188
190
192
194
196
198
200
202
204
206
208
210
212
214
°F
PSIG
216
218
220
222
224
226
228
230
232
234
236
238
240
242
244
246
248
250
252
254
256
258
260
262
264
266
268
270
272
274
276
278
280
282
284
286
288
290
292
294
296
298
300
302
304
306
308
310
312
314
316
°F
PSIG
318
320
322
324
326
328
330
332
334
336
338
340
342
344
346
348
350
352
354
356
358
360
362
364
366
368
370
372
374
376
378
380
382
384
386
388
390
392
394
396
398
400
402
404
406
408
410
412
414
416
418
°F
PSIG
420
422
424
426
428
430
432
434
436
438
440
442
444
446
448
450
452
454
456
458
460
462
464
466
468
470
472
474
476
478
480
482
484
486
488
490
492
494
496
498
500
502
504
506
508
510
512
514
516
518
520
°F
PSIG
522
524
526
528
530
532
534
536
538
540
544
548
552
556
560
564
568
572
576
580
584
588
592
596
600
604
608
612
616
620
624
628
632
636
640
644
648
652
656
660
664
668
672
676
680
684
688
692
696
°F
37.8
38.7
39.5
40.5
41.3
42.2
43.0
43.8
44.7
45.5
46.3
47.1
47.9
48.7
49.5
50.3
51.1
51.8
52.5
53.3
54.0
54.8
55.5
56.2
57.0
57.7
58.4
59.0
59.8
60.5
61.1
61.8
62.5
63.1
63.8
64.5
65.1
65.8
66.4
67.0
67.7
68.3
68.9
69.5
70.1
70.7
71.4
72.0
72.6
73.2
73.8
74.3
74.9
75.5
76.1
76.7
77.2
77.8
78.4
78.9
79.5
80.0
80.6
81.1
81.6
82.2
82.7
83.3
83.8
84.3
84.8
85.4
85.9
86.4
86.9
87.4
87.9
88.4
88.9
89.4
89.9
90.4
90.9
91.4
91.9
92.4
92.8
93.3
93.8
94.3
94.8
95.2
95.7
96.2
96.6
97.1
97.5
98.0
98.4
98.9
99.3
99.7
100.2
100.7
101.1
101.6
102.0
102.4
102.9
103.3
103.7
104.2
104.6
105.1
105.4
105.8
106.3
106.6
107.1
107.5
107.9
108.3
108.8
109.2
109.6
110.0
110.4
110.8
111.2
111.6
112.0
112.4
112.6
113.1
113.5
113.9
114.3
114.7
115.0
115.5
115.8
116.2
116.6
117.0
117.3
117.7
118.1
118.5
118.8
119.2
119.6
119.9
120.3
120.7
121.0
121.4
121.7
122.1
122.5
122.8
123.2
123.5
123.9
124.2
124.6
124.9
125.3
125.6
126.0
126.3
126.6
127.0
127.3
127.7
128.0
128.3
128.7
129.0
129.3
129.7
130.0
130.3
130.7
131.0
131.3
131.6
132.0
132.3
132.6
132.9
133.3
133.6
133.9
134.0
134.5
134.8
135.2
135.5
135.8
136.1
136.4
136.7
137.0
137.3
137.6
137.9
138.3
138.6
138.9
139.2
139.5
139.8
140.1
140.4
141.0
141.6
142.1
142.7
143.3
143.9
144.5
145.0
145.6
146.2
146.7
147.3
147.9
148.4
149.0
149.5
150.1
150.6
151.2
151.7
152.3
152.8
153.4
153.9
154.5
155.0
155.5
156.1
156.6
157.1
157.7
158.2
158.7
159.2
159.8
160.3
160.8
161.3
161.8
–34.7
–32.0
–29.4
–26.9
–24.5
–22.2
–20.0
–17.9
–15.8
–13.8
–11.9
–10.1
–8.3
–6.5
–4.5
–3.2
–1.6
0.0
1.5
3.0
4.5
5.9
7.3
8.6
10.0
11.3
12.6
13.8
15.1
16.3
17.5
18.7
19.8
21.0
22.1
23.2
24.3
25.4
26.4
27.4
28.5
29.5
30.5
31.2
32.2
33.2
34.1
35.1
35.5
36.9
3. Refer to Table 5. Find the temperature point at which the
required subcooling temperature intersects the measured
liquid line pressure.
Subcooling Method — For 38HDR units only, the sub-
cooling method is used to check and adjust charge during the
cooling season. Refer to Table 5 and the following procedure:
4. If the measured liquid line temperature does not agree
with the required liquid line temperature, ADD refriger-
ant to lower the temperature, or REMOVE refrigerant to
raise the temperature (allow a tolerance of 3° F).
NOTE: For use with residential fan coils and the 40QA060
under ceiling unit only.
1. Operate unit a minimum of 15 minutes before checking
charge.
2. Measure liquid line temperature near liquid line service
valve, and measure the liquid pressure at the liquid line
service valve. Use a digital thermometer for all tempera-
ture measurements. DO NOT use mercury or dial-type
thermometers.
13
Table 5 — Subcooling Charging Table
Compressor Lockout Switch — The 38HDR units
are provided with a compressor lockout protective device. If
the compressor shuts down due to any safety device, a current
loop monitoring the compressor current senses no current flow.
The unit will lock out until the control power is interrupted to
reset the lockout. Determine the reason for the safety trip. To
restart, turn the thermostat to the OFF position and then set the
thermostat to an operating position.
REQUIRED LIQUID LINE
TEMPERATURE (F)
Required Subcooling
Temperature (F)
LIQUID PRESSURE
AT SERVICE VALVE
(psig)
8
58
10
56
12
54
14
52
16
50
18
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
189
195
202
208
215
222
229
236
243
251
259
266
274
283
291
299
308
317
326
335
345
354
364
374
384
395
406
416
427
439
450
462
474
486
499
511
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
MAINTENANCE
Before performing recommended maintenance, be sure
unit main power switch is turned off. Failure to do so may
result in electric shock or injury from rotating fan blade.
Lubrication
COMPRESSOR — Compressor contains factory oil charge;
replace oil when lost. Use Mobile 3MA-POE oil.
Cleaning Coils — Coil should be washed out with water
or blown out with compressor air. Note that the blow-thru
design causes dirt and debris to build up on the inside of the
coils.
Clean coil annually or as required by location and outdoor
air conditions. Inspect coil monthly and clean as required. Fins
are not continuous through coil sections. Dirt and debris may
pass through first section, become trapped between the row of
fins and restrict condenser airflow. Use a flashlight to deter-
mine if dirt or debris has collected between coil sections. Clean
coil as follows:
92
94
96
98
90
92
94
96
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
96
98
1. Turn off unit power.
2. Using a garden hose or other suitable equipment, flush
coil from the outside to remove dirt. Be sure to flush all
dirt and debris from drain holes in base of unit. Fan
motors are waterproof.
100
102
104
106
108
110
112
114
116
118
TROUBLESHOOTING
See Fig. 9 for troubleshooting information.
14
Fig. 9 — Troubleshooting the Cooling Cycle
15
Copyright 2006 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 02-38HD0001-SI Printed in U.S.A. Form 38HD-4SI Pg 16 2-06A 1-06 Replaces: 38HDC-3SI
Book 1
4
Tab 3e 2f
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