Carrier 38HDF018-036, 38HDR018-060 User Manual
Installation, Start-Up and
Service Instructions
CONTENTS
Page
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
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
38HDF018-036
Duct Free Condensing Units
38HDR018-060
Ducted Condensing Units
Puron® (R-410A) refrigerant systems operate at higher
pressures than standard R-22 systems. Do not use R-22 service equipment or components on Puron refrigerant equipment. If service equipment is not rated for Puron refrigerant,
equipment damage or personal injury may result.
INSTALLATION
Step 1 — Complete Pre-Installation Checks
UNPACK UNIT (See Fig. 1) — Move the unit to final location. Remove unit from carton, being careful not to damage
service valves and grilles.
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 literature, 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.
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. Electrical 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.
Book 1 4
Ta b 3 e 2 f
Catalog No. 02-38HD0001-SI Printed in U.S.A. Form 38HD-4SI Pg 1 1-06 Replaces: 38HDC-3SI
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 residential fan coils. Refer to separate indoor unit literature for
more information.
Fig. 1 — 38HDF,HDR Unit
Support Feet
15.88 166 75.3
15.88 176 79.8
19.05 187 84.8
19.05 250 113.4
15.88 166 75.8
15.88 176 79.8
19.05 187 84.8
19.05 250 113.4
22.22 278 126.1
4
/
030
3
4
/
036
7
8
/
048
22.22 306 138.8
8
/
7
060
M OPERATING WT
8
8
4
4
8
/
030
3
/
036
5
/
018
5
8
/
024
3
/
/
5
5
3
in. mm lb kg
018
024
DIMENSIONS
MINIMUM MOUNTING PAD
ft-in. mm
UNIT SIZE
38HDF
38HDR
UNIT SIZE
CHASSIS SIZES 0 & .6 1′-11″ x3′-6″ 584.2 x 1066.8
CHASSIS SIZES 1 & 1.6 2′-0″ x4′-2″ 609.6 x 1270
on coil side and coil end, and 3 feet minimum clearance on compressor
end and fan side. With fan facing wall, allow 8 in. minimum clearance on
fan side and coil end, and 3 feet minimum clearance on compressor end
and coil side. With multi-unit application, arrange units so discharge of one
″
″
2
2
/
/
1
1
″ 0′-6″
″ 0′-6″
″ 0′-6
16
/
/
15
15
″ 0′-2
″ 0′-2
4
/
/
1
5
″ 0′-11
″ 0′-11
8
/
/
5
3
″ 0′-6
16
16
16
/
/
7
7
″ 0′-3
″ 0′-3
8
8
8
/
/
7
7
″ 1′-3
″ 1′-6
4
8
2
/
/
1
1
″ 0′-8
″ 0′-8
16
2
/
/
1
11
NOTES:
1. Required clearances: with coil facing wall, allow 6 in. minimum clearance
does not enter inlet of another.
2. Dimensions in parenthesis are in millimeters.
3. Center of Gravity .
ABCD E FG H J KL NP
SIZE
CHASSIS
(Reference)
″ 1′-1
″ 1′-2
16
/
16
/
1
1
″ 2′-4″ 1′-2″ 0′-6
″ 1′-10″ 1′-1″ 0′-6
8
/
/
1
1
″ 1′-5
″ 1′-11
16
/
/
3
3
″ 1′-5
″ 1′-5
16
/
/
7
7
″ 1′-4″ 1′-11
″ 1′-4″ 1′-11
16
/
/
9
9
″ 1′-2
″ 1′-2
16
/
/
15
15
″ 3′-0
″ 3′-0
8
/
/
1
1
2′-1
2′-7
(638.2) (938.2) (369.9) (406.4) (595.3) (436.6) (435) (559.1) (330.2) (168.3) (285.8) (75) (152.4)
″ 3′-4
″ 2′-10
8
16
16
16
16
8
16
16
/
/
3
13
″ 2′-5
″ 2′-1
8
8
/
/
5
5
″ 1′-7
″ 1′-7
2
2
/
/
1
1
″ 2′-6
″ 2′-6
16
16
/
/
7
7
″ 1′-6
″ 1′-6
16
16
/
/
1
1
″ 1′-5
″ 1′-5
16
16
/
/
9
9
″ 3′-8
″ 3′-8
16
16
/
/
3
3
(790.6) (938.2) (369.9) (406.4) (595.3) (436.6) (587.4) (711.5) (355.6) (171.5) (295.3) (75) (152.4)
(1097) (1131.9) (433.4) (468.3) (774.7) (498.5) (893.4) (1017.9) (354.2) (215.9) (479.4) (88) (165.4)
(944.6) (1131.9) (433.4) (468.3) (774.7) (498.5) (741) (865.5) (347.7) (206.4) (403.2) (88) (165.4)
3′-1
3′-7
(FIELD PROVIDED AND INSTALLED)
Fig. 2 — 38HDF,HDR Unit Dimensions
38HDR
Unit Size
UNIT MODELS
018 018 0
38HDF
Unit Size
024,030 024 0.6
— 048,060 1.6
036 030,036 1.0
NOTE: Dimensions shown in feet-inches. Dimensions in ( ) are millimeters.
2
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 tubing from structure.
RIGGING
Be sure unit panels are securely in place prior to rigging.
Loose unit panels could result in equipment damage or personal injury.
Keep the unit upright and lift unit using a sling. Use cardboard or padding under the sling, and spreader bars to prevent
sling damage to the unit. See Fig. 3. See Fig. 2 for center of
gravity reference. Install the unit so that the coil does not face
into prevailing winds. If this is not possible and constant winds
above 25 mph are expected, use accessory wind baffle. See
installation instructions provided with the accessory kit.
NOTE: Accessory wind baffles should be used on all units
with accessory low ambient temperature control.
Field-fabricated snow or ice stands may be used to raise unit
when operation will be required during winter months. Units
may also be wall mounted using the accessory wall-mounting
kit.
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, interconnecting 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 transmitted to structure. Leave some slack in refrigerant tubes between
structure and outdoor unit to absorb vibration. Refer to separate
indoor unit installation instructions for additional information.
CHECK ACCURATER CONTROL — The correct AccuRater (bypass type) refrigerant control is required for system
capacity optimization. An AccuRater device with fieldreplaceable 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 instructions. After system installation is complete, see the Refrigerant
Charging section on page 12 to check and/or adjust refrigerant
charge.
FILTER DRIER — The filter drier must be replaced whenever the refrigeration system is exposed to the atmosphere. See
Fig. 4 for filter drier installation.
Fig. 3 — Lifting Unit with Sling
Step 3 — Complete Refrigerant Piping Connections —
units using field-supplied tubing of refrigerant grade and condition. See Tables 1A and 1B for correct line sizes. Do not use
less than 10 ft of interconnecting tubing.
DO NOT BURY MORE THAN 36 IN. OF REFRIGERANT 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.
Outdoor units may be connected to indoor
NOTE: Arrow on AccuRater body points in free flow direction, away from the
indoor coil.
38HDF018-036
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.
MAKE PIPING SWEAT CONNECTIONS — Remove plastic
To avoid damage while brazing, service valves should be
wrapped with a heat-sinking material such as a wet cloth.
caps from liquid and suction service valves. Use refrigerant
grade tubing. Service valves are closed from the factory and are
ready for brazing. After wrapping the service valve with a wet
cloth, the tubing set can be brazed to the service valve using either silver bearing or non-silver bearing brazing material. Consult local code requirements. Refrigerant tubing and the indoor
coil are now ready for leak testing.
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 018 024 030 036
NOMINAL CAPACITY (Tons) 1.5 2.0 2.50 3.0
OPERATING WEIGHT (lb) 166 176 187 250
REFRIGERANT TYPE R-410A
METERING DEVICE AccuRater (Located at Fan Coil)
CHARGE (lb)* 4.8 5.3 5.0 7.1
OUTDOOR FAN
Rpm/Cfm 840/1720 840/1720 840/1720 850/1720
Diameter (in.) 18 18 18 24
No. Blades 333 3
Motor (hp)
1
/
8
OUTDOOR COIL
Face Area (sq ft) 5.82 7.27 7.27 12.1
No. Rows 233 2
FPI 20 20 20 20
HIGH PRESSURE SWITCH
Cut-In (psig) 420 ± 25 420 ± 25 420 ± 25 420 ± 25
Cutout (psig) 650 ± 10 650 ± 10 650 ± 10 650 ± 10
LOW PRESSURE SWITCH
Cut-In (psig) 45 ± 25 45 ± 25 45 ± 25 45 ± 25
Cutout (psig) 20 ± 5 20 ± 5 20 ± 5 20 ± 5
REFRIGERANT LINES
Connection Type Sweat
Liquid Line (in.) OD
Vapor Line (in.) OD
Max Length (ft) 200 200 200 200
Max Lift (ft) 65 65 65 65
3
/
8
5
/
8
Max Drop (ft) 150 150 150 150
COMPRESSOR
Type Scroll
Model ZP16K5E-PFV ZP21K5E-PFV ZP25K5E-PFV ZP34K5P-PFV
Oil Charge (POE - oz) 25.0 25.0 25.0 42.0
Accumulator Ye s
CONTROLS
Fusible Plug (F) 210
Control Voltage† 24 vac
System Voltage 208/230 v 208/230 v 208/230 v
FINISH Gray
LEGEND *Unit shipped with full factory charge. See ARI (Air Conditioning and
FPI — Fins Per Inch
POE — Polyol E st er
1
/
8
3
/
8
5
/
8
1
/
8
3
/
8
3
/
4
1
/
4
3
/
8
3
/
4
208/230 v, Single and 3 Phase,
460 v, 3 Phase
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 018 024 030 036 048 060
NOMINAL CAPACITY (Tons) 1.5 2.0 2.50 3.0 4.0 5.0
OPERATING WEIGHT (lb) 166 176 250 250 278 306
REFRIGERANT TYPE R-410A
METERING DEVICE AccuRater (Located at Fan Coil)
CHARGE (lb)* 6.3 6.5 10.0 8.9 12.0 12.2
OUTDOOR FAN
Rpm/Cfm 840/1720 840/1720 850/3900 850/3900 850/3900 850/3900
Diameter (in.) 18 18 24 18 24 24
No. Blades 333333
Motor (hp)
1
/
8
OUTDOOR COIL
Face Area (sq ft) 5.8 7.3 12.1 12.1 14.1 14.1
No. Rows 232233
FPI 20 20 20 20 20 20
HIGH PRESSURE SWITCH
Cut-In (psig) 420 ± 25 420 ± 25 420 ± 25 420 ± 25 420 ± 25 420 ± 25
Cutout (psig) 650 ± 10 650 ± 10 650 ± 10 650 ± 10 650 ± 10 650 ± 10
LOW PRESSURE SWITCH
Cut-In (psig) 45 ± 25 45 ± 25 45 ± 25 45 ± 25 45 ± 25 45 ± 25
Cutout (psig) 20 ± 5 20 ± 5 20 ± 5 20 ± 5 20 ± 5 20 ± 5
REFRIGERANT LINES
Connection Type Sweat
Liquid Line (in.) OD
Vapor Line (in.) OD
Max Length (ft) 200 200 200 200 200 200
3
/
8
5
/
8
Max Lift (ft) 65 65 65 65 65 65
Max Drop (ft) 150 150 150 150 150 150
COMPRESSOR
Type Scroll
Model ZP16K5E-PFV ZP21K5E-PFV ZP25K5E-PFV ZPZ9K5E-PFV ZP42K5E-PFV ZP51K5E-PFV
Oil Charge (POE - oz) 25.0 25.0 25.0 25.0 42.0 42.0
Crankcase Heater (watts) — — 40 40 40 40
Accumulator Ye s
CONTROLS
Fusible Plug (F) 210
Control Voltage** 24 vac
System Voltage 208/230 v 208/230 v 208/230 v 208/230 v, Single and 3 Phase, 460 v, 3 Phase
FINISH Gray
LEGEND *Unit shipped with full factory charge. See ARI (Air Conditioning
FPI — Fins Per Inch
POE — Polyol E st er
1
/
8
3
/
8
5
/
8
1
/
4
3
/
8
3
/
4
1
/
4
3
/
8
3
/
4
1
/
4
3
/
8
7
/
8
1
/
4
3
/
8
7
/8†
and Refrigeration Institute) capacity table for proper charge and
piston for each fan coil type.
†Valve connection size is
11/8inches.
7
/8inch. Recommended line size is
**24 v and a minimum of 40 va is provided in the fan coil unit.
5
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