Carrier 38HDL018-060 User Manual
Light Commercial Condensing Units
Installation, Start-Up and
Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS ...................1
INSTALLATION ..............................1-7
Step 1 — Complete Pre-Installation
Checks ....................................1
• UNPACK UNIT
• INSPECT SHIPMENT
• CONSIDER SYSTEM REQUIREMENTS
Step 2 — Rig and Mount Unit .................3
• MOUNTING ON GROUND
• MOUNTING ON ROOF
• RIGGING
Step 3 — Complete Refrigerant Piping
Connections ...............................3
• CHECK ACCURATERt CONTROL
• MAKE PIPING SWEAT CONNECTIONS
• PROVIDE SAFETY RELIEF
Step 4 — Make Electrical Connections ........4
• POWER WIRING
• CONTROL CIRCUIT WIRING
• CONNECTIONS TO DUCT-FREE
FAN COIL UNITS
Step 5 — Accessory Installation ..............4
START-UP ...................................7
SERVICE ...................................7-9
MAINTENANCE .............................10
TROUBLESHOOTING ........................11
SAFETY CONSIDERATIONS
Install and servicing air-conditioning equipment can be hazardous due to system pressure and electrical components. Only
trained and qualified service personnel should installor service air-conditioning equipment
Untrained personnel may 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 on tags and labels attached to unit.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for brazing operations. Have a
fire extinguisher available. Read these instructions thoroughly.Consult local building codes and National Electrical
Code (NEC, U.S.A. Standard) for special installation
requirements.
38HDL018-060
COOLING
Fig. 1 — 38HDL Condensing Unit
Before installing or servicing system, always turn off
main power to system. There maybe more than one disconnect switch. Turn off accessory heater power if
applicable. Electrical shock can cause personal injury.
Step 1 — Complete Pre-Installation Checks
UNPACK UNIT — Move unit to final location. Remove carton from unit, being careful not to damage service valves or
grilles.
INSPECT SHIPMENT — File claim with 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,
refrigerant piping, and servicing unit. See Fig. 1 and 2. Unit
can be mounted on a level pad directly on base legs or
mounted on raised pads at support points. See Fig. 2for center of gravity.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 3a 2a
PC 111 Catalog No. 563-899 Printed in U.S.A. Form 38HDL-1SI Pg 1 9-98 Replaces: New
UNIT
SIZE
38HDL
018 2-1
024 2-1
030 2-1
036 2-1
048 3-1
060 3-1
ABCDEFGHJKLM
OPERATING
WEIGHT
ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm lb kg
1
⁄8638.2 3-015⁄16938.2 1-29⁄16369.9 1-4 406.4 1-117⁄16595.3 1-53⁄16436.6 1-51⁄2444.5 1-81⁄8511.2 1-1 330.2 0-65⁄8168.3 0-111⁄4285.8 0-05⁄815.88 130 58.9
1
⁄8638.2 3-015⁄16938.2 1-29⁄16369.9 1-4 406.4 1-117⁄16595.3 1-53⁄16436.6 1-51⁄2444.5 1-81⁄8511.2 1-1 330.2 0-63⁄4171.5 0-115⁄8295.3 0-05⁄815.88 136 61.6
1
⁄8638.2 3-015⁄16938.2 1-29⁄16369.9 1-4 406.4 1-117⁄16595.3 1-53⁄16436.6 1-51⁄2444.5 1-81⁄8511.2 1-1 330.2 0-63⁄4171.5 0-115⁄8295.3 0-03⁄419.05 161 73.0
1
⁄8638.2 3-015⁄16938.2 1-29⁄16369.9 1-4 406.4 1-117⁄16595.3 1-53⁄16436.6 1-51⁄2444.5 1-81⁄8511.2 1-1 330.2 0-63⁄4171.5 0-115⁄8295.3 0-03⁄419.05 185 83.9
3
⁄16944.6 3-89⁄161131.9 1-51⁄16433.4 1-67⁄16468.3 2- 61⁄2774.7 1-75⁄8498.5 2-55⁄8752.5 2-83⁄16817.6 1-17⁄8352.4 0-81⁄4209.5 0- 4 406.4 0-07⁄822.22 222 100.5
3
⁄16944.6 3-89⁄161131.9 1-51⁄16433.4 1-67⁄16468.3 2- 61⁄2774.7 1-75⁄8498.5 2-55⁄8752.5 2-83⁄16817.6 1-111⁄16347.7 0-81⁄8206.4 0- 37⁄8403.2 0-07⁄822.22 249 112.9
UNIT SIZE
38HDL
018,024,030
and 036
Support Feet Snow Stand Ice Stand
ft-in. mm ft-in. mm ft-in. mm
1-11 x 3-6 584.2 x 1066.8 2-2 x 3-6 660.4 x 1066.8 2-2 x 3-6 660.4 x 1066.8
MINIMUM MOUNTING PAD DIMENSIONS
048 and 060 2- 0 x 4-2 609.6 x 1270.0 2-4 x 4-4 711.2 x 1270.0 2-2 x 4-2 660.4 x 1270.0
NOTES:
1. Required clearances: With coil facing wall, allow 69 (156.4 mm)minimumclearance on coil side and
coil end, and 3 ft (914.4 mm) minimum clearance on compressor end and fan side. With fan facing
wall, allow 89 (203.2 mm) minimum clearanceonfan side and coilend, and 3 ft (914.4mm) minimum
clearance on compressorend and coil side.Withmulti-unit application, arrange unitsso discharge of
one does not enter inlet of another.
2. Dimensions in parenthesis are in millimeters.
3. Center of gravity .
2
Fig. 2 — 38HDL018-060 — Dimensional Drawing
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 into unit. Field-fabricated stacking kits can
be used when units are to be stacked. If conditions or local
codes require unit to 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 level platform or
frame at least 6 in. (154 mm) above roof surface.Isolate unit
and tubing from structure.
RIGGING
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 spreader bars to prevent sling damage to unit. See Fig. 3. See Fig. 2 for center of gravity reference. Install unit so coil does not face into prevailing winds.
If this is not possible and constant winds above 25 mph are
expected, use field-fabricated wind baffle.
NOTE: Field-fabricated wind baffles should be used on all
units with accessory low-ambient control.
Field-fabricated snow stand may be used to raise unit when
operation will be required during the winter. Units may also
be wall mounted using the accessory wall mounting kit.
Step 3 — CompleteRefrigerant Piping Connections —
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 (3 m) of interconnecting tubing.
DO NOT BURY MORE THAN 36 IN. (922 mm) OF
REFRIGERANT PIPE IN THE GROUND. If any section of pipe is buried, there must be a 6 in. (154 m) vertical rise to the valve connections on the outdoor unit.
If more than the recommended length is buried, refrigerant may migrate to the cooler, buried section during
extended periods of system shutdown. This causes
refrigerant slugging and could damage compressor at
start-up.
Outdoor units may be connected to indoor units
Fig. 3 — Lifting Unit with Sling
with field-replaceable piston should be supplied with the indoor unit. Refer toAccuRater metering device table in separate indoor unit installationinstructionstodeterminethecorrect
AccuRater piston size required for the condenser/evaporator
system being installed.
Note that one of 2 types of the AccuRater devices can be
found on the indoor unit. See Fig. 4. Do notinterchangecomponents between AccuRater device types. Matching of outdoor unit with indoor unit may require field replacement of
piston. Replace piston, if required, before connecting refrigerant lines. Piston replacement instructions are included
in the indoor unit installation instructions. After system installation is complete, see Refrigerant charging section on
page 8 to check and/or adjust refrigerant charge.
The 38HDL018-060 units may also be installedwith units
using a thermostatic expansion valve (TXV). If a TXV is
used, be sure to remove the piston from the indoor coil. See
installation instructions shipped with the TXV for proper positioning and adjustment.
When more than 50 ft (15.2 m) of interconnecting tubing
and more than 30 ft (9.1 m) of vertical lift is used, refer to
Part 3 of the Carrier System Design Manual for design details, or contact your local distributor.
If either refrigerant tubing or indoor coil is exposed to atmospheric conditions for longer than 5 minutes, it must be
evacuated to 1000 microns to eliminate contamination and
moisture in the system.
Run refrigerant tubes as directly as possible, avoiding unnecessary turns and bends. Suspendrefrigerant tubes so they
do not damage insulation on vapor tube and do not transmit
vibration to the structure.Also,whenpassingrefrigeranttubes
through the wall, seal opening so that vibration is not transmitted to structure. Leave some slack inrefrigerant tubes between structure and outdoor unit to absorb vibration. Refer
to separate indoor unit installation instructions for additional information.
CHECK ACCURATERt CONTROL — The correct
AccuRater (bypass type) refrigerant control is required for
cooling system capacity optimization.AnAccuRater device
TYPE A (BYPASS TYPE)
TYPE B
NOTE: Arrow on AccuRater body points in free-flow direction, away
from the indoor coil.
Fig. 4 — AccuRater Metering Device Components
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 ready for brazing.After wrapping the service valve
3
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 indoor coil are ready for leak testing.
NOTE: Unit is shipped with R-22 full factory charge indicated on nameplate.
Pass nitrogen or other inert gas throughpiping while braz-
ing to prevent formation of copper oxide.
To avoid damage while brazing, service valves should
be wrapped in a heat-sinking material such as a wet cloth.
When brazing tubing sets to the service valves, a brazing shield must be used to prevent damagetothe painted
unit surface.
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.
Step 4 — Make Electrical Connections
Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal
injury if an electrical fault should occur. This ground
may consist of electrical wire connected totheunitground
lug in control compartment, or conduit approved for
electrical ground when installed in accordance with
NEC, ANSI/NFPA (American National Standards
Institute/National Fire Protection Association) 70 (U.S.A.
Standards), and local electrical codes. Failure to follow
this warning could result in the installer being liable for
personal injury to others.
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 operation will invalidate any applicable Carrier
warranty.
POWER WIRING — Unit is factory-wired for voltage shown
on nameplate. Provideadequate,fuseddisconnectswitchwithin
sight of unit, readily accessible but out of reach of children.
Provision for locking the switch open (off) is advisable to
prevent power from being turned on while unit is being serviced. Disconnect switch, fuses, and field wiring must be
in compliance with NEC (U.S.A. Standard) and applicable
local codes. Use minimum 60 C wire for field power
connection.
Route power wires through opening in the unit side panel
and connect in unit control box as shown on unit label diagram and Fig. 5 and 6. Unit must be grounded.
CONTROL CIRCUIT WIRING — Control voltage is 24 v.
See Fig. 5 and unit label diagram for field-supplied wiring
details. Route control wire through opening in the unit side
panel to connection in unit control box.
NOTE: For wire runs up to 50 ft (15 m), use no. 18 AWG
(American Wire Gage) insulated wire (35 C minimum). For
50 to 75 ft (15 to 23 m), use no. 16AWG insulated wire. For
more than 75 ft (23 m), use no. 14 AWG insulated wire. See
Table 2 for conversion to European wire sizes.
NOTE: Operation of unit on improper line voltage constitutes abuse and could affect Carrier warranty. See Table 3.
Do not install unit in system where voltage may fluctuate
above or below permissible limits.
See Table 3 for recommended fuse sizes. When making
electrical connections, provide clearance at unit for refrigerant piping connections.
Use indoor unit transformer as 24-v (40-va minimum)
supply for system as shown in Fig. 5 or use accessory
transformer.
Before performing service or maintenance, be sure the
indoor unit main power switch is off and indoor blower
has completely stopped. Failure to do so may result in
electrical shock or injury from rotating fan blades.
CONNECTIONS TO DUCT-FREE FAN COIL UNITS —
The 38HDL units are designed for easy match-up to 40QAB,
40QKB, and 40QNB018,024 duct-free fan coils. These units
provide 24-v power for the outdoor unit from the fan coil.
Connect the Y and C terminals of the indoor unit to the blue
and brown wires of the outdoor unit with 20 gage (minimum) thermostat wire.
Step 5 — Accessory Installation — Install all unit
accessories per accessory installation instructions prior to
start-up.
Do not use accessory Time Guardt II device when combining a 38HDL unit with 40QNB indoor units.
When ambient temperature will fall below 55 F (13 C),
accessory low ambient controller (part no. 53DS900060) is
required. When accessory low ambient kit is used, unit should
also be equipped with accessory winter start kit and fieldfabricated wind baffles.
4
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