40GXC / 38GXC
40GXQ / 38GXQ
Installation Instructions
NOTE: Read the entire instruction manual before starting the installation.
High---Wall Duct Free Split System
Size 9k, 12k, 18k, and 24k
TABLE OF CONTENTS
PAGE
PARTS LIS T 2.......................................
SAFETY CONSIDERATIONS 3.........................
SYSTEM REQUIREMENTS 3..........................
9k & 12k
18k & 24k
DIMENSIONS 4......................................
CLEARANCES 5.....................................
INSTALLATION GUIDE 6.............................
INDOOR UNIT INSTALLATION 6.......................
OUTDOOR UNIT INSTALLATION 7 -- 8..................
SYSTEM VACUUM AND CHARGE 9....................
START--UP 10........................................
TROUBLESHOOTING 11..............................
PARTS LIST
Part
No.
1 Mounting Plate 1
2 Mounting Screw ST4.2X25TA 5
3 Remote Control 1
Name of Part Qty
1
2
A08274
Front Panel
18k & 24k Display Close Up
38/40GXC(Q)
RUN
TEMPERATURE
HEAT INDICATOR
9k & 12k Display Close Up
COOL
TEMPERATURE
RUN
SIGNAL
DEHUMIDIFY
HEAT
RECEIVING
WINDOW
Remote
Control
COOL INDICATOR
3
Drain Hose
DEHUMIDIFY MODE
INFRARED SIGNAL
RECEPTOR
Fig. 1 --- 38GXC(Q) / 40GXC(Q) 009, 012, 018 and 024 Parts List
2
Connecting Pipe
and Connecting Wires
A09663
SAFETY CONSIDERATIONS
Installing, starting up, and servicing air--conditioning equipment
can be hazardous due to system pressures, electrical components,
and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should
install, start--up, and service this equipment.
Untrained personnel can perform basic maintenance functions such
as cleaning coils. All other operations should be performed by
trained service personnel.
When working on the equipment, observe precautions in the
literature and on tags, stickers, and labels attached to the
equipment.
Follow all safety codes. Wear safety glasses and work gloves. Keep
quenching cloth and fire extinguisher nearby when brazing. Use
care in handling, rigging, and setting bulky equipment.
Read these instructions thoroughly and follow all warnings or
cautions included in literature and attached to the unit. Consult
local building codes and current editions of the National Electrical
Code ( NEC ) NFPA 70. In Canada, refer to current editions of the
Canadian electrical code CSA 22.1.
!
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.Understand
these signal words: DANGER, WARNING, and CAUTION.
These words are used with the safety--alert symbol. DANGER
identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which may result in minor personal injury
or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability, or
operation.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF
position. There may be more than 1 disconnect switch.
Lock out and tag switch with a suitable warning label.
!
CAUTION
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Do not bury more than 36 in. (914 mm) of refrigerant pipe
in the ground. If any section of pipe is buried, there must be
a 6 in. (152 mm) vertical rise to the valve connections on
the outdoor units. 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 possibly damage the
compressor at start--up.
!
GENERAL
These instructions cover the installation, start--up and servicing of
38GXC(Q) outdoor and 40GXC(Q) indoor units duct free systems.
SYSTEM REQUIREMENTS
Allow sufficient space for airflow and servicing unit. See Fig. 2
and 3 for minimum required distances between unit and walls or
ceilings.
Piping
IMPORTANT: Both refrigerant lines must be insulated
separately.
S Minimum refrigerant line length between the indoor and outdoor
units is 10 ft. (3 m).
S The following maximum lengths are allowed:
REFRIGERANT LINE LENGTHS ft. (m)
Unit Size Max Line Length
9 & 12K 65 (20) 35 (11) 35 (11)
18K 80 (25) 50 (15) 50 (15)
24K 100 (30) 50 (15) 50 (15)
S The following are the piping sizes.
.
Unit Size Mix Phase Vapo r
9, 12 & 18K 1/4” 1/2”
24K 3/8” 5/8”
Refrigerant Charge
Unit Size
REFRIGERANT CHARGE
9K 2.65 (1.2)
12 K 2.8 (1.27)
18 K 3.5 (1.6)
24 K 5.4 (2.5)
S Above charge is for piping runs up to 25 ft. (7.6 m).
S For piping runs greater than 25 ft. (7.6 m), add 0.1 oz. of
refrigerant per foot of extra piping up to the allowable
length.
S Capillary tubes are used as metering devices.
Connecting (Power and Control
S The main power is supplied to the outdoor unit. The field
supplied connecting cable from the outdoor unit to indoor unit
consists of four wires and provides the power for the indoor unit
as well as the communication signal and ground between the
outdoor and indoor unit.
Two wires are high voltage AC power, one is low voltage and
one is a ground wire.
S Consult local building codes, NEC (National Electrical Code) or
CEC (Canadian Electrical Code) for special requirements.
Model Size Power Source
9K 1 1 5 --- 1 --- 6 0 20/25
12 K 1 1 5 --- 1 --- 6 0 20/25
12 K 208/230 --- 1 --- 60 10/15
18 K 208/230 --- 1 --- 60 14/25
24 K 208/230 --- 1 --- 60 16/30
S Connecting Cable: Voltage drop on the connecting cable
should be kept to a minimum. Do not use thermostat wire. Use
cable size and max length below:
18 AWG 50 Feet (16 m)
16 AWG 65 Feet (19.8 m)
14 AWG >65Feet(19.8m)
Max Elevation
(ID over OD)
PIPE SIZES
Cable)
Amount of Charge lb. (kg)
Max Elevation
(OD over ID)
MIN CKT AMP
MAX FUSE/CB
AMP
38/40GXC(Q)
3
DIMENSIONS -- INDOOR
H
Unit Size
9k 30.3 (770) 9.8 (250) 7.84 (1.99) 18.7 (8.50)
12k 32.7 (830) 11.2 (285) 8.9 (225) 24.2 (11.0)
18k 32.7 (830) 11.2 (285) 8.1 (206) 26.4 (12.0)
24k 42.9 (1090) 13.0 (330) 8.2 (208) 38.5 (17.5)
38/40GXC(Q)
DIMENSIONS -- OUTDOOR
W
In. (mm)
W
H
In. (mm)
D
In. (mm)
D
A08289
Net Operating Weight
Lbs. (Kg)
W
D
H
Unit Size
9k & 12k 33.4 (848) 12.6 (320) 21.3 (541) 88.0 (40)
18k 33.3 (846) 11.8 (300) 27.0 (685) 114.4 (52)
24k 37.4 (950) 16.5 (420) 33.1 (840) 140.3 (64)
W
In. (mm)
D
In. (mm)
H
In. (mm)
Net Operating Weight
Lbs. (Kg)
A08290
4
CLEARANCES -- INDOOR
CLEARANCES -- OUTDOOR
5
"
(0.13m)
min.
CEILING
6" (0.15m) min.
(1.8m)
6'
FLOOR
Fig. 2 --- Indoor unit clearance
5
"
(0.13m)
min.
A07891
38/40GXC(Q)
A
Air-inlet
E
D
B
C
Air-outlet
A07894
UNIT 12k in. (mm)
A 20 (508)
B 20 (508)
C 24 (610)
D 12 (305)
E 12 (305)
Fig. 3 --- Outdoor Unit Clearance
5
INSTALLATION GUIDE
3
Ideal installation locations include:
Indoor
Unit
S A location where there are no obstacles near inlet and outlet area.
S A location which can bear the weight of indoor unit.
S Do not install indoor units near a direct source of heat such as
direct sunlight or a heating appliance.
S A location which provides appropriate clearances as outlined in
Fig. 2 (pg. 5).
Outdoor
S A location which is convenient to installation and not exposed to
S A location which can bear the weight of outdoor unit and where
S A location which provides appropriate clearances as outlined in
S Do not install the indoor or outdoor units in a location with
Unit
strong wind. If unit is exposed to strong winds it is
recommended that a wind baffle be used. Contact your Carrier
Representative for drawings. (See Fig. 11, pg. 7)
the outdoor unit can be mounted in a level position.
Fig. 3 (pg. 5).
special environmental conditions. For those applications, contact
your Carrier Representative.
10.1 (256)
25.6 (650.5)
A09664
Fig. 6 --- 18k Mounting Plate Spacing
11.4 (290)
38/40GXC(Q)
INSTALL MOUNTING PLATE
INDOOR UNIT INSTALLATION
1. Carefully remove the mounting plate, which is attached to
the back of the indoor unit.
2. The mounting plate should be located horizontally and level
on the wall. All minimum spacings shown in Fig. 4
through Fig. 7 should be maintained.
3. If the wall is block, brick, concrete or similar material, drill
.2” (5 mm) diameter holes and insert anchors for the appropriate mounting screws.
4. Attach the mounting plate to the wall.
2.64 (67)
8.58 (218)
65
.04 (1)
Fig. 4 --- 9k Mounting Plate Spacing
3.15 (80)
10.4 (264)
7" (178)
.08 (2)
15.47 (393)
18.94 (481)
21.93 (557)
4.09 (104)
.52 (13)
A085862
10.4 (264)
A09665
Fig. 7 --- 24k Mounting Plate Spacing
DRILL HOLE IN WALL FOR INTERCONNECTING
PIPING, DRAIN AND WIRING
Refrigerant Line Routing
The refrigerant lines may be routed in any of the four directions
shown in Fig. 8 (a) and (b).
For maximum serviceability, it is recommended to have refrigerant
line flare connections and the drain connection on the outside of
the wall that the fan coil is mounted on.
As viewed from front
3
1
Right Exit
2
( a )
Right Rear Exit
( b )
Left Exit
Left Rear Exit
4
Fig. 8 --- Refrigerant Line Routing
If piping is going through the back:
1. Determine pipe hole position using the mounting plate as a
template. Drill pipe hole diameter per chart below. The
outside pipe hole is 1/2--in. (13 mm) min. lower than inside
pipe hole, so it slants slightly downward (see Fig. 9).
If piping is going to exit from the left rear, it is recommended to field--fabricate piping extensions to get the flare connections to the outside of the wall.
1/2 in. (13 mm)
Min.
Knockout
Knockout 2
Knockout 1
( c )
A08281
65
Note: Units in ( ) = mm
Fig. 5 --- 12k Mounting Plate Spacing
A08291
INDOOR
OUTDOOR
Fig. 9 --- Drill Holes
Model Size
9k, 12k and 18k 2.56 (65)
24k 3.75 (95)
6
A07371
Hole Diameter
in. (mm)
If piping is going through the right or left side:
1. Use a small saw blade to carefully remove the corresponding plastic covering on side panel and drill the appropriate
size hole where the pipe is going through the wall. See Fig.
8(c).
2. Remove knockout 1 if you are running only the wiring.
Remove knockout 1 and 2 or knockout 1, 2 and 3 if you are
running both piping and wiring through the side of the unit.
OUTDOOR UNIT INSTALLATION
1. Use a rigid base to support unit in a level position.
2. Locate outdoor unit and connect piping and wiring.
!
CAUTION
INSTALL ALL POWER AND INTERCONNECTING
WIRING TO OUTDOOR UNIT
Strong
wind
A07350
Fig. 11 --- High Wind Installation
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Excessive torque can break flare nut depending on
installation conditions.
Piping Connections to Outdoor
IMPORTANT: Use refrigeration grade tubing ONLY. No
other type of tubing may be used. Use of other types of tubing
will void manufacturer’s warranty.
Make sure there is enough piping to cover the required length
between the outdoor and indoor unit.
Piping Guide:
S Do not open service valves or remove protective caps from
tubing ends until all the connections are made.
S Bend tubing with bending tools to avoid kinks and flat spots.
S Keep the tubing free of dirt, sand, moisture, and other
contaminants to avoid damaging the refrigerant system.
S Avoid sags in the suction line to prevent the formation of oil
traps. Insulate each tube with minimum 3/8--in. (10 mm) wall
thermal pipe insulation. Inserting the tubing into the insulation
before making the connections will save time and improve
installation quality.
1. Remove service valve cover if provided with unit.
2. Cut tubing with tubing cutter.
3. Install correct size flare nut onto tubing and make flare connection.
4. Apply a small amount of refrigerant oil to the flare connection on the tubing.
5. Properly align tubing in with service valve.
6. Tighten flare nut and finish installation using two wrenches
as shown in Fig. 10.
Unit
Outdoor Unit Wiring
1. Mount outdoor power disconnect.
2. Run power wiring from main box to disconnect per NEC
and local codes. Set outdoor unit in place.
3. Remove field wiring cover (on sizes 9k, 12k, and 18k) from
unit by removing screws. On size 24k, use the knockout
provided on the end panel.
4. Connect conduit to the conduit panel on sizes 9k, 12k, and
18k. (See Fig. 12)
5. Properly connect both power supply and control lines to terminal block per the connection diagram.
6. Ground unit in accordance with NEC and local electrical
codes.
7. Use lock nuts to secure conduit.
8. Reinstall field wiring cover on 9k, 12k, and 18k units.
!
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
S Be sure to comply with local codes while running wire
from indoor unit to outdoor unit.
S Every wire must be connected firmly. Loose wiring may
causeterminal to overheat or result in unit malfunction.
A fire hazard may also exist. Therefore, be sure all wiring
is tightly connected.
S No wire should be allowed to touch refrigerant tubing,
compressor or any moving parts.
S Disconnecting means must be provided and shall be
located within sight and readily accessible from the air
conditioner.
S Connecting cable with conduit shall be routed through
hole in the conduit panel.
Connections
CAUTION
38/40GXC(Q)
Fig. 10 --- Tighten Flare Nut
A07354
7
G
Outdoor unit
Ground
Contro l
38GXQ-40GXQ009, 012 115-1-60 Co nnection Diagram
All 40GXQ 115-1-60 Indoor Units
115-1-60
115-1-60
115-1-60
All 38GXQ 115- 1-60 Ou tdoo r Uni ts
CONNECTING CABLE
OUTDOOR TO INDOOR
All 38GX Q 208/230-1-60 Outdoor Uni ts
All 40GX Q 208/230-1-60 Indoo r Units
208/230-1-60
208/230-1-60
208/230-1-60
38GXQ-40GXQ012, 018 & 024 208/230-1-60 Conne ction Dia gram
CONNEC TING C ABL E
OUTDOOR TO INDOOR
Terminal Block
Conduit panel
Conduit
LNLNGNDS LNGNDS
Main Power to
Pow er
Supply Unit Supp ly
Indoor Pow er
38/40GXC(Q)
L1 L2 L1 L2 GND S L1 L2 GND S
Main Power to Indoor Unit
Power Indoor Pow er
Supply Unit Supp ly
INSTALL ALL POWER, INTERCONNECTING
WIRING, AND PIPING TO INDOOR UNIT.
1. Run interconnecting piping and wiring from outdoor unit to
indoor unit.
2. Pass interconnecting cable through hole in wall (outside to
inside).
3. Lift indoor unit into position and route piping and drain
through hole in wall (inside to outside). Fit interconnecting
wiring into back side of indoor unit.
4. Hang indoor unit on upper hooks of wall mounting plate (as
shown in Fig. 13)
Indoor Unit
Ground Control Ground Control
Ground Control
Fig. 12 --- Field Wiring
Field Wiring
Cover
Interconnecting
Cable
Fig. 14 --- Field Wiring Cover
A09666
A08279
5. Open front cover of indoor unit and remove field wiring terminal block cover (see Fig. 14)
A08283
Fig. 13 --- Hanging Indoor Unit
6. Pull interconnecting wire up from back of indoor unit and
position in close to the terminal block on indoor unit.
7. Push bottom of indoor unit onto mounting plate to complete wall mount.
8. Connect wiring from outdoor unit per connection diagram
(see Fig. 12).
NOTE: Polarity of power wires must match original
connection on outdoor unit.
9. Replace field wiring cover and close front cover of indoor
unit.
10. Connect refrigerant piping and drain line outside of indoor
unit. Refer to Fig. 10 for proper installation of flare connections. Complete pipe insulation at flare connection then
fasten piping and wiring to the wall as required. Completely seal the hole in the wall.
8
!
t
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Never use the system compressor as a vacuum pump.
Refrigerant tubes and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. The alternate
triple evacuation method may be used if the procedure outlined
below is followed. Always break a vacuum with dry nitrogen.
SYSTEM VACUUM AND CHARGE
Using Vacuum Pump
1. Completely tighten flare nuts A, B, C, D, connect manifold
gage charge hose to a charge port of the low side service
valve. (See Fig. 15.)
2. Connect charge hose to vacuum pump.
3. Fully open the low side of manifold gage. (See Fig. 16)
4. Start vacuum pump
5. Evacuate using either deep vacuum or triple evacuation
method.
6. After evacuation is complete, fully close the low side of
manifold gage and stop operation of vacuum pump.
7. The factory charge contained in the outdoor unit is good for
up to 25 ft. (8 m) of line length. For refrigerant lines longer
than 25 ft (8 m), add 0.1 oz. per foot of extra piping up to
the maximum allowable length.
8. Disconnect charge hose from charge connection of the low
side service valve.
9. Fully open service valves B and A.
10. Securely tighten caps of service valves.
Outdoor Unit
Service Valve
Refrigerant
Low Side
A
High Side
B
Fig. 15 --- Service Valve
Manifold Gage
Indoor Uni
C
D
A07360
Deep Vacuum
Method
The deep vacuum method requires a vacuum pump capable of
pulling a vacuum of 500 microns and a vacuum gage capable of
accurately measuring this vacuum depth. The deep vacuum method
is the most positive way of assuring a system is free of air and
liquid water. (See Fig. 17)
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
01234567
MINUTES
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
A95424
Fig. 17 --- Deep Vacuum Graph
Triple Evacuation
Method
The triple evacuation method should only be used when vacuum
pump is only capable of pumping down to 28 in. of mercury
vacuum and system does not contain any liquid water.
Refer to Fig. 18 and proceed as follows:
1. Pump system down to 28 in. of mercury and allow pump to
continue operating for an additional 15 minutes.
2. Close service valves and shut off vacuum pump.
3. Connect a nitrogen cylinder and regulator to system and
open until system pressure is 2 psig.
4. Close service valve and allow system to stand for 1 hr. During this time, dry nitrogen will be able to diffuse throughout
the system absorbing moisture.
5. Repeat this procedure as indicated in Fig. 18. System will
then be free of any contaminants and water vapor.
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
38/40GXC(Q)
500 microns
Low side valve
Charge hose
Low side valve
High side valve
Charge hose
Fig. 16 --- Manifold
Vacuum pump
A07361
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
RELEASE CHARGE INTO SYSTEM
A95425
Fig. 18 --- Triple Evacuation Method
Final Tubing
Check
IMPORTANT: Check to be certain factory tubing on both indoor
and outdoor unit has not shifted during shipment. Ensure tubes are
not rubbing against each other or any sheet metal. Pay close
attention to feeder tubes, making sure wire ties on feeder tubes are
secure and tight.
9
START--UP
Tes t Operation
Perform test operation after completing gas leak and electrical
safety check.
1. Push the “ON/OFF” button on Remote Control to begin
testing.
NOTE: A protection feature prevents the air conditioner from
being activated for approximately 3 minutes.
2. Push MODE button, select COOLING, HEATING, FAN
mode to check if all functions work correctly.
SYSTEM CHECKS
1. Conceal the tubing where possible.
2. Make sure that the drain tube slopes downward along its entire length.
3. Ensure all tubing and connections are properly insulated.
4. Fasten tubes to the outside wall, when possible.
5. Seal the hole through which the cables and tubing pass.
INDOOR UNIT
38/40GXC(Q)
1. Do all Remote Control buttons function properly?
2. Do the display panel lights work properly?
3. Does the air deflection louver function properly?
4. Does the drain work?
OUTDOOR UNIT
1. Are there unusual noises or vibrations during operation?
Explain Following Items To Customer With The Aid Of The
Owner’s Manual:
1. How to turn air conditioner on and off; selecting
COOLING, HEATING and other operating modes; setting
a desired temperature; setting the timer to automatically start
and stop air conditioner operation; and all other features of
the Remote Control and display panel.
2. How to remove and clean the air filter.
3. How to set air deflection louver.
4. Explain care and maintenance.
5. Present the Owner’s Manual and installation instructions to
customer.
10
TROUBLESHOOTING
This unit has onboard diagnostics. Error codes will appear on the LED display on the front panel of the indoor unit in place of the
temperature display. Error codes are also displayed on the outdoor unit microprocessor board with colored LED lights. The table below
explains the error codes for both units.
38GXC/GXQ -- 40GXC/GXQ 009--024 Diagnostic Codes
LED Display on Outdoor Unit Board
Equipment Fault
Freeze Protection, Indoor Coil E2 4 3
High Compressor Discharge Temperature E4 7
Low Voltage Protection E5 5 Low Voltage
Communication Error E6 0 Wiring Error, or Communication Failure
Indoor Air Temperature Thermistor F1 Bad Connection, or Sensor Failure
Indoor Coil Temperature Thermistor F2 Bad Connection, or Sensor Failure
Outdoor Air Temperature Thermistor F3 6 Bad Connection, or Sensor Failure
Outdoor Coil Temperature Thermistor F4 5 Bad Connection, or Sensor Failure
Compressor Discharge Line Thermistor F5 7 Bad Connection, or Sensor Failure
Defrost H1 2 Unit going through normal defrost cycle
Compressor Overload Protection H3 8
Compressor Over Current Protection H4 6
IPM Module Protection H5 4
Code Displayed
on Indoor Unit
Front Pane l
Green
LED
Number
of Flashes
Red
LED
Number
of Flashes
Yellow
LED
Number
of Flashes
Possible Cause
Low Refrigerant Charge, Blocked Indoor Air
Flow,orDirtyAirFilter
Low Refrigerant Charge, Blocked Capillary,
or High Ambient Temperature
Low Refrigerant Charge, Blocked Capillary,
or Compressor Motor Failure
High Ambient Temperature, or Loss of
Condenser Airflow
Loss of Cooling to Heat Sink, High Ambient,
Low Voltage, or Bad Connections
38/40GXC(Q)
11
38/40GXC(Q)
Copyright 2009 CAC / BDP S 7310 W. Morris St. S Indianapolis, IN 46231
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
Printed in U.S.A. Edition Date: 11/09
12
Catalog No: 38---40GX--- 4SI
R e p l a c e s : 3 8 --- 4 0 G X --- 3 S I
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