Carrier 38HB series Manual

INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
38HB/HF
Nominal cooling capacity 19,3 - 36,9 kW
Nominal heating capacity 22,3 - 41,9 kW
50 Hz
Split-system units
Translation of the original document 80127, 07.2015

Contents
1. Introduction .......................................................................................................................................................................................................3
2. Operating limits .................................................................................................................................................................................................3
3. Technical characteristics (EN-14511-2013) ......................................................................................................................................................4
4. Unit identification...............................................................................................................................................................................................5
5. Safety advice.....................................................................................................................................................................................................5
6. Transport...........................................................................................................................................................................................................6
7. Location and assembling ..................................................................................................................................................................................6
Choise of location..............................................................................................................................................................................................6
Sound level .......................................................................................................................................................................................................7
Anchorage for silent-blocks...............................................................................................................................................................................7
Minimum free space for commissioning and maintenance operations (mm)....................................................................................................8
8. Checking before commissioning .....................................................................................................................................................................8
Electrical connections .......................................................................................................................................................................................8
Condensate drain connection ...........................................................................................................................................................................9
Checks in the centrifugal fans.........................................................................................................................................................................10
Air ducts connections......................................................................................................................................................................................10
Cooling connections........................................................................................................................................................................................11
9. Safety elements ..............................................................................................................................................................................................12
10. Optional...........................................................................................................................................................................................................12
Condensation pressure control (38HB/HF) ................................................................................................................................................................. 12
Filters (40HB/HF) ............................................................................................................................................................................................13
Hot water coil (40HB/HF) ................................................................................................................................................................................13
Electrical heater (40HB/HF) ............................................................................................................................................................................13
11. Commissioning................................................................................................................................................................................................15
Checks prior to commissioning .......................................................................................................................................................................15
Possible problems at commissioning..............................................................................................................................................................15
Operational checks .........................................................................................................................................................................................16
12. Maintenance....................................................................................................................................................................................................16
13. Control and analysis of breakdowns................................................................................................................................................................19
Split-system cooling units
and heat pumps
2

1. INTRODUCTION
2. OPERATING LIMITS
The 38HB/HF cooling units and heat pumps are units which feature a
split-system construction with components optimised for the R-410A
refrigerant.
They are presented in two different elements:
- An outdoor unit (38HB/HF series) which features a horizontal
construction and is equipped with a centrifugal fan, a hermetic
scroll-type compressor and an electric panel with electronic control.
Supply and return air on the same side.
- An indoor unit or or air-conditioning unit (40HB/HF series) which
features a horizontal construction and has supply and return air on
the same side.
• 38HB/HF series
38HB series: Outdoor unit cooling-only air-condensed with
centrifugal fan, horizontal design, designed for installation indoors.
38HF series: Outdoor unit heat pump air-air reversible with
centrifugal fan and expansion valve, horizontal construction,
designed for indoor installation.
• 40HB/HF series
40HB series: Indoor unit cooling only with centrifugal fan and
expansion valve, horizontal construction, designed for installation
on premises connected to a network of ducts.
40HF series: Indoor unit heat pump reversible with centrifugal fan
and expansion valve, horizontal construction, designed for installation
on premises connected to a network of ducts.
The units comply with standards: EN 60-204 - EN 378-2, and directives:
Machinery 2006/42/EC - EMC 2004/108/EC - LVD 2006/95/EC - PED
2014/68/EC (Category 2).
Those in charge of the installation, commissioning, operation and
maintenance of the unit must know the instructions contained in this
brochure and the specific technical characteristics of the installation
place.
With a condensation pressure control operating down to -10ºC.
When the outdoor temperature is usually below 5ºC WB it is recommended
installing a support element.
Inlet air conditions Cooling Heating
Indoor
coil
Minimum 14 ºC WB 10 ºC
Maximum 22 ºC WB 27 ºC
Outdoor
coil
Minimum 12 ºC -10 ºC WB 
Maximum 48 ºC 15 ºC WB
Split-system cooling units
and heat pumps
3

3. TECHNICAL CHARACTERISTICS (EN-14511-2013)
38HB/HF 80 90 120 160
Cooling
capacities
Cooling capacity (kW) 19,3 21,2 27,3 36,9
Power input (kW) 8,0 9,6 11,5 14,2
EER performance 2,40 2,20 2,38 2,60
Heating
capacities
Heating capacity (kW) 22,3 24,2 32,0 41,9
Power input (kW) 7,7 9,1 10,6 13,5
COP performance 2,88 2,67 3,03 3,11
Outdoor
circuit
centrifugal
fan
Nominal air flow (m3/h) 6.500 7.000 10.000 12.200
Available static pressure (mm.w.c) 25 20 20 20
Number / turbines 1 / 1
Motor output (kW) 3345,5
Power input (kW) 2,33 2,71 2,51 3,18
Speed (r.p.m.) 1.489 1.522 940 836
Compressor
Type Scroll
No. compressors / circuits / stages 1 / 1
Oil type Copeland 3MAF 32 cST, Danfoss POE 160 SZ, ICI Emkarate RL32 CF, Mobil EAL Artic 22 CC
Volume of oil (l) 1,6 3,0 3,3 3,3
Cooling
connections
Liquid line 1/2" 1/2" 5/8" 5/8"
Gas line 7/8" 7/8" 1 1/8" 1 1/8"
Refrigerant
Type R-410A
Global warming potential (GWP) 2.088
Load up to 7,5 m (kg) 6,5 6,6 7,8 10,2
Environment impact (tCO2 e) 13,6 13,8 16,3 21,3
Electrical
features
Mains voltage 400 V / III ph / 50 Hz (±10%)
Power supply 3 Wires + GND
Maximum
absorbed
current
Compressor (A) 15,9 15,3 20,1 25,1
Fan (A) 6,9 6,9 9,0 11,6
Control (A) 0,9 0,9 0,9 0,9
Total (A) 23,7 23,1 30,0 37,6
Dimensions
Length (mm) 1.680 1.680 2.088 2.088
Width (mm) 915 915 1.198 1.198
Height (mm) 670 670 810 810
Weight (kg) 224 245 322 344
40HB/HF 80 90 120 160
Indoor
circuit
centrifugal
fan
Nominal air flow (m3/h) 4.000 4.600 6.000 7.000
Available static pressure (mm.w.c) 20 20 20 20
Number / turbines 1 / 1
Motor output (kW) 1,5 2,2 2,2 2,2
Power input (kW) 1,07 1,48 1,56 1,62
Speed (r.p.m.) 1.497 1.613 1.219 1.030
Max. abs.current Fan (A) 3,6 5,0 5,0 5,0
Dimensions
Length (mm) 1.500 1.500 1.831 1.831
Width (mm) 870 870 1.103 1.103
Height (mm) 639 639 706 706
Weight (kg) 125 128 171 181
Cooling capacity calculated in accordance with the EN-14511-2013 standard given for indoor temperature conditions 27ºC (19ºC WB) and 35ºC outdoor temperature.
Heating capacity calculated in accordance with the EN-14511-2013 standard given for indoor temperature conditions 20ºC and 6ºC WB outdoor temperature.
Total power input by compressors and motorised fans under nominal conditions, calculated in accordance with the EN-14511-2013 standard.
Climatic warming potential of a kilogram of fluorinated greenhouse gas in relation to a kilogram of carbon dioxide over a period of 100 years.
Split-system cooling units
and heat pumps
4

4. UNIT IDENTIFICATION
Note: The serial number must be used in all communications
regarding the unit.
Check the condition of the equipment upon delivery.
Check that the details on the label, the packing and the data plate
match the order.
If equipment has been damaged, or there is a shortfall in delivery,
notify accordingly.
All units bear, legibly and indelibly, a data plate located in a prime space,
as appears in the attached image: Check that this plate matches the
correct model.
An.Year
CARRIER SCS
Route de Thil
01122 Montluel–France
Tél: [phone]
Ref. Produit\Item Nb
r
Designation\Description
Refrigerant kW Absorbee\Input Poids\Weight
Refrigerant kg Tension\Voltage Temperature Maxi C
BP Mini PSM\MOP Intensité\Current A IP
HP Maxi PSM\MOP Int. Kit Elect. No CE
0056
No Serie\Serial Nb
r
No Produit
Contains fluorinated greenhouse gases regulated by the Kyoto protocol
UTC BIS
P.I. Llanos de Jarata
14550 Montilla - SPAIN
Phone: [phone]
Made in Spain
5. SAFETY ADVICE
These units work with refrigerant gas R-410A. This fluid is used up
to a maximum service pressure of 42 bar.
To avoid any risk of accident during installation, commissioning or
maintenance, it is obligatory to take into consideration the following
specifications for the units: refrigerated circuits under pressure,
refrigerant presence, electrical voltage presence and implantation place.
Because of all of this, only qualified and experienced personnel can
perform maintenance tasks or unit repairs.
It is required to follow the recommendations and instructions
in the maintenance brochures, the labels, and the specific
instructions.
It is necessary to comply with the norms and regulations in
effect. It is recommended to consult the competent authorities
regarding the applicable regulations for users of units or
components under pressure. The characteristics of these units
or components are included on the plates of characteristics
or in the regulatory documentation provided with the product. In case of a leak:
- Toxicity: According to ASHRAE 34, R-410Abelongs to the A1/A1 group,
i.e. with high safety both in the mix and also in the case of a leak.
- Although it is not toxic, in case of a leak to atmospheric pressure the
liquid phase evaporates. The resulting vapours are heavier than air and
can displace the technician local air. In case of an accidental discharge
in a closed enclosure, fans must be used to eliminate said vapours.
- Although the R-410A is not flammable, when in contact with a flame
o hot spot it can decompose in fluorhydric acid HF and fluophosgene
COF2which are highly toxic and corrosive.
- To detect leaks, an electronic leak detector, an ultraviolet lamp or
soapy water must be used. Flame detectors do not help.
Important: Immediately repair any refrigerant leak, using
a recovery unit specific for R-410A that avoids a possible
mixture of refrigerants and/or oils.
The compressor and line surfaces can reach temperatures
above 100ºC causing burns to the body. In the same fashion,
under certain conditions these surfaces can reach very cold
temperatures that can cause freezing risks.
Use safety goggles and gloves on the job. Be careful with sharp
parts or elements in the unit.
V-220005
V-220004
Caution: Before intervening in the unit, verify that the main
power to the unit is cut off. An electric shock can cause
personal damage.
Refrigerant leaks:
A periodical check must be performed for refrigerant gas leaks as
per Regulation (CE) Nº517/2014 over certain greenhouse effect
fluoride gases. Please, consult the frequency of checks in chapter
of “Maintenance”.
Components of the R-410A R-32 R-125
Chemical formula CH2F2 CHF2CF3
Weight ratio 50% 50%
Unitary global warming potential (GWP) 675 3.500
Global warming potential (GWP) 2.088
Note: In order to recycle these units follow the stipulations of
Directives 2002/96/EC and 2003/108/EC regarding electrical
and electronic equipment and the management of the resulting
waste.
Split-system cooling units
and heat pumps
5

38HB/
HF
Centre of
gravity (mm)
Weight
(kg)
XYZ
80 879 522 283 224
90 903 543 276 245
120 1087 708 337 322
160 1100 705 337 344
40HB/
HF
Centre of
gravity (mm)
Weight
(kg)
XYZ
90 710 422 241 125
100 702 422 245 128
120 847 549 275 171
160 821 548 286 181
6. TRANSPORT
The unit must be handled with care to avoid transport damage. Thus
we recommend:
- Do not dispose of the transport supports or the packaging materials
until the unit is in its final location.
- For transport in a container, one must be selected that has an easy
load and unload to the installation location.
- The unit must be lifted and fixed with care, with maximum inclination
of 15º, since it could harm its operation. Please see the weight and
the gravity centre coordinates of each model stated in the following
table.
Outdoor unit
38HB/HF
7. LOCATION AND ASSEMBLING
Choise of loc at ion
Before moving the unit, make sure that all panels are fastened in place.
Lift and lower with care.
When choosing the location, whatever may be the selected fashion, the
following precautions have to be taken into consideration:
- It is mandatory to comply with norm EN 378-3 on Safety and
Environmental Requirements. Part 3: “In situ” installation and
protection to people.
- The area where the unit will be located must be perfectly accessible
for cleaning and maintenance operations (check minimum free space
for maintenance). Leave enough space for air circulation around the
unit.
- Foresee appropriate damping devices in all the installation so that
noise and vibration transmission is avoided (refer to the section
“Anchorage for silent-blocks”).
- It is necessary to check that the surface of the floor or the structure
supports the weight of the unit (please, consult the weight of the unit
in the section “Centre of gravity coordenates”).
Both the outdoor unit 38HB/HF and the indoor unit 40HB/HF have been
designed for working indoors, with ducted supply and return air. In this
case, the following aspects must also be considered: :
- All models can be installed on the floor or on a brick frame or steel
profile. In any case, check that the unit is perfectly level.
- All models of 40HBHF units can be attached to the ceiling using the
threaded rod:
• Insert in the framework ceiling 4 threaded rods.
• Insert the rods through the holes the unit has in its base.
• Place the antivibration mounts, insert a washer and turn the nuts
until the unit is well secured.
• If there is enough space between the framework and the unit, a
rubber or neoprene plate can be squeezed in.
• Once these operations are finished, a false ceiling can be mounted
to hide the unit, leaving a register cover to perform the maintenance
and filter cleaning operations
.
.
- When installing a false ceiling, it is necessary to leave a register
cover to perform the maintenance operations. Access for cleaning
the filter must be prepared for the indoor unit
.
. If the installation has
an air return which is not ducted, appropriately-sized grids must be
planned in the space formed by the false ceiling, the framework and
the walls so that the unit sucks the return air from the air-conditioned
spaces.
- Ensure that the location of the outlet and return grilles does not
generate air recirculation.
- Check that there is no obstruction in the air outlet and return due to
tightly closed grille slats.
- The units can be handled with a forklift truck, taking all necessary
precautions to avoid sliding of the unit on the truck’s fork.
Indoor unit
40HB/HF
Split-system cooling units
and heat pumps
6

Anc hora ge for sile nt -block s
B
A
B
A
38HB/HF A (mm) B (mm) Ø
80 and 90 1630 728 M8
120 and 160 2038 974 M8
40HB/HF A (mm) B (mm) Ø
80 and 90 1450 630 M8
120 and 160 1781 863 M8
Outdoor unit
38HB/HF
Indoor unit
40HB/HF
Sound level
These units have been designed to operate with a low sound level. In any case, in the design of the installation, it must be taken into consideration:
the outdoor environment for the acoustic radiation, the type of building for the noise transmitted in the air and the solid elements for the vibration
transmission. If necessary, a study must be commissioned to an acoustic technician.
38HB/HF 80 90 120 160
dB(A) 79,1 81,5 79,2 83,9
38HB/HF 80 90 120 160
dB(A) 65,0 68,4 68,5 69,7
40HB/HF 80 90 120 160
dB(A) 65,9 64,6 65,2 64,2
C) The sound pressure level of the indoor unit, with the ducted supply and discharge connections, measured at a distance of 5 metres, in
open field, directivity at 2 and 1.5 metres from the ground, is:
B) The sound pressure level of the outdoor unit, measured at a distance of 5 metres, in open field, directivity at 2 and 1.5 m from the ground, is:
A) The sound power level in the outdoor unit fan supply to be taken into account for the silencer operation:
Note: The sound pressure level depends on the installation conditions and, as such, is only indicated as a guide.
Split-system cooling units
and heat pumps
7

8. CHECKING BEFORE COMMISSIONING
Electronic control
• CARRIERrtc basic
All 38HB/HF units have the CARRIERrtc basic electronic control,
comprised of a control board and a TCO user terminal.
Optionally, this control can have a pGD1 terminal for maintenance
that facilitates the initial scheduling of the unit, the modification of the
operating parameters and the description of the alarms produced.
Recommendations for installation of the TCO terminal
From the thermostat some of the unit
operation aspects are controlled: operation
modes, setpoint, differential, timings...
Because of this, it is very important to
chose an appropriate location within the
room since in it is where the unit’s control
probe is located. This probe must report
about the environmental conditions of the
occupied area.
The thermostat must be fixed at a height of 1,5 metres from the
ground and all possible interferences must be avoided: sun, outdoor
air, internal heat sources... Mount the thermostat to the wall using
the bracket, do not leave it hanging from the wire or embedding it
in the wall.
750
750
750
750
750
750
Outdoor unit 38HB/HF
Indoor unit 40HB/HF
Minim um fre e spa c e for c om m issioning and ma intenanc e ope rat ions (mm )
NOTE: Under no circumstance should the unit be started without having read the brochure completely.
Electric a l c onnections
Installation norms
To perform the electric installation of the unit (cable glands, conductor
section and their calculations, protections, etc.), refer to the information
provided in this document (see the technical characteristic table), the
electrical scheme included with the unit and norms in effect that regulate
the installation of air conditioning units and electrical receivers.
The electric power supply of the unit must be sized in accordance with
the maximum power input by the unit taking into account all the options
it features (if necessary, refer to the technical brochure).
Verify that electrical power corresponds to the one on the data plate
and that the voltage remains constant.
Check that the electrical connections are correct and tight
(an electrical diagram is included with each unit, along with
its legend).
Note: All connections in the site are the responsibility of
the installer. These connections are always made as per
the current regulation.
To prevent electrical shocks, make all electrical connections
before energizing the unit. Check that the automatic switch is
closed. Omitting this can cause personal damage. Make the
ground connection before any other electrical connection.
V-220004
V-220005
The installer must fix line protection elements according to
the effective legislation.
Note: Please refer to the CARRIERrtc basic & medium control brochure
to obtain more detailed information about its operation.
Split-system cooling units
and heat pumps
8

Connection chart
31
32
33
1
2
5
6
16
17
4
14
12
11
7
13
15
Return or ambient T probe (opt.)
Indoor fan thermal protection
Indoor fan power supply
Outlet T probe
Electrical heaters (opt.)
Electrical heaters safety (opt.)
HWC 24Vac signal (opt.)
Air flow control (opt.)
Clogged filter detector (opt.)
Without neutral (std.)
and/or soft starter (opt.)
HWC valve (opt.)
pGD1 maintenance terminal (opt.)
Remote on/off (opt.)
Main failure signal (opt.)
Power supply
TCO user terminal
Outdoor unit
38HB/HF Indoor unit
40HB/HF
No. 38HB/HF - 40HB/HF 80 90 120 160
1 Power supply 400 III (±10%) 3 + GND
2TCO user terminal connection 
2 wires for power supply 230V + 1
shielded cable for communication
type AGW20 / 22 (1 braided pair
+ drainwire + shielding)
4 Indoor fan power supply 3 + GND
5 Thermal relay signal of the indoor fan 2 wires
6 Outlet temperature probe 2 wires
7Return or ambient temperature probe
(optional) 2 wires
11 Clogged filters detector (optional) 2 wires
12 Air flow control (optional) 2 wires
13 Unit without neutral (std) and/or soft
starter (opt.) 1 wire
14 HWC 24 Vac signal (optional) 2 wires
15 HWC valve (optional) 1 wire
16 Electrical heaters (optional) 3 wires (per stage) + GND
17 Safety thermistors of electrical
heaters (optional) 2 wires
31 pGD1 maintenace terminal
connection (optional)
telephone cable 6 wires
standard (RJ12 connector)
32 Remote on/off (optional) 2 wires
33 Main failure signal (optional) 2 wires
Conde nsate drain conne c t ion
CONNECT SIPHON
METTRE SIPHON
PONER SIFON
V220014
All the units, both outdoor and indoor,
are equipped with a condensates drain
pan, with a bronze, gas threaded M 3/4”
drain junction.
Pan drain
Outdoor unit
38HB/HF
Indoor unit
40HB/HF
If the unit is going to be installed in an industrial environment with a high level
of electromagnetic interference, it is recommended to shield the cables of the
thermostat control.
The power supply for the electrical heater must be protected by an automatic
switch and/or fuses to be foreseen by the installer.
Siphon installation norms
All water drain tubes must be provided with a siphon to avoid bad smell
and water spills.
Pan in overpressure:
- It’s installed to avoid the access through the drain piping of bad smells.
Pan in underpressure:
- Besides the above application, water must be suctioned from the pan
because of the depression with respect to the motorfan assembly.
- Perform the siphon assembly as per the scheme of the attached
starting diagram:
• For the correct siphon design, the "A" height must be at least twice
that of the underpressure (mmwc) where the condensate pan is
placed.
• Check that the condensate outlet is not clogged.
• The drain piping must be slightly sloped to ease circulation towards
the drain.
• The original diameter of the piping must be respected. No reduction
can be made.
• In the case of units installed outdoors, with outdoor temperatures
which are lower than 0ºC the necessary precautions must be taken
to prevent the water in the drain piping from freezing.
Check the watertightness of the connection.
A
Condensates pan
in depression
A
Siphon drain
Slight slope
5/1000
To drainage
Split-system cooling units
and heat pumps
9

• Soft starter detail (optional):
Soft starter of the supply centrifugal
fan which prolongs the set time,
available for indoor units 40HB/HF.
It’s mainly aimed at installations with
cloth ducts.
Pulley and belt calibration
Attention: Before performing these operations, it is necessary to verify
that the unit is disconnected from mains.
Centrifugal motorfans are coupled with pulleys and belts.
In this type of fans, the following must be taken into consideration:
- The pulleys must be on the same plane, so it is important to check
them with the help of a ruler or a laser aligner.
- In case they are not aligned, remove the pulley screws, remove the
pulley and, after removing the taper pin, it can be slid over the axle
(this action can be performed both in the motor as well as in the fan).
- After fixing the pulleys on the same plane, the belt tension is made
by tightening the tensor screw.
- The belt tension must be checked after 24 hours of motor operation.
Che ck s in the cent rifugal fans
- Before commissioning, check the blade rotation direction and that
the axis turns without strokes nor vibrations
- Once running, check the operation conditions: pressures, flows and
consumptions.
- The overlapping of characteristic curves of the fan and the room is
very important, so that the flows and pressures provided to the duct
network are as required.
Pulleys must stay on the same plane
Tensor
screw
Pulley
screws
Taper pin
Caution: Indoor units are designed to connect to a duct
network. In the event that the outlet fan of the indoor circuit
is accessible from a particular point in the duct network, the
installer must install a protection mesh in the discharge as
per the current regulation.
Air duc t s c onnections
The air supply and return ducts must be calculated in accordance with
the rated flow and the unit’s available pressure (refer to the technical
characteristics table). The duct calculation and design must be made
by qualified technical personnel.
It is advisable to take into consideration the following recommendations:
- Curves in the fan supply outlet(s) must be avoided. It is
recommendable to have a straight section of duct measuring
approximately 1 metre. If it is not possible, they must be as smooth
as possible, using indoor deflectors when the duct is of large
dimensions.
- When making the ducts, direction sharp changes must be avoided
since they can generate occasional pressure drops, which affect
the available pressure and the flow. The location of discharge and
aspiration grilles must be studied carefully to avoid the air recirculation
and the transmission and generation of noises to the interior.
- Flexible connections must be made between the ducts and the unit
that avoid the noise and vibration transmission.
- No matter the type of ducts type to use, these must be insulated
and not be composed of materials that propagate fire nor expel toxic
gases in the event of a fire. The internal surfaces must be smooth
and should not pollute the air that circulates within them. In any case,
the effective legislation about this issue must be respected.
Split-system cooling units
and heat pumps
10