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

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. 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. 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: 33(0)4 72 25 21 21

Ref. Produit\Item Nb

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

No Produit

Contains fluorinated greenhouse gases regulated by the Kyoto protocol

UTC BIS

P.I. Llanos de Jarata

14550 Montilla - SPAIN

Phone: 34 957 65 23 11

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

38HB/

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/

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

Anc hora ge for sile nt -block s

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

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

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

Connection chart

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.

Condensates pan

in depression

Siphon drain

Slight slope

5/1000

To drainage

Split-system cooling units

and heat pumps

• 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

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