Download Carrier 40CS024 Instruction manual

40CG Indoor Unit/38CG Outdoor Unit
40CS Indoor Unit/38CS Outdoor Unit
Console and Underceiling Duct Free Systems
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Installation and Start-Up Instructions
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS .....................................................1
INTRODUCTION ..........................................................................1
General ......................................................................................1
Electrical Requirements ............................................................1
Indoor and Outdoor Unit Location ..........................................1
Outdoor Unit .............................................................................4
Indoor Unit (General) ...............................................................4
INSTALLATION ...........................................................................4
Installing the Indoor Unit (Console) ........................................4
Refrigerant Line Routing ....................................................4
Installing the Mounting Bracket .........................................5
Drilling a Hole in the Wall for Drainage and Inter-Unit
Connections..........................................................................5
Wiring the Indoor Unit........................................................5
Drainage...............................................................................5
Attaching the Remote Controller Rack ..............................5
Ceiling Installation ..............................................................5
Installing the Indoor Unit—Under Ceiling ..............................5
Mounting the Air Conditioner On the Bracket........................5
Continuing the Installation .......................................................7
Installing the Outdoor Unit ......................................................7
Wiring the Outdoor Unit.....................................................7
Connecting the Refrigerant Lines ............................................7
Flaring and Connecting .......................................................7
Air Vacuum and Refrigerant Charge .......................................7
Leak Test...................................................................................8
Electrical Data and Connections ..............................................8
Two-Way Air Conditioner (Optional Accessory)
—Console Only ........................................................................8
Air Feedback System Installation (Optional)
(Two-Way Air Conditioner)...................................................10
START-UP PROCEDURES........................................................10
Finishing the Job.....................................................................10
Indoor Unit ........................................................................11
Outdoor Unit......................................................................11
Explain the following items to the customer, with the aid of
the User Manual: ...............................................................11
CARE AND MAINTENANCE...................................................12
Maintenance (Outdoor Unit) ..................................................12
Cleaning Coils ...................................................................12
Maintenance (Indoor Unit) .....................................................12
Lubrication.........................................................................12
To Remove And Clean Or Replace Air Filters................12
TROUBLESHOOTING ...............................................................17
SAFETY CONSIDERATIONS
Installation and servicing of this air conditioning equipment can be
hazardous due to mechanical and electrical components. Only
trained and qualified personnel should install, repair, or service air
conditioning equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on this
equipment, observe precautions in the literature, on tags, on labels
attached to or shipped with the unit and other safety precautions
that may apply.
Follow all safety codes. Installation must be in compliance with
local and national building codes. Wear safety glasses and work
gloves. Have a fire extinguisher available during start-up and
adjustment procedures and service calls.
Recognize safety information. This is the safety-alert symbol
.
When you see this symbol in instructions or manuals, be alert to
the potential for personal injury.
Understand the signal words DANGER, WARNING, or 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 a hazard that could
result in personal injury or death. CAUTION is used to identify
unsafe practices which would result in personal injury or product
or property damage.
INTRODUCTION
Step 1—General
These instructions are intended as general guidelines. The air
conditioner must be installed by trained and authorized personnel.
Use the following size copper tubing for connecting the outdoor
and indoor units:
MODELS
38 & 40CG/CS-018
38 & 40CG/CS-024
38 & 40CG/CS-030
COPPER TUBING
SIZE (IN.)
1/4 and 1/2
3/8 and 5/8
3/8 and 5/8
Installation must be performed in accordance with the manufacturer’s specifications, using only approved tubing, electrical cables
and accessories.
Step 2—Electrical Requirements
The air conditioner must be directly connected to an appropriate
power source.
Use only Type “G” or “C” fuses, per Tables 4 and 5.
Use a single-length power cable, without extensions.
NOTE: All Wiring and power disconnects must meet local
electrical codes. Control wires should be THHN 600v 18ga.
Step 3—Indoor and Outdoor Unit Location
The indoor and outdoor units should be installed as close to each
other as possible.
Do not exceed the tubing lengths and height differences which
appear in Table 3.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 533-80013
Printed in U.S.A.
Form 38C/40C-1SI
Pg 1
8-01
Replaces: New
Tab misc. misc
A01084
Fig. 1—Ceiling Installation
A01212
Fig. 2—Console Installation
2
Table 1—Standard Parts (Console)
PART NAME
QTY
Mounting Bracket(s)
1
Long Screws
9
Nut
2
Outdoor Sensor
Connecting Cable
1
Absorption Cushions
4
Electric Terminals
16
Remote Controller Rack
1
DIAGRAM
WIRELESS REMOTE CONTROLLER
S TA R T
S TO P
1
2
3
SLEEP
D A I LY
MODE
FAN
I I I II
I II I
II I II
II I I
Remote Controller
and Batteries
1
A
Insulation for Fittings
Drain Hose Adapter
1
User Manual
1
3
A
SWEEP
Table 2—Standard Parts (Under Ceiling)
PART NAME
QUANTITY
Upper and Lower
Mounting Strips
2
Right and Left
Mounting Strips
2
Left Side Strip
1
Right Side Strip
1
Anchor Screw
(3/8-in. X 2-in.)
6
Screw
(UNC 10 X 2-in.)
8
Nut
(UNC 10)
8
Metal Screw
(#10–1/2-in.)
2
DIAGRAM
IIIIIIIII III
III
IIIIII
Table 3—Maximum Tubing Lengths and Heights
INDOOR UNIT
OUTDOOR UNIT
40CG/CS-018
40CG/CS-024
40CG/CS-030
38CG/CS-018
38CG/CS-024
38CG/CS-030
LENGTH
Mtr
30
40
30
HEIGHT
Ft
98
131
98
Mtr
15
20
10
Ft
49
66
33
INSTALLATION
Step 4—Outdoor Unit
1. Make sure to leave sufficient space around the unit. See Fig.
3 for minimum required distances between the unit and nearby
walls. DO NOT BOX IN UNIT.
Step 1—Installing the Indoor Unit (Console)
REFRIGERANT LINE ROUTING
The refrigerant lines may be routed in either of the two directions
shown in Fig. 7.
2. Install the unit in a location with convenient access for service
and maintenance purposes.
INSTALLING THE MOUNTING BRACKET
3. Position the unit to minimize motor noise which reaches the
customer and neighbors.
1. Carefully remove the air intake grille; remove the two screws
at its sides and pull the grille out with its center retaining
spring, as shown in Fig. 5.
4. In heating mode, water can form in the condenser. A drainage
hose may be attached to the unit. Use an adapter as shown in
Fig. 4.
Step 5—Indoor Unit (General)
2. Remove the seven screws which appear in Fig. 5 and remove
the front panel.
NOTE: Make sure that the stepper motor and display cables are
disconnected from the electronic control. (See Fig. 13.)
1. Make sure to leave sufficient space around the unit. See Fig.
6 and Fig. 16 for minimum required distances between the unit
and the ceiling, floor and surrounding walls.
3. Position the mounting bracket on the wall and level.
4. Mark seven (minimum) drilling holes on the wall, as they
appear in Fig. 8.
2. Locate the unit to ensure free air flow around it.
3. For greater convenience, place the power disconnect near the
unit on the right side.
5. Drill the holes, insert the wall plugs and use the long screws
to attach the mounting bracket to the wall.
4. Avoid installing the unit near a source of heat, such as direct
sunlight, steam or a flame.
6. Check that the bracket is level and securely fastened to the
wall.
5. Install the unit in a location with convenient access to
refrigerant line connections for service and maintenance
purposes.
7. Hang unit on mounting bracket and mark (2) holes from the
bottom of the unit for the hold down screws.
4
4. Fill the remaining wall hole gap with an appropriate sealant
material.
a
WIRING THE INDOOR UNIT
1. Route the inter-unit electric cable and the outdoor sensor cable
towards the lower right corner of the indoor unit.
0.15m(6”)
min.
2. Use a screw driver to insert the stripped wire ends into the
terminal block, as shown in Fig. 13.
3. Make sure that the wires are connected in accordance with the
wiring diagram on the drain pan.
0.15m(6”)
min.
0.6m(2’)
min.
c
4. Attach the inter-unit electric cable with the cable clamp
located on the unit.
5. Connect the Outdoor Sensor TH3 connector to its mating
connector. (See Fig. 13.)
0.6m(2’)
min.
DRAINAGE
1. Connect the unattached end of the drainage tube to the
drainage hose outlet.
b
2. Seal the drainage connection to prevent leakage.
3. Make sure there are no kinks, “U” bends or flattened sections
in the tube.
4. Check that the drainage functions properly. Fill the pan below
the unit’s coil with water and observe that it drains out freely.
A01146
UNIT
38CG/CS-018/024
38CG/CS-018/030
A
9.8-in.
(320mm)
12.6-in.
(320mm)
B
25.2-in.
(641mm)
25.2-in.
(641mm)
C
35.4-in.
(900mm)
43.3-in.
(1,100mm)
5. Connect the ends of the refrigerant lines to their appropriate
fittings, following the guidelines in the “Connecting the
Refrigerant Lines” section.
6. Make sure the drainage hose is at the bottom side of the wall
hole. (See Fig. 9.)
Fig. 3—Dimensional Drawing (Outdoor Unit)
7. Connect the display panel connector to the display panel
printed circuit board. (See Fig. 13.)
8. Reassemble the front panel, using the seven screws which
appear in Fig. 5.
ATTACHING THE REMOTE CONTROLLER RACK
Use the two screws supplied to attach the remote controller rack to
the wall in the location selected by the customer. (See Fig. 12.)
CEILING INSTALLATION
IMPORTANT: When performing a ceiling installation, make sure
that Switch 1 on the Display Board is set to the ON position. (See
Fig. 11.) The remaining switches are factory set and should not be
changed.
Step 2—Installing the Indoor Unit—Under Ceiling
1. The tubing connecting the indoor and outdoor units can be
routed in one of two directions, as shown in Fig. 16.
A01147
Fig. 4—Drainage Adapter Connection
2. If the tubing is routed horizontally (direction no. 1), the pipe
cover at the bottom of the air conditioner must be removed.
(See Fig. 19.)
8. Remove unit from bracket and install wall plugs. After
attaching tubing and control/power wires. Remember to install
(2) hold down screws at bottom of unit.
3. If the tubing is routed vertically (direction no. 2), a condensate
pump must be installed for drainage.
4. To assemble the ceiling bracket, use the 4 mounting strips and
the 8 UNC–10 screws and nuts, as shown in Fig. 17.
DRILLING A HOLE IN THE WALL FOR DRAINAGE AND
INTER-UNIT CONNECTIONS
5. Fasten the ceiling bracket to the ceiling using the 6 anchor
screws, as shown in Fig. 18.
1. To make the connections between the indoor and outdoor
units, a 3-in. hole should be drilled for the refrigerant lines,
drainage hose and electric cables as shown in Fig. 9.
6. The location of the ceiling bracket should allow a minimum
gap between the indoor unit and nearby walls, as shown in Fig.
16.
2. Make sure to drill outwards and downwards, so that the
opening in the outside wall is at least 1/2-in. lower than the
opening on the inside.
NOTE: The anchor screws provided are intended for use with
concrete ceilings.
3. Make sure the drainage hose is at the bottom side of the hole.
(See Fig. 9.)
NOTE: Use fasteners which are appropriate for the type of ceiling
present at the installation site.
5
A01096
Fig. 5—Removing Air Intake Grille and Front Panel
c
a
0.2m
0.2m
(8”)min.
b
10mm(0.5”)
min.
(8”)min.
0.1m
(4”)min.
REFRIGERANT
LINES
OUTDOOR SENSOR
CABLE
ø70mm(3”)
INDOOR
LLATION
OR INSTA
OUTDOOR
DRAINAGE
TUBE
ELECTRICAL
CABLE
A01151
FLO
Fig. 9—Suggested Tubing Diameter and Contents
A01202
40CG/CS-018
40CG/CS-024/030
A
8.74-in.
(225mm)
8.74-in.
(225mm)
B
24-in.
(610mm)
24-in.
(610mm)
C
39.4-in.
(1000mm)
42.24-in.
(1200mm)
Indoor
Power Outdoor Control
Fan
Fig. 6—Dimensional Drawing (Indoor Unit)
Step
Motor
1
3
2 8
TH3
TH2
TH1
Heat
UNIT
8
Display
7
5
4
10
9
A01207
Fig. 10—Mounting Indoor Unit on Mounting
Bracket
A01203
Fig. 7—Refrigerant Line Routing Options
A01206
A01100
Fig. 8—Inserting Drilling Holes on Wall
Fig. 11—Switch 1 Factory Default ON Position
6
5. Connect the outdoor sensor cable, making sure the connector
is properly inserted.
11:45
S TA R T
STOP
1
2
3
D A I LY
MODE
SLEEP
72
FAN
6. Secure the inter-unit electric and sensor cable to the outdoor
unit with the clamp shown in Fig. 14.
SWEEP
I I I II
II I I I
I II I
II I I
A
A
7. Reassemble the plastic side cover.
NOTE: A drainage tube can be connected to the outdoor unit to
remove condensation formed during heating mode operation.
Make sure that all screws and wires are properly fastened.
Loose wires or connections can cause damage and present a
fire hazard.
Step 6—Connecting the Refrigerant Lines
WIRELESS REMOTE CONTROLLER
A01157
1. To connect the refrigerant lines, use only “L” type sealed,
dehydrated copper refrigerant tubing. No other type of tubing
may be used. Use of other types of tubing will void the
manufacturer’s warranty.
Fig. 12—Remoter Controller and Rack
Step 3—Mounting the Air Conditioner On the Bracket
1. Remove the air conditioner front panel and air intake grille, as
shown in Fig. 5.
2. Do not open service valves or remove protective caps from
tubing ends until all the connections are made.
2. Fasten the left and right side strips to the air conditioner using
6 sheet metal screws, as shown in Fig. 19. Ensure that:
3. Take care to avoid kinks or flattening of the tubing.
4. Bend tubing with special bending tools to avoid the formation
of sharp bends.
a. The wide side of the strip is located at the bottom of the air
conditioner.
5. Keep the tubing free of dirt, sand, moisture, and other
contaminants to avoid damaging the refrigerant system.
b. The strip angle faces inward.
3. Mount the indoor unit on the bracket. Slide the protruding
parts of the side strips onto the ceiling bracket so that the 4
safety screw holes on the left and right strips align with those
on the ceiling bracket.
6. Avoid sags in the suction line to prevent the formation of oil
traps.
7. Insulate the tubing with 3/8-in. walled thermal pipe insulation.
Inserting the tubing into the insulation before making the
connections will save time and improve installation. The
suction and liquid lines should never come in direct contact.
4. Make sure that the air conditioner is tilted slightly toward the
drainage outlet on the right side. Use water to test for proper
drainage. Fix the tilt by adjusting the height of the right strip
relative to the left one.
FLARING AND CONNECTING
1. Remove the protective cap from the flare fitting.
5. Fasten the air conditioner to the ceiling bracket using the 4
side screws. (See Fig. 20.)
2. Remove the protective cap from the tubing and cut to the
required length. Make sure that the cut is perpendicular and
clean, without burrs.
Step 4—Continuing the Installation
After attaching the air conditioner to the ceiling bracket, continue
the installation procedure in the previous section, titled
“Drainage.”
3. Slip the flare nut on the tubing and flare the tube end, using
standard flaring tools.
4. Tighten the nut until resistance is met. Mark the nut and the
fitting. Using a suitable wrench tighten an additional 1/4 turn.
Use the following specified torque, according to connection
size:
NOTE: If the drainage is routed in direction no. 1, as shown in
Fig. 16, cut out the oval opening in the air intake opening for the
drainage tube and route the tube through the air intake grille. (See
Fig. 21.)
Liquid line:
1/4-in. - (12.3 ft/lb)
3/8-in. - (29 ft/lb)
Suction line:
1/2-in. - (36 ft/lb)
5/8-in. - (47 ft/lb)
3/4-in. - (72 ft/lb)
5. The valves on the outdoor unit must remain closed until all
four connections have been made.
NOTE: Set DIP switch no. 1 to the “ON” position. (See Fig. 11.)
The other factory switches are set at the factory and should not be
changed.
Step 5—Installing the Outdoor Unit
1. The outdoor unit must be installed on a solid surface.
2. Make sure that the unit is level.
3. Fasten the outdoor unit legs to the base, as shown in Fig. 14.
Place the rubber absorption cushions (supplied with the
outdoor unit) under the unit’s legs to prevent vibrations.
Step 7—Air Vacuum and Refrigerant Charge
When all the fittings are connected, air must be expelled, as
follows:
WIRING THE OUTDOOR UNIT
1. Remove the outdoor unit plastic side cover.
2. Loosen the screws on the terminal block.
1. Open the service port cap on the suction line valve (large
valve).
3. Attach the electrical terminals supplied to the inter-unit
control and power cable wires.
2. Connect the vacuum pump to the service port via the pressure
gauge and operate the pump for 15 minutes.
4. Connect the wires to the terminal block, in accordance with
the coding which appears in Fig. 15.
3. Make sure that full vacuum is present and disconnect the
vacuum pump.
7
POWER INDOOR OUTDOOR
FAN CONTROL
TH3
TH2
TH1
Heat
Control
3
2 8
5
4
8
Display
7
10
9
STEP
MOTOR
1
TH3
TH2
TH1
HEAT
Fan
Power Outdoor Indoor
Step
Motor
1
3
4
5
7
HEAT
TH3
TH2
TH1
STEP
MOTOR
DISPLAY
10
DISPLAY
2 6
8
9
A01210
Fig. 13—Connecting Wire Ends to Terminal Block
1 23 456 7
1 23 456 7
PLUG TO CONNECT
WITH OUTDOOR
SENSOR CABLE (TH3)
INTER-UNIT
ELECTRIC CABLE
CLAMP
ABSORPTION
CUSHION X4
A01158
Fig. 14—Outdoor Unit Installation Guideline
INDOOR UNIT
HIGH SPEED
HEAT PUMP
MEDIUM
SPEED
LOW SPEED
COMPRESSOR
*HEATER HDE
PHASE
NEUTRAL
1
3
4
5
7
10
2
6
8
9
OUTDOOR UNIT
BLACK
~ BROWN
YELLOW
GRAY/ORANGE
RED
~ BLUE
WHITE
1
2
3
4
5
6
7
8
9
10
8. Make sure that the valves are properly opened. Be careful not
to open them more than required as this may damage the
thread.
DISCONNECT SWITCHES
(NOT SUPPLIED)
OUTDOOR INDOOR
2 POWER
BROWN
6 POWER
BLUE
GROUND
GR/YEL
GREEN/YELLOW
9. Replace the stem cap. Oil the cap beam and hand tighten the
cap, until resistance is met. Use a suitable wrench to tighten
the cap by an additional 1/2 turn.
Step 8—Leak Test
Leak test all fittings with appropriate test equipment.
OUTDOOR SENSOR
CABLE (TH3)
Step 9—Electrical Data and Connections
Refer to Table 4 or 5 for unit electrical information.
* FOR H/P MODELS
A01159
Step 10—Two-Way Air Conditioner (Optional Accessory)
—Console Only
Fig. 15—Wiring Diagram Schematic
4. Open the liquid line valve (small valve) with an Allen wrench.
5. Open the suction line valve (large valve) with an Allen
wrench.
6. The outdoor unit is supplied with sufficient refrigerant for 26
ft of tubing. Add 0.9 oz of refrigerant and 0.35 oz of oil for
each additional foot of tubing used. If the tubing is shorter
than 26 ft, remove gas from the system through the service
valve into a recycling device.
7. Close the service port caps on the suction line and the liquid
valves.
Allows simultaneous air conditioning of adjacent rooms when
installed as a console
1. Prepare a wooden frame with the proper dimensions. (See Fig.
22.)
2. Locate the indoor unit and install its mounting bracket.
3. Before mounting the indoor unit on the wall, open a hole in the
wall to install the wooden frame using the unit as a guide
4. Insert the frame in the wall and fill in any gaps between the
frame and the wall hole with an appropriate material.
8
2
1
OUTDOOR
SENSOR
CABLE
REFRIGERANT
LINES
ELECTRICAL
CABLE
DRAINAGE
TUBE
10 cm MINIMUM
A01093
Fig. 16—Tubing Routing Options
2
1
2
2
1
2
1
2
2
2
1
1
BRACKET SCREWS
2
ANCHOR SCREWS
2
A01094
Fig. 17—Assembling the Ceiling Bracket
A01095
Fig. 18—Mounting Ceiling Bracket to Ceiling
9
PIPE COVER
WIDE
SIDE
A01097
Fig. 19—Fastening Left and Right Sides to Air Conditioner
PROTRUSION
3
FASTEN THE 4 SAFETY
SCREWS ON THE SIDES OF
THE AIR-CONDITIONER
2
MAKE SURE
THAT THE
PROTRUDING
PARTS OF THE
SIDE STRIPS FIT
INTO THE
RUNNERS ON
THE MOUNTING
BRACKETS
1
SLIDE THE
AIR CONDITIONER
INTO THE
MOUNTING STRIPS
A01098
Fig. 20—Mounting Indoor Unit onto Ceiling Bracket
A01099
Fig. 21—Drainage Tube Routing Option
5. Cut the required openings in the insulation material on the
back of the unit.
The air feedback grille is installed when air from the adjacent room
is to be sampled by the thermostat when installed as a console.
1. Affix a gasket around the air feedback opening at the rear of
the air conditioner (approximately 12-in. from the opening).
2. Drill a hole in the shared wall to insert the return air tube.
3. Mount the indoor unit on its mounting bracket.
4. Insert the tube into the hole until it reaches the opening at the
rear of the unit.
5. Insert the grille on the end of the tube.
6. Complete the installation by attaching the plastic frame to the
wall using screws.
6. Mount the indoor unit on its mounting bracket, as previously
described.
7. Seal any gaps between the back of the unit and the wall using
a sealing material.
8. Install the grille into the wooden frame and attach it to the
frame using two wood screws.
9. Finish the installation by performing all the necessary steps
located throughout this instruction.
Step 11—Air Feedback System Installation (Optional)
(Two-Way Air Conditioner)
See Fig. 23.
10
Table 4—Electrical Data - Indoor Unit
MODEL
MCA
MOCP
Power Supply
Full Load Amps
Fan Motor Amps
Electric Heater (watts)
Electric Heater (amps)
40CG-018
0.8
15
40CG-024
0.8
15
0.6
0.6
n/a
n/a
0.6
0.6
n/a
n/a
40CG-030
40CS-018
0.8
11.5
15
20
208/230V, 60 Hz, 1 Ph
0.6
8.9
0.6
0.6
n/a
2000
n/a
8.3
40CS-024
17.0
30
40CS-030
17.0
30
13.1
0.6
3000
12.5
13.1
0.6
3000
12.5
40CS-024
30.4
35
40CS-030
36.1
40
1.5
9.6
61.0
1.5
14.2
94.0
Specifications and performance data are subject to change without notice.
MCA–Minumum Circuit Amps
MOCP–Maximum Over Current Protection
Table 5—Electrical Data - Outdoor Unit
MODEL
MCA
MOCP
Power Supply
Fan Motor Amps
Full Load Amps
Locked Rotor Amps
40CG-018
11.4
15
40CG-024
14.1
20
1.5
7.4
48.0
1.5
9.6
61.0
40CG-030
40CS-018
19.8
22.1
30
25
208/230V, 60 Hz, 1 Ph
1.5
1.5
14.2
7.4
94.0
48.0
Specifications and performance data are subject to change without notice.
MCA–Minumum Circuit Amps
MOCP–Maximum Over Current Protection
WALL
THICKNESS
REAR AIR
OUTLET
REAR
OUTLET
GRILL
112(4.4”)
173(6.8”)
A
12(0.5
WALL
EVAPORATOR
”) min
45
(1
.8”
)
B
WOODEN
FRAME
A01101
BACK OPENINGS
OPEN
SIZE
A
B
(in.)
2
3
4
5
6
7
9.1
13.4
17.7
22.1
26.4
30.7
(mm)
230
340
450
560
670
780
(in.)
11.2
15.5
19.85
24.2
28.5
32.8
(mm)
284
394
504
514
724
834
AIR
FEEDBACK
GRILLE
Fig. 22—Dimensional Drawing
PVC
TUBE
AIR
SPONGY
FEEDBACK GASKET
OPENING
A01102
START-UP PROCEDURES
Fig. 23—Two Way Air Conditioner
Step 1—Finishing the Job
OUTDOOR UNIT
1. Hide the tubing where possible.
1. Are there unusual noises or vibrations during operation?
2. Make sure that the drainage tube slopes downwards along its
entire length.
2. Is noise, drain water or air flow from the unit likely to disturb
the neighbors?
3. Insulate tubing and connections.
3. Are there any gas leaks?
4. Fasten tubes to the outside wall.
EXPLAIN THE FOLLOWING ITEMS TO THE CUSTOMER,
WITH THE AID OF THE USER MANUAL:
5. Seal the hole through which the cables and tubing pass.
6. Connect the air conditioner to the power source and turn it on.
1. How to turn the 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 the other features of the remote
controller and display panel.
7. Check all air conditioner operating modes. Consult the User
Manual.
INDOOR UNIT
1. Do all the remote controller buttons function properly?
2. How to remove and clean the air filter.
2. Do the display panel lights work properly?
3. How to set the air deflection louver.
3. Does the air deflection louver function properly?
4. Present the User Manual and this installation sheet to the
customer.
4. Does the drainage work?
11
CARE AND MAINTENANCE
Step 1—Maintenance (Outdoor Unit)
TO REMOVE AND CLEAN OR REPLACE AIR FILTERS
Operating your system with dirty air filters may damage the
indoor unit and, in addition, can cause reduced performance,
intermittent system operation, frost build up on the indoor
coil, and blown fuses. Inspect and clean or replace the air
filters monthly.
Before performing recommended maintenance, be sure unit
main power switch is turned off. Failure to do so may result
in electric shock or injury from rotating fan blade.
CLEANING COILS
Coil should be washed out with water or blown out with compressed air. Clean coil annually or as required by location and
outdoor air conditions. Inspect coil monthly and clean as required.
Fins are not continuous through coil sections. Dirt and debris may
pass through first section, become trapped between the row of fins
and restrict outdoor unit airflow. Use a flashlight to determine if
dirt or debris has collected between coil sections.
To Remove Air Filters
Remove filters by pulling them straight out.
To Clean Or Replace Filters
Filters can be vacuumed or washed in warm water. Shake filter to
remove any excess water, and replace by sliding filter behind grille
until filter snaps in place. If the filter has begun to break down or
is torn, replace it. Replacement filters are available through your
Carrier distributor.
Clean coil as follows:
1. Turn off unit power
To Clean Indoor Unit Bottom/Front Panel
2. Using a garden hose or other suitable equipment, flush coil
from the outside to remove dirt. Be sure to flush all dirt and
debris from drain holes in base of unit. Fan motors are
waterproof.
If the bottom/front panel of the unit becomes dirty or smudged,
wipe the outside of the panel with a soft dry cloth. Use a mild
liquid detergent and wipe off carefully with a dry cloth.
Step 2—Maintenance (Indoor Unit)
To Clean Indoor Coil
To clean the coil, remove indoor unit bottom/front panel and
vacuum the coil fins, using care not to bend or damage fins.
To avoid the possibility of electric shock, before performing
any cleaning and maintenance operations, always turn off
power to the system by pressing the mode button on the
remote control until the display shows ’’OFF,’’ and turn off
the separate disconnect switch located near the unit. If the
indoor unit is on a separate switch, be sure to turn this
disconnect off as well.
To Clean Condensate Drains
Clean all drains and drain pans at the start of each cooling season.
Check the flow by pouring water into the drain.
To Clean Or Replace Drain Pan
1. Place a plastic sheet on the floor to catch any water that may
spill from drain pan.
2. Remove the intake grille and distribution assembly.
3. Remove the condensate water in the drain pan by letting water
drain into a 3-gallon bucket.
Do not wash filter in water over 120°F (to avoid shrinkage).
Do not expose filter to fire (to avoid fire damage). Do not
expose filter to direct sunlight. Clean filter more frequently
when air is extremely dirty.
Do not attempt to clean or service components in control box.
LUBRICATION
The indoor-fan, automatic air sweep, and the outdoor-fan motors
are factory lubricated and require no oiling.
12
INDOOR UNIT
WIRING DIAGRAM
TH2
TH1
OUTDOOR UNIT
RVS
MAIN
DISPLAY
TAC - 460
TH3
BK
TH3
5A
CON5-4
CON7
OR
N
BR
¥¥BR
2
GR/YEL
CONTACTOR
IH
RL6
¥12VDC
CON9
5A
CON6-3
¥ BLUE
FC
BR
BLUE
FAN
MOTOR
BLUE
5A RED
CON6-1
BLK
BLK
IL
5
1 2
1
¥ RED
¥ RED
CON6-9
HEATER(OPT)
HEATER
TC
ST
1
1 23 456
POWER
SUPPLY
2
CON4
13
BLUE
BR
GR/YEL
MODELS (Indoor)
40CS-018-301
40CS-024-301
40CS-030-301
FC
A2
2
¥BR
HEATERÕS
THERMOSTAT
¥ BR
CON8
4
6
3 4
¥ RED
¥
6
¥GR/YEL 5
¥¥ GR/YEL
OR
RL
¥ BLUE
WH
BLK
5A
CON6-5
¥ GR/YEL 5
CON5-7
IT
WHT
¥¥BLUE
6
BK 12
CON6
J3
¥¥YEL
4 A1
CONTACTOR
J5
PS
OVERLOAD
ONLY ON
ROTARY
COMP
1 23 456
BK
BLUE
P3
RED 16
¥ BLUE 9
WH 3
BR 13
RL3
RL
BLUE
GRAY/OR
5A
CON5-5
OH
3
6
TB
WH 2
WH
OL
RL
¥¥ WH
¥¥ OR
¥YEL
¥ OR
7
10
BR
RED
YEL/GR
CON1
WH
¥¥ RED
¥ BLUE
CONTR
¥¥YEL
YEL
WH 2
3
4
5
1
2
3
4
5
6
7
10
BLUE 10
YEL
RED
5A
CON5-6
1
2
3
4
5
6
7
10
¥¥ BR 15
RVS
OH
1
BK 12
¥BR 15
BK (YEL)
¥ BR 14
RL1
RL
1A
CON5-1
1A
CON5-3
¥ BR
COMP
¥¥ BK
¥ GR/YEL
RL2
BK
¥ BK
CON5
¥ BLUE
CON3
¥OR
¥YEL
CON2
SWEEP
MOTOR
TH3
R C S
FUSE 6A
ST ¥ SAFETYTHERMOSTAT
TC ¥ THERMAL CUTOFF
FC ¥ FAN CAPACITOR
¥ REVERSING VALVE
RVS SOLENOID
¥ 12 AWG WIRE
¥¥ 14AWG WIRE
Fig. 24—Wiring Diagram
COMPR.
FAN MOTOR
MODELS: (Outdoor)
38CS-018-301
38CS-024-301
38CS-030-301
A01196
I N D O O R U N I T
E L E C T R I C A L
D I A G R A M
O U T D O O R U N I T
CONTRACTOR
TH2
TH1
2
2
7 COMP.
MAIN
DISPLAY
TAC-460
5
CON2
CON3
7
COMPRESSOR
OL
5
5
CON5
COMP.
RL1
RVS
OH
1A
CON5-1
1A
CON-5
1
OH
1
2
5A
CON5-8
3
HEAT
OL
5A
CON5-4
OM
5A
CON5-5
RL3
CON6
CON7
RL5
LT
RL7
IL
IH
RL5
14
12VOC
CON9
5
4
2
5
1
C
FC
3
OVERLOAD
ONLY ON
ROTATY
COMP.
POWER
SUPPLY
3
4
10
1
10
2
3
5A
CON6-5
5A
CON6-1
FC
ST
HEATERÕS
THERMOSTAT
TC
FAN
MOTOR
6
0
6
CON6-9
HEATER (OPT)
TH3
0
CON4
CON8
S
6
2
CON6-7
5A
CON6-3
1
RVS
HEATER
RL4
R
8
CON1
SWEEP
MOTOR
4
8
FAN
MOTOR
RL2
RL3
CONTR
1
5
TH3
TH3
FUSE BA
MODELS (Outdoor):
38CS-018-301
38CS-024-301
38CS-030-301
MODELS (Indoor):
40CS-018-301
40CS-024-301
40CS-030-301
Fig. 25—Wiring Diagram
A01197
I N D O O R
U N I T
W I R I N G
TH1
D I A G R A M
T H2
O U T D O O R
M AIN
D ISPL AY
TAC - 4 6 0
U N I T
RVS
TH 3
TH3
BK
TH3
CON2
CON5
CON3
RL2
COMP.
RL1
RVS
BK
1A
BK 1 2
¥ ¥ BK
1
CON5-1
1A
YEL
G R AY /D R
CON5-3
RL8
CONTR
4
RED
5
WH
7
5A
OM
CON5-6
¥ ¥Y E L
3
¥ ¥ RED
¥ ¥WH
CON1
1
2
2
3
3
4
4
5
5
6
6
7
7
¥ BR 1 5
BK( YEL )
R ED 1 6
¥ BL U E 9
WH 2
P3 J 3
5A
OL
RL4
1
CON5-4
RED 16
¥ G R /Y E L
¥ G R / YEL 5
BLUE
FC
¥ FAN CAPACITOR
FUSE BA
RVS
¥ REVERSINGVALVE
SOLENOID
¥ 12 AWG WIRE
¥ ¥ 14 AWG WIRE
1P H - S 2675706- A
CONTRACTOR
R
1 2 3 4 5 6
OVERLOAD
ONLY ON
ROTARY
COMP
BK
P5
¥BK
)
J5
FAN MOTOR
S
C
BR
G R /Y E L
CH
¥ CRANKCASE HEATER
(OPTION).
A1
1 2 3 4 5 8
C O N4
ALL HIDDEN LINES (
ON H MODELS.
4
FC
WH
BR
RED
Y E L /G R
0
A2
L
P OWE R
S UP P LY
HEATER( O PT)
1
BK
¥ BR 15
¥ BR
N
0
¥BR
CON8
2
FA N
MOTO R
CON6-9
CON9
4
BLUE
¥ BR 14
- 1 2 VD C
B
5A
CON6-3
¥ GR/YEL
FC
BR
BK
IM
RL6
¥ BLUE
RED
CON6-1
BLK
BLK
15
OR
5A
IL
RL7
WH 3
BR 13
BLK
CON6-5
BLUE 10
IT
G R /Y E L
WH 2
RL5
CON7
2
WH
CON5-7
5A
WH T
¥¥ BR
¥ BLUE
CON6
SWEEP
M OTO R
6
BR
CON5-5
¥¥ BLUE
BK 12
5A
OM
RL3
0
¥ G R /Y E L 5
BLUE
MODELS (Indoor)
40CG-018-301
40CG-024-301
40CG-030-301
CH
BK
COMPR.
MODELS (Outdoor)
38CG-018-301
38CG-024-301
38CG-030-301
Fig. 26—Wiring Diagram
A01198
INDOOR UNIT
ELECTRICAL DIAGRAM
OUTDOOR UNIT
CONTACTOR
TH2
TH1
2
MAIN
DISPLAY
TAC - 460
CON2
CONTR
CON3
2
7
COMP 7
5
OL
1
4
5
6
COMPRESSOR
5
5
FAN
MOTOR
CON5
R
RL2
COMP
RL1
RVS
RL8
OH
1A
CON5-1
1A
CON5-3
1
OH
1
2
5A
CON5-6
3 HEAT
1
DL
5A
CON5-4
OH
5A
CON5-5
RL3
C
CH
FC
3
OVERLOAD
ONLY ON
ROTARTY
COMP
CON1
RL4
POWER
SUPPLY
S
6
RVS
CON6
CON5-7
16
SWEEP
MOTOR
RL5
CON7
IT
RL7
RL6
¥12VDC
CON9
5A
CON6-5
IL
5A
CON6-1
IH
5A
CON6-3
FC
FAN
MOTOR
6
HEATER(OPT)
¥
6
4
MODELS (Indoor)
40CG-018-301
40CG-024-301
40CG-030-301
TH3
2
CON8
6
CON6-9
CON4
TH3
TH3
MODELS (Outdoor)
38CG-018-301
38CG-024-301
38CG-030-301
FUSE 6A
Fig. 27—Wiring Diagram
A01199
TROUBLESHOOTING
Table 6—Indicator Lamps Troubleshooting
LAMPS STATUS
INDICATION
CORRECTIVE ACTION
POWER flashes 10 seconds after A/C
start-up (with or without other signal lamps)
Communication problem.
• Check connection between indoor
(TAC-440) and outdoor (TAC-420) units (for TAC-400, ANC).
• Check connection between TAC-444 and TAC-460 (for TAC-404).
POWER, COMPRES. and PRESSURE
lamps flash.
Thermistor failure.
• Check TH-1 for correct resistance.
• Check for proper connection between TH-1 and TAC-444.
• Replace TH-1 if necessary.
POWER, COMPRES. and IMPEDANCE
lamps flash.
Thermistor failure.
• Check TH-2 for correct resistance.
• Check for proper connection between TH-2 and TAC-444.
• Replace TH-2 if necessary.
POWER lamp flashes and PRESSURE
is lit, AIR CON is Off.
Low Pressure
• Check if the filters are clean.
• Check TH-1 and TH-2 for correct resistance.
• Check cooling system for normal operation.
POWER and PRESSURE lamps flash,
AIR CON is Off.
High Pressure.
• In Heat mode: Check if the evaporator is blocked. (Check if filters
are clean.)
• Check TH-2 (in Heating mode) or TH-3 (in Cool mode) for correct
resistance.
• Check cooling system for normal operation.
FILTER is lit.
Filter cleaning.
• Clean all filters.
POWER, IMPEDANCE lamps flash,
COMPRES. is lit.
Low voltage.
• Check power supply voltage.
• Check electrical connections.
• Replace TAC-444.
POWER lamp flashes, IMPEDANCE
and COMPRES. lamps lit. AIR CON
lamp flashes after A/C start-up.
Voltage failure at start-up.
• Check power supply voltage.
• Check electrical connections.
• Replace TAC-444.
POWER lamp flashes, IMPEDANCE
and COMPRES. are lit before A/C startup.
High Voltage.
• Check power supply voltage.
• Check electrical connections.
• Replace TAC-444.
POWER lamp flashes, IMPEDANCE and
COMPRES. are lit. AIR CON is lit
after A/C startup.
High voltage during compressor operation.
• Check power supply voltage.
• Check electrical connections.
• Replace TAC-444.
17
Table 7—General Troubleshooting Chart
SYMPTOM
PROBABLE CAUSE
a. Power supply to unit not connected
(POWER LED Off).
CORRECTIVE ACTION
Check for proper connection of power
at disconnect
Reset automatic circuit breaker or
b. Fuse Blown (POWER LED Off).
replace line fuse.
Press ON/SEND button on Remote Control, or use
the AUTO 3-position slide switch for
A/C fails to start.
c. ON/SEND has not been pressed.
automatic constant 22°C Set Point
(when Remote Control is not available).
d. Indoor unit does not receive transmitted
Make sure that nothing is blocking the Remote Control
commands.
transmission to the A/C display.
Slide the 3-position switch on the Display
e. AUTO-OFF-REMOTE switch is set to Off.
to REMOTE (RMOT) position.
Check if the Remote Control is on the desired mode.
If not, select the correct mode (refer
a. The selected mode is on Fan Only,
to your User manual). Also note that
or on Cool when heating is desired.
each 15 minutes (max), the compressor
Only indoor fan ventilator works,
will be switched on for 3 minutes (at least).
although cooling or heating is desired.
Observe the temperature setting on the Remote Control.
b. Temperature is set to a value which
Also note that each 15 minutes (max),
is too high (in Cool mode.)
the compressor will be switched on
for 3 minutes (at least).
a. In Heat Mode: Indoor fan motor blocked. Remove obstruction.
Only indoor fan motor and compressor
b. In Cool mode: System runs while
Wait up to 90 seconds until Anti-Ice routine
working. Outdoor fan motor stopped.
evaporator Anti-ice routine take place.
is completed.
a. Run capacitor of outdoor fan
Replace outdoor fan motor run capacitor.
In Cool mode: High pressure, or;
motor is burnt.
in Heat mode: Outdoor coil freeze
b. Winding of outdoor fan motor is shorted. Replace outdoor fan motor.
a. Overload safety device on compressor
Switch Off power and try again after one hour.
Only indoor fan motor and outdoor fan is cut out due to high temperature.
motor are working. No cooling and/or
b. Compressor run capacitor is burnt.
Replace compressor run capacitor.
heating take place.
c. Compressor winding shorted.
Replace compressor.
1. Check voltage. Repair wiring if necessary.
a. Indoor fan motor is blocked
2. Check indoor fan wheel if tight on
or turns slowly.
motor shaft. Tighten if necessary.
b. Indoor fan motor capacitor is burnt.
Replace indoor fan motor capacitor.
No air supply at indoor unit
(compressor operates).
c. Indoor fan motor winding is burnt.
Replace indoor fan motor.
d. In Heat mode: Delayed start for
Normal software delay (max. 20 sec)
indoor fan motor.
e. Clogged air filters.
Clean filters.
a. Lack of refrigerant (will be accompanied Unit must be charged (according to
by whistling noise): Causes ice formation
the nameplate) after localizing the
Low Capacity.
on the evaporator coil (in Cool mode).
gas leak.
b. Clogged air filters.
Clean filters.
In Heat mode: only compressor runs,
Wait (max.) 10 minutes until the A/C
outdoor and indoor fan motors are
A/C operates in De-Icing cycle.
resumes normal operation.
stopped. AIR CON indicator flashes.
Note: Check for broken wires and loose cable lugs first!
Warning
: Always unplug the A/C before performing cleaning or maintenance activities.
18
Table 7—General Troubleshooting Chart (Continued)
SYMPTOM
PROBABLE CAUSE
Water accumulates and overflows
from evaporator drain pan.
Drain pan pipe or hose is clogged or
the spout of drain pan is clogged.
Water dripping from the condenser
base (in Heat mode).
Water drain outlet or the spout is clogged.
a. The 3-position slide switch on the A/C
display is in AUTO or OFF position.
b. Faulty Remote Control settings.
Unit does not operate in desired mode.
c. Remote Control low battery.
d. IR detector.
The A/C is interfered by other Remote
Control or our Remote Control interfering other instruments.
Common IR Code.
In Cool mode: the unit (compressor)
do not start.
a. Faulty TH-3 (outdoor) sensor.
b. Faulty TH-3 Extension Cable (between
indoor and outdoor).
Note: Check for broken wires and loose cable lugs first!
Warning
: Always unplug the A/C before performing cleaning or maintenance activities.
19
CORRECTIVE ACTION
Disassemble plastic drain-pipe from
spout of evaporator drain pan. Flush
with clean water.
Open condenser cover, clean out water
outlet, clean the base inside thoroughly.
Change the slider position to
REMOTE (RMOT).
1. If Remote Control symbols respond to
the commands correctly, check the A/C ID
Code (Standard or Alternative). Refer to
“Changing A/C ID
Code” and to Remote Control DIP switch 3
setting.
2. If Cool commands are OK, but Heat
symbol is skipped on LCD, refer to Remote
Control DIP switch 7 setting.
3. Replace Remote Control.
Replace Remote Control batteries.
Try shorter distance between Remote
Control and A/C.If no response, replace IR
detector.
Modify the Remote Control IR transmission
code.
Refer to “Changing A/C ID Code” and to
Remote Control DIP switch 3 setting.
Replace the TH-3 sensor.
Replace TH-3 Extension Cable.
Copyright 2001 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
38c40c1si
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 533-80013
Printed in U.S.A.
Form 38C/40C-1SI
Pg 20
8-01
Replaces: New
Tab misc. misc