Instruction manual

ManualsBrandsCarrier ManualsAir Conditioner40CS024

40CG Indoor Unit/38CG Outdoor Unit

40CS Indoor Unit/38CS Outdoor Unit

Console and Underceiling Duct Free Systems

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 CAU-

TION. These words are used with the safety-alert symbol. DAN-

GER 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

COPPER TUBING

SIZE (IN.)

38 & 40CG/CS-018 1/4 and 1/2

38 & 40CG/CS-024 3/8 and 5/8

38 & 40CG/CS-030 3/8 and 5/8

Installation must be performed in accordance with the manufac-

turer’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.

Visit www.carrier.com

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4

Tab misc. misc

PC 101 Catalog No. 533-80013 Printed in U.S.A. Form 38C/40C-1SI Pg 1 8-01 Replaces: New

Summary of content (20 pages)

PAGE 1
40CG Indoor Unit/38CG Outdoor Unit 40CS Indoor Unit/38CS Outdoor Unit Console and Underceiling Duct Free Systems Visit www.carrier.com Installation and Start-Up Instructions NOTE: Read the entire instruction manual before starting the installation. TABLE OF CONTENTS SAFETY CONSIDERATIONS .....................................................1 INTRODUCTION ..........................................................................1 General ......................................................................
PAGE 2
A01084 Fig. 1—Ceiling Installation A01212 Fig.
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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
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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.
PAGE 5
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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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 O
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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.
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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.
PAGE 16
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
PAGE 17
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.
PAGE 18
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.
PAGE 19
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.
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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.