Concepcion

Carrier

Air conditioning

Company

INSTALLATION, START-UP AND

SERVICE INSTRUCTIONS

38ASB/CCARS240~600 (036~060)

Philippines

AIR-COOLED CONDENSING UNIT

CONTENTS

Safety Considerations 1

Dimensional Drawing 2

Complete Electrical Connections 5

Start-up 5

Model Identification 2 Refrigerant Charging 5 - 6

Specifications 3 Service and Maintenance 6 - 7

Installation 4 Wiring Diagram 7 - 13

Refrigerant Piping 4

Piping Connections 5

Trouble-Shooting Guide 14

FIG. 1

38ASB/CCARS240~600

(036~060) Export

SAFETY CONSIDERATIONS

Installation and s ervicing of air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service air conditioning equipment.

Observe precautions in the literature, tags and labels attached to the unit and other safety codes. Wear safety glasses and gloves. Use quenching cloth and have fire extinguisher available for all brazing operations.

RECEIVING

38ASB/CCARS240~600 condensing units (Fig. 1) are shipped individually packed in carton boxes. When cartons are individually off loaded from truck, do not roll, nor throw, or drop the carton, to avoid damages to the content. Store boxes upright as the symbols or the boxes indicate. Do not stack units more than 2 high.

INSPECTION

Check the shipment against shipping list and remove unit from the carton and take off protective covering. If the unit has been damaged, file claim with Transportation Company and notify Carrier immediately.

PROTECTION

Protect unit from damage caused by job site debris. Do not allow dust, debris and water get into the unit.

These will damage unit’s component and unit’s performance will be affected.

WARNING

Before installing or servicing system always turn off main power supply. There may be more than one disconnect switch. Electrical shock can cause personal injury.

1

FIG. 2 38ASB/CCARS024~060 DIMENSIONAL DRAWING

TABLE 1 – MODEL IDENTIFICATION

SERIES

2TR

STD

3TR

(EXPORT)

OLD MODEL NUMBER 38ASB 38ASB240BA 38ASB360BA 38ASB036BA

STD

38ASB600DB *

38ASB600DC **

5TR

(EXPORT)

38ASB060BA

NEW MODEL NUMBER CCAR CCARS024EA CCARS036EA CCARS060KA -

REMARKS

Single phase supply volatge

Legend:

* - Model used for 40KMC/GKX, 42GX/AR, 40LX

** - Model used for SlimPack ASBFE600BA

2

TABLE 2 SPECIFICATIONS

MODEL

38ASB / CCARS

036BA

(Export)

060BA

(Export)

600DA/DB 240BA 360BA 600DC

OPERATING WEIGHT

GROSS WEIGHT

REFRIGERANT

COMPRESSORS

CONDENSER FAN

FAN MOTOR

CONDENSER COIL

CONNECTIONS

(kg)

(kg)

Type

Factory charged (kg)

Type

Oil Charged (l)

LRA (A) Nominal

Running Amps (A)*

Power Supply

Type

Number

Blade Dia. (mm)

Speed (rpm)

Drive

Type

Power Supply

Running Amps (A)*

Rows - Fins/inch

Face Area (m

2

)

Type

Liquid, (mm) inch.

67

69.5

1.5

0.90

66

12.6

2R - 15

0.379

80.5

83

80.5

83

95

97.5

R-22

2.52

2.52

2.55

Hermetic

1.30

91

1.30

91

16.8

16.8

230V-1Ph-60Hz

1.66

175

26.8

2.5 - 15

0.536

Propeller

1

550

950

Direct Drive

Permanent Split Capacitor

230V-1Ph-60Hz

1.7

3.5R - 15

Flare

(9.5) 3/8

85

87.5

2.27

85

87.5

1.95

139

1.95

135

16.7

15.0

230V-3Ph-60Hz

0.654

3R - 15

2.50

CONTROLS; PRESSURES SWITCH

SETTINGS

Suction, (mm) inch.

High Cut Out (psi)

Cut In (psi)

Low Cut Out (psi)

(15.88) 5/8

426

?

20

320

?

10

27

?

4

67

?

7

(19.05) 3/4

NOMINAL POWER SOURCE

Cut In (psi)

V-Ph-Hz 230V-1Ph-60Hz 230V-3Ph-60Hz

ABSOLUTE MIN. - MAX VOLTAGE (V) 197 - 253

LRA : Locked Rotor Amps

??

Data rated to PNS standard at 35

0

C (95

0

F) Ambient, 27.0

0

C / 19.0

0

C (80.6

0

F / 66.2

0

F) Indoor Condition.

FIG. 3 GROUND MOUNTING FIG. 4 WALL MOUNTING

180 - 253

3

INSTALLATION

SELECTION OF MOUNTING POSITION

1) The unit should be installed outdoors.

2) A place where air will not be stagnant.

3) A place where the exhausted air will not be sucked in for the second time.

4) Allow sufficient space for airflow clearance, wiring, refrigerant piping and servicing unit. See Fig. 2.

5) Avoid positioning unit in such a manner that water will pour directly onto the unit.

6) Do not install the unit near a source of heat, steam or flammable gas.

7) Ducting of the fan inlet or discharge is not permitted.

UNIT MOUNTING

1)

MOUNTING ON GROUND

– Mount on a solid, level concrete base. If conditions or local building codes require unit to be fastened to base, tie down bolts should be used and fastened through slots provided in unit’s mounting feet (Fig. 3). Do not install unit directly on ground.

2)

MOUNTING ON AND AGAINST THE WALL

– the bracket is to be locally procured (Fig. 4).

3)

MOUNTING ON ROOF

– Mount on a level platform or frame. When multiple unit are installed, the air outlet side should be opened as shown in Fig. 5.

When installation base is used, secure the required spacing as per (Fig. 6). Fabricate the stand so that it will have sufficient strength.

Run refrigerant tubes as directly as possible, avoiding unnecessary turns and bends. Condensing unit may be connected to evaporator sections using field-supplied tubing of refrigerant grade, correct size and condition.

Suspend refrigerant tubes so they do not transmit vibration to structure. Also when passing refrigerant tubes through walls, seal opening so vibration is not transmitted to structure. Leave some slack in refrigerant tubes between structure and unit to absorb vibration.

The longer the piping, the lower the cooling capacity of the unit. See table 3.

TABLE 3 – REDUCTION IN CAPACITY VS

INCREASE IN PIPE LENGTH

MODEL

PIPING LENGTH (ONE WAY)

38ASB /

CCAR

240

360 / 036

600 / 060

5m

0%

0%

0%

10m

1.2%

1.6%

2.8%

15m

2.0%

2.6%

4.8%

20m

2.8%

3.6%

6.7%

25m

3.5%

4.6%

8.7%

30m

4.5%

5.6%

10.2%

As such the following are the operating limits. Refer to

Table 4 and fig. 7.

TABLE 4 – VERTICAL AND HORIZONTAL

SEPARATION BETWEEN INDOOR

AND OUTDOOR UNIT

MODEL MAX.

MAX.

LIQUID LINE

38ASB / HEIGHT LENGTH MAX. ALLOWABLE MAX. ALLOWABLE

CCARS024~060 H(m) L(m) PRESSURE DROP TEMPERATURE

(kPa)

LOSS (

0

C)

024

360 / 036

600 / 060

(20)15

(20)15

(25)15

25

25

30

151 5

Note: 1) Values shown are for units operating at 7.2

0

C saturated suction

and 35

0

C entering air.

2) Values in ( ) indicate a case when the outdoor unit is located at

a lower height than the indoor unit.

FIG. 5 ROOF MOUNTING

FIG. 6 MINIMUM SPACING REQUIREMENT

REFRIGERANT PIPING

Size Refrigerant Lines. Consider length of piping required between unit and evaporator, amount of liquid lift and compressor oil return (Table 4).

FIG. 7 MAXIMUM ALLOWABLE PIPING LENGTH

AND ELEVATION DIFFERENCE

Do not bury section of line set underground. If any section is buried, refrigerant may migrate to cooled buried section during extended period of unit shutdown. This causes refrigerant slugging and possible compressor damage at start-up.

If either refrigerant tubing or indoor coil is exposed to atmospheric conditions for longer than 5 minutes, it must be evacuated to 1000 microns to eliminate contamination and moisture in the system.

4

PIPING CONNECTIONS

Complete all installation and piping work required for indoor and outdoor units. If brazing is required pass nitrogen or other inert gas through piping to prevent formation of cooper oxide. Unit contains R-

22 charge, do not open Schreader valve at this time. Leak test field piping by pressure method.

PIPING INSULATION

No refrigerant control device is shipped with the unit except 024 model. It is already installed in matching Fan coil units, check carefully the indoor unit. Insulate suction line adequately (Fig. 8)

NOTE: Model 240 need to insulate both Suction and liquid pipes

FIG. 8 PIPING INSULATION

COMPLETE ELECTRICAL CONNECTIONS

CAUTION

THE CONTROL VOLTAGE FROM THE FAN COIL UNIT

MUST BE OF 230V. DO NOT CONNECT THE POWER

SUPPLY TO THE SIGNAL

POWER

– Unit is factory wired for voltage shown on name plate.

Provide adequate fused disconnect switch within sign of unit, readily accessible, but out of reach children.

Provide for locking switch open (OFF) is advisable to prevent power from being turned on w hile unit is being serviced.

Route power wires through opening in unit side panel and connect in unit control box (fig. 9). Unit must be grounded.

Note: - Operation of unit on improper line voltage constitutes

abuse and could affect Carrier Warranty. Do not install

unit in system where voltage may fluctuate above or below

permissible limits.

START-UP

PRELIMINARY CHECKS:

1) Check that all internal wiring connections are tight and all barriers, covers and panels are in place.

2) Field electrical power source must agree with unit name plate rating.

3) All service valves must be opened.

START SYTEM

1. Check that field disconnect is closed.

2. Set room thermostat to below room temperature, and unit compressor will start after 3 minutes delay o.

3. Check back pressure when compressor runs. A dd charge to keep back pressure at approximately 448kPa (65 PSIG).

REFRIGERANT CHARGING

CAUTION

TO PREVENT PERSONAL INJURY, WEAR SAFETY

GLASSES AND GLOVES WHEN HANDLING

REFRIGERANT. DO NOT OVERCHARGED SYSTEM.

THIS CAN CAUSE COMPRESSOR FLOODING.

I M P O R T A N T

For accurate system performance, charge by superheat method as shown in table 5 and 6.

To check and adjust charge, follow the following procedures:-

1) Operate unit for a minimum of 15 minutes before checking charge.

2) Measure suction pressure by attaching a gauge to suction line service port.

3) Measure suction line temperature by attaching a service thermometer to unit suction line near suction valve.

Insulate thermometer for accurate readings.

4) Measure outdoor coil air inlet dry-bulb temperature with a second thermometer.

5) Measure indoor coil air inlet wet-bulb temperature with a sling psychrometer.

6) Refer to table 5. Find air temperature entering outdoor coil

& wet-bulb temperature entering indoor coil. At this intersection, note the superheat.

7) Refer to table 6 . Find superheat temperature and suction pressure, note suction line temperature.

FIG. 9 POWER WIRES TO THE SIDE OF UNIT

CONTROL CIRCUIT WIRING

Refer to wiring diagram for field supplied wiring details.

See Fig. 11 & 12.

5

R E F R I G E R A N T C H A R G I N G ( c o n t )

8)

If unit has higher suction line temperature than charted temperature add refrigerant until charted temperature is reached.

9)

If unit has lower suction line temperature than charted temperature, bleed refrigerant until charted temperature is reached.

10)

If air temperature entering outdoor coil or pressure at suction line charge to new suction line temperature indicated on chart.

11) This procedure is valid independent of indoor air quantity.

SERVICE AND MAINTENACE

CAUTION

BEFORE PERFORMING RECOMMENDED MAINTENANCE

AND SERVICE, 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 COIL –

Coil should be washed out with water or blow out with compressed air. The draw thru design causes dirt and debris to built up on the outside of the coils. Clean coil as follows:-

1) Turn off unit power.

2) Using a water hose or other suitable equipment, flush coil from the inside to remove dirt (see Fig. 10). Be sure to flush all dirt and debris from drain holes in base of unit. Fan motor is water proof but it is more safe to cover or wrap motor shell with plastic sheet (or plastic bag) to prevent water from getting inside.

Clean coil semi-annually or as required. Fins are not continuous through coil sections. Dirt and debris may pass between the row of fins and become trapped between the row of fins and restrict condenser air flow. Use a flashlight to determine if dirt or debris has collected between coil section.

FIG. 11 38ASB240BA, 360 & 036 / 060 (export models) WIRING

FIG. 10 CLEANING COIL WITH WATER

LUBRICATION

Fan motor is permanently sealed lubricated bearings. Do not oil.

Compressor is supplied charged with oil. Replace oil when lost.

See table 2 for oil recharge quantity.

PE720113

6

FIG. 12 38ASB600DC WIRING DIAGRAM

PE740132

PE740133

FIG. 13 38ASB600DB WIRING DIAGRAM

NOTE:

FOR OTHER 38ASB WIRING DIAGRAM NOT SHOWN HERE, PLEASE REQUEST COPIES FROM

CCAC ENGINEERING DEPARTMENT.

7

TABLE 5

Superheat Charging Table

(Superheat Entering Suction Service Valve)

OUTDOOR

TEMP (

0

F)

INDOOR COIL ENTERING AIR (

0

F) WET-BULB

50 52 54 56 58 60 62 64 66 68 70 72 74 76

9 12 14 17 20 23 26 29 32 35 37 40 42 45 55

60

65

70

75

80

85

90

95

7

--

--

--

--

--

--

--

10

6

--

--

--

--

--

--

12

10

7

--

--

--

--

--

15

13

10

6

--

--

--

--

18

16

13

9

5

--

--

--

21

19

16

12

24

21

19

15

27

24

21

18

30

27

24

21

33

30

27

24

35

33

30

28

38

36

33

31

40

38

36

34

43

41

39

37

8 12 15 18 21 25 28 31 35

--

--

--

8

5

--

11

9

6

15

13

10

19

16

14

22

20

18

26

24

22

30

27

25

33

31

29

100

105

110

115

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

8 12 15 20 23 27

5 9 13 17 22 26

6

--

11

8

15

14

20

18

25

23

- Do not attempt to charge system under these conditions of

refrigerant slugging may occur.

TABLE 6

Required Suction Tube Temperature (

0

F)

(Entering Suction Service Valve)

36

38

40

30

32

34

20

22

24

26

28

SUPERHEAT

TEMP (

0

F)

SUCTION PRESSURE AT SERVICE PORT (psig)

61.5

64.2

67.1

70.0

73.0

76.0

79.2

82.4

85.7

0

2

35

37

37

39

39

41

41

43

43

45

45

47

47

49

49

51

51

53

10

12

14

4

6

8

16

18

39

41

43

45

47

49

51

53

41

43

45

47

49

51

53

55

43

45

47

49

51

53

55

57

45

47

49

51

53

55

57

59

47

49

51

53

55

57

59

61

49

51

53

55

57

59

61

63

51

53

55

57

59

61

63

65

53

55

57

59

61

63

65

67

61

63

65

55

57

59

67

69

55

57

59

61

63

65

67

69

71

73

75

57

59

61

63

65

67

69

71

73

75

77

59

61

63

65

67

69

71

73

75

77

79

61

63

65

67

69

71

73

75

77

79

81

63

65

67

69

71

73

75

77

79

81

83

65

67

69

71

73

75

77

79

81

83

85

67

69

71

73

75

77

79

81

83

85

87

85

87

89

79

81

83

69

71

73

75

77

87

89

91

81

83

85

71

73

75

77

79

12.8

15.5

18.3

21.1

23.9

26.7

29.4

32.2

36.0

37.8

40.6

43.3

46.1

Superheat Charging Table

(Superheat Entering Suction Service Valve)

OUTDOOR

TEMP (

0

C)

--

--

--

--

--

--

--

--

--

--

INDOOR COIL ENTERING AIR (

0

C) WET-BULB

10 11.1 12.2

13.3

14.4

15.6

16.7

17.8

18.9

20 21.1

22.2

23.3

24.4

5

3.9

--

6.7

5.6

3.3

7.8

6.7

5.8

9.4

8.3

7.2

11.1

10

8.9

12.8

11.7

10.6

14.4

13.3

11.7

16.1

15

13.3

17.8 19.4

16.7 18.3

15 16.7

20.6

19.4

18.3

22.2

21.1

20

23.3

22.2

21.1

25

23.9

22.8

--

--

--

--

--

--

--

--

--

--

--

--

--

--

3.9

--

--

--

--

--

--

--

--

--

5.6

3.3

--

--

--

--

--

--

--

--

7.2

5

2.8

--

--

--

--

--

--

--

8.9

10.6

11.7

13.3

15 16.7

18.3

20

6.7

8.3

10 11.7 13.3

15.6

17.2

18.9

21.7

20.6

4.4

6.7

-4.4

--

--

2.8

--

8.3

6.1

5

4.4

10

8.3

7.2

5.6

11.7

10.6

8.9

7.8

13.9

12.2

11.1

10

15.6

14.4

13.3

12.2

17.2

16.7

15

13.9

19.4

18.3

17.2

16.1

--

--

--

--

--

--

--

--

3.3

2.8

--

--

6.7

5

3.3

--

8.3

7.2

6.1

4.4

11.1

8.3

7.8

12.8

9.40 12.2

11.1

10

15

14.4

13.9

12.8

- Do not attempt to charge system under these conditions or

refrigerant slugging may occur.

Required Suction Tube Temperature (

0

C)

(Entering Suction Service Valve)

4.4

5.6

6.7

7.8

0

1.1

2.2

3.3

8.9

10.0

SUPERHEAT

TEMP (

0

K)

424

SUCTION PRESSURE AT SERVICE PORT (KPaG)

443 463 483 503 524 546 568 591

6.1

7.2

8.3

9.4

1.7

2.8

3.9

5

2.8

3.9

5

6.1

7.2

8.3

9.4

10.6

3.9

5

6.1

7.2

8.3

9.4

10.6

11.7

5

6.1

7.2

8.3

9.4

10.6

11.7

12.8

10.6

11.7

12.8

13.9

11.7

12.8

13.9

15

6.1

7.2

8.3

9.4

11.7

12.8

13.9

15

16.1

7.2

8.3

9.4

10.6

12.8

13.9

15

16.1

17.2

8.3

9.4

10.6

11.7

13.9

15

16.1

17.2

18.3

9.4

10.6

11.7

12.8

10.6

11.7

12.8

13.9

15

16.1

17.2

18.3

19.4

10.6

11.7

12.8

13.9

15

16.1

17.2

18.3

19.4

20.6

11.1

12.2

13.3

14.4

15.6

12.8

13.9

13.9

15

15

15

16.1

16.1

17.2

17.2

18.3

18.3

19.4

19.4

20.6

20.6

21.7

21.7

22.8

16.1

17.2

18.3

19.4

20.6

21.7

22.8

23.9

16.1

17.2

18.3

19.4

20.6

21.7

22.8

23.9

17.2

18.3

19.4

20.6

21.7

22.8

23.9

25

25

26.1

16.7

17.8

18.9

20.0

21.2

22.2

18.3

19.4

20.6

21.7

22.8

23.9

19.4

20.6

21.7

22.8

23.9

20.6

21.7

22.8

23.9

25

25

25 26.1

27.2

26.1

27.2

28.3

26.1

27.2

28.3

29.4

21.7

22.8

23.9

22.8

23.9

25

23.9

25

25

26.1

26.1

27.2

27.2

28.3

28.3

29.4

29.4

30.6

30.6

31.7

26.1

27.2

28.3

29.4

30.6

31.7

32.8

8

38ASB240BA MATCHED WITH 42PGA026 38ASB240BA MATCHED WITH 42AR024 / 42GX024

38ASB360BA MATCHED WITH 42AR036 / 42GX040

FIG. 14 SCHEMATIC SYSTEM WIRING DIAGRAM

9

38ASB240BA MATCHED WITH 40GKX / KMC024

38ASB360BA MATCHED WITH 40GKX / KMC036

38ASB360BA MATCHED WITH ASBFM360BA

FIG. 15 SCHEMATIC SYSTEM WIRING DIAGRAM

10

38ASB360BA MATCHED WITH 40LX040 38ASB600DC MATCHED WITH 42AR / 42GX060

FIG. 16 SCHEMATIC SYSTEM WIRING DIAGRAM

11

38ASB600DC MATCHED WITH 40GKX / KMC060

38ASB600DB MATCHED WITH 40LX060

12

38ASB600DC MATCHED WITH ASBFE600BA

13

TROUBLE-SHOOTING CHART – COOLING CYCLE

NO COOLING OR

IN-SUFFICIENT

COOLING

COMPRESSOR

WILL NOT RUN

COMPRESSOR RUNS

BUT CYCLES ON

INTERNAL OVERLOAD

COMPRESSOR RUNS

BUT INSUFFICIENT

COOLING

CONTACTOR OPEN

FAULTY POWER

SUPPLY

OPEN CONTROL

CIRCUIT

DEFECTIVE TIME

DELAY

CONTACTOR OR

COIL DEFECTIVE

LOOSE ELECTRICAL

CONNECTION

CONTACTOR

CLOSED

OUTDOOR FAN

STOPPED OR CYLING

COOLING

LOOSE LEAD AT

FAN MOTOR

COMPRESSOR

POWER

SUPPLY OPEN

LOSE LEADS

AT COMPRESSOR

OUTDOOR AIR

RESTRICTED OR

RECIRCULATING

RESTRICTED

DISCHARGE LINE

OPEN SHORTED OR

GROUNDED

COMPRESSOR

MOTOR WINDINGS

COMPRESSOR

STUCK

OVERCHARGE OR

NONCONDENSABLES

IN SYSTEM

LOW REFRIGERANT

CHARGE

COMPRESSOR

INTERNAL

PROTECTION OPEN

LINE VOLTAGE

TO HIGH OR LOW

MOTOR DEFECTIVE

INCORRECT

OUTDOOR FAN MOTOR

CAPACITOR

INTERNAL

OVERLOAD OPEN

COMPRESSOR

BEARINGS

HIGH SUPERHEAT

OPEN DISCHARGE

LINE

PRESSURE SWITCH

LOW SUCTION

PRESSURE

DIRTY AIR FILTERS

DUCT RESTRICTED

DAMPERS PARTY

CLOSED

INDOOR COIL

FROSTED

SLIGHTLY LOW OR

REFRIGERANT

LIQUID LINE SLIGHTLY

RESTRICTED

METERING DEVICE

RESTRICTED

INCORRECT

METERING DEVICE

INDOOR COIL

STRAINER

RESTRICTED

HIGH SUCTION

LOW HEAD

PRESSURE

HIGH SUCTION

LOW SUPERHEAT

DEFECTIVE

COMPRESSOR

VALVE

INTERNAL

PRESSURE

RELIEF OPEN

UNIT OVERCHARGED

INCORRECT

METERING DEVICE

14

Concepcion

Carrier

Air conditioning

Company

Philippines

Concepcion Carrier Air Conditioning Company

Km. 20 East Service Road, South Superhighway,

Alabang, Muntinlupa City

Tel. No. (63)2 850 1367

Fax No. (63)2 809 9979

Website:

www.carrier.com.ph

Manufacturer reserve the right to discontinue, or charge at any time, specifications or designs without notice and without incurring obligations

Form 38ASB/CCARS024~060-1IOM

Replaces: NEW

15