Carrier Console Type Air Conditioner Installation Guide

The following accessories are related to remote controller.

Note: The accessories related to the remote controller will be unavailable for the models with a wired controller. For wired controller accessories, please refer to the attached manual of wired controllers.

INDOOR UNIT INSTALLATION

INSTALLATION SITE CHOOSING

INDOOR UNIT

• Where it is out of direct sunlight.
• Where the airflow is not blocked.
• Where optimum air distribution is ensured.
• Where the condensate can drain correctly and safely.
• Install the indoor unit on a wall/ceiling that prevents vibration and is strong enough to hold the product weight.
• Maintain sufficient clearance around the indoor unit for maintenance and servicing.
• Where the air filter can be removed and cleaned easily.
• Where the piping between the indoor and outdoor units is within the allowable limits.
•  Install the indoor unit 1m or more away from the TV or radio to prevent the screen from being distorted or noise from being generated.
• Install the indoor unit as far away as possible from fluorescent and incandescent lights so that the remote control can be operated well.

SPACE REQUIREMENT FOR INDOOR UNIT

The size of the Outline dimension

INSTALL THE INDOOR UNIT

2.2.1 Fix the hook by a tapping the screw onto the wall.

2.2.1 Hang the indoor unit on the hook.

CAUTION

• The unit must be installed vertically.
• There should be no gap between the unit and the ground.

2.3 HOW TO CONNECT THE PIPES AND WIRES
2.3.1 Push the two switches simultaneously, then open the panel.
2.3.2 Remove the string and take off the panel.

2.3.3 Remove 4 screws and then remove the frame from the bottom side. A piping connection port and drain hose connection port can be observed after take off the frame.

2.3.4 Remove the installation bearer and take off the control box cover. A wiring terminator can be observed.

INSTALL THE DRAIN PIPE

The drain line must not have a trap anywhere in its length, must pitch downwards, and must be insulated up to the outside wall.

OUTDOOR UNIT INSTALLATION

INSTALLATION SITE CHOOSING

OUTDOOR UNIT

• Where it is out of the rain or direct sunlight.
• Where it is well-ventilated and free from obstacles near the air inlet and air outlet.
• Where does not increase the operating noise or vibration of the outdoor unit?
• Where does not cause any drainage problem with discharged water?
• Install the outdoor unit properly at a place that is durable enough to the weight of the outdoor unit.
• Where provides appropriate clearances as outlined
• Where the piping between the indoor and outdoor units is within the allowable limits.
• In regions with snowfall and cold temperatures, avoid installing the outdoor unit in areas where it can be covered by snow. If heavy snow is expected, field-supplied ice or stand and field-supplied-installed wind baffle should be installed to protect the unit from snow accumulation and blocked air intake.
• When installing the outdoor unit in a place that is constantly exposed to strong wind, it is recommended that a wind baffle be used.

OUTDOOR UNIT MOUNTING DIMENSION

Model

(38QUS)

| O utline dimension
---|---
W| H| D| A| B
009| 770| 555| 300| 298| 487
012/018| 800| 554| 333| 340| 514

OUTDOOR UNIT INSTALLATION

SPACE REQUIREMENT FOR OUTDOOR UNIT

Single Unit Installation

INSTALL THE OUTDOOR UNIT

• Before installation, check the strength and horizontality of the base so that abnormal sound does not generate.
• Fix the base firmly with anchor bolts (M10) to prevent it from collapsing.
• Install the foundation and vibration-proof rubbers to directly support the bottom surface of the fixing leg that is in contact with the bottom plate of the outdoor unit.

INSTALL THE DRAIN PIPE FOR THE OUTDOOR UNIT

• Connect the drain outlet with an extension drain hose
• Fit the gasket onto the drain outlet.
• Insert the drain outlet into the base pan hole of the outdoor unit, and rotate 90 degrees to securely assemble them.

REFRIGERANT PIPING WORK

CAUTION

• Check if the height difference between the indoor unit & the outdoor unit and the total length of the refrigerant pipe meets the system requirements.
• Refrigerant piping work follows the indoor unit and outdoor unit installation, connect the pipe at the indoor side first, then the outdoor side.
• Always keep the ends of tubing sealed by placing a cap or covering them with tape during installation and do NOT remove them until you are ready to connect the piping.
• Be sure to insulate any field piping all the way to the piping connection inside the unit. Any exposed piping may cause condensation or burns if touched.

FLARING

NOTE

• Tools required for flaring are pipe cutter, reamer, flaring tool, and pipe holder.
• For R32 refrigerant models, the pipe connection points must be placed outside of the room.

4.1.1 Using a pipe cutter to cut the pipe to the requested length. Ensure that the cut edge remains at 90° with the side of the pipe.

4.1.2 Use a reamer to remove burrs with the cut surface downward so that the chips do not enter the pipe.
4.1.3 Carry out flaring work using flaring tools as below.

4.1.4 Check if the flaring is properly made. See incorrectly flared pipes sample below.

PIPING WORK

4.2.1 Align the center to tighten the flare nut and finish connection using two wrenches.

4.2.2 Select the appropriate insulation material for the refrigerant pipe. (Min. 10mm, thermal insulating foam C)

• Use separate thermal insulation pipes for gas & liquid pipes.

• The thickness above is a standard of the indoor temperature of 27°C and humidity of 80%. If installing in unfavorable conditions such as near bathrooms,
  kitchens, and other similar locations, reinforce the insulation.

• Insulation’s heat-resistance temperature should be more than 120°C.

• Use the adhesives on the connection part of insulation to prevent moisture from entering.

• Repair and cover any possible cracks in the insulation especially check the bent part or hanger of pipe

CAUTION

• In case of needing brazing, work with Nitrogen gas blowing.
• Improper torque will cause flare damage or gas leaks.

REFRIGERANT PIPING WORK

REFRIGERANT PIPE

(38QUS)| Liquid Side| Model
Gas Side| pipe length (m)| Max. Height
difference (m)| Charge less
length (m)| Additional charge
per meter (R410A/R32)
---|---|---|---|---|---|---
009/012| 436.35mm| Q9.52mm| 25| 10| 5| 15/12 g/m
18| 436.35mm| 0)12.7mm| 30| 20| 5| 15/12 g/m

NOTE: 1) Please use tools for R410A/R32 system respectively;
2) When the pipe length is over 5m, the additional refrigerant should be added according to the piping length.

4.4 AIR EVACUATION

• Connect the charge hose from the manifold gauge to the service port of the gas side-packed valve.
• Connect the charge hose to the port of the vacuum pump.
• Fully open the handle Lo of manifold gauge.
• Operate the vacuum pump to evacuate air from the system until 76cmHg.
• Close the handle Lo of manifold gauge.
• Fully open the valve stem of the packed valves.
• Remove the charging hose from the service port.
• Securely tighten caps of the packed valve.

LEAKAGE TEST

After the piping work is finished, make sure to check the connection part of each refrigerant pipe and confirm that there is no gas leak by applying soapy water to them or by using a leak detector specific for HFC refrigerants.
Refer the below picture for an illustration.

A: Low-pressure stop valve
B: High-pressure stop valve
C& D: Indoor unit flare nuts

WIRING

CAUTION

• All the electrical connections must be carried out by qualified installers and all the wirings must be connected according to the wiring diagram.
• Make ground connection prior to any other electrical connections.
• All power sources must be turned off before wiring work and do not turn on the power until you have made sure all the wirings have been safety checked.
• The main switch and circuit breaker or fuse must be installed, the capacity should be above 1.5 times of maximum current in the circuit.
• An individual branch circuit and single socket used only for this appliance must be available.
• Wire cross-section is depending on the rated current and national, state, and local electrical wiring code. Consult local building codes and National electrical codes for special requirements.
• If the supply cord is damaged, it must be replaced by the manufacturer, its service agent, or similarly qualified persons in order to avoid a hazard.
• The unit must be connected to the main power supply by means of a circuit breaker or a switch with a contact separation of at least 3mm in all poles. Installation of a residual current device (RCD) having a rated residual operating current not exceeding 30mA is advisable.

POWER FROM OUTDOOR SIDE

Wiring figure

• Power supply and connecting wires specification

3×2.5mm2
Indoor/outdoor connecting wiring HO7RN-F; 4×1.5mm2
(Field Supply)| HO7RN-F; 4×1.5mm2| HO7RN-F; 4×2.5mm2

NOTE OF FUSE SPECIFICATIONS:
(applicable to units adapt R32 refrigerant only, and the fuse is made of ceramic.)

1. The specification of outdoor unit fuse is T20A/250VAC(for <24000Btu/h unit), T30A/250VAC(for >24000Btu/h unit )
2. The specification of indoor unit fuse is T5A/250VAC, T10A/250VAC.

FINAL CHECK AND TRIAL OPERATION

FINAL CHECKLIST

To complete the installation, perform the following checks before the trial operation.

• Strength of the installation site for both indoor and outdoor sides, confirm no obstruction of the unit air outlet or return.
• Tightness of Refrigerant piping connection and confirm no leakage
• Electric wiring connections are correctly completed and the unit has been grounding connected
• Check the total length of the piping and record the volume of the additionally charged refrigerant
• The power supply should comply with the rated voltage of the air conditioner Insulation of the pipe
• Drainage

MANUAL OPERATION

Manual operation can be accessed by pressing the manual button on the display panel.
Press the manual button repeatedly to change modes as follows:

• Once = AUTO mode [heat, cool or fan, 24°C and auto fan speed.
• Twice = COOLING mode [switch to AUTO mode after 30 minutes (mainly used for trial operation)]
• Three times = OFF

TRIAL OPERATION

Set the air conditioning under the COOLING mode with the remote controller (or manual button) and check the running status of both the indoor unit and outdoor unit. In case of any malfunction, resolve it according to chapter “Troubleshooting” in the “Service Manual”.
Indoor unit

• Whether the buttons (such as ON/OFF, MODE, TEMPERATURE, FAN SPEED, etc.) on the remote controller work well.

• Whether the louver moves normally.

• Whether the room temperature is adjusted well.

• Whether the indicator lights on the display panel are normal.

• Whether the “manual” button works well.

• Whether the drainage is normal.

• Whether there is a vibration or abnormal noise during the operation.

• Whether the indoor unit works well in COOLING or HEATING mode.
  Outdoor unit

• Whether there is a vibration or abnormal noise during the operation.

• Whether the wind, noise or condensed generated by air conditioner have disturbed your neighborhood.

• Whether there is any refrigerant leakage.

CAUTION
When restarting the unit, there will be approximately 3 minutes delay to run for protection.

INFORMATION SERVICING

7.1 CHECKS TO THE AREA
Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimized. For repair to the refrigerating system, the following precautions shall be complied with prior to conducting work on the system.
7.2 WORK PROCEDURE
Works shall be undertaken under a controlled procedure so as to minimize the risk of flammable gas or vapor being present while the work is being performed.
7.3 GENERAL WORK AREA
All maintenance staff and others working in the local area shall be instructed on the nature of the work being carried out. work in confined spaces shall be avoided. The area around the workspace shall be sectioned off. Ensure that the conditions within the area have been made safe by control of flammable material.
7.4 CHECKING FOR PRESENCE OF REFRIGERANT
The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with flammable refrigerants, i.e. no sparking, adequately sealed or intrinsically safe.
7.5 PRESENCE OF FIRE EXTINGUISHER
If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate fire extinguishing equipment shall be available to hand. Have a dry power or CO2 fire extinguisher adjacent to the charging area.
7.6 NO IGNITION SOURCES
No person carrying out work in relation to a refrigeration system that involves exposing any pipework that contains or has contained flammable refrigerant shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion. All possible ignition sources, including cigarette smoking, should be kept sufficiently far away from the site of installation, repairing, removing, and disposal, during which flammable refrigerant can possibly be released to the surrounding space. Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no flammable hazards or ignition risks. “NO SMOKING” signs shall be displayed.
7.7 VENTILATED AREA
Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work.
A degree of ventilation shall continue during the period that the work is carried out.
The ventilation should safely disperse any released refrigerant and preferably expel it externally into the Matmosphere.
7.8 CHECKS TO THE REFRIGERATION EQUIPMENT
Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer’s maintenance and service guidelines shall be followed. If in doubt consult the manufacturer’s technical department for assistance. The following checks shall be applied to
installations using flammable refrigerants:

• the charge size is in accordance with the room size within which the refrigerant containing parts are installed;
• the ventilation machinery and outlets are operating adequately and are not obstructed;
• if an indirect refrigerating circuit is being used, the secondary circuits shall be checked for the presence of refrigerant; marking to the equipment continues to be visible and legible.
• marking and signs that are illegible shall be corrected;
• refrigeration pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant containing components unless the components are constructed of materials that are inherently resistant to being corroded or are suitably protected against being so corroded.

7.9 CHECKS TO ELECTRICAL DEVICES
Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. If a fault exists that could compromise the safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, and an adequate temporary solution shall be used. This shall be reported to the owner of the equipment so all parties are advised.

Initial safety checks shall include:

• that capacitor are discharged: this shall be done in a safe manner to avoid the possibility of sparking
• that there no live electrical components and wiring are exposed while charging, recovering or purging the system;
• that there is continuity of earth bonding.

7.10 REPAIRS TO SEALED COMPONENTS CAUTION
10.1 During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc. If it is absolutely necessary to have an electrical supply to equipment during servicing, then a permanently operating form of leak detection shall be located at the most critical point to warn of a potentially hazardous situation.
10.2 Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not altered in such a way that the level of protection is affected. This shall include damage to cables, an excessive number of connections, terminals not made to original specification, damage to seals,
incorrect fitting of glands, etc.

• Ensure that apparatus is mounted securely.
• Ensure that seals or sealing materials have not degraded such that they no longer serve the purpose of preventing the ingress of flammable atmospheres. Replacement parts shall be in accordance with the manufacturer s specifications.

NOTE: The use of silicone sealant may inhibit the effectiveness of some types of leak detection equipment.
Intrinsically safe components do not have to be isolated prior to working on them.
7.11 REPAIR TO INTRINSICALLY SAFE COMPONENTS
Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and currently permitted for the equipment in use. Intrinsically safe components are the only types that can be worked on while living in the presence of a flammable atmosphere. The test apparatus shall be at the correct rating. Replace components only with parts specified by the manufacturer. Other parts may result in the ignition of refrigerant in the atmosphere from a leak.

7.12 CABLING
Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.
7.13 DETECTION OF FLAMMABLE REFRIGERANTS
Under no circumstances shall potential sources of ignition be used in the searching for or detection of refrigerant leaks. A halide torch(or any other detector using a naked flame) shall not be used.
7.14 LEAK DETECTION METHODS
The following leak detection methods are deemed acceptable for systems containing flammable refrigerants.
Electronic leak detectors shall be used to detect flammable refrigerants, but the sensitivity may not be adequate or may need re-calibration.(Detection equipment shall be calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant. Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed and the appropriate percentage of gas (25% maximum) is confirmed. Leak detection fluids are suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work. If a leak is suspected, all naked flames shall be removed or extinguished. If leakage of refrigerant is found which requires brazing, all of the refrigerants shall be recovered from the system, or isolated(by means of shut-off valves) in a part of the system remote from the leak. Oxygen-free nitrogen(OFN) shall then be purged through the system both before and during the brazing process.
7.15 REMOVAL AND EVACUATION
When breaking into the refrigerant circuit to make repairs of for any other purpose conventional procedures shall be used, However, it is important that best practice is followed since flammability is a consideration. The following procedure shall be adhered to:

• remove refrigerant;
• purge the circuit with inert gas;
• evacuate;
• purge again with inert gas;
  open the circuit by cutting or brazing.

The refrigerant charge shall be recovered into the correct recovery cylinders. The system shall be flushed with OFN to render the unit safe. This process may need to be repeated several times.
Compressed air or oxygen shall not be used for this task.
Flushing shall be achieved by breaking the vacuum in the system with OFN and continuing to fill until the working pressure is achieved, then venting to the atmosphere, and finally pulling down to a vacuum. This process shall be repeated until no refrigerant is within the system.
When the final OFN charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. This operation is absolutely vital if brazing operations on the pipe-work are to take place. Ensure that the outlet for the vacuum pump is not closed to any ignition sources and there is ventilation available.

7.16 CHARGING PROCEDURES
In addition to conventional charging procedures, the following requirements shall be followed:

• Ensure that contamination of different refrigerants does not occur when using charging equipment. Hoses or
  lines shall be as short as possible to minimize the amount of refrigerant contained in them.

• Cylinders shall be kept upright.

• Ensure that the refrigeration system is earthed prior to charging the system with refrigerant.
  Label the system when charging is complete(if not already).

• Extreme care shall be taken not to overfill the refrigeration system.

• Prior to recharging the system, it shall be pressure tested with OFN. The system shall be leak tested on completion of charging but prior to commissioning. A follow-up leak test

7.17 DECOMMISSIONING
Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. It is recommended good practice that all refrigerants are recovered safely. Prior to the task being carried out, an oil and refrigerant sample shall be taken.
In case analysis is required prior to re-use of reclaimed refrigerant. It is essential that electrical power is available before the task is commenced.
a) Become familiar with the equipment and its operation.
b) Isolate system electrically
c) Before attempting the procedure ensure that:

• mechanical handling equipment is available, if required, for handling refrigerant cylinders;
• all personal protective equipment is available and being used correctly;
• the recovery process is supervised at all times by a competent person;
• recovery equipment and cylinders conform to the appropriate standards.

d) Pump down the refrigerant system, if possible.
e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system.
f) Make sure that the cylinder is situated on the scales before recovery takes place.
g) Start the recovery machine and operate in accordance with the manufacturer s instructions.
h) Do not overfill cylinders. (No more than 80% volume liquid charge).
i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
j) When the cylinders have been filled correctly and the process completed, make sure that the cylinders and the equipment are removed from site promptly and all isolation valves on the equipment are closed off.
k) Recovered refrigerant shall not be charged into another refrigeration system unless it has been cleaned and checked.
7.18 LABELLING
Equipment shall be labelled stating that it has been de-commissioned and emptied of refrigerant. The label shall be dated and signed. Ensure that there are labels on the equipment stating the equipment contains flammable refrigerant.

7.19 RECOVERY

• When removing refrigerants from a system, either for service or decommissioning, it is recommended good practice that all refrigerants are removed safely.
• When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct numbers of cylinders for holding the total system charge are available. All cylinders to be used are designated for the recovered refrigerant and labeled for that refrigerant(i.e special cylinders for the recovery of refrigerant). Cylinders shall be complete with a pressure relief valve and associated shut-off valves in good working order.
• Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
• The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of flammable refrigerants. In addition, a set of calibrated weighing scales shall be available and in good working order.
• Hoses shall be complete with leak-free disconnect couplings and in good condition. Before using the recovery machine, check that it is in satisfactory working order, has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event of a refrigerant release. Consult the manufacturer if in doubt.
• The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant Waste Transfer Note arranged. Do not mix refrigerants in recovery units and especially not in cylinders.
• If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that flammable refrigerant does not remain within the lubricant. The evacuation process shall be carried out prior to returning the compressor to the suppliers. Only electric heating to the compressor body shall be employed to accelerate this process. When oil is drained from a system, it shall be carried out safely.

7.20 TRANSPORTATION, MARKING, AND STORAGE FOR UNITS

1. Transport of equipment containing flammable refrigerants
   Compliance with the transport regulations

2. Marking of equipment using signs
   Compliance with local regulations

3.  Disposal of equipment using flammable refrigerants
   Compliance with national regulations

4. Storage of equipment/appliances
   The storage of equipment should be in accordance with the manufacturer’s instructions.

5. Storage of packed (unsold) equipment
   Storage package protection should be constructed such that mechanical damage to the equipment inside the package will not cause a leak of the refrigerant charge.
   The maximum number of pieces of equipment permitted to be stored together will be determined by local regulations.

Carrier is committed to continuous improvement of Carrier products according to national and international standards to ensure the highest quality and reliability standards, and to meet market regulations and requirements.
All specifications are subject to change without prior notice according to Carrier policy of continuous development

AHI CARRIER S.E. EUROPE AIRCONDITIONING S.A.
18, KIFISOU AVENUE 10442 ATHENS, GREECE
TEL: +30-210-6796300.

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