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INSTALLATION, START-UP ANDSERVICE INSTRUCTIONS

38LZA50Hz

AIR-COOLED CONDENSING UNIT

CONTENTS

Safety Considerations 1

Specifications 2

Installation 2

Dimensional Drawing 3

Refrigerant Piping 4 - 5

Piping Connection 6

Filter Drier 6

Complete Electrical Connections 6

System Wiring Diagram 7 - 8

Start-Up 9

Service and Maintenance 9

Trouble-Shooting Guide 10

FIG. 1 38LZA080, 100 & 125

SAFETY CONSIDERATIONS

Installation and servicing of air conditioning equipment canbe hazardous due to system pressure and electricalcomponents. Only trained and qualified service personnelshould install, repair or service air conditioning equipment.Observe precautions in the literature, tag and labelsattached to the unit and other safety codes.

Only used "Original Spare Parts" for repairs. Specialattention must be paid to the correct installation of thespare parts. The Parts must always be installed in theiroriginal position.

During unit operation, some of the refrigerant circuitelements could reach a temperature in excess of 70°C soonly trained or qualified personnel should access areasprotected by access panels.

The unit should not be installed in an explosiveatmosphere. The unit can operate in normal atmosphere inresidential, commercial and light industrial installation. Forother applications, please consult Carrier.

INSPECTION

Check the shipment received against the shipping list tomake sure that shipment is complete. Remove the unit fromplastic and take off the protective foams. If the unit hasbeen damaged in transit, file a claim with the TransportationCompany.

PROTECTION

Protect unit from damage caused by job site debris. Do notallow dust and debris from being deposited on coil, fins,motor or other interior surfaces, unit efficiency will reduce.

WARNING

Before installing or servicing system always turns off mainpower switch on the unit. There may be more than onedisconnects switch. Turn off accessory heater power ifapplicable. Electrical shock can cause personal injury.

A United Technologies Company

CarrierInternationalSdn. Bhd.Malaysia®�

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LRA : Locked Rotor Amps* Data rated to JIS standard at 350C (950F) Ambient, 27.00C/19.00C (80.60F/66.20F) Indoor Condition, when matched with carrier approved

Fan Coil Units.* Data is measured at 1m above the ground.

MODEL 38LZA

080 100 125

OPERATING WEIGHT kg 175 189 195

REFRIGERANT Type R 22

Factory Charged (kg) 1.0

COMPRESSOR Type Hermetic Scroll

Quantity 1

Oil charged (l) 3.25 3.3

LRA Nominal (A) 130 145

Protection Internal Line Brake (KLIXON)

CRANKCASE HEATER Output (W) 65

CONDENSER FAN Type Propeller

Quantity 1

Diameter (in/mm) 24” / 610 26” / 660

FAN MOTOR Speed (rpm) 900

Drive Direct Drive

Type Permanent Induction Motor

Split Capacitor

Power Supply (V - PH - Hz) 230 - 1 - 50 400 - 3 - 50

Full Loads Amps. (A) 1.85 1.75

CONDENSER COIL Rows - Fins per m 2 - 591

Face area (m2) 1.57 1.94

TUBES CONNECTION Type Sweat

Suction (in/mm) 11/8” / 28.58

Liquid (in/mm) 1/2” / 12.7

CONTROLS PRESSURESTAT High Cut Out (kPa) 2724 ± 68

SETTINGS High Cut In (kPa) 2034 ± 138

Low Cut Out (kPa) 48 ± 20

Low Cut In (kPa) 152 ± 34.5

POWER SOURCE V-Ph-Hz 400 - 3 - 50ABSOLUTE VOLTAGE Minimum (V) 380

Maximum (V) 415

TABLE 1

INSTALLATION

SELECTING INSTALLATION SITE:1. Check that the local power supply agrees with the

specification on the nameplate.2. Select a location free of dust or foreign matters, which

may cause coil clogging. A place where air will not bestagnant, exhausted air will not be re-circulated intocoil. The unit must not be installed near a source ofheat, steam or flammable gas.

3. When installing the unit on the ground, select site whereis not subject to flooding. Avoid position the unit in sucha manner that water will pour directly onto the unit.

4. Allow sufficient space for air for clearance, wiring,refrigerant piping and service. (Fig. 2 & 3)

5. Consult all applicable local rules and standard, whichgovern the installation of air conditioning equipment.

6. Ducting of the fan inlet or discharge is not permitted.

FIG. 2 SERVICE AREA

SPECIFICATIONS

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FIG. 3 38LZA080 DIMENSIONAL DRAWING

DIMENSIONAL DRAWING

FIG. 3.1 38LZA100 & 125 DIMENSIONAL DRAWING

4

UNIT MOUNTING:1. MOUNTING ON GROUND - Mount on a solid, level

concrete base. If conditions or local building codesrequire unit to be fastened to base, tie down boltsshould be used and fastened through mounting holeprovided in unit mounting base. (Fig. 4)

2. MOUNTING ON WALL - The bracket is to be locallyprocured and qualified to sustain the weight of the unit.(Fig. 5). The unit must be installed and conform to theminimum service area. (Fig. 2)

FIG. 4 GROUND MOUNTING

FIG. 5 WALL MOUNTING

3. MOUNTING ON ROOF - Mount on a level platform orframe. When multiple unit are installed, the air outletside should be opened as shown as Fig. 6. Wheninstallation base is used, secure the following space.(Fig. 7)

RIGGING AND HANDLING:1. When rigging, use spreaders to prevent damage to the

panel and coil. Avoid violent movement.2. To prevent damage while in transit, do not remove the

unit from the skid unit until it is at its final location.3. Never roll or tip the unit more than 15°.

REFRIGERANT PIPING

1. Piping length is very important to compressor reliabilityand performance. The longer the piping or the morebends or turns, the lower the cooling capacity of the air-cooled condensing unit. Avoid unnecessary turns andbends, do not over or under size the original suctionand liquid pipe.

2. Warranty void if the piping length is more than Carrierspecifies on this literature. Please refer to Table 2 and 3for the piping length limitation. (Fig. 8.1, 8.2 & 8.3)

3. Suspend refrigerant pipes in order to isolate the pipingvibration from the building, especially on the piping topassing through the wall, seal the opening to protect thepiping from vibration. Leave some slack in therefrigerant pipes between structure and unit to absorbvibration.

4. Do not bury any section of line set underground. If anysection is buried, refrigerant may migrate to coolerburied section during extended periods of unitshutdown. This causes refrigerant slugging and possiblecompressor damage at start-up.

5. If refrigerant pipes or indoor coil are exposed toatmosphere for longer than 5 minutes, it must beevacuated to 1000 microns to eliminate contaminationand moisture in the system.

FIG. 6 ROOF MOUNTING

FIG. 7 MINIMUM SPACING REQUIREMENT

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FIG. 8.1 MINIMUM ALLOWABLE PIPING LENGTH ANDELEVATION DIFFERENCE

FIG. 8.2 MINIMUM ALLOWABLE PIPING LENGTH ANDELEVATION DIFFERENCE

FIG. 8.3 MINIMUM ALLOWABLE PIPING LENGTH ANDELEVATION DIFFERENCE

TABLE 2.VERTICAL AND HORIZONTAL SEPARATION BETWEENINDOOR AND OUTDOOR UNIT

MODELS MAX.LENGTH (m)

38LZA 40LZA T U L

080

100 30 15 40

125

PRESSURE AT Required Subcooling Temperature (°C)LIQUID VALVE (kPa) 0 2 4 6 8 10

924 24 22 20 18 16 14

972 26 24 22 20 18 16

1020 28 26 24 22 20 18

1076 30 28 26 24 22 20

1124 31 29 27 25 23 21

1179 33 31 29 27 25 23

1234 34 32 30 28 26 24

1289 36 34 32 30 28 26

1351 38 36 34 32 30 28

1413 40 38 36 34 32 30

1475 41 39 37 35 33 31

1538 43 41 39 37 35 33

1606 45 43 41 39 37 35

1675 46 44 42 40 38 36

1744 48 46 44 42 40 38

1820 50 48 46 44 42 40

1889 51 49 47 45 43 41

1965 53 51 49 47 45 43

2048 55 53 51 49 47 45

2130 56 54 52 50 48 46

TABLE 3. SUBCOOLING CHARGING TABLE

WARNING !!!

WARRANTY VOID IF PIPING LENGTH IS MORETHAN THE FIGURES ABOVE.

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PIPING CONNECTION

1. Unit has R 22 holding charge. Do not open Schreadervalve.

2. Only trained and qualified technician is allowed for thebrazing process.

3. Connect piping between indoor and outdoor unit. Wetcloth should be wrapped on the unit pipes duringbrazing pipes to prevent heating on the panel andinternal closed cell insulation. Pass nitrogen or inert gasthrough the piping to prevent formation of copper oxideafter brazing.

4. Leak test must be conducted after all connection withpressure method. Use R 22 at approximately 170 kPaback up with nitrogen to a total pressure not exceed1690kPa.

5. Use soup bubble or electronic leak detector for testingthe leaks.

FILTER DRIER

Filter drier is field supplied and must be installed. If systemis vacuumed during service, it is advice to replace filterdrier with new one.

PIPING INSULATION

Insulate suction adequately with minimum 10 mm thickness.Closed cell insulation is field supplied. ( Fig. 9 )

WARNING !!!

DO NOT MODIFY THE TUBING DESIGN INSIDE THEUNIT OR WARRANTY VOID.

WARNING !!!

WARRANTY VOID IF LIQUID LINE FILTER DRIER ISNOT FIELD INSTALLED.

CONTAMINANT REMOVAL - EVACUATION

Proper evacuation of a unit remove non-condensable andassure a tight dry system before charging. Deep vacuum isone of the good methods.

Prepare a vacuum pump of capable pulling a vacuum of1000 microns furnished with a vacuum gage for measuringthe vacuum depth. Deep Vacuum method is assuring asystem is free of air and water.

Evacuation taken from both high and low side of thesystem.

COMPLETE ELECTRICAL CONNECTIONS

POWER - Unit is factory wired for voltage shown onnameplate. Provide adequate fused disconnect switchwithin sight of unit, readily accessible, but out of reach ofchildren.

Please lock the main switch during unit servicing in ordersto prevent power from being turned on.

A rubber grommet on the unit side panel is the filed wireroute to control box. Unit power must be grounded. Openthe control box cover for wiring connection. (Fig. 10)

FIG. 9 PIPING INSULATION

WARNING !!!

DO NOT USE A MEGAOHMMETER OR APPLYPOWER TO THE SYSTEM WHILE THE SYSTEM ISUNDER VACUUM.

WARNING !!!

OPERATING THE UNIT ON IMPROPER LINEVOLTAGE CONSTITUTES ABUSE AND COULD VOIDCARRIER WARRANTY. DO NOT INSTALL UNIT INSYSTEM WHERE VOLTAGE MAY FLUCTUATEABOVE AND BELOW PERMISSIBLE LIMITS STATEDIN THE TABLE 1.

FIG. 10 POWER WIRES TO THE CONSENSER

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38LZA080 c/w 40LZA080 System Wiring Diagram

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38LZA100/125 c/w 40LZA100/125 System Wiring Diagram

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START-UP

PRELIMINARY CHECK:1. Check that all internal wiring connections are tight and

that crankcase heater is propeller installed.2. Field electric power source must agree with unit

nameplate rating.3. All covers barriers and panels should be in place.4. This condenser is coupled with 40LZA Fan Coil unit with

Thermostatic Expansion Valve pre-installed. ThusSubcooling Charging Method must be used.

SUBCOOLING CHARGING METHOD:

1. All 38LZA 080, 100 & 125 are factory pre-charged 1 kgR 22.

2. A charging manifold and refrigerant bottle properlyconnected to liquid tubes Schreader valve.

3. Operate the unit few minutes before checking charge.4. Measure liquid pressure from the attaching manifold.5. Measure the liquid line (near outdoor coil) temperature

by attaching an accurate thermometer.6. Refer to Table 3 to check and adjust charge.7. To obtain the required subcooling temperature at a

specific liquid line pressure, add refrigerant if liquid linehigher than indicated or remove refrigerant iftemperature is lower. Allow a tolerance of ± 1° C.

8. Ensure that crankcase heater has been energized for24 hours before start.

SERVICE AND MAINTENANCE

CLEANING COIL:Coil surfaces can be cleaned with vacuum cleaner, washedout with water. The fan draw through design causes dirtand debris to build up on the outside of the coil. Clean coilannually or required. Fins are not continues through coilsection. Dirt and debris trapped between fins and restrict airpassing through, thus lower the coil heat exchange rate.

1. Switch off all power supply to unit.2. Use compressed air or water to blow toward condenser

coil. (Fig. 11)3. Flush all dirt and debris from drain holes in the base

pan of the condenser.

WARNING !!!

TO PREVENT PERSONAL INJURY, WEAR SAFETYGLASSES AND GLOVES WHEN HANDLINGREFRIGERANT. DO NOT OVERCHARGE SYSTEM,THIS CAN CAUSE COMPRESSORS AND OTHERPARTS FAILURE.

WARNING !!!

BEFORE PERFORMING RECOMMENDEDMAINTENANCE AND SERVICE, BE SURE ALLPOWER SWITCHES ARE DISCONNECTED.FAILURE TO DO SO MAY RESULT IN ELECTRICSHOCK OR INJURY.

FIG. 11 CLEANING COIL WITH WATER

LUBRICATION:Fan motor is equipped with permanently sealed lubricatedbearings. Do not dismantle the motor.Compressor is supplied with factory pre-charged oil.Replaced oil when the oil levels low. Compressor oil levelcan be identified on compressor oil sightglass built-in.Check oil level after unit has been running for an hour.

FAN ADJUSTMENT:1. Switch off all power supply to unit.2. Remove fan grille.3. Loosen setscrew on fan bracket.4. Adjust fan depth as shown as Fig. 12 and Table 4.5. Tighten setscrew and grille.

FIG. 12 FAN POSITION MOUNTING

TABLE 4. FAN POSITION MOUNTING

Model X (mm) Y (mm)

38LZA080 10 ± 5 45 ± 538LZA100 or 125 10 ± 5 50 ± 5

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TROUBLE-SHOOTING CHART - COOLING CYCLE

NO COOLING OR INSUFFICIENT COOLING

COMPRESSOR RUNSBUT CYCLES ON

INTERNAL OVERLOAD

COMPRESSORWILL NOT RUN

CONTACTOR OPEN

COMPRESSORPOWER

SUPPLY OPEN

CONTACTOR CLOSED

LOOSE LEADAT COMPRESSOR

OPEN SHORTED ORGROUNDED COMPRESSOR

MOTOR WINDINGS

COMPRESSORINTERNAL

PROTECTION OPEN

COMPRESSORSTUCK

RESTRICTEDDISCHARGE TUBE

OUTDOOR FANSTOPPED OR CYCLING

ON OVERLOAD

OUTDOOR AIRRESTRICTED ORRECIRCULATING

OVERCHARGE ORNON-CONDENSABLE

IN SYSTEM

LINE VOLTAGE TOOHIGH OR LOW

LOW REFRIGERANTCHARGE

COMPRESSORBEARINGS

LOOSE LEAD ATFAN MOTOR

MOTOR DEFECTIVE

INCORRECTOUTDOOR FAN

MOTOR CAPACITOR

LOW SUCTIONPRESSURE

DIRTY AIR FILTERS

DUCT RESTRICTED

DAMPER PARTLYCLOSED

INDOOR COILFROSTED

SLIGHTLY LOW INREFRIGERANT

LIQUID LINE SLIGHTLYRESTRICTED

METERING DEVICERESTRICTED

INCORRECTMETERING DEVICE

INDOOR COILSTRAINER

RESTRICTED

COMPRESSOR RUNSBUT INSUFFICIENT

COOLING

FAULTY POWERSUPPLY

OPEN CONTROLCIRCUIT

DEFECTIVE TIMERELAY

CONTACTOR ORCOIL DEFECTIVE

INTERNALOVERLOAD OPEN

OPEN HIGH OR LOWPRESSURE SWITCH

FAULT START GEAR(1-PH)

INDOOR BLOWERMOTOR DEFECTIVE

OR CYCLING ONOVERLOAD

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MEMO

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Manufacturer reserves the right to discontinue, orchange at any time, specifications or designswithout notice and without incurring obligations.38LZ-502-001

11 2003

38 LZA NEW

Carrier International Sdn. Bhd. (3385-T)Lot 4, Jalan P/6, 43650 Bandar Baru Bangi,

Selangor, Malaysia.Tel: 03-8925 8001Fax: 03-8925 3578

CarrierInternationalSdn. Bhd.Malaysia®�

! IMPORTANT

PLACE ATTACHED WARNING LABELON THE MAIN SWITCH BOARD