Carrier

International
Sdn. Bhd.
Malaysia

INSTALLATION, START-UP AND 38LZA

50Hz
SERVICE INSTRUCTIONS
AIR-COOLED CONDENSING UNIT

CONTENTS
Safety Considerations

Filter Drier

Specifications

Complete Electrical Connections

Installation

System Wiring Diagram

Dimensional Drawing

Start-Up

Service and Maintenance

Refrigerant Piping

4-5

Piping Connection

Trouble-Shooting Guide

7-8

10

FIG. 1 38LZA080, 100 & 125

SAFETY CONSIDERATIONS

INSPECTION

Installation and servicing 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, tag and labels
attached to the unit and other safety codes.

Check the shipment received against the shipping list to

make sure that shipment is complete. Remove the unit from
plastic and take off the protective foams. If the unit has
been damaged in transit, file a claim with the Transportation
Company.

Only used "Original Spare Parts" for repairs. Special

attention must be paid to the correct installation of the
spare parts. The Parts must always be installed in their
original position.

PROTECTION

During unit operation, some of the refrigerant circuit

elements could reach a temperature in excess of 70C so
only trained or qualified personnel should access areas
protected by access panels.
The unit should not be installed in an explosive
atmosphere. The unit can operate in normal atmosphere in
residential, commercial and light industrial installation. For
other applications, please consult Carrier.

Protect unit from damage caused by job site debris. Do not

allow 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 main
power switch on the unit. There may be more than one
disconnects switch. Turn off accessory heater power if
applicable. Electrical shock can cause personal injury.

A United Technologies Company

SPECIFICATIONS
TABLE 1
MODEL

38LZA
080

OPERATING WEIGHT

kg

REFRIGERANT

Type

COMPRESSOR

Type
Quantity
Oil charged (l)
LRA Nominal (A)
Protection
Output (W)
Type
Quantity
Diameter (in/mm)
Speed (rpm)
Drive
Type

Factory Charged (kg)

CRANKCASE HEATER
CONDENSER FAN

FAN MOTOR

CONDENSER COIL
TUBES CONNECTION

Power Supply (V - PH - Hz)

Full Loads Amps. (A)
Rows - Fins per m
Face area (m2)
Type
Suction (in/mm)

CONTROLS PRESSURESTAT
SETTINGS

125

189

195

R 22
1.0
Hermetic Scroll
1
3.25
3.3
130
145
Internal Line Brake (KLIXON)
65
Propeller
1
24 / 610
26 / 660
900
Direct Drive
Permanent
Induction Motor
Split Capacitor
230 - 1 - 50
400 - 3 - 50
1.85
1.75
2 - 591
1.57
1.94
Sweat
11/8 / 28.58

Liquid (in/mm)

1/2 / 12.7

High Cut Out (kPa)

2724 68

High Cut In (kPa)

2034 138

Low Cut Out (kPa)

POWER SOURCE
ABSOLUTE VOLTAGE

175

100

Low Cut In (kPa)

V-Ph-Hz
Minimum (V)
Maximum (V)

48 20
152 34.5
400 - 3 - 50
380
415

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.

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 be
stagnant, exhausted air will not be re-circulated into
coil. The unit must not be installed near a source of
heat, steam or flammable gas.
3. When installing the unit on the ground, select site where
is not subject to flooding. Avoid position the unit in such
a 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, which
govern the installation of air conditioning equipment.
6. Ducting of the fan inlet or discharge is not permitted.
FIG. 2 SERVICE AREA
2

DIMENSIONAL DRAWING

FIG. 3 38LZA080 DIMENSIONAL DRAWING

FIG. 3.1 38LZA100 & 125 DIMENSIONAL DRAWING

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 mounting hole
provided in unit mounting base. (Fig. 4)
2. MOUNTING ON WALL - The bracket is to be locally
procured and qualified to sustain the weight of the unit.
(Fig. 5). The unit must be installed and conform to the
minimum service area. (Fig. 2)

FIG. 6 ROOF MOUNTING

FIG. 4 GROUND MOUNTING

FIG. 7 MINIMUM SPACING REQUIREMENT

REFRIGERANT PIPING

FIG. 5 WALL MOUNTING

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 as Fig. 6. When
installation 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.

1. Piping length is very important to compressor reliability

and performance. The longer the piping or the more
bends or turns, the lower the cooling capacity of the aircooled condensing unit. Avoid unnecessary turns and
bends, do not over or under size the original suction
and liquid pipe.
2. Warranty void if the piping length is more than Carrier
specifies on this literature. Please refer to Table 2 and 3
for the piping length limitation. (Fig. 8.1, 8.2 & 8.3)
3. Suspend refrigerant pipes in order to isolate the piping
vibration from the building, especially on the piping to
passing through the wall, seal the opening to protect the
piping from vibration. Leave some slack in the
refrigerant pipes between structure and unit to absorb
vibration.
4. Do not bury any section of line set underground. If any
section is buried, refrigerant may migrate to cooler
buried section during extended periods of unit
shutdown. This causes refrigerant slugging and possible
compressor damage at start-up.
5. If refrigerant pipes or indoor coil are exposed to
atmosphere for longer than 5 minutes, it must be
evacuated to 1000 microns to eliminate contamination
and moisture in the system.

FIG. 8.1 MINIMUM ALLOWABLE PIPING LENGTH AND

ELEVATION DIFFERENCE

FIG. 8.2 MINIMUM ALLOWABLE PIPING LENGTH AND

ELEVATION DIFFERENCE

TABLE 2.
VERTICAL AND HORIZONTAL SEPARATION BETWEEN
INDOOR AND OUTDOOR UNIT
MODELS
38LZA

MAX.LENGTH (m)

40LZA

30

15

40

080
100
125
FIG. 8.3 MINIMUM ALLOWABLE PIPING LENGTH AND
ELEVATION DIFFERENCE

WARNING !!!
WARRANTY VOID IF PIPING LENGTH IS MORE
THAN THE FIGURES ABOVE.

TABLE 3. SUBCOOLING CHARGING TABLE

PRESSURE AT
LIQUID VALVE
(kPa)

Required Subcooling Temperature (C)

0

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
5

PIPING CONNECTION
WARNING !!!
DO NOT MODIFY THE TUBING DESIGN INSIDE THE
UNIT OR WARRANTY VOID.
1. Unit has R 22 holding charge. Do not open Schreader
valve.
2. Only trained and qualified technician is allowed for the
brazing process.
3. Connect piping between indoor and outdoor unit. Wet
cloth should be wrapped on the unit pipes during
brazing pipes to prevent heating on the panel and
internal closed cell insulation. Pass nitrogen or inert gas
through the piping to prevent formation of copper oxide
after brazing.
4. Leak test must be conducted after all connection with
pressure method. Use R 22 at approximately 170 kPa
back up with nitrogen to a total pressure not exceed
1690kPa.
5. Use soup bubble or electronic leak detector for testing
the leaks.

FILTER DRIER
Filter drier is field supplied and must be installed. If system
is vacuumed during service, it is advice to replace filter
drier with new one.

WARNING !!!
WARRANTY VOID IF LIQUID LINE FILTER DRIER IS
NOT FIELD INSTALLED.

CONTAMINANT REMOVAL - EVACUATION

Proper evacuation of a unit remove non-condensable and
assure a tight dry system before charging. Deep vacuum is
one of the good methods.
Prepare a vacuum pump of capable pulling a vacuum of
1000 microns furnished with a vacuum gage for measuring
the vacuum depth. Deep Vacuum method is assuring a
system is free of air and water.
Evacuation taken from both high and low side of the
system.

WARNING !!!
DO NOT USE A MEGAOHMMETER OR APPLY
POWER TO THE SYSTEM WHILE THE SYSTEM IS
UNDER VACUUM.

COMPLETE ELECTRICAL CONNECTIONS

POWER - Unit is factory wired for voltage shown on
nameplate. Provide adequate fused disconnect switch
within sight of unit, readily accessible, but out of reach of
children.
Please lock the main switch during unit servicing in orders
to prevent power from being turned on.
A rubber grommet on the unit side panel is the filed wire
route to control box. Unit power must be grounded. Open
the control box cover for wiring connection. (Fig. 10)

WARNING !!!

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

OPERATING THE UNIT ON IMPROPER LINE

VOLTAGE CONSTITUTES ABUSE AND COULD VOID
CARRIER WARRANTY. DO NOT INSTALL UNIT IN
SYSTEM WHERE VOLTAGE MAY FLUCTUATE
ABOVE AND BELOW PERMISSIBLE LIMITS STATED
IN THE TABLE 1.

FIG. 9 PIPING INSULATION

FIG. 10 POWER WIRES TO THE CONSENSER

38LZA080 c/w 40LZA080 System Wiring Diagram

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

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. Thus
Subcooling Charging Method must be used.

SUBCOOLING CHARGING METHOD:

WARNING !!!
TO PREVENT PERSONAL INJURY, WEAR SAFETY
GLASSES AND GLOVES WHEN HANDLING
REFRIGERANT. DO NOT OVERCHARGE SYSTEM,
THIS CAN CAUSE COMPRESSORS AND OTHER
PARTS FAILURE.
1. All 38LZA 080, 100 & 125 are factory pre-charged 1 kg
R 22.
2. A charging manifold and refrigerant bottle properly
connected 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 line
higher than indicated or remove refrigerant if
temperature is lower. Allow a tolerance of 1 C.
8. Ensure that crankcase heater has been energized for
24 hours before start.

FIG. 11 CLEANING COIL WITH WATER

LUBRICATION:
Fan motor is equipped with permanently sealed lubricated
bearings. Do not dismantle the motor.
Compressor is supplied with factory pre-charged oil.
Replaced oil when the oil levels low. Compressor oil level
can 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.

SERVICE AND MAINTENANCE

WARNING !!!
BEFORE PERFORMING RECOMMENDED
MAINTENANCE AND SERVICE, BE SURE ALL
POWER SWITCHES ARE DISCONNECTED.
FAILURE TO DO SO MAY RESULT IN ELECTRIC
SHOCK OR INJURY.

CLEANING COIL:
Coil surfaces can be cleaned with vacuum cleaner, washed
out with water. The fan draw through design causes dirt
and debris to build up on the outside of the coil. Clean coil
annually or required. Fins are not continues through coil
section. Dirt and debris trapped between fins and restrict air
passing 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.

FIG. 12 FAN POSITION MOUNTING

TABLE 4. FAN POSITION MOUNTING
Model

X (mm)

Y (mm)

38LZA080
38LZA100 or 125

10 5
10 5

45 5
50 5

TROUBLE-SHOOTING CHART - COOLING CYCLE

NO COOLING OR INSUFFICIENT COOLING

COMPRESSOR
WILL NOT RUN

CONTACTOR OPEN

CONTACTOR CLOSED

FAULTY POWER
SUPPLY

COMPRESSOR
POWER
SUPPLY OPEN

OPEN CONTROL
CIRCUIT

LOOSE LEAD
AT COMPRESSOR

DEFECTIVE TIME
RELAY

FAULT START GEAR

(1-PH)

CONTACTOR OR
COIL DEFECTIVE

OPEN SHORTED OR
GROUNDED COMPRESSOR
MOTOR WINDINGS

INTERNAL
OVERLOAD OPEN

COMPRESSOR
STUCK

OPEN HIGH OR LOW

PRESSURE SWITCH

COMPRESSOR
INTERNAL
PROTECTION OPEN

COMPRESSOR RUNS
BUT CYCLES ON
INTERNAL OVERLOAD

OUTDOOR FAN
STOPPED OR CYCLING
ON OVERLOAD

LOOSE LEAD AT
FAN MOTOR

OUTDOOR AIR
RESTRICTED OR
RECIRCULATING

MOTOR DEFECTIVE

RESTRICTED
DISCHARGE TUBE

INCORRECT
OUTDOOR FAN
MOTOR CAPACITOR

OVERCHARGE OR
NON-CONDENSABLE
IN SYSTEM
LOW REFRIGERANT
CHARGE

LINE VOLTAGE TOO

HIGH OR LOW

COMPRESSOR
BEARINGS

COMPRESSOR RUNS
BUT INSUFFICIENT
COOLING

LOW SUCTION
PRESSURE

DIRTY AIR FILTERS

DUCT RESTRICTED

DAMPER PARTLY
CLOSED

INDOOR COIL
FROSTED

SLIGHTLY LOW IN
REFRIGERANT

LIQUID LINE SLIGHTLY

RESTRICTED

METERING DEVICE
RESTRICTED

INCORRECT
METERING DEVICE
INDOOR COIL
STRAINER
RESTRICTED
INDOOR BLOWER
MOTOR DEFECTIVE
OR CYCLING ON
OVERLOAD

10

MEMO

11

IMPORTANT

PLACE ATTACHED WARNING LABEL

ON THE MAIN SWITCH BOARD

Carrier
International
Sdn. Bhd.
Malaysia

Carrier International Sdn. Bhd. (3385-T)

Lot 4, Jalan P/6, 43650 Bandar Baru Bangi,
Selangor, Malaysia.
Tel: 03-8925 8001
Fax: 03-8925 3578

38LZ-502-001
12

38 LZA

NEW

11

2003

Manufacturer reserves the right to discontinue, or

change at any time, specifications or designs
without notice and without incurring obligations.