Carrier 38CKC(Q) Air Conditioner User Manual
Contents
1. A95282 A95283 NOTES 1 CORPORATE THERMOSTAT WIRING DIAGRAMS ARE ONLY ACCURATE FOR MODEL NUMBERS BEGINNING WITH TSTAT_ WIRING MUST CONFORM TO NEC OR LOCAL CODE SOME UNITS ARE EQUIPPED WITH PRESSURE SWITCH ES TEMPERATURE SWITCH OR 5 MINUTE COMPRESSOR CYCLE PROTECTION CONNECT 24 VOLT FIELD WIRING TO FACTORY PROVIDED STRIPPED LEADS A LIQUID LINE SOLENOID VALVE IS REQUIRED ON SOME UNITS SEE SPECIFIC UNIT INSTRUCTIONS THERMOSTATS ARE FACTORY CONFIGURED WITH 5 MINUTE COMPRESSOR CYCLE PROTECTION AND 4 CYCLES PER HOUR LIMIT SEE THERMOSTAT INSTRUCTIONS FOR DETAILS TO STAGE THE ELECTRIC RESISTANCE HEAT CONSULT OUTDOOR THERMOSTAT INSTALLATION INSTRUCTIONS ow Pp p gt o op LEGEND 24 VOLT FACTORY WIRING 24 VOLT FIELD WIRING m FIELD SPLICE CONNECTION C CONTACTOR A94394 Fig 10 Typical 24 v Circuit Connections Continued Copyright 1997 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 38brc1si ees Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations reek x k PC 101 Catalog No 533 840 Printed in U S A Form 38BRC 1SI Pg 8 2 97 Replaces New al a 2a2. ON Carrier ee HEATING amp COOLING 38CKC Q 38CMC 38BRC Split System Air Conditioner Visit www carrier com Installation and Start Up Instructions NOTE Read the entire instruction manual before starting the installation SAFETY CONSIDERATIONS Improper installation adjustment alteration service maintenance or use can cause explosion fire electrical shock or other conditions which may cause death personal injury or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing Follow all safety codes Wear safety glasses protective clothing and work gloves Use quenching cloth for brazing operations Have fire extinguisher available Read these instructions thor oughly and follow all warnings or cautions included in literature and attached to the unit Consult local building codes and National Electrical Code NEC for special requirements Recognize safety information This is the safety alert symbol A When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAU TION These words are used with the safety alert symbol DAN
3. For tubing requirements beyond 50 ft consult your local distributor or the Long Line Application Guideline SWEAT CONNECTION 1 Consult local code requirements 2 Connect tubing to fittings on outdoor unit vapor and liquid service valves 3 Service valves are closed from factory and ready for brazing AIR DISCHARGE DO FIELD POWER SUPPLY CONN 7 DIA HOLE WITH 1 1 DIA KNOCKOUT AND 1 3 DIA KNOCKOUT FIELD CONTROL SUPPLY CONN 7 DIA HOLE SUCTION LINE CONN LIQUID LINE CONN A97009 LIQUID TUBE VAPOR TUBE UNIT SIZE Conn Dia Tube Dia Conn Dia Tube Dia 018 024 3 8 3 8 5 8 5 8 030 036 3 8 3 8 3 4 3 4 042 048 3 8 3 8 7 8 7 8 060 3 8 3 8 7 8 1 1 8 NOTE Tube diameters are for lengths up to 50 ft For tubing lengths greater than 50 ft consult your local distributor If refrigerant tubing or indoor coil is exposed to atmosphere it must be evacuated to a minimum of 500 microns to eliminate contamination and moisture in the system Fig 4 Refrigerant Tube Dimensions Connections 4 After wrapping service valve with a wet cloth tubing set can be brazed to service valve using either silver bearing or non silver bearing brazing material 5 Refrigerant tubing and indoor coil are now read for leak testing This check should include all field and factory joints MECHANICAL CONNECTION 38CKQ MODELS 1 Cut tubing to correct length deburr and size as necessary making sur
4. if it matches the required piston shown on outdoor unit rating plate If it does not match replace indoor coil piston with piston shipped with outdoor unit The piston shipped with outdoor unit is correct for any approved indoor coil combination 3D 9 53 TIEDOWN KNOCKOUTS 2 PLACES 38CKC Q 030 042 A94199 TIEDOWN KNOCKOUT MIN PAD LOCATIONS UNIT SIZE DIM IN 7A B T In In In 38CKC Q 018 024 18 X 18 3 15 10 3 16 38CMC018 030 22 1 2 X 22 1 2 3 11 16 18 1 8 14 3 8 38BRC024 060 38CKC Q 048 060 30 X 30 6 1 2 23 1 2 20 38CMC036 060 Fig 3 Mount Unit to Pad Step 6 Make Tubing Connections A WARNING Relieve pressure and recover all refrigerant before system repair or final unit disposal to avoid personal injury or death Use all service ports and open all flow control devices including solenoid valves A CAUTION To prevent compressor damage DO NOT bury more than 36 in of refrigerant tubing If ANY tubing is buried provide 6 in vertical rise at service valve A CAUTION To prevent damage to unit or service valves observe the following e Use a brazing shield e Wrap service valves with wet cloth or use a heat sink material Connect outdoor unit to indoor sections using accessory tubing package or field supplied tubing of refrigerant grade correct size and condition Refer to Fig 4 for refrigerant tube dimensions and connections
5. GER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage A WARNING Before installing modifying or servicing system main elec trical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label Electrical shock can cause personal injury or death INSTALLATION RECOMMENDATIONS NOTE In some cases noise in the living area has been traced to gas pulsations from improper installation of equipment 1 Locate unit away from windows 2 Ensure that vapor and liquid tube diameters are appropriate to capacity of unit See Model Specific Instructions for proper tube sizing 3 Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends 4 Leave some slack between structure and unit to absorb vibration 5 When passing refrigerant tubes through the wall seal opening with RTV or other pliable silicon based caulk See Fig 2 6 Avoid direct tubing contact with water pipes ductwork floor joists wall studs floors and walls A97005 Fig 1 Split System Air Conditioner 7 Do not suspend refrigerant tubing from joists and studs with a rigid wire or strap which comes in direct cont
6. USED NOT USED OPTIONAL OUTDOOR SENSOR CONNECTION A94386 CORPORATE NON PROGRAMMABLE THERMOSTAT PROG MODEL AC FAN COIL 24 VAC HOT 24 VAC COM Tha HEAT STAGE 1 Ln g nStE2 COOL STAGE 1 INDOOR FAN t A94385 CORPORATE PROGRAMMABLE THERMOSTAT a a FC MODEL AC FAN COIL CONDITIONER 24 VAC HOT INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED NOTE NOT USED 24 VAC COM NOT USED NOT USED OPTIONAL OUTDOOR SENSOR CONNECTION A94387 Fig 10 Typical 24 v Circuit Connections CORPORATE PROGRAMMABLE CORPORATE THERMOSTAT FK4B AIR NON PROGRAMMABLE MODEL AC FAN COIL CONDITIONER THERMOSTAT Ne NB MODEL AC FAN COIL CONDITIONER 24 VAC HOT e4vacHoT RH 24 VAC COM INDOOR FAN HEAT STAGE 1 SEE HEAT STAGE 1 Wawi 8 ie COOL STAGE 1 COOL STAGE 1 Y Y2 INDOOR FAN NOT USED NOT USED 24 VAC COM NOT USED NOT USED OPTIONAL OUTDOOR SENSOR A94388 CONNECTION I f I lel Elle A94389 NON CORPORATE NON PROGRAMMABLE THERMOSTAT MODEL AC 24vacHoT R HEAT STAGE 1 COOL STAGE 1 INDOOR FAN Lo A95281 Fig 10 Typical 24 v Circuit Connections Continued 7 NON CORPORATE NON PROGRAMMABLE NON CORPORATE THERMOSTAT Se re FC Aik NON PROGRAMMABLE MODEL AC FAN COIL CONDITIONER THERMOSTAT SINGLE savacnot R H a MODEL AC FLRNAGE CONDITIONER 24 VAC HOT na NOTE 2 aa HEAT STAGE 1 COOL STAGE 1 INDOOR FAN HEAT STAGE 1 COOL STAGE 1 INDOOR FAN
7. act with the tubing See Fig 2 8 Ensure that tubing insulation is pliable and completely sur rounds vapor tube 9 When necessary use hanger straps which are 1 in wide and conform to shape of tubing insulation See Fig 2 10 Isolate hanger straps from insulation by using metal sleeves bent to conform to shape of insulation When outdoor unit is connected to factory approved indoor unit outdoor unit contains system refrigerant charge for operation with factory approved indoor unit of the same size when connected by 15 ft of field supplied tubing For proper unit operation check refrigerant charge using charging information located on control box cover INSTALLATION Step 1 Check Equipment and Jobsite INSPECT EQUIPMENT If shipment is damaged or incom plete file claim with shipping company prior to installation Locate unit rating plate on unit service panel It contains informa tion needed to properly install unit Check rating plate to be sure unit matches job specifications Step 2 Install on a Solid Level Mounting Pad If conditions or local codes require the unit be attached to pad use tiedown bolts to fasten through knockouts provided in unit base pan Refer to Fig 3 for pad dimensions and dimensions needed to mount unit to pad 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 Ca
8. atures may be hot e In 3 phase application incorrect phasing will cause reverse rotation resulting in elevated noise levels equalized pres sures and reduced current draw Correct by reversing power connection L1 and L2 on contactor A CAUTION To prevent personal injury wear safety glasses protective clothing and gloves when handling refrigerant and observe the following e Back seating service valves are not equipped with Schrader valves Fully back seat counter clockwise valve stem before removing gage port cap e Front seating service valves are equipped with Schrader valves 4 CAUTION Do not vent refrigerant to atmosphere Recover during system repair or final unit disposal Follow these steps to properly pumpdown a system and avoid negative suction pressure 1 Fully back seat open liquid and vapor tube service valves 2 Unit is shipped with valve stem s front seated closed and caps installed Replace stem caps after system is opened to refrigerant flow Replace caps finger tight and tighten with wrench an additional 1 6 turn for front seating valves female hex stem or 1 12 turn for back seating valves male square stem 3 Close electrical disconnects to energize system 4 Set room thermostat at desired temperature Be sure set point is below indoor ambient temperature 5 Set room thermostat to COOL and fan to FAN or AUTO mode as desired Operate unit for 15 minutes Check system refrigeran
9. e tube ends are square If a large burr is evident ID and OD must be deburred to allow tube to bottom in valve 2 Remove lock nuts and ferrules from plastic bags taped to service panel See Fig 5 VALVE FITTING FERRULE iii na LOCK NUT A92120 Fig 5 Mechanical Fitting Assembly 38CKQ 4 CAUTION If undersized damaged or elliptically shaped tubing is used when making connection leaks could result 3 Slide lock nut and ferrule onto each tube See Fig 6 FERRULE LOCK NUT TUBING Ag2121 Fig 6 Lock Nut Ferrule Positioning 38CKQ 4 Apply a few drops of refrigerant oil to ferrule and valve threads to reduce assembly torque and assist sealing 5 Insert tube end into service valve until it bottoms 6 Push ferrule into place and hand tighten nut until an increase in torque is felt 7 Mark nut and tube and tighten 1 1 2 turns from mark See Fig 7 Keep tube bottomed in valve while tightening nut NOTE A backup wrench on the hex part of the suction valve is required while tightening 4 CAUTION The tube end must stay bottomed in the service valve during final assembly to ensure proper seating sealing and rigidity MECHANICAL FITTING REPAIR To replace damaged ferrule or tubing proceed as follows 1 Attach gages to service valves 2 Close liquid service valve and operate unit to pump refrigerant charge into condenser coil 3 When suction pressure
10. it NOTE Install branch circuit disconnect of adequate size per NEC to handle unit starting current Locate disconnect within sight from and readily accessible from unit per Section 440 14 of NEC ROUTE GROUND AND POWER WIRES Remove access panel to gain access to unit wiring Extend wires from disconnect through power wiring hole provided and into unit control box A WARNING The unit cabinet must have an uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes Failure to follow this warning can result in an electric shock fire or death CONNECT GROUND AND POWER WIRES Connect ground wire to ground connection in control box for safety Connect power wiring to contactor as shown in Fig 9 DISCONNECT PER N E C AND OR LOCAL CODES CONTACTOR E E E E G FIELD POWER WIRING Ree APHASE OMY 02 gt BLUE O E FIELD GROUND m WIRING Siaga GROUND LUG A94025 Fig 9 Line Power Connections CONNECT CONTROL WIRING Route 24 v control wires through control wiring grommet and connect leads to control wiring See Fig 10 Use No 18 AWG color coded insulated 35 C minimum wire If thermostat is located more than 100 ft from unit as measured along the control voltage wires use No 16 AWG color coded wire to avoid excess
11. ive voltage drop Use furnace transformer fan coil transformer or accessory trans former for control power 24 v 40 va minimum NOTE Use of available 24 v accessories may exceed the mini mum 40 va power requirement Determine total transformer load ing and increase the transformer capacity or split the load with an accessory transformer as required Step 9 Compressor Crankcase Heater When equipped with a crankcase heater furnish power to heater a minimum of 24 hr before starting unit To furnish power to heater only set thermostat to OFF and close electrical disconnect to outdoor unit A crankcase heater is required if refrigerant tubing is longer than 50 ft NOTE The Seasonal Energy Efficiency Ratio SEER is ob tained with crankcase heater de energized To de energize crank case heater disconnect black crankcase heater wires at contactor After disconnecting make sure wires are isolated from all other electrical connections and components to prevent electrical short ing Step 10 Insitall Electrical Accessories Refer to the individual instructions packaged with kits or acces sories when installing Step 11 Start Up and Check Charge A CAUTION To prevent compressor damage or personal injury observe the following e Do not overcharge system with refrigerant e Do not operate unit in a vacuum or at negative pressure e Do not disable low pressure switch In scroll compressor applications e Dome temper
12. reaches 5 psig shut unit off Do not operate unit in a vacuum 4 Close suction service valve and recover refrigerant in tubing 5 Back off locknut and ferrule onto tube 6 Remove damaged part of tubing using tubing cutter Repeat installation procedure previously outlined using new ferrule 7 Evacuate tubing set and indoor coil Check for leaks 8 Open service valves or recharge unit Check refrigerant charge Step 7 Install Solenoid Valve In Liquid Tube If Re quired 4 CAUTION Not all applications require use of a liquid tube solenoid valve If your unit has been shipped with a liquid tube solenoid valve in the unit it must be installed for performance enhancement The liquid tube solenoid valve must be ener gized during evacuation for complete removal of refrigerant Before making liquid tube connections install factory supplied solenoid valve on indoor liquid fitting See Fig 8 Be sure to use flare adapter supplied with the indoor coil when making connec tions LOCK NUT TUBING MARK ON LOCK NUT AND TUBE A92122 Fig 7 Proper Marking of Valve Assembly 38CKQ ELECTRICAL JUNCTION ae COIL PL a F VALVE FLOW ARROW STRAIGHT 3 8 IN STUD NOTE System flow direction must match arrow on bottom of body A87044 Fig 8 Solenoid Valve Installation A CAUTION Wiring must comply with local codes and NEC requirements if a field supplied control power source is needed
13. t charge 6 Factory charge is shown on unit rating plate Adjust charge by following procedure shown on charging tables located on unit SEQUENCE OF OPERATION Turn on power to indoor and outdoor units Transformer is energized On a call for cooling thermostat makes circuits R Y and R G Circuit R Y energizes contactor starting outdoor fan motor and compressor circuit R G energizes indoor unit blower relay starting indoor blower motor on high speed When thermostat is satisfied its contacts open de energizing contactor and blower relay Compressor and motors stop If indoor unit is equipped with a time delay relay circuit the indoor blower will run an additional 90 sec to increase system efficiency CARE AND MAINTENANCE For continued high performance and to minimize possible equip ment failure periodic maintenance must be performed on this equipment Leave User s Manual with homeowner Explain system operation and periodic maintenance requirements outlined in manual Fre quency of maintenance may vary depending on geographic areas such as coastal applications which require more frequent mainte nance CORPORATE NON PROGRAMMABLE THERMOSTAT MODEL AC 24 VAC HOT 24 VAC COM HEAT STAGE 1 NOTE 2 COOL STAGE 1 INDOOR FAN A94384 CORPORATE PROGRAMMABLE THERMOSTAT SINGLE MODEL AC FORNREE CONDITIONER 24 VAC HOT INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED NOT USED 24 VAC COM NOT
14. talog No 533 840 Tab 3a 2a Printed in U S A Form 38BRC 1SI Pg 1 2 97 Replaces New NOTE Avoid contact between tubing and structure OUTDOOR WALL INDOOR WALL ae Ni wa _y j UOUID TUBE 3 t VAPOR TUBE INSULATION THROUGH THE WALL p OST HANGER STRAP AROUND VAPOR INSULATION VAPOR TUBE O O O a 3 17MIN gt a LIQUID TUBE SUSPENSION A94028 Fig 2 Connecting Tubing Installation Step 3 Clearance Requirements When installing allow sufficient space for airflow clearance wiring refrigerant piping and service Common clearances are 6 in on side 12 in on 2 sides and 30 in on service side of unit Allow 24 in between units Discharge air must be unobstructed and must not recirculate Position so water snow or ice from roof or eaves cannot fall directly on unit On rooftop applications locate unit at least 6 in above roof surface Place unit above a load bearing wall and isolate unit and tubing set from structure Arrange supporting members to adequately support unit and minimize transmission of vibration to building Consult local codes governing rooftop applications Step 4 Operating Ambients The minimum outdoor operating ambient in cooling mode is 55 F and the maximum outdoor operating ambient in cooling mode is 125 F Step 5 Metering Device If unit is being installed with piston check indoor coil piston to see
15. when adding solenoid 1 Remove coil liquid connection cap and discard 2 Mount solenoid valve on liquid tube making sure valve flow arrow points toward indoor coil Mount valve in any position except valve body at top and electric coil at bottom See Fig 8 Solenoid valve is to be installed a maximum of 2 ft from indoor coil A CAUTION Avoid valve damage while brazing by wrapping valve with a heat sinking material such as a wet cloth 3 Braze valve onto end of liquid tube using silver bearing or non silver bearing brazing material Consult local code re quirements 4 Braze flare adapter onto outlet end of solenoid valve 5 Wire solenoid coil into system control circuit Step 8 Make Electrical Connections A WARNING To avoid personal injury or death do not supply power to unit with compressor terminal box cover removed Be sure field wiring complies with local and national fire safety and electrical codes and voltage to system is within limits shown on unit rating plate Contact local power company for correction of improper voltage See unit rating plate for recommended circuit protection device NOTE Operation of unit on improper line voltage constitutes abuse and could affect unit reliability See unit rating plate Do not install unit in system where voltage or phase imbalance 3 phase may fluctuate above or below permissible limits NOTE Use copper wire only between disconnect switch and un
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