Carrier 38CKB Air Conditioner User Manual

38CKB—50 Hz
Air Conditioning Unit
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 thoroughly and follow all warnings or cautions included in literature
and attached to the unit. Consult local building codes and national
electric codes for special requirements.
Recognize safety information. This is the safety-alert symbol
.
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal word DANGER, WARNING, or CAUTION. These words are used with the safety-alert symbol. DANGER 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.
Before installing, modifying, or servicing system, main electrical 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.
A94356
Fig. 1—Model 38CKB
For proper airflow, a 6-in. (152mm) clearance on 1 side of unit and
12 in. (305mm) on all remaining sides must be maintained.
Maintain a distance of 24 in. (610mm) between air conditioners.
Position so water, snow, or ice from roof or eaves cannot fall
directly on unit.
On rooftop applications, locate unit 6 in. (152mm) above roof
surface. Where possible, place unit above a load-bearing wall.
Arrange supporting members to adequately support unit and
minimize transmission of vibration to building. Consult local
codes governing rooftop applications.
Step 3—Replace Indoor AccuRater® Piston, if Required
Check indoor coil piston to see if it matches the required piston
shown on unit rating label. If it does not match, replace indoor coil
piston with piston shipped with this unit. The piston shipped with
outdoor unit is correct for any approved indoor coil combination.
INSTALLATION
Step 1—Check Equipment and Jobsite
UNPACK UNIT — Move to final location. Remove carton taking
care not to damage unit.
INSPECT EQUIPMENT — File claim with shipping company
prior to installation if shipment is damaged or incomplete. Locate
unit rating label on unit service panel. (See Fig. 2.) It contains
information needed to properly install unit. Check rating label 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,
tiedown bolts should be used and fastened through knockouts
provided in unit base pan. Refer to unit mounting pattern in Fig. 2
to determine base pan size and knockout hole location.
When installing, allow sufficient space for airflow clearance,
wiring, refrigerant piping, and service. Allow 30-in. (762mm)
clearance to service end of unit and 48 in. (1219mm) above unit.
Remove indoor coil piston if unit is to be installed on system
with a TXV metering device.
Step 4—Make Piping Connections
Outdoor units may be connected to indoor sections using accessory
tubing package or field-supplied refrigerant grade tubing of correct
size and condition. For tubing requirements beyond 50 ft (15.24m),
consult Long-Line Application Guideline which is available at
your local distributor.
NOTE: In some cases, noise in the living area has been traced to
gas pulsations from improper installation of equipment.
INSTALLATION RECOMMENDATIONS
1. Locate the unit away from windows.
2. Ensure that vapor and liquid tube diameters are appropriate to
the capacity of the unit. (See Table 1.)
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
Catalog No. 013-862
Printed in U.S.A.
Form 38CKB-C1SI
Pg 1
12-94
Replaces: New
Tab 3a 2a
AIR IN
AIR
DISCHARGE
AIR
IN
NOTES:
1. Allow 30 in. (762) clearance to service sides of unit, 48 in.
(1219.2) above unit, 6 in. (152.4) on one side, 12 in. (304.8) on remaining
side, and 24 in. (609.6) between units for proper airflow.
2. Minimum outdoor operating ambient in cooling mode is 55 F (12.8 C),
max 115 F (46.1 C).
3. Dimensions in parenthesis are in millimeters.
4. Series designation is the 13th position of the unit model number.
AIR IN
A
AIR
DISCHARGE
AIR IN
AIR DISCHARGE
E
AIR DISCHARGE
RATING LABEL
B
FIELD POWER
SUPPLY CONN
7⁄8 IN. DIA (22.22) HOLE WITH
1 1⁄8 IN. DIA (28.57) KNOCKOUT
AND 1 3⁄8 IN. DIA (34.92) KNOCKOUT
C
D
FIELD CONTROL
SUPPLY CONN
7⁄8 IN. DIA (22.22) HOLE
F DIA SUCTION LINE CONN
3⁄8 IN.
DIA (9.53) LIQUID LINE CONN
A91173
UNIT SIZE
018
024
036
048, 060
A/B
In.
18
22-1/2
22-1/2
30
C
mm
457.2
571.5
571.5
762.0
In.
3
3-11/16
3-11/16
6-1/2
D
mm
76.2
93.6
93.6
165.1
In.
15
18-1/8
18-1/8
23-1/2
E
mm
381.0
460.4
460.4
596.9
In.
10-3/16
14-3/8
14-3/8
20
F
mm
258.8
365.1
365.1
508.0
In.
5/8
5/8
3/4
7/8
mm
15.9
15.9
19.1
22.2
Fig. 2—Unit Reference Drawing
3. Run refrigerant tubes as directly as possible by avoiding
unnecessary turns and bends.
To prevent compressor damage DO NOT bury more than 36
in. (914mm) of refrigerant tubing. If ANY tubing is buried,
provide 6 in. (152mm) vertical rise at service valve.
4. Leave some slack between the structure and the unit to absorb
vibration.
5. When passing refrigerant tubes through the wall, seal the
opening with RTV or other pliable silicon-based caulk. (See
Fig. 3.)
OUTDOOR UNITS CONNECTED TO FACTORY-APPROVED
INDOOR UNITS — Outdoor unit contains correct system refrigerant charge for operation with indoor unit of the same size when
connected by 15 ft (4.55m) of field-supplied or factory-accessory
tubing. Check refrigerant charge for maximum efficiency.
6. Avoid direct lineset contact with water pipes, ductwork, floor
joists, wall studs, floors, and walls.
7. Do not suspend refrigerant tubing from joists and studs with a
rigid wire or strap which comes in direct contact with the
tubing. (See Fig. 3.)
REFRIGERANT TUBING — Connect tubing to fittings on outdoor unit vapor and liquid service valves. (See Fig. 2.)
8. Ensure that tubing insulation is pliable and completely surrounds the vapor tube.
9. When necessary, use hangar straps which are 1 in. (25mm)
wide and conform to the shape of the tubing insulation. (See
Fig. 3.)
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.
10. Isolate the hangar straps from the insulation by using metal
sleeves bent to conform to the shape of the insulation.
If refrigerant tubes or indoor coil is exposed to atmospheric
conditions for longer than 5 minutes, it must be evacuated to 500
microns to eliminate contamination and moisture in the system.
2
Table 1—Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters
LIQUID
Connection Dia.
In.
mm
3/8
9.53
3/8
9.53
3/8
9.53
3/8
9.53
UNIT SIZE
018, 024
036
048
060
VAPOR
Tube Dia.
In.
mm
3/8
9.53
3/8
9.53
3/8
9.53
3/8
9.53
Connection
In.
5/8
3/4
7/8
7/8
Dia.
mm
15.88
19.05
22.23
22.23
Tube Dia.
In.
5/8
3/4
7/8
1-1/8
mm
15.88
19.05
22.23
28.58
1. Tube diameters are for lengths up to 50 ft (15.24m). For tube sets over 50 ft (15.24m), consult Long-Line Application Guideline.
2. Do not apply capillary tube indoor coils to these units.
NOTE: Operation of unit on improper line voltage constitutes
abuse and could affect unit reliability. See unit rating label. Do not
install unit in system where voltage or phase imbalance may
fluctuate above or below permissible limits.
NOTE: Use copper wire only between disconnect switch and
unit.
NOTE: Install branch circuit disconnect per local codes of
adequate size to handle unit starting current. Locate disconnect
within sight from and readily accessible from unit per local codes.
To prevent damage to unit or service valves observe the
following:
• Use a brazing shield.
• Wrap service valves with wet cloth or use a heat sink
material.
SWEAT CONNECTION — Use refrigerant grade tubing. Service
valves are closed from factory and ready for brazing. After
wrapping the service valve with a wet cloth, the tubing set can be
brazed to the service valve using either silver bearing or non-silver
bearing brazing material. Consult local code requirements. Refrigerant tubing and indoor coil are now ready for leak testing. This
check should include all field and factory joints.
To avoid personal injury or death, do not supply power to unit
with compressor terminal box cover removed.
NOTE: Avoid contact between tubing and structure.
OUTDOOR WALL
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.
INDOOR WALL
CAULK
LIQUID TUBE
ROUTE GROUND AND POWER WIRES — Remove access
panel and control box cover to gain access to unit wiring. Extend
wires from disconnect through power wiring hole provided and
into unit control box. (See Fig. 2.) Size wires per local codes, but
not smaller than minimum wire size shown on unit rating label.
VAPOR TUBE
INSULATION
THROUGH THE WALL
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. 4.
JOIST
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
INSULATION
DISCONNECT
PER N.E.C. AND/OR
LOCAL CODES
VAPOR TUBE
CONTACTOR
FIELD POWER
1″ MIN
(25 mm)
WIRING
LIQUID TUBE
3 PHASE ONLY
SUSPENSION
BLUE
FIELD GROUND
A94330
WIRING
Fig. 3—Piping Installation
GROUND
LUG
A94025
Fig. 4—Line Power Connections
Step 5—Make Electrical Connections
NOTE: Use No. 18 AWG (American Wire Gage) color-coded,
insulated (35° C minimum) wire. If thermostat is located more than
100 ft (30.5m) from unit as measured along the control voltage
wires, use No. 16 AWG color-coded wires to avoid excessive
voltage drop.
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 label. Contact local power company for correction of
improper voltage. See unit rating label for recommended circuit
protection device.
3
CONNECT CONTROL WIRING — Route 24-v control wires
through control wiring grommet and connect to brown and blue
pigtails supplied in unit splice box. (See Fig. 5.)
Do not vent refrigerant to atmosphere. Recover during system
repair or final unit disposal.
Use furnace transformer, fan-coil transformer, or accessory transformer for control power, 24-v/40va minimum.
1. Fully back seat (open) liquid and vapor tube service valves.
NOTE: Use of available 24-v accessories may exceed the minimum 40-va power requirement. Determine total transformer loading and increase the transformer capacity or split the load with an
accessory transformer as required.
2. Unit is shipped with valve stem(s) front seated and caps
installed. Replace stem caps after system is opened to refrigerant flow (back seated). Replace caps finger-tight and tighten
additional 1/6 turn with wrench.
Step 6—Compressor Crankcase Heat
3. Close electrical disconnects to energize system.
When equipped with a crankcase heater, energize heater a minimum of 24 hrs before starting unit. To energize heater only, set
thermostat to OFF position and close electrical disconnect to
outdoor unit.
A crankcase heater is required if the refrigerant tubing is longer
than 50 ft (15.24m).
4. Set room thermostat at desired temperature. Be sure set point
is below indoor ambient temperature.
5. Set room thermostat at COOL and fan switch at FAN or
AUTO, as desired. Operate unit for 15 minutes. Check system
refrigerant charge.
Step 7—Install Electrical Accessories, If Any
6. Factory charge is shown on unit rating label. Adjust charge by
following procedure shown on charging tables located on unit.
Refer to the individual instructions packaged with the kit or
accessory when installing.
Step 9—Leave User’s Manual with Owner
Step 8—Start-Up and Check Charge
For continued high performance and to minimize possible equipment failure, periodic maintenance MUST be performed on this
equipment.
Leave User’s Manual with owner. Explain system operation and
periodic maintenance requirements outlined in manual. Frequency
of maintenance may vary depending on geographic areas, such as
coastal applications which require more frequent maintenance.
To prevent compressor damage or personal injury, observe
the following:
• Do not overcharge system with refrigerant.
• Do not operate unit in a vacuum or at negative pressure.
• Do not disable low-pressure switch.
In scroll compressor applications:
• Dome temperatures may be hot.
• In 3 phase application, incorrect phasing will cause reverse
rotation, resulting in elevated noise levels, equalized pressures and reduced current draw. Correct by reversing power
connection L1 and L2 on contactor.
To prevent personal injury wear safety glasses, protective
clothing, and gloves when handling refrigerant and observe
the following:
• Back seating service valves are not equipped with Schrader
valves. Fully back seat (counter clockwise) valve stem before
removing gage port cap.
• Front seating service valves are equipped with Schrader
valves.
4
THERMOSTAT
THERMOSTAT
FURNACE
R
R
R
M
G
MOTOR
POWER
SUPPLY
C
TRANS
IFR
C
Y
COOLING ONLY
G
G
Y
Y
W
W/
W1
ONE STAGE COOLING / GAS HEATING
THERMOSTAT
FAN COIL
THERMOSTAT
INDOOR UNIT
R
R
R
R
C
G
G
Y
W
C
C
C
G
G
Y
Y
Y
W2
W
W
ONE STAGE COOLING / ELECTRIC HEAT
LLS
C
ONE STAGE COOLING / HEATING
ACCESSORY LIQUID LINE SOLENOID
NOTES:
1. Wiring must conform to local codes.
2. LLS required on some units. See specific unit instructions.
3. Transformer required is 24-v, 40-va minimum. A 60-va or external power source may
be necessary when installing accessories.
4. When installing electronic thermostat, connect transformer common to thermostat C.
LEGEND:
C
LLS
M
– COMPRESSOR CONTACTOR
– LIQUID LINE SOLENOID
– INDOOR FAN MOTOR
TRANS – TRANSFORMER
IFR
– INDOOR FAN RELAY
A94331
Fig. 5—24-v Control Circuit Connections
5
Copyright 1994 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
38ckbc1s
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
Catalog No. 013-862
Printed in U.S.A.
Form 38CKB-C1SI
Pg 6
12-94
Replaces: New
Tab 3a 2a