Carrier 38CKC(Q) Air Conditioner User Manual

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 thoroughly 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
.
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 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.
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 contact with the
tubing. (See Fig. 2.)
8. Ensure that tubing insulation is pliable and completely surrounds 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 incomplete, file claim with shipping company prior to installation.
Locate unit rating plate on unit service panel. It contains information 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
Catalog No. 533-840
Printed in U.S.A.
Form 38BRC-1SI
Pg 1
2-97
Replaces: New
Tab 3a 2a
NOTE: Avoid contact between tubing and structure
OUTDOOR WALL
INDOOR WALL
CAULK
C
LIQUID TUBE
VAPOR TUBE
INSULATION
THROUGH THE WALL
3⁄8″D. (9.53) TIEDOWN
JOIST
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
KNOCKOUTS (2) PLACES
A
B
INSULATION
VAPOR TUBE
A94199
MIN PAD
DIM (IN.)
UNIT SIZE
38CKC(Q)018, 024
38CKC(Q)030-042
38CMC018-030
38BRC024-060
38CKC(Q)048, 060
38CMC036-060
1″ MIN.
LIQUID TUBE
SUSPENSION
A94028
Fig. 2—Connecting Tubing Installation
18 X 18
TIEDOWN KNOCKOUT
LOCATIONS
A
B
C
(In.)
(In.)
(In.)
3
15
10-3/16
22-1/2 X 22-1/2
3-11/16
18-1/8
14-3/8
30 X 30
6-1/2
23-1/2
20
Fig. 3—Mount Unit to Pad
Step 6—Make Tubing Connections
Step 3—Clearance Requirements
When installing, allow sufficient space for airflow clearance,
wiring, refrigerant piping, and service. Common clearances are 6
in. on 1 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
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.
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.
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.
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.
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. 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.
2
AIR DISCHARGE
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.)
FIELD POWER
SUPPLY CONN
7⁄8″ DIA HOLE WITH
1 1⁄8″ DIA KNOCKOUT
AND 1 3⁄8″ DIA
KNOCKOUT
FERRULE
LOCK NUT
FIELD CONTROL
SUPPLY CONN
7⁄8″ DIA HOLE
SUCTION LINE CONN
TUBING
LIQUID LINE CONN
A97009
UNIT SIZE
018, 024
030, 036
042, 048
060
LIQUID TUBE
Conn Dia
Tube Dia
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
A92121
VAPOR TUBE
Conn Dia
Tube Dia
5/8
5/8
3/4
3/4
7/8
7/8
7/8
1-1/8
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.
NOTE: Tube diameters are for lengths up to 50 ft. For tubing lengths greater
than 50 ft, consult your local distributor.
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.
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.
The tube end must stay bottomed in the service valve during
final assembly to ensure proper seating, sealing, and rigidity.
MECHANICAL FITTING REPAIR
5. Refrigerant tubing and indoor coil are now read for leak
testing. This check should include all field and factory joints.
To replace damaged ferrule or tubing proceed as follows.
1. Attach gages to service valves.
MECHANICAL CONNECTION (38CKQ MODELS)
2. Close liquid service valve and operate unit to pump refrigerant
charge into condenser coil.
1. Cut tubing to correct length, deburr, and size as necessary,
making sure tube ends are square. If a large burr is evident, ID
and OD must be deburred to allow tube to bottom in valve.
3. When suction pressure reaches 5 psig, shut unit off. Do not
operate unit in a vacuum.
2. Remove lock nuts and ferrules from plastic bags taped to
service panel. (See Fig. 5.)
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.
VALVE FITTING
8. Open service valves or recharge unit. Check refrigerant
charge.
Step 7—Install Solenoid Valve In Liquid Tube (If Required)
FERRULE
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 energized during evacuation for complete removal of refrigerant.
LOCK NUT
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 connections.
A92120
Fig. 5—Mechanical Fitting Assembly (38CKQ)
3
5. Wire solenoid coil into system control circuit.
LOCK NUT
Step 8—Make Electrical Connections
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.
TUBING
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.
MARK ON LOCK NUT
AND TUBE
A92122
Fig. 7—Proper Marking of Valve Assembly (38CKQ)
NOTE: Use copper wire only between disconnect switch and
unit.
ELECTRICAL JUNCTION
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.
ELECTRICAL COIL
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.
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.
VALVE
FLOW ARROW
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.
STRAIGHT 3/8 IN. STUD
NOTE: System flow direction
must match arrow on
bottom of body.
DISCONNECT
PER N.E.C. AND/OR
LOCAL CODES
A87044
CONTACTOR
Fig. 8—Solenoid Valve Installation
FIELD POWER
Wiring must comply with local codes and NEC requirements,
if a field-supplied control power source is needed when
adding solenoid.
WIRING
3 PHASE ONLY
1. Remove coil liquid connection cap and discard.
BLUE
FIELD GROUND
WIRING
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.
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.)
Avoid valve damage while brazing by wrapping valve with a
heat-sinking material such as a wet cloth.
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 excessive voltage drop.
3. Braze valve onto end of liquid tube using silver bearing or
non-silver bearing brazing material. Consult local code requirements.
Use furnace transformer, fan coil transformer, or accessory transformer for control power, 24-v/40-va minimum.
4. Braze flare adapter onto outlet end of solenoid valve.
4
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.
Do not vent refrigerant to atmosphere. Recover during system
repair or final unit disposal.
Step 9—Compressor Crankcase Heater
Follow these steps to properly pumpdown a system and avoid
negative suction pressure.
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.
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).
A crankcase heater is required if refrigerant tubing is longer than
50 ft.
NOTE: The Seasonal Energy Efficiency Ratio (SEER) is obtained with crankcase heater de-energized. To de-energize crankcase 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 shorting.
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
refrigerant charge.
Step 10—Install Electrical Accessories
Refer to the individual instructions packaged with kits or accessories when installing.
6. Factory charge is shown on unit rating plate. Adjust charge by
following procedure shown on charging tables located on unit.
Step 11—Start-Up and Check Charge
SEQUENCE OF OPERATION
Turn on power to indoor and outdoor units. Transformer is
energized.
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.
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
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.
For continued high performance and to minimize possible equipment 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. Frequency of maintenance may vary depending on geographic areas,
such as coastal applications which require more frequent maintenance.
5
CORPORATE
NON-PROGRAMMABLE
THERMOSTAT
MODEL AC
CORPORATE
NON-PROGRAMMABLE
THERMOSTAT
MODEL AC
SINGLE
AIR
STAGE
FURNACE CONDITIONER
R
24 VAC HOT
R
C
C
24 VAC COM
W/W1
COOL STAGE 1 Y/Y2
Y/Y2
G
R
24 VAC COM
C
HEAT STAGE 1 W/W1
HEAT STAGE 1 W/W1
INDOOR FAN
24 VAC HOT
C
SEE
NOTE 2
FA, FB, FC,
FD, FF
AIR
FAN COIL CONDITIONER
R
C
W2
SEE
NOTE 2
C
COOL STAGE 1 Y/Y2
INDOOR FAN
G
G
G
A94385
A94384
CORPORATE
PROGRAMMABLE
THERMOSTAT
MODEL AC
SINGLE
STAGE
FURNACE
24 VAC HOT
R
R
INDOOR FAN
G
G
HEAT STAGE 1
W/W1
W/W1
COOL STAGE 1
Y/Y2
Y/Y2
NOT USED
NOT USED
CORPORATE
PROGRAMMABLE
THERMOSTAT
MODEL AC
AIR
CONDITIONER
FA, FB, FC,
FD, FF
AIR
FAN COIL CONDITIONER
24 VAC HOT
R
R
INDOOR FAN
G
G
HEAT STAGE 1
W/W1
COOL STAGE 1
Y/Y2
NOT USED
O/W2
NOT USED
Y1/W2
W2
SEE
NOTE 2
O/W2
C
Y1/W2
24 VAC COM
C
NOT USED
B
NOT USED
L
OPTIONAL
OUTDOOR
SENSOR
CONNECTION
S1
C
SEE
NOTE 2
C
S2
24 VAC COM
C
NOT USED
B
NOT USED
L
OPTIONAL
OUTDOOR
SENSOR
CONNECTION
S1
A94386
C
S2
A94387
Fig. 10—Typical 24-v Circuit Connections
6
CORPORATE
NON-PROGRAMMABLE
THERMOSTAT
MODEL AC
24 VAC HOT
R
24 VAC COM
C
HEAT STAGE 1 W/W1
COOL STAGE 1
INDOOR FAN
Y/Y2
G
CORPORATE
PROGRAMMABLE
THERMOSTAT
MODEL AC
FK4B
AIR
FAN COIL CONDITIONER
R
C
W2
C
SEE
NOTE 2
Y/Y2
FK4B
AIR
FAN COIL CONDITIONER
24 VAC HOT
R
R
INDOOR FAN
G
G
HEAT STAGE 1
W/W1
W2
COOL STAGE 1
Y/Y2
Y/Y2
NOT USED
O/W2
O
NOT USED
Y1/W2
Y1
SEE
NOTE 2
C
G
W3
W3
O
24 VAC COM
C
C
Y1
NOT USED
B
E
E
NOT USED
L
L
L
OPTIONAL
OUTDOOR
SENSOR
CONNECTION
S1
A94388
S2
A94389
NON-CORPORATE
NON-PROGRAMMABLE
THERMOSTAT
MODEL AC
24 VAC HOT
FK4B
AIR
FAN COIL CONDITIONER
R
R
C
HEAT STAGE 1
W
W2
COOL STAGE 1
Y
Y/Y2
INDOOR FAN
G
G
C
SEE
NOTE 2
W3
O
Y1
E
L
A95281
Fig. 10—Typical 24-v Circuit Connections (Continued)
7
NON-CORPORATE
NON-PROGRAMMABLE
THERMOSTAT
MODEL AC
24 VAC HOT
R
NON-CORPORATE
NON-PROGRAMMABLE
THERMOSTAT
MODEL AC
FA, FB, FC,
FD, FF
AIR
FAN COIL CONDITIONER
R
24 VAC HOT
R
C
HEAT STAGE 1
W
COOL STAGE 1
Y
INDOOR FAN
G
C
W2
SINGLE
AIR
STAGE
FURNACE CONDITIONER
R
C
SEE
NOTE 2
HEAT STAGE 1
W
W/W1
COOL STAGE 1
Y
Y/Y2
INDOOR FAN
G
G
C
SEE
NOTE 2
G
A95282
A95283
NOTES:
1. CORPORATE THERMOSTAT WIRING DIAGRAMS ARE ONLY ACCURATE FOR MODEL
NUMBERS BEGINNING WITH TSTAT _ _ _ _ _ _ _
2. WIRING MUST CONFORM TO NEC OR LOCAL CODE.
3. 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.
4. A LIQUID LINE SOLENOID VALVE IS REQUIRED ON SOME UNITS. SEE SPECIFIC UNIT
INSTRUCTIONS.
5. THERMOSTATS ARE FACTORY CONFIGURED WITH 5 MINUTE COMPRESSOR CYCLE
PROTECTION AND 4 CYCLES PER HOUR LIMIT. SEE THERMOSTAT INSTRUCTIONS
FOR DETAILS.
6. TO STAGE THE ELECTRIC RESISTANCE HEAT, CONSULT OUTDOOR THERMOSTAT
INSTALLATION INSTRUCTIONS.
LEGEND
24 VOLT FACTORY WIRING
24 VOLT FIELD WIRING
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
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. 533-840
Printed in U.S.A.
Form 38BRC-1SI
Pg 8
2-97
Replaces: New
Tab 3a 2a