Carrier 38QH Air Conditioner User Manual

38TXA 13.0 SEER
Air Conditioner With R-410A
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 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 and work gloves. Use
quenching cloth for brazing operations. Have fire extinguisher
available. Read these instructions thoroughly and follow all
warnings or cautions attached to the unit. Consult local building
codes and the National Electrical Code (NEC) for special installation requirements.
Recognize safety information. This is the safety-alert symbol .
When you see this symbol on the unit or in instructions and
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.
R-410A systems operate at higher pressures than standard
R-22 systems. Do not use R-22 service equipment or components on R-410A equipment.
Before installing or servicing system, always turn off main
power to system. There may be more than 1 disconnect
switch. Turn off accessory heater power if applicable. Electrical shock can cause personal injury or death.
INSTALLATION
A92446
Fig. 1—38TXA
INSPECT EQUIPMENT — File claim with shipping company
prior to installation if shipment is damaged or incomplete. Locate
unit rating plate on unit corner panel. (See Fig. 4.) 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 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. 4. to
determine base pan size and knockout hole location.
When installing, allow sufficient space for airflow, wiring, refrigerant piping, and service. Allow 30-in. clearance to service end of
unit and 48 in. above unit. For proper airflow, a 6-in. clearance on
1 side of unit and 12 in. on all remaining sides must be maintained.
Maintain a distance of 24 in. between air conditioners. Position so
snow, ice, and water from roof or eaves cannot fall directly on unit.
Specifications for this unit in residential new construction market
require outdoor unit, indoor unit, refrigerant tubing sets, metering
device, and filter drier listed in presale literature. There can be no
deviation. Consult Application Guideline and Service Manual to
obtain required unit changes for specific applications, and for R-22
retrofit.
On rooftop applications, locate unit at least 6 in. above roof
surface. Where possible, place unit above a load-bearing wall.
Step 1—Check Equipment and Jobsite
Step 3—Install TXV (Optional)
UNPACK UNIT — Move to final location. Remove carton taking
care not to damage unit.
The accessory thermostatic expansion valve is specifically designed to operate with R-410A. Do not use an R-22 TXV. An
Arrange supporting members to adequately support unit and
minimize transmission of vibration to building. Consult local
codes governing rooftop applications.
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. 563-813
Printed in U.S.A.
Form 38TXA-1SI
Pg 1
1-96
Replaces: New
Tab 3a 2a
2. Ensure that vapor and liquid tube diameters are appropriate to
capacity of unit. (See Table 1)
PISTON
RETAINER
PISTON
RING
PISTON
3. Run refrigerant tubes as directly as possible by avoiding
unnecessary turns and bends.
PISTON
BODY
4. Leave some slack between structure and unit to absorb
vibration.
5. When passing refrigerant tubes through wall, seal opening
with RTV or other pliable silicon-based caulk. (See Fig. 3.)
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 tubing.
(See Fig. 3.)
FIELD
CONNECTION
STRAINER
NOTE: Avoid contact between tubing and structure
OUTDOOR WALL
FLARE
ADAPTOR
INDOOR WALL
CAULK
LIQUID TUBE
LIQUID LINE STRAINER
APPROX. 2” LONG
STRAINER LABEL
(AFFIX TO LIQ. LINE
NEAR STRAINER LOCATION)
VAPOR TUBE
INSULATION
THROUGH THE WALL
A95615
Fig. 2—Accurater Components
JOIST
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
existing R-22 TXV must be replaced with a factory-approved TXV
specifically designed for R-410A. To replace an R-22 TXV see
accessory kit instructions.
INSULATION
VAPOR TUBE
NOTE: FK4 fan coils are equipped with an R-22 TXV. If an FK4
fan coil is used with an R-410A air conditioner, the R-22 TXV
must be replaced.
Step 4—Install AccuRater® Piston and Ring
ACCURATER PISTON
1″ MIN.
1. If unit is to be installed with a piston metering device, check
indoor piston to see if it matches required piston on outdoor
unit rating plate. If it does not match, replace with piston
shipped with outdoor unit. The piston shipped with outdoor
unit is correct for any approved indoor coil combination.
LIQUID TUBE
SUSPENSION
A94028
Fig. 3—Piping Installation
2. After correct piston is installed, locate brass piston ring
shipped in piston bag. Install piston ring behind metering
piston as shown in Fig. 2. The piston ring will ensure piston
stays seated during all operating conditions.
8. Ensure that tubing insulation is pliable and completely surrounds vapor line.
Step 5—Make Piping Connections
9. When necessary, use hanger straps which are 1 in. wide and
conform to shape of tubing insulation. (See Fig. 3.)
10. Isolate hanger straps from insulation by using metal sleeves
bent to conform to shape of insulation.
Do not leave system open to atmosphere any longer than
minimum required for installation. POE oil in compressor is
extremely susceptible to moisture absorption. Always keep
ends of tubing sealed during installation.
DO NOT BURY MORE THAN 36 IN. OF REFRIGERANT
TUBING IN GROUND. If any section of tubing is buried,
there must be a 6-in. vertical rise to the valve connections on
the outdoor unit. If more than the recommended length is
buried, refrigerant may migrate to cooler buried section
during extended periods of unit shutdown, causing refrigerant
slugging and possible compressor damage at start-up.
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, consult
Application Guideline and Service Manual for air conditioners
with R-410A.
INSTALLATION RECOMMENDATIONS
1. Locate unit away from windows.
2
AIR IN
AIR DISCHARGE
3/8" DIA TIEDOWN KNOCKOUTS
(2) PLACES IN BASEPAN
AIR IN
D
C
L
E
NOTES:
1. Allow 30 in. (762 mm) clearance to service end of
unit, 48 in. (1219 mm) above unit, 6 in. (152 mm) on one side, 12 in. (305 mm)
on remaining side, and 24 in. (610 mm) between
units for proper airflow.
2. Minimum outdoor operating ambient in cooling mode is
55° F (12.8° C) (unless low ambient control is used) max 125° F (51.7° C).
5. Series designation is the 13th position of the unit model number.
6. Center of gravity
SERIAL
PROD
MODEL
C
ID
PISTON
OD
FACTORY CHARGED R-22
AIR DISCHARGE
Kg
LBS
AIR IN
POWER SUPPLY
VOLTS
HZ
PH
UNIT RATING
PLATE
VAPOR LINE CONN
FIELD POWER SUPPLY CONN
7/8 IN. DIA HOLE WITH
1 1/8 IN. DIA KNOCKOUT
AND
1 3/8 IN. DIA KNOCKOUT
A
AIR DISCHARGE
PERMISSIBLE VOLTAGE AT UNIT
MIN
MAX
SUITABLE FOR OUTDOOR USE
COMPRESSOR
VOLTS AC
PH
HZ
B
RLA
LRA
FAN MOTOR
VOLTS AC
PH
HZ
FLA
FIELD CONTROL
SUPPLY CONN
7/8 IN. DIA HOLE
DESIGN/TEST PRESSURE GAGE
PSI
kPa
LO PSI
kPa
HI
MINIMUM CIRCUIT AMPS
ACCESS
PANEL
MAX OVERCURRENT PROTECTIVE DEVICE
USA
TYPE
CANADA
MAX FUSE
N/A
MAX HACR CKT-BKR
MAX CKT-BKR
3/8 IN. DIA LIQUID
N/A
®
®
LINE CONN
CARRIER CORP
INDIANAPOLIS IN
313948-401
REV A
46206
A92471
UNIT
SIZE
024-060
A
In.
34-15/16
B
In.
30
C
In.
8-3/16
D
In.
4
E
In.
9-3/4
Fig. 4—Unit Reference Drawing
In some cases noise in the living area has been traced to gas
pulsations from improper installation of equipment.
Installation of filter drier in liquid line is required.
Step 6—Install Liquid-Line Filter drier (See Fig. 5)
OUTDOOR UNITS CONNECTED TO FACTORY-APPROVED
INDOOR UNITS — Outdoor unit contains correct system refrigerant charge for operation with tested indoor unit listed in presale
literature when connected by 15 ft of field-supplied or factory
accessory tubing. Check refrigerant charge for maximum efficiency.
1. Braze 5-in. connector tube to liquid service valve. Wrap filter
drier with damp cloth.
2. Braze filter drier between connector tube and liquid tube to
indoor coil. Flow arrow must point towards indoor coil.
Table 1—Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters (In.)
UNIT
SIZE
024
030, 036
042, 048
060
LIQUID
Connect
Tube
Diameter
Diameter
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
LIQUID-LINE
FILTER-DRIER
LIQUID
SERVICE
VALVE
VAPOR
Connect
Tube
Diameter
Diameter
5/8
5/8
3/4
3/4
7/8
7/8
7/8
1-1/8
R-
4 1 0A
CONNECTOR
TUBE
Note: 1. Tube diameters are for lengths up to 50 ft. For tubing lengths greater
than 50 ft, consult Application Guideline and Service Manual for air conditioners with R-410A.
A95509
Fig. 5—Liquid-Line Filter drier
3
Step 7—Refrigerant Tubing
Connect vapor tube to fitting on outdoor unit vapor service valve
and connect liquid tube to filter drier. (See Fig. 5.)
The cabinet must have an uninterrupted or unbroken ground
according to NEC, ANSI/NFPA 70-1996, or local codes to
minimize personal injury if an electrical fault should occur.
This may consist of electrical wire or conduit approved for
electrical ground when installed in accordance with existing
electrical codes. Failure to follow this warning could result in
an electrical shock, fire, or death.
A brazing shield MUST be used when tubing sets are being
brazed to the service valves to prevent damage to the painted
unit surface.
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 avoid personal injury or death, do not supply power to unit
with compressor terminal box cover removed.
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. 6.
To avoid valve damage while brazing, service valves must be
wrapped with a heat-sinking material such as a wet cloth.
DISCONNECT
PER N.E.C. AND/OR
LOCAL CODES
SWEAT CONNECTION — Use refrigerant grade tubing. Service
valves are closed from factory and ready for brazing. After
wrapping service valve and filter drier with wet cloth, tubing set
can be brazed to service valve and filter drier 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.
Step 8—Evacuate
Refrigerant tubes and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. The alternate
triple evacuation method may be used if the procedure outlined in
the Service Manual is followed. Always break a vacuum with dry
nitrogen.
CONTACTOR
FIELD POWER
WIRING
3 PHASE ONLY
BLUE
FIELD GROUND
WIRING
GROUND
LUG
A94025
Fig. 6—Line Power Connections
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. 7.)
Never use the system compressor as a vacuum pump.
Step 9—Make Electrical Connections
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. (See Fig. 4.)
NOTE: Operation of unit on improper line voltage constitutes
abuse and could affect unit reliability. See unit rating plate.
NOTE: Use only copper wire between disconnect switch and
unit.
NOTE: Install branch circuit disconnect per NEC of adequate
size to handle unit starting current, but not larger than maximum
fuse size shown on unit rating plate. Locate disconnect within sight
from and readily accessible from unit, per Section 440-14 of NEC.
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.
Use furnace transformer, fan coil transformer, or accessory transformer for control power, 24v/40va minimum.
NOTE: Use of available 24-v accessories may exceed the minimum 40-va power requirement. Determine total transformer loading and increase transformer capacity or split load with an
accessory transformer as required.
Step 10—Install Electrical Accessories
Refer to individual instructions packaged with kits or accessories
when installing.
Step 11—Start-Up
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. 4.) Size wires per NEC but not
smaller than minimum wire size shown in presale literature.
1. After system is evacuated, fully back seat (open) liquid and
vapor service valves. Unit is shipped with valve stem(s) front
seated and caps installed.
2. Replace stem caps after system is opened to refrigerant flow
(back seated). Replace caps finger tight and tighten additional
1/12 turn with wrench.
3. Close electrical disconnects to energize system.
4. Be sure thermostat set point is below indoor ambient temperature. Set room thermostat at COOL and fan at ON or AUTO,
as desired. Operate unit for 15 minutes. Check system
refrigerant charge.
4
5. Factory charge and superheat charging method are shown on
unit information plate. (See Fig. 4.) R-410A refrigerant
cylinders contain a dip tube which allows liquid refrigerant to flow from cylinder in upright position. Charge
R-410A units with cylinder in upright position and a
commercial-type metering device in manifold hose. Charge
refrigerant into suction-line.
Do not vent refrigerant to atmosphere. Recover for system
repair or final unit disposal.
CARE AND MAINTENANCE
For continuing high performance and to minimize possible equipment failure, it is essential that periodic maintenance be performed
on this equipment. Consult servicing contractor or User’s Manual
for the proper frequency of maintenance. Frequency of maintenance may vary depending upon geographic areas, such as coastal
applications.
Do not disable low-pressure switch during a condenser pump
down. Compressor damage may occur if run at a negative
suction pressure.
Step 1—Leave User’s Manual With Homeowner
Explain system operation and maintenance procedures outlined in
User’s Manual.
Compressor damage may occur if system is overcharged.
Service valve gage ports are not equipped with Schrader
valves. To prevent personal injury, make sure valves are fully
back seated before removing gage port caps. Wear safety
glasses and gloves when handling refrigerant.
ATTENTION INSTALLERS AND SERVICE TECHNICIANS!
AIR CONDITIONER WITH R-410A—QUICK REFERENCE GUIDE
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
R-410A refrigerant operates at 50%-70% higher pressures than R-22. Be sure that servicing equipment
and replacement components are designed to operate with R-410A.
R-410A refrigerant cylinders are rose colored.
R-410A refrigerant cylinders have a dip tube which allows liquid to flow out of cylinder in upright
position.
R-410A systems should be charged with liquid refrigerant. Use a commercial type metering device in the
manifold hose.
R-410A, as with other HFCs, is only compatible with POE oils.
Vacuum pumps will not remove moisture from oil.
Do not use liquid-line filter driers with rated working pressures less than 600 psig.
Do not install a suction-line filter drier in liquid line.
POE oils absorb moisture rapidly. Do not expose oil to atmosphere.
Wrap all filter driers and service valves with wet cloth when brazing.
A liquid-line filter drier is required on every unit.
Do not use an R-22 TXV.
If indoor unit is equipped with a TXV, it must be changed to an R-410A TXV.
Never open system to atmosphere while it is under a vacuum.
When system must be opened for service, break vacuum with dry nitrogen and replace filter driers.
Do not vent R-410A into the atmosphere.
Observe all warnings, cautions, and bold text.
Do not use capillary tube indoor coils.
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
C
SEE
NOTE 2
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. 7—Typical 24-v Circuit Connections
6
CORPORATE
PROGRAMMABLE
THERMOSTAT
MODEL AC
CORPORATE
NON-PROGRAMMABLE
THERMOSTAT
MODEL AC
FK4C
AIR
FAN COIL CONDITIONER
FK4C
AIR
FAN COIL CONDITIONER
24 VAC HOT
R
R
INDOOR FAN
G
G
HEAT STAGE 1 W/W1
W1
Y/Y2
24 VAC HOT
R
R
COOL STAGE 1 Y/Y2
24 VAC COM
C
C
NOT USED
O/W2
O
NOT USED
Y1/W2
Y1
HEAT STAGE 1 W/W1
W1
COOL STAGE 1 Y/Y2
Y/Y2
INDOOR FAN
G
C
SEE
NOTE
2
C
W2
24 VAC COM
C
C
W2
NOT USED
B
DH
O
NOT USED
L
Y1
COOL STAGE 1
S1
DH
INDOOR FAN
S2
G
A95502
NON-CORPORATE
NON-PROGRAMMABLE
THERMOSTAT
MODEL AC
24 VAC HOT
R
A95503
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
W2
C
SEE
NOTE
2
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
Fig. 7—Typical 24-v Circuit Connections (Continued)
7
NON-CORPORATE
NON-PROGRAMMABLE
THERMOSTAT
MODEL AC
24 VAC HOT
FK4C
AIR
FAN COIL CONDITIONER
R
R
C
HEAT STAGE 1
W
W1
COOL STAGE 1
Y
Y/Y2
INDOOR FAN
G
G
C
SEE
NOTE
2
W2
O
Y1
DH
A95501
Fig. 7—Typical 24-v Circuit Connections (Continued)
NOTES:
1. Corporate thermostat wiring diagrams are only accurate for model numbers beginning with TSTAT_______.
2. Some units are equipped with pressure switches, temperature switch, or 5 minute compressor cycle protection. Connect 24-v field wiring
to factory-provided stripped leads.
3. Wiring must conform to NEC or local codes.
4. 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
A95500
Fig. 8—Typical 24-v Circuit Connections Legend
Copyright 1996 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
38txa1si
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. 563-813
Printed in U.S.A.
Form 38TXA-1SI
Pg 8
1-96
Replaces: New
Tab 3a 2a