Carrier 38AN User Manual

38AN,BK with 40QN009,012 Cooling Only/Heat Pump Systems

Installation, Start-Up an

Service Instructions

(For Use in High Wall Applications)

CONTENTS

	Page
SAFETY CONSIDERATIONS....	.. I
GENERAL......................................	. 1,2
INSTALLATION.............................................	.2-13
Step 1 - Complete Pre-Installation Checks ...
• UNPACK UNIT
• INSPECT SHIPMENT		.2
Step 2 - Select Location.......................................
Step 3 - Mount Mounting Bracket on Wall ...		.3
Step 4 - Mount Outdoor Section..........................		.9
Step 5 - Connect Refrigerant Piping ..................		10
• RIGHT REAR AND BOTTOM PIPING
CONNECTIONS
• RIGHT SIDE PIPING CONNECTIONS
• LEFT SIDE PIPING CONNECTIONS
• ALL TYPES PIPING CONNECTIONS
Step 6 - Make Piping Connections......................		10
Step 7 - Connect Condensate Drain Line_____		11
Step 8 - Make Electrical Connections ................		11
• INDOOR SECTION WIRING
• OUTDOOR SECTION WIRING
Step 9 - Install Fan Coil Unit Onto
Mounting Bracket..............................................		13
START-UP ...................................................	14-17
40QN Control System ...............................	..	14
Wireless Remote Controllers ...................	..	14
After Extended Shutdowns ......................	..	14
Seasonal Changeovers.............................	..	14
To Turn the Unit On and Off .....................	..	14
Adjusting Airflow .......................................	..	14
Operating Mode Memory ..........................	..	14
Automatic Operation (Auto) Mode...........	,.	14
Operating Fault Diagnosis........................	..	15
Microprocessor Control Operation..........	.. 15
CLEANING AND MAINTENANCE......................	18-19
Lubrication ............................................................		18
To install or Replace Remote Controller		18
Batteries .............................................................
To Set the Current Time.......................................		18
To Remove and Clean or Replace Air Filters ..	18
• TO REMOVE AIR FILTERS
• TO CLEAN OR REPLACE FILTERS
To Clean Indoor Unit Front Panel .......................		19
To Clean Indoor Coil .............................................		19
To Clean Outdoor Coil (Outdoor Unit) ................		19
To Clean Condensate Drains...............................		19
SERVICE ........................................................		.20
Diagnostic Codes..........................................		.20
System Tests..................................................		.20

•THERMISTOR TESTS

•COMPRESSOR FAILURE

•REVERSING VALVE FAILURE (38BK Only)

	Page
System Safeties and Interlocks	...........................20

•INDOOR FAN FAILURE

•COMPRESSOR SHORT-CYCLING PROTECTION

•INDOOR COIL FREEZE PROTECTION

•INDOOR COIL HIGH-TEMPERATURE PROTECTION

TROUBLESHOOTING ..	.......... 20-27
START-UP CHECKLIST	.CL-1, CL-2

SAFETY CONSIDERATIONS

Installing and servicing air-conditioning equipment ean be hazardous due to system pressure and electrical compo­ nents. Only trained and qualified service personnel should install or service air-conditioning equipment.

Untrained personnel can perform basic maintenance func­ tions such as cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel.

When working on air conditioning equipment, observe pre­ cautions in the literature and on tags and labels attached to unit. Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Before installation, read these in­ structions thoroughly. Consult local building codes and Na­ tional Electrical Code (NEC) for special installation requirements.

A WARNING

Electrical shock can cause personal injuiy or death. Be­ fore installing or servicing system, be sure to turn off main power to system. There may be more than one dis­ connect switch. Turn olf indoor fan coil power as applicable.

GENERAL

The Carrier 40QNH012 heat pump high wall fan coil unit (Fig, 1) comes with supplemental electric heat (40QNE009 heat pmnp fan coil unit does not have electric heat). If your application requires heating, heat pump units must be used both outdoors and indoors. See Table 1 for recommended system combinations.

The matched cooling and heat pump systems consist of an outdoor section (condensing unit or heat pump) and an in­ door section (fan coil). The outdoor section (38AN or 38BK) is installed alongside the building structure. It can also be installed on a flat roof, deck, or on an apartment building balcony. The indoor section (40QNB009,012 or 40QNE009, 40QNH012) is mounted high on an interior wall that is con­ venient for piping connection to the outdoor section. Two sizes are available: 9,000 and 12,000 Btuh cooling capaci­ ties. See Fig. 1 for system components. Table 1 for system

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obiigations.

Book|1 |4	PC 111 Catalog No. 533-848 Printed In U.S.A. Form 38A.B/40Q-1SI Pg 1	5-99 Replaces; 53AN,BK-1 SI
Tab 3e 2f

combinations, and Table 2 for application range. Refer to this manual for proper installation of the complete system. Refer to Table 1 to make sure the correct indoor unit is in­ stalled with the correct outdoor unit. Be sure the unit will be operated within the application guidelines shown in Table 2. When installing the 38AN or 38BK unit, it is important to note that for cooling operation when the outdoor air tem­ perature is below 55 F, it is necessary to equip the outdoor unit with the low-ambient accessory.

To install this unit you will need:

1 — 40QNB or 40QNE/H Fan Coil unit with standard wire­ less remote controller and indoor unit wire

1 — 38AN or 38BK. Outdoor Unit

1 — Low-Ambient Kit (if required for your application)

NOTE: Field-supplied wire, drain pipe, refrigerant tubing, etc., are also required to install unit.

The installation materials provided are for use on instal­ lations where the indoor section is mounted to gypsum wall board with wall studs. Other types of applications require field-supplied mounting hardware. Be sure to follow all in­ stallation instructions in this manual carefully in order to achieve proper unit operation, and be sure that you have all of the required parts before beginning installation.

Note that the cooling only and heat pump systems utilize a microprocessor control system to deliver optimum levels of comfort and efficiency. Refer to Microprocessor Control Operation section on page 15 for details.

Table 1 — System Combinations for Indoor and Outdoor Units

	SYSTEM	INDOOR	OUTDOOR
		UNIT	UNIT
	High Wall Cooling Only	40QNB009	38AN009
		40QNB012	38AN012
	High Wall Heat Pump	40QNE009	38BK009
		40QNH012	38BK012

NOTE: A cooling only outdoor unit may not be matched with a heat pump indoor unit, a heat pump outdoor unit may not be matched with a cooiing only indoor unit. Do not mismatch systems.

Table 2 — Application Range

		COOLING
	Maximum			Minimum
Indoor		Outdoor	Indoor		Outdoor
95 F DB		115 F DB	67 F DB		55 F DB*
71 F WB			57 F WB
		HEATING
	Maximum			Minimum
Indoor		Outdoor	Indoor		Outdoor
80 F DB		75 F DB	55FDB		0° F DB
71 F WB		65 F WB

LEGEND

DB — Dry Bulb

WB — Wet Bulb

'Unit may be equipped with a low-ambient control that will allow op­ eration down to —20 F.

INSTALLATION

Step 1 — Complete Pre-Installation Checks

UNPACK UNIT(S) — Store unit{s) in original packaging until moved to the final site for installation. When removing unit from carton, lift by its 4 comers. Note that there is a plastic bag containing mounting screws taped to the mount­ ing bracket.

INSPECT SHIPMENT — Upon receipt of shipment, in­ spect unit (Fig. 1) for damage. Forward claim papers di­ rectly to the transportation company. Manufacturer is not re­ sponsible for damage incurred in transit.

Check all items (see Table 3), and if any item is missing, notify your Carrier distributor. To prevent loss or damage, leave all parts in the original packages until installation.

NOTE: The expansion device is located in outdoor unit.

Step 2 — Select Location — Consult local building codes and NEC for special installation requirements.

NOTE: There are several ways the unit may be installed in different types of wall construction. These instructions do not cover all installation methods. As a typical installation, these instructions focus primarily on mounting the unit to wall studs in new construction.

Plan your installation carefully before you begin. Listed below are some guidelines to follow when determining a lo­ cation for the unit;

1.Center unit (horizontally) on the wall selected.

2.Allow sufficient space for airflow clearance, wiring, re­ frigerant piping, and servicing the unit. See Fig. 2-4.

3.Place the unit so it faces normal location of room occupants.

TYPICAL FAN COL UNIT

TYPICAL OUTDOOR UNIT

Fig. 1 — Typical Cooling Only/

Heat Pump System

*A clearance of 31^" is the absolute minimum, A clearance of 10” is recommended.

NOTE: Remove unit front cover for controi box access.

Fig. 2 — Minimum Required Fan Coil Unit

Clearances

4, Select walls that are;

a.Strong enough to support the weight of the unit (see Tables 4A-4D for unit operating weight).

b.Accessible to convenient condensate drainage.

c.Free of obstacles that may block air circulation to the fan coil.

d.Outside walls (if possible) to make piping easier,

5.Place top of fan coil unit as high on wall as possible, mak­ ing sure that unit is at least 3 ’/i in. down from ceiling to permit proper airflow (the recommended clearance is 10 inches). Also, make sure that the unit is not placed directly over anything that would prevent filter removal or block airflow.

6, Make sure units are easily accessible to electric power.

7.Reirigerant piping can enter the unit through the prepunched holes. Refrigerant piping can run down along the wall, to the right or left along the wall, straight through the wall, or into the wall (recommended location: right rear). See Fig, 5, Once the piping is through the wall, it can run inside walls, in ceilings, between floors, or straight to the outside. See Fig. 6 for maximum line lengths. See Table 5 for System Piston Guide and Refrigerant Charging.

NOTE: Run refrigerant piping as directly as possible, and avoid any unnecessary turns or bends.

8. Condensate piping can be directed through the inside wall to an approved drain or directed straight outside,

NOTE: The piping hole for condensate line must be made at a downward slope to ensure proper drainage. See Mount Mounting Bracket on Wall section below for details.

Step 3 — Mount Mounting Bracket on Wall

1.Decide how refrigerant will be piped. If necessary, knock out the appropriate pre-punched holes (Fig. 5) on unit for piping and electrical connections.

2.Remove bracket from fan coil unit by pulling it down from fan coil unit bottom as shown in Fig, 7.

3.Using a carpenter’s level, fasten mounting brackets into the studs in the wall at least 10 in. away from the ceiling

with all the screws provided. Always be sure to insert screws into the top 2 holes indicated in Fig, 7. Make sure the attached bracket will support a 200 Tbvertical load. For

a masonry wall, anchor shields can be used to attach bracket to the wall.

4.Temporarily hang unit on bracket to check location and level.

A CAUTION

If mounting bracket is not mounted level, the indoor sec­ tion will be mounted unevenly, and condensate drain­ age water may drip onto the floor. Also, a gap between the bracket and the wall may result in vibration and noise from the indoor section.

5.Mark and cut condensate and piping holes.

a.For piping through the wall, mark the wall below the condensate connection and cut a 2'/i-in. hole into the wall at either point “A” or point “B” in Fig. 8.

NOTE: The 2’/2-in hole must be made at a downward slope to ensure proper condensate drainage. See Fig. 9. Slope condensate line at a minimum pitch of

'A in, per foot of line. The condensate line cannot be run up for upper piping connections — only refriger­ ant lines may be run up.

b.Push the wall sleeve (factory supplied with the xmit) through the 2‘/2-in. wall opening.

Table 3 — High Wall Unit Package Contents

ITEM	QUANTITY
Unit Mounting Template	1
Unit Mounting Bracket	1
1-in. Lag Screws for Unit Mounting	8
Hollow Wall Anchor Bolts for Unit Mounting	5
Wall Sleeve with Wall Cap	1
Infrared Wireless Remote Control	1
AAA Batteries (for Remote Control)	2
Remote Control Mounting Bracket	1
ya-in. Lag Screws for Remote Mounting Bracket	2
35 ft High Voltage Power Wiring
40QNB009 (3-Wire with Ground)	1
40QNEQ09 (2-Wire with Ground)	1
40QNB012 (2-Wire with Ground)	1
40QNH012 (2-Wire with Ground)	1
35 ft High Voltage Control Power Wiring (3-Wire)	1
35 ft Low Voltage Thermistor Wiring	1
Owner’s Manual	1
Installation Instructions	1
Warranty Registration Card	1

Table 4A — Physical Data, 38AN Cooling Only Condensing Units*

UNIT 3SAN	009		012
NOMINAL CAPACITY (Tons)	%		1
OPERATING WEIGHT (lb)	55		62
REFRIGERANT TYPE		R-22
Control (Cooling)		Capillary Tube
Factory Charge (lb)	1.5	1.8
COMPRESSOR TYPE	EAA090111A	Carrier Hernietic Rotary
Model			E8B120111A
Oil (Recharge) (oz)	10.1	10.1
Crankcase Heater		None
Accumulator		Yes
OUTDOOR FAN		Propeller, Direct Drive
Rpm	850		850
Diameter (in.)...No. of Blades	12y4...4		12У4...4
Motor Watts	87		87
Nominal Air Cfm	750		750
OUTDOOR COIL	Copper Tube, Aluminum Fin
Face Area (sq ft)...No. of Rows	3.5...1		3.5...2
FIns/in.	18		17
CONTROLS
Fusible Plug (F)	210		210
Control Voltage	115		230
REFRIGERANT LINES
Connection Type		Male	Flare
Liquid Line OD (in.)	У4		'/4
Vapor Line OD (in.t
Maximum Length (ft)	35		35
Maximum Lift Fan Coil (Above Outdoor) (ft)	16		16
Maximum Lift Fan Coil (Below Outdoor) (ft)	30		30

‘These units may only be used with 40QNB009,012 fan coil units.

Table 4B — Physical Data, 40QNB Cooling Only High Wall Units

UNIT 40QNB	009*	012*
NOMINAL CAPACITY (Tons)	n	1
NOMINAL SIZE (Btuh)	9000	12,000
OPERATING WEIGHT (lb)	18.7	24.2
MOISTURE REMOVAL RATE (Pints/Hr)	2.4	3.4
FINISH	White
REFRIGERANT	R-22
Control (Cooling)	Capillary Tube in Outdoor Unit
Factory or System Charge (ib)t	1.5	1.8
INDOOR FAN	Direct Drive	Centrifugal
Rpm...Cfm High	1200...240	1040...260
Rpm...Cfm Medium	1100...210	940...240
Rpm...Cfm Low	1000...180	850...210
Motor Watts	34	35
Biowers — No. ...Size (in.)	1...3.54 X27.75	1...3.94X 27.75
INDOOR COIL	Copper Tube, Aluminum Fin
Face Area (sq ft)	1.45	1.6
No. of Rows	2	2
Finsfin.	18	17
Circuits	2	3
FILTERS	Cieanable
(Quantity) Size (in.)	(2) 9x 12	(2) 914 X 13W
AIRSWEEP
Horizontai	Manual
Vertical	Automatic
CONTROLS	integrated Microprocessor
Remote Controller	Wireless
Freeze Protection	Yes
Auto. Restart	Yes
Diagnostics	Yes
Timer Mode	24-Hour Startup/Shutdown Type
Test Mode	Yes
Dehumidification Mode	Yes
Fan Mode	Hig h/Medium/Low/Auto.
Control Voltage	115 V	230 V
REFRIGERANT LINES
Connection Type	Male Flare
Liquid Line OD (in.)	W	14
Vapor Line OD (In.)	14	'4
Maximum Len^h (ft)	35	35
Maximum Lift Fan Coil (Above Outdoorl (ft)	16	16
Maximum Lift Fan Coll (Below Outdoor) (ft)	30	30
CONDENSATE DRAIN CONNECTION (in.)	OD, VieID

•Units may only be matched with 38AN outdoor units.

tFull factory charge shipped in outdoor unit. Charge is determined based on 25 ft of line.

Table 4C — Physical Data, 38BK009.012 Outdoor Heat Pump Units*

UNIT 38BK	009		012
NOMINAL CAPACITY (Tons)	V*		1
OPERATING WEIGHT (lb)	60.7		66.5
REFRIGERANT TYPE		R-22
Control (Cootingt	AccuRater® Piston at Outdoor Unit
Control (Heating)	AccuRater Piston at Outdoor Unit
Factory Charge (lb)	1.5	2.0
COMPRESSOR TYPE		Carrier Hermetic Rotary
Model	EBA095111H		EBC130111H
Oil (Recharge) (oz)	10.1	10.1
CRANKCASE HEATER (Watts)		40
OUTDOOR FAN		Propeller, Direct Drive
Rpm	850		850
Diameter (in.)...No. of Blades	12'^...4		12'/4...4
Motor Watts	87		87
Nominal Air Cfm	756		756
OUTDOOR COIL		Copper Tube, Aluminum Fin
Face Area (sq ft)...No. of Rows	3.5...1		3.5...2
Fins/ln.	18		17
CONTROLS
Fusible Plug	210 F		210 F
Accumulator	Yes		Yes
Defrost Method	Demand		Demand
Control Voltage	115 V		230 V
REFRIGERANT LINES
Connection TVpe		Male	Flare
Liquid Line OD (in.)	V4		V4
Vapor Line OD (in.)			W
Maximum Length (ft)	35		35
Maximum Lift (Fan Coll Above) (ft)	16		16
Maximum Lift (Fan Coll Below) (ft)	30		30

•These units may only be used with 40QNE/H fan coil units.

Table 4D — Physical Data, 40QNE/H Heat Pump High Wall Units

UNIT	40QNE009*		40QNH012*
NOMINAL CAPACITY (Tons)	%		1
NOMINAL SIZE (Btuh)	9000		12,000
OPERATING WEIGHT (lb)	18.7		24,2
MOISTURE REMOVAL RATE (PInts/hr)	2.4		3.4
REFRIGERANT	R-22
Control (Cooling)	Accu Rater® Piston at Outdoor Unit
Control Seating)	AccuRater Piston at Outdoor Unit
Factory Charge (lb)t	_...... ............... _..15.................. ...............		2.0
INDOOR FAN	Direct Drive Centrifugal
RpmyCfm High	1200/240		1040/260
RpnrVCfm Medium	1100/210		940/240
Rpm/Cfm Low	1000/180		850/210
Motor Watts	34		35
Blowers Quantity...Size (in.)	1...3.54 * 27.75		1...3.94 X 27.75
INDOOR COIL	Copper Tube, Aluminum Fin
Face Area	1.45		1.6
No. of Rows	2		2
Fins/in.	18		17
Circuits	2		3
FILTERS	Cieanabie
Quantity...Size (in.)	2...9X 12		2...91/4X 13V4
AIRSWEEP
Horizontal	Manual
Vertical	Automatic
CONTROLS	Integrated Microprocessor
Remote Controller Options	Wireless
Diagnostics	Yes
Defrost Method	Demand Defrost
Timer Mode	Yes
Warm Start Feature	Yes
Test Mode	Yes
Freeze Protection	Yes
Dehumidification Mode	Yes
Fan Mode	High/Medium/Low/Auto
Auto Changeover	Yes
Auto Restart	Yes		230 V
Control Voltage	115 V
REFRIGERANT LINES
Connection Type	Male Flare
Liquid Line OD (in.)			W
Vapor Line OD (in.)			Vi
Maximum Length (m	35		35
Maximum Lift (Fan Coil Above) (ft)	16		16
Maximum Lift (Fan Coil Below) (ft)	30		30
CONDENSATE DRAIN SIZE (in.)	% OD, Vie ID

'These units may oniy be matched with 38BK outdoor units. The 40QNH unit available in size 012 only. tFuil factory charge is shipped in the outdoor unit. The charge is determined based on 25 ft of line.

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	*	[235]	^			> i e n T t i » i v n *
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NOTES;
				UNIT		WEIGHT
1. Dimensions in ( ] are in miliimelers.
2.	Direction of airflow.			38	Lb		Kg
				AN009	55.0		25.0
	Center of Gravity.			AN012	62,0		28.1
4.	Minimum dearances: 4 in. on coil sides, 24 in. on fan side, and			BKD09	60.7		27.5
				BK012	66.5		30.2
	30 in. service side.

Fig. 3 — 38AN/BK Dimensional Drawing

HiNIHUM CLEARANCE FOR SERVICE

[NL£T AIR

EVAPORATOR

COIL

¿-KWCICOUT FOR LEFT SIDE REFRIGERANT, DRAIN, POUER AND SIGNAL LINES

2.36 OIA 160]

IRISHT SIDE VIEW I

INFRARED	REMOTE OVERRIDE SWITCH
CBEHIND ACCESS COVER)
	KNOCKOUT FOR RIGHT SIDE -
	REFRIGERANT, DRAIN, POWER
	AND SIGNAL LINES
	‘INDOOR FAN MOTOR
I BOTTOM VIETI	KNOCKOUT FOR BOTTOM
INDOOR AIR BLOWER WHEEL	REFRIGERANT. DRAIN, POWER
	AND SIGNAL UNES

NOTES:

1.Dimensions are in inches. Dimensions in [ ] are in miliimeters.

2.Direction of airflow.

3.Refrigerant, drain, and power connections may be made rear, left side or right side.

4.Refrigerant ts metered by capillary tubes in the outdoor unit. Insulate both refrigerant lines.

5.Clearances of ZW on top of and to the left of the fan coil unit are absolute minimums, Clearances of 10" are recommended.

6.Do not insert a trap in condensate drain line. Drain is internally trapped.

UNIT	WEIGHT		A			B			c
40QN	Lb	Kg	in.	mm	in.		mm	in.		mm
009	18.7	8.5	33.46	850	11.02		280	6.29		160
012	24.2	11.0	36.61	930	11.81		300	7.28		185

Fig. 4 — 40QN Dimensional Drawing

8

Table 5 — System Piston Guide and

Refrigerant Charges

	UNIT		INDOOR	OUTDOOR	REQUIRED
					SYSTEM
			PISTON	PISTON
	Indoor	Outdoor	SIZE	SIZE	CHARGE
					(lb)*
	40QNB009	38AN009	Capillary Tube	Capillary Tube	1.50
	40QNB012	38AN012	Capillary Tube	Capillary Tube	1.80
	40QNE009	38BK009	32t	30t	1.50
	40QNH012	38BK012	42t	42t	2.00

'Charge is based on 25 ft of interconnecting tubing. Charge may need to be added for longer tubing runs or when used with certain fan coiis. Check unit namepiate for required charge. This is a totai sys­ tem charge.

tNon-serviceabie Aeroquip piston.

POSSiBLE PIPiNG DIRECTIONS

PREPUNCHED HOLES

BOTTOM/REAR

PIPING

Fig. 5 — Fan Coil Unit Refrigerant Piping

as" MAX (FOR COOLING ONLY AND HEAT PUMP SYSTEMS)

UNIT	ROOFTOP
GROUND-LEVEL
INSTALLATION	INSTALLATION

Fig. 6 — Maximum System Line Lengths

Step 4 — Mount Outdoor Section

1.If outdoor section is to be installed at ground level, mount on a solid, level support pad one in. longer and one in. wider than the outdoor section dimensions.

2.Provide sufficient clearance for airflow, wiring, refriger­ ant piping, service and maintenance. Provide a minimum clearance of 2 ft from obstructions in front of outdoor section, 2 ft on outdoor coil side, and 2’/2 ft on electrical and piping side. If more than one outdoor section is in­ stalled, provide a minimum clearance of 2 ft between sec­ tions. Position outdoor section so that water or ice from roof cannot fall directly on unit.

NOTE: The outdoor section can be installed higher than, lower than, or level with the elevation of the indoor section. If outdoor section is mounted higher than the in­ door section, the vertical distance between the 2 units should not exceed 30 ft. If the outdoor section is installed lower than indoor section, the vertical distance between the units should not exceed 16 ft. See table below:

MAXIMUM DISTANCE BETWEEN OUTDOOR UNITS

Outdoor Section Higher	30 Ft Maximum
Than Indoor Section	(Vertical)
Outdoor Section Lower	16 Ft Maximum
Than Indoor Section	(Vertical)

NOTE: Maximum system piping length between indoor and outdoor units is 35 ft.

Fig. 7 — Fan Coil Unit Bracket Mounting (Size 009 Shown)