Carrier 38QB User Manual

Number One AirConditbninq Maker

Installation, Start-Up

Division of Carrier Corporation

Carrier Parkway • Syracuse NY 13221

and Service Instructions

Heat Pump — Outdoor Section

CONTENTS

SAFETY CONSIDERATIONS............................. 1

INSTALLATION Step 1 —Check Equipmentand Jobsite.. 1

• UNPACK UNIT

• INSPECT EQUIPMENT

• COMPLETE OR CONSIDER SYSTEM REQUIREMENTS

Step 2 — Mount Outdoor Heat Pump ... 2

• ON THE GROUND: MOUNT ON A SOLID, LEVEL CONCRETE PAD

• ON THE ROOF: MOUNT ON A LEVEL PLATFORM OR FRAME

Step 3 — Make Piping Connections

• REPLACE THE ACCURATER™ RE FRIGERANT CONTROL PISTON IN THE INDOOR COIL AS REQUIRED

• CONNECT REFRIGERANT LINES

Step 4 — Make Electrical Connections... 5-6

• INSTALL A BRANCH CIRCUIT

DISCONNECT PER NEC

• ROUTE LINE POWER LEADS

INTO UNIT

• CONNECT GROUND LEAD AND POWER WIRING

• SEE INDOOR UNIT AND ELECTRIC HEATER INSTALLATION, START-UP AND SERVICE INSTRUCTIONS

• CONNECT CONTROL POWER WIRING (24 v)

START-UP..........................................................6-8

SERVICE

MAINTENANCE

Installation and servicing of air conditioning

equipment can be hazardous due to system pres

sure and electrical components. Only trained and

qualified service personnel should install, repair or

service air conditioning equipment.

Untrained personnel can perform basic mainte nance functions of cleaning coils and cleaning and replacing filters. All other operations should be per

formed by trained service personnel. When working

on air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply.

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SAFETY CONSIDERATIONS

8-16'* 16-19

Page

1-6

2-5

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing opera tions. Have fire extinguisher available for all brazing operations.

INSTALLATION

Step 1 — Check Equipment and Jobsite

UNPACK UNIT — Move to final location. Lift carton off, taking special care not to damage service valves or grilles.

INSPECT EQUIPMENT — File claim with ship ping company if shipment is damaged or incomplete.

COMPLETE OR CONSIDER SYSTEM RE QUIREMENTS before installing the 38QB.

Consult local building codes and National Elec trical Code (NEC) for special installation requirements.

When installing, allow sufficient space for airflow clearance, wiring, refrigerant piping and servicing. Position so water or ice from roof cannot drop directly on top of unit.

Make provisions for condensate drainage and defrost water disposal whether unit is installed on ground or roof. (Ensure unit basepan drainage holes are not blocked.) See Step 2 for details. Roof instal lation method for 38QB depends on building con struction and special requirements of local codes. Be sure that roof can support unit weight.

It is recommended that 38 QB units be used with

Carrier approved indoor sections; see Table I.

System Refrigerant Control on 38QB units and matching Carrier indoor units is a factory-installed AccuRater device (bypass-type). Bypass-type AccuRater components are discussed in the service sec tion of this booklet. The AccuRater piston has a refrigerant metering hole thru it and is field replace able. Table 1 indicates indoor units for which the required replacement piston is factory supplied with specified 38QB outdoor unit. Replace piston as described under AccuRater Servicing on page 15.

^ Table 1 — Carrier Approve^^6^ Systems

OUTDOOR

UNIT

38QB

015

018

024

030

036

042

048

060

‘Replace factory-installed piston with this piston size

REQUIRED OUTDOOR

PISTON

SIZE

INDOOR

UNIT

MODEL 8i

SIZE

28HQ.VQ018

40AQ018 40DQ018

28HQ.VQ024

40AQ024 40DQ024

28HQ.VQ024 55

40AQ024 40DQ024 59

28HQ.VQ030

40AQ030 40DQ030

28HQ.VQ030

40AQ030

40DQ030

28HQ.VQ036

40AQ036

40FS160 1 28HQ.VQ036

28HQ.VQ036

40AQ036

40FS160 1 28HQ.VQ036

28HQ.VQ042

40FS160 1 28HQ.VQ042

40QB.QH042

28HQ.VQ042

40FS160 I 28HQ,VQ042

40QB.QH042 28HQ.VQ048

40FS200 1 28HQ.VQ048

40QB.QH048 40QB.QH060

REQUIRED

INDOOR

PISTON

SIZE

46 46*

52*

55*

61*

63 63* 63

70*

86*

4'-0" (1220 mm) OVERHEAD SPACE REQUIRED FOR SERVICE AND AIRFLOW

TOP COVER

DIAM HOLE FOR POWER WIRING

LIQUID VALVE SERVICE PORT f VAPOR VALVE SERVICE PORT

[//> AIRFLOW SUCTION SERVICE PORT

Top Cover Removal — Top cover can be removed for wiring or servicing heat pump. Loosen decora tive strip and slide down off screw heads. Remove

3 screws in connector plate and 2 screws on front of unit. Loosen remaining 4 serews. Lift top from unit (see Fig. 1).

Step 2 — Mount Outdoor Heat Pump

ON THE GROUND: MOUNT ON A SOLID

LEVEL CONCRETE PAD (see Fig. 1). Swing 3

legs down and lock in position, except when using

accessory rack. Use accessory heat pump rack

(Fig. 2) in areas where prolonged subfreezing tem

peratures or heavy snow occur. (Refer to installation

instructions included with rack.) Drainage holes in

unit base must not be obstructed.

ON THE ROOF; MOUNT ON A LEVEL PLAT FORM OR FRAME. Proper precaution must be

taken for support of unit in roof design. Elevate unit

for proper clearance as described under ground installation, above. Plan roof design and water drainage to prevent unit from setting in water. Flash all roof openings to prevent leaks.

Roof mounted units exposed to winds above 5 mph (8 km/h) may require protective wind baffles (field fabricated) to achieve adequate defrost.

12 (305mm) GRAVEL APRON

I-4 (407mm) TYPICAL 3 PLACES

(6.35 mm) TIEDOWN BOLTS

CENTERLINE BETWEEN VALVES

6^ (172 mm)

Г-н" (585mm) DIAM x 6"(l52mm)THK CONCRETE MOUNTING PAD FOR 38QB0I5

(572 mm) TYPICAL 3 PLACES

(6.35 mm) TIEDOWN BOLTS

CENTERLINE BETWEEN

9^ (241 mm)

VALVES

Step 3 — Make Piping Connections — Heat

pumps may be eonneeted to indoor sections using Carrier aecessory tubing package (Table 3) or fieldsupplied tubing of refrigerant grade, correct size and

2-6" (762 mm) DIAM x 6" (152mm) THK CONCRETE

MOUNTING PAD FOR 38QB0i8-060

Fig. 1 — Dimensions, Connections and

Mounting Pad (Refer to Table 2.)

condition (Table 2). For requirements beyond 50 ft, obtain information from loeal Carrier distributor.

If 1-1/8in. tubing is used (38QB042,048,060), braze it to the accessory 1-1/8 x 3/4-in. suction connection adapter (Carrier Part No. 28AU900061) or to a correctly sized field-supplied adapter, then make Compatible Fitting connections. Isolate inter connecting tubing from framing and ductwork or where tubing runs thru stud spaces, enelosed ceilings or pipe chases. Use isolation type hangers. Fig. 3, since rigid fastening transmits pulsations to struc ture creating objectionable sound.

I'-O" (305 mm) GRAVEL APRON

Г-И" (584mm) DIAM

б" (152 mm) THICK

CONCRETE MOUNTING PAD FOR 38QB0I5

2-6" (762mm) DIAM

6" (152 mm)

THICK

CONCRETE MOUNTING PAD FOR 38QB0I8-060

Fig. 2

- Accessory Mounting Rack

‘marker tape

(HIDDEN)

Table 2 — Installation Data (Fig. 1)

UNIT 38QB 015 OPERATING WEIGHT

(l|))

140 179

018

Fig. 3 — Refrigerant Line Hangers

024 030

185 187 , 197

036

042 229

048 240

060 252

DIMENSIONS

Diameter (ft-in.)

(mm)

Height (ft-in.)

(mm)

REFRIGERANT CONNECTIONS

Suction (ODF)

Liquid (ODF)

REFRIGERANT LINES

Suction (ODF)

Liquid (ODF)

‘May use 7/8-in (22 22-mm) accessory tubing package with slight capacity loss See Table 3

Table 3 — Accessories

PART NO.

99TZ90040106

99TZ90041106 38QB90002106

99TZ90029101 28AU90006112

38R090008106 HN65DE026* 38HQ900002

38CQ900172 38RQ900091 38QB90001106 38QF90000106 38HQ90014106 38QB90003106 HC95DD120* Start Capacitor HC95DD12V Start Capacitor HC95DD058* Start Capacitor

HC95DD088* Start Capacitor HN61HB515* Relay HN61HB496* 38EB660002*

TUBING

PACKAGE

Low-Voltage Control — Honeywell Thermostat HH07AT171 and Thermostat Subbase HH93AZ173 — (Automatic Changeover)

Low-Voltage Control — Honeywell Thermostat HH07AT171 and Thermostat Subbase HH93AZ175 — (Manual Changeover)

Service Sentry (Six HN65CT004) Honeywell — Manual Changeover. 2-Stage Heating, 1-Stage Cooling Twelve 3/4- x 1-1/8 in. Connection Adapters Bi-Flow Heat Pump Filter Drier (Six KH45LD077) Supplemental Heat Relay-

(Service Parts) Outdoor Thermostat (Six 38HQ900011) 0ptimizerControlOutdoorThermostat(Six38CO900161 ref HH22AG110) Optimizer II Control Assembly (Use with HH2AG1 lOoutdoorthermostat.) Heat Pump Rack (Six) Heat Pump Rack (Six) Optimizer III (Six 38HQ900141) Solid-State Time Guard II (24-volt)

Relay

Wire Bundle for Start Capacitor and Relay

__________

DESCRIPTION

- (Required with 2 Outdoor Thermostats )

TUBING

UNIT 38QB

All

042-060

All

015-018 024-060

All

015 018

024,030

036

015,018

024,030,036

015-036

38LS958151 38LS958201 38LS958251 38LS958301

38LS958351 38LS958401 38LS958501

38LS934151 38LS934201 38LS934251

38LS934301

38LS934351

38LS934401

38LS934501

38LS978151

38LS978201

38LS978251

38LS978301

38LS978351

38LS978401

38LS978501

*Available thru Carrier Service Parts tSuction line is insulated and has 90° bend tFor 5/8-in (15 9-mm) evaporator connection, cut off 3/4-in (19 05-mm) belled end

‘‘Capacity reduction may occur when 7/8-in (22 22-mm) accessory tubing is used on 38QB042,048,060

A capacity reduction will result if accessory tub ing is used in 38QB042 systems. For example, when a 25-ft (7.6-m) 7/8-in. (22-mm) accessory package is used, there is a capacity reduction of 1-1/2percent.

When other than 25 ft (7.6 m) of interconnecting tubing is used, follow special requirements described

in Refrigerant Charging. Do not use less than 10 ft (3 m) of interconnecting tubing. Do not cut 5/ 16-in. (7.9-mm) or 1/4-in. (6.4-mm) liquid line due to

swage at ends. Do not cut 7/8-in. (22.22-mm) suction line. Bend or coil to fit.

Do not use damaged or contaminated tubing. Always evacuate or purge evaporator coil and tubing system (use field-supplied refrigerant, not unit refrigerant).

When making tubing connections, be sure to provide clearance at unit for electrical connections.

REPLACE THE ACCURATER™ REFRIGER ANT CONTROL PISTON IN THE INDOOR

COIL AS REQUIRED before connecting refriger ant lines. See Table I. Correct piston is supplied with 38QB unit. For piston replacement instruc tions, see AccuRater Servicing on page 15.

CONNECT REFRIGERANT LINES to fittings on

unit suction and liquid service valves (Fig. 1).

Liquid service valve has flare fitting; suction service valve has Compatible Fitting. Make suction line

connection first. Slide flare nut on liquid line, then

flare and connect liquid line. Use a maximum

torque of 15ft-lb (20N-m) to tighten flare nut. (Do

not disassemble AccuRater.) Unit Compatible Fitting permits mechanical or sweat connection as

described below.

When a 7/8-in. (22.22-mm) field-supplied suction

line is used on 38QB036,042,048 and 060, a field-

supplied 3/4-in. (19.05-mm) to 7/8-in. (22.22-mm) suction line adapter must be provided (not required if 38LS accessory tubing is used).

When a 1-1/8in. (28.57-mm) field-supplied

suction line is used on 38QB042,048 and 060, use accessory adapter 28AU900061 or other fieldsupplied connection. Sweat connect refrigerant suction line to 1-1/8 in. (28.57-mm) end of adapter.

Connect 3/4-in. (19.05-mm) end of adapter to unit suction line Compatible Fitting.

Mechanical Connection to Compatible Fitting (Mate one set of connections at a time.)

1. Loosen nut on Compatible Fitting one turn. Do not remove.

2. Remove plug and be sure O-ring is in the groove inside the Compatible Fitting.

3. Cut tubing to correct length.

4. Insert tube into Compatible Fitting until it bottoms.

5. Tighten nut until it bottoms on back coupler

flange. Keep tube bottomed in Compatible

Fitting while tightening nut.

Sweat Connection to Compatible Fitting (Use refrigerant grade tubing.)

1. Remove locking nut, rubber O-ring and Schrader core from valve.

2. Cut tubing to correct length.

3. Insert tube into Compatible Fitting. Wrap top and bottom of service valves in wet cloth to pre vent damage by heat. Solder with low tempera

ture (430 F [221 C]) silver alloy solder.

4. Replace Schrader core.

5. Evacuate or purge system with field-supplied

refrigerant.

nameplate. Contact local power company for cor rection of improper line voltage.

Do not apply units in system where voltage may

fluctuate above or below permissible limits.

When making electrical connections, provide

clearance at unit for refrigerant piping connections.

See Table 4 for recommended wire and fuse sizes. INSTALL A BRANCH CIRCUIT DISCONNECT

PER NEC of adequate size to handle unit starting current. Provide a separate disconnect for outdoor unit, indoor unit and for each accessory electric heater circuit as required. (See Indoor Unit and

Electric Heater Installation, Start-Up and Service Instructions.) Locate disconnect(s) within sight from and readily accessible from the unit per section

440-14 of National Electrical Code (NEC).

ROUTE LINE POWER LEADS INTO UNIT — Extend leads from disconnect thru power wiring

hole provided (see Fig. 1) and into unit splice area.

Remove top cover to gain access to unit wiring.

CONNECT GROUND LEAD AND POWER WIRING — Connect ground lead to a ground lug in control box for safety. Then connect power wiring. See Fig. 4. Splice line power leads to yellow

and black pigtails. Use wire nuts and tape at each connection. Connect unit wiring to copper power wiring.

Fig. 4 — Line Power Connections

Step 4 — Make Electrical Connections — Field

wiring must comply with local and national fire, safety and electrical codes. Voltage to unit must be within permissible limits of voltages indicated on

SEE INDOOR UNIT AND ELECTRIC HEATER INSTALLATION, START-UP AND SERVICE INSTRUCTIONS for line power wiring details. All

control wiring is shown in this booklet.

Table 4 — Electrical Data (60 Hz)

UNIT

38QB

015 018 024 208-230/1 030 036 042 048 060

036 042 048 060

AWG — American Wire Gage FLA — Full Load Amps FIACR — Heating, Air Conditioning and Refrigeration

LRA — Locked Rotor Amps MCA — Minimum Circuit Amps RLA — Rated Load Amps

‘Permissible limits of the voltage range at which the unit will

operate satisfactorily

V/PH

208-230/1 254 208-230/1 254

230/1 254 207 230/1 254 207 105 230/1 254 207

208-230/3 208-230/3 254 197 80 13 3 24 14 29 1 208-230/3 208-230/3

460/3 460/3 506 460/3 506 460/3 506

OPER

VOLTAGE*

Min

Max

197 197 48 124

254 197

197 197 88 20 6

254 197

254 197 80 16 3 24 12 254 197 98

506 414 30 5 1 1 2 14 159 1

414 35 72 1 2 14 120 1 414 40 414 49 104 1 2

COMPR

LRA

RLA

15 5 24 12 32 ;l 12

165

199 24

22 4

130 27 8

11 7 24 14 32 1

20 9 24

7 7

FAN

FLA

1 25 1 25

24 24

1 2 14 109 1

Min Wire

Size (AWG)t

14 14

12 32 1 12 10 10

8 8

tCopper wire sizes based on 60C Use copper wire only. tRequired when using nonmetallic conduit

“Time-delay fuse NOTE: All units have 24-v control circuit which requires external

power source

Max \

40 1 27 1

39 1

44 1

62 1 51 I

24 1

_3I ■

BRANCH CIRCUIT

'Vire ; 1 Min Gnd

Wire Sizel

M 10

__________

14 u

10 10 10

14 14 12

14 14 14

______

Max Fuse**

or HACR Type

Ckt Bkr Amps

15 109 25 35 35 23 0 45 45 50 60

25 30 35 45

15 15 20

MCA

168

21 8

28 2 27 3 30 4 37 2

170

190 22 8 28 5

102 11 2

142

CONNECT CONTROL POWER WIRING (24 V) — Extend wiring thru hole provided (Fig. I) and into low-voltage section of unit control ring. Connect leads to control wiring terminal board as shown in Fig. 5.

Use indoor unit transformer as 24-v supply for system. At least a 60-va transformer is recom mended. Carrier approved indoor units are

equipped with a 60-va transformer. See indoor

unit data.

Use Carrier accessory indoor thermostat with

suhbase, Table 3.

START-UP

The 38QB unit is equipped with a crankcase

heater. It is recommended that heater be energized a minimum of 24 hours before starting unit. To ener gize heater only, turn the thermostat to OFF posi tion and close electrical disconnect to heat pump.

Heat Anticipator Settings for Room Thermo

stat (HH0IAT171) — Set anticipator for room

^ Table 5 — Thermostat Anticipator Settings

UNIT

38QB

015

018

024

030

036

042

048

060

FIRSTSTAGE

ANTICIPATOR

SETTING

Fixed

INDOOR

UNIT WITH

ELECTRIC

HEATER

40DQ and

40AQ Fan Coil

with 40AQ Htrs

or 40QB,QH

Fan Coil with

40QB Htrs

HTR

150 20 0 25 0

30 0 34 0

ANTICIPATOR

7 5

100

SECOND-

STAGE

SETTINGS

thermostat according to Table 5. These settings may

be changed slightly to provide a greater degree of

comfort for a particular installation.

Accessory Outdoor Thermostat provides adjust

able outdoor control of accessory electric heater. This thermostat makes contact when a drop in out door temperature occurs. It energizes a stage of elec tric heat when the outdoor temperature setting is reached, provided the room thermostat is on the second stage of heating. One outdoor thermostat is recommended for each stage of electric heat after the first stage. Set the outdoor thermostat(s) pro gressively lower for each stage. Refer to heat load of building and unit capacity to determine the correct outdoor thermostat settings.

The accessory supplemental heat relay is required when 2 outdoor thermostats are used. It is auto matically energized by the manually operated supplemental heat switch in the indoor thermo stat subbase. The thermostat locks out compressor and the relay bypasses the outdoor thermostats for electric heater operation during heat pump shut down. When one outdoor thermostat is used, a sup plemental heat relay is not required. The supple mental heat switch in the indoor thermostat subbase bypasses outdoor thermostat, locks out compressor and activates electric heater.

MOUNT OUTDOOR THERMOSTAT on control ring, to the left of the low-voltage control connec

tion. See Fig. 1.

Attach brackets with short sheet metal screws to

avoid contaet with coil. Leave capillary tube coiled in control compartment making sure it is clear of all

electrical connections and sharp metal edges.

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