Carrier 38QF User Manual

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Page 1

Number One Air Conditioning i\Mer

^Sb Division of

^ 0 Carrier Corporation

Carrier Parkway • Syracuse, N.Y. 13221

Heat Pump — Outdoor Section

CONTENTS

Page

SAFETY CONSIDERATIONS INSTALLATION Step 1 — Check Equipment and Jobsite

.............................

.. 1

. 1-5

.. 1

• UNPACK UNIT

• INSPECT EQUIPMENT

• COMPLETE OR CONSIDER SYSTEM REQUIREMENTS

Step 2 — Mount Outdoor Heat Pump..................2

• ON THE GROUND; MOUNT UNIT ON A SOLID, LEVEL CONCRETE PAD

• ON THE ROOF: MOUNT UNIT 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 ... 4

• 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

SERVICE................................................................. 7-14

MAINTENANCE.....................................................14-17

..............................................................

SAFETY CONSIDERATIONS

5-7

Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and quali

fied service personnel should install, repair or serv ice air conditioning equipment.

Untrained personnel can perform basic main

tenance functions of cleaning coils and cleaning and replacing filters. All other operations should be performed 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.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing oper ations. Have fire extinguisher available for all braz ing operations.

W.ARNING: Before performing scr\icc or maintenance operations on sxstem. turn ofl

main powci switches to indoor unit and out door unil. 1 urn ofl acccssoiA heater power switch if applicable, riectrical shock could cause personal itijur\.

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 38QF.

Consult local building codes and National

Electrical Code (NEC) for special installation requirements.

When installing, allow sufficient space for air

flow clearance, wiring, refrigerant piping and serv icing. 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 in stallation method for 38QF depends on building construction and special requirements of local codes. Be sure that roof can support unit weight.

It is recommended that 38QF units be used with

Carrier approved indoor sections; see Table 1.

System Refrigerant Control on 38QF units and matching Carrier indoor units is a factory-installed AccuRater™ device (bypass type). Bypass-type

AccuRater components are discussed in the service section 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 38QF outdoor unit. Replace piston as

described under AccuRater™ Servicing on page 13.

Page 2

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 screws. Lift top from unit (see Fig. 1).

Step 2 — Mount Outdoor Heat Pump

ON THE GROUND: MOUNT UNIT ON A SOLID, LEVEL CONCRETE PAD (see Fig. I).

4-0"0VERHEAD SPACE REQUIRED

FOR SERVICE AND AIRFLOW

DIAM HOLE FOR CONTROL WIRING

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.

AIRFLOW AND SERVICE CLEARANCE

LIQUID VALVE SERVICE PORT / VAPOR VALVE SERVICE PORT

AIRFLOW SUCTION SERVICE PORT

CONCRETE MOUNTING PAD

Fig. 1 — Dimensions, Connections and

Mounting Pad (Refer to Table 2)

Fig. 2 — Accessory Mounting Rack

Table 1 — Carrier Approved 38QF Systems

OUTDOOR

UNIT 38QF

018

024 46

030

036

042

048

060

^Factory-supplied piston packages shipped in outdoor unit. Replace remain

ing indoor pistons with size indicated.

REQUIRED OUTDOOR

PISTON

SIZE

76 40QB/QH060 86*

INDOOR

UNIT

MODEL &

SIZE

40AQ018

28HQ/VQ018

40AQ024

28HQ/VQ024

40FS075,28HQ/VQ042

40AQ024

28HQ/VQ024

40AQ030

28HQ/VQ030

40FS075,28HQ/VQ042

40AQ030

28HQ/VQ030

40DQ030

40AQ036

28HQ/VQ036

40AQ036 28HQ/VQ036 40QB/QH042 28HQ/VQ042

40QB/QH042 28HQ/VQ048 40QB/QH048

40QB/QH048 84 28HQ/VQ048 84

40QB/QH062 28HQ/VQ060

40QB/QH060 40QB/QH062

REQUIRED

INDOOR

PISTON

SIZE

70* 70*

70 70 73* 73*

76 78 78

86* 86*

52 52 55* 55*

59 59 61* 61* 65

Page 3

ON THE ROOF; MOUNT UNIT ON A LEVEL

PLATFORM 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 unit exposed to winds above 5 mph may require protective wind baffles (field fabricated) to achieve adequate defrost.

Step 3 — Make Piping Connections — Heat

pumps may be connected to indoor sections using

Carrier accessory tubing package (Table 3) or field-

supplied tubing of refrigerant grade, correct size and condition (Table 2). For requirements beyond 50 ft obtain information from local Carrier distributor.

-> Table 3 — Accessories

Table 2 — Installation Data (Fig. 1)

UNIT 38QF OPER WT(lb) DIMEN (ft-in.)

DIam (A) Height (B) Mtg Pad

(Diam X Thick)*

REFRIG CONN (in.)

Suction (ODF) Liquid (ODF)

REFRIG LINES (in.)

Suction (ODF) Liquid (ODF)

“■Mounting pad is fieid suppiied, fMay use Vs-'m. accessory tubing package (slight capacity loss). See Tabie 3.

024 030 036 042

018

163 181 189 209

160

2-2'V32 j 2-8Y32 [3-13/4

2- 53/32

2-6 X 0-6

1-1

1-10/2

% 1 1 Vaf

048 265

3-23/33

2-83/61 3-2’/e

3-3 X 0-6

1 -5%

3/s

3/8

060 298

2-7

PART NO.

99TZ90040106

99TZ90041106 38QB90002106

28VQ900011 38RQ90008106

HN61KL704 380890004106

38CQ900172 38RQ90009106

38QB90001106 38QF90000106 38QB90003106 38QF90001106t HC95DE088* HC95DD121* HC95DD121“ HC95DE070* HN61KA054*

HN61HB515* HN61HB510* HN61HB505* HN61HB504* 38EB660002*

TUBING

PACKAGE

38LS978151 38LS978201 38LS978251 38LS978301 38LS978351 38LS978401 38LS978501

■“Available thru Carrier Service Parts. fStart capacitor and relay are required when using liquid line solenoid valve.

{Suction line is insulated and has 90° bend.

“■“Capacity reduction may occur when %-in. accessory tubing is used on 38QF042.

Low-Voltage Control — Honeywell Thermostat HH07AT171 and Thermostat Subbase HH93AZ173 — Automatic Changeover (Six 99TZ900401)

Low-Voltage Control — Subbase HH93AZ175 ■

Service Sentry — Standard on 38QF060 (Six HN65CT004)

Twelve M x IVs-in. connection adapters

Bi-Flow Heat Pump Filter Drier — Ref KH45LD077 (Six 38RQ900081)

Supplemental Heat Relay ■ (Six 38RQ900001)

Outdoor Thermostat (Six 38QB900041) Optimizer Control Outdoor Thermostat — Ref HH22AG110 (Six 38CQ900161) Optimizer II Control Assembly — Use with HH22AG110 outdoor thermostat.

(Six 38RQ900091) Heat Pump Rack (Six) Heat Pump Rack (Six)

Solid-State Time Guard I

Liquid Line Solenoid (Six 38QF900011) Start Capacitor

Start Capacitor Start Capacitor Start Capacitor Start Relay Start Relay Start Relay Start Relay Start Relay

Wire Bundle for Start Capacitor and Relay

LENGTH

(ft)

25 30 35 40 50

(in.)

Ve Va

Ye Ys Ya Ya

Honeywell Thermostat HH07AT171 and Thermostat

DESCRIPTION

Manual Changeover (Six 99TZ900411)

■ Required with 2 outdoor thermostats.

24 volt (Six 38QB900031)

Liquid

Tube End OD

(in.

Ya Ya Ya Ya Ya Ya

(in.)

Ya** Ya**

Ya** Ya** Ya** Ya** Ya**

TUBING

Suction^

Tube End OD

Evap

(in.)

% 3/4 3/4

34 3/4 3/4

Cond

(in.)

3/4

Ya Ya

3/4 3/4

MODEL 38QF

All

018-048 030-060

All

018-042

048,060

All 018 024 030

036,042

018 024

030 036 042

All

MODEL

38QF

All

Page 4

WARNING: If unclcrsi7ed. damaged or elliptiv.-all\-s!iapL'd uibing is used when making Compatible bitting, leaks ma\ result.

If 1-1/8 in. tubing is used, braze it to the accessory

1-1/8 X 3/4-in. suction connection adapter (Carrier Part No. 28VQ900011) or to a correctly sized fieldsupplied adapter, then make Compatible Fitting connections. Isolate interconnecting tubing from

framing and ductwork or where tubing runs thru stud spaces, enclosed ceilings or pipe chases. Use isolation type hangers. Fig. 3, since rigid fastening transmits pulsations to structure creating objec tionable sound.

^ ( \l 1 ION. IK) \OI Ml \<\ MORI I II \\

'' I I ()l I INI SI I IN (.ROl N1). II .m> '•ac tion of liucsel is burictl. there must be b-in. \ertical rise to the \al\e connections on the outdoor unit. If more than the recommended

length i.s buried, refrigerant ma\ migrate to the eooler buried .section during extended periods of

unit shutdown, causing relrigerant slugging and

possibh compressor damage at start-up.

A capacity reduction will result if accessory tub ing is used in 38QF systems. For example, when a 25-ft 7/8-in. accessory package is used, there is a capacity reduction of 1-1/2 percent.

When other than 25 ft of interconnecting tubing is used, follow special requirements described in Refrigerant Charging. Do not use less than 10 ft of interconnecting tubing. Do not cut 7/8-in. 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™ REFRIG

ERANT CONTROL PISTON IN THE INDOOR

COIL AS REQUIRED before connecting refrig erant lines. See Table 1. Correct piston is supplied with 38QF unit. For piston replacement instruc tions, see AccuRater Servicing on page 13.

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 15 ft-lb to tighten flare nut. (Do not dis assemble AccuRater.) Unit Compatible Fitting permits mechanical or sweat connection as de scribed below.

When a 7/8-in. field-supplied suction line is used on 38QF, a field-supplied 3/4-in. to 7/8-in. suction line adapter must be provided (not required if 38LS accessory tubing is used).

When a 1-1/ 8 in. field-supplied suction line is used on 38QF, use accessory adapter 28VQ900011 or other field-supplied connection. Sweat connect re

frigerant suction line to 1-1/8 in. end of adapter. Connect 3/4-in. 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 0-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) silver alloy solder.

4. Replace Schrader core.

5. Evacuate or purge system with field-supplied refrigerant.

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 indicated on nameplate.

Contact local power company for correction of

improper line voltage.

W.AR.NTNG: Operation of units on improper line \oliagc constiiiitcs abuse and could affect

Carrier warrantx. See fable4.

Do not apply units in system where voltage may

fluctuate above or below permissible limits.

Page 5

Table 4 — Electrical Data (60 Hz)

OPER

UNIT

38QF

018 024

030 036 042

048 060

AWG — American Wire Gage FLA — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration LRA — Locked Rotor Amps MCA — Minimum Circuit Amps RLA — Rated Load Amps

V/PH

230/1

208-230/1

230/1

VOLTAGE*

Max

254

Min LRA RLA

197

207

COMPR

50 54

69 17.7 75 90

101

130

FAN

FLA

10.8 14 30

13.0

16.8 10 50

20.0

21.2

28.6

1.1

1.7

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 sec tion 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 con nection. Connect unit wiring to copper wire only.

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.

BRANCH CIRCUIT

Min Wire

(AWG)t

12 10 48

10 43 10 10

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

operate satisfactorily. tCopper wire sizes based on 60 C. Use copper wire only. fRequired when using nonmetallic conduit.

**Time-delay fuse

Max Wire Min Gnd

(ft)

39 46

Wire Size$

14 12

10 10

CONNECT CONTROL POWER WIRING (24 V) — Extend wiring thru hole provided (Fig. 1) 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

subbase, Table 3.

START-UP

The 38QF 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 (HH07AT171) — Set anticipator settings for

room thermostat according to Table 5. These set tings may be changed slightly to provide a greater degree of comfort for a particular installation.

Max Fuse or

HACR Type

Ckt Bkr Amps**

25 14.6 30

40 35 22.0 45

45 60

MCA

17.3

23.1

26.0

28.1

37.5

1 PHASE

CONN. TO -

DISCONNECT PE.R NEC

.<1

_______

Field '.Virinq

_______

Fditory Wiiinq

---------------

Splicii Cfjnnpctions

GROUND _EAD-|(^ GROUNDING LUG

-BLK

I-PHASE rCND UNIT

Fig. 4 — Line Power Connections

-------------

Table 5 — Thermostat Anticipator Settings

UNIT

38QF

018

024 030 036 042 048 060

FIRST-

STAGE

ANTICIPATOR

SETTING

Fixed

INDOOR UNIT WITH ELECTRIC

HEATER

40AQ Fan Coil

with 40AQ Htrs

or 40QB/QH Fan Coil

with 40QB Htrs

HTR

5.0

7.5

10.0

15.0

20.0

25.0

30.0

34.0

ANTICIPATOR

SETTINGS

SECOND-

STAGE

.25

.50

.75

Page 6

THERMOSTAT

SUBBASE

HH93AZI73

OR HH93AZI75

40AQ.40FQ OR 40QB FAN COIL 38QF

COOLING CONTROL KIT TERM INAL

TERMINAL BOARD BOARD

THERMOSTAT

SUBBASE

HH93AZI73

OR HH93AZI75

40AQ,40FQ OR 40QB

ELECTRIC HEATER TERMINAL BOARD

38QF

TERMINAL

BOARD

(38QF/40AQ 0R40QB/QB WITHOUT ELECTRIC HEATER)

COOLING AND ONE-STAGE HEATING

THERMOSTAT

SUBBASE

HH93AZ173

(38QF WITH 40AQ, 40QB/QH OR 40FS/28VQ

SUPPLEMENTAL HEAT, NO OUTDOOR THERMOSTATS)

40AQ,40FQ OR 40QB

ELECTRIC HEATER

TERMINAL BOARD

COOLING AND TWO-STAGE HEATING

EQUIPPED WITH ELECTRIC HEATER;

38QF

TERMINAL

BOARD

EQUIPPED WITH ELECTRIC HEATER;

SUPPLEMENTAL HEAT, ONE OUTDOOR THERMOSTAT)

THERMOSTAT

SUBBASE

COOLING AND TWO-STAGE HEATING

EQUIPPED WITH ELECTRIC HEATER;

SUPPLEMENTAL HEAT, TWO OUTDOOR THERMOSTATS)

40AQ,40FQ OR 40QB ELECTRIC HEATER

(38QF WITH 40FS/28VQ

38QF

TERMINAL

SHR — Supplemental Heat Relay ODT — Outdoor Thermostat _______

_______

Factory Wiring

Field Wiring

*Transformer (60 va) located in cooling control kit or electric heater. fRemove factory-installed jumper (Connection B) when installing outdoor thermostats (ODT).

Fig. 5 — Control Circuit Connections

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) progres

sively 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 sup plemental heat switch in the indoor thermostat 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 supplemental heat relay is not required. The sup plemental heat switch in the indoor thermostat subbase bypasses outdoor thermostat, locks out compressor and activates electric heater.

Page 7

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 contact with coil. Leave capillary tube coiled in control compartment making sure it is clear of all electrical connections and sharp metal edges.

MOUNT SUPPLEMENTAL HEAT RELAY in convenient location on indoor unit. Attach with sheet metal screw.

To Start Unit — (Make sure crankcase heater

has been energized for 24 hours.) Adjust the thermo stat as follows:

1. Set selector switch at OFF.

2. Turn on main disconnect switch(es) to indoor

and outdoor units.

3. Set fan switch as desired (ON or AUTO.).

4. Set thermostat dial at desired temperature.

5. Set selector switch at HEAT or COOL. Check system refrigerant charge. See Refrigerant

Charging.

When recharging is necessa^ during heating or

cooling season, weigh in total charge indicated in

Table 6. (Charge must be weighed in during heating

season.) Remove any refrigerant remaining in system before recharging. If system has lost com plete charge, triple-evacuate system to 5000 microns (29.7 in. vacuum) before recharging. Service port connections are provided on liquid and suction line service valves for evacuation and charging (See Fig. 6 for correct service port location on cooling

and heating cycles.) Dial-a-charge charging cylinder is an accurate device used to recharge systems by weight. These cylinders are available at refrigeration supply firms.

Table 6 — Service Data

UNIT38QF 018 R-22 CHARGE (lb)

REFRIG CONTROL FAN

Cfm Rpm

Diam (in.)

024

030 036 042 048

5.7 6.1 6.7 7.4 8.7 AccuRater™ (Bypass Type)

2400 2750

840

060

9.3 9.8

4500

SERVICE

CM'llON: Unit has high-picssiire piping whicli ma\ also be lu)t to touch, cncrgi/.ed elec trical components and a rotating fan. Before ser\icing or checking unit, be sure all s\stem power is off and tubing is cool.

( \l ll()\ III pu\..il pei'oiul in, !i\. weai

satety glasses and glcues when handling

Do not overeharge system. \n o\erchargeean

cause compressor flooding.

Refrigerant Charging — The 38QF units contain

correct operating charge for complete system when connected to 28VQ, 40QB/ QH or 40AQ indoor units with 25 ft of tubing of recommended diameter. Charge adjustment is required on other systems. Adjust system charge for refrigerant line lengths and diameters that differ from 25 ft and 3/8 in. OD

(liquid line), respectively, using refrigerant weights

below. Twenty-five ft 3/8-in. OD tubing contains

14.4 oz of R-22. Add R-22 charge to system if liquid line is over 25 ft; remove charge if liquid line is shorter than 25 feet.

COOLING CYCLE

LIQUID LINE

DIAM (in.)

OUNCES OF R-22/FT LENGTH

OF LIQUID LINE

.58

AT SERVICE VALVE (CLG CYCLE) (BYPASSING)

piÌBilÌÌlBSB«Eip0IipÌ*®Ì5!SEBÌ

Fig. 6 — 38QF Refrigerant Flow Diagrams

SWITCH

Page 8

To check and/or adjust charging during cooling

season, use correct Cooling Cycle Charging Chart

(Fig. 7, 9, 11, 13, 15, 17, 19) and follow Charging

Chart Method below. The charging chart may also

be used as an alternate method of recharging system.

To check system operation during heating cycle, use correct Heating Cycle Operation Check Chart (Fig. 8, 10, 12, 14, 16, 18, 20).These charts indicate whether a correct relationship exists between system operating pressures and air temperatures entering indoor and outdoor units. If pressure and tempera

ture lines do not intersect on chart, the system re frigerant charge may not be correct or other system abnormalities may exist. Do not use Operation

Check Charts to adjust refrigerant charge. Weigh charge into system.

COOLING CYCLE CHARGING CHART METHOD

1. Operate unit a minimum of 10 minutes before checking charge, and after each charge

adjustment.

2. Measure suction pressure by attaching a gage to outdoor unit suction service port. (See Fig. 6 for correct service port location on cooling cycle.)

3. Measure outdoor (coil inlet) air dry-bulb tem perature with service thermometer.

4. Using a sling psychrometer, measure wet-bulb temperature of air entering indoor unit.

5. Refer to correct Charging Chart. Locate on curves where outdoor air dry-bulb and indoor

air wet-bulb temperature lines intersect.

6. From intersect point, project vertically down ward to chart suction pressure line. Compare

chart suction pressure to unit suction pressure (Step 2).

7. If unit suction pressure is lower than chart pres sure, add refrigerant to system until chart pressure is reached. If unit suction pressure is higher than chart pressure, remove refrigerant until chart pressure is reached.

Unit Single-Phase Compressors

COMPRESSORS OF THE SPLIT CAPACITOR (PSC) TYPE require an equalized system pressure to start. When supply voltage is within nameplate limit and compressor does not start, give com pressor a temporary capacitance boost. See Carrier Standard Service Techniques Manual, Chapter 2,

for details.

WARNING: C’apacilance boost or installation of start capacitor and slaii relay should be per formed b\ trained personnel. Improper pro cedure could cause personal injur\ or equipment

CHARGING AND PRESSURE CHECK CHARTS

160

66 68 70 72 74 76 78 80 82 84 86 88

PRESSURE AT SUCTION SERVICE VALVE (PSIG)

Fig. 7 — 38QF018 with 40AQ018,024,

28HQ,VQ018 or 024, 40FS075 with

28HQ,VQ042 Cooling Cycle Charging Chart

Fig. 8 — 38QF018 with 40AQ018,024,

28HQ,VQ018 or 024, 40FS075 with 28HQ,

VQ042 Heating Cycle Operation Check Chart

Page 9

COOLING CYCLE

CFM-860

320

62 f:

67 F

172 F

II5F

300

:WET BULB TEMP AIR

280

ENT INDOOR UNIT

o >

260

□:

■D

240

^ 220

</)

200

180

160

:75F

66 68 70 72 74 76 78 80 82 84 86 88

PRESSURE AT SUCTION SERVICE VALVE (PSIG)

85 F^

DRY BULB TEMP AIR ENT OUTDOOR UNIT

Fig. 9 — 38QF024 with 40AQ024,030.

28HQ,VQ024 or 030, 40FS075 with

28HQ,VQ042 Cooling Cycle Charging Chart

105 F

95 F:

Fig. 10 — 38QF024 with 40AQ024,030,

28HQ,VQ024 or 030, 40FS075 with 28HQ,

VQ042 Heating Cycle Operation Check Chart

if)

O ui

CFM-1020

340

WET BULB TEMP AIR ENT INDOOR UNIT

5 320

300

^ 280

o 260

240

220

62 F

DRY BULB TEMP AIR: ENT OUTDOOR UNIT

85 F

200

75 F

180

66 70 74 78 82 86 90

PRESSURE AT SUCTION SERVICE VALVE(PSIG)

Fig. 11 — 38QF030 with 28AR036,

28HQ,VQ036 or 40AQ036, 40DQ030

Cooling Cycle Charging Chart

:67F:

95 F

72 F:

II5F±

I05F

Fig. 12 — 38QF030 with 28AR036,

28HQ,VQ036 or 40AQ036, 40DQ030

Heating Cycle Operation Check Chart

Page 10

'®° 70 74 78 82 86 90

PRESSURE AT SUCTION SERVICE VALVE (PSIG)

Fig 13 — 38QF036 with 28HQ.VQ042,

40AQ036 or 40QB/QH042

Cooling Cycle Charging Chart

Fig. 14 — 38QF036 with 28HQ,VQ042,

40AQ036 or 40QB/QH042

Heating Cycle Operation Check Chart

67 F

DRY BULB TEMP AIR: ENT OUTDOOR UNIT!

o 320

</)

UJ >

o >

CO a

(/) u

CFM-1400

340

WET BULB TEMP AIR ENT INDOOR UNIT

300

280

260

240

220

200

180

70 74 78 82 86 90 94

PRESSURE AT SUCTION SERVICE VALVE(PSIG)

62 F

75 F

Fig. 15 — 38QF042 with 28HQ.VQ048,

or 40QB/QH042,048

Cooling Cycle Charging Chart

85 F

72 f:

95 F:

II5F+

I05F

Fig. 16 — 38QF042 with 28HQ.VQ048,

or 40QB/QH042,048

Heating Cycle Operation Check Chart

Page 11

66 68 70 72 74 76 78 80 82 84 86 88

PRESSURE AT SUCTION SERVICE VALVE (PSIG)

Fig. 17 — 38QF048 with

40QB/QH048,060,062. 28HQ,VQ048 or060

Cooling Cycle Charging Chart

Fig. 18 — 38QF048 with

40QB/QH048,060,062, 28HQ,VQ048 or 060

Heating Cycle Operation Check Chart

Fig. 19 — 38QF060 with 40QB/QH060,062

Cooling Cycle Charging Chart

Fig. 20 — 38QB060 with 40QB/QH060,062

Heating Cycle Operation Check Chart

Page 12

Compressor Removal — See Table? for com

pressor information and Fig. 21 for component location. Shut off power to unit. Remove refrigerant from unit using refrigerant removal methods de scribed in Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants.

Be sure system pressure is 0 psig before

proceeding.

Table 7 — Compressor Data (60 Hz)

UNIT 38QF

018

024 208-230/1

030 208-230/1 036 208-230/1 CRG1-0251-PFV 042 208-230/1 CRJ1-0301-PFV 048 060

*Refer to Carrier Service Parts Catalog for replacement com

pressor model numbers.

STRAINER VAPOR REVERSING

V/PH

230/1 H22B173ABCA

230/1 PC4616CD

230/1 PC6016BD

\ LINE VALVE

PRODUCTION COMPRESSOR

Model*

CRC2-0175-PFV

CRF1-0250-PFV

OUTDOOR COIL

Oil Recharge

Ounces

37 51 51 51 51 66 66

ACCUMULATOR

pull them thru the wire access opening into the coil section. Lift fan orifice/control ring after pinching and pressing down on 3 plastic pins of tube supports.

5. Remove louvered casing by taking out screws securing it to the cabinet and sliding it away

from the coil.

Using a midget tubing cutter, cut liquid and

discharge lines on the coil and suction and dis charge lines at a convenient place near the com pressor for easy reassembly with copper slip couplings.

C.\LTJO\: F.xcvssivc movement of copper lines at compressor may cause a break where lines connect to condenser coil.

7. After plugging connections, remove condenser coil by pinching plastic pins of tube supports that extend into basepan and lift vertically. Set coil on a clean, flat surface.

8. Remove compressor holddown bolts and slide out compressor. Remove crankcase heater.

WARNING: For bra/ing and unbrazing have lire extinguisher and or quenching cloth available in case oil vapor ignites.

MUFFLER SOLENOID

COIL

HOT GAS DISCHARGE LINE

COMPRESSOR

Fig. 21 — Component Location

Follow safety codes. Wear safety glasses and

work gloves. Have quenching cloth available.

CATTIO.N; .'Mumimim tubing is used in unit coils. Do not o\erlieat or place c.xcessi\c .strain on lubinii or damce inav result.

Remove top cover as described in Installation,

Step I. Disconnect high- and low-voltage field wiring

and fan motor leads from capacitor and contactor.

Remove screws holding discharge grille in place.

Lift grille from unit. Disconnect compressor leads (crankcase heater,

low-pressure switch, defrost thermostat and solenoid coil) from electrical components and

9. Carefully unbraze suction and discharge line piping stubs from compressor after noting posi tion of stubs to assist when reinstalling.

10. Install new compressor, placing crankcase heater around compressor. Be sure compressor holddown bolts are in place.

11. Replace coil; braze suction and discharge lines to compressor piping stubs (at points where cut. Step 6); rewire compressor and leak test.

12. Replace fan orifice/control ring; connect com

pressor wires after feeding them thru control ring; replace fan/grille assembly and rewire; connect high- and low-voltage power wiring; and replace louvered casing.

13. Replace top cover by running 4 screws into orifice loosely (2 on each side of unit) and tighten when cover is in place. Replace remain ing screws.

14. Evacuate and recharge system.

Filter Drier — Install field-supplied filter drier

(Table 3) in system liquid line when refrigerant system is opened for service as described under Compressor Removal. Position drier in liquid line at convenient location.

Pumpdown Procedure — The system may be

pumped down in order to make repairs on low side without losing complete refrigerant charge.

1. Attach pressure gage to suction service valve gage port.

2. Frontseat the liquid line valve.

Page 13

3. Start unit and run until suction pressure reaches 5 psig (see Caution).

4. Shut unit off and frontseat suction valve.

5. Vent remaining pressure to atmosphere.

C.Al'llOX; 3SQP unit coils will hold onl> lactoi>-supplied amount of refrigerant. Addi tional rd'rigeranl ma\ cause units to reliese

pressure thru internal pressuie relief sake (indi cated b\ a sudden rise of suetion pressure) be fore suction pressure reaehes 5 psig. [1 this occurs, shut off unit irnmediateK: Iront.seat suction \al\c and \ent remaining piessiire to

Unit Controls and Safety Devices

HIGH-PRESSURE RELIEF VALVE is located in compressor. Relief valve opens at a pressure differ ential of approximately 500 psig between suction (low side) and discharge (high side) to allow pressure equalization.

INTERNAL CURRENT AND TEMPERATURE SENSITIVE OVERLOAD resets automatically when internal compressor motor temperature drops to a safe level (overloads may require up to 45 minutes to reset). When an internal overload is sus pected of being open, check by using an ohmmeter or continuity tester. If necessary, refer to Carrier Standard Service Techniques Manual, Chapter 2,

for complete instructions. LIQUID LINE LOW-PRESSURE SWITCH

(LLPS) is connected in liquid line to work with compressor internal thermostat in providing loss-ofcharge protection during the heating cycle. Control

is mounted on liquid line.

With a high-side leak, pressure gradually de

creases until low-pressure control stops the com pressor. (Low-pressure control settings are shown in Table 8.)

^ Table 8 — Pressure Switch Settings

UNIT

38QF

018 024 030 036 042 048 060

Cut-in

22 ±5 psig

LIQUID LINE

LOW-PRESSURE SWITCH

Cutout

7 ± 3 psig

With a low-side leak there is always some pressure in the liquid line. However, compressor motor tem perature increases because of insufficient suction

gas cooling. This causes internal thermostat to

actuate and stop compressor. When compressor stops, system pressure equalizes and contacts on

pressure control open. The compressor cannot re start until leak is repaired and system recharged.

CRANKCASE HEATER is connected across line side of contactor and operates continuously.

The purpose of the heater is to keep the crankcase

warm during the off cycle and thus prevent dilution

of the oil with refrigerant. This assures good lubri cation and prevents loss of oil from crankcase during start-up.

To energize crankcase heater, turn thermostat to

OFF position and close electrical disconnect to heat

pump.

If the electrical disconnect switch to the outside

unit has been off for an extended period of time, the

crankcase heater should be energized for 24 hours before starting the compressor.

DEFROST CONTROL, consisting of defrost control board and defrost thermostat, interrupts normal system heating operation every 90 minutes to defrost outdoor coil, if the coil saturated suction

temperature indicates freezing temperatures.

Defrost control simultaneously stops outdoor fan, energizes reversing valve solenoid to return system

to cooling cycle (outdoor unit as condenser, indoor unit as evaporator), and activates accessory electric heater.

For the heat pump to defrost, 2 conditions are

necessary:

1. Defrost timer contacts must be closed.

2. Refrigerant temperature from outdoor unit must be cold enough to cause defrost thermostat con tacts to close. Contacts close at 31 ±4 F.

Every 90 minutes of elapsed running time, the de frost timer contacts close for 10 seconds. If the defrost thermostat contacts are closed, the unit defrosts. The defrost timer limits defrosting period to 10 minutes. Normally, the frost is removed and the defrost thermostat contacts open to terminate defrosting before 10 minutes have elapsed. Defrost

thermostat contacts open at 80 ± 6 F liquid refrig erant temperature. When defrosting is terminated, the outdoor fan motor is energized and reversing valve solenoid is de-energized, returning unit to heating cycle.

HEAT PUMP CIRCUITS shown in Fig. 6 are re frigerant flow diagrams for heating and cooling cycles.

AccuRater™ (Bypass Type) Servicing — See

Fig. 22 for bypass type AccuRater components. The piston has a refrigerant metering hole thru it. The retainer forms a stop for the piston in the refrigerant bypass mode, and a sealing surface for liquid line flare connection. To check, clean or replace piston:

1. Shut off power to unit.

2. Pump unit down using Pumpdown Procedure described previously.

3. Remove liquid line flare connection from AccuRater.

4. Pull retainer out of body, being careful not to scratch flare sealing surface. If retainer does not pull out easily, carefully use Vise Grip pliers to remove retainer.

Page 14

rLARE NUT

FLARE CONNECTION

RETAINER

Fig. 22 — AccuRater™ (Bypass Type)

Components

5. Slide piston out by inserting a small soft wire, with small kinks, thru metering hole. Ensure metering hole, sealing surface around piston

cones and fluted portion of piston are not

damaged.

6. Clean piston refrigerant metering hole.

7. Replace retainer O-ring before reassembling by

pass type AccuRater. Carrier O-ring part no. is 99CC501052.

LIQUID LINE STRAINER (protects AccuRater)

made of wire mesh is located in the liquid line inside

38QF unit behind liquid line service valve. Liquid line is belled and sweat connected where strainer is located. If strainer is plugged, unsweat belled liquid line connection and replace strainer. See Fig. 21.

LEAKING SWEAT CONNECTION — Frontseat service valves and relieve refrigerant pressure in tubing. Clean and flux area around leak and apply low-temperature solder (430 F).

Condenser Fan Motor Removal

1. Shut off power to unit. Failure to do so may result in electric shock or injury from rotating

fan blade.

2. Remove top cover as described on page 2.

3. Disconnect fan motor leads from controls.

4. Remove 6 screws holding fan motor/discharge grille in place and lift assembly from unit.

5. Remove Carrier nameplate by straightening tabs.

6. Remove 4 nuts holding fan motor to discharge grille. Remove motor and leads.

7. Reverse procedure for reassembly. Before replac ing metal fan, be sure rain shield is in place on motor shaft. Seal with Permagum sealer around hub to prevent entry of water between hub and shaft. Make sure fan is positioned correctly as shown in Fig. 24.

MSCHARGl SPi.Lf

Rf (048- 060)

FROM DISCHARGE GRILLE

TO TOP OF FAN BLADE

■ .',‘J •-I .'.OF r.S'l'FW

MOTOR

Compatible Fitting Repair

LEAKING MECHANICAL CONNECTION —

Frontseat outdoor section service valves after reliev ing refrigerant pressure in system. Back locknut off Carrier Compatible Fitting onto tube. Cut fitting between threads and O-ring shown in Fig. 23. Remove tubing section remaining in threaded por tion of fitting. Discard locknut.

CARRIER

V ■■ .•

.........

Clean, flux, and insert new tube end into remain ing portion of Carrier Compatible Fitting. Wrap valve base in wet rag. Heat and apply lowtemperature solder (430 F).

Fig. 24 — Outdoor Fan Position

MAINTENANCE

CM'IION: Before pertorming recoinmended maintenance, be sure unit main power switch is turned oil. Failure to do so ma\ result in electric shock or injtiiy from iota ting fan blade.

Lubrication

FAN MOTOR BEARINGS — Oiling holes are provided at each end of condenser fan motor. Re move fan motor and lubricate motor with 32 drops (16 drops per hole) of SAE-10 nondetergent oil at intervals described below.

a. Annually, when environment is very dirty,

ambient temperature is higher than 105 F, and average unit operating time exceeds 15 hours a day.

b. Every 3 years when environment is reasonably

clean, ambient temperature is less than 105 F and unit operating time averages 8 to 15 hours a day.

c. Every 5 years when environment is clean,

ambient temperature is less than 105 F and unit operating time averages less than 8 hours a day.

Page 15

COIL REPAIR — A flare-union coupling is used for E-coil repair. A kit is available, with instructions, thru Carrier Service Parts.

COMPRESSOR contains factory oil charge. If oil requires replenishment, see Table 7 for oil recharge and Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants, page 1-21, for instructions. Use Carrier PP33-1, Texaco WFI-32 or Suniso3GS oil.

Coil Cleaning to be done at the beginning of each

cooling season or more often if required.

C.'M'TION: Fin damage or remo\al can result in higher operating costs or compressor damage. Do not use flame, high-pressure water, steam or volatile or corrosive cleaners »m fins and tubing. Follow these tnstruetions carefulh.

Contact voiii dealer i1 vou encounter problems.

1. Shut off power to unit.

2. Remove louvered casing by taking out 16 screws securing it to the cabinet and sliding it away from the coil.

Clean coil using vacuum cleaner and its crevice

3. tool (see Fig. 25). Work crevice tool vertically making sure tool only touches dirt on fins. To

prevent fin removal, do not “scrub”fins with tool

or move tool horizontally.

6. Reinstall louvered casing being careful not to damage coil.

7. Restore power to unit.

4. If oil deposits are present, spray coil with house hold detergent (Fantastic, Lestoil, 409, or any similar type). Wait 10 minutes then proceed to step 5.

5. Using garden hose, spray coil vertically down ward with a constant stream of water at moderate pressure (see Fig. 26). Keep nozzle at a 15 to 20 degree angle, about 3 in. from coil face and 18 in.

from tube. Spray so debris is washed out and away from coil.

Page 16

TROUBLESHOOTING CHART — COOLING CYCLE

Page 17

TROUBLESHOOTING CHART — HEATING CYCLE

Page 18

For replacement items use Carrier Specified Parts.

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

1 4

Book

Tab 5a

Form 38QF-2SI Supersedes 38QF-1 SIM

Printed in U.S.A.

4-83

PC 101 Catalog No. 563-816