Carrier 38YKC060 SERIES300, 38YKC048 SERIES300, 38YKC042 SERIES330, 38YKC036 SERIES330, 38YKC042 SERIES300 Installation Guide

HEATING & CCOUNG

Visil www.carrier.com

Installation and Start-Up Instructions

NOTE: Read the entire instruction manual belore starting the

installation.
This symlx)l --+ indicates a change since the last issue.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory-authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth lor brazing operations.
Have fire extinguisher available. Read these instructions thor-
oughly and follow all warnings or cautions included in literature
and attached to the unit. Consult local building codes and National
Electrical Code (NEC) for special requirements.

Recognize safety information. This is the safety-alert symbol/_.
When you see this symbol on the unit and in instructions or

manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAU-

TION. These words are used with the sal_ty-alert symbol. DAN-
GER identifies the most serious hazards which will result in severe

personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage.

Before installing, modifying, or servicing system, main elec-
trical disconnect switch must be in the OFF position. There
may be more than 1 disconnect switch. Lock out and tag
switch with a suitable warning label. Electrical shock can

cause personal injury or death.

INSTALLATION RECOMMENDATIONS

NOTE: In some cases noise in the living area has been traced to

gas pulsations from improper installation of equipment.

I. Locate unit away from windows, patios, decks, etc. where unit

operation sounds may disturb customer.

2. Ensure that vapor and liquid tube diameters are appropriate to
capacity of unit.

3. Run refrigerant tubes as directly as possible by avoiding

unnecessary turns and bends.

4. Leave some slack between structure and unit to absorb
vibration.

5. When passing refrigerant tubes through the wall, seal opening
with RTV or other pliable silicon-based caulk. (See Fig. 2.)

6. Avoid direct tubing contact with water pipes, duct work, floor

joists, wall studs, floors, and walls.

38YKC

10 SEER Split System

Heat Pump

A98519

Fig. 1--Model 38YKC

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. 2.)

8. Ensure that tubing insulation is pliable and completely sur-
rounds vapor tube.

9. When necessary, use hanger straps which are 1 in. wide and

conform to shape of tubing insulation. (See Fig. 23

10. Isolate hanger straps from insulation by using metal sleeves
bent to conform to shape of insulation.

When outdoor unit is connected to factory-approved indoor unit,
outdoor unit contains system refrigerant charge for operation with
indoor unit of the same size when connected by 15 ft of
field-supplied or factory accessory tubing. For proper unit opera-
tion, check refrigerant charge using charging infi>rmation located

on control box cover.
IMPORTANT: Maximum liquid-line size is 3/8-in. O.D. for all

residential applications including long line.
IMPORTANT: Always install a liquid-line filter drier. RelEr to

Product Data Sheet fi_rappropriate part number. Obtain filter drier
from service parts or your distributor or branch.

INSTALLATION

Step 1---Check Equipment and Job Site

UNPACK UNIT

Move to final location. Remove carton taking care not to damage

unit.

INSPECT EQUIPMENT

File claim with shipping company prior to installation if shipment
is damaged or incomplete. Locate unit rating plate on unit comer
panel. It contains inlbrmation needed to properly install unit.
Check rating plate to be sure unit matches job specifications.

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

PC 101 Catalog No. 563 718 Printed in U.S,A Form 38YKC-281 Pg 1 11-98 38YKC-181

Replaces:

NOTE: Avoid contact between tubing and structure

OUTDOORWALL--k ,NDOORWALtz

(_ LIQUID TUBE_CAULK

J_'_ _ VAPOR TUBE

SULATION -_"

THROUGH THE WALL

3/8 IN.DIA TIEDOWN "_

KNOCKOUTS IN BASEPAN

(2) PLACES

? -- &-

2/-% .........

HANGER STRAP'_ J_"-JOIST

(AROUND VAPOR %= --

TUBE ONLY) _,' \ /_ INSULATION

I1 tl

_--- LIQUID TUBE

SUSPENSION

Fig. 2---Connecting Tubing Installation

---) Step 2--Install on a Solid, Level Mounting Pad

If conditions or local codes require the unit be attached to pad, tie
down bolts should be used and fastened through knockouts
provided in unit base pan. Refer to unit mounting pattern in Fig. 3
to determine base pan size and knockout hole location.

On rooftop applications, mount on level platform or frame 6 in.
above roof surface. Place unit above a load-bearing wall and

isolate unit and tubing set from structure. Arrange supporting

members to adequately support unit and minimize transmission of
vibration to building. Consult local codes governing rooftop

applications.
Roof mounted units exposed to winds above 5 mph may require

wind baffles to achieve adequate defrost. Consult Low-Ambient
Guideline for wind baffle construction.

NOTE: Unit must be level to within _+ 2° (_+ 3/8 in./ft) per

compressor manufacturer specifications.

A94028

--8 3/16"

A97548

Dimensions (In.)

MINIMUM MOUNTING

UNIT LOCATIONS
SIZE

018, 024 4-1/8 7-1/8
030-060 5-1/16 9-11/16

PAD DIMENSIONS

Support Snow

Feet Stand

20 X 27 24 X 28
26 X 32 31 X 35

TIEDOWN KNOCKOUT

A B

Fig. 3_Mounting Unit to Pad

Step5---Elevate Unit

eqmpment damage.

Elevate unit per local climate and code requirements to provide
clearance above estimated snowfall level and ensure adequate

drainage of unit. Fig. 4 shows unit with accessory support feet
installed. Use accessory snow stand in areas where prolonged
freezing temperatures are encountered. Refer to separate Installa-
tion Instructions packaged with accessories.

Step 3_Clearance Requirements

When installing, allow sufficient space for airflow clearance,
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 units.
Position so water, snow, or ice from root" or eaves cannot fall

directly on unit.

On rooI_Lop applications, locate unit at least 6 in. above roof
surface.

Step 4_Operating Ambients

The minimum outdoor operating ambient in cooling mode is 55°F,
and the maximum outdoor operating ambient in cooling mode is

125°F. The maximum outdoor operating ambient in heating mode

is 66°F.

A98534

Fig. 4---Accessory Support Feet

_) Step 6_Check Indoor and Outdoor AccuRater_ Piston

Check indoor coil piston to see if it matches the required piston
shown on outdoor unit rating plate. If it dees not match, replace

2

indoor coil piston with piston shipped with outdoor unil. The
piston shipped with outdoor unit is correct Ior any approved indoor

coil combination.

To prevent damage to unit or service valves observe the
following:

• Use a brazing shield.

• Wrap service valves with wet cloth or use a heat sink
material.

Check outdoor unit piston. Remove retainer on liquid service valve
and check piston size with matching number listed on outdoor unit

rating plate.

Step 7--Check Defrost Thermostat

Check del¥ost thermostat to ensure it is properly located and
securely attached. There is a liquid header with a brass distributor
and Ieeder tube going into outdoor coih At the end of I of the
feeder tubes, there is a 3/8-in. O.D. stub tube approximately 3 in.
long. (See Fig. 5.) The defi-ost thermostat should be located on stub
tube. Note that there is only 1 stub tube used with liquid header.

and on most units it is the bottom circuit.

FEEDER TUBE

STUB TUBE

DEFROST

THERMOSTAT

---)' Outdoor units may be connected to indoor section using accessory

tubing package or field-supplied relrigeranl grade tubing of correct
size and condition. For tubing requirements beyond 50 It, substan-

tial capacity and perfi,_rmance losses can occur. Following the
recommendations in the Residential Split System Long-Line
Application Guideline will reduce these losses. Relk'r to Table I
lbr field tubing equivalent line length. Refer to Table 2 for
accessory requirements.

---)' For buried-line applications greater than 36 in., consult your local
distributor.

If refrigerant tubes or indoor coil are exposed to atmosphere, they
must be evacuated to 500 microns to eliminate contamination and

moisture in the system.

OUTDOOR UNIT CONNECTED TO FACTORY-APPROVED

INDOOR UNIT

Outdoor unit contains correct system refrigerant charge for opera-
tion with indoor unit of same size when connected by 15 ft of
field-supplied or factory-accessory tubing. Check refrigerant
charge for maximum efficiency.

REFRIGERANT TUBING
Connect tubing to fittings on outdoor unit vapor and liquid service

valves. (See Table I.) Use refrigerant grade tubing.

SWEAT CONNECTION

Ag7517

Fig. 5_Defrost Thermostat Location

Step 8--Make Piping Connections

Relieve pressure and recover all refl'igerant 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 valve damage while brazing, service valves must be
wrapped in a heat-sinking material such as a wet cloth.

Remove plastic retainer holding outdoor piston in liquid service
valve and connect sweat/flare adapter provided to valve. (See Fig.

6.) Connect refrigerant tubing to fittings on outdoor unit vapor and
liquid service valves. Service valves are closed from factory and

ready for brazing. Alter wrapping service valve with a wet cloth,

tubing set can be brazed to service valve using either silver bearing
or non-silver beating brazing material. Consult local code require-
ments. Refrigerant tubing and indoor coil are now ready for leak
testing. This check should include all field and factory joints.

----).IMPORTANT: Check to be certain factory tubing on both indoor
and outdoor unit has not shifted during shipment. Ensure tubes are
not rubbing against each other or any sheet metal. Pay close
attention to IEeder tubes, making sure wire ties on feeder tubes are
secure and tight.

Table 1--Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters (In.)

UNIT
SIZE

018, 024
030, 036

042, 048

060

NOTES:

1. Tube diameters are for lengths up to 50 It, For tubing lengths greater than 50 It, consult Residential Split System Long-Line Application Guideline.

2. Do not apply capillary tube indoor coils to these units.

Connection Diameter Tube Diameter Connection Diameter Tube Diameter

LIQUID VAPOR

3/8 3/8 5/8 5/8
3/8 3/8 3/4 3/4

3/8 3/8 7/8 7/8
3/8 3/8 7/8 1-1/8

VAPOR (LONG LINE)

Connection Diameter Tube Diameter

5/8 3/4
3/4 7/8
7/8 1-1/8
7/8 1-1/8

Table 2--Accessory Usage

REQUIRED FOR REQUIRED FOR

ACCESSORY APPLICATIONS APPLICATIONS*

Crankcase Heater Yes Yes

Evaporator Freeze Thermostat Yes No

Accumulator No No

Compressor Start Assist Yes Yes

Capacitor and Relay

Low-Ambient Controller,

MotorMaster_ Control, Yes NO

Low-Ambient Pressure Switch

Liquid-Line Solenoid Valve See Long-Line

Ball Bearing Fan Motor Yes_ No

• Fortubinglinesetsbetween 50and 175 ft, referto ResidentialSplitSystem Long-LineApplicationGuideline.

_:Requiredfor Low-AmbientController(fullmodulation feature) and MotorMasterControlonly

PISTON

or

Wind Baffle See Low-Ambient Instructions No

Support Feet Recommended No

or No Application

Hard Shutoff TXV Guideline

LOW-AMBIENT LONG-LINE

(BELOW 55°F) (OVER 50 FT)

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.

PISTON

PISTON RETAINER

SWEAT/FLARE ADAPTER

A94029

Fig. 6---Liquid Service Valve with Sweat Adapter

Tube

Step 9---Make Electrical Connections

¥!_ I[VI'__T=II: [_

To avoid personal injury or death, do not supply power to unit
with compressor terminal box cover removed.

Be sure field wiring complies with local and national fire, sal_ty,
and electrical codes, and voltage to system is within limits shown
on unit rating plate. Contact local power company lor correction of
improper voltage. See unit rating phne liar recommended circuit

protection device.
NOTE: Operation of unit on improper line voltage constitutes

abuse and could afl_ct unit reliability. See unit nning plale. Do not

install unit in system where voltage may Yluctuate above or below

permissible limits.

NOTE: Use copper wire only belween disconnect switch and
unit.

NOTE: Install branch circuit disconnect of adequate size per
NEC Io handle unit starling current. Locate disconnect within sight
from and readily accessible from unit, per Section 440-14 of NEC.

r!_ lvI.Jl;] :11_[,

The unit cabinet must have an uninterrupted or unbroken
ground to minimize pe_onal injury if an electrical fault
should occur. The ground may consist of electrical wire or
metal conduit when installed in accordance with existing
electrical codes. Failure to follow this warning can result in an

electric shock, fire, or death.

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. 7.

DISCONNECT

PER N. E. C. AND/OR
LOCAL CODES

CONTACTOR

FELD POWER I

WIRING

.©°©

©o©

FIELD GROUND

WIRING j GROUND

Fig. 7--Line Power Connections

CONNECT CONTROL WIRING
Route 24-v control wires through control wiring grommet and

connect leads to control wiring. (See Fig. 8-12.)

Use No. 18 AWG color-coded, insulated (35°C minimum) wire. If

thermostat is Ioca[ed 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.

-") All wiring must be NEC Class I and must be separated from
incoming power leads.

4

®

LUG

A91056