Carrier 40KMQ03036301, 40KMQ01824301, 40KMC03036301, 40KMC024301, 40KMC018300 Installation Guide

Installation Instructions

40KMC, KMQ Unit

38HDF/QRF Unit

to the expe_

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other

conditions which may cause death, personal iniury, 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 for brazing operations.

Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes and

current editions of the National Electrical Code ( NEC ) NFPA 70.
In Canada, refer to current editions of the Canadian electrical code

CSA 22.1.

Recognize safety information. This is the safety-alert symbol/_k
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal iniury. Understand

these signal words; DANGER, WARNING, and CAUTION. These
words are used with the safety-alert symbol. DANGER identifies

the most serious hazards which will result in severe personal iniury
or death. WARNING signifies hazards which could result in

personal iniury or death. CAUTION is used to identify unsafe
practices which would result in minor personal iniury or product

and property damage. NOTE is used to highlight suggestions

which will result in enhanced installation, reliability, or operation.

NOTE: Read the entire instruction manual before starting the
installation.

UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal iniury or

equipment damage.
Puron refrigerant systems operate at higher pressures than

standard R-22 systems. To avoid damage to the unit or
possible personal iniury, do not use R-22 service equipment or
components on Puron refrigerant equipment.

ELECTRICALSHOCK HAZARD
Failure to follow this warning could result in personal

iniury or death.
Before installing, modifying, or servicing system, main

electrical 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.

PERSONAL INJURY AND EQUIPMENT DAMAGE
HAZARD

Failure to follow this caution may result in personal iniury
and / or equipment damage.

DO NOT operate the unit without a filter or with grille
removed.

DIMENSIONS - INDOOR

!I , .... ,:

1 10_5_ ,_

40KMC018

,.,.,,.,---"--Adjacent Room Supply

1' - 10-5/8"(575)

Fresh Air Inlet 3/8

,,,,2"(52)

1-5/16"(4)_

Supply air T

Model Unit Size OPlbratin g Wkegght

4OKMC 18 49 I 22.3

Supply aF Return _r Supply_air

Return air

2'-8-1/2"(825)

A

Supply air

2L4-11/32(720)

1'@-21/32 "(550 )

}

40KMC024-036 / 40KMQ018-036

.........._

- ....... J

2'-8-1/2 (825)

1'- 11-7/16"(595)

FRESH AIR

INLET

Model Unit Size

4OKMC

4OKMQ

024 91

030 / 036 95

018 / 024 91

030 / 036 95

NOTE: Dimensions in () are in mm.

Operating Weight

Ib kg

A08447

Fig. 1 - 40KMC,KMQ Indoor [}nit Dimensions

DIMENSIONS - OUTDOOR

JUNCTION BOX FOR_

POWER SUPPLY g

CONTROL CONNECTIONS

FIELD CONTROL SUPPLY_

718"(22,2) HOLE WIGROMMET

WIRE ENTRY

=I o

SERVICE PORTS
(ADDITIONAL PORTS

COMPRESSOR ACCESS)

_ PROVIDED INSIDE "G"

"B"

I _ o'-9°

I ___NI_I _ 0"-4lJ2° I

L, e I= . (114)

(204,01

-

(28) // I\\

/ =4, 1<-3 9/16"

JR]GHT SIDE VEIW \ I 19o)

___ _TYP

(FIELD PROVIDED AND INSTALLED)

WIND BAFFLE ACCESSORY

[ _ I' (191)'z_-

ORAIN HOLES_.< _ _ _1 "M"_ "PiF

(TYP_ \ | i<l |' " -I _ 1-0'(2841)/2"

"E" o'-7 1/2"

/ E I 1,,,,-- ........ 7:_-_ J_o 7

v0 IiI', '

/ l & _ LZ.,_........... [_" "-_

_,__ L_J 'A ' I LnJ LnJ

0'-0 11/1B "_ I I Z & !_ " "

118) _ o'-_" k- qmF J

UNIT IVODELS CHASSIS

38HDF 38QRF SIZE

Unit Size Unit Size (Reference)

018 018 O 2'-1V8" 3'-015/16" 1'-29/16 " 1'-4" 1'-117/16 " 1'-53/16 " 1'-51/8 " 1'-10" 1'-1" 0'-65/8 " 0'-11V4" 0'-2W16" 0'-6"

024,030 024 0.6 (790.6) (938.2) (369.9) (406.4) (595.3) (436.6) (587.4) (711.5) (355.6) (171.5) (295.3) (75) (152.4)

036 030,036 1.0 (944.6) (1131.9) (433.4) (468.3) (774.7) (498.5) (741) (865.5) (347.7) (206.4) (403.2) (88) (165.4)

NOTE: Dimensions shown in feet-inches. Dimensions in ( ) are millimeters.

CLEARANCES - OUTDOOR

- _-- J !

(_Sp2) _TOP VIEW

A B C D E F G H J K L N P

(638.2) (938.2) (369.9) (406.4) (595.3) (436.6) (435) (559.1) (330.2) (168.3) (285.8) (75) (152.4)

2'-7V8" 3'-015/16" 1'-29/16 " 1 '-4" 1'-117/16" ] 1 '-53/16 " 1'-11 VB" 2'-4" 1'-2" 0'-63/4 " 0'-115/8" 0'-215/16" 0'-6"

3'-13/16 " 3'-89/16 " 1'-51/16 " 1 '-67/16 " 2'-61/2 " 1'-7s/8 " 2'-53/16 " 2'-101/16 " 1 '-111/16" 0'_81/8 ', 1'_37/@', 0'_37/16 ', 0'_61/2 ',

Fig. 2 - 38HDF, QRF Unit Dimensions

]' 4 _

(406)

"_-¢o_/_

FRONT VIEW

UNIT SIZE

018 _/@ 15.88 166 75.3

38HDF

38QRF 030 3/4 19.05 187 84.8

024 5/@ 15.88 176 79.8

030 3/4 19.05 187 84.8

036 3/4 19.05 250 113.4
018 s/8 15.88 166 75.3
024 s/@ 15.88 176 79.8

036 3/4 19.05 232 105.2

* Male flare connection for Heat Pumps

OPERA "ING WT

in. mm Ib kg

"DIA VAPOR LINE CONN.

FEMALE SWEAT CONN.

--3/8" DIA.(9.S3)
LIQUID LINE

FEMALESWEATCONN*

A08434

Air-outlet

C

UNIT Coil Facing Wall - in. (mm) Fan Facing Wall - in. (mm)

A 24 (610) 24 (610)

B 36 (914) 36 (914)
C 36 (914) 8 (203)
a 6 (152) 8 (203)

E 6 (152) 36 (914)

Fig. 3 - Outdoor Unit Clearance

E

A08436

Parts List
Indoor Unit

The following items are included with the indoor unit:

Table 1 - Installation Materials

Description Qty Usage

Baffle (size 18) 1 Required for fresh air intake

Template 1 tions

NOTE: The grille and the User Interface are not included with
unit. For User Interface, a wireless remote, wired remote, or a
Zone Manager can be ordered.

Outdoor Unit
The following items are included with the outdoor unit:

Mark hangers, piping and wiring Ioca-

These instructions cover the installation and start-up of the systems
listed in Table 2.

Table 2 - Matched Systems

SYSTEM SYSTEM

TYPE SIZE BER

Cooling 024 38HDF024-3 40KMC024-3

Only 030 38HDF030-3 40KMC03036-3

Heat Pump 030 38QRF030-3 40KMQ03036-3

Cooling 018 38HDF018-3 40KMQ01824-3

with 024 38HDF024-3 40KMQ01824-3

Electric 030 38HDF030-3 40KMQ03036-3

Heat 036 38HDF036-3/5/6 40KMQ03036-3

018 38HDF018-3 40KMC018-3

036 38HDF036-3/5/6 40KMC03036-3
018 38QRF018-3 40KMQ01824-3

024 38QRF024-3 40KMQ01824-3

036 38QRF035-3/5/6 40KMQ03036-3

OUTDOOR UNIT MODEL NUM-

INDOOR UNIT

BODY

METERED FLOW

C00L[NG

38HDF018-036

Fig. 4 - 38HDF018-036

BODY

Fig. 5 - 38QRF018-036

Model Filter Drier Pistons*

38HDF _* _* _* _*
38QRF _* _* (qty 2) _* _* (qty 3)

Multiple pistons. Quantity varies with size.

Piston Flare

Cap Connector

A09499

A09500

SYSTEM REQUIREMENTS

Clearances

Allow sufficient space around the indoor and outdoor unit for
proper airflow circulation and servicing. Refer to Fig. 1 and Fig. 3

for minimum required clearances,
Piping: Piping and insulation is field supplied,

PiDinu Lenuths

The minimum length between the indoor and outdoor units is 10 fl
(3 m). Refer to table 3 for the maximum lengths allowed.

Table 3 - Maximum Refrigerant Line Lengths

Unit Max Line Max Elevation Max Elevation

Size Length* ft(m) (ID over OD) ft(m) (OD over ID) ft (m)

18K 200 (61) 65 (19.8) 200 (61)
24K 200 (61) 65 (19.8) 200 (61)

30K 200 (61) 65 (19.8) 200 (61)
36K 200 (61) 65 (19.8) 200 (61)

Note:For lengths greater than 25 ft (7.6 m), refer to the Duct Free Long

Line Guide.

Pipe Sizes

Refer to table 4 for pipe sizes.

Table 4 - Pipe Sizes

Unit Size Mix Phase - in Vapor - in

18K 3/8 5/8

24K 3/8 5/8
30K 3/8 3/4

36K 3/8 3/4

Note:Both lines need to be insulated using at least 1/2 inch closed foam

insulation.

Pipe Sizes (in)

Condensate Drain Pipe Sizes

Refer to table 5 for the required sizes.

Table 5 - Drain Pipe Sizes

Unit Size Inside Diameter - in

18K 1

24K 1
30K 1

36K 1

Refriuerant Charge

The 38HDF and 38QRF units can be matched with multiple
outdoor units and thus additional charge might be required when

matched with the 40KMC or 40KMQ units,

Table 6 - Additional Charge

Additional Charge Ib (kg)

Unit Size 38HDF 38QRF

018 0 0

024 1.2(0.55) 0
030 3.0 (1.40) 1.8(0.82)

036 0.8 (0.36) 0

Note:The above additional charge is required amount forline lengths up to
25ft (7.6m), For line lengths exceeding 25ft (7.6 m), additional charge will
be required. Referto the Duct Free SpfitsLong Line Guide.

Metering Device

The metering device(s) for these systems is a type B Accurator
installed with the outdoor unit. One Accurator is required for the
cooling only system and two are required for the heat pump

systems. The Accurators are supplied with the outdoor unit.
However, since the same outdoor unit can be matched with

multiple indoor units, the correct Accurator must be selected. Refer
to Table 7 for the correct Accurator size.

Table 7 - Accurator Sizes

System Type Size Accurator

018 49
024 57

Cooling Only 030 61

036 74
018 51

024 55

Heat Pumps 030 63

036 70

Cooling

Heating

Accurator

46

53
55

63

Power and Connecting Cables - Field Supplied
Power:

• The indoor and outdoor units require a dedicated power supply.

• Consult local building codes, NEC (National Electric Code) or
CEC (Canadian Electric Code) for any special requirements.

• Use Table 8 for the electrical requirements for the outdoor units
and Table 9 for the indoor units to correctly size the cables and

disconnect switches.

Table 8 - 38HDF

Unit

Size Voltage

018 208/230-1-60
024 208/230-1-60

030 208/230-1-60

035/36 208/230-1-60
035/36 208/230-3-60

035/36 460-3-60

QRF Electrical Requirements

38HDF

Min Ckt Amps/

Fuse HACR Bkr

Amps

12.1/20

16.8/25

18.4/30

23.8/40

18.0/30

8.3/15

Min Ckt Amps/

Fuse HACR Bkr

38QRF

Amps

12.1/20

16.8/25

18.4/30

23.3/35

14.5/20

8.7/15

Control Wiring

Thermostat wires should be used for control wiring between the
indoor and outdoor units. A two conductor cable is required for
the cooling only units and a seven conductor cable is required on

heat pumps. 18 AWG is recommended for any length up to 50 ft
(15.2 m). 16 AWG is recommended for lengths between 50 and

200 ft (15.2 and 61.0 m).

User Interface

For 38HDF and 38QRF units matched with 40KMC and 40KMQ
units, the following accessories are available

• Wall mounted control. Up to 6 units can be daisy chained and
controlled by one wired control.

• Zone manager c@able of controlling up to 32 units divided up
to 8 different zones.

• Wireless remote control.

NOTE: Units are factory ready for wall mounted wired
controls. See User Interface Installation section in this
document.

Operating Range

Ensure that the system operates within the @plication guidelines
shown in the following tables,

Cooling Operating Range

Maximum Minimum

DB°F (°C) WB°F (°C) DB°F (°C) WB°F (°C)

Outdoor

Unit 125 (51.7) -- 55 (12.8) --

Indoor

Unit 90 (32.2) 74 (23.3) 62 (17.0) 56 (13)

Heating Operating Range

Maximum Minimum

Outdoor

Unit 75 (23.9) 67 (19.4) 17 (-8.3) --

Indoor

Unit 81 (27.2) -- 62 (17.0) --

DB°F (°C) WB°F (°C) DB°F (°C) WB°F (°C)

Accessories

An extensive list of field installed accessories is available for both
indoor and outdoor units. Identify what accessories, if any, are

required for the application at hand and consult the separate
installation instructions for the accessories. Some of the

accessories, especially on the indoor units, can be installed much

easier if planned ahead.

Table 9 - 40KMC / KMQ Electrical Requirements

40KMC 40KMQ

Unit Voltage Min Ckt Amps/ Min Ckt Amps/

Size Fuse HACR Bkr Fuse HACR Bkr

018 208/230-1-60 0.8/15 16.3/20
024 208/230-1-60 0.7/15 16.3/20

030 208/230-1-60 1.3/15 16.9/20
036 208/230-1-60 1.3/15 16.9/20

Amps Amps

INSTALLATION

Complete Pre-installation Checks

1. Unpack Unit - Store the indoor and outdoor units in the
original packaging until it is moved to the final site for in-

stallation. When unpacking indoor unit, be careful not to
lift unit by condensate drain discharge pipe or by refrigerant

connections.

2. Inspect Shipment - Upon receipt of shipment, check the
indoor and outdoor units for damage. If there is any dam-

age, forward claim papers directly to the transportation
company. Manufacturer is not responsible for damage in-

curred in transit.

3. Inspect Parts Supplied With Units - Check all items
against parts list (see page 4). If any items are missing, noti-

fy your distributor or Carrier office.

To prevent loss or damage, leave all parts in original packages until
installation.

Consider System Requirements

1. Consult local building codes and NEC for special installa-
tion requirements.

2. When deciding the location of the indoor and outdoor units,
ensure that the piping run does not exceed the allowed dis-

tances listed in Table 3.

3. Make sure the indoor and outdoor units are easily accessible
to electrical power.

4. Allow sufficient clearances for airflow, wiring, refrigerant
piping, and servicing the unit. See Fig. 2 and Fig. 3.

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

INSTALL INDOOR UNIT

Plan the installation carefully before you begin.

1. Select indoor unit location.

a. A location that can bear the weight of the unit.

b. Install the unit a centrally as possible in the room.

c. Choose a location that does not obstruct air circulation.

NOTE: A maximum of two air outlets can be restricted at one
time. See Fig. 6. The Air Supply Outlet Obstruction accessory

kit can be used to obstruct air outlets.

NOTE: If the mounting location is in a plaster board ceiling,

the maximum dimensions of the unit housing cutout must not
exceed 2 It, 2 in. (0.66 mm) square for the 40KMC018 units
and 2 ft. 11 in. (0.66 mm) square for the 40KMC024-036 and
40KMQ018-036 units.

NOTE: The unit is in two sections: The unit and the grille.

a. Use the factory supplied cardboard template as a guide

to mark the position of the hangers, refrigerant lines and
condensate drain pipes, power supply cables and remote

control cables. See Fig. 1 for dimensions.

b. Depending on the type of ceiling, fix the threaded

hangers as shown in Fig. 7 and Fig. 8.

--®
®

(T) Nut ® Washer
@ Washers (_) Threaded hangers
® Threaded hangers @ Washer

® Wooden frame @ Nut
@ Nut @ Nut

A07186

Fig. 7 - Attaching Hangers to Ceiling

_4._.___._/_ Threaded hangers

3: 7=

"T" ar

(to be removed)

A07187

Fig. 8 - Threaded Hangers and "T"Bar

m

c-7=-=-c3

¢-7='=-.--I

{, )

r------

Max. 2 louvers closet

T--7=--=-C3

_t --" 1

Fig. 6 - Air Outlet Obstruction

d. Choose a location that is easily accessible for service

and maintenance.

e. Do not install indoor units near a direct source of heat

such as direct sunlight or heating appliance.

f. Do not install units too close to humid conditions.

2. Mounting Indoor Unit

_m,=_=_=_=___

A07184

c. Insert the washers as shown in Fig. 7 and Fig. 8.

d. Remove the "T"bar in ceiling to facilitate installation.

See Fig. 8. If the "T" bar cannot be removed from the

ceiling, the unit may have to be tilted as shown in Fig.

9.

'l

T T

T-Bar T-Bar

• B kupenslon rac es SupensionBrackets

A07188

Fig. 9 - Positioning Unit in Ceiling

e. If Fresh Air Intake or Conditioning an Adjacent Room

is required, perform the modification required to the unit

at this point. Refer to the Installation Options section

for additional details.

£Usea stacker to lift the unit to the installation location.

See Fig. 10.

;k

A07185

Fig. 10 - Positioning []nit

g. Carefully lift the unit using the four suspension brackets

and insert the four suspension brackets into the threaded
hanger as shown in Fig. 11.

False

Ceiling

to 1-3/16"

Fig. 11 - Align and Level []nit

h. Align and level the unit by adjusting the nuts and lock-

nuts on the threaded hangers maintaining a distance of 1
in. to 1-3/16 in. between the sheet metal body and the
underside of the false ceiling. See Fig. 11.

3. Drill the hole for the piping (refrigerant and condensate)
and control wiring in the external wall.

a. Drill a 2-3/4 in. (70 ram) hole in the wall with a 3/16

in. to 3/8 in. (4.8 - 9.5 ram) slope toward the outside.
Refer to Fig. 12.

_[ i/ •

Spirit

A07189

INSTALL OUTDOOR UNIT

The outdoor units can be installed on the ground, on the roof, or
mounted on a wall.

NOTE: Install the unit so that the coil does not face into
prevailing winds. If this is not possible and constant wind

winds above 25 mph are expected, use accessory wind baffle.

See installation instructions provided with accessory kit. Wind
baffles should also be used on all units with accessory low
ambient temperature control.

Mounting on Ground

1. Mount unit on a solid level concrete pad.

2. If a heat pump is being installed, use a field- provided snow
stand or ice rack where prolonged subfreezing temperatures

or heavy snow occurs.

3. Position unit so water or ice from roof does not fall directly
onto unit.

4. On cooling only units, an accessory stacking kit can be used

when units are to be stacked. See installation instructions

provided with the accessory kit.

Mounting on Roof

PERSONAL INJURY AND/OR EQUIPMENT
DAMAGE HAZARD

Failure to follow this caution may result in personal injury
and / or equipment damage.
Be sure unit panels are securely in place prior to rigging.

1. Rig the unit. Keep the unit upright and lift using a sling.
Use cardboard or padding under the sling, and spreader bars

to prevent sling damage to the unit. See Fig 13. See Fig. 2
for center of gravity reference

2. Mount unit on a solid concrete pad or platform.

3. Isolate unit and piping from structure

4. If a heat pump is being installed, use a field- provided snow
stand or ice rack where prolonged subfreezing temperatures

or heavy snow occurs.

5. On cooling only units, an accessory stacking kit can be used

when units are to be stacked. See installation instructions

provided with accessory kit.

A07190

Fig. 12 - Drilling for Connections

4. Drill hole for Fresh Air Intake, if required. Refer to Installa-
tion Options section for additional information.

NOTE: In rooms with high humidity, brackets should be

insulated using self-adhesive insulation.

SUNG

Fig. 13 - Lifting []nit with Sling

SLING PADDING

COMPRESSOR

END

CENTER OF
GRAVmTY

A07396

Mounting Unit on Wall
The units can also be mounted on the wall using the accessory

mounting kit.

Complete Outdoor Refrigerant Piping Connec-
tions

Follow the following general guidelines:

1. Use refrigerant grade field - supplied tubing.
Refer to Table 4 for the correct line sizes.

2. Do not use less than 10 ft (93.05 m) of interconnecting
tubing.

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in equipment
damage or improper operation.

If any section of pipe is buried, there nmst be a 6 in. (152.4
ram) vertical rise to the valve connections on the outdoor
unit. If more than the recommended length is buried,
refrigerant may nfigrate to cooler, buried section during
extended periods of system shutdown. This causes
refrigerant slugging and could possibly damage the
compressor at start-up.

When more than 80 fl (24.4 m) of interconnecting tubing is used,
consult the Duct-Free Split System Long Line Application Guide

for required accessories.

3. Insulate both lines. A minimum of 1/2 inch foam pipe insu-
lation is recommended.

4. Run the refrigerant tubes as directly as possible and avoid
unnecessary turns and bends.

5. Suspend refrigerant tubes to avoid damage to insulation or
tubes so they do not transnfit vibration to the structure.

6. When passing refrigerant tubes through the wall, seal the
opening so rain and insects do not enter the structure. Leave

some slack in refrigerant tubes between structure and out-
door unit to absorb vibration.

NOTE: A fusible plug is located in unit suction line; do not cap

this plug. If local codes require additional safety devices, install
as directed.

Connection at Outdoor Unit

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage
or improper operation.

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

• A brazing shield MUST be used.

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

38HDF []nits:

1. Assemble the connector tube to the factory supplied filter

drier by:

a. Braze the field supplied connector to the inlet of the

filter drier (see Fig. 14)

b. Braze the factory supplied flare connector to the outlet

end of the filter drier (see Fig.14)

COOL[NG

FILTER

"/DRIER

Fig. 14 - 38HDF018-036 Connector Tube Assembly

2, Assemble the Accurator body (see Fig, 15) using the correct

factory supplied piston (refer to Table 7),

TEFLON SEAL

\ _ _ TO INDOOR

__}__ _ COIL

CAP WITH ORIFICE BODY

NOTE: Arrow on AccuRater body points in free flow direction, away from the
indoor coil.

PISTON \

Fig. 15 - AccuRater (bypass type) Metering Device

Components

PISTON BODY

A09499

A09501

3, Attach the complete Accurator assembly to the flare connec-

tion end of the filter drier

4, Braze the completed filter drier/Accurator assembly to the

liquid service valve.

5, Connect the field supplied line set to the filter drier/Accura-

tor assembly and the suction valve. A sweat connection is
required at the suction valve and flare connection is required

for the nfixed phase line,

6. Insulate any exposed areas between the line set and the li-
quid valve.

38QRF Units

1. Assemble the connector tubes to the factory supplied filter

drier by brazing the factory supplied flare connectors to the
inlet and outlet for the filter drier (see Fig. 16)

Fig. 16 - 38QRF018-036 Connector Tube Assembly

2. Perform step 2 and 3 from the 38HDF section.

3. Remove the plastic cap from the liquid and suction service
valve on the 38QRF unit and assemble the heating piston

and piston cap supplied with the outdoor unit as shown in
Fig. 17.

--P ISTON

HEAT IN6

PISTON CAP

L/ ] METEREDFLOW

J "=HEATING

Fig. 17 - AccuRater (bypass type)

Metering Device Components

Heat Pump Systems Only

BODY

TOR

A09507

A07407

UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage

or improper operation.
Unit failure as a result of operation on improper line voltage or

excessive phase imbalance constitutes abuse and may cause
damage to electrical components. Such operation could void
any applicable Carrier warranty.

ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal iniury

or death.
Before performing service or maintenance, be sure indoor

unit main power switch is turned OFF and indoor blower has
stopped.

Lock out and tag switch with a suitable warning label.

Power Wiring

1. Mount outdoor power disconnect. The unit is factory wired
for the voltage shown on the unit nameplate. The fused dis-
connect switch nmst be provided within sight of the unit,

readily accessible, but out of reach of children. Provisions
for locking the disconnect switch on the OFF (open) posi-

tion is advisable. The disconnect switch must comply with
NEC and local codes, Protect the unit and wiring using

only the recommended fuse/circuit breaker size. See
Table 8.

2. Run power wiring from main box to disconnect per NEC
and local codes.

3. Run power wiring from the disconnect switch to outdoor
unit. Use only minimum 60°C copper conductors between

the disconnect switch and the unit for field power connec-
tion,

4. Route the field power wires through the conduit connection
opening in the unit side panel and connect in junction box

as shown in Fig 18. The unit and power wiring must be
grounded,

NOTE: The Teflon seal on the piston should point towards the
liquid service valve. The size of the factory supplied piston
might have to be adjusted for long line applications (over 80 ft
/ 24.4 m). Refer to the Duct Free Long Line Application Guide

for additional information.

4. Attach the flare end of the filter drier assembly to the piston
cap (see Fig. 17).

5. Connect the field supplied line set to the filter drier as-
sembly and to the suction valve.

6. Insulate any exposed areas between filter drier and liquid
valve.

Complete Outdoor Power and Control Wiring

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or
death.

The unit cabinet must have an uninterrupted or unbroken
ground to minimize personal 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.

TO--"

THREE-PHASE
CONNTO
DISCONNECT

PER NEC

=GROUND LEAD,

LEGEND

NEC -- National Electrical Code

-- Splice (field)

-- -- ' Field Wiring
Factory Wiring

Fig. 18 - Line Power Connections

NOTE: Operating unit on improper line voltage constitutes
abuse and may affect Carrier warranty. DO NOT install unit
in a system where voltage may fluctuate above or below
permissible limits.
9

_----- BLK

NGLE-PHAS7

=d_ BLK

=_i BLU --

=_::_- YEL

._] GROUNDING LUG

THREE-PHASE UNIT

A08251

Control Wiring

The control circuit is 24 volts AC (naininmm 40VA) supplied from
the indoor unit,

1. Make sure you have enough control wires to cover the dis-
tance between the indoor and outdoor unit,

Indoor

Terminal

Board

Indoor _ _4v

Board

COHPR

T°v2°;

Board I_ I

2, Route one end of the control wiring through the opening

provided in the unit side panel and connect to the control
terminal strip using either Fig. 19 for 38HDF units and Fig.
20 for 38QRF units,

Indoor_

Board

Terminal

Board

Outdoor ...... _o i41_i_ _

Board ............._o _LL r_

A09509

Fig. 19 - 38HDF Control Terminal Strip

A09508

Fig. 20 - 38QRF Control Terminal Strip

NOTE: Use No. 18 AWG color-coded, insulated (35°C minimum) wire. If the distance between the indoor and outdoor unit is
greater than 100 ft. (30.5 m), as measured along the control voltage wires, use No. 16 AWG color-coded wire to avoid excessive
voltage drop.

10

ELECTRICAL DATA

38HDF/38QRF

UNIT SIZE

018

O24
36QRF030
36HDF030

035

036

40KMC

Unit Size

018
024

030
036

V-PH-Hz

208/230-1-60
208/230-1-60

208/230-1-60
208/230-1-60
208/230-1-60

208/230-3-60

460-3-60
208/230-1-60
208/230-3-60

460-3-60

V-PH-Hz

208/230-1-60
208/230-1-60
208/230-1-60

208/230-1-60

Table 10 - 38HDF/38QRF Electrical Data

VOLTAGERANGE* COMPRESSOR OUTDOORFAN MOTOR

Min Max

187 253
187 253

187 253
187 253

187 253
187 253

414 506

187 253
187 253

414 506

RLA

9.0

12.8

14.1

14.1

16.7

10.4

5.8

17.9

13.2

6.0

LRA

48.0

58.3

73.0

73.0

79.0

73.0

38.0

112.0

88.0

44.0

FLA

0.80

0.80

1.50

0.80

1.50

1.50

0.80

1.45

1.45

0.80

NEC Hp

0.125

0.125

0.25

0.125

0.25

0.25

0.25

0.25

0.25

0.25

kW Out

Table 11 - 40KMC Fan coil Electrical Data

Voltage Range FAN

Louver

Motor

FLA

0.01

0.01

0.01

0.01

Min. Max

187 253
187 253

187 253
187 253

FLA Wafts

0.55 120

0.50 110

0.95 210

0.95 210

Condensate

Pump FLA

0.06

0.06

0.06

0.06

0.09

0.09

0.19

0.09

0.19

0.19

0.19

0.19

0.19

0.19

MIN CKT

AMPS

12.1

16.8

18.4

18.4

22.3

14.5

8.7

23.8

18.0

8.3

MIN CKT

AMPS

0.8

0.7

1.3

1.3

FUSE/

CKT

BKR

AMPS

2O
25

3O
3O

35
2O

15

4O
3O

15

Power

FUSE/

CKT

BKR

AMPS

15
15

15
15

Table 12 - 40KMQ Fan Coil Electrical Data

Voltage

40KMQ

Unit Size

018
024

030
036

*Permissible limits of the voltage range at which unit will operate satisfactorily.

FLA - Full Load Amps
MCA - Minimum Circuit Amps per NEC Section 430-24

NEC - National Electrical Code
RLA - Rated Load Amps (Compressor)

V-PH-Hz

208/230-1-60
208/230-1-60

208/230-1-60
208/230-1-60

LEGEND

Range

Min. Max

187 253
187 253

187 253
187 253

FAN

FLA Power

0.50 110

0.50 110

0.95 210

0.95 210

Motor

(Wa_s)

Electric

Condensate

Pump FLA

0.06 0.01

0.06 0.01

0.06 0.01

0.06 0.01

1. In compliance with NEC requirements for multi-motor and combination
load equipment (refer to NEC Articles 430 and 440), the over-current
protective device for the unit shall be fuse or equipped with a breaker.

2. Motor RLA values are established in accordance with UL (Underwriters
Laboratories) Standard 465.

Louver

Motor

FLA

Heaters

kW FLA CKT

3 12.5 16.3
3 12.5 16.3

3 12.5 16.9
3 12.5 16.9

NOTES:

MIN

AMPS

Power

FUSE/

CKT
BKR

AMPS

@s

2O
2O

2O
2O

11

OISPLAYP__

TH COIL TM AIR

RED 2 }

REO

3PL4 / F

GRA

_F

p• ...............s ....1_ BLK__oR_HTwHT

1P 1 ......... GRA_

_pce ___ TB2!_

I ill I _

NODULAR "D"

CONTROL 1PCB

1FC

40KNC GLOBAL CASSETTE

38HDF OUTDOOR CONDENSER

TB1

8LK _" TO CASSETTE Y

_L--TO CASSETTE R

LEGEND

NOTES

7 _;_aH_NA SHAH, OR CARR rR ROOH CONTROLLrR {CRC} CUkM'C_ON

o US _ H_N_MUM SO"C NRE FOR THE FELD pOIJER *HR[NG

THERMISTOR EQUIVALENCE

TEMPERATURE RESISTANCE

°F °C

95 35 6,500
72 22 11,400

32 0 32, SO0

ALL THERH[STORS ARE IDENTICAL

Fig. 21- 40KMC/38HDF Cooling Only System Wiring Diagram

12

50057

DISPLAY

COHM

TB3 i

RED_ _ _R_ _ _ .............i

BARE COPPER

TO UNIT DISCONNECT/

(USE CABLE PRO/IDED}

DUIP. 6ND

PL

/FC

\ £ED

40KMO (L(}I}A,L (}A ETTE

_SH)F L T)(L < ..... S /Es E

YEL 8LK 7_ _ _ _qEE

LK EO'!2:...... ........

LEGEND

H C I

*;LK_]]LT( A :ETTE Y

2 [( (AS ETTE

2 .......

[_A_ED i _ 80NCI DN 0 BE JNSE_ O[ " S" q p _C
+E _C _ _CTO _ST_[ 0 *rRC" ON_TeR) OR JR OPTON

7 T R_P_A ST, b* F_R C_RR]ER ROOH CONTROl E,_ (CRC2 CON ECT[O_

OU OR UN _ 50_HR S AClO '_IRO D_ 23@_ OR 2O8,' .O_E
TIE *_LAC_ _]RE TO E 2O, A

OTE o)

[IS_ NE}T

b : )

THERH[STOR EOU[VALENCE

TEMPERATURE RESISTANCE

95 3S B,SO0
/2 22 1/,400
32 0 32,500

ALL THERMISTORS ARE IDENTICAL

Fig. 22 - 40KMQ / 38HDF Heat/Cool System Wiring Diagram with Electric Heaters

13

50058

THCILTHAIR _ _ ) K__OhJ _0_

............................................. L8 1

HODULSI: "D"

('ONT _OL 1P(

40KPO GLOBAL C# !}ETTE

180 F OUTOOOR COS[}E",!E

.... S

r_L_ EB

I.J[GEND uiE;

TO CASSETTE B

TO C_SE_ETTE A _/I

TO CASSETTE DT

TO CASBETTE G

....... TO CASSETTE Y

133

....... TO {:ASSETTE R .....//I

DS

TS_,

El ICll iCAl COl (H i i A_l) I IC>i COgll

I lolIrllso_ i rl fin IIo_I irl I_otl_id b_ [rllnll _II_IiI olelldl

{O!PRIiBOR AN) AN !OiORl ARI RO?IC I0 IY ]IIIRIA{
IIERIIL O_ERLOAIS

i }NOO(R IN} ?RAISIORI_!R l_S IN !RNA{ 2= ilRIAI if10l

PIE PR]IARY 51D£

}NNIIRiB {}I ION_q!C11 N 18 Ii HIIIRiE; ON "J} = RE j,_ !
Pli Ai At I{;101 _II A 1[!8 "CRO" 101111 {R R)R [ R OP ION

7 ERIINAL STRIP iOR ClRRJER IIOH CONTROLLSR 18R6 80NXECT]OI

1 CO!PRSIBOR IRAHIIIAil HiASR {NIIAIIID Ol 18111O11, +I !IOR 0i0

OUTDOOR UNIT IANIFORME! 11 FIOTOI IIRE8 FOR 130, OR 2!1'_ IO,E

IPiE }[AOI I}Ri 10 HI 2111 AP

10 8]E MI!I!IU_ 80+1 II_E @R HII IE[D POIE_ II_iNI

THERH[STOR E U[VALENOE

TEMPERATURE RES [STANCE

+F 'C

SS _D 6, O0
? , 400
! 0 3, ,00

ALL THER'¢I',TORIi ARE IDENTICAL

Fig. 23 - 40KMQ / 38QRF Heat Pump System Wiring Diagram with Electric Heaters

i

/

50059

14

Run Power Wiring for Indoor Unit

Be sure field wiring complies with local building codes and NEC,
and unit voltage is within linfits shown in Table 11 and Table 12.

Contact local power company for correction of improper line
voltage.

ELECTRICALSHOCK HAZARD
Failure to follow this warning could result in personal injury

or death.
Before installing, modifying, or servicing system, main

electrical disconnect switch nmst be in the OFF position.
There nmy be more than 1 disconnect switch. Lock out and
tag switch with a suitable warning label.

[]NIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage

or improper operation.
Unit failure as a result of operation on improper line voltage or

excessive phase imbalance constitutes abuse and may cause
damage to electrical components. Such operation could void

any applicable Carrier warranty.

NOTE: Use copper wire only between disconnect switch(es)
and unit.

NOTE: Install branch circuit disconnect of adequate size to
handle unit starting current per NEC. Locate disconnect

within sight of, and readily accessible from, unit, per section
440-14 of NEC. Some codes allow indoor unit to share

disconnect with outdoor unit if disconnect can be locked; check
local code before installing in this manner.

The 40KMC/KMQ units require their own power supply.

1. Locate the indoor power supply.

2. Locate and install disconnect switch per NEC and local
codes.

3. Run power supply wiring to disconnect switch.

4. Run power wiring from disconnect switch to control box
area. Use copper wire only between the disconnect switch

and unit. Use minimum 60°C wires for field power con-
nection.

5. Remove the external control box cover.

6. Place wiring through the 7/8 in. or 1-1/8 in. knockouts on
the bottom and on the right hand side of the external control

box (high voltage side). See Fig. 24 and Fig. 25.

15

II I
II I

II I

O Con nection

Room Controller
Connections

Outdoor Unit
Connections

II I
II I_-

II I
II I

II I
II I
II I

II I

_: High

Low

Voltage

Voltage

Fig. 24 - 40KMC Unit Matched to 38HDF Outdoor Unit - Wiring Connection

(Cooling Only System)

16

A07208

©

lOW

Voltage

_m

Voltage

Fig. 25 - 40KMQ Unit Matched to 38HDF Outdoor Unit - Wiring Connection

(Cooling with Electric Heat System)

17

A07209

7. Connect L1 to the black wire and L2 to the red wire using

wire nuts and fix the ground wire between the two washers.

The internal control panel can be accessed by opening the grille
and removing the metal cover attached by four screws.

NOTE: The internal control panel does not need to be accessed
during the installation process unless there is a need for service.

8. If any accessories are being installed, refer to the individual
accessory instructions for guidance on wire routing at this

time.

Install All Power_ Interconnecting Wiring_ Piping and
Drain Hose to Indoor Unit.

1. Run control wiring from the outdoor unit through the access
hole in the wall and make sure you have enough wire to

reach the control box of the unit once hung on the mounting
plate.

2. Complete refrigerant piping connections.

a. cut the extreme end of the tubes and remove any copper

shavings with a de-burring blade.

b. Remove the flare nut from the "Flare" connection body

of the indoor unit and insert them into the pipes.

c. make the flares to the pipe ends with the proper flaring

too. The flare end nmst not have any burrs or imperfec-
tions, the flared walls must be uniform. See Fig. 26
and Fig. 27.

d. Lubricate the end of the pipe and thread of the flare

connection with refrigerant oil. Tighten by hand and
then use two wrenches (see Fig. 28) to tighten all con-

nections fully applying the tightening torque shown in
Table 13.

@ Outdoor end n or _orque wrench -_\ &...._

@ Indoor end _ \ "-/

A07201

Fig. 28 - Tightening Connections

Table 13 -TighteningTorque

TUBE DIAMETER (in.) TORQUE fft.-Ib)

3/8 in. 31
5/8 in. 48

3/4 in. 74

Fig. 26 - Removing Burrs

I
I

i

I
I
I

I

i

I
I

I

Fig. 27 - Flared Walls are Equal

A07199

A07200

_) (f) Indoor unit piping

@ Connection w_ring

@ Drain hose

_--_

r _f_

J

Fig. 29 - Location of Piping, Hose, and Wiring

3,

Connect condensate drain piping
Observe all local sanitary codes when installing condensate

drains. The condensate may be discharged at a maximum
height of 7-1/8 in, (181 ram) above the unit as long as the

ascending tube is vertical and aligned with drainage flange.
If it is necessary to discharge the condensate from a level
above 7-1/8 in. (181 ram), install an auxiliary water dis-

charge pump and a float valve. A float valve is recommen-
ded to stop the compressor if there is a fault at the auxiliary

pump.

A08364

18

a.Usehardpolyvinylchloride(PVC)pipematerialwith

nominalIDof1in.toconnectatdrainline.Toensure
correctcondensatewaterflow,thepipeshouldhavea
gradientof2%withoutobstruction.SeeFig.30

PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.

The drain tube extension must be securely fastened to the
condensate drain. Failure to do so could result in condensate

water dripping on to the floor.

b. A trap of at least 2 in. (51 mm) in depth should be made

to prevent unpleasant odors from reaching the room.

c. Insulate condensate pipe with condensation proof mater-

ial such as polyurethane, propylene, or neoprene of 3/16
in. to 3/8 in. thickness.

4. Complete Control Wiring
a. Route the control wiring through the 7/8 in. knockouts

on the left or right hand side of the external control box
(low voltage side).

b. Connect R and Y wires to the terminal block for cooling

only units (40KMC) and heat pump units (40KMQ) that

are matched with the 38HDF outdoor units. See Fig. 24.

c. Connect the R, Y, O, G, DT, A, and B wires to the

(PGB-1) 1 terminal on the 40KMQ heat pump indoor
units. See Fig. 25.

5. Perform any modifications required for the accessory user

interface. Three types of user interface can be used with the
unit: Wall mounted wired control, Wireless remote control

and Zone Manager.

a. Wall Mounted Remote Control

The unit comes ready from the factory for use with a
wall mounted wired control. Refer to the installation

instructions of the wired remote control for additional
information. The wall mounted wired control connects

to terminals P, G, and C located in the external control
box. See Fig. 24 and Fig. 25. If there is a desire to

control multiple units (up to 6) from one wired remote
control, the units should be wired as shown in Fig. 31.

Fig. 30 - Condensate Drain Pipe

UNIT1 UNIT

A07191

(9

J

5

__J5

*@

UNIT 3 ---

(9 ®

!

UP TO 6 UNITS

(9

A - MAIN BOARD

(9 " WIRING KIT 33MC9005
(9 " BLACK

(9 " RED

(9 - WHITE

* 100 ohm Resistor

Fig. 31 - Multiple Unit Control Wiring

19

A09513

b. Wireless Remote Control

The unit is factory equipped with a wire harness that has one end connecting to the receiver board (Display PCB) and the other
end is loose. See Fig. 32.

4---- Loose

5 4J_ 2 1 1S

1_12131_1511_12131_151A

I Jll I I J8 I I Js I

Fig. 32 - Wire Harness

To modify the unit for use with wireless remote do the following:

a. Remove the cover of the Internal Control Panel to get access to the microprocessor board. See Fig. 33.

End

A09547

®

INTERNAL CONTROL PANEL INTERNAL CONTROL PANEL

40KMC018 40KMC024-036

@ Capacitor [] Fan connector
@ GMC board [] LED/RECEIVER connector

@ Electric heater board

(only on modets with etectdc heater) [] Float connector
@ Transformer [] Pump connector
@ Holes for fixing panel in position [] Louver connector
@ Emergency push-button

Fig. 33 - Internal Control Panel

b. Unplug the J5 connector (A) from the board (see Fig. 32).

c. Plug the Loose end (B) into the J5 Connector on the board

d. Reinstall the cover of the internal control panel

®

40KMQ018-036

A07180

20

If you have two units installed in the same space and they need to
work independently, the remote controls and the units need to be

configured as follows:

Unit Configuration

Turn the unit off by pressing the IQL). Press and hold the/_ and
=_/_/IIbuttons of the remote control for more than 5 seconds. The

display will be cleared and the time segments will display the first
configuration item (rAdr=remote address) and the temperature

segments will display the default value of this configuration item
(ab=control of both indoor units). Press A and V to change the

default value to the new value of (a) or (b). Press the ;'/_ button to

transmit the new configuration to the unit. Press the 1_ button to
leave the configuration menu.

A

,,..a.,,

Remote Control Configuration

A

Turn the unit off by pressing the IQL)button. Press and hold the

and buttons for more than 5 seconds. The display will be
cleared and the time segments will display the first configuration

item (CH=remote address) and the temperature segments will
display the default value of this configuration item (Ab=control of

both indoor units).

Press A and V to change the default value to the new value of (a)

or (b). Press the ;'/_ button to transmit the new configuration to the

unit. Press the 1_ button to leave the configuration menu.
NOTE: When 30 seconds have elapsed and no buttons have been

pressed, the remote control will automatically exit the
configuration menu and resume its normal operation.

A wall mounted control or zone manager can be used to control a
unit or multiple units.

v

Zone Manager

If a Zone Manager is required, the following steps should be
performed at the same time the indoor control and power wiring

are being connected:

a. Remove the cover of the Internal Control Panel to get

access to the microprocessor board. See Fig. 33.

b. Plug the communication board to the J8 as shown in

Fig. 34.

c. Connect one end of the wire harness supplied with the

Zone Manager to the communication board.

d. Route the other end of the wire harness along the

voltage control to the back of the unit.

e. Connect the other end of the wire harness to the field

supplied wiring that will be connected to the zone man-

ager as shown in Fig. 34 (shielded cables are required.

Refer to Zone Manager Installation Instructions).

f. Reinstall the cover of the internal control panel.

@

®

J8

6

/

(_) Main board
0 Communication board (suppl}ed with the kit)

0 5-cable wiring (supplied with the kit)
@ Auxiliary terminal block (supplied with the kit)

0 Wiring by the installer
(_) Zone Manager terminal block (mounted on the Zone Manager)

O Indoor unit

Fig. 34 - Wiring for Zone Manager

WHITE

GREY

®

® ±

®

®

,.-.\

-F-. _

-- t---- ,1-i

;I

"' ]

! ,,

r

I

ii i i i L,,II®

Zcx_

t.0 t.O

A09514

21

6. Conduct a final check to make sure that the unit is level

7. Install the Grille and Frame Assembly
a. Carefully unpack the assembly and check for damage

sustained in transport.

b. Attach the assembly to the unit by using the two hooks.

See Fig. 35.

Frame support brackets

Fig. 35 - Attach Frame Assembly

c. Tighten the factory supplied screws to fix the frame in

position. See Fig. 36.

d. Link the electrical connectors and insert the wires in

cable clamp. See Fig. 36.

@ Safety cord
(2) Cable clamp

@ Power connection

cables from unit

@ Power connection

cables from frame

@ Frame support

screws

Fig. 36 - Fix Frame in Position

e. Ensure that the frame is not distorted by excessive tight-

ening, that it is aligned with false ceiling and that there
is seal between the air inlet and outlet. See Fig. 37.

////////////////////

A. Gasket '%"

A09548

A09549

NOTE: Gasket "A" prevents return air from mixing with the
supply air and gasket "B" prevents the supply air from leaking
into the ceiling void. Once the unit is mounted in the ceiling,
the gap between the unit frame and false ceiling must not be

more than 3/16 in. wide.

INSTALLATION OPTIONS

The 40KMC,KMQ units can be used to cool an adjacent room or
for fresh-air ventilation. Plan the installation carefully. Measure
carefully and follow acceptable building practices and the National

Electric Code (NEC).
Fresh Air Intake

1. Using Fig. 38, locate and remove the factory-installed insu-
lation from the side of the unit where the pre-punched

knockouts are located.

2. Remove the pre-punched knockouts for fresh air intake.
Refer to Fig. 38. Be careful not to damage internal parts
such as the heat exchanger coil.

3. If installing a 40KMC018 unit, install baffle. Refer to Fig.

38.

4. Install ductwork using field-supplied, insulated flex duct, or
insulated sheet metal suitable for working temperatures up
to 140°F (60°C). Conduits can be of flexible polyester

(with spiral core) or corrugated aluminum, externally
covered with anti-condensate material (fiberglass from 1/4

in. to 1 in. thickness).

5. Use Fig. 39 to determine the allowable static pressure loss
for the ductwork airflow. The ductwork design must not ex-

ceed this value or the job airflow requirements will not be
met.

IMPORTANT: Ventilated air must not exceed 10% of the total
airflow or problems with operation will result. If the ventilated

air surpasses 10 % of the total airflow, a field supplied primary
air treatment system with separate deflectors is recommended.

6. Use a field-supplied fan if airflow does not meet job re-
quirements. The field-supplied fan motor for outside air in-

take nmst be controlled by a bipolar ON/OFF switch with
safety fuses.

7. Install an air inlet grille with filter inspection port to prevent
dust and dirt from entering and fouling the indoor unit heat

exchanger. Filter installation also makes the installation of a
duct closing damper during shutdown periods unnecessary.

8. All non-insulated ducts must be covered with anti-con-
densate insulation (such as expanded neoprene, 1/4 in.

thickness).

Conditioned Air Supply to Adjacent Room -- Air supply to an
adjacent room requires that the outlet corresponding with the duct

is closed, using the air supply outlet obstruction accessory kit.
An air inlet grille must be fitted (if possible near the floor) between

the air conditioned room (where the unit is situated) and the

adjacent room or, alternatively, the door nmst be undercut, as

shown in Fig. 38. The duct lengths can be calculated in accordance
with Fig. 39, also taking into account the pressure drop through air

diffusers and fresh air filters.
IMPORTANT: DO NOT use active carbon or electrostatic

filter kits for ducts towards adjacent rooms.

Fig. 37 - Gasket Location

A09550

22

®

NOTE: Dimensions in ( ) are in mm.

Air intake grille

®

® ®

Unit 40KMC018 40KMQ01824, 03036

OA 5-29/32"(150 mm) 5-29/32"(150 mm)

B 4-3/4"(120 ram) 4-3/4"(120 ram)

O C 2-3/4"(70 mm) 3-15/16"(100 ram)

(_) Wall
® Undercut door

@ Wall-fitted grille
(_) Door-fitted grille

Fig. 38 - Installation Options

40KMC024, 03036

<

®

0 Duct connection flange
(_) Clip
® 1/4" (6 ram) neoprene gasket

(_ Insulated flexible duct
(_) Fresh air intake

(_) Conditioned air supply to an

adjacent room
® Polystyrene partition
® Baffle (40KMC018 Only)

(_) Frame

@ @

i

A09551

0.18

0.16

0.14

0.12

0.1

,¢

40KMC,KMQ 03036

0.08

0.06

0.04

0.02

x

uJ

40KMC018,024
40KMQ01824

0

0

NOTE: When two louvers are closed, the fresh airflow towards the adjacent room
is 50% higher than when one louver is closed (with equal static external pressure)

Fig. 39 - Pressure Drop for Conditioned Air Supply to an Adjacent Room (one louver closed)

50

1O0 150

Airflow (cfm)

Supply air duct to adjacent room

200 250

/ \

\ .i

\

/

A07178a

23

START-UP

Preliminary Checks

1. Make sure all wiring connections are correct and they are
tight.

2. Field electrical power source must agree with unit name
plate rating.

3. Check that all barriers, covers, and panels are in place. En-
sure that the filters and return-air grilles on the indoor unit

have been installed and that the discharge louvers are posi-
tioned correctly.

4. All service valves must be closed.

5. On units with crankcase heaters, ensure belly-band heaters
are tight around the compressor.

6. Check that the condensate drain plug is in place and prop-
erly sealed.

Evacuate and Dehydrate the System

[]NIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.

Never use the system compressor as a vacuum pump.

Refrigerant tubes and indoor coil should be evacuated using the
recommended deep vacuum method of 500 nficrons, the alternate

triple evacuation method may be used if the procedure outlined
below is followed. Always break a vacuum with dry nitrogen.

[]sing Vacuum Pump

1. Completely tighten flare nuts A, B, C, D, connect manifold
gage charge hose to a charge port of the low side service

valve. (See Fig. 40.)

2. Connect charge hose to vacuum pump.

3. Fully open the low side of manifold gage. (See Fig. 41)

4. Start vacuum pump

5. Evacuate using either deep vacuum or triple evacuation
method.

6. After evacuation is complete, fully close the low side of
manifold gage and stop operation of vacuum pump.

7. The factory charge contained in the outdoor unit is good for
up to 25 ft. (8 m) of line length. For refrigerant lines longer

than 25 ft (8 m), add 0.3 oz. per foot of extra piping up to
the maximum allowable length.

8. Disconnect charge hose from charge connection of the low
side service valve.

9. Fully open service valves B and A.

10. Securely tighten caps of service valves.

Outdoor Unit Refrigerant

Low Side

I I /_2QB High Side

Service Valve

Fig. 40 - Service Valve

Indoor Unit

A07360

Manifold Gage

500 microns "_ "

_'_r'-High side valve

Low side valve _['_

Charge hose--_

,_ Charge hose

Vacuum pump

\

Low side valve

A07361

Fig. 41 - Manifold

Deep Vacuum Method
The deep vacuum method requires a vacuum pump capable of

pulling a vacuum of 500 nficrons and a vacuum gage capable of

accurately measuring this vacuum depth. The deep vacuum method

is the most
liquid water.

if)
Z
O

O

_ositive way of assuring a system is free of air and

See Fig. 42)

LEAK IN
SYSTEM

,VACUUM TIGHT

TOO WET
TIGHT

DRY SYSTEM

1 2 3 4 5 6 7

MINUTES

A95424

Fig. 42 - Deep Vacuum Graph

Triple Evacuation Method
The triple evacuation method should only be used when vacuum

pump is only capable of pumping down to 28 in. of mercury
vacuum and system does not contain any liquid water.

Refer to Fig. 43 and proceed as follows:

1. Pump system down to 28 in. of mercury and allow pump to
continue operating for an additional 15 nfinutes.

24

2. Close service valves and shut off vacuum pump.

3. Connect a nitrogen cylinder and regulator to system and
open until system pressure is 2 psig.

4. Close service valve and allow system to stand for 1 hr. Dur-
ing this time, dry nitrogen will be able to diffuse throughout

the system absorbing moisture.

5. Repeat this procedure as indicated in Fig. 43. System will
then be free of any contaminants and water vapor.

IEVACUATEI

lBREAKVACUUMWITH DRYNITROGENI

[EEEI

IEVACUATEI

IBREAKVACUUM WITH DRY NITROGENI

[EEEI

IEVACUATEI

[ CHECK FORTIGHT, DRY SYSTEM I

(IF IT HOLDS DEEP VACUUM)

I RELEASE CHARGE INTO SYSTEM]

A95425

Fig. 43 - Triple Evacuation Method

To Start the Unit:

1. If the outdoor unit is equipped with a crankcase heater, turn
on the indoor and outdoor disconnect switches to supply
power the system 12 hours before starting the system.

2. Release charge into the system by opening (back-seating)
liquid and suction line service valves.

3. Set the wireless remote control or wired remote control be-
low ambient temperature. Operate the unit for 15 minutes.

4. Refer to Table 6 to determine if additional charge is re-
quired. Also, if you have a long line application, refer to the

Duct Free Long Line Application Guide to determine the
additional charge that is required beyond 25 fl (7.6 m).

5. Calculate the total additional charge required and weigh in.

6. Charge should be added as liquid (not gas) slowly and care-
fully to low side to avoid liquid slugging.

7. Start unit with operation test. In test mode the unit will run
in cooling and heating (on heat pumps) regardless if there is

demand or not.

Set Unit in Test Mode Using Wireless Remote
Turn power on to the unit. Insert batteries in remote control. Press

the A and the =_/k_/11buttons on the remote control for 5 seconds.
The remote control will be cleared and the time segment will

display the Srcl=service test mode. Press the _'/_ button to
transmit the service test signal to the unit. After the test has

completed press the _ button to leave the test menu.
NOTE: When 30 seconds have elapsed and no buttons have been

pressed, the remote control will automatically exit the test menu
and resume its normal operation.

Set Unit in Test Mode Using Wired Control

There is a hidden service test mode that is initiated through a
combination of button presses when the remote is off. The

following combination must be pressed within a 6 second period:
"DOWN-FAN-UP -FAN-MODE"

Once in service test mode, the service test mode message will be

sent and "Sr" will be displayed in the temperature icons until the
"DOWN" button is pressed.

During Service Test mode, all the icons are off. the only button
that is active is the "DOWN" button.

To cancel Service Test mode, press the "DOWN" button to send a
normal message with "OFF" mode.

Service Test mode automatically times out after 30 minutes and the

remote will operate normally.
Test Mode Sequence of Operation

Once unit is in TEST MODE, all remote control messages are

ignored except for a message to turn the unit OFF. Buzzer will
beep twice.

When in TEST MODE, the unit will operate as follows:

• The unit Status (Green) and Timer (Yellow) LEDs will
blink every 2 seconds (see Fig. 45).

• Indoor fan will operate according to user - selected
speed. IfAuto fan is selected, the fan will run in High

speed

• Cooling only system

-- Unit will operate in cool mode with demand

-- Louver will operate according to user - selected
position or in cool position if louvers are set to

Auto

• Heat pump system

-- Unit will run in cooling mode with demand for 3
minutes

-- Unit will run in heat pump mode with demand for
2 minutes or until indoor coil temperature is

greater than 104°F (40°C). If coil temperature
reaches 104°F (40°C), the unit will run in cool

mode until test mode is exited.

-- Louver will operate according to user - selected
position or in cool/heat position if louvers are set

to Auto.

• Following will cancel Test Mode:

-- Unit is turned off by controller

-- Power is cycled during Test Mode

-- 30 minutes elapsed

-- Fail Mode

8. Visually check that the condensate is being discharged from
the unit. If the unit is running in heating mode, the condens-

ate needs to be checked and the following needs to be per-
formed:

a. Remove grille and frame from the unit.

b. On the opposite side of the drain connection, insert a

water bottle up into the fan coil unit and fill drain pan.

See Fig. 44. Water must flow regularly with condensate

pump energized. If not, check the pipe slope or see f
there are any pipe restrictions.

NOTE: The unit is equipped with a safety float switch
to de-energize the compressor if the drain pan water

level gets too high.

25

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in equipment
damage or improper operation.

Operating the system with dirty air filters may damage the
indoor unit and can cause reduced cooling performance,

intermittent system operation, frost build-up on the indoor
coil, and blown fuses. Inspect and clean or replace the air

filters monthly.

A09552

Fig.44- Inserting Water Into Drain Pan

PERSONAL INJURY AND/OR UNIT DAMAGE
HAZARD

Failure to follow this caution may result in personal iniury

and/or equipment damage or improper operation.

Never operate unit without a filter or with grille removed.

SERVICE AND MAINTENANCE

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal
iniury or death.

Before installing, modifying, or servicing system, main
electrical 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.

Remove unit grille, filter, and condensate pan for cleaning,
lubricating, or replacing parts.

Minimum Maintenance

1. Check, clean, or replace airfilter each month or as required.

2. Check cooling coil, drain pan, condensate trap, and con-
densate drain pan each cooling season for cleanliness. Clean

as necessary.

3. Check fan motor and wheel for cleanliness each heating and
cooling season.

4. Check electrical connections for tightness and controls for
proper operation each heating and cooling season. Service

as necessary.

Service

TO CLEAN OR REPLACE AIR FILTERS

1. Place a plastic sheet on the floor to catch any water that may
spill from drain pan.

2. Slide filter out.

3. Vacuum clean or wash filter with soapy water. Rinse and let
air dry. If filter needs replacing, filters are available from a

local dealer.

TO CLEAN OR REPLACE DRAIN PAN

1. Place a plastic sheet on the floor to catch any water that nmy
spill from drain pan.

2. Remove the air intake and distribution assembly. Remove
the condensate water in the drain pan by pulling out the rub-

ber drain plug and letting water drain into a 3-gallon buck-

et.

[]NIT DAMAGE HAZARD

Failure to follow this caution may result in personal injury
and/or equipment damage or improper operation.

Do not use a screw driver to pry drain pan out of assembly.

3. Remove screws holding the drain pan. Carefully hold the
drain pan to remove it from the assembly.

4. Re-install the drain pan using the appropriate number of
screws. Center and align the metal fan inlet orifice with the

fan. Ensure the fan spins freely.

TROUBLESHOOTING

FAULT CODE -- Once a failure occurs with the indoor unit in
operation, the green LED on the indoor unit flashes at intervals of

0.5 seconds. The fault code is deduced from the number of times
the green LED flashes, blocking unit operation.

Table 14 - Green LED (Indoor []nit Fault)

CODE DESCRIPTION

2 Condensate discharge pump

3 Room air sensor fault
4 Indoor unit coil sensor fault

6* Filter dirty

7 Outdoor unit failure
10 EEPROM corrupt
11 Card serial number damaged

12 Address or zone incomplete
13 Gas flow distributor corrupt

14 Outdoor air thermistor fault

*When code is enabled

[]SING THE EMERGENCY BUTTON -- The Emergency
button is for use by a qualified service technician only. The

Emergency button is for use when the room controller is
inoperative. Use a screwdriver to press the emergency button

through the metal protection grille. See Fig. 45.
Emergency Operation -- When the unit is in the OFF mode and

the Emergency button is pressed for 5 seconds, the unit will
operate as follows:

• Automatic mode

• Temperature preset to 72°F (22.2°C)

• Automatic fan speed

• Louvers set automatically according to the operating mode

• Timer flmction is cancelled

26

• Buzzer beeps

When the unit is ON and the Emergency button is pressed for 5
seconds, the unit will operate as follows:

• The unit is turned off

• Buzzer beeps

When a signal is received by the remote control, the unit operates
accordingly,

Table 15 - Troubleshooting

PROBLEM

Compressor and Fan of the Outdoor

Unit Will Not Start

Compressor Will Not Start, But Out-
door Fan is Operating

Compressor Stops Due to Over-tem-

perature

Compressor Runs Continuously

Frequent Ice-Build-Up on Outdoor

Coil

Discharge Pressure Too High

Discharge Pressure Too Low

Suction Pressure Too High

Suction Pressure Too Low

Outdoor Fan Cycling Due to Over-
Temperature Protection

Unit not energized
Main switch is set to OFF

Main switch fuses are blown
Compressor cycling protection is on

Main power voltage is too low
Electrical connections are too loose or are wrong

Electrical connections of compressor are loose or

wrong

Compressor burnt out; seized or protection device
on

Wrong refrigerant charge in unit (excessive or low)
or air or other non-condensable gasses in the

circuit
Main voltage is too high or too low

Condenser coil obstructed
Outdoor fan off

Wrong indoor unit thermistors
Refrigerant circuit clogged

Reversing valve faulty on heat pump models

Expansion device clogged or covered with ice

Unit selected is too small for application require-
ments

Indoor temperature setting too low or too high
Outdoor unit fan faulty

Air or other non-condensable gasses in the cir-

cuit

Obstructions at air intake or dirty indoor unit filters

Outdoor fan is stopped
Outdoor coil dirty or obstructed

Condenser fan faulty
Indoor temperature setting too low or too high

Air or other non-condensable gasses in the cir-

cuit

Indoor temperature setting too high or too low
Outdoor coil dirty or obstructed

Indoor unit air filter dirty
Indoor temperature setting too high or too low

Reversing valve faulty or internal leak
Indoor temperature setting too high or too low

Evaporator coil covered with ice

Expansion device or suction line clogged
Outdoor fan does not stop during defrost periods

Electrical connection loose
Fan motor burn out

Fan bearing seized

Expansion device clogged or covered with ice

POSSIBLE CAUSE

Fig. 45 - Warning Lamps and Emergency Button

SOLUTION

Check the main power connection.
Check and put it to ON position.

Replace fuses.
Wait for 3 minutes.

Check and set to the correct voltage.
Check and tighten or correct connections.

Check and tighten or repair compressor.

Check for the cause and replace compressor if neces-
sary.

Drain refrigerant, evacuate and recharge.
CAUTION: Do not vent refrigerant to the atmosphere; use
refrigerant recovery equipment.

Check voltage setting and adjust if necessary.
Remove obstruction.

Check cause and resume operation or repair.
Replace thermistors.

Check and remove obstructions.
Replace reversing valve.

Drain refrigerant, evacuate and recharge.
CAUTION: Do not vent refrigerant to the atmosphere; use
refrigerant recovery equipment.

Contact a qualified service technician for a system evalu-
ation.

Check temperature setting.
Replace outdoor fan.

Drain refrigerant, evacuate and recharge.
CAUTION: Do not vent refrigerant to the atmosphere; use
refrigerant recovery equipment.

Remove obstruction and/or clean filter.

Check cause and repair.
Clean or remove obstructions.

Replace condenser fan.
Check temperature setting.

Drain refrigerant, evacuate and recharge.
CAUTION: Do not vent refrigerant to the atmosphere; use
refrigerant recovery equipment.

Check temperature setting.
Clean or remove obstructions.

Clean filter.
Check temperature setting.

Replace reversing valve.
Check temperature setting.

Air circulation on the evaporator not sufficient; check and
repair.

Check and repair.
Check electrical parts.

Check connections.
Replace.

Check and repair.
Drain refrigerant, evacuate and replace.

CAUTION: Do not vent refrigerant to the atmosphere; use
refrigerant recovery equipment.

/

A09553

/

27

Copyright 2010 Carrier Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 12/10

Manufacturer reserves the right to change, at any time, specification8 and design8 without notice and without obligations,

28

Catalog No: 40KMC-Q-3SI

Replaces: 4OKMC-Q-2Sl