Carrier 40QA024-060 User Manual
40QA024-060
Ceiling-Suspended Fan Coil Units
Installation, Start-Up and Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Step 1 — Complete Pre-Installation
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
• UNPACK UNIT
• INSPECT SHIPMENT
• BEFORE INSTALLATION
Step 2 — Select Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 3 — Mount Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• WOODEN STRUCTURE
• NEWLY BUILT CONCRETE SLAB
• METAL STRUCTURE
• PREVIOUSLY BUILT CONCRETE SLAB
• TO MOUNT UNIT
• TO INSTALL THERMOSTAT
Step 4 — Connect Refrigerant Piping. . . . . . . . . . . . . . . . 7
Step 5 — Connect Condensate Drain Line . . . . . . . . . . .8
Step 6 — Make Electrical Connections . . . . . . . . . . . . .10
Step 7 — Install Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 12
Step 8 — Make Connections Between
Indoor and Outdoor Units . . . . . . . . . . . . . . . . . . . . . . . .15
• CHECK ACCURATOR METERING DEVICE
• COOLING ONLY SYSTEMS
• HEAT PUMP SYSTEMS
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,19
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . .18
Seasonal Changeovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Adjusting Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Operating Mode Memory . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Automatic Operation (Auto.) Mode. . . . . . . . . . . . . . . . . .18
Operating Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
•FAN OPERATION
• COOLING MODE OPERATION
• HEAT PUMP OPERATION
• DEFROST (Heat Pump Only)
• SYSTEM SAFETIES
• SPECIAL OPERATION, HEATING
CLEANING AND MAINTENANCE . . . . . . . . . . . . . . . . 19,20
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Air Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
• REMOVE AIR FILTERS
• CLEAN OR REPLACE FILTERS
Clean Indoor Unit Bottom Panel . . . . . . . . . . . . . . . . . . . .20
Clean Indoor Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clean Outdoor Coil (Outdoor Unit). . . . . . . . . . . . . . . . . .20
Clean Condensate Drains . . . . . . . . . . . . . . . . . . . . . . . . . .20
• CLEAN OR REPLACE DRAIN PAN
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Before Calling for Service . . . . . . . . . . . . . . . . . . . . . . . . . .20
• IF SYSTEM FAILS TO OPERATE
FRESH AIR INSTALLATION OPTION . . . . . . . . . . . . . . . .20
Ventilation-Air Accessory . . . . . . . . . . . . . . . . . . . . . . . . . .20
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . .CL1, CL-2
SAFETY CONSIDERATIONS
Installing and servicing air-conditioning equipment can be
hazardous due to system pressure and electrical components.
Only trained and qualified service personnel should install or
service air-conditioning equipment.
Untrained personnel can perform basic maintenance, such
as cleaning and replacing filters. All other operations should be
performed by trained service personnel. When working on airconditioning equipment, observe precautions in literature and
on tags and labels attached to unit.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for brazing operations. Have fire
extinguisher available. Read these instructions thoroughly.
Consult local building codes and National Electrical Code
(NEC) for special installation requirements.
Before installing or servicing system, always turn off
main power to system. There may be more than one disconnect switch. Turn off accessory heater power if applicable. Electrical shock can cause personal injury.
INSTALLATION
Installation instructions for fan coil units (Fig. 1) are contained in this manual. Refer to this manual for proper installation of the complete system. Note that the outdoor units are
shipped with installation and service instructions for basic installation of the outdoor section. Be sure to make the connections in Cooling Only Systems and Heat Pump Systems sections on page 15 of this literature so that the unit will operate
properly.
Refer to Table 1 for proper system matches.
Fig. 1 — Ceiling-Suspended Fan Coil Unit
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Ta b 3 d 2 c
Catalog No. 02-40QA0007-SI Printed in U.S.A. Form 40QA-7SI Pg 1 706 3-06 Replaces: 40QA-5SI
Table 1 — System Matches
SYSTEM TYPE INDOOR SECTION NUMBER OUTDOOR SECTION NUMBER
40QAC 38HDR-3,5,6
024* 018
024 024
Cooling Only
Heat Pumps
Heating/Cooling
*Units must be field reconfigured for 11/2 ton (18,000 Btuh) operation. See Before Installation sec-
tion on page 3 for details.
NOTE: Numbers in ( ) indicate quantities when there is more than one fan coil unit in the system.
036 030
036 036
048 048
060 060
40QAQ 38QRR-3,5,6
024* 018
024 024
036 030
036 036
048 048
060 060
40QAQ 38HDR-3,5,6
024* 018
024 024
036 030
036 036
048 048
060 060
Ensure unit operation within the application guidelines
shown in Table 2. When installing the outdoor unit, for cooling
operation when the outdoor-air temperature is below 55 F, the
following accessories are required:
• low ambient kit
• crankcase heater
• winter start kit
• isolation relay (38QRR heat pump units only)
This will provide cooling operation down to 40 F ambient
temperature. For operation down to –20 F ambient temperature, a field-installed wind baffle will also be required.
To complete installation of the system, the following items
must be field-supplied for connection of the indoor and outdoor
units:
• refrigerant piping
• condensate drain piping
• thermostat
• power and control wiring
For some applications, a fresh air intake, power vent fan,
and/or condensate pump kit may be required.
Table 2 — Application Range
COOLING
Maximum Minimum
Indoor Outdoor Indoor Outdoor
95 F DB
71 F WB
Maximum Minimum
Indoor Outdoor Indoor Outdoor
80 F DB
71 F WB
LEGEND
DB — Dry Bulb
WB — Wet Bulb
*This value is for single-zone systems and may be equipped with an
accessory low-ambient control or winter start kit that will allow
operation down to –20 F.
125 F DB 67 F DB
HEATING (Heat Pump Systems Only)
75 F DB
65 F WB
57 F WB
55 F DB –20 F DB
55 F DB*
40 F DB
2
Table 3A — Physical Data, Under Ceiling Cooling Only Units
SYSTEM SIZE 018* 024 030 036 048 060
NOMINAL CAPACITY (tons) 1
NOMINAL SIZE (Btuh) 18,000 24,000 30,000 36,000 48,000 60,000
OPERATING WEIGHT (lb) 108 108 117 117 149 179
MOISTURE REMOVAL WEIGHT
(Pints/Hr)
FINISH GM Motorhome White with Black Trim
REFRIGERANT R-410A
Control (Cooling) AccuRater Control
INDOOR FAN Direct Drive Centrifugal
Rpm...Cfm High 862...500 1050…600 1275...840 1275...840 1435...1200 1275...1600
Rpm...Cfm Medium 690...400 690...400 972...740 972...740 1388...1160 972...1220
Rpm...Cfm Low 552...320 552...320 830...640 830...640 1315...1100 830...1040
High Speed Watts 92 92 282 282 425 564
Motor Quantity 111122
Blowers — No. ...Size (in.) 2...6x8 2…6x8 2…6x8 2…6x8 3…6x8 4…6x8
INDOOR COIL Copper Tube, Aluminum Fin
Face Area (sq ft) 2.2 2.2 2.6 2.6 3.0 4.0
No. of Rows 444444
Fins/in. 14.9 14.9 14.9 14.9 14.9 14.9
Circuits 444488
FILTERS Cleanable
Quantity 445568
AIRSWEEP
Horizontal User select ON/OFF
Vertical Manual
CONTROLS
Control Voltage 24 V
Auto Restart Ye s
Fan Speed High/Medium/Low
Condensate Pump Safety Yes (Accessory)
Indoor Coil Freeze Protection Standard shutoff at 28 F
Filter Change Indication 250 Hours of Indoor Fan Operation
REFRIGERANT LINES
Connection Type Flare
Liquid Line OD (in.)
Vapor Line OD (in.)
Max Line Length For maximum line lengths see condensing unit instructions.
CONDENSATE DRAIN
CONNECTION
CONDENSATE DRAIN SIZE (in.)
*Field reconfigured to 18,000 Btuh (11/2 tons). See Before Installa-
tion section on this page for details.
1
/
2
4.0 7.3 6.0 9.0 13.0 14.5
5
/
8
23345
3
/
1
/8 inch.
8
3
/
4
3
/
4
7
/
8
7
/8†
5
/
8
3
/
4
Pipe Thread (MPT)
† The valve connection size is 7/8 inch. The recommended line size
is 1
Step 1 — Complete Pre-Installation Checks
UNPACK UNIT — Store fan coil unit in the original packaging until it is moved to the final site for installation. When removing unit from carton, lift unit by its 4 corners; DO NOT lift
unit by its plastic parts.
INSPECT SHIPMENT — Upon receipt of shipment, check
fan coil unit for damage. Forward claim papers directly to the
transportation company. Manufacturer is not responsible for
damage incurred in transit.
Check all items; if any item is missing, notify your dealer.
To prevent loss or damage, leave all parts in original packages
until installation.
BEFORE INSTALLATION — Perform the following steps
before installing indoor fan coil unit. Place the indoor unit upside down on the floor, then:
1. Remove side panels by sliding forward, then away
from sides of unit (Fig. 2). Reinstall prior to unit startup.
2. Remove air filters from inlet grilles; then remove and
retain screws securing inlet grilles to indoor unit. Reinstall prior to unit start-up.
NOTE: Dimensions shown in brackets [ ] are in mm.
Fig. 2 — Removal of Mounting Brackets
from Indoor Unit
3
Table 3B — Physical Data, Under Ceiling Heat Pump Units
UNIT SIZE 018* 024 030 036 048 060
NOMINAL CAPACITY (tons) 1
NOMINAL SIZE (Btuh) 18,000 24,000 30,000 36,000 48,000 60,000
OPERATING WEIGHT (lb) 110 110 119 119 151 181
MOISTURE REMOVAL WEIGHT
(Pints/Hr)
FINISH GM Motorhome White with Black Trim
REFRIGERANT R-410A
Control (Cooling) AccuRater Control
INDOOR FAN Direct Drive Centrifugal
Rpm...Cfm High 900…480 1050…550 1275...840 1275...840 1435...1130 1275...1600
Rpm...Cfm Medium 862...400 900…480 972...740 972...740 1388... 975 972...1220
Rpm...Cfm Low 770...320 862...400 830...640 830...640 1315... 820 830...1040
High Speed Watts 92 92 282 282 425 564
Motor Quantity 111122
Blowers — No. ...Size (in.) 2...6x8 2...6x8 2...6x8 2...6x8 3...6x8 4...6x8
INDOOR COIL Copper Tube, Aluminum Fin
Face Area (sq ft) 2.2 2.2 2.6 2.6 3.0 4.0
No. of Rows 444444
Fins/in. 14.9 14.9 14.9 14.9 14.9 14.9
Circuits 444488
FILTERS Cleanable
Quantity 445568
HEATERS (kW) 2.0 2.0 3.0 3.0 4.0 5.0
AIRSWEEP
Horizontal User select ON/OFF
Ver tical Manual
CONTROLS
Control Voltage 24 V
Defrost Method Timed
Dehumidification Ye s
Auto Restart Ye s
Fan Speed High/Medium/Low
Condensate Pump Safety Yes (Accessory)
Filter Change Indication 250 Hours of Indoor Fan Operation
Freeze Protection Indoor coil less than 28 F, resets at 50 F.
REFRIGERANT LINES
Connection Type Flare
Liquid Line OD (in.)
Vapor Line OD (in.)
Max Line Length For maximum line lengths see condensing unit instructions.
CONDENSATE DRAIN
CONNECTION
CONDENSATE DRAIN SIZE (in.)
*Field reconfigured to 18,000 Btuh (11/2 tons). See Before Installa-
tion section on page 3 for details.
1
/
2
4.0 7.3 6.0 9.0 13.0 14.5
5
/
8
23345
TXV
3
/
5
/
8
3
/
4
Pipe Thread (MPT)
†The valve connection size is 7/8 inch. The recommended line size
is 11/8 inch.
8
3
/
4
3
/
4
7
/
8
7
/8†
3. Remove inlet grilles from indoor unit by sliding forward. Reinstall prior to unit start-up.
IMPORTANT: If necessary, reconfigure the 24,000 Btuh
fan coil unit to 18,000 Btuh. Unplug the fan motor at the
control box harness and plug into the 40QA018 marked
connector.
Step 2 — Select Location — Consult local building
codes and NEC for special installation requirements. See Fig. 3
and 4 for unit dimensions and required clearances.
There are several ways the unit may be installed to different
types of ceiling construction. These instructions do not cover
all installation methods. As a typical installation, these instructions focus primarily on mounting the unit to metal in new
construction. Plan the installation carefully before you begin.
Listed below are some guidelines that should be followed
when determining location for the unit.
1. Place unit adjacent to an outside wall if fresh air is
required, ensuring that location allows for complete air
distribution.
2. Locate the thermostat in an area that is not subjected to
drafts or direct sunlight through windows. Locate the
thermostat on an internal wall whenever possible.
3. Allow sufficient clearance for airflow, wiring, refrigerant piping, and servicing unit (Fig. 3 and 4).
4. Make sure the unit is easily accessible to electrical
power.
4
NOTES:
1. Dimensions in [ ] are in millimeters.
2. Direction of airflow.
3. Standard unit clearances are as follows:
•0″ on top and rear
•3″ on left side
•12″ on right side
•36″ on bottom
(When facing unit discharge.)
UNIT
SIZE
024 108 110 4- 2
036 117 119 4-10
048 149 151 5-11
060 179 181 7- 8 2336 7- 3 2211 7- 6
WEIGHT (lb) A B E F G
Cooling Only Heat Pump ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm
15
/161294 3-10 1169 4- 15/81260 — — 1- 95/8549
13
/161493 4- 57/81368 4- 91/21459 — — 2- 11/2648
9
/161817 5- 65/81692 5-101/41783 1- 97/8555 3- 31/16992
5
/82302 1-115/8601 4-119/161512
Fig. 3 — Base Unit Dimensions
5
Fig. 4 — Fan Coil Unit Clearances
5. Run refrigerant piping as directly as possible and avoid
any unnecessary turns or bends.
6. Condensate piping can be directed through the inside
wall to an approved drain or straight outside.
NOTE: The piping hole for condensate line must slope at a
minimum pitch of
1
/4 in. per foot to ensure proper drainage. If
proper pitch cannot be achieved, install accessory condensate
pump at this time.
Step 3 — Mount Unit — Refer to Fig. 4 for clearances
and dimensions. Use mounting template included inside box to
locate mounting bolt holes, piping holes, electrical connections, and accessory outdoor-air intake, if used.
Select proper type of hardware from the guidelines below.
See Fig. 5.
Solid structure in ceiling must be used due to the weight of
the unit.
WOODEN STRUCTURE — Install hanging bolts on a
square wooden piece placed over beams.
NEWLY BUILT CONCRETE SLAB — Install hanging bolts
with inserts, embedded bolts, etc.
METAL STRUCTURE — Install hanging bolts utilizing an
existing angle or by installing a new support angle.
PREVIOUSLY BUILT CONCRETE SLAB — Install hanging bolts with expansion anchor.
TO MOUNT UNIT:
1. Remove mounting bracket and reinstall the 2 hex-head
bolts (factory-supplied) into each side of indoor unit as
shown in Fig. 6. Allow approximately
between bolt head and unit.
3
/8-in. space
Fig. 5 — Fan Coil Unit Mounting Methods
(Hardware is Field-Supplied)
2. Determine installation position, paying particular
attention to piping lengths, wiring connections, clearances, etc. See Fig. 3 for connection locations, Fig. 4
for clearances, and Fig. 7 and 8 for bolt locations.
3. Open knockout if right-side piping connections are
required (Fig. 9), by removing the pre-slit portion in
the rear of the right side panel with a saw or cutter
knife.
4. Mount hanging brackets on ceiling (Fig. 10) for either
concealed or exposed bolt hanging position.
5. Lift the unit into place, and fit the hex-head bolts on
sides of indoor unit into mounting slots of mounting
brackets (Fig. 11). Ensure unit is mounted with a slight
tilt to the right rear side for properly drainage.
6. Tighten indoor unit hex-head bolts securely.
6
Fig. 6 — Installing Hex-Head Mounting Bolts
in Fan Coil Unit
TO INSTALL THERMOSTAT:
If there is at least
3
/8 in. of space between the back of indoor
unit and wall:
1. Route thermostat wires (field-supplied) through slot in
right side or rear panel of indoor unit (Fig. 3).
2. Route wires over refrigerant and drain piping as shown
in Fig. 12.
IMPORTANT: Do not route wires under the piping, or
wires could impede air filter removal.
Step 4 — Connect Refrigerant Piping — Fan coil
units may be connected to outdoor units using field-supplied
refrigerant grade piping. Refer to Tables 3A and 3B for the correct size piping. The length of refrigerant pipe depends on the
unit placement and building structure; run pipes as directly as
possible. For piping requirements over 50 ft of total run, or
more than 25 ft of lift, consult the Residential Long Line Application Guide.
DIMENSIONS (in.)
UNIT SIZE A B C
024 50
036 5813/
048 719/
060 92 87 905/
15
/
16
16
16
46 495/
537/
8
665/
8
Fig. 7 — Fan Coil Unit Hanging Dimensions
DIMENSIONS (in.)
UNIT SIZE B C
024 46 49
036 537/
048 665/
060 87 905/
*Exposed mounting holes.
†Reverse bracket holes (concealed mounting).
8
8
Fig. 8 — Mounting Included with
Fan Coil Unit
571/
701/
571/
701/
5
/
8
2
4
8
DO NOT BURY MORE THAN 36 IN. OF REFRIGERANT PIPE IN THE GROUND. If any section of pipe is
buried, there must be a 6-in. vertical rise to the valve con-
8
2
4
8
nections on the outdoor unit. If more than the recommended
length is buried, refrigerant may migrate to the cooler, buried section during extended periods of unit shutdown, causing refrigerant slugging and possible compressor damage at
start-up.
To connect piping:
1. Install insulation. It is extremely important that all
refrigerant lines and the metering device be insulated
on heat pumps and multi-splits. On cooling only units,
the liquid line may be left uninsulated. Use any acceptable heat resistant closed-cell foam insulation (mini-
3
mum
/8-in. wall thickness). When insulating piping,
cap ends and slide insulation over the piping. Insulation can also be cut and placed over piping.
2. Run liquid and gas refrigerant piping.
a. Run pipes as directly as possible, and avoid any
unnecessary turns and bends.
b. Suspend refrigerant pipes so that the insulation is
not damaged and vibrations are not transmitted to
the structure.
c. Leave slack in the refrigerant pipe between the
structure and the unit to absorb vibrations.
d. A piston is shipped in the factory-installed meter-
ing device body (Fig. 13) with the indoor unit. Use
Tables 4A-4C to verify that you have the required
piston size for the system being installed.
IMPORTANT: The metering device is factoryinstalled and only needs to be replaced for long line
applications or if the system combination requires it.
See Tables 4A-4C. See Fig. 13.
Fig. 9 — Removing Rear Knockout in Side Panel
if Right-Side Piping Connection is Used
e. For special applications such as long lines or raised
elevations, consult the Residential Long Line
Application Guide for specific system requirements. The arrow on the metering device body
must face away from the indoor coil.
7
f. Refer to the outdoor unit Installation, Start-Up and
Service Instructions for additional information.
g. Install a factory-supplied filter drier near the out-
door unit. On heat pump systems, a bi-flow filter
drier must be used.
3. Insulate and caulk wall openings to reduce air infiltration and refrigerant pipe vibrations on structure.
4. Evacuate piping, if necessary. If either refrigerant piping or the indoor coil is exposed to atmospheric conditions, it must be evacuated to 1000 microns to
eliminate contamination and moisture in the system.
Step 5 — Connect Condensate Drain Line —
Observe all local sanitary codes when installing condensate
drains. Refer to Fig. 3 and 14 for drain pipe connection from
indoor unit.
1. Use hard polyvinyl chloride (PVC) pipe material with
nominal ID of
insulation
exposed piping inside the conditioned space.
3
/4 in. to connect at drain line. Use pipe
1
/4-in. thick, such as Armaflex insulation, on
Table 4A — Piston and Charge Combinations — Cooling Only Systems
2. To ensure regular flow of condensate water, the drain
pipe should be pitched toward an open drain or sump
at a downward slope of at least
1
/4-in. per ft.
3. Attach plate with screws under piping hole.
4. Attach drain pipe with nylon wire tie passing through
hole (Fig. 15).
NOTE: Do not fasten nylon wire ties tight enough to
deform the insulation, as this affects its performance.
5. Insulate condensate drain line(s) that are located in or
above an occupied area with a condensate-proof material such as polyurethane or neoprene.
6. Install an external trap at the end of the condensate
line.
NOTE: Should the installation require one, a condensate pump may be ordered as a field-installed
accessory.
COOLING
INDOOR UNIT SIZE
024
036
048 048 80 12.2
060 060 90 12.5
OUTDOOR UNIT
38HDR
018 57 7.0
024 57 7.75
030 65 10.1
036 70 8.9
PISTON
SIZE
CHARGE (lb)
Table 4B — Piston and Charge Combinations — Heat Pump Systems
HEAT PUMP
INDOOR UNIT SIZE
024
036
048 048 82 73 12.2
060 060 —* 80 12.8
*Size 060 indoor heat pump systems use a TXV (thermostatic expansion valve), part no. EA36YD250.
OUTDOOR UNIT
38QRR
018 49 40 7.5
024 55 43 7.8
030 65 55 12
036 70 63 13
PISTON SIZE
INDOOR
PISTON SIZE
OUTDOOR
CHARGE (lb)
Table 4C — Piston and Charge Combinations — Heat and Cool Systems
HEAT PUMP
INDOOR UNIT SIZE
024
036
048 048 80 12.2
060 060 —* 12.5
*Size 060 indoor heat pump systems use a TXV (thermostatic expansion valve), part no. EA36YD250.
OUTDOOR UNIT
38HDR
018 57 7.0
024 57 7.75
030 65 10.1
036 70 8.9
PISTON
SIZE
CHARGE (lb)
8
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