Carrier BK User Manual

Installation, Start-Up an

Service Instructions

(For Use in High Wall Applications)

CONTENTS

Page

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

GENERAL .................................. 1,2

INSTALLATION ............................. 2-13

Step 1 - Complete Pre-lnstallation Checks .... 2

• UNPACK UNIT

• INSPECT SHIPMENT

Step 2 - Select Location ..................... 2

Step 3 - Mount Mounting Bracket on Wall .... 3

Step 4 - Mount Outdoor Section ............. 9

Step 5 - Connect Refrigerant Piping ........ I0

• RIGHT REAR AND BOTTOM PIPING CONNECTIONS

• RIGHT SIDE PIPING CONNECTIONS

• LEFT SIDE PIPING CONNECTIONS

• ALL TYPES PIPING CONNECTIONS

Step 6 - Make Piping Connections .......... 10

Step 7 - Connect Condensate Drain Line .... ll

Step 8 - Make Electrical Connections ....... 11

• INDOOR SECTION WIRING

• OUTDOOR SECTION WIRING

Step 9 - Install Fan Coil Unit Onto

Mounting Bracket ......................... 13

START-UP ................................ 14-17

40QN Control System ....................... 14

Wireless Remote Controllers ................ 14

After Extended Shutdowns .................. 14

Seasonal Changeovers ...................... 14

To Turn the Unit On and Off ................. 14

Adjusting Airflow ........................... 14

Operating Mode Memory .................... 14

Automatic Operation (Auto) Mode ............ 14

Operating Fault Diagnosis ................... 15

Microprocessor Control Operation ........... 15

CLEANING AND MAINTENANCE ............ 18-19

Lubrication ................................. 18

To Install or Replace Remote Controller

Batteries ................................. 18

To Set the Current Time ..................... 18

To Remove and Clean or Replace Air Filters .. 18

• TO REMOVE AIR FILTERS

• TO CLEAN OR REPLACE FILTERS

To Clean Indoor Unit Front Panel ............ 19

To Clean Indoor Coil ........................ 19

To Clean Outdoor Coil (Outdoor Unit) ........ 19

To Clean Condensate Drains ................. 19

SERVICE ................................... 20

Diagnostic Codes ........................... 20

System Tests ............................... 20

• THERMISTOR TESTS

• COMPRESSOR FAILURE

• REVERSING VALVE FAILURE (38BK Only)

38AN,BK

with 40QN009,012

Cooling Only/Heat Pump Systems

Page

System Safeties and Interlocks .............. 20

• INDOOR FAN FAILURE

• COMPRESSOR SHORT-CYCLING PROTECTION

• INDOOR COIL FREEZE PROTECTION

• INDOOR COIL HIGH-TEMPERATURE PROTECTION

TROUBLESHOOTING ...................... 20-27

START-UP CHECKLIST ............... CL-I, CL-2

SAFETY CONSIDERATIONS

Installing and servicing air-conditioning equipment can be

hazardous due to system pressure and electrical compo- nents. Only trained and qualified service personnel should

install or service air-conditioning equipment.

Untrained personnel can perform basic maintenance func-

tions such as cleaning coils and filters and replacing filters. All other operations should be performed by trained service

personnel.

When working on air conditioning equipment, observe pre-

cautions in the 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. Before installation, read these in-

structiens thoroughly. Consult local building codes and Na- tional Electrical Code (NEC) for special installation

requirements.

Electrical shock cancause personal injury or death. Be- fore installing or servicing system, be sure to turn off

main power to system. There may be more than one dis-

connect switch. Turn off indoor fan coil power as applicable.

GENERAL

The Carrier 40QNHOI 2 heat pump high wall fan coil unh

(Fig. 1) comes with supplemental electric heat (40QNE009 heat pump fan coil unit does not have electric heat). If your

application requires heating, heat pump units must be used both outdoors and indoors. See Table 1 for recommended

system combinations.

The matched cooling and heat pump systems consist of an

outdoor section (condensing unit or heat pump) and an in- door section (fan coil). The outdoor section (38AN or 38BK) is installed alongside the building structure. It can also be

installed on a flat roof, deck, or on an apartment building balcony. The indoor section (40QNB009,012 or 40QNE009,

40QNH012) is mounted high on an interior wall that is con- venient for piping connection to the outdoor section. Two

sizes are available: 9,000 and 12,000 Btuh cooling capaci-

ties. See Fig. 1 for system components, Table 1 for system

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

Book 1 4 PC 111 Catalog NO. 535-848 Printed in U.S.A. Form 38A,BI40Q-1SI Pg 1 5-99 Replaces: 53AN,BK-1SI

combinations, and Table 2 for application range. Refer to this manual for proper installation of the complete system.

Refer to Table 1 to make sure the correct indoor unit is in- stalled with the correct outdoor unit. Be sure the unit will be

operated within the application guidelines shown in Table 2. When installing the 38AN or 38BK unit, it is important to note that for cooling operation when the outdoor air tem-

perature is below 55 F, it is necessary to equip the outdoor unit with the low-ambient accessory.

To install this unit you will need:

1 40QNB or 40QNE/H Fan Coil unit with standard wire-

less remote controller and indoor unit wire

1 -- 38AN or 38BK Outdoor Unit 1 -- Low-Ambient Kit (if required for your application)

NOTE: Field-supplied wire, drain pipe, refrigerant tubing, etc., are also required to install unit.

The installation materials provided are for use on instal-

lations where the indoor section is mounted to gypsum wall board with wall studs. Other types of applications require field-supplied mounting hardware. Be sure to follow all in-

stanation instructions in this manual carefully in order to achieve proper unit operation, and be sure that you have all of the

required parts before beginning installation.

Note that the cooling only and heat pump systems utilize

a microprocessor control system to deliver optimum levels of comfort and efficiency. Refer to Microprocessor Control

Operation section on page 15 for details.

Table 1 -- System Combinations for Indoor

and Outdoor Units

SYSTEM UNIT UNIT

HighWall Cooling Only 40QNB009 38AN009

HighWail Hea_Pump 40QNH012 38BK012

NOTE:Acoolingonlyoutdoorunitmaynotbe matchedwitha heat pumpindoorunit.a heatpumpoutdoorunitmaynotbe matchedwith

a coolingonlyindoorunit.Donotmismatchsystems.

INDOOR OUTDOOR

40QNB012 38AN012 40QNE009 38BK009

INSTALLATION

Step 1 -- Complete Pre-lnstallation Checks

UNPACK UNIT(S) Store unit(s) in original packaging until moved to the final site for installation. When removing unit from carton, lift by its 4 comers. Note that there is a

plastic bag containing mounting screws taped to the mount- ing bracket.

INSPECT SHIPMENT -- Upon receipt of shipment, in- spect unit (Fig. 1) for damage. Forward claim papers di-

rectly to the transportation company. Manufacturer is not re- sponsible for damage incurred in transit.

Check all items (see Table 3), and if any item is missing,

notify your Carrier distributor. To prevent loss or damage, leave all parts in the original packages until installation.

NOTE: The expansion device is located in outdoor unit. Step 2 -- Select Location -- Consult local building

codes and NEC for special installation requirements. NOTE: There are several ways the unit may be installed in

different types of wall construction. These instractions do not cover all installation methods. As a typical installation,

these instructions focus primarily on mounting the unit to wall studs in new construction.

Plan your installation carefully before you begin. Listed

below are some guidelines to follow when determining a lo- cation for the unit:

1. Center unit (horizontally) on the wall selected.

2. Allow sufficient space for airflow clearance, wrong, re- frigerant piping, and servicing the unit. See Fig. 2-4.

3. Place the unit so it faces normal location of room occupants.

Table 2 -- Application Range

COOLING

Maximum Minimum

Indoor I Outdoor Indoor Outdoor

95 F DB ] 115 F DB 67 F DB 55 F DB*71 F WB 57 F WB

HEATING

Maximum Minimum

Indoor Outdoor Indoor Outdoor

80FDB 75FDB 55FDB 0°FDB

71 F WB 65 F WB

LEGEND

DB -- Dry Bulb

WB -- Wet Bulb "Unit may be equipped with a low-ambient control that will allow op-

eration down to -20 F.

TYPICAL FAN COL UNIT

TYPICAL OUTDOOR UNIT

Fig. I -- Typical Cooling Only/

Heat Pump System

m 8 "....._

36"

*Aclearanceof 31,_"istheabsoluteminimum.Aclearanceof 10"is

recommended.

NOTE: Remove unitfront cover for control box access.

Fig. 2 -- Minimum Required Fan Coil Unit

Clearances

4. Select walls that are: a. Strong enough to support the weight of the unit (see

Tables 4A-4D for unit operating weight).

b. Accessible to convenient condensate drainage. c. Free of obstacles that may block air circulation to the

fan coil.

d. Outside walls (if pussible) to make piping easier.

5. Place top of fan coil unit as high on wall as possible, mak- ing sure that unit is at least 31Ain. down from ceiling to

permit proper airflow (the recommended clearance is

10 inches). Also, make sure that the unit is not placed

directly over anything that would prevent filter removal or block airflow.

6. Make sure units are easily accessible to electric power.

7. Refrigerant piping can enter tbe unit through the prepunched holes. Refrigerant piping can run down along the wall, to

the right or lef_ along the wall, straight through the wall,

or into the wall (recommended location: right rear). See Fig. 5. Once the piping is through the wall, it can run

inside walls, in ceilings, between floors, or straight to the outside. See Fig. 6 for maximum line lengths. See

Table 5 for System Piston Guide and Refrigerant Charging.

NOTE: Run refrigerant piping as directly as possible, and

avoid any unnecessary turns or bends.

8. Condensate piping canbe directed through the inside wall

to an approved drain or directed straight outside. NOTE: The piping hole for condensate line must be made

at a downward slope to ensure proper drainage. See Mount Mounting Bracket on Wall section below for details.

Step 3 -- Mount Mounting Bracket on Wall

l. Decide how refrigerant will be piped. If necessary, knock

out the appropriate pre-puncbed holes (Fig. 5) on unit for piping and electrical connections.

2. Remove bracket from fan coil nnit by pulling it down from fan coil unit bottom as shown in Fig. 7.

3. Using a carpenter's level, fasten mounting brackets into the studs in the wall at least 10 in. away from the ceiling

with all the screws provided. Always be sure to insert screws into the top 2 holes indicated in Fig. 7. Make sure the

attached bracket will support a 200 lb vertical load. For a masonry wall, anchor shields can be used to attach bracket

to the wall.

4. Temporarily hang unit on bracket to check location and

level.

I_] [,,"_lii[.] _"I

If mounting bracket is not mounted level, the indoor sec- tion will be mounted unevenly, and condensate drain-

age water may drip onto the floor. Also, a gap between thebracket and the wall may result in vibration and noise

from the indoor section.

Mark and cut condensate and piping holes. a. For piping through the wall, mark the wall below the

condensate connection and cut a 2V2-in. hole into the wall at either point "A" or point "B" in Fig. 8. NOTE: The 2V2-in hole must be made at a downward

slope to ensure proper condensate drainage. See

Fig. 9. Slope condensate line at a minimum pitch of

1/4in. per foot of line. The condensate line cannot be

run up for upper piping connections -- only refriger-

ant lines may be run up.

b. Push the wall sleeve (factory supplied with the unit)

through the 2]/2-in. wall opening.

Table 3 -- High Wall Unit Package Contents

ITEM QUANTITY

Unit Mounting Template 1 Unit Mounting Bracket 1

1-in. Lag Screws for Unit Mounting 8 Hollow Wall Anchor Bolls for Unit Mounting 5

Wall Sleeve with Wall Cap 1 Infrared Wireless Remote Control 1

AAA Batteries (for Remote Control) 2 Remote Control Mounting Bracket 1 3/n-in. Lag Screws for Remote Mounting Bracket 2

35 ff High Voltage Power Wiring

40QNB009 (3-Wiro with Ground) 1 40QNE009 (2-Wire with Ground) 1

40QNB012 (2-Wire with Ground) 1 40QNH012 (2-Wiro with Ground) 1

35 ft High Voltage Control Power Wiring (3-Wire) 1 35 ft Low Voltage Thermistor Wiring 1

Owner's Manual 1

Installation Instructions 1

Warranty Registration Card 1

Table 4A-- Physical Data, 38AN Cooling Only Condensing Units*

UNIT 38AN NOMINAL CAPACITY (Tons)

OPERATING WEIGHT (Ib) REFRIGERANT TYPE

Control (Cooling) Factory Charge (Ib)

COMPRESSOR TYPE

Model Oil (Recharge) (oz)

Crankcase Heater Accumulator

OUTDOOR FAN

Rpm

Diameter (in.)...No. of Blades Motor Watts

Nominal Air Cfm

OUTDOOR COIL

Face Area (sq tt),..No, of Rows Fins/In,

CONTROLS

Fusible Plug (F) Control Voltage

REFRIGERANT LINES

Connection Type Liquid Line OD (in,)

Vapor Line OD (in,)

Maximum Length (ft) Maximum Lift Fan Coil (Above Outdoor) (ft)

Maximum Lift Fan Coil (Below Outdoor) (ft)

*These units may only be used with 40QNB009,012 fan coil units

EAA090111A10.1 I EBB120111A10.1

12¼...4 12¼...4

Table 4B -- Physical Data, 40QNB Cooling Only High Wall Units

UNIT 40QNB 009* 012" NOMINAL CAPACITY (Tons) ¥4 1 NOMINAL SIZE (Btuh) 9000 12,000

OPERATING WEIGHT (Ib) 18.7 24.2 MOISTURE REMOVAL RATE (Pints/Hr) 2.4 3.4

FINISH White REFRIGERANT R-22

Control (Cooling) Capillary Tube in Outdoor Unit Factory or System Charge (Ib)t 1.5 I 1,8

INDOOR FAN Direct Drive Centrifugal

Rpm..,Cfm High 1200,,.240 1040...260 Rpm..,Cfm Medium 1100..,210 940,,,240

Rpm...Cfm Low 1000,..180 850,,,210 Motor Watts 34 35

Blowers -- No...,Size (in.) 1,..3.54 x 27.75 1,,,3,94 x 27.75

INDOOR COIL Copper Tube, Aluminum Fin

Face Area (sq ft) 1.45 t6 No. of Rows 2 2

Fins/in, 18 17

Circuits 2 3

FILTERS Cleanable

(Quantity) Size (in.) (2) 9 x 12 I (2) 9_,_x 13_A

AIRSWEEP

Horizontal Manual

Vertical Automatic

CONTROLS integrated Microprocessor

Remote Controller Wireless Freeze Protection Yes

Auto. Restart Yes

Diagnostics Yes Timer Mode 24-Hour Startup/Shutdown Type Test Mode Yes

Dehumidification Mode Yes

Fan Mode HighlMediumlLowlAuto.

Control Voltage 115 v I 230 v

REFRIGERANT LINES

Connection Type Male Flare

Liquid Line OD (in.) ¼ ¼ Vapor Line OD (in.) ½ _,_

Maximum Length (ft) 35 35

Maximum Lift Fan Coil (Above Outdoor)(ft) 16 16

Maximum Lift Fan Coil (Below Outdoor) (ft) 30 30

CONDENSATE DRAIN CONNECTION (in.) % OD, 7/_8ID

*Units may onlybe matched with 38AN outdoorunits.

1"Fullfactory charge shipped in outdoor unit. Charge is determined based on 25 ft of line.

009 012

¾ 1 55 62

R-22

1.5 1.8

87 87

850 Propeller, iirect Drive 850 750 750

3.5...1 3.5...2 18 17

210 210

115 230

¼ ¼ ½ ½

35 35 16 16

30 30

Capilla_ Tube

Carrier Hermetic Rotary

None

Yes

Copper Tube, Aluminum Fin

Male Flare

Table 4C -- Physical Data, 38BK009,012 Outdoor Heat Pump Units*

UNIT 38BK NOMINAL CAPACITY (Tons) OPERATING WEIGHT (Ib)

REFRIGERANT TYPE

Control (Cooling) Control (Heating)

Factory Charge (Ib)

COMPRESSOR TYPE

Model Oil (Recharge) (oz)

CRANKCASE HEATER (Watts) OUTDOOR FAN

Rpm Diameter (in,),..No. of Blades Motor Wafts Nominal Air Cfm

OUTDOOR COIL

Face Area (sq ft)...No, of Rows Finslln.

CONTROLS

Fusible Plug Accumulator Defrost Method

Control Voltage

REFRIGERANT LINES

Connection l_jpe Liquid Line OD (in.) Vapor Line OD (in.) Maximum Length (ft)

Maximum Lift (Fan Coil Above) (ft) Maximum Lift (Fan Coil Below) (ft)

*These units may only be used with40QNF-./H fan coil units.

009 012

60,7 66.5

AccuRatar _ Piston at Outdoor Unit

AccuRater Pistonat Outdoor Unit

1.5 I 2.0

Carder Hermetic Rotary

EBA095111H10.1 I EBC130111H10.1

850

12¼...4

756

210 F 210 F

Yes Yes

Demand Demand

3.5._118 Copper Tube, Aluminum 115 v 230 v

¼ ¼ ½ ½

35 35

16 16

30 30

R-22

Propeller, Direct Drive

Male Flare

Fin

850

121/4._4

756

3.5...2 17

Table 4D -- Physical Data, 40QNEIH Heat Pump High Wall Units

UNIT NOMINAL CAPACITY (Tons)

NOMINAL SIZE (Btuh) OPERATING WEIGHT (Ih)

MOISTURE REMOVAL RATE (Pints/hr) REFRIGERANT

Control (Cooling) Control (Heating)

Factory Charge (Ib)t

INDOOR FAN

RpndCfm High Rpm/Cfm Medium

RpndCfm Low Motor Watts

Blowers Quantity...Size (in.)

INDOOR COIL

Face Area NO. of Rows

Fins/in. Clrculta

FILTERS

Quantity...Size (in.)

40QNEO09* 40QNH012*

_, 1

9000 12.000

18.7 242 24 3.4

AccuRate_ Piston at Outdoor Unit

AccuRater Piston at Outdoor Unit

15 I 20

1200/240 1040/280 1100/210 940/240

Direct Dnve Centrifugal

10001180 850/210

34 35

1354 x 27.75 1394 x 27.75

Copper Tube. Aluminum Fin

1.45 1.6 2 2

18 17

2 3

Cleanabie

2...9 x 12 I 2...91/2x 13_/4

AIRSWEEP

Horizontal Vertical

CONTROLS

Remote Controller Options Diagnostics Defrost Method Timer Mode

Integrated Microprocessor

Manual

Automatic

Wireless

Demand Defrost

Warm Start Feature Teat Mode

Freeze Protection Dehumidification Mode

Fan Mode

Auto Changeover Auto Restart

Control Voltage

115 v I

High/MediumlLowlAuto

REFRIGERANT LINES

Connection Type Liquid Line OD (in.)

Vapor Line OD (in.)

Maximum Length (ft) Maximum Lift (Fan Coil Above) (ft)

Maximum Lift (Fan Coil Below) (tt)

CONDENSATE DRAIN SIZE (in.)

¼ ¼ ½ ½

35 35

16 16

30 30

Male Flare

OD, 7A6ID

"These units may only be matched with 38BK outdoor units. The 40QNH unit available in size 012 only.

l-Full factory charge is shipped in the outdoor unit. The charge is determined based on 25 It of line.

R-22

Yes Yes

230 v

2'_0" [6103

- 19 u

2 O"

C6101

, 1

°..5o._sciso,

7/8"-

[2513

2"_2 o

HIGH VOLTA_I_ TO _1

I 1/8" Dik.

INDOOR _ECT]ON _!

i I I,,', i-- --* _ \ ' _ _ "_q

_ _ ._ - ,

TOP VIEW

0"-1 3/1_"

'f 0''1[4215/B"

[3o] [o'&_]i/e"

? ,

0"-3 11/16"

[941

_'_HI_'IV_-TAGE TO

3/4" DIA,

0".23 1/4"

C590]

_ "_0,_4.

[101_

PIIONT VlE_

NOTES:

1. Dimensions in [ ] are in millimeters.

2. _ Direction of airflow.

3. _ Center of Gravity.

4. Minimum clearances: 4 in. on coil sides, 24 in. on fan side, and

30 in. service side.

LJI]%,,:-I

Fig. 3 -- 38AN/BK Dimensional Drawing

UNIT

AN009 AN012

BK009 BK012

NleHT 810E VIEW

WEIGHT

55.0

62.0

60.7

66.5

25,0

28.1

27.5

30.2

I_T A]R

MINIMUM CLEARANCE FOR SERVICE

I I I I I I

I_] DU_(NOTE3)

NOTES: 1, Dimensionsare in inches.Dimensions in[ ]areinmillimeters,

2. _ Diroctionof airflow.

3. _erant, d_in, Bnd power conneofionsrubybe _de rear,leftsideor rightside.

4. Refrigerantismetered by capilla_tubesintheoutdoorunit.Insulatebeth

refrigerantlines.

5. Clearancesof 3½ on topof and tothe leftofthefancoilunitareabsolute

minLmu_. Clea_nc_=sof10" arerecommended.

6. Do not inset{a trapincondensatedrainline,Drainisinternallytrapped,

Fig. 4 -- 40QN Dimensional Drawing

012 )NIT OUTLI_ 012 MOLWWTI_BR:T 7

6 30 24 O0 _ O_

_ 2_ _4] DIA(NOTE 3)

UNIT WEIGHT A B C

4OGNI Lb I Kgl i.. I mml in. I mmlie. I mm

00,118,I°8133401=0011102]28016201160012 24.2 11.0 36.61 930 11.81 300 7.28 185

Table 5 -- System Piston Guide and

Refrigerant Charges

35" MAX (FOR COOLING ONLY AND

HEAT PUMP SYSTEMS)

UNIT INDOOR

Indoor Outdoor SIZE

40QNB009 38AN009 Capillary Tube 40QNB012 38AN012 Capillary Tube

40QNEO09 38BK009 321" 40QNH012 38BK012 421"

*Charge is based on25 f_of interconnectingtubing.Charge may need

to be added for longer tubing runs or when used with certain fan coils. Check unit nameplate for required charge. This is a total sys-

tem charge.

tNon-serviceable Aeroquip piston.

POSSIBLE PIPING DIRECTIONS

RIGHT SIDE

BoTroM KNOCKOUT

PISTON

PREPUNGHED HOLES

OUTDOOR

PISTON

SIZE

Capillary Tube

30t

42"_

REQUIRED

SYSTEM CHARGE

(Ib)*

1.50 180

150

2.00

LEFT SIDE

KNOCKOUT

"_1_ UNIT

30"

INDOOR ELEVATION INDOOR UNIT IT

MAX

/t/Hi--till/I/I////// // H//////H

OUTDOOR UNIT

GROUND-LEVEL ROOFTOP

INSTALLATION INSTALLATION

Fig, 6 -- Maximum System Line Lengths

Step 4 -- Mount Outdoor Section

1. If outdoor section is to be installed at ground level, mount on a solid, level support pad one in. longer and one in.

wider than the outdoor section dimensions.

Provide sufficient clearance for airflow, wiring, refriger- ant piping, service and maintenance. Provide a minimum

clearance of 2 ft from obstructions in front of outdoor section, 2 ft on outdoor coil side, and 2_A ft on electrical

and piping side. If more than one outdoor section is in- stalled, provide aminimum clearance of 2 ft between sec-

tions. Position outdoor section so that water or ice from roof cannot fall directly on unit.

NOTE: The outdoor section can be installed higher than, lower than, or level with the elevation of the indoor

section. If outdoor section is mounted higher than the in- door section, the vertical distance between the 2 units

should not exceed 30 i_. If the outdoor section is installed lower than indoor section, the vertical distance between

the units should not exceed 16 ft. See table below:

FOR LEFT

SIDE PIPING

FOR RIGHT SIDE PIPING

FOR

BOTi-OM/REAR

PIPING

Fig. 5 -- Fan Coil Unit Refrigerant Piping

Jlllll!_ilj=*:'=_: ! " _--H "-'-'': *="0_: : : : " : ::::=:l_

FAN COIL UNIT BOTI OM

BACK VIEW

MAXIMUM DISTANCE BETWEEN OUTDOOR UNITS

Outdoor Section Higher 30 Ft Maximum Than Indoor Section (Vertical) Outdoor Section Lower 16 Ft Maximum

Than Indoor Section (Vertical)

NOTE: Maximum system piping length between indoor and outdoor

units is 35 ft.

TOP HOLES

FRONT VIEW

Fig. 7 -- Fan Coil Unit Bracket Mounting (Size 009 Shown)

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