Carrier 38CKCQ User Manual

38CKC(Q), 38CMC, 38BRC  
Split-System Air Conditioner  
Installation and Start-Up Instructions  
NOTE: Read the entire instruction manual before starting the  
installation.  
SAFETY CONSIDERATIONS  
Improper installation, adjustment, alteration, service, maintenance,  
or use can cause explosion, fire, electrical shock, or other  
conditions which may cause death, personal injury, or property  
damage. Consult a qualified installer, service agency, or your  
distributor or branch for information or assistance. The qualified  
installer or agency must use factory-authorized kits or accessories  
when modifying this product. Refer to the individual instructions  
packaged with the kits or accessories when installing.  
Follow all safety codes. Wear safety glasses, protective clothing,  
and work gloves. Use quenching cloth for brazing operations.  
Have fire extinguisher available. Read these instructions thor-  
oughly and follow all warnings or cautions included in literature  
and attached to the unit. Consult local building codes and National  
Electrical Code (NEC) for special requirements.  
Recognize safety information. This is the safety-alert symbol  
.
When you see this symbol on the unit and in instructions or  
manuals, be alert to the potential for personal injury.  
A97005  
Fig. 1—Split-System Air Conditioner  
Understand the signal words DANGER, WARNING, and CAU-  
TION. These words are used with the safety-alert symbol. DAN-  
GER identifies the most serious hazards which will result in severe  
personal injury or death. WARNING signifies hazards which  
could result in personal injury or death. CAUTION is used to  
identify unsafe practices which would result in minor personal  
injury or product and property damage.  
7. Do not suspend refrigerant tubing from joists and studs with a  
rigid wire or strap which comes in direct contact with the  
tubing. (See Fig. 2.)  
8. Ensure that tubing insulation is pliable and completely sur-  
rounds vapor tube.  
9. When necessary, use hanger straps which are 1 in. wide and  
conform to shape of tubing insulation. (See Fig. 2.)  
10. Isolate hanger straps from insulation by using metal sleeves  
bent to conform to shape of insulation.  
Before installing, modifying, or servicing system, main elec-  
trical disconnect switch must be in the OFF position. There  
may be more than 1 disconnect switch. Lock out and tag  
switch with a suitable warning label. Electrical shock can  
cause personal injury or death.  
When outdoor unit is connected to factory-approved indoor unit,  
outdoor unit contains system refrigerant charge for operation with  
factory-approved indoor unit of the same size when connected by  
15 ft of field-supplied tubing. For proper unit operation, check  
refrigerant charge using charging information located on control  
box cover.  
INSTALLATION RECOMMENDATIONS  
NOTE: In some cases noise in the living area has been traced to  
gas pulsations from improper installation of equipment.  
INSTALLATION  
1. Locate unit away from windows.  
Step 1—Check Equipment and Jobsite  
2. Ensure that vapor and liquid tube diameters are appropriate to  
capacity of unit. (See Model Specific Instructions for proper  
tube sizing.)  
INSPECT EQUIPMENT — If shipment is damaged or incom-  
plete, file claim with shipping company prior to installation.  
Locate unit rating plate on unit service panel. It contains informa-  
tion needed to properly install unit. Check rating plate to be sure  
unit matches job specifications.  
3. Run refrigerant tubes as directly as possible by avoiding  
unnecessary turns and bends.  
4. Leave some slack between structure and unit to absorb  
vibration.  
Step 2—Install on a Solid, Level Mounting Pad  
5. When passing refrigerant tubes through the wall, seal opening  
with RTV or other pliable silicon-based caulk. (See Fig. 2.)  
If conditions or local codes require the unit be attached to pad, use  
tiedown bolts to fasten through knockouts provided in unit base  
pan. Refer to Fig. 3 for pad dimensions and dimensions needed to  
mount unit to pad.  
6. Avoid direct tubing contact with water pipes, ductwork, floor  
joists, wall studs, floors, and walls.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 3a 2a  
1
4
PC 101  
Catalog No. 533-840  
Printed in U.S.A.  
Form 38BRC-1SI  
Pg 1  
2-97  
Replaces: New  
AIR DISCHARGE  
If undersized, damaged, or elliptically shaped tubing is used  
when making connection, leaks could result.  
3. Slide lock nut and ferrule onto each tube. (See Fig. 6.)  
FIELD POWER  
SUPPLY CONN  
FERRULE  
LOCK NUT  
7
DIA HOLE WITH  
8
1
1 ⁄ DIA KNOCKOUT  
8
3
AND 1 DIA  
8
KNOCKOUT  
FIELD CONTROL  
SUPPLY CONN  
7
DIA HOLE  
8
SUCTION LINE CONN  
LIQUID LINE CONN  
TUBING  
A97009  
A92121  
LIQUID TUBE  
VAPOR TUBE  
Fig. 6—Lock Nut/Ferrule Positioning (38CKQ)  
UNIT SIZE  
Conn Dia  
Tube Dia  
3/8  
Conn Dia  
5/8  
Tube Dia  
5/8  
4. Apply a few drops of refrigerant oil to ferrule and valve  
threads to reduce assembly torque and assist sealing.  
018, 024  
030, 036  
042, 048  
060  
3/8  
3/8  
3/8  
3/8  
3/8  
3/4  
3/4  
3/8  
7/8  
7/8  
5. Insert tube end into service valve until it bottoms.  
3/8  
7/8  
1-1/8  
6. Push ferrule into place and hand tighten nut until an increase  
in torque is felt.  
NOTE: Tube diameters are for lengths up to 50 ft. For tubing lengths greater  
than 50 ft, consult your local distributor.  
7. Mark nut and tube and tighten 1-1/2 turns from mark. (See  
Fig. 7.) Keep tube bottomed in valve while tightening nut.  
If refrigerant tubing or indoor coil is exposed to atmosphere, it  
must be evacuated to a minimum of 500 microns to eliminate  
contamination and moisture in the system.  
NOTE: A backup wrench on the hex part of the suction valve is  
required while tightening.  
Fig. 4—Refrigerant Tube Dimensions/Connections  
4. After wrapping service valve with a wet cloth, tubing set can  
be brazed to service valve using either silver bearing or  
non-silver bearing brazing material.  
The tube end must stay bottomed in the service valve during  
final assembly to ensure proper seating, sealing, and rigidity.  
MECHANICAL FITTING REPAIR  
5. Refrigerant tubing and indoor coil are now read for leak  
testing. This check should include all field and factory joints.  
To replace damaged ferrule or tubing proceed as follows.  
1. Attach gages to service valves.  
MECHANICAL CONNECTION (38CKQ MODELS)  
2. Close liquid service valve and operate unit to pump refrigerant  
charge into condenser coil.  
1. Cut tubing to correct length, deburr, and size as necessary,  
making sure tube ends are square. If a large burr is evident, ID  
and OD must be deburred to allow tube to bottom in valve.  
3. When suction pressure reaches 5 psig, shut unit off. Do not  
operate unit in a vacuum.  
2. Remove lock nuts and ferrules from plastic bags taped to  
service panel. (See Fig. 5.)  
4. Close suction service valve and recover refrigerant in tubing.  
5. Back-off locknut and ferrule onto tube.  
6. Remove damaged part of tubing using tubing cutter. Repeat  
installation procedure previously outlined using new ferrule.  
7. Evacuate tubing set and indoor coil. Check for leaks.  
VALVE FITTING  
FERRULE  
8. Open service valves or recharge unit. Check refrigerant  
charge.  
Step 7—Install Solenoid Valve In Liquid Tube (If Re-  
quired)  
Not all applications require use of a liquid tube solenoid  
valve. If your unit has been shipped with a liquid tube  
solenoid valve in the unit, it must be installed for performance  
enhancement. The liquid tube solenoid valve must be ener-  
gized during evacuation for complete removal of refrigerant.  
LOCK NUT  
Before making liquid tube connections, install factory-supplied  
solenoid valve on indoor liquid fitting. (See Fig. 8.) Be sure to use  
flare adapter supplied with the indoor coil when making connec-  
tions.  
A92120  
Fig. 5—Mechanical Fitting Assembly (38CKQ)  
3
5. Wire solenoid coil into system control circuit.  
LOCK NUT  
Step 8—Make Electrical Connections  
To avoid personal injury or death, do not supply power to unit  
with compressor terminal box cover removed.  
Be sure field wiring complies with local and national fire, safety,  
and electrical codes, and voltage to system is within limits shown  
on unit rating plate. Contact local power company for correction of  
improper voltage. See unit rating plate for recommended circuit  
protection device.  
TUBING  
NOTE: Operation of unit on improper line voltage constitutes  
abuse and could affect unit reliability. See unit rating plate. Do not  
install unit in system where voltage or phase imbalance (3 phase)  
may fluctuate above or below permissible limits.  
MARK ON LOCK NUT  
AND TUBE  
A92122  
Fig. 7—Proper Marking of Valve Assembly (38CKQ)  
NOTE: Use copper wire only between disconnect switch and  
unit.  
ELECTRICAL JUNCTION  
ELECTRICAL COIL  
NOTE: Install branch circuit disconnect of adequate size per  
NEC to handle unit starting current. Locate disconnect within sight  
from and readily accessible from unit, per Section 440-14 of NEC.  
ROUTE GROUND AND POWER WIRES — Remove access  
panel to gain access to unit wiring. Extend wires from disconnect  
through power wiring hole provided and into unit control box.  
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. Failure to follow this warning can result in an  
electric shock, fire, or death.  
VALVE  
FLOW ARROW  
CONNECT GROUND AND POWER WIRES — Connect ground  
wire to ground connection in control box for safety. Connect  
power wiring to contactor as shown in Fig. 9.  
3
STRAIGHT  
/
IN. STUD  
8
NOTE:System flow direction  
must match arrow on  
bottom of body.  
DISCONNECT  
PER N.E.C. AND/OR  
LOCAL CODES  
A87044  
CONTACTOR  
Fig. 8—Solenoid Valve Installation  
FIELD POWER  
WIRING  
Wiring must comply with local codes and NEC requirements,  
if a field-supplied control power source is needed when  
adding solenoid.  
BLUE  
3 PHASE ONLY  
1. Remove coil liquid connection cap and discard.  
FIELD GROUND  
WIRING  
2. Mount solenoid valve on liquid tube, making sure valve flow  
arrow points toward indoor coil. Mount valve in any position  
except valve body at top and electric coil at bottom. (See Fig.  
8.) Solenoid valve is to be installed a maximum of 2 ft from  
indoor coil.  
GROUND  
LUG  
A94025  
Fig. 9—Line Power Connections  
CONNECT CONTROL WIRING — Route 24-v control wires  
through control wiring grommet and connect leads to control  
wiring. (See Fig. 10.)  
Avoid valve damage while brazing by wrapping valve with a  
heat-sinking material such as a wet cloth.  
Use No. 18 AWG color-coded, insulated (35°C minimum) wire. If  
thermostat is located more than 100 ft from unit, as measured  
along the control voltage wires, use No. 16 AWG color-coded wire  
to avoid excessive voltage drop.  
3. Braze valve onto end of liquid tube using silver bearing or  
non-silver bearing brazing material. Consult local code re-  
quirements.  
Use furnace transformer, fan coil transformer, or accessory trans-  
former for control power, 24-v/40-va minimum.  
4. Braze flare adapter onto outlet end of solenoid valve.  
4
NOTE: Use of available 24-v accessories may exceed the mini-  
mum 40-va power requirement. Determine total transformer load-  
ing and increase the transformer capacity or split the load with an  
accessory transformer as required.  
Do not vent refrigerant to atmosphere. Recover during system  
repair or final unit disposal.  
Step 9—Compressor Crankcase Heater  
Follow these steps to properly pumpdown a system and avoid  
negative suction pressure.  
When equipped with a crankcase heater, furnish power to heater a  
minimum of 24 hr before starting unit. To furnish power to heater  
only, set thermostat to OFF and close electrical disconnect to  
outdoor unit.  
1. Fully back seat (open) liquid and vapor tube service valves.  
2. Unit is shipped with valve stem(s) front seated (closed) and  
caps installed. Replace stem caps after system is opened to  
refrigerant flow. Replace caps finger-tight and tighten with  
wrench an additional 1/6-turn for front seating valves (female  
hex stem) or 1/12 turn for back seating valves (male square  
stem).  
A crankcase heater is required if refrigerant tubing is longer than  
50 ft.  
NOTE: The Seasonal Energy Efficiency Ratio (SEER) is ob-  
tained with crankcase heater de-energized. To de-energize crank-  
case heater, disconnect black crankcase heater wires at contactor.  
After disconnecting, make sure wires are isolated from all other  
electrical connections and components to prevent electrical short-  
ing.  
3. Close electrical disconnects to energize system.  
4. Set room thermostat at desired temperature. Be sure set point  
is below indoor ambient temperature.  
5. Set room thermostat to COOL and fan to FAN or AUTO  
mode, as desired. Operate unit for 15 minutes. Check system  
refrigerant charge.  
Step 10—Install Electrical Accessories  
Refer to the individual instructions packaged with kits or acces-  
sories when installing.  
6. Factory charge is shown on unit rating plate. Adjust charge by  
following procedure shown on charging tables located on unit.  
Step 11—Start-Up and Check Charge  
SEQUENCE OF OPERATION  
Turn on power to indoor and outdoor units. Transformer is  
energized.  
To prevent compressor damage or personal injury, observe  
the following:  
• Do not overcharge system with refrigerant.  
• Do not operate unit in a vacuum or at negative pressure.  
• Do not disable low-pressure switch  
On a call for cooling, thermostat makes circuits R-Y and R-G.  
Circuit R-Y energizes contactor, starting outdoor fan motor and  
compressor circuit. R-G energizes indoor unit blower relay,  
starting indoor blower motor on high speed.  
In scroll compressor applications:  
• Dome temperatures may be hot.  
When thermostat is satisfied, its contacts open, de-energizing  
contactor and blower relay. Compressor and motors stop.  
• In 3 phase application, incorrect phasing will cause reverse  
rotation, resulting in elevated noise levels, equalized pres-  
sures, and reduced current draw. Correct by reversing power  
connection L1 and L2 on contactor.  
If indoor unit is equipped with a time-delay relay circuit, the  
indoor blower will run an additional 90 sec to increase system  
efficiency.  
CARE AND MAINTENANCE  
To prevent personal injury wear safety glasses, protective  
clothing, and gloves when handling refrigerant and observe  
the following:  
• Back seating service valves are not equipped with Schrader  
valves. Fully back seat (counter clockwise) valve stem before  
removing gage port cap.  
For continued high performance and to minimize possible equip-  
ment failure, periodic maintenance must be performed on this  
equipment.  
Leave User’s Manual with homeowner. Explain system operation  
and periodic maintenance requirements outlined in manual. Fre-  
quency of maintenance may vary depending on geographic areas,  
such as coastal applications which require more frequent mainte-  
nance.  
• Front seating service valves are equipped with Schrader  
valves.  
5
CORPORATE  
NON-PROGRAMMABLE  
THERMOSTAT  
CORPORATE  
NON-PROGRAMMABLE  
THERMOSTAT  
FA, FB, FC,  
FD, FF  
FAN COIL  
AIR  
CONDITIONER  
MODEL AC  
SINGLE  
STAGE  
AIR  
R
R
24 VAC HOT  
MODEL AC  
CONDITIONER  
FURNACE  
R
C
R
24 VAC HOT  
24 VAC COM  
C
W/W1  
Y/Y2  
G
24 VAC COM  
C
SEE  
C
C
NOTE 2  
HEAT STAGE 1  
COOL STAGE 1  
INDOOR FAN  
W2  
SEE  
W/W1  
C
NOTE 2  
HEAT STAGE 1 W/W1  
Y/Y2  
G
Y/Y2  
G
COOL STAGE 1  
INDOOR FAN  
G
A94385  
A94384  
CORPORATE  
PROGRAMMABLE  
THERMOSTAT  
MODEL AC  
CORPORATE  
PROGRAMMABLE  
THERMOSTAT  
MODEL AC  
FA, FB, FC,  
FD, FF  
AIR  
SINGLE  
CONDITIONER  
FAN COIL  
AIR  
STAGE  
CONDITIONER  
FURNACE  
R
R
G
24 VAC HOT  
INDOOR FAN  
HEAT STAGE 1  
COOL STAGE 1  
NOT USED  
R
R
G
24 VAC HOT  
INDOOR FAN  
HEAT STAGE 1  
COOL STAGE 1  
NOT USED  
G
W/W1  
Y/Y2  
G
W2  
W/W1  
Y/Y2  
W/W1  
Y/Y2  
SEE  
NOTE 2  
O/W2  
O/W2  
C
SEE  
NOTE 2  
Y1/W2  
NOT USED  
C
Y1/W2  
NOT USED  
24 VAC COM  
NOT USED  
NOT USED  
C
B
L
C
24 VAC COM  
NOT USED  
NOT USED  
C
C
B
L
OPTIONAL  
OUTDOOR  
SENSOR  
S1  
S2  
OPTIONAL  
OUTDOOR  
SENSOR  
S1  
S2  
CONNECTION  
CONNECTION  
A94386  
A94387  
Fig. 10—Typical 24-v Circuit Connections  
6
CORPORATE  
PROGRAMMABLE  
THERMOSTAT  
MODEL AC  
CORPORATE  
NON-PROGRAMMABLE  
THERMOSTAT  
FK4B  
FAN COIL  
AIR  
CONDITIONER  
FK4B  
AIR  
MODEL AC  
FAN COIL  
CONDITIONER  
R
R
G
24 VAC HOT  
INDOOR FAN  
HEAT STAGE 1  
COOL STAGE 1  
NOT USED  
R
C
R
C
24 VAC HOT  
24 VAC COM  
G
W/W1  
Y/Y2  
W2  
Y/Y2  
O
SEE  
C
NOTE 2  
HEAT STAGE 1 W/W1  
COOL STAGE 1 Y/Y2  
W2  
Y/Y2  
SEE  
NOTE 2  
O/W2  
C
INDOOR FAN  
G
G
Y1/W2  
NOT USED  
Y1  
W3  
C
W3  
24 VAC COM  
NOT USED  
NOT USED  
O
Y1  
E
C
B
L
E
L
OPTIONAL  
OUTDOOR  
SENSOR  
S1  
S2  
L
A94388  
CONNECTION  
A94389  
NON-CORPORATE  
NON-PROGRAMMABLE  
THERMOSTAT  
FK4B  
FAN COIL  
AIR  
MODEL AC  
CONDITIONER  
R
R
24 VAC HOT  
C
SEE  
C
NOTE 2  
HEAT STAGE 1  
COOL STAGE 1  
INDOOR FAN  
W
Y
W2  
Y/Y2  
G
G
W3  
O
Y1  
E
L
A95281  
Fig. 10—Typical 24-v Circuit Connections (Continued)  
7
NON-CORPORATE  
NON-PROGRAMMABLE  
THERMOSTAT  
NON-CORPORATE  
NON-PROGRAMMABLE  
THERMOSTAT  
FA, FB, FC,  
FD, FF  
FAN COIL  
AIR  
CONDITIONER  
MODEL AC  
SINGLE  
STAGE  
AIR  
MODEL AC  
CONDITIONER  
FURNACE  
R
R
24 VAC HOT  
R
R
24 VAC HOT  
C
C
SEE  
C
NOTE 2  
W
Y
HEAT STAGE 1  
COOL STAGE 1  
INDOOR FAN  
W2  
SEE  
W/W1  
C
NOTE 2  
HEAT STAGE 1  
COOL STAGE 1  
INDOOR FAN  
W
Y
Y/Y2  
G
G
G
G
A95282  
A95283  
NOTES:  
1. CORPORATE THERMOSTAT WIRING DIAGRAMS ARE ONLY ACCURATE FOR MODEL  
NUMBERS BEGINNING WITH TSTAT _ _ _ _ _ _ _  
2. WIRING MUST CONFORM TO NEC OR LOCAL CODE.  
3. SOME UNITS ARE EQUIPPED WITH PRESSURE SWITCH(ES), TEMPERATURE SWITCH,  
OR 5 MINUTE COMPRESSOR CYCLE PROTECTION. CONNECT 24 VOLT FIELD WIRING  
TO FACTORY PROVIDED STRIPPED LEADS.  
4. A LIQUID LINE SOLENOID VALVE IS REQUIRED ON SOME UNITS. SEE SPECIFIC UNIT  
INSTRUCTIONS.  
5. THERMOSTATS ARE FACTORY CONFIGURED WITH 5 MINUTE COMPRESSOR CYCLE  
PROTECTION AND 4 CYCLES PER HOUR LIMIT. SEE THERMOSTAT INSTRUCTIONS  
FOR DETAILS.  
6. TO STAGE THE ELECTRIC RESISTANCE HEAT, CONSULT OUTDOOR THERMOSTAT  
INSTALLATION INSTRUCTIONS.  
LEGEND  
24 VOLT FACTORY WIRING  
24 VOLT FIELD WIRING  
FIELD SPLICE CONNECTION  
C
CONTACTOR  
A94394  
Fig 10—Typical 24-v Circuit Connections (Continued)  
Copyright 1997 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231  
38brc1si  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 3a 2a  
1
4
PC 101  
Catalog No. 533-840  
Printed in U.S.A.  
Form 38BRC-1SI  
Pg 8  
2-97  
Replaces: New  

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