38TKB Air Conditioning Unit Installation and Start
Contents
1. A98519 Fig 1 Model 38TKB 5 When passing refrigerant tubes through the wall seal the opening with RTV or other pliable silicon based caulk See Fig 3 6 Avoid direct lineset contact with water pipes ductwork floor joists wall studs floors and walls 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 3 8 Ensure that tubing insulation is pliable and completely sur rounds the vapor line 9 When necessary use hanger straps which 1 in wide and conform to the shape of the tubing insulation See Fig 3 10 Isolate the hanger straps from the insulation by using metal sleeves bent to conform to the shape of the insulation 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 IMPORTANT Maximum liquid line size is 3 8 in O D for all residential applications including long line IMPORTANT Always install a liquid line filter drier Refer to Product Data Digest for appropriate part number Obtain filter driers from your local distributor or branch Manufacturer reserves the right to discontin2. Cam Carrier gt SS HEATING amp COOLING 38TKB Air Conditioning Unit Visit www carrier com Installation and Start Up Instructions NOTE Read the entire instruction manual before beginning the installation This symbol indicates a change since last issue SAFETY CONSIDERATIONS Improper installation adjustment alteration service maintenance or use can cause explosion fire electrical shock or other conditions which may cause 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 pack aged with the kits or accessories when installing Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for brazing operations Have fire extinguisher available Read these instructions thoroughly and follow all warning or cautions attached to the unit Consult local building codes and National Electrical Code NEC for special require ments Recognize safety information This is the safety alert symbol A When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand these signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most s
3. A crankcase heater is required if the refrigerant tubing is longer than 50 ft Refer to Residential Split System Long Line Applica tion Guideline Step 9 Install Electrical Accessories If Any Refer to the individual instructions packaged with the kit or accessory when installing CARRIER NON PROGRAMMABLE THERMOSTAT SINGLE STAGE AIR MODEL AG FURNACE CONDITIONER 24 VAC HOT 24 VAC COM SEE HEAT STAGE 1 NOTE 2 COOL STAGE 1 INDOOR FAN A97467 CARRIER PROGRAMMABLE THERMOSTAT SINGLE STAGE AIR MODEL AC FURNACE CONDITIONER 24 VAC HOT INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED SEE NOTE 2 JB NOT USED 24 VAC COM NOT USED NOT USED A97469 OPTIONAL OUTDOOR SENSOR CONNECTION n OTHER NON PROGRAMMABLE SINGLE STAGE AIR AC THERMOSTAT FURNACE CONDITIONER 24 VAC HOT SEE HEAT STAGE 1 NOTE 2 COOL STAGE 1 INDOOR FAN A97367 CARRIER NON PROGRAMMABLE FA FB FC THERMOSTAT FD FF AIR MODEL AC FAN COIL CONDITIONER 24 VAC HOT 24 VAC COM SEE HEAT STAGE 1 NOTE 2 COOL STAGE 1 INDOOR FAN A9468 CARRIER PROGRAMMABLE FA FB THERMOSTAT FD FF FX AIR MODEL AC FAN COIL CONDITIONER 24 VAC HOT INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED SEE NOTE 2 NOT USED 24 VAC COM NOT USED NOT USED A97595 OPTIONAL OUTDOOR SENSOR CONNECTION OTHER FA FB FC NON PROGRAMMABLE FD FF FX AIR AC THERM
4. 79 81 83 85 36 79 81 83 85 87 38 81 83 85 87 89 40 83 85 87 89 91 Copyright 1998 CARRIER Corp 7310 W Morris St Indianapolis 46231 38tkb5si Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Replaces 38 451 Book 1 4 Tab 2 PC 101 Catalog No 563 754 Printed in U S A Form 38 551 Pg 8 11 98
5. Checklist and place in customer file CARE AND MAINTENANCE For continuing high performance and to minimize possible equip ment failure periodic maintenance must be performed on this equipment Frequency of maintenance may vary depending on geographic areas such as coastal applications which may require more frequent maintenance Table 3 Superheat Charging EVAPORATOR ENTERING AIR TEMPERATURE F WB F 50 52 54 56 76 55 9 12 14 17 45 60 7 10 12 15 43 65 6 10 13 41 70 7 10 39 75 6 37 80 35 85 33 90 31 95 29 100 27 105 26 110 25 115 23 Where a dash appears do not attempt to charge system under these conditions or refrigerant slugging may occur Charge must be weighed in NOTE Superheat F is at low side service port Table 4 Required Suction Line Temperature ee SUCTION PRESSURE AT SERVICE PORT PSIG F 61 5 64 2 67 1 70 0 73 0 76 0 79 2 82 4 85 7 0 35 37 39 41 43 45 47 49 51 2 37 39 41 43 45 47 49 51 53 4 39 41 43 45 47 49 51 53 55 6 49 51 53 55 57 8 51 53 55 57 59 10 53 55 57 59 61 12 55 57 59 61 63 14 57 59 61 63 65 16 59 61 63 65 67 18 61 63 65 67 69 20 63 65 67 69 71 22 65 67 69 71 73 24 67 69 71 73 75 26 69 71 73 75 77 28 71 73 75 77 79 30 73 75 77 79 81 32 75 77 79 81 83 34 77
6. ISCHARGE AIR DISCHARGE AIR IN 21 2 AIR DISCHARGE 63 7 SIZES ONLY on 22 266 7 Bs gt 2 gt _ 106 3 3 8 9 53 DIA LIQUID 154 e LINE CONNECTION 44 6 NOTES 1 ALLOW 30 762 CLEARANCE TO SERVICE END OF UNIT 48 1219 ABOVE UNIT 6 152 ON ONE SIDE 12 306 ON REMAINING SIDE AND 24 610 BETWEEN UNITS FOR PROPER AIRFLOW UNIT MOUNTING PATTERN 85 16 1 916 X Ain 39 6 D POWER SUPPLY CONN 22 22 DIA HOLE WITH ae 28 57 DIA KNOCKOUT a ALL SIZES AND 1 3 g 34 92 DIA KNOCKOUT 036 THRU 060 4 95 FIELD CONTROL SUPPLY PANEL CONN 7 8 22 22 DIA HOLE 3 4 5 2 MINIMUM OUTDOOR OPERATING AMBIENT IN COOLING MODE IS 55 F 12 8 C UNLESS LOW AMBIENT CONTROL IS USED 125 F 51 7 C provided in unit base pan Refer to unit mounting pattern shown in Fig 2 to determine base pan size and knockout hole location On rooftop applications mount on level platform or frame Place unit above a load bearing wall and isolate unit and tubing set from structure Arrange supporting members to adequately support unit and minimize transmission of vibration to building Consult local codes governing rooftop applications Roof mounted units exposed to winds above 5 mph may require wind baffle
7. OSTAT FAN COIL CONDITIONER 24 VAC HOT SEE NOTE 2 _ INDOOR FAN A97593 Fig 5 24 v Control Circuit Connections CARRIER NON PROGRAMMABLE THERMOSTAT FK4C FV4A AIR MODEL AC FAN COIL CONDITIONER 24 VAC HOT 24 VAC COM HEAT STAGE 1 COOL STAGE 1 INDOOR FAN A97596 OTHER NON PROGRAMMABLE FK4C FV4A AIR AC THERMOSTAT FAN COIL CONDITIONER 24 VAC HOT HEAT STAGE 1 SEE COOL STAGE 1 NOTE 2 INDOOR FAN A97592 NOTES CARRIER PROGRAMMABLE THERMOSTAT FK4C FV4A AIR MODEL AC FAN COIL CONDITIONER 24 VAC HOT INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED NOT USED SEE NOTE 2 24 VAC COM NOT USED NOT USED A97597 OPTIONAL OUTDOOR SENSOR CONNECTION 1 CARRIER THERMOSTAT WIRING DIAGRAMS ARE ONLY ACCURATE FOR MODEL NUMBERS BEGINNING WITH TSTAT 2 WIRING MUST CONFORM TO NEC OR LOCAL CODES 3 SOME UNITS ARE EQUIPPED WITH PRESSURE SWITCH ES TEMPERATURE SWITCH OR 5 MINUTE COMPRESSOR CYCLE PROTECTION CONNECT 24 V FIELD WIRING TO FACTORY PROVIDED STRIPPED LEADS 4 A LIQUID LINE SOLENOID VALVE IS REQUIRED ON SOME UNITS 5 THERMOSTATS ARE FACTORY CONFIGURED WITH 5 MINUTE COMPRESSOR CYCLE PROTECTION AND 4 CYCLES PER HOUR LIMIT SEE THERMOSTAT INSTALLATION INSTRUCTIONS FOR DETAILS 6 TO STAGE ELECTRIC RESISTANCE HEAT CONSULT OUTDOOR THERMOSTAT INSTALLATION INSTRUCTIONS LEGEND 24 V FACTORY WIRING 24 V FIELD WIRING FIELD SPLICE CONNECTION CONTAC
8. TOR A97368 Fig 5 Typical 24 v Circuit Connections Continued Step 10 Start Up and Check Charge 4 CAUTION 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 not disable low pressure switch In scroll compressor applications Dome temperatures may be hot 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 4 CAUTION To prevent personal injury wear safety glasses protective clothing and gloves when handling refrigerant and observe the following Back seating service valves not equipped with Schrader valves Fully back seat counter clockwise valve stem before removing gage port cap e Front seating service valves are equipped with Schrader valves CAUTION Do not vent refrigerant to atmosphere Recover during system repair or final unit disposal Follow these steps to start up the system 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 12 turn 3 Close electric
9. al disconnects to energize system 4 Set room thermostat at desired temperature Be sure set point is below indoor ambient temperature 5 Set room thermostat at COOL and fan control at ON or AUTO mode as desired Operate unit for 15 minutes Check system refrigerant charge SEQUENCE OF OPERATION Turn on power to indoor and outdoor units Transformer is energized On a call for cooling the thermostat makes circuits R Y and R G Circuit R Y energizes contactor starting outdoor fan motor and compressor circuit R G energizes the indoor unit blower relay starting the indoor blower motor on high speed When the thermostat is satisfied its contacts open de energizing contactor and blower relay Compressor and motors stop If indoor unit is equipped with a time delay relay circuit the indoor blower will run an additional 90 seconds to increase system efficiency Step 11 Check Charge UNIT CHARGE Factory charge is shown on unit rating plate Adjust charge by following procedure shown on charging tables located on unit NOTE If superheat or subcooling charging conditions are not favorable charge must be weighed in accordance with unit rating plate 0 6 oz ft of 3 8 in liquid line above or below 15 ft respectively EXAMPLE 25 ft 15 ft 10 ft X 0 6 oz ft 6 oz of additional charge COOLING ONLY PROCEDURE The following procedure is valid when indoor airflow is within 21 of its rated CFM 1 Operate
10. er to gain access to unit wiring Extend wires from disconnect through power wiring hole provided and into unit control box 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 4 CONNECT CONTROL WIRING Route 24 v control wires through control wiring grommet and connect leads to control wiring See Fig 5 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 wires to avoid excessive voltage drop All wiring must be NEC Class 1 and must be separated from incoming power leads FIELD POWER WIRING a 2 KWO FIELD GROUND WIRING GROUND LUG A91056 Fig 4 Line Power Connections Use furnace transformer fan coil transformer or accessory trans former for control power 24 v 40va minimum 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 Step 8 Compressor Crankcase Heater When equipped with a crankcase heater furnish power to heater a minimum of 24 hrs before starting unit To furnish power to heater only set thermostat to OFF position and close electrical disconnect to outdoor unit
11. erious 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 A WARNING Before installing modifying or servicing system main elec trical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label Electrical shock can cause personal injury or death INSTALLATION RECOMMENDATIONS NOTE In some cases noise in the living area has been traced to gas pulsations from improper installation of equipment 1 Locate the unit away from windows 2 Ensure that vapor and liquid line diameters are appropriate to the capacity of the unit See Table 1 3 Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends 4 Leave some slack between the structure and the unit to absorb vibration
12. ing SWEAT CONNECTION Service valves are closed from fac tory and ready for brazing After wrapping the service valve with a wet cloth the tubing set can be brazed to the service valve using either silver bearing or non silver bearing brazing material Con sult local code requirements Refrigerant tubing and indoor coil are now ready for leak testing This check should include all field and factory joints 4 CAUTION To avoid valve damage while brazing service valves must be wrapped in a heat sinking material such as a wet cloth Step 7 Make Electrical Connections 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 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 may fluctuate above or below permissible limits NOTE Use copper wire only between disconnect switch and unit Table 2 Accessory Usage REQUIRED FOR REQUIRED FOR REQUIRED FOR LOW AMBIENT LONG LINE SEA COAST ACCESSORY APPLICATIONS APPLICATIONS APPLICATIONS BELOW 55 F OVER 50 FT WITHIN 2 MILES Crankcase Heater Yes Yes No Evaporator Freeze Therm
13. lling allow sufficient space for airflow wiring refrig erant piping and service Allow 30 in clearance to service end of unit and 48 in abouve unit For proper airflow a 6 in clearance on 1 side of unit and 12 in on all remaining sides must be maintained Maintain a distance of 24 in between units Position so water snow or ice from roof or eaves cannot fall directly on unit On rooftop applications locate unit at least 6 in above roof surface Step 4 Operating Ambients The minimum outdoor operating ambient in cooling mode is 55 F and the maximum outdoor operating ambient in cooling mode is 125 F Step 5 Replace Indoor AccuRater Piston if Required Check indoor coil piston to see if it matches the required piston shown on unit rating plate If it does not match replace indoor coil piston with piston shipped with this unit The piston shipped with outdoor unit is correct for any approved indoor coil combination CAUTION Remove indoor coil piston if unit is to be installed on system with a thermostatic expansion valve TXV metering device Step 6 Make Tubing Connections A WARNING Relieve pressure and recover all refrigerant before system repair or final unit disposal to avoid personal injury or death Use all service ports and open all flow control devices including solenoid valves 4 CAUTION If ANY refrigerant tubing is buried provide a 6 in vertical rise at service valve Refrigerant tubi
14. ng lengths up to 36 in may be buried without further special consideration For lengths above 36 in consult your local distributor 4 CAUTION To prevent damage to unit or service valves observe the following e Use a brazing shield e Wrap service valves with wet cloth or use a heat sink material Outdoor units may be connected to indoor section using accessory tubing package or field supplied refrigerant tubing of correct size and condition For tubing requirements beyond 50 ft substantial capacity and performance losses can occur Following the recom mendations in the Residential Split System Long Line Application Guideline will reduce these losses Refer to Table 1 for field tubing equivalent line length Refer to Table 2 for accessory require ments For buried line applications greater than 36 in consult your local distributor If refrigerant tubes or indoor coil are exposed to atmosphere they must be evacuated to 500 microns to eliminate contamination and moisture in the system OUTDOOR UNIT CONNECTED TO FACTORY APPROVED INDOOR UNIT Outdoor unit contains correct system refriger ant charge for operation with indoor unit of same size when connected by 15 ft of field supplied or factory accessory tubing Check refrigerant charge for maximum efficiency REFRIGERANT TUBING Connect tubing to fittings on out door unit vapor and liquid service valves See Table 1 Use refrigerant grade tub
15. ostat Yes No No Winter Start Control Yest No No Accumulator No No No Compressor Start Assist Capacitor and Relay a8 Ne Low Ambient Controller ee Control Yes No No Low Ambient Pressure Switch Wind Baffle See Low Ambient Instructions No No Coastal Filter No No Yes Support Feet Recommended No Recommended Liquid Line Solenoid Valve See Long Line or No Application No Hard Shutoff TXV Guideline Ball Bearing Fan Motor Yes No No For tubing line sets between 50 and 175 ft refer to Residential Split System Long Line Application Guideline t Only when low pressure switch is used 3 Required for Low Ambient Controller full modulation feaature and MotorMaster Control only DISCONNECT WARNING PERN E C AND OR To avoid personal injury or death do not supply power to unit LOCAL CODES CONTACTOR with compressor terminal box cover removed NOTE Install branch circuit 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 A WARNING 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 electrical shock fire or death ROUTE GROUND AND POWER WIRES Remove access panel and control box cov
16. s Consult Low Ambient Guideline for wind baffle construction NOTE Unit must be level to within 2 per compressor manu facturer specifications 3 8 9 53 DIA TIEDOWN KNOCKOUTS IN BASEPAN 2 PLACES SERIAL VIEW FROM TOP 207 9 POWER UNIT RATING PLATE ACCESS CARRIER CORP INDIANAPOLIS IN 313948401 REVA 46206 MAXIMUM OUTDOOR OPERATING AMBIENT IN HEATING MODE IS 66 18 9 DIMENSIONS IN PARENTHESIS ARE IN MILLIMETERS SERIES DESIGNATION IS THE 13TH POSITION OF THE UNIT MODEL NUMBER A91055 MODEL 38TKB In In In In 018 024 030 036 22 1 2 27 1 2 2 13 16 6 15 16 042 048 060 30 34 15 16 4 9 3 4 Fig 2 Unit Reference Drawing 2 NOTE Avoid contact between tubing and structure OUTDOOR WALL INDOOR WALL CAULK 1 11 2 LIQUID TUBE VAPOR TUBE INSULATION THROUGH THE WALL a OST HANGER STRAP AROUND VAPOR TUBE ONLY INSULATION 0 KY VAPOR TUBE O amp T T 17MIN 1 LIQUID TUBE SUSPENSION A94028 Fig 3 Piping Installation Step 3 Clearance Requirements When insta
17. ue or change at any time specifications or designs without notice and without incurring obligations 1 4 101 Catalog No 563 754 Tab 2a Printed in U S A Form 38TKB 5SI Pg 1 11 98 Replaces 38TKB 4SI Table 1 Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters In UNIT LIQUID VAPOR VAPOR LONG LINE SIZE Connection Diameter Tube Diameter Connection Diameter Tube Diameter Connection Diameter Tube Diameter 018 024 3 8 3 8 5 8 5 8 5 8 3 4 030 036 3 8 3 8 3 4 3 4 3 4 7 8 042 048 3 8 3 8 7 8 7 8 7 8 1 1 8 060 3 8 3 8 7 8 1 1 8 7 8 1 1 8 Notes 1 Tube diameters are for lengths up to 50 ft For tube sets over 50 ft consult Residential Long Line Application Guideline 2 Do not apply capillary tube indoor coils to these units INSTALLATION Step 1 Check Equipment and Job Site UNPACK UNIT Move to final location Remove carton taking care not to damage unit INSPECT EQUIPMENT File claim with shipping company prior to installation if shipment is damaged or incomplete Locate unit rating plate on unit service panel See Fig 2 It contains information needed to properly install unit Check rating plate to be sure unit matches job specifications Step 2 Install on a Solid Level Mounting Pad If conditions or local codes require the unit be attached to a pad tie down bolts should be used and fastened through knockouts AIR IN AIR D
18. unit a minimum of 10 minutes before checking charge 2 Measure suction pressure by attaching an accurate gage to suction valve service port 3 Measure suction temperature by attaching an accurate ther mistor type or electronic thermometer to suction line at service valve 4 Measure outdoor air dry bulb temperature with thermometer 5 Measure indoor air entering indoor coil wet bulb tempera ture with a sling psychrometer 6 Refer to Table 3 Find outdoor temperature and evaporator entering air wet bulb temperature At this intersection note superheat 7 Refer to Table 4 Find superheat temperature located in item 6 and suction pressure At this intersection note suction line temperature 8 If unit has a higher suction line temperature than charted temperature add refrigerant until charted temperature is reached 9 If unit has a lower suction line temperature than charted temperature reclaim refrigerant until charted temperature is reached 10 If outdoor air temperature or pressure at suction valve changes charge to new suction line temperature indicated on chart Step 12 Final Checks IMPORTANT Before leaving job be sure to do the following 1 Securely fasten all panels and covers 2 Tighten service valve stem caps to 1 12 turn past finger tight 3 Leave User s Manual with owner Explain system operation and periodic maintenance requirements outlined in manual 4 Fill out Dealer Installation
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