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38BYW Split-System Heat Pump Installation and

1. 3 Connect refrigerant tubing to fittings on outdoor unit vapor and liquid service valves 4 Service valves are closed from factory and ready for brazing 5 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 6 Refrigerant tubing and indoor coil are now ready for leak testing This check should include all field and factory joints Step 10 Make Electrical Connections A WARNING 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 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 NOTE Use copper wire only between disconnect switch and unit NOTE Install branch circuit disconnect per NEC of adequate size 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 a
2. COM NOT USED TROUBLE OPTIONAL OUTDOOR SENSOR CONNECTION CARRIER PROGRAMMABLE THERMOSTAT MODEL HP 24 VAC HOT INDOOR FAN HEAT STAGE 2 COOL HEAT STAGE 1 RVS COOLING NOT USED 24 VAC COM NOT USED TROUBLE OPTIONAL OUTDOOR SENSOR CONNECTION FA FB FC FH FAN COIL WITH SMART HEAT ae IL ee a a a me peer sma gla ee r t t FA FB FC FH FAN COIL WITH SMART HEAT SUPPLEMENTAL HEATING HEAT PUMP E Tee i s A97541 HEAT PUMP A97543 CARRIER PROGRAMMABLE THERMOSTAT MODEL HP 24 VAC HOT INDOOR FAN HEAT STAGE 2 COOL HEAT STAGE 1 RVS COOLING NOT USED 24 VAC COM NOT USED TROUBLE CARRIER PROGRAMMABLE THERMOSTAT MODEL 2S 24 VAC HOT FAN COOL HEAT STAGE 1 HEAT STAGE 2 HEAT STAGE 3 RVS COOLING 24 VAC COMM RVS HEATING TROUBLE OUTDOOR SENSOR CONNECTION FA FB FC FH ONE FAN COIL WITH OUTDOOR HEAT SMART HEAT THERMOSTAT PUMP J T1 Ff A97542 Smart Sequencing Application Model 2S thermostat with switch C OFF and switch D ON uses single speed heat pump FK4 fan coil with selected 2 1 size ratio heaters Provides 3 stages of auxiliary heat for even heating comfort via W W1 and Y1 W2 Refer to FK4 Installation Instructions A97540 Fig 11 Typical 24 v Circuit Connections using Carrier Model HP Thermostat with Smart Heat and No Outdoor Thermostat 1 Outdoor Thermostat or
3. Supplemental Heat Relay and Carrier Model 2S Thermostat with FK4C Fan Coil and Smart Staging FA FB FC FH OTHER FAN COIL FA FB FC FH HP THERMOSTAT SMART HEAT OTHER FAN COIL HEAT HP THERMOSTAT SMART HEAT PUMP 24 VAC HOT 24 VAC HOT 24 VAC COM 24 VAC COM COOL HEAT STAGE 1 COOL HEAT STAGE 1 HEAT STAGE 2 A97411 A97410 FA FB FC FH OTHER FAN COIL HP THERMOSTAT SMART HEAT 24 VAC HOT 24 VAC COM COOL HEAT STAGE 1 INDOOR FAN RVS COOLING o EMERGENCY HEAT HEAT STAGE 2 A97412 Fig 12 Typical 24 v Circuit Connections using Other HP Thermostats with Smart Heat and No Outdoor Thermostat 1 Outdoor Thermostat or Supplemental Heat Relay CARRIER CARRIER DUAL FUEL TWO STAGE OR DUAL FUEL THERMOSTAT VARIABLE SPEED THERMOSTAT SINGLE STAGE MODEL DF FURNACE HEAT PUMP MODEL DF FURNACE HEAT PUMP 24 VAC HOT FURNACE LO W W COMPRESSOR v v 24 VAC HOT FAN FURNACE RVS COOLING RVS COOLING FURNACE HI N A 24 VAC COM 24 VAC COM RVS HEATING RVS HEATING See notes 7 and 8 See note 7 RVS SENSING RVS SENSING OUTDOOR I 1 qe OUTDOOR OUTDOOR J 9L mpT 9 OUTDOOR SENSOR TEMPERATURE SENSOR TEMPERATURE CONNECTION S2 F 4 SENSOR CONNECTION S2 4 SENSOR A97539 A97538 Fig 13 Typical 24 v Circuit Connections using Carrier Model DF Thermostat with Single or 2 Stage Furnace WIRING DIAGRAM NOTES LEGEND 1 CARRIE
4. climate and code requirements to provide clearance above estimated snowfall level and ensure adequate drainage of unit Step 6 Check Defrost Thermostat Check defrost thermostat to ensure it is properly located and securely attached There is a liquid header with a brass distributor and feeder tube going into outdoor coil At the end of 1 of the 3 D 9 53 TIEDOWN KNOCKOUTS 2 PLACES A94199 TIEDOWN KNOCKOUT MIN PAD LOCATIONS DIM IN A B In In 38BYWO024 060 30X30 23 1 2 Fig 3 Mount Unit to Pad UNIT SIZE feeder tubes there is a 3 8 in OD stub tube approximately 3 in long See Fig 4 The defrost thermostat should be located on stub tube Note that there is only 1 stub tube used with liquid header and on most units it is the bottom circuit Metering Device Step 7 Metering Device NOTE A thermostatic expansion valve TXV is required on all 38BYW units Step 8 refers to installation of the TXV FEEDER TUBE STUB TUBE DEFROST THERMOSTAT A97517 Fig 4 Defrost Thermostat Location CAUTION Remove indoor coil piston 1f unit is to be installed on system with a TXV metering device Step 8 Remove Indoor AccuRater Piston and Install TXV CAUTION For proper unit operation and reliability units must be installed with a field supplied hard shut off TXV Do not install with evaporator coils having capillary tube metering Step 9 Make Tubing
5. elevated noise levels equalized pres sures and reduced current draw Correct by reversing power connection L1 and L2 on contactor CAUTION To prevent personal injury wear safety glasses protective clothing and gloves when handling refrigerant and observe the following e Back seating service valves are 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 properly charge a 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 6 turn for front seating valves female hex stem or 1 12 turn for back seating valves male square stem 3 Close electrical disconnects to energize system 4 Set room thermostat at desired temperature 5 Set room thermostat to HEAT or COOL and fan to ON or AUTO mode as desired Operate unit for 15 minutes Check system refrigerant charge 6 Factory charge is shown on outdoor unit rating plate Adjust charge in cooling mode by following procedure shown on the charging table Check charge in heating mode by following pr
6. option contacts close to complete circuit and bring on second bank of supplemental electric heat When thermostat is satisfied its contacts open de energizing the contactor and sequencer All heaters and motors should stop Defrost The defrost control is a time temperature control which includes a field selectable quick connects located at board edge time period between defrost cycles 30 50 and 90 minutes factory set at 90 minutes The electronic timer and defrost cycle start only when contactor is energized and defrost thermostat is closed The defrost mode is identical to cooling mode except that outdoor fan motor stops and second stage heat is turned on to continue warming conditioned space CARE AND MAINTENANCE For continuing high performance and to minimize possible equip ment failure it is essential that 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 upon geographic areas such as coastal applications which require more frequent maintenance CARRIER CARRIER DUAL FUEL DUAL FUEL THERMOSTAT SINGLE STAGE THERMOSTAT MODEL DF FURNACE HEAT PUMP MODEL DF 24 VAC HOT FAN FURNACE COMPRESSOR RVS COOLING N A 24 VAC COM RVS HEATING See note 7 RVS SENSING RVS SENSING OUTDOOR 951 Fara OUTDOOR OUTDOOR SENSOR TEMPERATURE SE
7. Connections 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 CAUTION To prevent compressor damage DO NOT bury more than 36 in of refrigerant tubing If ANY tubing is buried provide 6 devices or piston After removing existing AccuRater from indoor coil install field supplied bi flow hard shut off TXV kit See Fig 5 and 6 SENSING BULB EQUALIZER TUBE THERMOSTATIC EXPANSION VALVE A88382 Fig 5 Typical TXV Installation 10 O CLOCK 2 O CLOCK A SRY Z SUCTION TUBE f 8 O CLOCK 4 O CLOCK IN OD amp SMALLER LARGER THAN IN OD A81032 Fig 6 Positioning of Sensing Bulb For TXV kit part number and charging instruction refer to TXV label on your unit If indoor unit fan coil comes factory equipped with a bi flow hard shut off TXV no TXV change is required Install TXV kit to indoor coil as follows Install suction tube adapter 2 Install liquid flare to sweat adapter 3 Connect external equalizer tube to fitting on suction tube adapter 4 Position sensing bulb on horizontal portion of suction tube adapter Secure using supplied hardware 5 Insulate bulb after installation See Fig 5 6 Leak check all connections in vertical rise at service valve CAUTION To prevent damage to u
8. NSOR CONNECTION S2 F4 NSOR CONNECTION 24 VAC HOT FAN FURNACE LO FURNACE HI 24 VAC COM RVS HEATING A97638 F wa COMPRESSOR RVS COOLING TWO STAGE OR VARIABLE SPEED FURNACE HEAT PUMP See notes 7 and 8 OUTDOOR TEMPERATURE SENSOR A97539 Fig 10 Typical 24 v Circuit Conncetion using Carrier Model DF Thermostat with Single or 2 Stage Furnace ACCESSORY Crankcase Heater Evaporator Freeze Thermostat Accumulator Compressor Start Assist Capacitor and Relay Low Ambient Controller MotorMaster Control or Low Ambient Pressure Switch Wind Baffle Unit Risers Liquid Line Solenoid Valve or Hard Shutoff TXV Ball Bearing Fan Motor Table 2 Accessory Usage REQUIRED FOR REQUIRED FOR REQUIRED FOR LOW AMBIENT LONG LINE BURIED LINE APPLICATIONS APPLICATIONS APPLICATIONSt BELOW 55 F OVER 50 FT OVER 3 FT Yes Yes Ve No Yes Yes See Low Ambient Instructions EE No No Ne ma Line No Application Yes Guideline No For tubing line sets between 50 and 175 ft refer to Residential Split System Long Line Application Guideline T For buried line applications refer to Residential Split System Buried Line Application Guideline ti Required for Low Ambient Controller full modulation feature and MotorMaster Control only 6 CARRIER PROGRAMMABLE THERMOSTAT MODEL HP 24 VAC HOT INDOOR FAN HEAT STAGE 2 COOL HEAT STAGE 1 RVS COOLING NOT USED 24 VAC
9. R THERMOSTAT WIRING DIAGRAMS ARE ONLY ACCU RATE FOR MODEL NUMBERS TSTAT 24N FACTORY WIRING 2 WIRING MUST CONFORM TO NEC OR LOCAL CODES 3 SOME UNITS ARE EQUIPPED WITH PRESSURE SWITCH ES TEM PERATURE SWITCH OR 5 MINUTE COMPRESSOR CYCLE PRO TECTION CONNECT 24 V FIELD WIRING TO FACTORY PROVIDED STRIPPED LEADS 4 THERMOSTATS ARE FACTORY CONFIGURED WITH 5 MINUTE COMPRESSOR CYCLE PROTECTION AND 4 CYCLES PER HR LIMIT SEE THERMOSTAT INSTALLATION INSTRUCTIONS FOR EMERGENCY HEAT RELAY DETAILS 5 TO STAGE ELECTRIC RESISTANCE HEAT CONSULT OUTDOOR SUPPLEMENTAL HEAT RELAY THERMOSTAT INSTALLATION INSTRUCTIONS 6 UNDERLINED LETTER ON DUAL TERMINAL INDICATES ITS USAGE A97413 FOR EXAMPLE O W2 MEANS O O W2 MEANS W2 7 OUTDOOR TEMPERATURE SENSOR MUST BE ATTACHED IN ALL DUAL FUEL INSTALLATIONS JUMPER WIRE BETWEEN O W2 AND L THERMOSTAT TERMI NALS MUST BE PRESENT 8 Yl AND O CONNECTIONS TO 2 STAGE FURNACES MAY NOT EXIST OR MAY ONLY BE A WIRE RATHER THAN A SCREW TERMINAL 24 V FIELD WIRING FIELD SPLICE CONNECTION OUTDOOR THERMOSTAT 10 SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual including Unit Familiarization Maintenance e Installation Overview Operating Sequence A large selection of product theory and skills programs is available using popular video based formats and materials All include video and o
10. an accessory transformer as required NOTE The defrost timer is factory set for 90 minute cycles The timer can be field set for 30 and 50 minute cycles depending on defrost conditions in your geographical location Step 11 Compressor Crankcase Heater When equipped with a crankcase heater energize heater a mini mum of 24 hr before starting unit To energize heater only set thermostat to OFF and close electrical disconnect to outdoor unit A crankcase heater is required if refrigerant tubing is longer than 50 ft NOTE The Seasonal Energy Efficiency Ratio SEER and Heat ing Seasonal Performance Factor HSPF is obtained with the crankcase heater de energized To de energize the crankcase heater disconnect black crankcase heater wires at contactor After disconnecting make sure wires are isolated from all other electri cal connections and components to prevent electrical shorting Step 12 Install Electrical Accessories Refer to the individual instructions packaged with kits or acces sories when installing Step 13 Start Up and Check Charge nu Yun 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 In scroll compressor applications Dome temperatures may be hot n 3 phase application incorrect phasing will cause reverse rotation resulting in
11. ap HERE Carrier HEATING amp COOLING 38BYW Split System Heat Pump Visit www carrier com 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 N When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAU TION These words are used with the safety alert symbol DAN GER identifies the mos
12. ccess to unit wiring Extend wires from disconnect through power wiring hole provided and into unit control box 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 electric shock fire or death 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 DISCONNECT PER N E C AND OR LOCAL CODES m CONTACTOR O NEN FIELD POWER WIRING pre FIELD GROUND E 717 77T ed 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 9 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 Use furnace transformer fan coil transformer or accessory trans former for control power 24 v 40 va 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
13. nit or service valves observe the following e Use a brazing shield e Wrap service valves with wet cloth or use a heat sink material Connect outdoor unit to indoor sections using accessory tubing package or field supplied tubing of refrigerant grade correct size and condition For tubing requirements beyond 50 ft consult your local distributor or the Long Line Application Guideline Refer to Fig 7 for refrigerant tube dimensions and connections AIR DISCHARGE FIELD POWER SUPPLY CONN 1 3 DIA HOLE WITH 1 s DIA KNOCKOUT AND 1 3 DIA KNOCKOUT FIELD CONTROL SUPPLY CONN 73 DIA HOLE SUCTION LINE CONN LIQUID LINE CONN A97009 UNIT SIZE LIQUID TUBE VAPOR TUBE Tube Dia 024 58 55 030 036 3 8 3 8 3 4 3 4 042 048 7 7i 060 3 8 3 8 1 1 8 NOTE Tube diameters are for lengths up to 50 ft For tubing lengths greater than 50 ft consult your local distributor Fig 7 Refrigerant Tube Dimensions Connections 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 SWEAT CONNECTION Consult local code requirements 2 Remove plastic retainer holding outdoor piston in the liquid service valve and connect sweat flare adapter provided to valve See Fig 8 PISTON PISTON RETAINER SWEAT FLARE ADAPTER A98048 Fig 8 Liquid Service Valve
14. ocedure shown on heating check chart Both are located on outdoor unit SEQUENCE OF OPERATION NOTE Defrost control board may be equipped with 5 minute lockout timer which may be initiated upon any interruption of power With power supplied to indoor and outdoor units transformer is energized Cooling On a call for cooling thermostat makes circuits R O R Y and R G Circuit R O energizes reversing valve switching it to cooling position Circuit R Y energizes contactor starting outdoor fan motor and compressor circuit R G energizes indoor unit blower relay starting the indoor blower motor on high speed When the thermostat is satisfied its contacts open de energizing the contactor and blower relay Compressor and motors should stop NOTE If indoor unit is equipped with a time delay relay circuit the blower will run an additional 90 sec to increase system efficiency Heating On a call for heating thermostat makes circuits R Y and R G Circuit R Y energizes contactor starting outdoor fan motor and compressor Circuit R G energizes indoor blower relay starting blower motor on high speed Should temperature continue to fall R W2 is made through second stage room thermostat bulb Circuit R W2 energizes a sequencer bringing on first bank of supplemental electric heat and providing electrical potential to second heater sequencer if used If outdoor temperature falls below setting of outdoor thermostat field installed
15. places NEW NOTE Avoid contact between tubing and structure INDOOR WALL CAULK LIQUID TUBE rn L VAPOR TUBE INSULATION THROUGH THE WALL HANGER STRAP AROUND VAPOR V INSULATION VAPOR TUBE 1 MIN gt _ SUSPENSION V LIQUID TUBE A94028 Fig 2 Connecting Tubing Installation Step 3 Clearance Requirements When installing allow sufficient space for airflow clearance wiring refrigerant piping and service Common clearances are 6 in on 1 side 12 in on 2 sides and 30 in on service side of unit Allow 24 in between units Discharge air must be unobstructed and must not recirculate Position so snow ice or water from roof or eaves cannot fall directly on unit On rooftop applications locate unit at least 6 in above roof surface 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 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 The maximum outdoor operating ambient in heating mode is 66 F Step 5 Elevate Unit A CAUTION Accumulation of water and ice in base pan may cause equipment damage In areas where prolonged freezing temperatures are encountered elevate unit per local
16. r slides plus companion book Classroom Service Training plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service Training A94328 Copyright 1998 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 38byw1si Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book z z PC 101 Catalog No 563 830 Printed in U S A Form 38BYW 1SI Pg 12 1 98 Replaces NEW a al 5a
17. t 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 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 Locate unit away from windows 2 Ensure that vapor and liquid tube diameters are appropriate to capacity of unit 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 5 When passing refrigerant tubes through the wall seal opening with RTV or other pliable silicon based caulk See Fig 2 6 Avoid direct tubing contact with water pipes ductwork floor joists wall studs floors and walls A97005 Fig 1 Split System Heat Pump 7 Do not suspend refrigerant tubing from joists and studs with a rigid wire or strap which comes in direct contact with tubing See Fig 2 8 Ensure that tubing insulation is pliable and completel
18. y 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 When outdoor unit is connected to factory approved indoor unit outdoor unit contains system refrigerant charge for operation with indoor unit of the same size when connected by 15 ft of field supplied or factory accessory tubing For proper unit opera tion check refrigerant charge using charging information located on control box cover INSTALLATION Step 1 Check Equipment and Jobsite INSPECT EQUIPMENT File claim with shipping company prior to installation if shipment is damaged or incomplete Locate unit rating plate on unit service panel 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 pad tiedown bolts should be used and fastened through knockouts provided in unit base pan Refer to Fig 3 for pad dimensions and dimensions needed to mount unit to pad Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 101 Catalog No 563 830 Tab 5a 5a Printed in U S A Form 38BYW 1SI Pg 1 1 98 Re

38BYW Split-System Heat Pump Installation and

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