38TKB Air Conditioning Unit Installation and Start
Contents
1. sm essc mE ora ee j T ss u Tas Superheat F is at low side service port SUPERHEAT TEMP CF 0 2 4 6 8 10 12 14 16 20 22 24 26 28 30 32 34 36 38 40 Table 4 Required Suction Line Temperature SUCTION PRESSURE AT SERVICE PORT PSIG s sz si we me me zz 3 TL 4 8 Eos p wrap a ws xw wert dec are quam p c m ae SN a up m Em EAE us mer DAMES NEUE MU Sr EAR NU UNI UR Ce p 4 sr 59 s s T e 4 4 s s ss sr 39 e m 4 m eee 5L 6 j e er 9 1 sr s i s e 1 4 s C s t w 59 sr S amp nT E e 9 s s P s n 5 7 pw jos per jJ e a ee e c ceres m Pu 038 1792 yo ew p m m 1 51 m 1 59 p 8 T oue SC a m pomi mcm ee M Loos doge ec qp om p Ban p s F s 7 risi Copyright 1999 CARRIER Com 7310 W Morris St Indianapolis 46231 a 76 45 43 41 39 37 35 33 31 29 27 26 25 23 85 7 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 38tkb5si Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 563 754 P2. 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 clectrical 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 serious hazards which will result in
3. 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 WARNING Before installing modifying or servicing system main elec trical disconnect switch must be in the OFF position There may be more than 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 4S L ASS 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 in
4. INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED NOT USED 24 VAC COM NOT USED NOT USED OPTIONAL OUTDOOR SENSOR CONNECTION OTHER FA FB FC NON PROGRAMMABLE FD FF FX AC THERMOSTAT FAN COIL 24 VAC HOT HEAT STAGE 1 COOL STAGE 1 INDOOR FAN Fig 5 24 v Control Circuit Connections 5 AIR CONDITIONER SEE NOTE 2 A9468 AIR CONDITIONER SEE NOTE 2 A97595 AIR CONDITIONER SEE NOTE2 A97593 CARRIER NON PROGRAMMABLE THERMOSTAT FV4A AIR MODEL AC FAN COIL CONDITIONER 24 VAC HOT 24 VAC COM HEAT STAGE 1 SEE NOTE2 COOL STAGE 1 INDOOR FAN A97596 OTHER NON PROGRAMMABLE FV4A AIR AC THERMOSTAT FANCOIL CONDITIONER J1 JUMPER 24 VAC HOT HEAT STAGE 1 SEE COOL STAGE 1 NOTE 2 INDOOR FAN A97592 NOTES 1 CARRIER THERMOSTAT WIRING DIAGRAMS ARE ONLY ACCURATE FOR MODEL NUMBERS BEGINNING WITH TSTAT 2 WIRING MUST CONFORM TO NEC OR LOCAL CODES CARRIER PROGRAMMABLE THERMOSTAT 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 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 SOLEN
5. 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 tubing 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 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 ACCESSORY Crankcase Heater RE
6. injury or death Use all service ports and open all flow control devices including solenoid valves A CAUTION If ANY refrigerant tubing is buried provide a 6 in vertical rise at service valve Retrigerant tubing lengths up to 36 in may be buried without further special consideration For lengths above 36 in consult your local distributor CAUTION To prevent damage to unit or service valves observe the following Use a brazing shield 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 ficld 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
7. subcooling charging conditions are not favorahle 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 15 fi 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 Operate unit a minimum of 10 minutes before checking charge 2 Measure suction pressure by attaching an accurate gage 0 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 bas a lower suction line temperature than charted temperature reclaim refrigerant unti charted temperature is reached 10 If outdoor air temperature or pressure at suction valve changes charge to new suction line tempera
8. OID 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 CONTACTOR A97368 Fig 5 Typical 24 v Circuit Connections Continued Step 10 Start Up and Check Charge 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 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 elevated noise levels equalized pres sures and reduced current draw Correct by reversing power connection L1 and L2 on contactor A CAUTION To prevent personal injury wear safety glasses protective clothing and gloves when handling retrigerant and observe the following lt Back seating service valves are not equipped with Schrader valves Fully back seat counter clockwise valve stem before removing gage port cap Front seating service valves are equipped with Schrader valves CAUTION Do not vent refrigerant to atmosphere Recover during system re
9. OUGH THE WALL P INSULATION VAPOR TUBE HANGER STRAP AROUND VAPOR U TUBE ONLY 1 MIN SUSPENSION LIQUID TUBE A94028 Fig 3 Piping Installation Step 3 Clearance Requirements When installing allow sufficient space for airflow wiring retrig 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 coi combination A CAUTION Remove indoor coil piston if unit is to be installed on system with a thermostatic expansion valve 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
10. QUIRED FOR LOW AMBIENT APPLICATIONS oo ww a e Ne rd No REQUIRED FOR REQUIRED FOR LONG LINE SEA COAST APPLICATIONS APPLICATIONS OVER 50 FT WITHIN 2 MILES Ye e No Winter Start Control Po ee c No Accumulator ae cO QE ERN SO No Compressor Start Assist Ves Yes No Capacitor and Relay Low Ambient Controller a MotorMaster Control Yes NS or Low Ambient Pressure Switch Wind Baffle See Low Ambient Instrucions No No Coastal Filter NO Ne Yes Support Feet Liquid Line Solenoid Valve or Hard Shutoff TXV Ball Bearing Fan Motor Recommended Recommended See Long Line Application Guideline No ep erc Ne No For tubing fine sets between 50 and 175 ft refer to Residential Split System Long Line Application Guideline t Only when low pressure switch is used Required for Low Ambient Controller full modulation feaature and MotorMaster Control only WARNING avoid personal injury death not supply power to unit 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 WARNING The unit cabinet must have an uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur The ground m
11. ay 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 cover to gain access to unit wiring Extend wires from disconnect through power wiring hole provided and into unit control box DISCONNECT PER N E C AND OR LOCAL CODES CONTACTOR FIELD POWER O GROUND LUG A91056 Fig 4 Line Power Connections 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 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 acce
12. pair 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 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 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 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
13. rinted in U S A Form 38TKB 5SI Pg8 11 98 Replaces 38TKB 3SI 11 4 a a PC 101
14. ssory 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 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 MODEL AC 24 VAC HOT 24 VAC COM HEAT STAGE 1 COOL STAGE 1 INDOOR FAN CARRIER PROGRAMMABLE THERMOSTAT MODEL AC 24 VAC HOT INDOOR FAN HEAT STAGE 1 COOL STAGE 1 NOT USED NOT USED 24 VAC COM NOT USED NOT USED OPTIONAL OUTDOOR SENSOR CONNECTION OTHER NON PROGRAMMABLE AC THERMOSTAT 24 VAC HOT HEAT STAGE 1 COOL STAGE 1 INDOOR FAN SINGLE STAGE AIR FURNACE CONDITIONER SEE NOTE2 A97467 SINGLE STAGE AIR FURNACE CONDITIONER SEE NOTE 2 A97469 SINGLE STAGE AIR FURNACE CONDITIONER SEE NOTE 2 A97367 CARRIER NON PROGRAMMABLE FA FB FC THERMOSTAT FD FF MODEL AC FAN COIL 24 VAC HOT 24 VAC COM HEAT STAGE 1 COOL STAGE 1 INDOOR FAN CARRIER PROGRAMMABLE FA FB FC THERMOSTAT FD FF FX MODEL AC FAN COIL 24 VAC HOT
15. sulation is pliable and completely sur rounds the vapor line 9 When necessary use hanger straps which are 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 ficld supplied tubing For proper unit operation check rcfrigerant 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 discontinue or change at any time specifications or designs without notice and without incurring obligations ab 2a Catalog No 563 754 Printed in U S A Form 38TKB 5SI Pg 1 11 98 Replaces 38TKB 3SI Table 1 Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters In VAPOR VAPOR LONG LINE w 98 o 090 036 e 938 7 asr s Notes 1 Tube diameters are for lengths up to 50 ft For tube sets over 50 ft con
16. sult 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 Connection Diameter Tube Diameter Ege j s es Tube Diameter 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 sct 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 baffles Consult Low Ambient Guideline for wind baffle construction NOTE Unit must be level to within 2 per compressor manu facturer specifications tie down bolts should be used and fastened through knockou
17. ts AIR IN AIR DISCHARGE 3 8 9 53 DIA TIEDOWN KNOCKOUTS IN BASEPAN 2 PLACES AIR IN AIR DISCHARGE UNIT MOUNTING PATTERN VIEW FROM TOP 207 9 2 1 2 A Ao FIELD POWER SUPPLY CONN UNIT RATING PLATE j 7 g 22 22 DIA HOLE WITH 27 z A 1 Ug 28 57 DIA KNOCKOUT Y ALL SIZES AND 1 3 g 34 92 DIA KNOCKOUT 036 THRU 060 w a L L SIZES ONLY ACCESS LT FIELD CONTROL SUPPLY PANEL i CONN 7 8 22 22 DIA HOLE EY oil J 1 10 1 2 fal 266 7 Bi ERN E J irani oe 3 8 9 53 DIA LIQUID 137 0 LINE CONNECTION 44 6 NOTES 1 ALLOW 30 762 CLEARANCE TO SERVICE END OF 3 MAXIMUM OUTDOOR OPERATING AMBIENT IN HEATING MODE IS 66 F 18 9 C UNIT 48 1219 ABOVE UNIT 6 152 ON ONE SIDE 12 306 4 DIMENSIONS IN PARENTHESIS ARE IN MILLIMETERS ON REMAINING SIDE AND 24 610 BETWEEN 5 SERIES DESIGNATION IS THE 13TH POSITION OF THE UNIT UNITS FOR PROPER AIRFLOW MODEL NUMBER 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 A91055 MODEL 38TKB 018 024 030 036 042 048 060 Fig 2 Unit Reference Drawing 2 NOTE Avoid contact between tubing and structure OUTDOOR WALL INDOOR WALL CAULK LIQUID TUBE L VAPOR TUBE INSULATION THR
18. ture 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 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 arcas such as coastal applications which may require more frequent maintenance Where a dash appears do not attempt to charge system under these conditions or refrigerant siugging may occur Charge must be weighed in NOTE OUTDOOR TEMP CF 55 60 65 70 75 80 85 90 95 100 105 110 115 Table 3 Superheat Charging EVAPORATOR ENTERING AIR TEMPERATURE F WB So s s se se e2 64 eo 2 72 7 3 L 2 23 Los 29 3 o az i T i 3 2 T 2 3e 39 35 2 4 6 3e 33 3e T 9 2 30 a 39 35 s L 2 27 39 p s tope pepe Ta EE Wa EZ Ice qoem Es as 3 j de j j paspa ej 3 s Eque E jS orem 1 vom eue om s p ie qo MT a
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