38BY Heat Pump Installation and Start-Up Instructions
Contents
1. 1 8 IN DIA KNOCKOUT AND 1 3 g IN DIA KNOCKOUT FIELD CONTROL SUPPLY CONN 7 8 IN DIA HOLE A 3 8 IN DIA LIQUID LINE CONN A92468 wr ae eg Op TE TR SIZE n 018 511 18 5 8 024 036 3 4 042 060 71 Fig 2 Unit Reference Drawing Step 4 Remove Indoor AccuRater Piston and Install TXV 4 CAUTION For proper unit operation and reliability this unit must be installed with a field supplied hard shut off thermostatic expansion valve TXV Do not install with evaporator coils having capillary tube metering devices or piston After removing existing AccuRater from indoor coil install field supplied bi flow hard shut off TXV kit See Fig 3 and 4 SENSING BULB EQUALIZER TUBE THERMOSTATIC EXPANSION VALVE A88382 Fig 3 Typical TXV Installation 10 O CLOCK 2 O CLOCK Z UCTION TUBE 8 O CLOCK LARGER THAN 7 IN OD 4 O CLOCK 3 IN OD amp SMALLER A81032 Fig 4 Positioning of Sensing Bulb For TXV kit part number and charging instruction refer to TXV label in your unit If the 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 1 2 3 Install suction tube adapter Install liquid flare to sweat adapter Connect external equalizer tube to fitting on suction tube adapter Position sensing bulb on horizontal portion of suction tube adapter Secure using2. GET Carrier HEATING amp COOLING 38BY Heat Pump 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 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 warnings or cautions attached to the unit Consult local building codes and the National Electrical Code NEC for special instal lation requirements Recognize safety information This is the safety alert symbolA When you see this symbol on the unit or in instructions and manuals be alert to the potential for personal injury Understand the signal word DANGER WARNING or 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 sig
3. IRING FIELD WIRING ODT OUTDOOR THERMOSTAT SHR EMERGENCY HEAT RELAY FIELD SPLICE USED WITH FB4A FB5A FC4A FH4A FA1A FK4A FAN COILS USED WITH FB4A FBSA FC4A FH4A FA1A FK4A FAN COILS REMOVE BREAK OFF JUMPERS ON INDOOR FAN COIL CIRCUIT BOARD WHEN INSTALLING OUTDOOR THERMOSTATS Fig 8 Typical Circuit Connections pelea 6 NOTES NOTES Copyright 1994 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 33012c Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations ook a PC 101 Catalog No 563 791 Printed in U S A Form 38BY 3SI Pg 8 2 94 Replaces 38BY 2SI a aj oa
4. NG Route 24 v control wires through control wiring grommet and connect leads to control wiring See Fig 8 Use No 18 AWG color coded insulated 35 C minimum wires 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 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 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 7 Install Electrical Accessories Refer to the individual instructions packaged with the kits or accessories when installing Step 8 Start up 1 If equipped with a crankcase heater energize heater a mini mum of 24 hrs before starting unit To energize heater only set thermostat at OFF position and close electrical disconnect to outdoor unit 2 Fully open liquid and vapor tube service valves 3 Unit is shipped with valve stem s front seated and caps installed Replace stem caps after system 1s opened to refrig erant flow Replace caps finger tight and tighten additional 1 6 tur
5. gths up to 50 ft For tubing lengths greater than 50 ft consult your local distributor REFRIGERANT TUBING Connect refrigerant tubing to fit tings on outdoor unit vapor and liquid service valves See Fig 2 Remove plastic retainer holding outdoor piston in the liquid service valve and connect sweat adapter provided to valve See Fig 6 Insert strainer as shown in Fig 6 SWEAT CONNECTION 4 CAUTION To avoid valve damage while brazing service valves must be wrapped with a heat sinking material such as a wet cloth Use refrigerant grade tubing Service valves are closed from factory 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 Consult local code requirements Refrigerant tubing and indoor coil are now ready for leak testing This check should include all field and factory joints Step 6 Make Electrical Connections 4 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 s 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 constitu
6. l remaining sides must be maintained Maintain a distance of 24 in between units Position so snow ice and 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 3 Elevate Unit For proper drainage the heat pump must be raised off the mounting surface 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 563 791 Tab 5a 5a Printed in U S A Form 38BY 3SI Pg 1 2 94 Replaces 38BY 2SI AIR DISCHARGE AIR IN gt AIR DISCHARGE F DIA SUCTION LINE CONN NOTES 1 Allow 30 In clearance to service end of unit 48 In above unit 6 In on one side 12 In on remaining side and 24 In between units for proper airflow Minimum outdoor operating ambient in cooling mode is 55 F Unless low ambient control is used Max 115 F Maximum outdoor operating ambient in heating mode is 66 F Series designation is the 13th position of the unit model number Center of gravity o1 amp NO AIR DISCHARGE FIELD POWER SUPPLY CONN 7 8 IN DIA HOLE WITH 1
7. motor on high speed Should the temperature continue to fall R W2 is made through the second stage room thermostat bulb Circuit R W2 energizes a sequencer bringing on the first bank of supplemental electric heat and providing electrical potential to the second heater sequencer if used If outdoor temperature falls below the setting of the outdoor thermostat field installed option contacts close to complete the circuit and bring on the second bank of supplemental electric heat When thermostat is satisfied 1ts 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 the defrost cycle will start only when contactor is energized and defrost thermostat is closed The defrost mode is identical to the cooling mode except the outdoor fan motor stops and a second stage heat is turned on to continue warming the conditioned space Step 9 Checking Charge Factory charge is shown on unit rating plate See Fig 2 4 WARNING Service valve gage ports are equipped with Schrader valves To prevent personal injury wear safety glasses and gloves when handling refrigerant 4 CAUTION Compressor damage may occur if system is overcharged Adjust charge in c
8. n using a backup wrench on valve body flats to prevent distortion of sheet metal 4 Close electrical disconnects to energize system 5 Set room thermostat at desired temperature 6 Set room thermostat at HEAT or COOL and fan switch at ON or AUTO as desired Operate unit for 15 minutes Check system refrigerant charge See Step 9 Checking Charge 44 WARNING 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 SEQUENCE OF OPERATION NOTE Defrost control board is equipped with 5 minute lockout timer which may be initiated upon any interruption of power NOTE With power supplied to indoor and outdoor units trans former is energized Cooling On a call for cooling the 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 R G energizes the indoor unit blower relay starting 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 Heating On a call for heating the 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
9. nifies hazards that 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 44 WARNING Before installing or servicing system always turn off main power to system There may be more than 1 disconnect switch Turn off accessory heater power if applicable Elec trical shock can cause personal injury or death INSTALLATION Step 1 Check Equipment and Jobsite 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 3 gt a z a a A A92055 Fig 1 Model 38BY 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 unit mounting pattern in Fig 2 to determine base pan size and knockout hole location When installing allow sufficient space for airflow clearance wiring refrigerant piping and service Allow 30 in clearance to service end of unit and 48 in above unit For proper airflow a 6 in clearance on side of unit and 12 in on al
10. ooling mode by following procedure shown on subcooling TXV label and check charge in heating mode by following procedure shown on heating check chart both located on unit 4 CAUTION Do not vent refrigerant to atmosphere Recover during system repair or final unit disposal CARE AND MAINTENANCE For continuing high performance and to minimize possible equip ment failure it is essential that periodic maintenance be performed on this equipment Consult User s Manual for the proper frequency of maintenance Frequency of maintenance may vary depending upon geographic areas such as coastal applications Leave User s Manual with homeowner Explain system operation and maintenance procedures outlined in User s Manual SYSTEMS WITHOUT OUTDOOR THERMOSTATS INDOOR OUTDOOR INDOOR OUTDOOR THERMOSTAT SPLICE SPLICE DEFROST THERMOSTAT TERMINAL SPLICE DEFROST SUBBASE CONNECTION CONNECTION BOARD SUBBASE BOARD CONNECTION BOARD _ HA A ae A FA A MA pa zn ee u ent eee EN N 2 EBEN A A FACTORY WIRING FIELD WIRING Y FIELD SPLICE USED WITH FD3A FF1A FAN COIL USED WITH FB4A FBSA FC4A FH4A FA1A FK4A FAN COILS A91326 SYSTEMS WITH ONE OUTDOOR THERMOSTAT SYSTEMS WITH TWO OUTDOOR THERMOSTATS INDOOR OUTDOOR INDOOR OUTDOOR THERMOSTAT TERMINAL SPLICE DEFROST THERMOSTAT TERMINAL SPLICE DEFROST SUBBASE BOARD CONNECTION BOARD SUBBASE BOARD CONNECTION BOARD FREE I I I ODT FACTORY W
11. r 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 5 8 Ensure that tubing insulation is pliable and completely sur rounds the vapor tube 9 When necessary use hangar straps which are 1 in wide and conform to the shape of the tubing insulation See Fig 5 10 Isolate the hangar straps from the insulation by using metal sleeves bent to conform to the shape of the insulation If refrigerant tubes or indoor coil is exposed to atmospheric condition for longer than 5 minutes it must be evacuated to 500 microns to eliminate contamination and moisture in the system OUTDOOR UNITS CONNECTED TO FACTORY APPROVED INDOOR UNITS Outdoor unit contains correct system refrig erant charge for operation with indoor unit of the same size when connected by 15 ft of field supplied or factory accessory tubing Check refrigerant charge for maximum efficiency See Step 9 Checking Charge Table 1 Refrigerant Connections and Recom mended Liquid and Vapor Tube Diameters In Tube Diameter NOTE AVOID CONTACT BETWEEN TUBING AND STRUCTURE OUTDOOR INDOOR WALL CITING g EN INSULATION THROUGH THE WALL VAPOR LINE Ds LIQUID LINE HANGER STRAP AROUND VAPOR LINE ONLY VAPOR v INSULATION SUSPENSION A92469 Fig 5 Piping Installation Tube diameters are for len
12. supplied hardware Insulate bulb after installation See Fig 4 5 Leak check all connections 4 CAUTION DO NOT BURY MORE THAN 36 IN OF REFRIGERANT TUBING IN GROUND If any section of tubing is buried there must be a 6 in vertical rise to the valve connections on the outdoor unit If more than the recommended length is buried refrigerant may migrate to cooler buried section during extended periods of unit shutdown causing refrigerant slugging and possible compressor damage at start up Step 5 Make Piping Connections Outdoor units may be connected to indoor sections using accessory tubing package or field supplied refrigerant grade tubing of correct size and condition For tubing requirements beyond 50 ft consult Long Line Application Guideline which is available at your local distributor NOTE In some cases noise in the living area has been traced to gas pulsations from improper installation of equipment INSTALLATION RECOMMENDATIONS 1 Locate the unit away from windows 2 Ensure that vapor and liquid tube 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 5 When passing refrigerant tubes through the wall seal the opening with RTV or other pliable silicon based caulk See Fig 5 6 Avoid direct lineset contact with wate
13. tes 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 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 PISTON PISTON RETAINER A92465 Fig 6 Liquid Service Valve DISCONNECT PER N E C AND OR LOCAL CODES CONTACTOR FIELD POWER O ne A Fa gt one MELLE AA 2 WIRING GROUND LUG A881 74 Fig 7 Line Power Connections panel to gain access to unit wiring Extend wires from disconnect through power wiring hole provided and into unit control box See Fig 2 44 WARNING The cabinet must have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 1993 or local codes to minimize personal injury if an electrical fault should occur This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes A failure to follow this warning could result in an electrical 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 See Fig 7 CONNECT CONTROL WIRI
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