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Number

One

ArConditbning

Maker

r^rrie^

Division

of

^1^

Carrier

Corporation

f

—--

't

w

Weathermaster

III

Dual-Compressor

Heat

Pump

(Outdoor

Coil

Section;

Indoor

Compressor

Section)

INDEX

Page

SAFETY

CONSIDERATIONS

.1

INSTALLATION.3

Step

1

—

Check

Equipment

and

Jobsite

.

3

•

UNPACKAGE

UNITS

•

INSPECT

EQUIPMENT

•

COMPLETE

OR

CONSIDER

SYSTEM

REQUIREMENTS

Step

2

—

install

Outdoor

Coil

Section.4

•

ON

THE

GROUND

•

ON

THE

ROOF

Step

3

—

Install

Indoor

Compressor

Section.5

Step

4

—

install

Indoor

Fan-Coil

and

Electric

Heater.5

Step

5

—

Make

Piping

Connections.5

•

REPLACE

THE

ACCURATER^^

REFRIGERANT

CONTROL

PISTON(S)

•

CONNECT

REFRIGERANT

LINES

Step

6

—

Install

Fan

Control

Package

...

6

Page

Step

7

—

Install

Outdoor

Ambient

Switch.6

Step

8

—

Install

Room

Thermostat,

Outdoor

Thermostat(s)

and

Emergency

Heat

Relay.

8

Step

9

—

Make

Electrical

Connections

...

8

•

INSTALL

A

BRANCH

CIRCUIT

DISCONNECT

PER

N.E.C.

•

ROUTE

LINE

POWER

LEADS

INTO

COMPRESSOR

SECTION

•

CONNECT

GROUND

LEADS

AND

POWER

WIRES

•

CONNECT

POWER

LEADS

FROM

INDOOR

COMPRESSOR

SECTION

TO

OUTDOOR

COIL

SECTION

•

CONNECTCONTROL

WIRING

INITIAL

START-UP.9

SEQUENCE

OF

OPERATION.

9

SERVICE.

11

MAINTENANCE

.

15

SAFETY

CONSIDERATIONS

Installation

and

servicing

of

air

conditioning

equipment

can

be

hazardous

due

to

system

pressure

and

electrical

components.

Only

trained

and

quali¬

fied

service

personnel

should

install,

repair

or

service

air

conditioning

equipment.

Untrained

personnel

can

perform

basic

mainten¬

ance

functions

of

cleaning

coils

and

filters

and

re¬

placing

filters.

All

other

operations

should

be

per¬

formed

by

trained

service

personnel.

When

working

on

air

conditioning

equipment,

observe

precautions

in

the

literature,

tags

and

labels

attached

to

the

unit

and

other

safety

precautions

that

may

apply.

Follow

all

safety

codes.

Wear

safety

glasses

and

work

gloves.

Use

quenching

cloth

for

brazing

opera¬

tions,

Have

fire

extinguisher

available

for

all

brazing

operations.

WARNING:

Before

perforisaisag;

servsoe

or

oa

tant:

OSS'

ijsain

SEWstchfes

mdoor

tnataad

otJt^oor

axat

ITarn

accessory

heater

power

if

'

shod:

cooSd

cause

per-

©

Carrier

Corporation

1979

Form

38HQ-6SI

A

VAPOR

LINE

CONN

(ON

SERVICE

VALVE)

liquid

line

CONN.

(ON

SERVICE

VALVE)

MTG

SLOTS

(USE

ANY

2)

VDIAM

HOLE

FOR

CONTROL

WIRING

DRAINAGE

HOLES

WM

SPACE

RE(3UIRED

FOR

SERVICE

^AIRFLOW

Certified

dimension

drawings

available

on

request

Fig.

1

—

Dimensions

and

Connections,

38HQ

Outdoor

Coil

Section

(Table

2)

Table

1

—

Carrier-Approved

38HQ

Weathermaster

III

Dual-Compressor

Heat

Pump

Systems

INDOOR

1

COMPRESSOR

1

SECTION

OUTDOOR

COIL

SECTION

INDOOR

FAN/COIL

38HQ227

38HQ940

40FS160/28VQ036

38HQ234

38HQ960

40FS200/28VQ042

VAPOR

LINE

CONN

TO

OUTDOOR

COIL

VAPOR

LINE

CON

TO

INDOOR

COIL

14

DIAM

HOLE

FOR

COMPRESSOR

SECTION

LINE

POWER

yC&K;

38HQ

INDOOR

COMPRESSOR

SECTION

i

DIAM

HOLE

FOR

OUTDOOR

COIL

SECTION

LINE

POWER

WIRING

(SEE

ELECTRICAL

DATA

AND

WIRING)

t

DIAM

HOLE

FOR

CONTROL

WIRING

Pill

SPACE

REQUIRED

FOR

SERVICE

Certified

dimension

drawings

available

on

request

Fig.

2

—

Dimensions

and

Connections,

38HQ

Indoor

Compressor

Section

(Table

2)

Table

2

—

Physical

Data

INDOOR

COMPR

SECTION

38HQ227

38HQ234

Operating

Wt

(lbs)

205

225

Dimensions

(ft-in.)

Width

A

2-2-3/32

Depth

B

1-4-3/16

Height

C

1-11-1/8

(add

3/4-in

for

Refrigerant

Fittings

Compressor

no.

1

IV1D2713GM

(46)

MD3413GIVI

(46)

(Oil

Recharge,

oz)

no.

2

MD3413GMi

(46)

MD3413GM

(46)

AccuRater

Size

(in.)

Indoor

no

6

(

0670)

no

7(0760)

Outdoor

no

3

(.0550)*

no

5

(

0635)

Refrig

Conn

(in.)

3/4

3/4

OUTDOOR

COIL

SECTION

38HQ940

38HQ960

Operating

Wt

(lb)

107

125

Dimensions

(ft-in.)

Diameter

A

2-5-1/4

2-5-1/4

Unit

Height

B

2-

8

3-

8

Coil

Height

C

1-11

2-11

Refrig

Conn

Vapor

(in.,

ODF)

3/4,

Compatible

Fitting

Liquid

(in.,

ODF)

3/8,

Flare

Fitting

*Piston

size

shown

is

shipped

with

section

Remove

factory-

installed

piston;

replace

with

size

shown

per

text

2

Table

3

—

Heater

Airflow

Data

■

i

INDOOR

COMPRESSOR

SECTION

HEATER

MINIMUM

ALLOWABLE

SIZE

Airflow

(cfm)

\

Fan

Speed

38HQ227

8

thru

20

kw

(40FQ91

6010

thru

090)

1150

j

Low

38HQ234

10

thru

25

kw

(40FQ920060

thru

1

50)

1550

Low

Table

4

—

Accessories

PART

NO.

38CQ900102

38CQ900122

38CQ900132

38CQ900152

38CQ900172

38HQ900011

38HQ900002

38RQ900012

38CQ900072

38RQ900072

DESCRIPTION

Six

38CQ900081

Low-voltage

Honeywell

Thermostat

(HH07AT071)

and

Thermostat

Subbase

(HH93AZ073)

with

automatic

changeover

Six

38CQ900111

Low-voltage

Honeywell

Thermostat

(HH07AT071)

and

Thermostat

Subbase

(HH93AZ075)

with

manual

changeover

Six

38CQ900091

Liquid

Line

Filter-Drier

Six

38CQ900141

Solid

State

Time

Guard

(24

v)

SixHH22AG110

Optimizer

Control

Hot

Shot

Heat

Reclaim

Device

Six

38

H

Q900001

Outdoor

Thermostat

Six

38RQ900001

Emergency

Heat

Relay

Six

38CQ900061

two-packs.

Flare

(3/8-in

)

to

compatible

(3/8-in

)

couplings

Six

38RQ900061

Heat

Pump

Stand

for

Outdoor

Coil

Section

TUBING

PACKAGE

TUBING

Length

(ft)

Liquid

Suction*

COMPR

SECTION

O.D

(in.)

Tube

End

0

D

(in

)

0

D.

(in.)

Tube

End

O

D.

(in

)

Evap

Cond

38GC900071

10

3/8

3/8

3/4

3/4

3/4

38GC900081

18

3/8

3/8

3/4

3/4

3/4

38GC900091

25

3/8

3/8

3/4

3/4

3/4

38HQ227

38GC900101

35

3/8

3/8

3/4

3/4

3/4

38GC900111

50

3/8

3/8

3/4

3/4

3/4

1-1/8

in

OD

Suction

Tube,

Field

Supplied

38HQ234

‘Suction

line

is

insulated

and

has

a

90°

bend

at

one

end

INSTALLATION

Step

1

—

Check

Equipment

and

Jobsite

UNPACKAGE

UNITS

—

Move

units

to

final

loca¬

tion.

Slide

units

from

cartons

taking

special

care

not

to

damage

service

valves,

compatible

fittings

or

grilles.

Check

unit

model

numbers.

Use

only

Carrier-approved

unit

combinations

in

system.

See

Table

I.

INSPECT

EQUIPMENT

—

File

claim

with

ship¬

ping

company

if

shipment

is

damaged

or

incomplete.

COMPLETE

OR

CONSIDER

SYSTEM

RE¬

QUIREMENTS

before

installing

the

38HQ

units.

Consult

local

building

codes

and

National

Elec¬

trical

Code

(NEC)

for

special

installation

requirements.

When

installing

units,

allow

sufficient

space

for

airflow

clearance

(outdoor

unit),

wiring,

refrigerant

piping

and

servicing

unit.

Position

outdoor

unit

so

water

or

ice

from

roof

cannot

drop

directly

on

top

of

unit.

Maximum

allowable

vertical

distance

be¬

tween

indoor

and

outdoor

sections

is

50

feet.

It

is

strongly

recommended

that

38HQ

units

be

used

with

only

Carrier-approved

indoor

sections

(see

Table

1).

Outdoor

Coil

Section

—

Make

provision

for

con¬

densate

drainage

and

defrost

water

disposal

whether

unit

is

installed

on

ground,

roof

or

off-the-wall

platform.

Outdoor

unit

must

be

elevated

12

in.

to

18

in.

in

areas

of

heavy

snowfall.

(Ensure

unit

base-

pan

drainage

holes

are

not

blocked.

See

Fig.

1.)

See

Step

2,

Install

Outdoor

Coil

Section

for

details.

Roof

installation

method

for

38HQ

depends

on

building

construction

and

special

requirements

of

local

codes.

Make

sure

roof

can

support

unit

weight.

Indoor

Compressor

Section

—

Locate

unit

in

base¬

ment,

garage

or

utility

room.

Indoor

locations

with¬

in

the

living

space

are

not

recommended.

Basement

installations

also

require

careful

planning

to

avoid

areas

directly

under

bedrooms,

living

rooms,

etc.

3

Insert

felt

isolation

pad

(factory

supplied)

be¬

tween

unit

and

a

level

rigid

mounting

base

to

absorb

vibration.

Isolate

interconnecting

tubing

from

framing

and

ductwork

or

where

tubing

runs

thru

stud

spaces,

enclosed

ceilings

or

pipe

chases.

Use

isolation

type

hanger,

Fig.

3,

since

rigid

fastening

will

transmit

pulsation

to

structure

creating

ob¬

jectionable

sound.

System

Refrigerant

Control

consists

of

factory-

installed

byp^s-type

AccuRateF”

devices

located

as

shown

in

Fig.

15.

These

metering

devices

include

a

replaceable

orifice

piston

that

is

calibrated

to

regulate

refrigerant

flow.

Piston

data

is

given

in

Table

2.

In

some

instances,

the

factory-installed

piston

must

be

replaced

by

a

factory-supplied

re¬

placement

piston.

Where

required,

substitute

pistons

as

described

in

Step

5

and

as

indicated

on

tags

attached

to

system

AccuRater

devices.

Step

2

—

Install

Outdoor

Coil

Section

ON

THE

GROUND

—

Use

a

solid,

level

concrete

pad

as

shown

in

Fig.

4.

Position

unit

so

that

coil

drainage

holes

in

basepan

overhang

the

pad.

(See

Fig.

1

for

drainage

hole

locations.)

Be

sure

pad

does

not

obstruct

drainage

holes

(water

drains

from

holes

during

heating

and

defrost

cycles).

Attach

unit

to

pad

with

1

/

4-in.

mounting

bolts.

Any

2

holes

in

unit

basepan

may

be

used

to

fasten

unit

to

pad.

Construct

round,

24-in.

diameter

6-in.

thick

pad

a

minimum

of

6

in.

above

grade

to

provide

clearance

under

holes

for

drainage

and

ice

build-up.

In

areas

where

prolonged

subfreezing

temperatures

or

snows

occur;

increase

clearance

by

using

accessory

heat

pump

stand

to

support

unit

12

to

18

in.

off

concrete

base.

See

Fig.

4.

Be

sure

stand

does

not

obstruct

coil

drainage

holes.

Avoid

mounting

unit

in

prevailing

Winds

to

minimize

effect

on

defrost

performance.

Construct

wind

break

if

necessary.

Extend

a

12-in.

gravel

apron

around

pad

for

condensate

and

defrost

water

drainage

field.

Provide

support

bracket

from

structure

or

other

solid

support

to

outdoor

unit

to

give

stability.

Since

it

is

lightweight,

the

outdoor

section

may

be

Fig.

4

—

Unit

Support

Details

mounted

on

a

platform

attached

to

or

built

out

from

structure.

Construct

platform

using

drainage

and

clearance

recommendations

above.

Locate

and

con¬

struct

platform

to

avoid

possible

transfer

of

unit

vibration

to

structure.

See

Table

2

for

unit

weight.

ON

THE

ROOF:

Install

a

level

platform

or

frame

to

support

unit.

Elevate

unit

for

proper

clearance

as

previously

described

for

on-the-ground

installation.

Plan

roof

design

and

water

drainage

to

prevent

unit

from

sitting

in

water.

Flash

all

roof

openings

to

prevent

leaks.

4

Step

3

—

Install

Indoor

Compressor

Section

on

a

level,

rigid,

solid

platform

or

concrete

floor.

Do

not

install

in

a

living

area.

Insert

1/4-in.

asphalt-impregnated

felt

pad

(supplied)

between

unit

basepan

and

mounting

surface

to

provide

full

unit

support

and

vibration

attenuation.

(Do

not

use

vibration

isolators

under

corners

of

basepan.)

Step

4

install

Indoor

Fan-Coil

and

Electric

Heater

as

described

in

Installation

Instructions

supplied

with

this

equipment.

Install

and

connect

thermostats

and

other

controls

as

described

in

the

steps

that

follow.

Step

5

—

Make

Piping

Connections

—

The

38HQ

sections

may

be

connected

to

indoor

fan-coil

using

Carrier

accessory

tubing

packages

or

field-

supplied

tubing

of

refrigerant

grade.

See

Table

2

for

unit

piping

connection

types,

sizes

and

line

size

recommendations

and

Table

4

for

accessory

tubing

sizes.

Maximum

allowable

system

liquid

line

length

is

100

feet.

Maximum

vapor

line

length

from

com¬

pressor

section

to

indoor

coil

is

50

feet.

Maximum

vapor

line

length

from

compressor

section

to

out¬

door

coil

is

50

feet.

When

other

than

25

ft

of

interconnecting

piping

!

is

used,

follow

special

requirements

described

in

^

Refrigerant

Charging.

Do

not

use

less

than

10

ft

of

vapor

or

liquid

line.

Do

not

use

damaged

or

contaminated

tubing.

Always

evacuate

or

purge

indoor

coil,

compressor

section

and

tubing

system.

When

purging,

use

field-

supplied

refrigerant,

not

unit

refrigerant.

When

making

tubing

connections,

be

sure

to

provide

clearance

at

unit

for

electrical

connections.

Follow

tubing

isolation

recommendations

described

previously.

REPLACE

THE

ACCURATER"”

REFRIG¬

ERANT

CONTROL

PISTON(S)

before

connect¬

ing

refrigerant

lines

as

applicable.

Refer

to

tags

attached

to

AccuRater

device.

Replacement

pistons

are

shipped

with

compressor

section

and

are

to

be

installed

as

directed

on

tag.

Replacement

procedure,

briefly

described

below,

is

detailed

on

tag.

Also,

see

AccuRater

Servicing

for

additional

information.

When

connecting

indoor

compressor

section

38HQ227

to

outdoor

coil

section

38HQ940,

remove

no.

4

piston

from

outdoor

coil

AccuRater

device;

replace

with

no.

3

piston.

Attach

AccuRater

identi¬

fication

sticker

to

unit

(replacing

existing

sticker,

if

any).

CONNECT

REFRIGERANT

LINES

to

fittings

on

indoor

and

outdoor

sections.

Fig.

1,

2

and

5.

Indoor

compressor

section

has

2

Compatible

Fitting

vapor

line

connections.

Outdoor

and

indoor

fan-coil

sections

have

Compatible

Fitting

vapor

line

connec¬

tion

and

liquid

line

flare

connection.

Flare

and

connect

liquid

line

from

outdoor

coil

section

to

indoor

fan-coil

unit.

It

is

not

necessary

to

flare

system

liquid

line

if

an

accessory

flare-to-

Fig.

5

—

Refrigerant

Piping

Connections

5

Compatible

Fitting

coupler

is

used

for

liquid

line

connection.

See

accessory

coupler,

Fig.

6.

Connect

vapor

line

from

outdoor

coil

section

to

indoor

compressor

section,

and

from

compressor

section

to

indoor

fan-coil.

Section

vapor

line

as

required

(Fig.

5).

Use

correct

compressor

section

vapor

line

connection

to

indoor

and

outdoor

coils.

Unit

Compatible

Fittings

permit

mechanical

or

sweat

connection

as

described

below.

When

a

1-1/8

in.

field-supplied

vapor

line

is

used

on

38HQ234,

four

field-supplied

3/4-in.

to

1-1/8

in.

vapor

line

adapters

must

be

provided.

Insulate

Refrigerant

Lines

—

After

making

tubing

connections,

the

compressor

section

fittings

must

be

insulated.

Butt

the

Armaflex

tubing

insulation

(pro¬

vided

in

tubing

package)

against

the

Compatible

Fittings.

Secure

the

insulation

with

Prestite

or

an

equivalent

material

which

provides

both

adhesion

and

insulation.

Also

wrap

the

Compatible

Fittings

with

Prestite

to

prevent

sweating.

Mechanical

Connection-to-Compatible

Fitting

(Mate

one

set

of

connections

at

a

time.)

1.

Loosen

nut

on

Compatible

Fitting

one

turn.

Do

not

remove.

2.

Remove

plug

and

be

sure

0-ring

is

in

the

groove

inside

the

Compatible

Fitting.

3.

Cut

tubing

to

correct

length.

4.

Insert

tube

into

Compatible

Fitting

until

it

bottoms.

5.

Tighten

nut

until

it

bottoms

on

back

coupler

flange.

Keep

tube

bottomed

in

Compatible

Fitting

while

tightening

nut.

Sweat

Connection-to-Compatible

Fitting

(Use

refrigerant

grade

tubing.)

1.

Remove

locking

nut,

rubber

O-ring

and

Schrader

core

from

valve.

2.

Cut

tubing

to

correct

length.

3.

Insert

tube

into

Compatible

Fitting.

Wrap

top

and

bottom

of

service

valves

in

wet

cloth

to

pre¬

vent

damage

by

heat.

Solder

with

low

tempera¬

ture

(430

F)

silver

alloy

solder.

4.

Replace

Schrader

core.

5.

Evacuate

or

purge

system

with

field-supplied

refrigerant.

Accessory

Flare-to-Compatible

Fitting

Coupler

is

shown

in

Fig.

6.

Attach

flare

nut

on

coupler

to

flare

fitting

on

unit

liquid

line

connection.

Connect

liquid

line

to

Compatible

Fitting

using

mechanical

or

sweat

connection.

When

mechanical

connection

is

made,

use

2

wrenches

to

tighten

Compatible

Fitting

nut

—

one

to

hold

coupler

and

one

to

tighten

nut.

Fig.

6

—

Accessory

Coupler

Step

6

—

Install

Fan

Control

Package

(factory

supplied;

packaged

separately

inside

indoor

com¬

pressor

section)

—

This

control,

consisting

of

a

transformer

and

a

relay,

provides

high-speed

fan

operation

when

both

compressors

are

energized.

Refer

to

connection

diagram

in

Fig.

7

for

wiring

details.

Install

control

as

follows:

1.

Remove

factory-installed

transformer

from

indoor

fan-coil

unit

electric

heater

package.

Refer

to

40FS

service

instructions

as

required.

2.

Install

fan

control

package

in

upper

right-hand

corner

of

the

40FS.

3.

Route

wires

from

controls

to

heater

package

thru

knockouts

provided.

Restore

transformer

wiring

connections

including

ground

wire.

4.

Connect

black

wire

from

indoor

fan

relay

(IFR)

terminal

no.

4

(or

no.

6)

to

black

wire

from

indoor

fan

relay

no.

2

(IFR-2)

terminal

no.

3.

(Cut

off

male

connector

from

IFR

wire;

supply

wire

nut

to

splice

wires.)

5.

Connect

black

wire

from

IFR-2

terminal

no.

6

to

fan

speed

selector

block

terminal

no.

1

(high

speed).

6.

Connect

blue

wire

from

IFR-2

terminal

no.

1

to

fan

speed

selector

block

terminal

no.

3

(low

speed).

7.

Connect

low-voltage

field

control

wires

between

indoor

compressor

section

and

indoor

fan

relay

(IFR-2)

orange

pigtails

(TB

OA

to

OFR-2,

ter¬

minal

no.

4;

contactor

C-2,

terminal

C

to

IFR-2,

terminal

no.

5).

Field-supplied,

24-gage,

NEC

Class

2

thermostat

wire

may

be

used.

Step

7

—

Install

Outdoor

Ambient

Switch

(OA)

(factory-supplied;

packaged

separately

inside

indoor

compressor

section)

—

This

switch

activates

compressor

no.

2

when

the

first

heating

thermal

balance

point

is

reached.

The

switch

is

installed

in

the

same

manner

as

the

outdoor

thermostat

(step

8),

except

refer

to

Fig.

7

for

correct

wiring.

FAN

CONTROL

PACKAGE

LEGEND

C-2

—

Contactor

IFR

—

Indoor

Fan

Relay

PL

—

Plug,

Fan

SEQ

—

Sequencer

TB

—

Terminal

Board

Tran

—

Transformer

#

Junction

o

Component

Connection

(Marked)

Field

Splice

HiW

Field

Power

Wiring

Field

Ground

Wiring

_Field

Control

Wiring

NOTES:

1

Use

copper

conductors

only.

2

May

be

terminal

board

or

fuse

block

depending

on

heater

model

used

3

Will

be

terminal

no

4

on

40FQ916

models,

and

terminal

no

6

on

40FQ920

models

THERMOSTAT

40FQ

SUBBASE

ELECTRIC

HEATER

HH93AZ073

0R

TERMINAL

HH93AZ075

BOARD

38HQ

COMPRESSOR

SECTION

TERMINAL

BOARD

THERMOSTAT

40FQ

SUBBASE

ELECTRIC

HEATER

HH93AZ0730R

TERMINAL

HH93AZ075

BOARD

38HQ

COMPRESSOR

SECTION

TERMINAL

BOARD

(38HQ

WITH

40FS/28HQ,VQ

EQUIPPED

WITH

ELECTRIC

HEATER;

EMERGENCY

HEAT,

ONE

OUTDOOR

THERMOSTAT)

THERMOSTAT

SUBBASE

HH93AZ073

OR

HH93AZ075

40FQ

ELECTRIC

HEATER

TERMINAL

BOARD

38HQ

COMPRESSOR

SECTION

TERMINAL

BOARD

COOLING

AND

TWO-STAGE

HEATING

(38HQ

WITH

40FS/28HQ,VQ

EQUIPPED

WITH

ELECTRIC

HEATER;

EMERGENCY

HEAT,

NO

OUTDOOR

THERMOSTATS)

THERMOSTAT

40FQ

38HQ

SUBBASE

ELECTRIC

HEATER

COMPRESSOR

HH93AZ0730R

TERMINAL

SECTION

HH93AZ075

BOARD

TERMINAL

BOARD

EQUIPPED

WITH

ELECTRIC

HEATER;

EMERGENCY

HEAT,

TWO

OUTDOOR

THERMOSTATS)

DFT

—

Defrost

Thermostat

EHR

—

Emergency

Heat

Relay

OA

—

Outdoor

Ambient

Switch

ODT

—

Outdoor

Thermostat

_

Factory

Wiring

_Field

Wiring

^Transformer

(75

va)

located

in

fan

control

package

tTerminal

L

is

identified

as

terminal

X

on

some

former

thermostats

(Required

for

system

malfunction

warning

indicator

on

compressor

section

)

^Remove

1

or

both

factory-installed

jumpers

(connection

B)

when

installing

outdoor

ther¬

mostats

(ODT)

shown

in

connections

C

and

D

Fig.

7

—

Control

Circuit

Connections

7

Attach

one

lead

to

compressor

terminal

board

connection

OA.

Connect

other

lead

to

line

side

of

defrost

thermostat.

Set

switch

at

temperature

of

first

thermal

balance

point

(heating).

This

balance

point

is

provided

by

CLIC

load

estimating

program.

Further

adjust¬

ments

can

be

made

following

operating

experience.

Step

8

—

Install

Room

Thermostat,

Outdoor

Thermostat(s)

and

Emergency

Heat

Relay

—

Follow

Installation

Instructions

shipped

with

these

accessories

plus

the

instructions

in

the

sections

that

follow.

Connect

as

described

in

step

9.

INDOOR

THERMOSTAT

—

Use

only

Carrier

indoor

thermostat

and

subbase

as

shown

in

Table

4.

Set

heat

anticipator

settings

according

to

Table

5.

These

settings

may

be

changed

slightly

to

provide

a

greater

degree

of

comfort

for

certain

installations.

Table

5

—

Thermostat

Heat

Anticipator

Settings

INDOOR

COM

PR

SECTION

OUTDOOR

COIL

SECTION

INDOOR

UNIT

WITH

ELECTRIC

HTR

HTR

KW

ANTICIPATOR

SETTINGS

First

Stage

Second

Stage

38HQ227

38HQ940

40FS160

with

40FQ916010

thru

090

8

thru

20

Fixed

16

38HQ234

38HQ960

40FS200

with

40FQ920060

thru

150

10

thru

25

Fixed

49

OUTDOOR

THERMOSTAT

ACCESSORY

pro¬

vides

adjustable

outdoor

control

of

accessory

electric

heater

(used

on

indoor

fan-coil).

This

ther¬

mostat

closes

on

a

drop

in

outdoor

temperature.

It

energizes

a

stage

of

electric

heat

when

the

out¬

door

temperature

setting

is

reached,

provided

the

room

thermostat

is

on

the

second

stage

of

heating.

One

outdoor

thermostat

is

recommended

for

each

stage

of

electric

heat

after

the

first

stage.

Connect

as

described

in

Step

9.

Set

the

outdoor

thermostats

progressively

lower

for

each

stage.

Refer

to

heat

load

of

building

and

unit

capacity

to

determine

the

correct

outdoor

thermostat

settings.

Locate

maxi¬

mum

of

2

outdoor

thermostats

in

control

voltage

section

of

outdoor

coil

section

junction

box.

Fasten

in

place

with

sheet

metal

screws.

EMERGENCY

HEAT

RELAY

—

This

accessory

is

required

when

2

or

more

outdoor

thermostats

are

used.

It

is

automatically

energized

by

the

manually-

operated

emergency

heat

switch

in

the

indoor

ther¬

mostat

subbase.

The

indoor

thermostat

locks

out

the

compressor

and

the

relay

bypasses

the

outdoor

thermostats

for

electric

heater

operation

during

heat

pump

shutdown.

When

one

outdoor

thermostat

is

used,

an

emergency

heat

relay

is

not

required.

The

emergency

heat

switch

in

the

indoor

thermostat

subbase

bypasses

the

outdoor

thermostat,

locks

out

the

compressor

and

activates

the

electric

heater.

Install

emergency

heat

relay

in

a

convenient

loca¬

tion

on

indoor

unit.

Attach

with

sheet

metal

screw.

Connect

relay

as

shown

in

Fig,

7.

Step

9

—

Make

Electrical

Connections

—

In¬

stall

field

wiring

in

accordance

with

local

and

national

fire,

safety

and

electrical

codes.

Be

sure

voltage

to

units

is

within

±

10%

of

voltage

indi¬

cated

on

nameplate.

Contact

local

power

company

for

correction

of

improper

line

voltage.

When

making

electrical

connections,

provide

clearance

at

unit

for

refrigerant

piping

connections.

See

Table

6

for

recommended

wire

and

fuse

sizes.

Line

power

connections

and

control

circuit

connec¬

tions

are

shown

in

Fig.

7

and

8.

Route

line

and

control

power

wiring

for

38HQ

outdoor

coil

from

connections

in

the

38HQ

in¬

door

compressor

section.

Use

14-ga

(minimum)

line

power

wire

size

to

outdoor

coil

section

when

total

wire

length

connecting

compressor

section

to

coil

is

under

25

feet.

If

over

25

ft,

use

same

wire

size

as

compressor

section

branch

circuit.

Table

6

—

Electrical

Data

INDOOR

COMPR

SECTION

OUTDOOR

COIL

SECTION

VOLTAGE

COMPR

1

COMPR

2

OFM

(FLA)

BRANCH

CIRCUIT

-

n

Nom

1-Ph

60-Hz

1

1

1

Operating*

Power

Wire

]

Gnd

Wire

Sizet

(AWG)

Min

Ckt

Amps

Max

Fuse

Amps**

_

Min

Size

(AWG)

Max

Ft

1

Max

Min

LRA

RLA

LRA

RLA

ICS

OCS

ICS

OCS

ICS

OCS

38

H0227

38HQ940

230

254

207

72

17

88

1

17

8

1

5

6

14t

55

25t

10

14t

40

8

38HQ234

38HQ960

230

254

207

88

20

94

S

__

1

21

2

2

3

4

14t

75

25t

10

14t

48

8

60

FLA

—

Full

Load

Amps

ICS

—

Indoor

Compressor

Section

LRA

—

Locked

Rotor

Amps

OCS

—

Outdoor

Coil

Section

OFM

—

Outdoor

Fan

Motor

RLA

—

Rated

Load

Amps

^Permissible

limits

of

the

voltage

range

(for

limited

period

of

time)

at

which

the

units

will

operate

satisfactorily

fOutdoor

coil

section

wiring

—

for

25

ft

wire

run

or

less,

use

minimum

14

AWG

size

wire

For

longer

wire

run

use

same

size

as

supply

to

compressor

section

^Required

when

using

nonmetallic

conduit

**Maximum

dual

element

fuse

size

NOTES;

1

All

units

have

24-v

control

circuit

which

requires

external

power

source

2

Copper

wire

size

table

based

on

60

C

Use

copper

or

copper-clad

aluminum

wire

to

indoor

section;

copper

wire

only

to

outdoor

section

Use

latest

National

Electrical

Code

for

wire

sizing

8

FACTORY

WIRING

Fig.

8

—

Line

Power

Connections

INSTALL

A

BRANCH

CIRCUIT

DISCONNECT

PER

N.E.C.

of

adequate

size

to

handle

compressor

section

starting

current.

Provide

a

separate

dis¬

connect

switch

for

outdoor

coil

section.

Provide

a

separate

disconnect

for

indoor

fan-coil

and

for

each

accessory

electric

heater

circuit

as

required,

(See

In¬

door

Unit

and

Electric

Heater

Installation,

Start-Up

and

Service

Instructions.)

Locate

disconnect(s)

within

sight

of

and

readily

accessible

to

the

units,

per

section

440-14

of

National

Electrical

Code

(NEC).

ROUTE

LINE

POWER

LEADS

INTO

COM¬

PRESSOR

SECTION

—

Extend

lead

from

discon¬

nect

per

N.E.C.

thru

1-1/8

in.

hole

provided

in

com¬

pressor

section

top

panel

(Fig.

2)

and

into

control

box.

Extend

line

power

leads

for

outdoor

coil

section

thru

7/8-in.

hole

provided

in

compressor

section

top

panel

and

into

control

box.

CONNECT

GROUND

LEADS

AND

POWER

WIRES

—

Connect

ground

leads

to

the

ground

lug

in

control

box

for

safety.

Splice

compressor

section

line

power

leads

to

yellow

and

black

pigtails,

and

outdoor

coil

section

power

leads

to

brown

and

blue

pigtails.

Use

wire

nuts

and

tape

at

each

splice

con¬

nection

as

shown

in

Fig.

8.

CONNECT

POWER

LEADS

FROM

INDOOR

COMPRESSOR

SECTION

TO

OUTDOOR

COIL

SECTION

thru

secondary

disconnect

switch.

From

this

disconnect

switch

extend

leads

thru

hole

provided

in

outdoor

coil

section

basepan

(Fig.

1)

and

into

line

voltage

section

of

junction

box.

Fig.

14.

Splice

leads

to

black

and

blue

pigtails

with

wire

nuts.

CONNECT

CONTROL

WIRING

(24-v)

—

Extend

wiring

thru

7

/

8-in.

grommeted

hole

in

compressor

section

top

panel

(Fig.

2),

and

to

control

wiring

terminal

board

on

side

of

control

box.

Connect

leads

to

terminal

board

as

shown

in

Fig.

7.

Extend

and

connect

control

wiring

from

compressor

section

to

outdoor

coil

section

as

required.

Make

splice

connections

in

low-voltage

section

of

coil

junction

box.

Use

indoor

fan-coil

transformer

as

24-v

supply

for

system.

Be

sure

fan

control

package

is

installed

as

described

in

Step

6.

Package

contains

75-va

trans¬

former

of

adequate

capacity

to

handle

system

current.

INITIAL

START-UP

The

compressors

in

the

indoor

compressor

section

are

equipped

with

crankcase

heaters.

It

is

recommended

that

the

heaters

be

energized

a

minimum

of

24

hours

before

starting

the

system.

To

energize

crankcase

heaters

only,

set

the

thermostat

at

OFF

position

and

turn

on

main

power

to

compressor

section.

To

Start

System

—

(Be

sure

crankcase

heaters

have

been

energized

for

24

hours.)

Adjust

the

ther¬

mostat

as

follows:

1.

Set

selector

switch

at

OFF.

2.

Turn

on

main

disconnect

switch(es)

to

indoor

and

outdoor

units.

3.

Set

fan

switch

as

desired

(ON

or

AUTO.).

4.

Set

thermostat

dial

at

desired

temperature.

5.

Set

selector

switch

at

HEAT

or

COOL.

Check

system

refrigerant

charge.

See

Service

—

Refrigerant

Charging.

SEQUENCE

OF

OPERATION

Fan

Switch

at

AUTO.

Position,

Thermostat

at

ON

Position

(Crankcase

heater

is

on

as

soon

as

the

field

power

supply

is

on.)

THERMOSTAT

CALLS

FOR

COOLING

1.

First-stage

cooling

thermostat

(Co)

closes

and

the

reversing

valve

solenoid

(RVS)

is

energized.

The

RVS

actuates

the

reversing

valve

and

switches

the

system

to

cooling.

2.

Second-stage

cooling

thermostat

(Cl)

closes.

If

the

low-pressure

switch

(LPS)

is

closed,

com¬

pressor

contactor

(C)

is

energized

and

compres-

9

sor

no.

1

starts.

At

the

same

time,

the

outdoor

fan

motor

(OFM)

starts

and

the

defrost

timer

(DT)

is

energized

although

it

is

not

functional

in

the

cooling

mode;

the

indoor

fan

relay

(IFR)

is

energized

and

the

indoor

fan

motor

(IFM)

starts.

Compressor

no.

2

does

not

run

in

COOL

mode.

When

the

second

stage

of

cooling

is

satisfied,

Cl

opens.

The

compressor

stops;

the

indoor

and

out¬

door

fans

stop;

DT

is

de-energized.

When

the

con¬

trolled

temperature

drops

approximately

1

F

below

the

cooling

set

point,

Co

opens.

RVS

is

de-energized

and

the

reversing

valve

switches

to

heating

(normal

position).

The

unit

is

shut

down

except

for

the

two

compressor

crankcase

heaters,

which

remain

on

as

long

as

the

field

power

supply

is

on.

THERMOSTAT

CALLS

FOR

HEATING

(The

reversing

valve

is

de-energized,

in

heating

position.)

1.

First

stage

heating

thermostat

(HI)

closes.

Com¬

pressor

contactor

no.

1

(Cl)

is

energized

and

compressor

starts;

outdoor

fan

motor

(OFM)

starts;

defrost

timer

(DT)

is

energized.

Indoor

fan

relay

(IFR)

is

energized

and

indoor

fan

motor

(IFM)

starts.

When

the

outdoor

ambient

switch

(OA)

closes

(at

first

thermal

balance

point),

compressor

contactor

no.

2

(C2)

is

ener¬

gized

and

compressor

no.

2

starts.

Compressor

no.

1

and

compressor

no.

2

operate

simul¬

taneously

as

long

as

OA

is

closed.

The

crankcase

heaters

are

de-energized

when

both

compressors

are

running.

2.

Second-stage

heating

thermostat

(H2)

closes

and

activates

the

first

accessory

heater

element

sequencer

thru

indoor

thermostat

terminal

W2.

The

first-stage

electric

heater

element

is

energized

immediately

and

the

other

heater

elements

are

energized

at

regular

intervals

thru

the

sequencers.

Separate

outdoor

thermostats

may

be

used

to

energize

the

second

sequencer

and

bring

on

addi¬

tional

heater

elements

if

more

incremental

heat

control

is

desired.

When

the

second

stage

of

heating

is

satisfied,

H2

opens

and

the

electric

heater(s)

shuts

off.

When

the

first

stage

of

heating

is

satisfied,

HI

opens

and

the

unit

shuts

down,

except

for

the

compressor

crank¬

case

heater,

which

remains

on

as

long

as

the

field

power

supply

is

on.

Unit

Controls

and

Safety

Devices

HIGH-PRESSURE

RELIEF

VALVE

is

located

in

compressor.

Relief

valve

opens

at

a

pressure

differential

of

approximately

500

psi

between

suction

(low

side)

and

discharge

(high

side)

to

allow

pressure

equalization.

INTERNAL

CURRENT

AND

TEMPERATURE

SENSITIVE

OVERLOAD

resets

automatically

when

internal

compressor

motor

temperature

drops

to

a

safe

level

(overloads

may

require

up

to

45

min¬

utes

to

reset).

When

an

internal

overload

is

suspected

of

being

open,

check

by

using

an

ohmmeter

or

con¬

tinuity

tester.

If

necessary,

refer

to

Carrier

Standard

Service

Techniques

Manual,

Chapter

2,

Electrical,

for

complete

instructions.

LOW-PRESSURE

SWITCH

is

located

in

compres¬

sor

section

on

suction

line

between

reversing

valve

and

accumulator.

Provides

loss-of-charge

protec¬

tion

by

shutting

compressor

off

if

suction

pressure

drops

below

setting.

Low-pressure

switch

settings

are:

open,

5

±

3

psig;

close,

20

±

5

psig.

CRANKCASE

HEATERS

are

activated

by

a

relay.

Heaters

derive

power

from

contactor

no.

2

and

are

energized

when

compressors

are

off

or

when

only

one

compressor

is

functioning.

The

heater

keeps

the

crankcase

warm

during

the

off

cycle

and

thus

prevents

dilution

of

the

oil

with

the

refrigerant,

assures

good

lubrication,

and

pre¬

vents

loss

of

oil

from

crankcase

during

start-up.

If

the

electrical

disconnect

switch

to

the

compres¬

sor

section

has

been

off

for

an

extended

period

of

time,

the

crankcase

heater

should

be

energized

for

24

hours

before

starting

the

compressor.

SIGNAL-LOC

™

SYSTEM

MALFUNCTION

WARNING

INDICATOR

AND

LOCKOUT

^

Indoor

compressor

section

is

equipped

with

a

solid-

state

warning

logic

circuit

that

protects

the

system.

In

case

of

a

malfunction

(compressors

do

not

oper¬

ate

due

to

safety

device

cutout),

emergency

heat

light

on

thermostat

comes

on

and

compressors

are

pre¬

vented

from

restarting.

Compressors

can

be

re¬

started

after

resetting

thermostat

(turn

thermostat

off

then

on).

If

either

compressor

malfunctions,

both

will

be

locked

out

(prevented

from

restarting).

The

emergency

heat

light

goes

out

when

com¬

pressors

are

restarted

or

when

indoor

thermostat

is

satisfied.

If

the

light

does

not

stay

out

after

two

or

three

attempts

to

restart,

check

for

cause

of

malfunction.

DEFROST

CONTROL,

consisting

of

a

defrost

timer,

defrost

thermostat

and

defrost

relay,

inter¬

rupts

normal

system

heating

operation

every

90

minutes

to

defrost

outdoor

coil,

if

the

coil

saturated

suction

temperature

indicates

freezing

tempera¬

tures.

Defrost

control

simultaneously

stops

outdoor

fan,

energizes

reversing

valve

solenoid

to

return

system

to

cooling

cycle

(outdoor

coil

as

condenser,

indoor

fan-coil

unit

as

evaporator),

and

activates

accessory

electric

heater.

For

the

heat

pump

to

defrost,

2

conditions

are

necessary;

1.

Defrost

timer

contacts

must

be

closed.

2.

Refrigerant

temperature

from

outdoor

unit

must

be

cold

enough

to

cause

defrost

thermostat

contacts

to

close.

Contacts

close

at

27

(±

4)

F.

Every

90

minutes

of

elapsed

running

time,

the

de¬

frost

timer

contacts

close

for

10

seconds.

If

the

defrost

thermostat

contacts

are

closed,

the

unit

defrosts.

The

defrost

timer

limits

defrosting

period

to

10

minutes.

Normally

the

frost

is

removed

and

the

10