Carrier Heat Pump 38BYC User Manual

38BYC, 38BYG  
12 SEER Split System  
Heat Pump  
Installation and Start-Up Instructions  
NOTE: Read the entire instruction manual before starting the  
installation.  
This symbol indicates a change since the last issue.  
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.  
A98525  
Fig. 1—Model 38BYG  
Recognize safety information. This is the safety-alert symbol  
When you see this symbol on the unit and in instructions or  
manuals, be alert to the potential for personal injury.  
.
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.)  
Understand the signal words DANGER, WARNING, and 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 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. NOTE is used to highlight  
suggestions which will result in enhanced installation, reliability,  
or operation.  
6. Avoid direct tubing contact with water pipes, duct work, floor  
joists, wall studs, floors, and walls.  
7. Do not suspend refrigerant tubing from joists and studs with a  
rigid wire or strap that comes in direct contact with tubing.  
(See Fig. 2.)  
8. Ensure that tubing insulation is pliable and completely 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.)  
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.  
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 RECOMMENDATIONS  
NOTE: In some cases noise in the living area has been traced to  
gas pulsations from improper installation of equipment.  
1. Locate unit away from windows, patios, decks, and so forth  
where unit operation sounds may disturb customer.  
IMPORTANT: Maximum liquid line size is 3/8-in. O.D. for all  
residential applications including long line.  
2. Ensure that vapor- and liquid-tube diameters are appropriate to  
capacity of unit.  
IMPORTANT: Always install a liquid line filter drier on any  
system using existing field service line sets and or existing indoor  
coil or fan coil units. Always use a filter direr on burnout unit  
replacements.  
3. Run refrigerant tubes as directly as possible by avoiding  
unnecessary turns and bends.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 5a 5a  
1
4
PC 101  
Catalog No. 533-80078  
Printed in U.S.A.  
Form 38BYC-3SI  
Pg 1  
11-02  
Replaces: 38BYC-2SI  
 
If TXV installation is required, remove existing AccuRater® from  
indoor coil. Refer to Figs. 4 and 5 and install TXV kit as follows:  
feeder tubes, there is a 3/8-in. O.D. stub tube approximately 2 in.  
long. (See Fig. 6.) 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.  
1. Install suction tube adapter.  
2. Install liquid flare-to-sweat adapter.  
FEEDER TUBE  
STUB TUBE  
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.  
DEFROST  
THERMOSTAT  
COIL  
SENSING  
BULB  
A97517  
Fig. 6—Defrost Thermostat Location  
Step 9—Make Piping Connections  
EQUALIZER  
TUBE  
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.  
THERMOSTATIC  
EXPANSION  
VALVE  
A88382  
Fig. 4—Typical TXV Installation  
If ANY refrigerant tubing is buried, provide a 6 in. vertical  
rise at service valve. Refrigerant tubing lengths up to 36 in.  
may be buried without further special consideration. For  
lengths longer than 36 in., refer to Application Guideline and  
Service Manual — Residential Split System Air Conditioners  
and Heat Pumps.  
10 O'CLOCK  
2 O'CLOCK  
SENSING BULB  
STRAP  
SUCTION TUBE  
To prevent damage to unit or service valves observe the  
8 O'CLOCK  
78 IN. OD & SMALLER  
4 O'CLOCK  
following:  
•Use a brazing shield.  
•Wrap service valves with wet cloth or use a heat-sink  
material.  
LARGER THAN 78 IN. OD  
A81032  
Outdoor units may be connected to indoor section using accessory-  
tubing package or field-supplied refrigerant grade tubing of correct  
size and condition. For tubing requirements beyond 50 ft, substan-  
tial capacity and performance losses can occur. Following the  
recommendations 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 requirements.  
Fig. 5—Positioning of Sensing Bulb  
Step 7—Check Outdoor AccuRater® Piston  
Check outdoor unit piston. Remove retainer on liquid service valve  
and check piston size with matching number listed on outdoor unit  
rating plate.  
For buried line applications greater than 36 in., refer to Table 2 and  
Residential Split System Buried Line Application Guideline.  
Buried line applications may not exceed 100 ft.  
Step 8—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  
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.  
3
 
Table 1—Refrigerant Connections And Recommended Liquid- And Vapor-Tube Diameters (In.)  
LIQUID  
Connection Diameter  
VAPOR  
Connection Diameter  
VAPOR (LONG LINE)  
Connection Diameter Tube Diameter  
UNIT  
SIZE  
Tube Diameter  
Tube Diameter  
018  
024  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
5/8  
3/4  
3/4  
7/8  
7/8  
5/8  
3/4  
5/8  
3/4  
3/4  
7/8  
7/8  
3/4  
3/4  
030, 036  
042  
3/4  
7/8  
7/8  
1-1/8  
1-1/8  
048, 060  
1-1/8  
NOTES:  
1. Tube diameters are for lengths up to 50 ft. For tubing lengths greater than 50 ft horizontal, or greater than 20 ft vertical differential, consult the Application Guideline  
and Service Manual — Air Conditioners and Heat Pumps.  
2. Do not apply capillary tube indoor coils to these units.  
OUTDOOR UNIT CONNECTED TO FACTORY APPROVED  
INDOOR UNIT  
attention to feeder tubes, making sure wire ties on feeder tubes are  
secure and tight.  
Outdoor unit contains correct system refrigerant charge for opera-  
tion with indoor unit of same size when connected by 15 ft of  
field-supplied or factory accessory tubing. Check refrigerant  
charge for maximum efficiency.  
Step 10—Make Electrical Connections  
To avoid personal injury or death, do not supply power to unit  
with compressor terminal box cover removed.  
REFRIGERANT TUBING  
Connect tubing to fittings on outdoor unit vapor- and liquid-  
service valves. (See Table 1.) Use refrigerant grade tubing.  
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.  
SWEAT CONNECTION  
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 may fluctuate above or below  
permissible limits.  
To avoid valve damage while brazing, service valves must be  
wrapped in a heat sink material such as a wet cloth.  
Remove plastic retainer holding outdoor piston in liquid service  
valve and connect sweat/flare adapter provided to valve. (See Fig.  
7.) Connect refrigerant tubing to fittings on outdoor unit vapor-  
and liquid-service valves. Service valves are closed from factory  
and ready for brazing. 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. Consult local code  
requirements. Refrigerant tubing and indoor coil are now ready for  
leak testing. This check should include all field and factory joints.  
NOTE: Use copper wire only between disconnect switch and  
unit.  
NOTE: Install branch circuit disconnect 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.  
ROUTE GROUND AND POWER WIRES  
Remove access panel to gain access to unit wiring. Extend wires  
from disconnect through power wiring hole provided and into unit  
control box.  
PISTON BODY  
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.  
PISTON  
PISTON  
RETAINER  
CONNECT GROUND AND POWER WIRES  
STRAINER  
Connect ground wire to ground connection in control box for  
safety. Connect power wiring to contactor as shown in Fig. 8.  
CONNECT CONTROL WIRING  
Route 24v control wires through control wiring grommet and  
connect leads to control wiring. See Thermostat Installation  
Instructions for wiring specific unit combinations. (See Fig. 9.)  
SWEAT/FLARE ADAPTER  
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.  
A97512  
Fig. 7—Liquid-Service Valve  
IMPORTANT: Check to be certain factory tubing on both indoor  
and outdoor unit has not shifted during shipment. Ensure tubes are  
not rubbing against each other or any sheet metal. Pay close  
All wiring must be NEC Class 1 and must be separated from  
incoming power leads.  
4
 
Table 2—Accessory Usage  
REQUIRED FOR  
LOW-AMBIENT  
APPLICATIONS  
(BELOW 55°F)  
REQUIRED FOR  
REQUIRED FOR  
BURIED LINE  
APPLICATIONS†  
(OVER 3 FT)  
LONG-LINE  
APPLICATIONS*  
(OVER 50 FT)  
ACCESSORY  
Crankcase Heater  
Evaporator Freeze Thermostat  
Accumulator  
Yes  
Yes  
No  
Yes  
No  
Yes  
No  
No  
Yes  
Compressor Start-Assist  
Capacitor and Relay  
Yes  
Yes  
Yes  
MotorMaster® Control,  
or  
Yes  
No  
No  
Low-Ambient Pressure Switch  
See low-ambient  
Instructions  
Wind Baffle  
No  
No  
No  
No  
Unit Risers  
Recommended  
Liquid-Line Solenoid Valve  
See Long-Line  
Application  
Guideline  
or  
No  
Yes  
No  
Hard-Shutoff TXV  
Ball-Bearing Fan Motor  
Yes‡  
No  
* For tubing line sets between 50 and 175 ft, refer to Application Guideline and Service Manual — Air Conditioners and Heat Pumps.  
† For buried line applications, refer to Application Guideline and Service Manual — Air Conditioners and Heat Pumps.  
‡ Required for low-ambient controller (full-modulation feature) and MotorMaster® Control only.  
Step 13—Start-Up  
DISCONNECT  
PER N. E. C. AND/OR  
LOCAL CODES  
CONTACTOR  
To prevent compressor damage or personal injury, observe  
the following:  
FIELD POWER  
WIRING  
•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:  
FIELD GROUND  
WIRING  
•Dome temperatures may be hot.  
GROUND  
LUG  
A91056  
To prevent personal injury wear safety glasses, protective  
clothing, and gloves when handling refrigerant and observe  
the following:  
•Back-seating service valves are not equipped with Schrader  
valves. Fully back seat (counterclockwise) valve stem before  
removing gage-port cap.  
Fig. 8—Line Power Connections  
Use furnace transformer, fan coil transformer, or accessory trans-  
former for control power, 24v/40va minimum.  
NOTE: Use of available 24v accessories may exceed the mini-  
mum 40va power requirement. Determine total transformer load-  
ing and increase the transformer capacity or split the load with an  
accessory transformer as required.  
•Front-seating service valves are equipped with Schrader  
valves.  
IMPORTANT: Check factory wiring and wire connections to  
ensure terminations are secured properly. Check wire routing to  
ensure wires are not in contact with tubing, sheet metal, and so  
forth.  
Federal Regulations require that you do not vent refrigerant to  
atmosphere. Recover during system repair or final unit  
disposal.  
Step 11—Compressor Crankcase Heater  
Follow these steps to properly pumpdown a system and avoid  
negative suction pressure.  
When equipped with a crankcase heater, furnish power to heater a  
minimum of 24 hr before starting unit. To furnish power to 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.  
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.  
Step 12—Install Electrical Accessories  
Refer to the individual instructions packaged with kits or acces-  
sories when installing.  
3. Close electrical disconnects to energize system.  
5
 
4. Set room thermostat to desired temperature. Be sure set point  
is below indoor-ambient temperature.  
outdoor temperature falls below setting of outdoor thermostat  
(field-installed option), contacts close to complete circuit and bring  
on second bank of supplemental electric heat.  
5. Set room thermostat to HEAT or COOL and fan control to ON  
or AUTO mode, as desired. Operate unit for 15 minutes.  
Check system-refrigerant charge.  
When thermostat is satisfied, its contacts open, de-energizing  
contactor and relay. All heaters and motors should stop.  
SEQUENCE OF OPERATION  
DEFROST  
NOTE: Defrost-control board may be equipped with 5-minute  
lockout timer that may be initiated upon any interruption of power.  
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, 60, or 90 minutes), factory set at 90  
minutes.  
With power supplied to indoor and outdoor units, transformer is  
energized.  
The electronic timer and defrost cycle start only when contactor is  
energized and defrost thermostat is closed.  
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 indoor-blower motor on high speed.  
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.  
To initiate defrost, the defrost thermostat must be closed. This can  
be accomplished as follows:  
When thermostat is satisfied, its contacts open, de-energizing the  
contactor and blower relay. Compressor and motors should stop.  
1. Turn off power to outdoor unit.  
NOTE: If indoor unit is equipped with a time-delay relay circuit,  
the blower runs an additional 90 sec to increase system efficiency.  
2. Disconnect outdoor-fan motor lead from OF2 on control  
board. (See Fig. 10.) Tape lead to prevent grounding.  
HEAT  
PUMP  
TYPICAL  
FAN COIL  
HP THERMOSTAT  
R
C
R
R
C
24 VAC HOT  
24 VAC COM  
HEAT STAGE 2  
C
*
W2  
W2  
W2  
*
*
E
W3  
G
COOL/HEAT  
STAGE 1  
Y
Y
G
INDOOR FAN  
O
E
RVS COOLING  
O
EMERGENCY  
HEAT  
IF AVAILABLE  
*
A02325  
Fig. 9—Generic Wiring Diagram  
(See Thermostat Installation Instructions for wiring specific unit combinations.)  
LEGEND  
24-V FACTORY WIRING  
24-V FIELD WIRING  
FIELD SPLICE CONNECTION  
ODT  
OUTDOOR THERMOSTAT  
EHR  
EMERGENCY HEAT RELAY  
SHR  
SUPPLEMENTAL HEAT RELAY  
A97413  
HEATING  
3. Restart unit in heating mode, allowing frost to accumulate on  
outdoor coil.  
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.  
4. After a few minutes in heating mode, liquid-line temperature  
should drop below closing point of defrost thermostat (ap-  
proximately 30°F).  
Should temperature continue to fall, R-W2 is made through  
second-stage room-thermostat bulb. Circuit R-W2 energizes a  
relay, bringing on first bank of supplemental electric heat and  
providing electrical potential to second heater relay (if used). If  
5. Short between speed-up terminals with a flat-blade screw-  
driver. (See Fig. 10.) This reduces the timing sequence to  
1/256th of original time. (See Table 3.)  
6
 
EXAMPLE:  
To calculate additional charge required for a 25–ft line set:  
25 ft – 15 ft = 10 ft X 0.6 oz/ft = 6 oz of additional charge  
OF2  
OF1  
Units installed with cooling mode TXV require charging with the  
subcooling method.  
1. Operate unit a minimum of 10 minutes before checking  
charge.  
2. Measure liquid service-valve pressure by attaching an accurate  
gage to service port.  
3. Measure liquid-line temperature by attaching an accurate  
thermistor type or electronic thermometer to liquid line near  
outdoor coil.  
O
R
T2  
Y
TI DFT  
C
TEST 30 50 90  
W1  
4. Refer to unit rating plate for required subcooling temperature.  
5. Refer to Table 4. Find the point where required subcooling  
temperature intersects measured liquid service-valve pressure.  
O
R
6. To obtain required subcooling temperature at a specific  
liquid-line pressure, add refrigerant if liquid-line temperature  
is higher than indicated or reclaim refrigerant if temperature is  
lower. Allow a tolerance of ± 3°F.  
W2  
Y
C
CES0110063,  
CES0130024  
Table 4—Required Liquid-Line Temperature (°F)  
A91444  
LIQUID  
PRESSURE AT  
SERVICE VALVE  
(PSIG)  
REQUIRED SUBCOOLING  
TEMPERATURE (°F)  
Table 3—Defrost Control Speedup-  
Timing Sequence  
5
10  
15  
20  
MINIMUM  
(MINUTES)  
MAXIMUM  
(MINUTES)  
SPEEDUP  
(NOMINAL)  
PARAMETER  
134  
141  
148  
156  
163  
171  
179  
187  
196  
205  
214  
223  
233  
243  
253  
264  
274  
285  
297  
309  
321  
331  
346  
359  
71  
74  
66  
69  
61  
64  
56  
59  
30–minute cycle  
50–minute cycle  
90–minute cycle  
10–minute cycle  
5 minutes  
27  
45  
81  
9
33  
55  
99  
11  
5.5  
7 sec  
77  
72  
67  
62  
12 sec  
21 sec  
2 sec  
80  
75  
70  
65  
83  
78  
73  
68  
86  
81  
76  
71  
4.5  
1 sec  
89  
84  
79  
74  
Fig. 10—Defrost Control  
92  
87  
82  
77  
95  
90  
85  
80  
6. When you hear reversing valve change position, remove  
screwdriver immediately; otherwise, control will terminate  
normal 10-minute defrost cycle in approximately 2 sec.  
98  
93  
88  
83  
101  
104  
107  
110  
113  
116  
119  
122  
125  
128  
131  
134  
137  
140  
96  
91  
86  
99  
94  
89  
102  
105  
108  
111  
114  
117  
120  
123  
126  
129  
132  
135  
97  
92  
NOTE: Length of defrost cycle is dependent upon length of time  
it takes to remove screwdriver from test pins after reversing valve  
has shifted.  
100  
103  
106  
109  
112  
115  
118  
121  
124  
127  
130  
95  
98  
101  
104  
107  
110  
113  
116  
119  
122  
125  
7. Unit will remain in defrost for remainder of defrost-cycle time  
or until defrost thermostat reopens at approximately 80°F coil  
temperature of liquid line.  
8. Turn off power to outdoor unit and reconnect fan motor lead  
to OF2 on control board. (See Fig. 10.)  
Step 14—Check Charge  
Factory charge is shown on unit rating plate. To check charge in  
cooling mode, refer to Cooling Only Procedure. To check charge  
in heating mode, refer to Heating Check Chart Procedure.  
HEATING CHECK CHART PROCEDURE  
To check system operation during heating cycle, refer to the  
Heating Check Chart on outdoor unit. This chart indicates whether  
a correct relationship exists between system operating pressure and  
air temperature entering indoor and outdoor units. If pressure and  
temperature do not match on chart, system refrigerant charge may  
not be correct. Do not use chart to adjust refrigerant charge.  
COOLING-ONLY PROCEDURE  
NOTE: If superheat- or subcooling-charging conditions are not  
favorable, charge must be weighed in accordance with unit rating  
plate ± 0.6 oz/ft of 3/8-in. liquid line above or below 15 ft  
respectively.  
7
 
NOTE: When charging is necessary during heating season,  
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.  
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.  
EXAMPLE:  
To calculate additional charge required for a 25–ft line set:  
25 ft – 15 ft = 10 ft X 0.6 oz/ft = 6 oz of additional charge  
Step 15—Final Checks  
CARE AND MAINTENANCE  
For continuing high performance and to minimize possible equip-  
ment failure, periodic maintenance must be performed on this  
equipment.  
IMPORTANT: Before leaving job, be sure to do the following:  
1. Securely fasten all panels and covers.  
Frequency of maintenance may vary depending upon geographic  
areas, such as coastal applications.  
2. Tighten service valve-stem caps to 1/12-turn past finger-tight.  
Copyright 2002 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231  
38byc3si  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Book  
Tab 5a 5a  
1
4
PC 101  
Catalog No. 533-80078  
Printed in U.S.A.  
Form 38BYC-3SI  
Pg 8  
11-02  
Replaces: 38BYC-2SI  
 

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