Carrier 40KMC User manual

40KMC / 38HDF
40KMQ / 38QRF
In—Ceiling Cassette Duct—Free Split System
Sizes 018 to 036
turn to the experts fF
Installation Instructions
40KMC, KMQ Unit
38HDF/QRF Unit
NOTE: Read the entire instruction manual before starting the
installation.
CA UA Le:
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury or
equipment damage.
Puron refrigerant systems operate at higher pressures than
standard R-22 systems. To avoid damage to the unit or
possible personal injury, do not use R-22 service equipment or
components on Puron refrigerant equipment.
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
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes and
current editions of the National Electrical Code ( NEC ) NFPA 70.
In Canada, refer to current editions of the Canadian electrical code
CSA 22.1.
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 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.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical 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.
PERSONAL INJURY AND EQUIPMENT DAMAGE
HAZARD
Failure to follow this caution may result in personal injury
and / or equipment damage.
DO NOT operate the unit without a filter or with grille
removed.

DIMENSIONS - INDOOR
40KMC018
Adjacent Room Supply
10-5/IRST5}
al
@
=
a
es
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g
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MWe
=
=
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6
Net
=P
abe
Ta
=
=
‘
—
©
Supply
air
Supply
air
=
_
2'-4-11/32"(720)
_
Return
air
1'-9-21/32"(650)
Model
|
Unit
Size
Operating
Weight
Ib
kg
40KMC
18
49
22.3
FRESH AiR
41-8
9/32"(515)
Return
40KMC024-036 / 40KMQ018-036
3-1-5
1164"(960)
INLET
Operating Weight
Model | Unit Size PPS
Ib kg
024 91 414
40KMC
030 / 036 95 43.2
018/024 91 414
40KMQ
030 / 036 95 43.2
NOTE: Dimensions in () are in mm.
A08447
Fig. 1 - 40KMC,KMQ Indoor Unit Dimensions
2

DIMENSIONS - OUTDOOR
JUNCTION BOX FOR————————
POWER SUPPLY &
CONTROL CONNECTIONS
FIELD CONTROL SUPPLY]
. WIRE_ENTRY
2/8" (22.2) HOLE W/GROMMET
K-11 1/2"
(38.19
SERVICE PORTS
CADDITIONAL PORTS *
PROVIDED INSIDE
COMPRESSOR ACCESS)
“M"DIA VAPOR LINE CONN.
FEMALE SWEAT CONN.
3/8” DIA. (9.53)
LIQUID LINE
FEMALE SWEAT CONN*
WIND BAFFLE ACCESSORY
DRAIN HOLES
eTYP)
L
! oe gt
Torna ape 2042
L— aia
oad fr \
(25)
| \ 3 9/16" pela
RIGHT SIDE VEIW “ | (406)
,| TYP
pe
SNOW STAND ACCESSORY ~~
(FIELD PROVIDED AND INSTALLED)
Je]
“-7 1/25
agi) nae
P
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f f
|
F “or aL
—
o’-0 11716"
as) el on
UNIT
38HDF
Unit Size
38QRF
Unit Size
018 o18
>
‘ ‘ se
“ 5 ~ o—
152)
TYP
CHASSIS
SIZE A Cc Dd
(Reference)
21%," | 3" "P4296" | 1-4"
Go
ad
(108)
JUNCTION BOX
(REFERENCE)
0'-2 1/2”
(64)
‘
re
“E 0-4 3/16
' aN
K
E F
VAT ig" | 15% 6"
411-5 1p”
FRONT VIEW * Male flare connection for Heat Pumps
UNIT SIZE : M OPERATING WT
in. mm Ib kg
oi8 5/y 15.88 166 75.3
024 Sly 15.88 176 79.8
38HDF
030 hy 19.05 187 84.8
036 Wy 19.05 250 113.4
018 Sly 15.88 166 753
024 5/g 15.88 176 79.8
38QRF 030 3/4 19.05 187 84.8
036 34 19.05 232 105.2
G H K L N
P
024,030 024
nop! qi a
06 2-7 3 1
406.
1-4"
406.
224g" V1! | 15% ig" | 11/5" | 2a"
. i
1'-10" 1
i
i "9"
1” | O'-65/p” | O%-111/." | 0'-275/,5” | 0-6"
68. 52
0'-63/,"
O'-115/_" | O'-2°5/,6” | 0-6"
71 52.
036 030,036
"P55" | 1-645"
15/46" | 3"
10 1131.
NOTE: Dimensions shown in feet-inches. Dimensions in ( ) are millimeters.
CLEARANCES -
1'-78}p"
2'-64o"
4. 498.
2-B3/46" | 2108/6"
41
Fig. 2 - 383HDF, QRF Unit Dimensions
OUTDOOR
A
Alr-inlet
-1'/ig" | O'-Bt_” | 1-37” | O'-37%/i5” | O'-6'/.”
. 65.
A08434
Ajir-outlet
UNIT Coil Facing Wall - in. (mm) Fan Facing Wall -— in. (mm)
A 24 (610) 24 (610)
B 36 (914) 36 (914)
Cc 36 (914) 8 (203)
D 6 (152) 8 (203)
E 6 (152) 36 (914)
Fig. 3 - Outdoor Unit Clearance
3
A08436

Parts List
Indoor Unit
The following items are included with the indoor unit:
Table 1 — Installation Materials
Description Qty Usage
Baffle (size 18) 1 Required for fresh air intake
Template 1 hoe hangers, piping and wiring loca-
NOTE: The grille and the User Interface are not included with
unit. For User Interface, a wireless remote, wired remote, or a
Zone Manager can be ordered.
Outdoor Unit
The following items are included with the outdoor unit:
PISTON CAP
PISTON
COGLING
PISTON BODY
LINE SET
; «BY OTHERS)
FLARE
CONNECTOR
CONNECTOR
«BY OTHERS)
FILTER
/DRIER
Loo
METERED FLOW
COOLING
38HDF018-036
A09499
Fig. 4 - 38HDF018-036
90° CONNECTOR
Fier <OPTIGNAL?
ORE PISTON CAP
PISTON
COOLING
PISTON BODY
LINE SET
(BY OTHERS)
coe =|
METERED
COOLING
PISTON CAP
FLARE,
CONNECTOR
METERED FLOW
HEATING
These instructions cover the installation and start-up of the systems
listed in Table 2.
Table 2 - Matched Systems
INDOOR UNIT
eid ila OUTDOOR UNIT MODEL NUM-
BER
018 38HDFO18—3 40KMC018—3
Cooling 024 38HDF024—3 40KMC024—3
Only 030 38HDFO30—3 40KMC03036—3
036 38HDFO36—3/5/6 | 40KMCO3036—3
018 38QRF018—3 40KMQ01824—3
024 38QRF024—3 40KMQ01824—3
Heat Pump 030 38QRF030—3 40KMQ03036—3
036 38QRF035—3/5/6 | 40KMQ03036—3
Cooling 018 38HDFO18—3 40KMQ01824—3
with 024 38HDF024—3 40KMQ01824—3
Electric 030 38HDFO30—3 40KMQ03036—3
Heat 036 38HDFO36—3/5/6 | 40KMQ03036—3
SYSTEM REQUIREMENTS
Clearances
Allow sufficient space around the indoor and outdoor unit for
proper airflow circulation and servicing. Refer to Fig. 1 and Fig. 3
for minimum required clearances.
Piping: Piping and insulation is field supplied.
Piping Lengths
The minimum length between the indoor and outdoor units is 10 ft
(3 m). Refer to table 3 for the maximum lengths allowed.
Table 3 - Maximum Refrigerant Line Lengths
Unit Max Line Max Elevation Max Elevation
Size | Length* ft(m) (ID over OD) ft( m) (OD over ID) ft (m)
18K 200 (61) 65 (19.8) 200 (61)
24K 200 (61) 65 (19.8) 200 (61)
30K 200 (61) 65 (19.8) 200 (61)
36K 200 (61) 65 (19.8) 200 (61)
Note: For lengths greater than 25 ft (7.6 m), refer to the Duct Free Long
Line Guide.
Pipe Sizes
Refer to table 4 for pipe sizes.
A09500
Fig.
5
-
38QRF018-036
Table
4
—
Pipe
Sizes
Pipe Sizes (in)
Model Filter Drier Piston Pistons* Flare Unit Size Mix Phase — in Vapor — in
Cap
Connector
18K
3/8
5/8
38HDF ia a aa aa 24k 3/8 5/8
38QRF
w
=
(aty
2)
lal
(qty
3)
30K
3/8
3/4
* Multiple pistons. Quantity varies with size. 36K 3/8 3/4
Note: Both lines need to be insulated using at least 1/2 inch closed foam
insulation.
Condensate Drain Pipe Sizes
Refer to table 5 for the
Table 5 — Drain Pipe Sizes
required sizes.
Unit Size Inside Diameter — in
18K
24K
30K
38K afoafoa}oa

Refrigerant Charge
The 38HDF and 38ORF units can be matched with multiple
outdoor units and thus additional charge might be required when
matched with the 4OKMC or 40KMO units.
Table 6 — Additional Charge
Additional Charge Ib (kg)
Unit Size 38HDF 38QRF
018 0 0
024 1.2 (0.55) 0
030 3.0 (1.40) 1.8 (0.82)
036 0.8 (0.36) 0
Note:The above additional charge is required amount for line lengths up to
25 ft (7.6 m). For line lengths exceeding 25 ft (7.6 m), additional charge will
be required. Refer to the Duct Free Splits Long Line Guide.
Metering Device
The metering device(s) for these systems is a type B Accurator
installed with the outdoor unit. One Accurator is required for the
cooling only system and two are required for the heat pump
systems. The Accurators are supplied with the outdoor unit.
However, since the same outdoor unit can be matched with
multiple indoor units, the correct Accurator must be selected. Refer
to Table 7 for the correct Accurator size.
Table 7 — Accurator Sizes
Control Wiring
Thermostat wires should be used for control wiring between the
indoor and outdoor units. A two conductor cable is required for
the cooling only units and a seven conductor cable is required on
heat pumps. 18 AWG is recommended for any length up to 50 ft
(15.2 m). 16 AWG is recommended for lengths between 50 and
200 ft (15.2 and 61.0 m).
User Interface
For 38HDF and 38QRF units matched with 40KMC and 40KMQ
units, the following accessories are available
¢ Wall mounted control. Up to 6 units can be daisy chained and
controlled by one wired control.
¢ Zone manager capable of controlling up to 32 units divided up
to 8 different zones.
¢ Wireless remote control.
NOTE: Units are factory ready for wall mounted wired
controls. See User Interface Installation section in this
document.
Operating Range
Ensure that the system operates within the application guidelines
shown in the following tables.
Cooling Operating Range
System T si Cooling Heating Maximum Minimum
ystem Type 126 Accurator Accurator DB°F CC) | WB°F(CC) | DB°FCC) | WB°F(CC)
018 49 = Outdoor
cooling Only 024 57 = Unit 125 (51.7) -- 55 (12.8) --
030 61 - Indoor
. 90 (32.2 74 (23.3 62 (17.0 56 (13
036 74 = Unit (32.2) (23.3) (17.0) (13)
018 51 46
Heat Pumps 024 55 53 Heating Operating Range
030 63 55 7 +
036 70 a3 Maximum Minimum
DB°FCC) | WB°F(°C) | DB°F(°C) | WB°F(°C)
‘ ‘ ‘ Outdoor | 75 (28.9 87 (19.4 17 (-8.3 --
Power and Connecting Cables - Field Supplied Unit (28.8) (18.4) (~8.3)
Power: indoor 81 (27.2) —- 62 (17.0) —-
¢ The indoor and outdoor units require a dedicated power supply.
¢ Consult local building codes, NEC (National Electric Code) or Accessories
CEC (Canadian Electric Code) for any special requirements.
¢ Use Table 8 for the electrical requirements for the outdoor units
and Table 9 for the indoor units to correctly size the cables and
disconnect switches.
Table 8 - 38HDF / QRF Electrical Requirements
38HDF 38QRF
Unit Voltage Min Ckt Amps/ Min Ckt Amps/
Size Fuse HACR Bkr Fuse HACR Bkr
Amps Amps
018 208/230 —1-60 12.1/20 12.1/20
024 208/230—1-60 16.8/25 16.8/25
030 208/230 —1-60 18.4/30 18.4/30
035/36 208/230—1-60 23.8/40 23.3/35
035/36 208/230-3-60 18.0/30 14.5/20
035/36 460—-3-—60 8.3/15 87/15
Table 9 - 40KMC / KMQ Electrical Requirements
40KMC 40KMQ
Unit Voltage Min Ckt Amps/ Min Ckt Amps/
Size Fuse HACR Bkr Fuse HACR Bkr
Amps Amps
018 208/230 —1-60 0.83/15 16.3/20
024 208/230—1-60 O.7/15 16.3/20
030 208/230 —1-60 1.3/15 16.9/20
036 208/230 —1-60 1.3/15 16.9/20
An extensive list of field installed accessories is available for both
indoor and outdoor units. Identify what accessories, if any, are
required for the application at hand and consult the separate
installation instructions for the accessories. Some of the
accessories, especially on the indoor units, can be installed much
easier if planned ahead.

INSTALLATION
Complete Pre-installation Checks
1. Unpack Unit - Store the indoor and outdoor units in the
original packaging until it is moved to the final site for in-
stallation. When unpacking indoor unit, be careful not to
lift unit by condensate drain discharge pipe or by refrigerant
connections.
bo . Inspect Shipment - Upon receipt of shipment, check the
indoor and outdoor units for damage. If there is any dam-
age, forward claim papers directly to the transportation
company. Manufacturer is not responsible for damage in-
curred in transit.
3. Inspect Parts Supplied With Units — Check all items
against parts list (see page 4). If any items are missing, noti-
fy your distributor or Carrier office.
To prevent loss or damage, leave all parts in original packages until
installation.
Consider System Requirements
1. Consult local building codes and NEC for special instaila-
tion requirements.
bo . When deciding the location of the indoor and outdoor units,
ensure that the piping run does not exceed the allowed dis-
tances listed in Table 3.
3. Make sure the indoor and outdoor units are easily accessible
to electrical power.
4. Allow sufficient clearances for airflow, wiring, refrigerant
piping, and servicing the unit. See Fig. 2 and Fig. 3.
5. Condensate piping can be directed through the inside wail
to an approved drain or straight outside.
INSTALL INDOOR UNIT
Plan the installation carefully before you begin.
1. Select indoor unit location.
a. A location that can bear the weight of the unit.
b. Install the unit a centrally as possible in the room.
c. Choose a location that does not obstruct air circulation.
NOTE: A maximum of two air outlets can be restricted at one
time. See Fig. 6. The Air Supply Outlet Obstruction accessory
kit can be used to obstruct air outlets.
t ‘ ’ ‘
it ¥ i q
\ , ‘ i
s ¢ “ ¢
Max. 2 louvers closed
‘ ‘
it 1
‘ i
x ’
4
A07184
Fig. 6 - Air Outlet Obstruction
d. Choose a location that is easily accessible for service
and maintenance.
e. Do not install indoor units near a direct source of heat
such as direct sunlight or heating appliance.
f. Do not install units too close to humid conditions.
2. Mounting Indoor Unit
NOTE: If the mounting location is in a plaster board ceiling,
the maximum dimensions of the unit housing cutout must not
exceed 2 ft, 2 in. (0.66 mm) square for the 40KMC018 units
and 2 ft. 11 in. (0.66 mm) square for the 40KMC024-036 and
40KMQ018-036 units.
NOTE: The unit is in two sections: The unit and the grille.
a. Use the factory supplied cardboard template as a guide
to mark the position of the hangers, refrigerant lines and
condensate drain pipes, power supply cables and remote
control cables. See Fig. 1 for dimensions.
b. Depending on the type of ceiling, fix the threaded
hangers as shown in Fig. 7 and Fig. 8.
4
|
C —©®
J @
=—__
@ ©D-——— ©
1D
®
@ Nut © Washer
@ Washers @ Threaded hangers
@® Threaded hangers Washer
@ Wooden frame @® Nut
® Nut Nut
A07186
Fig. 7 - Attaching Hangers to Ceiling
é
|—_}* Threaded hangers
L
a “T bar
La” be removed)
ale
AO7187
1
“4
Fig. 8 - Threaded Hangers and “T” Bar
c. Insert the washers as shown in Fig. 7 and Fig. 8.
d. Remove the “T”bar in ceiling to facilitate installation.
See Fig. 8. If the “T” bar cannot be removed from the
ceiling, the unit may have to be tilted as shown in Fig.
9,
Threaded Hangers Threaded Hangers
x, LLe
|
te” &
S| | x
ef
pe
T-Bar T-Bar
Supension Brackets Supension Brackets
A07I88
Fig. 9 - Positioning Unit in Ceiling
e. If Fresh Air Intake or Conditioning an Adjacent Room
is required, perform the modification required to the unit
at this point. Refer to the Installation Options section
for additional details.

f. Use a stacker to lift the unit to the installation location.
See Fig. 10.
A07L85
Fig. 10 - Positioning Unit
g. Carefully lift the unit using the four suspension brackets
and insert the four suspension brackets into the threaded
hanger as shown in Fig. 11.
Spirit
False
Ceiling Level
A07189
Fig. 11 - Align and Level Unit
h. Align and level the unit by adjusting the nuts and lock-
nuts on the threaded hangers maintaining a distance of 1
in. to 1-3/16 in. between the sheet metal body and the
underside of the false ceiling. See Fig. 11.
3. Drill the hole for the piping (refrigerant and condensate)
and control wiring in the external wail.
a. Drill a 2-3/4 in. (70 mm) hole in the wall with a 3/16
in. to 3/8 in. (4.8 - 9.5 mm) slope toward the outside.
Refer to Fig. 12.
(70/80
ram)
~
Outdoor
” 3e"s3/e" Om
~ \erto mm) Y ©)
Indoor
A07L90
Fig. 12 - Drilling for Connections
4. Drill hole for Fresh Air Intake, if required. Refer to Instaila-
tion Options section for additional information.
NOTE: In rooms with high humidity, brackets should be
insulated using self-adhesive insulation.
INSTALL OUTDOOR UNIT
The outdoor units can be installed on the ground, on the roof, or
mounted on a wall.
NOTE: Install the unit so that the coil does not face into
prevailing winds. If this is not possible and constant wind
winds above 25 mph are expected, use accessory wind baffle.
See installation instructions provided with accessory kit. Wind
baffles should also be used on all units with accessory low
ambient temperature control.
Mounting on Ground
1. Mount unit on a solid level concrete pad.
2. Ifa heat pump is being installed, use a field- provided snow
stand or ice rack where prolonged subfreezing temperatures
or heavy snow occurs.
3. Position unit so water or ice from roof does not fall directly
onto unit.
4. On cooling only units, an accessory stacking kit can be used
when units are to be stacked. See installation instructions
provided with the accessory kit.
Mounting on Roof
& CAUTION
PERSONAL —= INJURY
DAMAGE HAZARD
Failure to follow this caution may result in personal injury
and / or equipment damage.
Be sure unit panels are securely in place prior to rigging.
AND/OR EQUIPMENT
1. Rig the unit. Keep the unit upright and lift using a sling.
Use cardboard or padding under the sling, and spreader bars
to prevent sling damage to the unit. See Fig 13. See Fig. 2
for center of gravity reference
. Mount unit on a solid concrete pad or platform.
Ww
be
. Isolate unit and piping from structure
fs . Ifa heat pump is being installed, use a field- provided snow
stand or ice rack where prolonged subfreezing temperatures
or heavy snow occurs.
5. On cooling only units, an accessory stacking kit can be used
when units are to be stacked. See installation instructions
provided with accessory kit.
| SLING PADDING
|. COMPRESSOR
[END
HA |. CENTER OF
UATE GRAVITY
OE
LeU
i
Fig. 13 - Lifting Unit with Sling
A07396

Mounting Unit on Wall
The units can also be mounted on the wall using the accessory
mounting kit.
Complete Outdoor Refrigerant Piping Connec-
tions
Follow the following general guidelines:
1. Use refrigerant grade field — supplied tubing.
Refer to Table 4 for the correct line sizes.
2. Do not use less than 10 ft (93.05 m) of interconnecting
tubing.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
If any section of pipe is buried, there must be a 6 in. (152.4
mm) 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 system shutdown. This causes
refrigerant slugging and could possibly damage the
compressor at start-up.
When more than 80 ft (24.4 m) of interconnecting tubing is used,
consult the Duct-Free Split System Long Line Application Guide
for required accessories.
3. Insulate both lines. A minimum of 1/2 inch foam pipe insu-
lation is recommended.
4. Run the refrigerant tubes as directly as possible and avoid
unnecessary turns and bends.
5. Suspend refrigerant tubes to avoid damage to insulation or
tubes so they do not transmit vibration to the structure.
6. When passing refrigerant tubes through the wall, seal the
opening so rain and insects do not enter the structure. Leave
some slack in refrigerant tubes between structure and out-
door unit to absorb vibration.
NOTE: A fusible plug is located in unit suction line; do not cap
this plug. If local codes require additional safety devices, install
as directed.
Connection at Outdoor Unit
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.
To prevent damage to unit or service valves observe the
following:
¢ A brazing shield MUST be used.
¢ Wrap service valves with wet cloth or use a heat sink
material.
38HDF Units:
1. Assemble the connector tube to the factory supplied filter
drier by:
a. Braze the field supplied connector to the inlet of the
filter drier (see Fig. 14)
b. Braze the factory supplied flare connector to the outlet
end of the filter drier (see Fig.14)
ate) oe,
CONNECTOR
CONNECTOR COCLING
<BY
OTHERS)
PISTON
BODY
FILTER
7DRIER LINE. SET
<BY OTHERS?
é
i; =f
METERED FLOW
ETERED Fe
COGLING
Aogagg
Fig. 14 - 38HDF018-036 Connector Tube Assembly
2. Assemble the Accurator body (see Fig. 15) using the correct
factory supplied piston (refer to Table 7) .
TEFLON SEAL TO INDOOR
COIL
2
a
eae
PISTON
WITH ORIFICE BODY
NOTE: Arrow on AccuRater body points in free flow direction, away from the
indoor coil.
AO9501
Fig. 15 - AccuRater (bypass type) Metering Device
Components
3. Attach the complete Accurator assembly to the flare connec-
tion end of the filter drier
4. Braze the completed filter drier/Accurator assembly to the
liquid service valve.
5. Connect the field supplied line set to the filter drier/Accura-
tor assembly and the suction valve. A sweat connection is
required at the suction valve and flare connection is required
for the mixed phase line.
6. Insulate any exposed areas between the line set and the li-
quid valve.

38QRF Units
1. Assemble the connector tubes to the factory supplied filter
drier by brazing the factory supplied flare connectors to the
inlet and outlet for the filter drier (see Fig. 16)
90° CONNECTOR
ist FILTER COPTIONAL)
HEXTING (DRIER PISTON CAP
PISTON
PISTON CAP ERaLINe
FLARE PISTON BODY
CONNECTOR LINE SET
(BY OTHERS)
METERED FLOW ese METERED PLOW
ne
HEATING COOLING
AOQ507
Fig. 16 - 38QRF018-036 Connector Tube Assembly
. Perform step 2 and 3 from the 38HDF section.
Ww
. Remove the plastic cap from the liquid and suction service
valve on the 38ORF unit and assemble the heating piston
and piston cap supplied with the outdoor unit as shown in
Fig. 17.
ISTON CAP
FLARE
CONNECTOR
METERED FLOW
@oooonnooonn
HEATING
A07407
Fig. 17 - AccuRater (bypass type)
Metering Device Components
Heat Pump Systems Only
NOTE: The Teflon seal on the piston should point towards the
liquid service valve. The size of the factory supplied piston
might have to be adjusted for long line applications (over 80 ft
/ 24.4 m). Refer to the Duct Free Long Line Application Guide
for additional information.
4. Attach the flare end of the filter drier assembly to the piston
cap (see Fig. 17).
5. Connect the field supplied line set to the filter drier as-
sembly and to the suction valve.
6. Insulate any exposed areas between filter drier and liquid
valve.
Complete Outdoor Power and Control Wiring
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
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.
& CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.
Unit failure as a result of operation on improper line voltage or
excessive phase imbalance constitutes abuse and may cause
damage to electrical components. Such operation could void
any applicable Carrier warranty.
& WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Before performing service or maintenance, be sure indoor
unit main power switch is turned OFF and indoor blower has
stopped.
Lock out and tag switch with a suitable warning label.
Power Wiring
1. Mount outdoor power disconnect. The unit is factory wired
for the voltage shown on the unit nameplate. The fused dis-
connect switch must be provided within sight of the unit,
readily accessible, but out of reach of children. Provisions
for locking the disconnect switch on the OFF (open) posi-
tion is advisable. The disconnect switch must comply with
NEC and local codes. Protect the unit and wiring using
only the recommended fuse/circuit breaker size. See
Table 8.
2. Run power wiring from main box to disconnect per NEC
and local codes.
an . Run power wiring from the disconnect switch to outdoor
unit. Use only minimum 60°C copper conductors between
the disconnect switch and the unit for field power connec-
tion.
4. Route the field power wires through the conduit connection
opening in the unit side panel and connect in junction box
as shown in Fig 18. The unit and power wiring must be
grounded.
== =GROUND LEAD = -{@] crounowe LUG
SINGLE-PHASE
CONNTO) =f . ax
DISCONNECT
PER NEC
om JZ tak
SINGLE-PHASE UNIT
THREE-PHASE
CONN TO
DISCONNECT
[oo
A
VEL
PER NEC
maz =GROUND LEAD uma GROUNDING LUG
THREE-PHASE UNIT
LEGEND
NEC -- National Electrical Code
fA -- Splice (field)
== ' Field Wiring
tmmmes Factory Wiring
A08251
Fig. 18 - Line Power Connections
NOTE: Operating unit on improper line voltage constitutes
abuse and may affect Carrier warranty. DO NOT install unit
in a system where voltage may fluctuate above or below
permissible limits.
9

Control Wiring
The control circuit is 24 volts AC (minimum 40VA) supplied from
the indoor unit.
1. Make sure you have enough control wires to cover the dis-
tance between the indoor and outdoor unit.
Indoor
Terminal
Board
Indoor ~
Board i
ae ae \
Outdoor |
Terminal ——>
Board |
a Lee TES AE ISHIRAL Ewen mm mr rr rr rn |
foo 7) HEGHMALL Fe © TT
A09508
Fig. 19 - 38HDF Control Terminal Strip
2. Route one end of the control wiring through the opening
rovided in the unit side panel and connect to the control
Pp Pp
terminal strip using either Fig. 19 for 33HDF units and Fig.
20 for 38ORF units.
Indoor
Board
\ Indoor
Terminal
Board |
EH — v0 siseeiai @ - ~ — — — — — — — =|
ae wos TO HEGHGRLL & —_
vow TO HLSOGRLA, OF _T TTT TT TT
Outdoor 1G MIG, & = —— — $s —— S$ —— S$ —— ss
Terminal —+> 09 teil ¢ =< —— —— —— —— — — — —|
Board [EB] 80 AEGHWALL Ro |
[Bplen #0 wisewL @ ©) —— ——- —- ——- —— —— —— —
A09509
Fig. 20 - 38QRF Control Terminal Strip
NOTE: Use No. 18 AWG color-coded, insulated 35°C minimum) wire. If the distance between the indoor and outdoor unit is
greater than 100 ft. 30.5 m), as measured along the control voltage wires, use No. 16 AWG color-coded wire to avoid excessive
voltage drop.
10

ELECTRICAL DATA
Table 10 —38HDF/38QRF Electrical Data
COMPRESSOR OUTDOOR FAN MOTOR FUSE/
38HDF/38QRF V-PH-Hz VOLTAGE RANGE* MIN CKT CKT
UNIT SIZE ven AMPS BKR
Min Max RLA LRA FLA NEC Hp kW Out AMPS
018 208/230 —1-60 187 253 9.0 48.0 0.80 0.125 0.09 12.4 20
024 208/230 —1-60 187 253 12.8 58.3 0.80 0.125 0.09 16.8 25
38QRF030 208/230 —1-60 187 253 14.4 73.0 1.50 0.25 0.19 18.4 30
38HDFO30 208/230 —1-60 187 253 14.4 73.0 0.80 0.125 0.09 18.4 30
208/230 —1-60 187 253 16.7 79.0 1.50 0.25 0.19 22.3 35
035 208/230-3-60 187 253 10.4 73.0 1.50 0.25 0.19 14.5 20
460—-3-—60 414 506 5.8 38.0 0.80 0.25 0.19 8.7 15
208/230 —1-60 187 253 17.9 112.0 1.45 0.25 0.19 23.8 40
036 208/230-3-60 187 253 13.2 88.0 1.45 0.25 0.19 18.0 30
460—-3-—60 414 506 6.0 44.0 0.80 0.25 0.19 8.3 15
Table 11 — 40K MC Fan coil Electrical Data
Voltage Range FAN Power
Louver
40KMC Condensate FUSE/
ee V-PH-Hz Motor
Unit Size : Pump FLA MIN CKT CKT
Min. Max FLA Watts FLA AMPS BKR
AMPS
018 208/230—1—60 187 253 0.55 120 0.08 0.01 0.8 15
024 208/230 —1-60 187 253 0.50 110 0.06 0.01 0.7 15
030 208/230 —1-60 187 253 0.95 210 0.06 0.01 1.3 15
036 208/230 —1-60 187 253 0.95 210 0.06 0.01 1.3 15
Table 12 —- 40KMQ Fan Coil Electrical Data
Voltage FAN Electric Power
Range L Heaters
ouver
40KMQ Condensate FUSE/
Unit Size V-PH-Hz Motor | Pump FLA Motor MIN CKT
Min. | Max | FLA | Power FLA kw FLA CKT
BKR
(Watts) AMPS | anaps
018 208/230 —1-60 187 253 0.50 110 0.06 0.01 3 12.5 16.3 20
024 208/230 —1-60 187 253 0.50 110 0.06 0.01 3 12.5 16.3 20
030 208/230 —1-60 187 253 0.95 210 0.06 0.01 3 12.5 16.9 20
036 208/230 —1-60 187 253 0.95 210 0.06 0.01 3 12.5 16.9 20
*Permissible limits of the voltage range at which unit will operate satisfactorily.
LEGEND NOTES:
FLA -
MCA -
NEC -
RLA -
Full Load Amps
Minimum Circuit Amps per NEC Section 430-24
National Electrical Code
Rated Load Amps (Compressor)
1. In compliance with NEC requirements for multi-motor and combination
load equipment (refer to NEC Articles 430 and 440), the over—current
protective device for the unit shall be fuse or equipped with a breaker.
2. Motor RLA values are established in accordance with UL (Underwriters
Laboratories) Standard 465.
11
Cc
@
US

DISPLAY PCB
@
2PCB
1
sfa[s]e|a
2
SLON
Odo
TM-COIL TM-AIR
& MODULAR “D”
~ CONTROL 1PCB
S
SLoN
GRA/YEL-[F15+ GRN/YEL-
oe
TO UNIT DISCONNECT
(USE CABLE PROVIDED)
EQUIP. GND
40KMC GLOBAL CASSETTE
~ 38HDF OUTDOOR CONDENSER
Ws
1
2
aLk
Wy
8s
—
Spo
NOTE
8
cout
ovo
Spe
me
208/230
CHS 1PH
YEL i. BLK a of am \(SEE NOTE 103
° ouTsoon
NIT
BLK t K RR dal gm | DISCONNECT
YEL BLU ct
COMP BLK BLK
aly —____}
co ——_Cenecloniclo
we YEL
ORN/YEL, au
K alk
OFM
“TQ CASSETTE Y — —— —— ——
LLPS
ieRN oOo 0 OFS ea apes
RED TO CASSETTE R — ——-~ —— ——
1. IF ANY OF THE ORIGINAL RE FURH] SHED
Cc CONT ACTOR (PCB MAIN CONTROL PRINTED CIRCUIT BOARD dust BE ooo ri 1T MUST
2POB DISPLAY BOARD WITH TYPE $O°C WIRE OR 115 UVNLENT,
3PCB PRINTED CIRCUIT BOARD FOR ELECTRIC HEAT 2. WIRE IN Acconpance WITH NATIONAL
a ae 8 caeneeney VALVE SOLENOID ELECTRICAL CODE (N.E.C.9 AND LOCAL CODES.
CRANCASE HEATER SWITCH 3
bes esr etme Sy SE esa ee ee ee ccm
DRAIN PUMP 7B TERMINAL BL + ne
E-HTR ELECTRIC HEATER ™ THERMAL OVERLO:
FAN CAPACITOR TRAN TRANSFORMER $. INDOOR UNIT Taro HAS INTERNAL 24 THERMAL FUSE ON
EQUIP.GND. EQUIPMENT GROUND THE PRIMARY 51D!
FS FLOAT SWITCH INFRARED CONNECTION 70,8 INSERTED ON YS" (REPLACE
@ND GROUND (2) TERMINAL (MARKED) TNE AG tad etetoay HASTALLED “Che! GoWNEgTON FoR {CR OPTION,
ves TNDDOR ea RTO TERMINAL (UNHARKED) TERMINAL, STREP FOR CARREER ROOM CONTROLLER (CRC? CONNECT 2ON.
SALACE COMPRESSOR CRANCKCASE HEATER INSTALLED ON S38QRFO3S, AND 38QRFO30.
3
VIP INDOOR TEST POINT @
LLPS L1GUID LOW PRESSURE SHITEH ED terninas, a.ook - OUTDOOR UNIT, TRANSFORMER, 38 FACTORY WIRED FOR 230". FOR 20eV HOVE
LM -LOUVER MOTOR
2
ean
FACTORY WIREN( A Rt Ht
UNS
LOWER
MICRO
SHITCH
ACTORY
WIRING
THE
BLACK
WIRE
TO
THE
208V
T.
ts) Cime? switch ——— FIELD CONTROL WIRING 30. USE MINIMUM GO"C WERE FOR THE FIELD POWER WIRING.
GAS —OUTNOOR AIR SENSOR
OFN © OU3DO0R FAN NOTOR
OFR © QUTDOOR FAN RELAY
OL OVERLOAD
FIELD POWER WIRING
ACCESSORY OR OPTIONAL WIRING
PLUG CONNECTOR
TEMPERATURE RESISTANCE
°F °C Q
5 35 6,500
72 22 11,400
32 9 32,500
ALL THERMISTORS ARE IDENTICAL
50057
Fig. 21 - 40K MC / 38HDF Cooling Only System Wiring Diagram

IL TM-AIR
ake —8]0—
v/ YELLS GRN/YEL:
cS aLK
BLK BLK
$ He
Fig. 22 - 40KMQ / 38HDF Heat/Cool System Wiring Diagram with Electric Heaters
LL: s
PO PL —9— BL bag aL
RATIONAL,
zc AND LOCAL Ci
3. Compressor and fan motors are protected by intemal thermal averloads.
4. conpne: AND FAN HOTORS ARE PROTEC
ALO
cOMPRE
NSFORMER HAS INTERNAL 24 THERON, FUSE 08
TEMPERATURE
oF of
50058
13

L
ALON
OW
COMM
or
RAYEL
ate [Tf om ah ee a
3
BLON
ORR/YEL GRN/YEL:
LECHTa
HO]
o}"
2E-HTR
xe
SEHTR
8 LEL2L2 LI PE PE
4E-HTR POGO9OD
BLK pee |
| OL ceneveL--
| T
: |
I
¢ CHR, CORES,
joressor and fan plotors are protected by internal thermal overloads,
MPRESEOR AND FAN MOTORS ARE PROTECTED BY INTERNAL
INPERNAL, 25 THERMAL
TERMINAL GYARKED?
TERHINSL GRBARKED?
WIRERS
OPPLONAL WERING
TEMPERATURE
°F
1cal
Fig. 23 - 40KMQ / 38QRF Heat Pump System Wiring Diagram with Electric Heaters
14

Run Power Wiring for Indoor Unit
Be sure field wiring complies with local building codes and NEC,
and unit voltage is within limits shown in Table 11 and Table 12.
Contact local power company for correction of improper line
voltage.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Before installing, modifying, or servicing system, main
electrical 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.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.
Unit failure as a result of operation on improper line voltage or
excessive phase imbalance constitutes abuse and may cause
damage to electrical components. Such operation could void
any applicable Carrier warranty.
NOTE: Use copper wire only between disconnect switch(es)
and unit.
NOTE: Install branch circuit disconnect of adequate size to
handle unit starting current per NEC. Locate disconnect
within sight of, and readily accessible from, unit, per section
440-14 of NEC. Some codes allow indoor unit to share
disconnect with outdoor unit if disconnect can be locked; check
local code before installing in this manner.
The 40KMC/KMO units require their own power supply.
1. Locate the indoor power supply.
2. Locate and install disconnect switch per NEC and local
codes.
3. Run power supply wiring to disconnect switch.
4. Run power wiring from disconnect switch to control box
area, Use copper wire only between the disconnect switch
and unit. Use minimum 60°C wires for field power con-
nection.
5. Remove the external control box cover.
6. Place wiring through the 7/8 in. or 1-1/8 in. knockouts on
the bottom and on the right hand side of the external control
box (high voltage side). See Fig. 24 and Fig. 25.
15

Room Controller | |
Connections
| | <—Veltage
foley Ae
Outdoor Unit ||"
Connections | |
| CI
VN y—oN
| Os@OsOsOsOs©ce
: OnCniCnenenene
boc; —a ri I
| | Ground tt
C) Connection
| | <——_ Voltage
A07208
Fig. 24 - 40KMC Unit Matched to 33HDF Outdoor Unit - Wiring Connection
(Cooling Only System)
16

( > aft
! ! Solio | |
7
OWS)
og
"
| | S © 2 oo! | |
: © © © © Room Controller m
| | Connections | |
| | | |
<—\
Stage
I | IG |
' EI CI EI EI CI CE) EI '
| |
ms ( Outdoor Unit | o
| QOIODAOQAIOD AOA OIA SO Connections 1
| | OCTNTIT TROT TET TET he | |
I |
| I,
‘i oa J
p> lll
{| U Connections U |
| | seme“ | |
C) Connection os
| | |
| | | |
<—
Valage
LL i= |
||
A07209
Fig. 25 - 40KMQ Unit Matched to 383HDF Outdoor Unit - Wiring Connection
(Cooling with Electric Heat System)
17

7. Connect L1 to the black wire and L2 to the red wire using
wire nuts and fix the ground wire between the two washers.
The internal control panel can be accessed by opening the grille
and removing the metal cover attached by four screws.
NOTE: The internal control panel does not need to be accessed
during the installation process unless there is a need for service.
8. If any accessories are being installed, refer to the individual
accessory instructions for guidance on wire routing at this
time.
Install All Power, Interconnecting Wiring, Piping and
Drain Hose to Indoor Unit .
1. Run control wiring from the outdoor unit through the access
hole in the wall and make sure you have enough wire to
reach the control box of the unit once hung on the mounting
plate.
bo . Complete refrigerant piping connections.
a. cut the extreme end of the tubes and remove any copper
shavings with a de-burring blade.
b. Remove the flare nut from the “Flare” connection body
of the indoor unit and insert them into the pipes.
c. make the flares to the pipe ends with the proper flaring
too. The flare end must not have any burrs or imperfec-
tions. the flared walls must be uniform. See Fig. 26
and Fig. 27.
A07L99
Fig. 26 - Removing Burrs
Vv
07200
Fig. 27 - Flared Walls are Equal
d. Lubricate the end of the pipe and thread of the flare
connection with refrigerant oil. Tighten by hand and
then use two wrenches (see Fig. 28) to tighten all con-
nections fully applying the tightening torque shown in
Table 13.
@
0) Adjustable wrench or torque wrench
@ Outdoor end
@
@ Indoor end
A07201
Fig. 28 - Tightening Connections
Table 13 — Tightening Torque
TUBE DIAMETER (in.) TORQUE (ft.—Ib)
3/8 in. 31
5/8 in. 48
3/4 in. 74
@ Indoor unit piping
@ Connection wiring
@® Drain hose
A08ae4
Fig. 29 - Location of Piping, Hose, and Wiring
3. Connect condensate drain piping
Observe ail local sanitary codes when installing condensate
drains. The condensate may be discharged at a maximum
height of 7-1/8 in. (181 mm) above the unit as long as the
ascending tube is vertical and aligned with drainage flange.
If it is necessary to discharge the condensate from a level
above 7-1/8 in. (181 mm), install an auxiliary water dis-
charge pump and a float valve. A float valve is recommen-
ded to stop the compressor if there is a fault at the auxiliary
pump.
18

a. Use hard polyvinyl chloride (PVC) pipe material with
nominal ID of 1 in. to connect at drain line. To ensure
correct condensate water flow, the pipe should have a
gradient of 2% without obstruction. See Fig. 30
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.
The drain tube extension must be securely fastened to the
condensate drain. Failure to do so could result in condensate
water dripping on to the floor.
LM
G
WL J,
é
’
H max. | 7-7/8"(200 mm) | J 22%
iP dh ih
b.
a.
b.
A trap of at least 2 in. (51 mm) in depth should be made
to prevent unpleasant odors from reaching the room.
. Insulate condensate pipe with condensation proof mater-
ial such as polyurethane, propylene, or neoprene of 3/16
in. to 3/8 in. thickness.
. Complete Control Wiring
Route the control wiring through the 7/8 in. knockouts
on the left or right hand side of the external control box
(low voltage side).
Connect R and Y wires to the terminal block for cooling
only units (40KMC) and heat pump units (40KMQ) that
are matched with the 383HDF outdoor units. See Fig. 24.
. Connect the R, Y, O, G, DT, A, and B wires to the
(PGB-1) 1 terminal on the 4OKMOQ heat pump indoor
units. See Fig. 25.
. Perform any modifications required for the accessory user
interface. Three types of user interface can be used with the
unit: Wall mounted wired control, Wireless remote control
and Zone Manager.
a. Wall Mounted Remote Control
The unit comes ready from the factory for use with a
wall mounted wired control. Refer to the installation
instructions of the wired remote control for additional
information. The wall mounted wired contro! connects
to terminals P, G, and C located in the external control
box. See Fig. 24 and Fig. 25. If there is a desire to
control multiple units (up to 6) from one wired remote
control, the units should be wired as shown in Fig. 31.
AO7194
Fig. 30 - Condensate Drain Pipe
UNIT1 UNIT 2 UNIT 3 --- UP TO 6 UNITS
A A A
O2@
Se 929 9eQ
POe@
©
PO
_OF-W-
~ MAIN BOARD
- WIRING KIT 33mMC9005
- BLACK
- RED
~ WHITE
CICIOIOr.
* 100 ohm Resistor
QeQ
929
WN
(P16) [WIRED CONTROLLER
A09513
Fig. 31 - Multiple Unit Control Wiring

b. Wireless Remote Control
The unit is factory equipped with a wire harness that has one end connecting to the receiver board (Display PCB) and the other
end is loose. See Fig. 32.
B
alo
&|O
wlol|* Loose End
nN} O
DISPLAY PCB |cpip-y “12
ob} 5—
2Pcb ~ 3 SpLE-2 C
JI 2 | Spans 6
s[4]3]2|i 1S B
TB2
gigigisig
ee Rte +
HIN [MH 1M |
@Lk | BLK
LITT COMM ia
7|6]s]4]al2|1 ']2]3]als 1f2[a]4]s
Ji J8 J5
A09547
Fig. 32 - Wire Harness
To modify the unit for use with wireless remote do the following:
a. Remove the cover of the Internal Control Panel to get access to the microprocessor board. See Fig. 33.
ee
=
=
INTERNAL CONTROL PANEL INTERNAL CONTROL PANEL
40KMCO18 40KMC024-036
40KMQ018-036
Capacitor
GMC board
Electric heater board
{only on models with electric heater)
Transformer
Holes for fixing panel in position
Emergency push-button
Fan connector
LED/RECEIVER connector
Float connector
Pump connector
Louver connector
€890
©o®
A07180
Fig. 33 - Internal Contro! Panel
b. Unplug the JS connector (A) from the board (see Fig. 32).
c. Plug the Loose end (B) into the JS Connector on the board
d. Reinstall the cover of the internal control panel