Installation, Start-Up and Service Instructions

Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS...1 INSTALLATION...1-9 Step 1 Complete Pre-Installation Checks...1 UNPACK UNIT INSPECT SHIPMENT Step 2 Select Location...1 Step 3 Mount Unit in Ceiling...2 Step 4 Connect Refrigerant Piping...6 Step 5 Connect Condensate Drain Line...6 Step 6 Make Electrical Connections...7 Step 7 Adjust Louvered Discharge Diffusers...8 HEATING AND COOLING REDISTRIBUTE AIRFLOW START-UP...10 SERVICE AND MAINTENANCE...10,11 Minimum Maintenance...10 Servicing...10 TO CLEAN OR REPLACE RETURN AIR FILTERS TO CLEAN OR REPLACE DRAIN PAN INSTALLATION OPTIONS...11,12 Ventilated Air Option...11 Conditioned Air Discharge Option...11 TROUBLESHOOTING...13-17 SAFETY CONSIDERATIONS Installing and servicing air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install or service air-conditioning equipment. Untrained personnel can perform basic maintenance, such as cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in literature and on tags and labels attached to unit. Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly. Consult local building codes and NEC (National Electrical Code) for special installation requirements. Before installing or servicing unit, turn off main power to system. There may be more than one disconnect switch. Turn off accessory heater power if applicable. Electrical shock can cause personal injury. INSTALLATION The 40QKB ceiling-mounted fan coil unit is installed with the 38HDC outdoor condensing unit, and the 38QR heat pump or the 38HDC outdoor condensing unit are installed with 40QKE fan coil units. Refer to Table 1 to make sure the correct indoor unit is installed with the correct outdoor unit. For 40QK 024-048 In-Ceiling Cassette Fan Coil Units 40QK fan coil installation instructions, refer to Steps 1 through 7. For 38HDC outdoor unit installation instructions, refer to the 38HDC Installation, Start-Up and Service Instructions. For the 38QR heat pump installation instructions, refer to the 38QR Installation, Start-Up, and Service Instructions. When installing the 38HDC or 38QR unit, it is important to note that for cooling applications where the outside-air temperature is below 55 F, it is necessary to equip the outdoor unit with the head pressure control accessory. NOTE: Grille and frame are shipped separately and are required to commplete assembly. Thermostat and AccuRater kits are also required. Table 1 System Combinations for Indoor and Outdoor Units INDOOR UNIT 40QKB/QKE024 40QKB/QKE036 40QKE024 40QKE036 40QKE048 OUTDOOR UNIT 38HDC018 38HDC024 38HDC030 38HDC036 38QR018-C 38QR024-C 38QR030-C 38QR036-C Step 1 Complete Pre-Installation Checks UNPACK UNIT Store unit in the original packaging until it is moved to the final site for installation. Carefully remove fan coil, control box, and plastic bag which contains drain connector and mounting screws. When removing fan coil unit from carton make sure it is lifted by its 4 corners and not by the condensate drain or refrigerant connections. The grille is packed separately for extra protection. INSPECT SHIPMENT Upon receipt of shipment check unit (Fig. 1) for damage. Forward claim papers directly to the transportation company. Manufacturer is not responsible for damage incurred in transit. After checking shipment, leave all parts in their original packages until installation. Step 2 Select Location Consult local building codes and NEC for special installation requirements. The ceiling-mounted fan coil unit can be installed several ways. As a typical installation, these instructions focus on mounting the unit above a false ceiling to wooden beams, newly built concrete slabs, metal structure, or a previously built concrete slab. Before you begin, plan carefully, measure carefully and follow acceptable building practices and the NEC. Listed below are some guidelines that should be followed when installing the unit. 1. Position unit as close to the center of the room as possible to ensure air is distributed evenly. 2. Allow sufficient space for airflow clearance, wiring, refrigerant piping, and servicing unit. Also, when determining the final location of the unit, consider if conditioned air will be discharged to an adjacent room or ventilated air will be used. Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 PC 111 Catalog No. 534-016 Printed in U.S.A. Form 40QK-4SI 6-97 Pg 1 Replaces: 40QK-2SI Tab 3d 2d

SIZE 024 FAN COIL UNIT SIZE 036,048 FAN COIL UNIT Fig. 1 40QK In-Ceiling Cassette Fan Coil Units 3. Install removable ceiling panels adjacent to the unit for servicing. Refer to Fig. 2 and 3. 4. Make sure thermostat is away from the fan coils direct air discharge. Step 3 Mount Unit in Ceiling 1. Remove enough ceiling panels to provide clearance space for mounting unit to ceiling joists. In some ceilings it may be necessary to temporarily remove sustaining T-bars. 2. Determine mounting method. On wooden beams use threaded rods, washers, and nuts to suspend support brackets. With metal structures, secure threaded rods on an existing angle or install a new support angle. On newly built concrete slabs secure threaded rods with inserts and embedded bolts. For previously built concrete slabs install hanging bolts with an expansion anchor. Refer to Fig. 4. a. Refer to Fig. 2 and 3 for distance between the holes for supporting brackets. Mark distance on the ceiling joists before drilling holes for securing rods to ensure they will line up with the holes on unit. b. Securely fasten 3 8-in. threaded rods to ceiling joists. Refer to Fig. 4. c. Place support bracket on the threaded rod 5 5 16 in. from false ceiling. Double-nut support brackets for safety. Install one nut and washer above the support bracket. Make sure extension rods do not protrude down through support bracket more than 3 8 of an inch; otherwise, the unit cannot be easily attached to the bracket. Refer to Fig. 5. NOTE: The final tightening of nuts and counter nuts on the support bracket should be done when all the connections are completed. 3. Secure and level fan coil unit. a. Carefully lift unit at the 4 corners to insert it onto the support brackets. The unit may have to be inclined to be lifted over the sustaining T-bars (Fig. 6). After the unit is inserted onto the support bracket, screw in safety screws. b. Place a carpenter s level on the unit. Refer to Fig. 7. A maximum slope of 1 8 in. toward the condensate drain is allowed. 4. Unpack grille and grille frame. NOTE: See Start-Up section for procedure that tests the drain pan condensate flow. a. On size 024 units, mount grille frame using the 4 screws provided. b. On the size 036 and 048 units that have a 2-piece frame, be sure to align and securely lock the dovetail (Fig. 8). Connect the frame with the 8 screws provided. NOTE: On both units, the frame should align with the false ceiling as shown in Fig. 9. If alignment is incorrect, re-adjust height and re-level. If the unit is too high, do not use excessive force on frame mounting screws. Internal gaskets must be sealed properly to prevent airflow leakage between inlet and outlet. Make sure the grille frame lines up with the false ceiling. Also, make sure the grille frame gasket seals are against the ceiling, keeping the unconditioned air from entering the occupied space. c. Hang grille(s) on the support hooks and swing grille up into the frame and fasten by turning slotted screws. 2

UNIT WEIGHT Lb Kg 40QKB024 (Without Heaters) 61.6 28 40QKE024 (With Heaters) 66.1 30 NOTES: 1. Indicates airflow. 2. Dimensions in [ ] are in millimeters. 3. Service clearance is 2 ft on control box side, zero in. all other sides. 4. Air discharge slots are adjustable; 1 or 2 may be closed to direct air in the desired direction. 5. Grille is shipped separately from unit. 6. Condensate pump has 20 in. lift capability. Fig. 2 Size 024 Dimensional Drawing 3

UNIT NOTES WEIGHT 1. Lb Kg Indicates airflow. 40QKB036* 105.8 48 2. Dimensions in [ ] are in millimeters. 3. Service clearance is 2 ft on control box side, zero in. all other sides. 40QKE036 114.4 52 4. Air discharge slots are adjustable; 1 or 2 may be closed to direct air in the desired 40QKE048 118.8 54 direction. 5. Grille is shipped separately from unit. 6. Condensate pump has 20 in. lift capability. Fig. 3 Sizes 036 and 048 Dimensional Drawing 4

Fig. 4 Mounting Methods (Hardware is Field Supplied) Fig. 7 Level Unit Fig. 5 Support Bracket Installation Fig. 8 Dovetail Connection Fig. 6 Unit Inclined for Insertion Over T-Bars Fig. 9 Line Up Frame with the False Ceiling 5

Step 4 Connect Refrigerant Piping Fan coil units may be connected to outdoor units using field-supplied refrigerant grade piping. Refer to Table 2 for the correct size piping. The length of refrigerant pipe depends on unit placement and building structure; be sure to run pipes as directly as possible. Use the following instructions to connect refrigerant piping. 1. Install insulation. a. Insulate suction line to prevent condensation. It is extremely important that the suction line and the Accu- Rater metering device be completely insulated. Use any acceptable heat resistant closed-cell foam insulation (minimum 3 8-in. wall thickness). b. Cap piping ends. c. Slide insulation over piping, or cut insulation and place over piping. 2. Run refrigerant piping. a. Run pipes as directly as possible, avoiding any unnecessary turns and bends. b. Suspend refrigerant pipes so that the insulation is not damaged and vibrations are not transmitted to the structure. c. Leave slack in the refrigerant pipe between the structure and the unit to absorb vibrations. d. Install flare connections at both liquid and vapor lines. When making these connections, slide flare nut on line, then flare line and connect. e. Install flare coupling and AccuRater metering device from accessory kit (Fig. 10) in liquid line at fan coil. Make sure arrow on metering device body points away from the fan coil. Use Table 3 to determine required piston size for the system being installed. f. On heat pump installations only, install provided heat pump piston in the AccuRater metering device located in service valve on outdoor unit (Fig. 11). Make sure the Teflon seal on the piston faces toward the outdoor unit. Use Table 3 to determine required piston size for the system being installed. Piston is provided with outdoor unit. g. Install filter drier for outdoor unit in the liquid line near the outdoor unit. Heat pump units use a bi-flow style filter drier. h. Refer to 38HDC and 38QR Installation, Start-Up, and Service Instructions for additional information. 3. Insulate wall openings to reduce air infiltration and refrigerant piping vibrations on structure. 4. Evacuate piping, if necessary. If either refrigerant piping or the indoor coil is exposed to atmospheric conditions for longer than 5 minutes, the piping must be evacuated to 1000 microns to eliminate contamination and moisture in the system. For instructions on evacuation and system charging, refer to Carrier Standard Service Techniques Manual, Chapter 1, Section 1-7. Fig. 10 AccuRater Metering Device Installed Liquid Line (Bypass Type Components) Fig. 11 AccuRater Metering Device at Service Valve (Bypass Type Components) The drain tube extension must be securely fastened to the condensate drain. Failure to do so can result in condensate water dripping onto the floor. 2. To ensure regular flow of condensate water, the drain pipe should be pitched toward open drain or sump at a downward slope. Refer to Fig. 12. Also, make sure that the line continually slopes with no rise or sags as shown in the lower right-hand side of Fig. 12. 3. Provide a trap of at least 2 in. near the end of the drain line to prevent odors from entering rooms. Refer to Fig. 12. 4. Insulate condensate drain line(s). Insulate the condensate drain lines that are located in or above an occupied area with a condensate proof material such as polyurethane or neoprene. Step 5 Connect Condensate Drain Line Observe all local sanitary codes when installing condensate drains. 1. Connect drain line by inserting the field-supplied hose connector on the condensate drain. Then place 1 in. rigid PVC pipe over the hose connector. Refer to Fig. 12. Fig. 12 Drainage System 6

Table 2 Physical Data UNIT 40QK B024 E024 B036 E036 E048 OPERATING WT (lb) 61.6 66.1 105.8 114.4 118.8 REFRIGERANT R-22 Control Type AccuRater Control FAN RpmHigh 1190 970 970 1220 Med 930 790 790 980 Low 840 635 635 760 Nominal Cfm (High Speed) 525 975 975 1100 COIL Rows 3 2 2 3 Face Area (sq ft) 2.66 5.67 5.67 5.42 Fins/in. 14 14 14 14 Number of Circuits 3 4 4 6 CONNECTIONS (in.) Suction Flare 5 8 Male 3 4 Male Liquid Flare 3 8 Male 3 8 Male LINE SIZES (in.) Suction 5 8 3 4 Liquid 3 8 3 8 Condensate Drain 1 1 Table 3 Required Piston Size for AccuRater Metering Device OUTDOOR UNIT INDOOR UNIT INDOOR PISTON INDOOR PISTON TYPE OUTDOOR PISTON OUTDOOR PISTON TYPE REQUIRED SYSTEM CHARGE* (lb) 38HDC018 40QKB/QKE024 52 B 5.5 38HDC024 40QKB/QKE036 62 B 5.2 38HDC030 40QKB/QKE036 63 B 4.8 38HDC036 40QKB/QKE036 65 B 5.9 38QR018-C 40QKE024 52 B 49 B 5.8 38QR024-C 40QKE036 62 B 49 B 5.9 38QR030-C 40QKE036 63 B 55 B 6.5 38QR036-C 40QKE048 67 B 59 B 9.3 *Charge amount is determined with 25 ft of line. Step 6 Make Electrical Connections Be sure field wiring complies with local building codes and NEC. Also, check that unit voltage is within limits as shown in Tables 4 and 5 for permissible operating limits. See pages 13-17 for wiring diagrams. Contact local power company for correction of improper line voltage. To avoid personal injury or damage to unit, do not make electrical connections until all power sources are shut down, locked out and tagged out. Failure to do so could result in personal injury or unit damage. Operation of unit on improper line voltage constitutes abuse and could affect warranty. Refer to Tables 4 and 5 for permissible operating limits. Do not install unit in system where voltage may fluctuate above or below permissible limits. 1. Install electrical control box. With the 2 screws provided, attach the electrical control box (Fig. 13) to the fan coil unit. 2. Route line power leads from indoor disconnect to the fan coil unit. a. Place wiring through top hole on right side of control box (Fig. 13). b. Using Fig. 14 and appropriate wiring diagrams, connect power from disconnect wire to high voltage terminal board (TB1) and ground. NOTE: Indoor disconnect should be within sight and readily accessible per NEC. Do not route the power leads from outdoor unit. 3. Route line power leads from indoor disconnect to the fan coil unit for power to heaters (if required). NOTE: If unit is equipped with electric heaters, the power source must be from an approved NEC disconnect and connected directly to contactor in control box. a. Run wire from disconnect to fan coil unit. Refer to Tables 4 and 5 for recommended fuse and wire sizes. b. Place wire through bottom hole on the right hand side of electric control box (Fig. 13). Using Fig. 14 and the appropriate wiring diagram connect disconnect wire to heater contactor. NOTE: Units equipped with electric heaters have an automatic safety thermostat set to 163 ±6F.Iftripped, this thermostat will reset automatically, but the cause should be investigated. (For example, a low air flow due to dirty inlet filter.) 4. Install wall-mounted thermostat and control power wiring. 7

LEGEND CR Control Relay DR Defrost Relay FR Fan Relay HC Heater Contactor HLC Heater Limit Contactor HTR Heater PCB Printed Circuit Board PDR Pump Delay Relay PL Plug TB Terminal Board TRAN Transformer Fig. 13 Electrical Control Box Do not short circuit the 40QK 60-va transformer. It is fused. The transformer can be short circuited by connecting wrong wires or by touching a live wire to the side of the grounded control box. a. Place thermostat in same room as fan coil unit. Make sure the thermostat is away from the direct air discharge. b. Run 24-v control wires from outdoor unit to indoor unit and to the thermostat. Units are factory wired for 230/24-v transformer operation. For 208/24-v operation, interchange blue (208-v) and red (240-v) wires at the primary connection. Cap unused wires with wirenuts. c. At the fan coil unit, connect 24-v control wire to (TB2) as shown on the appropriate wiring diagrams. 5. Connect heater and unit plugs. a. Using Fig. 13 and wiring diagram, connect unit plug (PL4) from control box to mating fan coil plug. b. Connect heater plug (PL5) from control box to mating fan coil plug. Step 7 Adjust Louvered Discharge Diffusers HEATING AND COOLING Direct diffusers so air blows outward across the ceiling (Fig. 15). REDISTRIBUTE AIRFLOW Close one or two diffusers. Never close more than two diffusers on fan coil or the effectiveness of the safety devices will be limited. Refer to Fig. 16. LEGEND HC Heater Contactor NEC National Electrical Code TB Terminal Board Fig. 14 Line Power Leads NOTE: If a unit must be placed in ceiling against a wall, close the diffuser on the wall side before installing. Also, to take advantage of the unit s flexibility, the ventilated air option or conditioned air option can be used. Depending on the length and restrictions of the ductwork, one or 2 discharge diffusers may have to be closed. Refer to the Installation Options section for detailed instructions. 8

Table 4 Electrical Data OPERATING VOLTAGE* FAN HEATER POWER UNIT V-PH-Hz Min Max FLA kw FLA MCA MOCP FLA MINIMUM WIRE SIZE 40QKB024 208/230-1-60 187 253 0.44 0.6 15 0.44 14/14 40QKB036 208/230-1-60 187 253 0.78 0.9 15 0.78 14/14 40QKE024 208/230-1-60 187 253 0.44 1.80 7.50 10.0 15 7.94 14/14 40QKE036 208/230-1-60 187 253 0.78 2.70 11.25 15.0 15 12.03 14/14 40QKE048 208/230-1-60 187 253 1.04 2.70 11.25 15.0 15 12.29 14/14 LEGEND FLA Full Load Amps MCA Minimum Circuit Amps per NEC Section 430-24 MOCP Maximum Overcurrent Protection *Permissible limits of the voltage range at which unit will operate satisfactorily. Separate heater and unit circuits required. NOTE: Control circuit is 24 v on all units. 40QK024 Only 2 diffusers may be closed. 40QK036,048 Only 2 diffusers may be closed. Fig. 16 Closing Diffusers Fig. 15 Diffuser Adjustments Table 5 Electric Heater Data (40QKE Only) INDOOR UNIT V-PH INPUT AMPS kw MIN WIRE SIZE MAX FUSE OR HACR TYPE CKT BREAKER AMPS 40QKE024 240-1 7.5 1.8 14 ga 15 40QKE036 240-1 11.25 2 x 1.35 14 ga 15 LEGEND HACR Heating, Air Conditioning, Refrigeration 9

START-UP The following checks should be made before system startup. Refer to outdoor unit Installation, Start-Up, and Service manual for system start-up instructions and refrigerant charging methods. Be sure to use the refrigerant charge shown in Table 3. 1. Check condensate drainage system. a. Remove grille and frame from the unit. b. On the opposite side of the drain connection, insert a water bottle up into the fan coil unit and fill drain pan. Refer to Fig. 17. Water must flow regularly with condensate pump energized. If water does not, check the pipe slope or see if there are any pipe restrictions. NOTE: The unit is equipped with a safety float switch to deenergize the compressor if the drain water level gets too high. 2. Make sure that all wiring connections are correct and that they are tight. 3. Make sure that all barriers, covers, and panels are in place. 4. Ensure that the filters and return air grilles have been installed and that the discharge louvers are correctly positioned. SERVICE AND MAINTENANCE Remove unit grille, filter, and condensate pan for cleaning, lubricating, or replacing parts. To avoid personal injury or damage to unit, do not service until all power sources are shut down, locked out, and tagged out. Failure to do so could result in personal injury or unit damage. Minimum Maintenance 1. Check, clean, or replace air filter each month or as required. 2. Check cooling coil, drain pan, condensate trap, and condensate drain pan each cooling season for cleanliness. Clean as necessary. 3. Check fan motor and wheel for cleanliness each heating and cooling season. 4. Check electrical connections for tightness and controls for proper operation each heating and cooling season. Service as necessary. Servicing TO CLEAN OR REPLACE RETURN AIR FILTERS 1. Open intake grille by turning screws as shown in Fig. 18. 2. Slide filter out. 3. Vacuum clean or wash filter with soapy water. Rinse and let air dry. If filter needs replacing, filters are available from the local dealer. If air filter is not replaced in the unit, dust and dirt gather in air conditioner and operation becomes impaired. Fig. 17 Inserting Water into Drain Pan Never operate unit without a filter or with grille removed. Damage to the unit or personal injury may result. TO CLEAN OR REPLACE DRAIN PAN 1. Place a plastic sheet on the floor to catch any water that may spill from drain pan. 2. Remove the air intake and distribution assembly. Remove the condensate water in the drain pan by pulling out the rubber drain plug (Fig. 19) and letting water drain into a 3-gallon bucket. Do not use a screw driver to pry drain pan out of assembly. It could damage the pan. 3. Remove screws holding the drain pan. On size 024, there are 4 screws, and on sizes 036 and 048 there are 6 screws. Carefully hold the drain pan to remove it from the assembly. 4. Re-install the drain pan using the appropriate number of screws. Center and align the metal fan inlet orifice (Fig. 19) with the fan. Ensure the fan spins freely. 10

Fig. 18 Intake Grille Slotted Screws NOTE: Unit is shown with grille up. 1 Pipe Fitting Entry 2 Clamp 3 Neoprene Gasket, 6 mm 4 Insulated Flexible Conduit 5 Fresh Air Fan Motor 6 Speed Regulator 7 ON-OFF Switch with Fuses 8 Intake Grille with Filter Holder Frame Fig. 19 Drain Plug INSTALLATION OPTIONS Fig. 20 Field Addition of Air Ventilation or Air Conditioning to an Adjacent Room The 40QK provides for the field addition of air-conditioning to an adjacent room or fresh air ventilation. Plan your installation carefully. Before you begin, measure carefully, and follow acceptable building practices and NEC. Ventilation Air Option 1. Using Fig. 2 or 3, locate and remove the factory-installed insulation from the side of the unit where the prepunched knockouts are located. 2. Remove the pre-punched knockouts for fresh air intake. Refer to Fig. 20. Be careful not to damage internal parts such as the heat exchanger coil. 3. Install ductwork using field-supplied, insulated flex duct, or insulated sheet metal suitable for working temperatures up to 155 F. 4. Use Fig. 21 and Table 6 to determine the allowable static pressure loss for the ductwork airflow. The ductwork design must not exceed this value or the job airflow requirements will not be met. 5. Use an accessory fan if airflow does not meet job requirements. Refer to Fig. 20. IMPORTANT: Ventilated air must not exceed 10% of the total airflow or problems with operation will result. 6. Install a filter and grille on outside wall at fresh air inlet. Refer to Fig. 20. Table 6 Maximum and Minimum Fresh Airflow for Fan Coil Units UNIT 40QK Fig. 21 Fresh Airflow for Fan Coil Units MAXIMUM FRESH AIR AIRFLOW (cfm, high speed) MINIMUM FRESH AIRFLOW (10% Permitted Limit) (Cfm) 024 647 64.7 036 983 98.3 048 1288 128.8 NOTE: Ventilated air must not exceed 10% of total airflow. Conditioned Air Discharge Option 1. Follow Ventilation Air Option, Steps 1-6. Refer to Fig. 2 and 3 for location of prepunched knockouts. 2. Completely insulate all ductwork to prevent condensation. 3. Close one or two discharge diffusers on the unit to increase the airflow to the adjacent room. See Fig. 16 and Fig. 22. 4. Provide a path for return air. See Fig. 23 for examples. 11

ONE DIFFUSER CLOSED TWO DIFFUSERS CLOSED Fig. 22 Available Static Pressure for 40QK 024-048 PATH FOR RETURN AIR Fig. 23 Installation Examples for Return Air Path 12

TROUBLESHOOTING Refer to Fig. 24-29 when troubleshooting. LEGEND CAP Capacitor CFS Condensate Float Switch CR Control Relay DR Defrost Relay FR Fan Relay IFM Indoor Fan Motor PCB Printed Circuit Board PL Plug PM Condensate Pump TB Terminal Block TRAN Transformer Circuit Board Run Terminal (Marked) Terminal (Unmarked) Terminal Block Factory Wiring Field Control Wiring Field Power Wiring Accessory or Optional Wiring NOTES: 1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent. 2. Wire in accordance with National Electrical Code (NEC) and local codes. 3. Thermostat and subbase combinations. THERMOSTAT SUBBASE COOLING ONLY HH07AT194 HH93AZ208 4. Use copper conductors only. 5. Transformer is factory wired for 230 v. 6. For 208 v, systems, change tap. FAN SPEEDS LO MED HI ENERGIZED RELAYS FR1 FR1 & FR2 FR2 UNIT (60 Hz) COLOR/PIN NO. 018 024 036 048 HIGH GRA/5 BLK/3 GRA/4 BLK/2 MEDIUM BLU/6 GRA/5 BLU/6 GRA/4 LOW RED/7 BLU/6 RED/8 BLU/6 Fig. 24 40QKB Unit Component Arrangement LEGEND CAP Capacitor CFS Condensate Float Switch CR Control Relay DR Defrost Relay FR Fan Relay HC Heater Contactor HTR Heater HLC Heater Limit Contactor IFM Indoor-Fan Motor LS Limit Switch PCB Printed Circuit Board PL Plug PM Condensate Pump TB Terminal Block TRAN Transformer Circuit Board Run Terminal (Marked) Terminal (Unmarked) Terminal Block NOTES: 1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent. 2. Wire in accordance with National Electrical Code (NEC) and local codes. 3. Thermostat and subbase combinations. HEAT PUMP THERMOSTAT HH07AT192 SUBBASE HH93AZ202 HH93AZ204 4. Use copper conductors only. 5. Transformer is factory wired for 230 v. 6. For 208 v, systems, change tap. FAN SPEEDS LO MED HI ENERGIZED RELAYS FR1 FR1 & FR2 FR2 Factory Wiring Field Control Wiring Field Power Wiring Accessory or Optional Wiring UNIT (60 Hz) COLOR/PIN NO. 018 024 036 048 HIGH GRA/5 BLK/3 GRA/4 BLK/2 MEDIUM BLU/6 GRA/5 BLU/6 GRA/4 LOW RED/7 BLU/6 RED/8 BLU/6 Fig. 25 40QKE Unit Component Arrangement 13

LEGEND C Contactor CAP Capacitor CKT BD Circuit Board CLO Compressor Lockout COMP Compressor CR Control Relay CT Current Transformer DR Defrost Relay DTS Discharge Temp. Sensor EQUIP. GND. Equipment Ground FL Fuse Link FPT Freeze Protection Thermostat FR Fan Relay HPS High-Pressure Switch IFM Indoor-Fan Motor LPS Low-Pressure Switch OFM Outdoor-Fan Motor OL Overload PDR Pump Delay Relay PL Plug PM Pump Motor PSS Pump Safety Switch RIDTS Remote Indoor Temp. Sensor TB Terminal Block TRAN Transformer Terminal (Marked) Terminal (Unmarked) Splice Terminal Block Factory Wiring Field Control Wiring Field Power Wiring Printed Circuit Board Accessory or Optional Wiring RELAY CHART INDOOR FAN HIGH FR2 INDOOR FAN MED FR1, FR2 INDOOR FAN LOW FR1 NOTES: 1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent. 2. Wire in accordance with National Electrical Code (NEC) and local codes. 3. Transformer is thermally protected and will reset automatically. 4. IFM(S), OFM and COMP have internal thermal protection. 5. The CLO locks out the COMP to prevent short cycling on COMP overloads and safety devices. Before replacing CLO check these devices. Minimum one amp turn required to hold contacts closed. 6. Heating contactor energizes electric heater in fan coil. Heater requires separate power source for electrical power. Fig. 26 Typical System Wiring Diagram; 40QKB With 38HDC 14

LEGEND C Contactor CAP Capacitor CKT BD Circuit Board CLO Compressor Lockout COMP Compressor CR Control Relay CT Current Transformer DFB Defrost Board (Outdoor Unit) DFT Defrost Thermostat DR Defrost Relay DTS Discharge Temp. Sensor EQUIP. GND. Equipment Ground FPT Freeze Protection FR Fan Relay HC Heater Contactor HLC Heating Limit Contactor HPS High-Pressure Switch IFM Indoor-Fan Motor LPS Liquid Low Pressure Switch LS Limit Switch OFM Outdoor-Fan Motor OL Overload PDR Pump Delay Relay PL Plug PM Pump Motor PSS Pump Safety Switch RIDTS Remote Indoor Temp. Sensor TB Terminal Block TDR Time Delay Relay TRAN Transformer Terminal (Marked) Terminal (Unmarked) Splice Terminal Block Factory Wiring Field Control Wiring Field Power Wiring Printed Circuit Board Accessory or Optional Wiring RELAY CHART INDOOR FAN HIGH FR2 INDOOR FAN MED FR1, FR2 INDOOR FAN LOW FR1 NOTES: 1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent. 2. Wire in accordance with National Electrical Code (NEC) and local codes. 3. Transformer is thermally protected and will reset automatically. 4. IFM(S), OFM and COMP have internal thermal protection. 5. The CLO locks out the COMP to prevent short cycling on COMP overloads and safety devices. Before replacing CLO check these devices. Minimum one amp turn required to hold contacts closed. 6. Heating contactor energizes electric heater in fan coil. Heater requires separate power source for electrical power. Fig. 27 Typical System Wiring Diagram; 40QKE With 38HDC 15

LEGEND C Contactor CAP Capacitor CKT BD Circuit Board CLO Compressor Lockout COMP Compressor CR Control Relay CT Current Transformer DFB Defrost Board (Outdoor Unit) DFT Defrost Thermostat DR Defrost Relay EQUIP. GND. Equipment Ground FPT Freeze Protection FR Fan Relay HC Heater Contactor HLC Heating Limit Contactor HPS High-Pressure Switch IFM Indoor-Fan Motor LLPS Liquid Low Pressure Switch LS Limit Switch NC Normally Closed NO Normally Open OFM Outdoor-Fan Motor OL Overload PDR Pump Delay Relay PL Plug PM Pump Motor PSS Pump Safety Switch RIDTS Remote Indoor Temp. Sensor RVS Reversing Valve Solenoid TB Terminal Block TG Time Guard TRAN Transformer Terminal (Marked) Terminal (Unmarked) Splice Terminal Block Factory Wiring Field Control Wiring Field Power Wiring Printed Circuit Board Accessory or Optional Wiring RELAY CHART INDOOR FAN HIGH FR2 INDOOR FAN MED FR1, FR2 INDOOR FAN LOW FR1 NOTES: 1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent. 2. Wire in accordance with National Electrical Code (NEC) and local codes. 3. Transformer is thermally protected and will reset automatically. 4. IFM(S), OFM and COMP have internal thermal protection. 5. The CLO locks out the COMP to prevent short cycling on COMP overloads and safety devices. Before replacing CLO check these devices. Minimum one amp turn required to hold contacts closed. 6. Heating contactor energizes electric heater in fan coil. Heater requires separate power source for electrical power. Fig. 28 Typical System Wiring Diagram; 40QKE With 38QR 16

LEGEND C Contactor CAP Capacitor CKT BD Circuit Board CLO Compressor Lockout COMP Compressor CR Control Relay CT Current Transformer DFB Defrost Board (Outdoor Unit) DFT Defrost Thermostat DR Defrost Relay DTS Discharge Temp. Sensor EQUIP. GND. Equipment Ground FPT Freeze Protection FR Fan Relay HC Heater Contactor HLC Heating Limit Contactor HPS High-Pressure Switch IFM Indoor-Fan Motor LLPS Liquid Low Pressure Switch OF Outdoor Fan OFM Outdoor-Fan Motor OL Overload PCB Printed Circuit Board PDR Pump Delay Relay PL Plug PM Pump Motor RIDTS Remote Indoor Temp. Sensor RVS Reversing Valve Solenoid TB Terminal Block TDR Time Delay Relay TRAN Transformer Terminal (Marked) Terminal (Unmarked) Splice Terminal Block Factory Wiring Field Control Wiring Field Power Wiring Printed Circuit Board Accessory or Optional Wiring RELAY CHART INDOOR FAN HIGH FR2 INDOOR FAN MED FR1, FR2 INDOOR FAN LOW FR1 NOTES: 1. If any of the original wire furnished must be replaced, it must be replaced with type 90 C wire or its equivalent. 2. Wire in accordance with National Electrical Code (NEC) and local codes. 3. Transformer is thermally protected and will reset automatically. 4. IFM(S), OFM and COMP have internal thermal protection. 5. The CLO locks out the COMP to prevent short cycling on COMP overloads and safety devices. Before replacing CLO check these devices. Minimum one amp turn required to hold contacts closed. 6. Heating contactor energizes electric heater in fan coil. Heater requires separate power source for electrical power. Fig. 29 Typical System Wiring Diagram; 40QKE With 38QR (Scroll Compressor) 17

PACKAGED SERVICE TRAINING Our packaged service training programs provide an excellent way to increase your knowledge of the equipment discussed in this manual. Product programs cover: Unit Familiarization Maintenance Installation Overview Operating Sequence A large selection of product, theory, and skills programs is available. All programs include a video cassette and/or slides and a companion booklet. Use these for self teaching or to conduct full training sessions. For a free Service Training Material Catalog (STM), call 1-800-962-9212. Ordering instructions are included. 18

Copyright 1997 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 PC 111 Catalog No. 534-016 Printed in U.S.A. Form 40QK-4SI 6-97 Pg 20 Replaces: 40QK-2SI Tab 3d 2d