38TDB WeatherMaker™ Two-Speed Air Conditioning Unit with
Contents
1. A98516 Fig 1 Model 38TDB 3 Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends 4 When passing refrigerant tubes through the wall seal opening with RTV or other pliable silicon based caulk See Fig 2 5 Avoid direct tubing contact with water pipes duct work floor joists wall studs floors and walls 6 Do not suspend refrigerant tubing from joists and studs with a rigid wire or strap which comes in direct contact with tubing See Fig 2 7 Ensure that tubing insulation is pliable and completely sur rounds vapor tube 8 When necessary use hanger straps which are 1 in wide and conform to shape of tubing insulation See Fig 2 9 Isolate hanger straps from insulation by using metal sleeves bent to conform to shape of insulation 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 chec2. LIQUID REQUIRED SUBCOOLING PRESSURE AT TEMPERATURE SERVICE VALVE PSIG 8 12 14 16 18 18 189 58 56 54 52 50 48 195 60 58 56 54 52404 50 202 62 60 58 56 54 52 208 64 62 60 58 56 54 215 66 64 62 60 58 56 222 68 66 64 62 60 58 229 70 68 66 64 62 60 236 72 70 68 66 64 62 243 74 72 70 68 66 64 251 76 74 72 70 68 66 259 78 76 74 72 70 68 266 80 78 76 74 72 70 274 82 80 78 76 74 72 283 84 82 80 78 76 74 291 86 84 82 80 78 76 299 88 86 84 82 80 78 308 90 88 86 84 82 80 317 92 90 88 86 84 82 326 94 92 90 88 86 84 335 96 94 92 90 88 86 345 98 96 94 92 90 88 354 100 98 96 94 92 90 364 102 100 98 96 94 92 374 104 102 100 98 96 94 384 106 104 102 100 98 96 395 108 106 104 102 100 98 406 110 108 106 104 102 100 416 112 110 108 106 104 102 427 114 112 110 108 106 104 439 116 114 112 110 108 106 450 118 116 114 112 110 108 462 120 118 116 114 112 110 474 122 120 118 116 114 112 486 124 122 120 118 116 114 499 126 124 122 120 118 116 511 128 126 124 122 120 118 the unit returns to low speed operation until first stage is satisfied or until second stage is required again When both first stage and second stage cooli
3. DEFROS ME MIN TO INDOORUNIT Fig 16 Wiring Diagram 037 A01439 15 DUAL CAPACITY LA CONNECTION DIAGRAM 208 230 1 60 POWER SUPPLY EQUIP GND 1 21314 C SE RVS C FORCED DEFROST PL4 DEFROST TME MIN OAT COMM SATUS OCT 1 2 P 4 5 BRN TOINDOORUNIT gt Fig 17 Wiring Diagram 060 A02212 Copyright 2002 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 38tdb4si Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 100 2 101 Catalog 533 80059 Printed U S A Form 38TDB 4SI Pg 16 8 02 Replaces 38TDB 3SI a
4. HEAT STAGE 2 ow2 HEAT STAGE 1 stage 2 vive FAN t 24 VAC HOT 4 4 24VACCOM FF 199M amp DEHUMIDIFY T PLIU HUMIDIFY HUMIDIFIER 050 Li 24 VAC N A OUTDOOR q OUTDOOR SENSOR a SENSOR CONNECTIONS 52 See notes 1 2 3 6 8 10 11 01499 RAMONA LE SINGLE STAGE MODEL 25 FURNACE 24 VAC HOT RE R 24 VAC COMM c HEAT STAGE 1 W W1 fw COOL STAGE 2 s COOL STAGE 1 N A OUTDOOR SENSOR CONNECTION See notes 1 2 3 and 5 01500 Fig 11 Typical 24V Wiring Diagram 6 PROGRAMMABLE VARIABLE SPEED THERMOSTAT SINGLE STAGE TWO SPEED 80 NON CONDENSING FURNACE MODEL 25 FURNACE AIR CONDITIONER 5 Ren NON PROGRAMMABLE BOARD COOL STAGE 1 THERMOSTAT m Yt MODEL 28 bee TWO SPEED FURNACE COOL STAGE 1 Yi w2H BOARD AIR CONDITIONER HEAT STAGE 1 W HEAT STAGE 2 O W2 y COOL STAGE 2 HEAT STAGE 1 W W1 COOL STAGE 2 2 2 24 VAC HOT FAN 8 R I s 24 VAC COMM 24 VAC COM COM 4 m 6 N A OUTDOOR SENSOR CONNECTION N A
5. HEATING amp COOLING 38TDB WeatherMaker Two Speed Air Conditioning Unit with Puron Visit www carrier com 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 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 Understand these signal words DANGER WARNING CAU TION and NOTE The
6. TWO SPEED MODEL 2S COIL AIR CONDITIONER _________ Ji UMPER 24 VAC HOT R R A JUMPER 5 m 1 COOL STAGE 1 v1 W2 4 lvi Hrs L3 COOL STAGE 2 2 2 L REMOVE HEAT STAGE 1 w w MH se JUMPER FOR HEAT HEAT STAGE 2 2 STAGING L3 24 VAC COMM c C 4 L NA 5 OUTDOOR SENSOR CONNECTION See notes 1 2 3 5 and 7 A01493 PROGRAMMABLE THERMOSTAT MODEL 2S HEAT STAGE 2 COOL STAGE 1 HEAT STAGE 1 COOL STAGE 2 FAN 24 VAC HOT N A OUTDOOR SENSOR 4 CONNECTION VARIABLE SPEED CONDENSING TWO SPEED URNACE AIR CONDITIONER THERMIDISTAT FK4C FV4A TWO SPEED CONTROL OR 40FK MODEL RH FAN COIL AIR CONDITIONER HEAT STAGE 2 REMOVE J2 JUMPER HEAT STAGE 1 FOR HEAT STAGING 3 COOL STAGE 1 L3 COOL STAGE 2 DEHUMIDIFY DHUM 24 VAC COMM HUMIDIFY HUM CB OUTDOOR SENSOR 4 CONNECTION 52 See notes 1 2 3 6 7 8 and 9 A01494 See notes 1 2 3 and 5 A01507 Fig 11 Typical 24V Wiring Diagram Cont required The LCC for standard PSC blower products consists of a standard humidistat which opens contacts on humidity rise and a pilot duty relay with 24v coil NOTE If an LCC is desired low speed airflow must be main tained so that a minimum of 300 CFM ton can be supplied during high speed LCC operation Step 9 Make Airflow
7. See notes 1 2 3 and 5 A01501 OUTDOOR 51 SENSOR S2 NON PROGRAMMABLE EUST ER CONNECTIONS THERMOSTAT PSC BLOWER TWO SPEED 5 AIR CONDITIONER See note 1 2 3 4 and 10 A01504 24 VAC HOT Rk VARIABLE SPEED 2avaccomm G 80 NON CONDENSING FURNACE AFS PROGRAMMABLE BOARD MEAT STAGE THERMOSTAT m Yt MODEL 25 e end i COOL STAGE 2 TWO SPEED COOL STAGE 1 Li BOARD AIR CONDITIONER HEAT STAGE 2 Ow2 HEAT STAGE 1 W W1 w COOL STAGE 2 HEAT STAGE 2 COOL STAGE 1 8 24 HOT ourooon 8 24 SENSOR tul See notes 1 2 3 4 and 10 JPL9 10 A01502 TWO SPEED N A AIR CONDITIONER rl CONNECTIONS See notes 1 2 3 5 and 10 A01505 STAGE 1 NON PROGRAMMABLE VARIABLE SPEED THERMOSTAT CONDENSING TWO SPEED MODEL 25 FURNACE AIR CONDITIONER COOL STAGE 2 HEAT STAGE 2 HEAT STAGE 2 jo wet d 2 cooLsmae 1 yt 24 VAC HOT HEAT STAGE 1 COOL stace 2 vve 24 VAC COMM FAN F4 24 H OUTDOOR SENSOR CONNECTION 24 VAC COMM See notes 1 2 3 5 and 10 01503 eese CONNECTION See notes 1 2 3 and 4 Fig 11 Typical 24V Wiring Diagram Cont 7 PROGRAMMABLE THERMOSTAT
8. 40FK AIR CONDITIONER FAN COIL J1 JUMPER 24 VAC HOT 24 c 4 c e 4 COOL STAGE 2 HEAT STAGE 1 W Wi REMOVE J2 JUMPER FOR HEAT HEAT STAGE 2 2 STAGING COOL STAGE 1 See N A OUTDOOR SENSOR CONNECTION See notes 1 2 3 4 and 7 01496 SINGLE STAGE TWO SPEED MODEL RH FURNACE AIR CONDITIONER N A O COOL STAGE 1 Y W HEAT STAGE 1 SSS COOL STAGE 2 2 4 R N A HUMIDIFY HUM N A 81 SENSOR 52 HUMIDIFIER 5 24 VAC OUTDOOR SENSOR 1 ee J See notes 1 2 3 6 and 8 A01497 TWO STAGE THERMIDISTAT FURNACE CONTROL WITH PSC TWO SPEED MODEL RH BLOWER MOTOR AIR CONDITIONER CooL srace 1 Yi W2 L 1 HEAT STAGE 1 w w1 COOL STAGE 2 Y2 1 v2 24vacHoT 44 0 7 6 24VAC COMM 1 m N A HUMIDIFY EM HUMIDIFIER PI 24 VAC N A R OUTDOOR OUTDOOR 1 H SENSOR SENSOR 4 See notes 1 2 3 6 8 and 10 A01498 VARIABLE SPEED 80 NON CONDENSING FURNACE AFS THERMIDISTAT BOARD CONTROL vi MODEL RH 221 TWO SPEED FURNACE COOL STAGE 1 AIR CONDITIONER
9. SPLICE CONNECTION RELAY SPDT PILOT DUTY 24 V COIL HN61KK324 OR EQUIVALENT HUMIDISTAT OPENS ON HUMIDITY RISE HL38MG026 AIRFLOW SELECTOR 01222 WIRING DIAGRAM NOTES 1 2 WIRING MUST CONFORM TO NEC OR LOCAL CODES UNDERLINED LETTER ON THERMOSTAT TERMINAL INDICATES USAGE FOR EXAMPLE O W2 MEANS O IS ENERGIZED IN COOLING MODE REFER TO INDOOR UNIT INSTALLATION INSTRUCTIONS FOR ANY ADDITIONAL FEATURES AND WIRING INFORMA TION NON PROGRAMMABLE MODEL 2501 WHEN USED IN AIR CONDITIONING INSTALLATION THE R19 JUMPER MUST BE CUT AND REMOVED 5 PROGRAMMABLE MODEL 2S01 B MUST HAVE DIP SWITCH ON WHEN USED IN AIR CONDITIONER APPLICATIONS THERMIDISTAT DIP SWITCH NO 1 SHOULD BE SET IN OFF POSITION FOR AIR CONDITIONER APPLICATIONS FACTORY DEFAULT AS AN OPTION O W2CAN CONTROL SECOND STAGE HEAT 8 THERMIDISTAT DIP SWITCH NO 2 SHOULD BE SET IN THE ON POSITION FOR DUAL CAPACITY COMPRESSOR 10 11 12 OPERATION TO ACTIVATE DEHUMIDIFY FUNCTION ON OR FV4 REMOVE J1 JUMPER AT FAN COIL CONTROL BOARD AS AN OPTION LOCK FURNACE INTO LOW FIRE OPERATION AND LET O W2 CONTROL HIGH FIRE OPERATION REFER TO FURNACE INSTALLATION INSTRUCTIONS FOR PROPER SETUP TO ACTIVATE DEHUMIDIFY FEATURE ON CURRENT STYLE VARIABLE SPEED 80 PERCENT NON CONDENSING FURNACE DISCONNECT GREEN DEHUM WIRE FROM G ON FURNACE CONTROL BOARD AND CONNECT TO DEHUMIDIFY TERMINAL DHUM ON THERMIDISTAT THE DE JUMPERS MUST BE REMO
10. cally designed for Puron two speed units NOTE FC4 and 40FK fan coils are equipped with an R 22 If an FK4 or 40FK fan coil is used with a Puron air 3 8 IN DIA TIEDOWN KNOCKOUTS IN BASEPAN 2 PLACES 83 16 VIEW FROM A97548 Dimensions In UNIT size MINIMUM MOUNTING PAD DIMENSIONS 024 19 24 2 13 16 6 15 16 036 060 26 32 4 9 3 4 Fig 3 Mounting Unit to conditioner the R 22 TXV must be replaced with a factory approved Puron TXV A CAUTION If indoor unit is equipped with piston remove indoor coil piston and replace with balance port hard shutoff TXV metering device IMPORTANT The 38TDB037 unit includes a factory supplied TXV kit All other sizes do not include factory supplied TXV kit TXV INSTALLATION IMPORTANT The TXV should be mounted as close to the indoor coil as possible and in a vertical upright position Avoid mounting the inlet tube vertically down A factory supplied or approved filter drier must be installed in the liquid line Installing TXV in Place of Piston 1 Remove any existing refrigerant and ensure coil has not been exposed to atmospheric pressure for more than 15 minutes 2 Remove indoor coil inlet tube at piston body inlet Use back up wrench to prevent damage 3 Remove piston retainer begin careful not to damage scaling surface of O ring 4 Remove and disca
11. respond as follows 1 De energize the compressor low or high speed contactor 2 Keep the outdoor fan operating for 15 minutes 3 Display the appropriate error code on the status light See Table 5 4 After a 15 minute delay if Yl or Y2 inputs are on and the LPS or HPS is reset energize appropriate compressor contactor either low or high 5 If LPS or HPS has not closed after a 15 minute delay the outdoor fan is turned off If the open switch closes anytime after the 15 minute delay then resume operation on call for Y1 and or Y2 MAJOR COMPONENTS 2 Speed Control The two speed control board controls the following functions Low and high compressor contactor operation Outdoor fan motor operation Crankcase heater operation Compressor protection Pressure switch monitoring Time delays Field Connections The two speed control received 24vac low voltage control system inputs through the screw connections on the left side of the control board Dual Capacity Compressor The dual capacity compressor contains motor windings that provide 2 pole 3500 RPM operation Refer to Table 6 for correct winding resistance Compressor Internal Relief The compressor is protected by an internal pressure relief IPR which relieves discharge gas into compressor shell when differen tial between suction and discharge pressures exceeds 525 psi The compressor is also protected by an internal overload attached to motor wi
12. 000 1500 1000 500 LEAK IN SYSTEM VACUUM TIGHT TOO WET TIGHT DRY SYSTEM 0 1 2 3 4 5 6 7 MINUTES 95424 Fig 8 Deep Vacuum Graph 5 Repeat this procedure as indicated in Fig 9 System will then contain minimal amounts of contaminants and water vapor FINAL TUBING CHECK 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 attention to feeder tubes making sure wire ties on feeder tubes are secure and tight Step 7 Make Electrical Connections WARNING To avoid personal injury death not supply power to unit with compressor terminal box cover removed Be sure field wiring complies with local and national fire safety and electrical codes and voltage to system 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 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 NOTE Use copper wire only between disconnect switch and unit BREAK VACUUM WITH DRY NITROGEN CHECK FOR TIGHT DRY SYSTEM IF HOLDS DEEP VACUUM v CHARGE SYSTEM Fi
13. Selections AIRFLOW SELECTION FOR 58CVA 58MVP FURNACES The 58CVA 58MVP Non Condensing Variable Speed Furnaces provide high and low speed blower operation to match the capacities of the compressor at high and low speeds To select the recommended airflow and for adjustments to the manual switches labeled SW1 A C and CF on the control board refer to the furnace Installation Start Up and Operating Instructions The 315AAV utilizes a control center that allows the installing technician to select the proper airflows The A C switch determines the airflow during high speed compressor operation Airflow for hight and low speed can be calculated at either 350 CFM per ton or 400 CEM per ton based on the positions of SW1 5 AIRFLOW SELECTION FOR FV4A OR 40 FAN COILS The FK4C and FV4A provide high and low speed blower operation to match the capacities of compressor at high and low speeds To select recommended airflow refer to the FV4A or 40FK Installation Instructions The FV4A and 40FK utilize an EASY SELECT control board that allows the installing technician to select proper airflows For adjustments to control board and recommended A C SIZE and CFM ADJUST selections This fan coil has an adjustable blower off delay factory set at 90 sec for high and low speed blower operation For other combinations of equipment consult the Product Data Digest LEGEND 24 VOLT FACTORY WIRING 24 VOLT FIELD WIRING FIELD
14. VED TO ENABLE THE DEHUMIDIFICATION FEATURE ON FURNACE Table 2 Accessory Usage REQUIRED FOR REQUIRED FOR LONG LINE SEACOAST ACCESSORY APPLICATIONS APPLICATIONS 50 175 FT WITHIN 2 MILES Coastal Filter No Yes Support Feet No Recommended Puron Balance Port Hard Shut off TXV Yest Yest For tubing line sets between 50 and 175 ft horizontal or 20 ft vertical differential refer to Application Guideline and Service Manual Air Conditioners and Heat Pumps Using Puron Refrigerant Crankcase heater and start assist are standard on two speed units 1 Required for all applications 9 58 959 oeise 2czcc doo CEBD430439 03A Ei Y E MESES 4 Low Pressure Switch Connector RES High Pressure Switch Connector lt Thermistor Connection ce Defrost Time xd Selectors UN E To Run H 5 Capacitor Thermostat 2 LOW 1 entras 5 Connection Connector VES amp sd Crankcase Heater Oe Connection A D 7 HK38EA001 Reserved for Future Use A01192 Fig 12 Control Board 90 D 70 60 50 2 40 5 30 20 10 0 0 20 40 60 80 100 120 TEMPERATURE DEG F 91431 Fi
15. all fitting panel in place 12 Sweat inlet of TXV marked IN to liquid line Avoid excessive heat which could damage valve 13 Install vapor elbow see Fig 5B with equalizer adapter to vapor line of line set and vapor connection to indoor coil Adapter has a 1 4 in male connector for attaching equalizer tube See Fig 5B 14 Connect equalizer tube of TXV by 1 4 in equalizer fitting on vapor line adapter Use backup wrench to prevent damage to equalizer fitting 15 Proceed with the remainder of unit installation LONG LINE APPLICATIONS For refrigerant piping arrangements with equivalent lengths greater than 50 ft or when elevation difference between indoor and or outdoor unit is more than 20 ft follow all requirements of the Long Line Guideline section in the Application Guideline and Service Manual Air Conditioners and Heat Pumps Using Pu ron Refrigerant Step 6 Make Piping Connections A WARNING 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 A CAUTION Do not leave system open to atmosphere any longer than minimum required for installation POE oil in compressor is extremely susceptible to moisture absorption Always keep ends of tubing sealed during installation A CAUTION If ANY refrigerant tubing is buried provide 6 in vertical ris
16. d gloves when handling refrigerant UNIT CHARGE Factory charge and charging method are shown on pink charging label With unit operating charge Puron units with liquid using a commercial type metering device in manifold hose Charge refrigerant into suction line NOTE Unit is to be charged in high capacity only Charging in low capacity may cause compressor chattering and possible damage to the compressor NOTE If 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 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 COOLING ONLY PROCEDURE 1 Operate unit a minimum of 15 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 4 Refer to Table 4 for required subcooling temperature 5 Refer to Table 3 Find the point where required subcooling temperature intersects measured liquid service valve pressure 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 o
17. d periodic maintenance requirements outlined in manual 4 Fill out Dealer Installation Checklist and place in customer file CARE AND MAINTENANCE For continuing high performance and to minimize possible equip ment failure periodic maintenance must be performed on this equipment Frequency of maintenance may vary depending upon geographic areas such as coastal applications DUAL CAPACITY CONNECTION DIAGRAM 8 208 230 1 60 L2 POWER SUPPLY 2 0 EQUIP GND NOTE 11 RED BLU 1314154081 HPAC C SV RS C Hi 271 FORCED DEFROST e DEFROST TIME MIN 1 0 Q AN COMM STATUS 20 a lo Qi X di WIG ABCD nd cQ 111 EN PED OCH TO INDOOR UNIT Fig 15 Wiring Diagram 024 036 048 A01513 14 DUAL CAPACITY CONNECTION DIAGRAM 208 230 1 60 wm POWER SUPPLY EQUIP GND NOTE 10 112131415 HP AC EXV RYS C FORCED DEFROST
18. during the minute compressor speed change time delay and if a pressure 12 switch or compressor overload should open Outdoor fan motor will continue to operate for one minute after the compressor shuts off when the outdoor ambient is greater than or equal to 100 F COMPRESSOR VOLTAGE FAILURE 6 FLASHES The control senses the voltage of the compressor run winding If compressor voltage Vc is less than 90v when control board is calling for compressor operation control shuts compressor off for 15 minutes with outdoor fan running After 15 minutes provided there is a call for Y1 or Y2 control attempts to start compressor During this time a code of 6 flashes appears at control board If Vc trip occurs 3 consecutive times during a Y1 request then low capacity operation is locked out and control responds to Y2 requests until a reset occurs If 3 consecutive trips occur in a combination of Yl and Y2 or all Y2 requests then both low and high capacity operation will be locked out The compressor voltage failure 6 flashes can be caused by compressor internal overload trip refer to Table 6 for correct winding resistance no 240 volt power supply to outdoor unit failed compressor contactor s failure of start relay to pick up properly improper wiring PRESSURE SWITCH PROTECTION The outdoor unit is equipped with high and low pressure switches If the control senses the opening of a high or low pressure switch it will
19. e at service valve Refrigerant tubing lengths up to 36 in may be buried without further special consideration Do not bury lines for lengths over 36 in CAUTION To prevent damage to unit or service valves observe the following Use a brazing shield Wrap service valves with wet cloth or use a heat sink material Outdoor units may be connected to indoor section using accessory tubing package or field supplied refrigerant grade tubing of correct size and condition Tubing diameters listed in Table 1 are adequate for equivalent lengths up to 50 ft For tubing requirements beyond 50 ft substantial capacity and performance losses will occur Follow the recommendations in the Application Guideline and Service Manual Air Conditioners and Heat Pumps Using Pu ron Refrigerant to minimize losses Refer to Table 1 for field tubing diameters Refer to Table 2 for accessory requirements Do not bury lines over 36 in long 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 Table 1 Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters In LIQUID LINE FILTER DRIER LIQUID SERVICE VALVE A01215 Fig 7 Filter Drier with Sweat Adapter Tube and Liquid Tube 1 Braze 5 in connector tube to liquid line service valve Wrap filter drier with damp cloth 2 Braze filter drier between co
20. es use No 16 AWG color coded wire to avoid excessive voltage drop All wiring must be NEC Class 1 and must be separated from incoming power leads The outdoor unit requires a minimum of 27va 24vac control power 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 etc Step 8 Install Electrical Accessories GENERAL Refer to the individual instructions packaged with kits or acces sories when installing Available electrical accessories include latent capacity control See Fig 11 for typical accessory wiring diagrams LATENT CAPACITY CONTROL LCC The purpose of an LCC is to provide a dehumidification mode to assure a 75 percent or less system sensible heat ratio If indoor unit installed contains an ECM blower such as an FK4C FV4A or 40FK fan coil or 58 or 58 gas furnace no LCC is THERMIDISTAT VARIABLE SPEED CONTROL CONDENSING TWO SPEED MODEL RH FURNACE AIR CONDITIONER HEAT STAGE 2 COOL STAGE 1 FAN 8 DEHUMIDIFY 24 VAC COMM e n HUMIDIFY HUM N A B OUTDOOR si SENSOR 4 CONNECTION UMIDIFIER 24 VAC OUTDOOR SENSOR 4 See notes 1 2 3 6 8 10 and 12 A01495 NON PROGRAMMABLE THERMOSTAT FV4A TWO SPEED MODEL 2S OR
21. f 3 F UNIT CHARGE Factory charge and charging method are shown on pink charging label Puron refrigerant cylinders contain a dip tube which allows liquid refrigerant to flow from cylinder in upright position Charge Puron units with cylinder in upright position and a commercial type metering device in manifold hose Charge refrigerant into suction line NOTE Unit is to be charged in high capacity only Charging in low capacity may cause compressor chattering and possible damage to the compressor NOTE If 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 EXAMPLE To calculate additional charge required for a 25 ft line set 25 ft 15 ft 2 10 ft x 0 6 oz ft 2 6 oz of additional charge Step 12 System Functions and Sequence of Operation The outdoor unit control system has special functions The following is an overview of the two speed control functions COOLING OPERATION This product utilizes a 2 stage cooling indoor thermostat With a call for first stage cooling Yl the outdoor fan and low capacity compressor are energized If low capacity cannot satisfy cooling demand high capacity is energized Yl and Y2 or Y2 only by the second stage of indoor thermostat After second stage is satisfied 11 Table 3 Required Liquid Line Temperature F
22. g 13 Resistance Values Versus Temperature Step 10 Start Up A CAUTION To prevent compressor damage or personal injury observe the following Do not overcharge system with refrigerant Do not operate unit in a vacuum or at negative pressure Do not disable low pressure switch 10 Control Box Side of Unit THERMISTOR PLACED UNDERNEATH BASE PAN ATTACHED TO BASE PAN WITH ADHESIVE A00430 Fig 14 View from Top of Base Pan A CAUTION 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 A CAUTION Do not vent refrigerant to atmosphere Recover during system repair or final unit disposal Follow these steps to properly start up the system 1 The outdoor unit is equipped with a crankcase heater which operates when the compressor is off Energize crankcase heater 24 hr before starting unit To energize heater only set indoor thermostat to OFF position and close power disconnect to unit NOTE Starting the compressor without a minimum of 12 hr of crankcase heat prior to initial start up may result in a compressor chattering noise and possible damage to the compressor 2 Fully back seat open liquid and vapor tube service valves 3 Unit is shipped with val
23. g 9 Triple Evacuation Method A95425 DISCONNECT PER N E C AND OR LOCAL CODES CONTACTOR FIELD POWER LA ee GROUND LUG A91306 Fig 10 Line Power Connections 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 Size wires per NEC but not smaller than minimum wire size shown in Product Data Digest A WARNING The unit cabinet must have as 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 CONNECT GROUND AND POWER WIRES Connect ground wire to ground connection in control box for safety Connect power wiring to leads provided as shown in Fig 10 CONNECT CONTROL WIRING Route 24v control wires through control wiring grommet and connect to leads provided in control box See Fig 11 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 wir
24. k refrigerant charge using charging information located on control box cover IMPORTANT Maximum liquid line size is 3 8 in O D for all residential applications IMPORTANT Only install the factory supplied Puron R 410A air conditioner liquid line filter drier Obtain replacement filter driers from your local distributor INSTALLATION Step 1 Check Equipment and Job Site UNPACK UNIT Move to final location Remove carton taking care not to damage unit Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 1 4 PC 101 Catalog 533 80059 Tab 2 Printed in U S A Form 38TDB 4SI Pg 1 8 02 Replaces 38TDB 3SI NOTE Avoid contact between tubing and structure OUTDOOR WALL INDOOR WALL CAULK Ar Pd m TUBE y L VAPOR TUBE INSULATION THROUGH THE WALL a OST INSULATION A VAPOR TUBE 17MIN HANGER STRAP AROUND VAPOR TUBE ONLY i3 LIQUID TUBE Fig 2 Connecting Tubing Installation SUSPENSION A01383 INSPECT EQUIPMENT File claim with shipping company prior to installation if shipment 18 damaged or incomplete Step 2 Install on a Solid Level Mounting Pad If conditions or local codes require the unit be attached to pad tie down bolts should be used and fastened through knockouts provided in unit base pan Refer to uni
25. ndings Table 6 Two Speed Compressor Winding Resistance at 70 F 20 WINDING 024 036 037 060 Start S C 0 740 Run R C 0 356 Compressor Control Contactors Low and high capacity contactor coils are 24 volts The electronic control board controls the operation of the low speed C L and the high speed C H contactors TEMPERATURE THERMISTORS Thermistors are electronic devices which sense temperature As the temperature increases the resistance decreases Thermistors are used to sense outdoor ambient and coil temperature Refer to Fig 13 for resistance values versus temperature If the outdoor ambient or coil thermistor should fail a fault code appears at two speed control IMPORTANT Outdoor Air Thermistor Placement Mount outdoor air thermistor underneath unit base pan lip on control box side of the unit as shown in Fig 14 Attach to base pan 13 with adhesive tape A small piece of TXV bulb insulation tape may be used IMPORTANT If outdoor air thermistor is not properly placed underneath base pan unit may see nuisance thermistor out of frame faults Step 13 Final Checks IMPORTANT Before leaving job be sure to do the following 1 Ensure that all wiring and tubing is secure in unit before adding panels and covers Securely fasten all panels and covers 2 Tighten service valve stem caps to 1 12 turn past finger tight 3 Leave Owner s Manual with owner Explain system operation an
26. ng are satisfied the compressor will shut off NOTE If unit has not operated within the past 12 hr or following a unit power up upon the next thermostat high or low speed demand unit operates for a minimum of 5 minutes on high speed NOTE When two speed unit is operating at low speed system vapor suction pressure will be higher than a standard single speed system or high speed operation NOTE Outdoor fan motor will continue to operate for one minute after compressor shuts off when outdoor ambient is greater than or equal to 100 F STATUS FUNCTION LIGHTS A system control STATUS function light is located on the outdoor unit control board See Fig 12 The STATUS light provides indication signals for several system operations See Table 5 for codes and definitions Table 5 also provides the order of signal importance NOTE Only one code will be displayed on the outdoor unit control board the most recent with the highest priority Table 4 High Capacity Only Subcooling TXV TYPE EXPANSION DEVICE UNIT HIGH CAPACITY ONLY SUBCOOLING AT SERVICE VALVE 024 14 036 15 037 11 048 12 060 16 Table 5 Control Function LED Code SIGNAL CODE DEFINITION IMPORTANCE Constant flash No demand 10 No pause Stand by 1 flash w pause Low speed operation 9 2 flashes w pause High speed operation 8 3 flashes Outdoor thermistor failure 7 w pause 4 flashes Outdoor coil
27. nnector tube and liquid tube to indoor coil Flow arrow must point toward indoor coil REFRIGERANT TUBING Connect vapor tube to fitting on outdoor unit vapor service valves Connect liquid tube to filter drier See Fig 7and Table 1 SWEAT CONNECTION Service valves are closed from factory and ready for brazing After wrapping service valve and filter drier with a wet cloth braze sweat connections using industry accepted methods and materials Do not use soft solder materials which melt below 800 F Consult local code requirements Refrigerant tubing and indoor coil are now ready for leak testing This check should include all field and factory joints LEAK CHECKING Leak test all joints in indoor outdoor and refrigerant tubing EVACUATE REFRIGERANT TUBING AND INDOOR COIL CAUTION Never use the system compressor as a vacuum pump Refrigerant tubes and indoor coil should be evacuated to 500 LIQUID VAPOR VAPOR LONG LINE iid Connection Tube Tube Connection Tube Diameter Diameter Diameter Diameter Diameter Diameter 024 3 8 3 8 5 8 5 8 5 8 3 4 036 3 8 3 8 3 4 3 4 3 4 7 8 037 048 3 8 3 8 7 8 7 8 7 8 7 8 060 3 8 3 8 7 8 1 1 8 7 8 1 1 8 Notes 1 Tube diameters are for lengths up to 50 equivalent ft 2 Do not apply capillary tube indoor coils to these units OUTDOOR UNIT CONNECTED TO FACTORY APPROVED INDOOR UNIT Outdoor unit contains correct s
28. not been exposed to atmospheric pressure for more than 15 minutes 2 Remove coil access panel and fitting panel from front of cabinet 3 Remove and save TXV support clamp using the 5 16 in nut driver Save the clamp E BULB INSULATION TAPE A01418 Fig 5 TXV Kit Contents SENSING BULB X 4 O CLOCK Fig 6 Positioning of Sensing Bulb 8 O CLOCK A00399 4 Remove TXV using a backup wrench on flare connections to prevent damage to tubing 5 Using wire cutters cut equalizer tube off flush with vapor tube inside cabinet 6 Remove bulb from vapor tube inside cabinet 7 Braze equalizer stub tube closed Use protective barrier as necessary to prevent damage to drain pan IMPORTANT Route the equalizer tube of the approved Puron TXV through suction line connection opening in fitting door prior to replacing fitting panel around tubing 8 Install TXV Fig 5A with 3 8 in copper tubing through small hole in service panel Use wrench and backup wrench to avoid damage to tubing valve 9 Reinstall TXV support clamp removed in item 3 10 Attach TXV bulb to vapor tube inside cabinet in same location as original was when removed using supplied bulb straps See Fig 5C See Fig 6 for correct positioning of sensing bulb Insulate bulb with factory supplied insulation tape See Fig 5E 11 Route equalizer tube through suction connection opening large hole in fitting panel and inst
29. rd factory installed piston Replace retainer if O ring is damaged 5 Reinstall piston retainer in piston body 6 Replace indoor coil inlet tube Use back up wrench to prevent damage CAUTION To prevent damage to the unit use a brazing shield and wrap TXV with wet cloth 7 Sweat swivel adapter see Fig 5D to inlet of indoor coil and attach to TXV see Fig 5A outlet Use backup wrench to avoid damage to tubing or valve Sweat Inlet of TXV marked to liquid line Avoid excessive heat which could damage valve SENSING BULB EQUALIZER TUBE THERMOSTATIC EXPANSION VALVE A91277 gt Fig 4 TXV Installed 8 Install vapor elbow see Fig 5B with equalizer adapter to suction tube of line set and suction connection to indoor coil Adapter has a 1 4 in male connector or attaching equalizer tube 9 Connect equalizer tube of TXV to 1 4 in equalizer fitting on vapor line adapter 10 Attach TXV bulb to horizontal section of suction line using bulb straps provided See Fig 5C Insulate bulb with factory supplied insulation tape See Fig 5E See Fig 6 for correct positioning of sensing bulb 11 Proceed with remainder of unit installation FAN COIL To obtain efficiency rating for 38TDB037 with FV4ANB006 fancoil TXV must be replaced with factory supplied TXV Replacing R 22 TXV or Non Balance Port Puron TXV 1 Remove any existing refrigerant and ensure coil has
30. se 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 WARNING Before installing modifying or servicing system main elec trical disconnect switch must be in the OFF position There may be more than disconnect switch Lock out and tag switch with a suitable warning label Electrical shock can cause personal injury or death A CAUTION Puron R 410A systems operate at higher pressures than standard R 22 systems Be certain that service equipment is rated for Puron Some R 22 service equipment may not be acceptable Check with your distributor 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 etc where unit operation sound may disturb customer 2 Ensure that vapor and liquid tube diameters are appropriate to capacity of unit
31. t mounting pattern in Fig 3 to determine base pan size and knockout hole location On rooftop applications mount on level platform or frame Place unit above a load bearing wall and isolate unit and tubing set from structure Arrange supporting members to adequately support unit and minimize transmission of vibration to building Consult local codes governing rooftop applications A CAUTION Do not allow POE lubricant to come into contact with roofing material POE may deteriorate certain types of synthetic roofing NOTE Unit must be level to within 2 3 8 in ft Step 3 Clearance Requirements When installing allow sufficient space for airflow clearance wiring refrigerant piping and service Allow 30 in clearance to service end of unit and 48 in above unit For proper airflow a 6 in clearance on 1 side of unit and 12 in on all remaining sides must be maintained Maintain a distance of 24 in between units Position so water snow or ice from roof or eaves cannot fall directly on unit Step 4 Operating Ambient The minimum outdoor operating ambient in cooling mode is 55 F and the maximum outdoor operating ambient in cooling mode is 125 F Step 5 Install TXV Puron fan coils and furnace coils come factory equipped with a bi flow hard shut off TXV specifically designed for Puron two speed units No TXV changeout is required An existing R 22 TXV must be replaced with a factory approved TXV specifi
32. thermistor failure 6 w pause 3 flashes pause Thermistor out of range 5 4 flashes 5 flashes pause Low pressure switch trip 4 1 flash 5 flashes pause High pressure switch trip 3 2 flashes 6 flashes w pause Compressor V JV trip 2 Constant light No pause Board failure 1 No flash Function light signal order of importance in case of multiple signal request 1 is most important FACTORY DEFAULTS Factory defaults have been provided in the event of failure of outdoor air thermistor coil thermistor and or furnace interface jumper ONE MINUTE SPEED CHANGE TIME DELAY When compressor changes speeds from high to low or low to high there is a 1 minute time delay before compressor restarts The outdoor fan motor remains running COMPRESSOR OPERATION When the compressor operates in second stage operation the motor rotates clockwise Both the lower and upper pistons are eccentric with the rotating crankshaft and both compress refriger ant When the compressor operates in single stage operation the motor reverses direction rotates counterclockwise The lower piston becomes idle and the upper piston compresses refrigerant The start and run windings are reversed CRANKCASE HEATER OPERATION The two speed control board energizes the crankcase heater during unit off cycle OUTDOOR FAN MOTOR OPERATION The outdoor unit control energizes outdoor fan any time compres sor is operating The outdoor fan remains energized
33. ve stem s front seated and caps installed Replace stem caps after system is opened to refrig erant flow back seated Replace caps finger tight and tighten additional 1 12 turn 20 ft lb torque with wrench 4 Close electrical disconnects to energize system 5 Set room thermostat at desired temperature Be sure set point is below indoor ambient and is set low enough to energize desired speed NOTE Carrier electronic thermostats are equipped with a 15 minute staging timer This timer prevents the two speed system from operating at high speed until unit has been operating in low speed for 15 minutes unless there is at least a 5 F difference between room temperature and thermostat set point To force high speed after a minimum of 2 minutes in low speed adjust the set point at least 5 below room ambient 6 Set room thermostat to COOL and fan control to AUTO or ON as desired Wait for appropriate time delay s Operate unit for 15 minutes Check refrigerant charge NOTE If unit has not operated within the past 12 hr or following a unit power up upon the next thermostat high or low speed demand unit operates for a minimum of 5 minutes in high speed 11 WARNING Service valve gage ports not equipped with Schrader valves To prevent personal injury make sure gage manifold is connected to the valve gage ports before moving valves off fully back seated position Wear safety glasses an
34. ystem 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 CAUTION Installation of filter drier in liquid line is required INSTALL LIQUID LINE FILTER DRIER Installation of filter drier in liquid line is required Refer to Fig 7 and install filter drier as follows microns Always break a vacuum with dry nitrogen Deep Vacuum Method The deep vacuum method requires vacuum pump capable of pulling a minimum vacuum of 500 microns and a vacuum gage or thermistor capable of accurately measuring this vacuum depth The deep vacuum method is the most positive way of assuring a system is free of air and liquid water See Fig 8 Triple Evacuation Method The triple evacuation method should only be used when vacuum pump is capable of pumping down to 28 in of mercury and system does not contain any liquid water Refer to Fig 9 and proceed as follows 1 Pump system down to 28 in of mercury and allow pump to continue operating for an additional 15 minutes 2 Close service valves and shut off vacuum pump 3 Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig 4 Close service valve and allow system to stand for 1 hr During this time dry nitrogen will be able to diffuse throughout the system absorbing moisture 5000 4500 4000 e 2500 e 2
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