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38YDB Weathermaker Two-Speed Split System

1. A98516 Fig 1 Model 38YDB 2 Ensure that vapor and liquid tube diameters are appropriate to capacity of unit 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 and brick 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 When necessary use hanger straps which 1 in wide and conform to shape of tubing insulation See Fig 2 8 Isolate hanger straps from insulation by using metal sleeves bent to conform to shape of insulation 9 Ensure that tubing insulation is pliable and completely sur rounds vapor tube 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 tu
2. See notes 1 2 3 5 7 8 9 10 11 and 13 See notes 1 2 3 5 7 8 and 12 A03033 A03036 VARIABLE SPEED 80 NON CONDENSING FURNACE PROGRAMMABLE TWO STAGE TWO SPEED DUAL FUEL FURNACE HEAT PUMP THERMIDISTAT THERMOSTAT CONTROL TWO SPEED MODEL RH HEAT PUMP 24 R COOLING Ce HEAT COOL STAGE 1 HEAT STAGE 3 FURNACE HEAT STAGE 3 COQL HEAT HEAT COOL STAGE 2 Y Y2 STAGE 2 COMPRESSOR FAN RVS COOLING COQL HEAT 24 HOT STAGE 1 COMPRESSOR LO 24 VAC COM 24 DEHUMIDIFY Let B L RVS SENSING OUTDOOR M N A OUTDOOR S1 SENSOR 7 52 4 OUTDOOR CONNECTION 52 SENSOR CONNECTIONS SUGGESTED DIP See notes 1 2 3 5 7 8 9 10 and 11 SWITCH SETTINGS 03034 See notes 1 2 3 5 7 8 and 12 01424 VARIABLE SPEED 80 0 NON CONDENSING FURNACE TWO SPEED THERMOSTAT HERMOSTA HEAT PUMP RVS COOLING 2 COOL HEAT STAGE 1 COMPRESSOR LO COOUMEAT 2 STAGE 2 24 HOT 24 VAC COMM B RVS SENSING L OUTDOOR SENSOR 1 CONNECTIONS 2 See notes 1 2 3 5 7 8 and 12 03035 Fig 12 Typical 24V C
3. CONNECTION DIAGRAM 1 A 208 230 1 60 12 POWER SUPPLY 4 O EQUIP GND RVS NOTE 11 BLK BLU PEP RN BRN 1 2 314 5 1 SEV RVS HI BRN LPS START 0 DEFROST een Z 97 H 2 BLU PNK YEL DEFROST 5 1 TIME MIN bias J BLU 2 BLU 1 COMM STATUS 28 YEL ORM le tt BLK 1 111 00 RED 1 INDOOR UNIT A03030 Fig 17 Wiring Diagram 024 036 048 DUAL CAPACITY CONNECTION DIAGRAM 208 230 1 60 2 A w o a E POWER SUPPLY 2 8 11 7210 EQUIP GND RVS 91 10 orn opn FED PLI 2131415 5 C Hi FORCED DEFROST H pwm MIN kai START RELAY BPN 2052 1 1 GRNYEL 1 i GEH
4. 4 D OUTDOOR SENSOR gt SENSOR CONNECTIONS See notes 1 2 3 7 8 and 12 THERMIDISTAT CONTROL MODEL RH RVS COOLING COOL HEAT STAGE 1 HEAT STAGE 3 COOL HEAT STAGE 2 FAN 24 VAC HOT 24 VAC COMM N A HUMIDIFY N A OUTDOOR SENSOR A01423 TWO STAGE FURNACE WITH PSG TWO SPEED BLOWER MOTOR HEAT PUMP Vela 1 Fimowormen 54 24 VAC OUTDOOR SENSOR 1 Sea es 4 See notes 1 2 3 5 7 8 9 10 and 11 Fig 12 Typical 24 Circuit Connections 9 A01426 THERMIDISTAT CONTROL MODEL VARIABLE SPEED CONDENSING FURNACE TWO SPEED HEAT PUMP H RVS COOLING COOL HEAT STAGE 1 HEAT STAGE 3 COOL HEAT STAGE 2 FAN 24 VAC HOT DEHUMIDIFY 24 VAC COMM HUMIDIFY N A OUTDOOR SENSOR CONNECTION o w2 HUMIDIFIER 24 VAC OUTDOOR SENSOR PROGRAMMABLE DUAL FUEL THERMOSTAT MODEL DF VARIABLE SPEED CONDENSING FURNACE TWO SPEED HEAT PUMP 24 VAC HOT FAN HEAT STAGE 3 FURNACE COOL HEAT STAGE 2 COMPRESSOR RVS COOLING COOL HEAT STAGE 1 COMPRESSOR LO 24 VAC COMM N A RVS SENSING OUTDOOR SENSOR CONNECTIONS 2 D
5. Control Box Side of Unit THERMISTOR PLACED UNDERNEATH BASE PAN ATTACHED TO BASE PAN WITH ADHESIVE A00430 Fig 16 View from Top of Base Pan 13 e Defrost interval selection e Electric heat operation during defrost mode 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 3500 RPM operation Refer to Table 7 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 windings 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 15 for resistance values versus temperature If the outdoor ambient thermistor or coil thermistor should fail a fault code appears at electronic control The crankcase h
6. HEATING amp COOLING 38YDB WeatherMaker Two Speed Split System Heat Pump with Puron Refrigerant 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 the signal words DANGER WARNING CAUTION and NO
7. INDOOR UNIT A03032 Fig 18 Wiring Diagram 037 14 DUAL CAPACITY CONNECTION DIAGRAM Li 208 2301 60 2 POWER SUPPLY D EQUIP GND RVS NOTE 11 ORN ORN RE 112 13 4 15 SEV RVS HI L LPS P YEL PNK DEFROST HPS BLUIPNK PL4 BLUIPNK DEFROST LI TIME MIN OAT BLK BLK BRN PL5 COMM STATUS OFM YEL B D BLK 00 16 0 2 12 YEL CCH RED D 2 cl 21 INDOOR UNIT A03031 gt Fig 19 Wiring Diagram 060 15 Copyright 2003 CARRIER Corp 7310 W Morris St Indianapolis 46231 38ydb5si Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 100 4 PC 101 Catalog No 533 80088 Printed in U S A Form 38YDB 5SI Pg 16 2 03 Replaces 38YDB 4SI al oa
8. STAGE 1 N A OUTDOOR SENSOR CONNECTION See notes 1 2 3 and 4 THERMIDISTAT 4 4 CONTROL 4 TWO SPEED MODEL RH FAN COIL HEAT PUMP RVS COOLING COOL HEAT STAGE 1 HEAT STAGE 3 m iwi COOL HEAT J2 JUMPER STAGE 2 mfa FAN DEHUMIDIFY PHUM lt a HUMIDIFY _ 1 0 24 OUTDOOR OUTDOOR H SENSOR SENSOR J CONNECTION 24 VAC HOT See notes 1 2 3 6 9 and 10 A01427 A01425 A01421 THERMIDISTAT CONTROL MODEL RH RVS COOLING COOL HEAT STAGE 1 HEAT STAGE 3 COOL HEAT STAGE 2 FAN 24 VAC HOT 24 VAC COMM N A HUMIDIFY N A OUTDOOR SENSOR CONNECTION SINGLE STAGE TWO SPEED FURNACE HEAT PUMP HumipiFieR _5 _ 24 VAC OUTDOOR SENSOR R See notes 1 2 3 7 8 9 10 and 11 PROGRAMMABLE DUAL FUEL THERMOSTAT MODEL DF FAN HEAT STAGE W W1 A01422 SINGLE STAGE TWO SPEED FURNACE HEAT PUMP TUE wi FURNACE COOL HEAT STAGE 2 COMPRESSOR RVS COOLING COOL HEAT stages Kwa COMPRESSOR LO 24 VAC COM N A RVS SENSING OUTDOOR bad 1
9. Connect vapor tubing to fittings on outdoor unit vapor service valve Connect liquid tubing to filter drier See Table 1 and Fig 9 Connect other end of filter drier to adapter tube on liquid line service valve Table 2 Accessory Usage REQUIRED FOR LONG LINE REQUIRED FOR ACCESSORY APPLICATIONS SEACOAST APPLICATIONS OVER 50 FT WITHIN 2 MILES Coastal Filter No Yes Support Feet No Recommended Puron Balance Port Hard Shutoff TXV Yest Yest Puron Liquid Line Solenoid Valve for Heating KHALS0401LLS No 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 SWEAT CONNECTION A 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 Braze sweat connections using industry accepted methods and materials Do not use soft solder materials which melt below 800 F Consult local code requirements LEAK CHECKING Leak test all joints in indoor outdoor and refrigerant tubing EVACUATE REFRIGERANT TUBING AND INDOOR COIL CAUTION To avoid compressor damage never use the system compres sor as a vacuum pump Refrigerant tubes and indoor coil must be
10. FOR 58MVP FURNACES The 58 Condensing Variable Speed Furnaces provide high and low speed blower operation to match the capacities of com pressor at high and low speeds To select recommended airflow refer to the 58 Installation Instructions The 58 utilizes a control center that allows the installing technician to select proper airflows For adjustments to the manual switches labeled A C and CF and recommended switch positions refer to Furnace Installation Instructions for setting required airflow High speed airflow is determined by the position of the A C switches and low speed airflow is determined by the position of the CF switches AIRFLOW SELECTION FOR FK4 FV4 OR 40FK FAN COILS The FK4 FV4 and 40FK 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 4 FV4 or 40FK Installation Instructions FK4 FV4 and 40FK utilizes an EASY SELECT control board that allows the installing technician to select proper airflows The ORANGE SYSTEM TYPE JUMPER wire should be set to HP EFF HP COMFORT The BLUE AC HP SIZE JUMPER is used to select airflow to match the outdoor unit nominal size in tons of cooling The BLACK AC HP CFM ADJUST jumper is used to make slight adjustments to the selected airflow tonnage See Fancoil Installation Instructions for setting required airflow This fan coil has an adjustable blowe
11. Product for Puron Heat Pump LSV should be installed between filter drier and indoor coil as close as possible to outdoor unit within 2 feet See Fig 13 for wiring diagram Follow the Installation Instructions included with accessory kit IMPORTANT Flow arrow must point toward outdoor unit Step 7 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 a 6 in vertical rise 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 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
12. a pressure switch or compressor overload should open Outdoor fan motor 12 Table 7 Two Speed Compressor Winding Resistance at 70 F 20 WINDING 024 036 037 048 060 Start 5 2280 1 850 1 459 0 740 0 770 0 745 0 552 0 356 will continue to operate for one minute after the compressor shuts off when the outdoor ambient is greater than 100 F After termination of a defrost cycle the outdoor fan delays coming on for 20 sec This allows refrigerant system to recover outdoor coil heat and minimize the steam cloud effect DEFROST TIME SELECTION The defrost interval can be field selected dependent on local or geographical requirements It is factory set at 90 minutes but can be changed to either 30 60 or 120 minutes To select defrost time set dip switches located on the left side of the unit board See Fig 14 See Table 5 for Defrost Dip Switch Settings DEFROST The dual capacity control logic for defrost function is time and temperature initiated time or temperature terminated Defrost only occurs at outdoor temperatures less than 50 F The control initiates defrost when outdoor coil thermistor is 30 F 2 or less and selected defrost time interval has been accumulated during unit operation Termination occurs when coil thermistor reaches 80 F 5 or defrost period reaches a maximum of 10 minutes Defrost will occur at the compressor capacity that is being called for During
13. applications 12 Dual Fuel Dip Switch D 4 must be set in the ON position for dual capacity compressor operation 13 The DE jumper located next to the DHUM terminal must be removed to enable the DEHUM input FK4 FV4 TWO SPEED FAN COIL HEAT PUMP 24 VAC HOT 24 oe ee 1 1 COOL HEAT STAGE 2 wya 1 4 HEAT STAGE 3 7 RVS COOLING COOL HEAT STAGE 1 N A OUTDOOR SENSOR CONNECTION A03039 Fig 13 Typical Solenoid Valve Wiring 11 p 8 lt 25 555 Lorg Wee gt c J00 OF eat i Low Pressure fe Switch Connector es High Pressure Switch Connector zg lt Thermistor Connection DEFROST Defrost Time Os Selectors 41 Capacitor Thermostat 5 ello aig Sgt O D F Connection Low Voltage 3 alas et amp Heater Oe Connection HK38EA001 Reserved for Future Use A01192 Fig 14 Control Board STATUS FUNCTION LIGHTS A system control STATUS function light is located on the outdoor unit control board See Fig 14 The STATUS light provid
14. 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 approved Puron through suction line connection opening in fitting door prior to replacing fitting panel around tubing 8 Install TXV Fig 6A with 3 8 in copper inlet tube 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 bulb to vapor tube inside cabinet in same location as original was removed from using supplied bulb strap See Fig 6C Insulate bulb with factory supplied insulation tape See Fig 6E See Fig 7 for correct positioning of sensing bulb 11 Route equalizer tube through suction connection opening large hole in fitting panel and install 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 6B with equalizer adapter to vapor line of line set and vapor connection to indoor coil Adapter has a 1 4 in male flare connector for attaching equalizer tube See Fig 6B 14 Connect equalizer tube of TXV to 1 4 in equalizer fitting on vapor li
15. correct winding resistance no 208 230 volt power supply to outdoor unit failed compressor contactor s e failure of start relay to pick up properly e improper wiring PRESSURE SWITCH PROTECTION The outdoor unit is equipped with high and low pressure switches If the control senses the opening of the high or low pressure switch it will respond as follows THERMISTOR CURVE 90 80 70 60 50 40 30 20 gt RESISTANCE KOHMS 10 0 20 40 60 80 100 120 TEMPERATURE DEG F A91431 Fig 15 Resistance Values Versus Temperature 1 De energize the compressor hi or low speed contactor 2 Keep the outdoor fan operating for 15 minutes 3 Display the appropriate error code on the status light see Table 4 4 After a 15 minute delay if or Y2 inputs 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 15 minute delay 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 Two Speed Control The two speed control board controls the following functions Low high compressor contactor operation Outdoor fan motor operation Crankcase heater operation Compressor protection e Pressure switch monitoring Time delays Time temperature defrost
16. 356 103 98 93 88 363 105 100 95 90 370 106 101 96 91 377 107 102 97 92 384 109 104 99 94 391 110 105 100 95 398 112 107 102 97 405 113 108 103 98 412 114 109 104 99 419 115 110 105 100 426 117 112 107 102 433 118 113 108 103 440 119 114 109 104 447 120 115 110 105 454 122 117 112 107 461 123 118 113 108 468 124 119 114 109 475 125 120 115 110 482 126 121 116 111 489 127 122 117 112 496 129 124 119 114 503 130 125 120 115 510 131 126 121 116 517 132 127 122 117 524 133 128 123 118 531 134 129 124 119 538 135 130 125 120 545 136 131 126 121 552 137 132 127 122 559 138 133 128 123 566 139 134 129 124 573 140 135 130 125 580 141 136 131 126 587 142 137 132 127 594 143 138 133 128 601 144 139 134 129 608 145 140 135 130 SWEAT FLARE ADAPTER TEFLON SEAL LIQUID SERVICE VALVE 01214 Fig 8 Liquid Service Valve with Sweat Adapter Tube LIQUID LINE FILTER DRIER LIQUID SERVICE 01215 Fig 9 Filter Drier with Sweat Adapter Tube Liquid Tube 5000 4500 4000 3500 LEAK IN SYSTEM 5 3000 amp 2500 2000 1500 1000 500 VACUUM TIGHT TOO WET TIGHT DRY SYSTEM 0 1 2 3 4 5 6 7 MINUTES A95424 Fig 10 Deep Vacuum Graph 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 a
17. 6 in above roof surface 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 Elevate Unit CAUTION Accumulation of water and ice in base pan may cause equipment damage Elevate unit per local climate and code requirements to provide clearance above estimated snowfall level and ensure adequate drainage of the unit Fig 4 shows unit with accessory support feet installed Use accessory snow stand in areas where prolonged freezing temperatures are encountered Refer to separate Installa tion Instructions packaged with accessories A98533 Fig 4 Accessory Support Feet SENSING BULB EQUALIZER i TUBE THERMOSTATIC EXPANSION VALVE A91277 Fig 5 TXV Installed Step 6 Check Indoor Expansion Device A CAUTION For proper unit operation and reliability units mus
18. Heat Pumps Using Pu ron Refrigerant to minimize losses Refer to Table 1 for field tubing diameters Refer to Table 2 for accessory requirements Data Digest for part numbers 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 OUTDOOR UNIT CONNECTED TO FACTORY APPROVED INDOOR UNIT These outdoor units are carefully evaluated and listed with specific indoor coils for proper system performance IMPORTANT Do not apply to indoor coils that are not factory approved combinations IMPORTANT For 036 size units matched with 40 005 or the FV 40FK FK006 or for the 38YDB048 used with the FV 40FK FK006 a piston change is required Refer to the KHAPX0201CPA Installation Instructions for details INSTALL ADAPTER TUBE 1 Remove plastic retainer holding outdoor piston in liquid line service valve 2 Check to be sure outdoor piston is properly installed in liquid line service valve 3 Locate plastic bag taped to unit containing adapter tube 4 Remove Teflon washer from bag and install on open end of liquid service valve 5 Remove adapter tube from bag and connect threaded nut to liquid service valve Tighten nut finger tight and then with wrench an additional 1 2 turn 15 ft lb DO NOT OVER TIGHTEN REFRIGERANT TUBING AND FILTER DRIER A CAUTION Installation of filter drier in liquid line is required
19. TE 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 A WARNING Before installing modifying or servicing system main elec trical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label Electrical shock can cause personal injury or death A CAUTION Puron Refrigerant systems operate at higher pressures than standard R 22 systems Be certain that service equipment is rated for R 410A 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
20. a minimum of 5 minutes in high speed Step 12 Check Charge A WARNING Service valve gage ports are 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 and gloves when handling refrigerant UNIT CHARGE Factory charge is shown on unit rating plate With unit operating charge Puron units with liquid using a commercial type metering device manifold hose Charge refrigerant into suction line To check charge in cooling mode refer to Cooling Only Procedure To check charge in heating mode refer to Heating Check Chart Procedure Adjust charge in both heating and cooling by following procedure shown on charging tables located on unit pink charging label on back side of access panel NOTE Unit is to be charged in high capacity only Charging in low capacity may cause compressor chattering and possible damage to the compressor COOLING ONLY PROCEDURE 1 Operate unit a minimum of 15 minutes before checking charge 2 Measure liquid service valve pressure by attaching and insu lating an accurate Puron 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 charging label for required subcooling temperatures 5 Refer to Table 3 Find the point where required subcool
21. bing For proper unit opera tion check refrigerant charge using charging information located on control box cover or in the Check Charge section of this instruction IMPORTANT Maximum liquid line size is 3 8 O D for all residential applications IMPORTANT Only install the factory supplied Puron heat pump bi flow liquid line filter drier Obtain replacement filter driers from your local distributor Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 1 4 101 Catalog 533 80088 Printed in U S A Form 38YDB 5SI Pg 1 2 03 Replaces 38YDB 4SI NOTE Avoid contact between tubing and structure OUTDOOR WALL INDOOR WALL CAULK F LIQUID TUBE 9 524 INSULATION THROUGH THE WALL OST HANGER STRAP AROUND VAPOR INSULATION VAPOR TUBE 6 SER 17 LIQUID TUBE SUSPENSION A94028 Fig 2 Connecting Tubing Installation INSTALLATION Step 1 Check Equipment and Job Site UNPACK UNIT Move to final location Remove carton taking care not to damage unit INSPECT EQUIPMENT File claim with shipping company prior to installation if shipment is damaged or incomplete Step 2 Install 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 th
22. defrost unit operates in high or low capacity energizes reversing valve O and auxiliary heat W2 and de energizes outdoor fan Upon termination there is a 20 sec delay in outdoor fan being energized FIELD INITIATED FORCED DEFROST By placing a jumper across forced defrost terminals See Fig 14 for a minimum of 5 sec and then removing it a defrost cycle can be initiated The cycle occurs only if outdoor ambient is less than 50 F regardless of outdoor coil temperature The cycle terminates when coil thermistor reaches 80 F 5 or defrost period reaches a maximum of 10 minutes 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 de energizes compressor contactor 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 combination of and Y2 or all Y2 requests then both low and high capacity operation will be locked out The compres sor voltage failure 6 flashes can be caused by compressor internal overload trip refer to Table 7 for
23. eater is turned on during all off cycles IMPORTANT OUTDOOR AIR THERMISTOR PLACEMENT Mount outdoor air thermistor underneath unit base pan lip on control box side of unit as shown in Fig 16 Attach to base pan with adhesive tape A small piece of bulb insulation tape may be used IMPORTANT If outdoor air thermistor is not properly placed underneath base pan unit may have nuisance thermistor out of range faults Step 14 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 User s Manual with owner Explain system operation and periodic maintenance requirements outlined in manual 4 Fill out Dealer Installation Checklist and place in customer file 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 fA
24. eplace 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 the 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 dual capacity system from operating at high capacity until unit has been operating in low capacity for 15 minutes unless there is at least a 5 F difference between room temperature and thermostat set point To force high capacity adjust the set point at least 5 below room ambient for Table 6 Factory Defaults FAILED COMPONENT FUNCTION DEFAULT Defrost Initiation Defrost is initiated based on coil temperature and time Ambient Thermistor One minute fan off delay in cooling greater than or equal to 100 F No delay function Outdoor Coil Thermistor Defrost Initiation and Termination cooling or 5 above room ambient for heating 6 Set room thermostat to COOL or HEAT 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
25. es indication signals for several system operations See Table 4 for codes and definitions Table 4 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 FACTORY DEFAULTS Factory defaults have been provided in the event of failure of outdoor air thermistor and or outdoor coil thermistor Refer to Table 6 for default and function 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 refrig erant When the compressor operates in single stage operation the motor reverses direction rotates counter clockwise The lower piston becomes idle and the upper piston compresses refrigerant During single capacity operation the start and run wind ings are reversed CRANKCASE HEATER OPERATION The two speed control board energizes the crankcase heater during unit s off cycle OUTDOOR FAN MOTOR OPERATION The two speed control energizes outdoor fan any time compressor is operating The outdoor fan remains energized during the 1 minute compressor speed change time delay and if
26. evacuated to 500 microns IMPORTANT Never open system under vacuum to atmosphere without first breaking it open with nitrogen Deep Vacuum Method The deep vacuum method requires a 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 10 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 8 Make Electrical Connections A WARNING To avoid personal injury or death do 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 disconnec
27. h 7 Sweat swivel adapter See Fig 6D to inlet of indoor coil and attach to TXV See Fig 6A outlet Use backup wrench to avoid damage to tubing or valve Sweat inlet of TXV marked IN to liquid line Avoid excessive heat which could damage valve 8 Install vapor elbow See Fig 6B with equalizer adapter to suction tube of line set and suction connection to indoor coil Adapter has a 1 4 in male flare connector for attaching equalizer tube 9 Connect equalizer tube of to 1 4 in equalizer fitting on vapor line adapter 10 Attach TXV bulb to horizontal section of suction line using bulb strap provided See Fig 6C Insulate bulb with factory supplied insulation tape See Fig 6E See Fig 7 for correct positioning of sensing bulb 11 Proceed with remainder of unit installation FAN COILS Indoor unit fan coil comes factory equipped with a bi flow balance port hard shut off specifically designed for Puron two speed units Changeout is not required To obtain efficiency rating for 38YDB037 with FV4ANBO006 fancoil TXV must be replaced with factory supplied TXV Replacing R 22 or Non Balance Port Puron 1 Remove any existing refrigerant and ensure coil has not been exposed to atmospheric pressure for more than 15 minutes 2 Remove coil access panel and fitting door from cabinet 3 Remove and save TXV support clamp using a 5 16 in nut driver 4 Remove TXV using a
28. ing 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 of 3 F HEATING CHECK CHARGE PROCEDURE To check system operation during heating cycle refer to the Heating Pump Charging Instructions on outdoor unit This chart indicates whether a correct relationship exists between system operating pressure and air temperature entering indoor and outdoor units If pressure and temperature do not match on chart system refrigerant charge may not be correct Do not use chart to adjust refrigerant charge Defrost occurs at each time interval but terminate after 5 minutes NOTE In heating mode check refrigerant charge only when pressures are stable If accessory vapor pressure switch is applied and operating conditions cause vapor pressure switch and thereby outdoor fan to cycle check refrigerant charge in cooling or lower indoor dry bulb temperature If in doubt remove charge and weigh in correct refrigerant charge NOTE When charging is necessary during heating season charge must be weighed in accordance with unit rating plate 0 6 oz ft of 3 8 in liquid line above or below 15 ft respectively EXAMPLE To calculate additional charge required for a 25 ft line set 25 ft 15 ft 10 ft 0 6 oz ft 6 oz of addi
29. ircuit Connections 10 LEGEND SS 24 VOLT FACTORY WIRING 24 VOLT FIELD WIRING ay FIELD SPLICE CONNECTION tt RELAY SPDT PILOT DUTY 24 V COIL HN61KK324 4 OR EQUIVALENT cio OPENS HUMIDITY RISE HL38MG026 AFS AIRFLOW SELECTOR 12 RELAY COIL A03038 WIRING DIAGRAM NOTES Wiring must conform to NEC or local codes Underlined letter on thermostat terminal indicates its usage For example O W2 means O is energized in cooling mode 1 2 3 Refer to indoor unit Installation Instructions for any additional features and wiring information 4 Non Programmable Model 2501 8 when used in heat pump installations jumper R19 NOT cut uses O W2 to control reversing valve 5 Furnace must control its own second stage operation via furnace control algorithms Refer to furnace Installation Instructions for proper setup To activate dehumidify function on FK4 or FV4 remove J1 jumper at fan coil control board Heat pump MUST have a high pressure switch for dual fuel applications Outdoor air temperature sensor must be attached in all dual fuel applications ND Thermidistat Dip Switch No 1 should be set in ON position for heat pump installations 10 Thermidistat Dip Switch No 2 should be set in the ON position for dual capacity compressor operation 11 Thermidistat Configuration Option No 10 Dual Fuel Selection must be turned ON in all dual fuel
30. irst stage heating Y1 the outdoor fan and low capacity compressor are energized If low capacity cannot satisfy heating demand high capacity is energized Y1 and Y2 by the second stage of the indoor thermostat Auxiliary or back up heat is controlled by third stage W1 After second stage of heat is satisfied the unit returns to low capacity operation until first stage is satisfied or until second stage is required again When both first stage and second stage heating 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 PROGRAMMABLE 40FK FV4 THERMOSTAT FK4 TWO SPEED MODEL 25 FAN COIL HEAT PUMP DAN i MPER 24 VAC COOL HEAT smee 4 174 COOLING o 4 rR COOL HEAT stace2 W827 1 2 HEAT STAGE 3 wwiHt 32 JUMPER OUTDOOR SENSOR CONNECTION See notes 1 2 and 3 NON PROGRAMMABLE 40FK FV4 THERMOSTAT 4 25 FAN COIL TWO SPEED HEAT PUMP J1 JUMPER 24 24 COOL HEAT STAGE 2 HEAT STAGE 3 J2 JUMPER RVS COOLING COOL HEAT
31. nd Operating Instructions The 58 58 utilizes a control center that allows the installing technician to select the proper airflows The A C switch deter mines the airflow during high speed compressor operation Air flow for high and low speed can be calculated at either 350 CFM per ton or 400 CFM per ton based on the positions of SW1 5 Table 4 LED Control Function Light Code CODE DEFINITION Constant flash No demand No pause Stand by 1 flash w pause 2 flashes w pause 3 flashes w pause 4 flashes w pause 3 flashes pause Thermistor out of ranget 4 flashes 5 flashes pause Low pressure switch trip 1 flash 5 flashes w pause High pressure switch trip 2 flashes 6 flashes w pause Constant light No pause No flash Function light signal order of importance in case of multiple signal request 1 is most important both thermistors to determine which is faulty Low speed operation High speed operation Outdoor ambient thermistor failure Outdoor coil thermistor failure Compressor V V trip Board failure DISCONNECT PERN E C AND OR LOCAL CODES pt CONTACTOR FIELD POWER _____ SR ENNY 23 WIRING WIRING GROUND LUG A91306 Fig 11 Line Power Connections Table 5 Defrost Dip Switch Settings TIME DIP SWITCH 1 DIP SWITCH 2 30 up down 60 down up 90 down down 120 up up AIRFLOW SELECTION
32. ne adapter Use backup wrench to prevent damage to equalizer fitting 15 Proceed with remainder of unit installation LONG LINE APPLICATIONS INSTALL LIQUID LINE SOLENOID VALVE LSV For refrigerant piping arrangements with equivalent lengths greater than 50 ft or when elevation difference between indoor and or outdoor unit is greater than 20 ft follow all requirements B SENSING BULB STRAP 17 5 8 O CLOCK 4 O CLOCK A00399 Fig 7 Positioning of Sensing Bulb E Table 1 Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters TAPE In UNIT LIQUID VAPOR VAPOR LONG LINE SIZE Connection Tube Connection Tube Connection Diameter Diameter Diameter Diameter Diameter Diameter 01418 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 Fig 6 TXV Contents 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 of the Long Line Guideline section in the Application Guideline Niessen and Service Manual Air Conditioners and Heat Pumps Using 1 Tube diameters are for lengths up to 50 equivalent ft and or 20 ft vertical differential Puron Refrigerant If required by Long Line Application Guide 5 Donor decrease tubing sizes line install LSV kit P N KHALSO401LLS specifically designed 3 If required by local codes Pressure Guard kit is available See
33. oor unit requires a minimum of 27 va 24v control power FINAL WIRING CHECK 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 9 Install Electrical Accessories GENERAL Refer to the individual instructions packaged with kits or acces sories when installing The liquid line solenoid valve accessory is available on these units See Fig 13 for wiring diagram Step 10 Make Airflow Selections AIRFLOW SELECTION FOR 58 58 FURNACES The 58 58 Non Condensing Variable Speed Furnaces provide high and low speed blower operation to match the Table 3 Required Liquid Line Temperature F LIQUID PRESSURE AT REQUIRED SUBCOOLING TEMPERATURE SERVICE VALVE F PSIG 5 10 15 20 174 56 51 46 41 181 58 53 48 43 188 61 56 51 46 195 63 58 53 48 202 65 60 55 50 209 67 62 57 52 216 69 64 59 54 223 71 66 61 56 230 73 68 63 58 237 75 70 65 60 244 77 72 67 62 251 79 74 69 64 258 81 76 71 66 265 82 77 72 67 272 84 79 74 69 279 86 81 76 71 286 88 86 78 73 293 89 84 79 74 300 91 86 81 76 307 93 88 83 78 314 94 89 84 79 321 96 91 86 81 328 97 92 87 82 335 99 94 89 84 342 100 95 90 85 349 102 97 92 87
34. r off delay factory set at 90 sec for high and low speed blower operation For other combinations of equipment consult the Product Data Digest Step 11 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 at negative pressure Do not disable low pressure switch 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 counter clockwise valve system 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 compressor chattering and possible damage to the compressor 2 Fully back seat open liquid and vapor tube service valves 3 Unit is shipped with valve stem s front seated and caps installed R
35. rough knockouts provided in unit base pan Refer to unit 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 3 8 IN DIA TIEDOWN KNOCKOUTS IN BASEPAN 2 PLACES B VIEW FROM TOP gt 89 6 A97548 TIEDOWN KNOCKOUT MOUNTING PAD LOCATIONS UNIT SIZE DIMENSIONS Support Feet Snow Stand A B 024 19 X 24 26 X 32 2 13 16 6 15 16 036 060 26 X 32 31 X 35 4 9 3 4 Fig 3 Mounting Unit to Pad On rooftop applications locate unit at least
36. t be installed with balance port hard shutoff TXV specifically designed to operate with Puron two speed unit Do not install with evaporator coils having capillary tube metering devices The 38YDBO037 unit includes a factory supplied kit No other size unit includes factory supplied TXV kit FURNACE COILS Puron furnace coils come factory equipped with bi flow hard shutoff TXVs specifically designed for Puron two speed units No changeout is required Remove existing AccuRater piston from indoor coil and install field accessory TXV 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 Install TXV kit to indoor coil as follows Installing in Place of Piston 1 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 being careful not to damage sealing surface of O ring 4 Remove and discard 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 A CAUTION To prevent damage to the unit use a brazing shield and wrap with wet clot
37. t switch and unit NOTE Install branch circuit disconnect of adequate size per NEC to handle unit starting current Locate disconnect within sight from and readily accessible from unit per Section 440 14 of NEC ROUTE GROUND AND POWER WIRES Remove access panel and control box cover 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 11 CONNECT CONTROL WIRING Route 24 control wires through control wiring grommet and connect to leads provided in control box See Fig 12 Use No 18 AWG color coded insulated 35 C minimum wire If thermostat is located more than 100 ft from unit as measured along the control voltage wires use No 16 AWG color coded wire to avoid excessive voltage drop All wiring must be NEC Class 1 and must be separated from incoming power leads The outd
38. tional charge Step 13 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 Y1 the outdoor fan and low capacity compressor are energized If low capacity cannot satisfy cooling demand high capacity is energized 1 and Y2 or just Y2 by the second stage of indoor thermostat After second stage is satisfied the unit returns to low capacity operation until first stage is satisfied or until second stage is required again When both first stage and second stage cooling 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 Outdoor fan motor will continue to operate for one minute after compressor shuts off when outdoor ambient is greater than 100 F NOTE When two speed unit is operating in low capacity cool ing system vapor suction pressure will be higher than a standard single speed system or high speed operation This normal opera tion is due to the reduced capacity operating with typically larger indoor and outdoor coils HEATING OPERATION This product utilizes a 3 stage heating indoor thermostat With a call for f

38YDB Weathermaker Two-Speed Split System

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