Carrier 38TDB User Manual

38TDB WeatherMaker™ Two-Speed

Air Conditioning Unit with Puron®

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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 thoroughly 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, CAUTION, and NOTE. 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.

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position. There may be more than 1 disconnect switch. Lock out and tag switch with a suitable warning label. Electrical shock can cause personal injury or death.

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.

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 surrounds 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 operation, check 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.

Book	1	4	PC 101	Catalog No. 533-80059	Printed in U.S.A.	Form 38TDB-4SI	Pg 1	8-02	Replaces: 38TDB-3SI
Tab	3a	2a

NOTE: Avoid contact between tubing and structure

OUTDOOR WALL INDOOR WALL

CAULK

LIQUID TUBE

VAPOR TUBE

INSULATION

THROUGH THE WALL

JOIST

HANGER STRAP

(AROUND VAPOR

TUBE ONLY) INSULATION VAPOR TUBE

1″ MIN.

LIQUID TUBE

SUSPENSION

A01383

Fig. 2—Connecting Tubing Installation

INSPECT EQUIPMENT

File claim with shipping company prior to installation if shipment is 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 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.

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 specifically designed for Puron® two-speed units.

NOTE: FK4, FC4, and 40FK fan coils are equipped with an R-22 TXV. If an FK4, FC4, or 40FK fan coil is used with a Puron® air

3/8-IN. DIA TIEDOWN KNOCKOUTS IN BASEPAN

(2) PLACES

C

A

L

B

	VIEW FROM TOP					8 3/16 ″
						A97548
	Dimensions (In.)
	MINIMUM MOUNTING	TIEDOWN KNOCKOUT
UNIT SIZE			LOCATIONS
	PAD DIMENSIONS
			A			B
024	19 X 24	2-13/16			6-15/16
036-060	26 X 32	4			9-3/4

Fig. 3—Mounting Unit to Pad

conditioner, the R-22 TXV must be replaced with a factoryapproved Puron® TXV.

→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 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.

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 “IN” to liquid line. Avoid excessive heat which could damage valve

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SENSING BULB

COIL

SENSING

BULB

EQUALIZER

TUBE

THERMOSTATIC

EXPANSION

VALVE

STRAP

8 O'CLOCK

4 O'CLOCK

A00399

Fig. 6—Positioning of Sensing Bulb

4.Remove TXV using a backup wrench on flare connections to prevent damage to tubing.

					A91277	5.	Using wire cutters, cut equalizer tube off flush with vapor tube
	→		Fig. 4—TXV Installed				inside cabinet.
						6.	Remove bulb from vapor tube inside cabinet.
		8.	Install vapor elbow (see Fig. 5B) with equalizer adapter to
						7.	Braze equalizer stub-tube closed. Use protective barrier as
			suction tube of line set and suction connection to indoor coil.
							necessary to prevent damage to drain pan.
			Adapter has a 1/4-in. male connector or attaching equalizer
						→ IMPORTANT: Route the equalizer tube of the approved Puron®
			tube.
		9.	Connect equalizer tube of TXV to 1/4-in. equalizer fitting on			TXV through suction line connection opening in fitting door prior
						to replacing fitting panel around tubing.
			vapor line adapter.
		10.	Attach TXV bulb to horizontal section of suction line using			8.	Install TXV (Fig. 5A) with 3/8-in. copper tubing through
							small hole in service panel. Use wrench and backup wrench,
			bulb straps provided. (See Fig. 5C.) Insulate bulb with
							to avoid damage to tubing valve.
			factory-supplied insulation tape. (See Fig. 5E.) See Fig. 6 for
			correct positioning of sensing bulb.			9.	Reinstall TXV support clamp (removed in item 3).
	→	11.	Proceed with remainder of unit installation.			10.	Attach TXV bulb to vapor tube inside cabinet, in same
		FAN COIL					location as original was when removed, using supplied bulb
		To	obtain efficiency rating for 38TDB037 with	FV4ANB006			straps. (See Fig. 5C.) See Fig. 6 for correct positioning of
							sensing bulb. Insulate bulb with factory-supplied insulation
		fancoil TXV must be replaced with factory supplied TXV.
							tape. (See Fig. 5E.)
		Replacing R-22 TXV or Non-Balance Port Puron TXV
	→					11.	Route equalizer tube through suction connection opening
					not been
		1.	Remove any existing refrigerant and ensure coil has				(large hole) in fitting panel and install fitting panel in place.
			exposed to atmospheric pressure for more than 15 minutes.			12.	Sweat inlet of TXV, marked “IN” to liquid line. Avoid
		2.	Remove coil access panel and fitting panel	from front of
							excessive heat which could damage valve.
			cabinet.
						13.	Install vapor elbow (see Fig. 5B) with equalizer adapter to
		3.	Remove and save TXV support clamp using the 5/16-in. nut
							vapor line of line set and vapor connection to indoor coil.
			driver. Save the clamp.
							Adapter has a 1/4-in. male connector for attaching equalizer
							tube. (See Fig. 5B.)
			B			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.

INLET

D A

COIL

E

BULB

INSULATION

TAPE

C

A01418

Fig. 5—TXV Kit Contents

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 Puron® Refrigerant.

Step 6—Make Piping Connections

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.

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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.

If ANY refrigerant tubing is buried, provide 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.

LIQUID-LINE FILTER-DRIER

LIQUID

SERVICE

VALVE

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 Puron® 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.)

	UNIT	LIQUID		VAPOR		VAPOR (LONG-LINE)
	SIZE	Connection	Tube	Connection	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 system refrigerant charge for operation with indoor unit of same size when connected by 15 ft of field-supplied or factory-accessory tubing. Check refrigerant charge for maximum efficiency

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:

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 connector 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

Never use the system compressor as a vacuum pump.

Refrigerant tubes and indoor coil should be evacuated to 500 microns. Always break a vacuum with dry 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. 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.

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5000
4500
4000						LEAK IN
3500
						SYSTEM
3000
2500
MICRONS2000						VACUUM TIGHT
1500
						TOO WET
1000
						TIGHT
500
						DRY SYSTEM
0	1	2	3	4	5	6	7
			MINUTES				A95424

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

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 disconnect switch and unit.

EVACUATE

BREAK VACUUM WITH DRY NITROGEN

WAIT

EVACUATE

BREAK VACUUM WITH DRY NITROGEN

WAIT

EVACUATE

CHECK FOR TIGHT, DRY SYSTEM (IF IT HOLDS DEEP VACUUM)

CHARGE SYSTEM

A95425

Fig. 9—Triple Evacuation Method

DISCONNECT

PER N. E. C. AND/ OR LOCAL CODES

FIELD POWER

WIRING

FIELD GROUND

WIRING

CONTACTOR

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.

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 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 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 accessories 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 a 58CVA or 58MVP gas furnace), no LCC is

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