Carrier 38TZA048 SERIES300, 38TZA060 SERIES330, 38TZA060 SERIES300, 38TZA024 SERIES330, 38TZA030 SERIES300 Installation Guide

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HEATUNG & COOUNG

%isitx__ _.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 fi_ctory=authorized kits or accessories when modifying this product. Refkr 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 fbr brazing operations.

Have fire extinguisher available. Read these instructions thor=

oughly and fbllow all warnings or cautions included in literature

and attached to the unit. Consuh local building codes and National

Electrical (?ode (NEC) tbr special requirements.

Recognize safety informatiom This is the safety-alert symbol z_.

When you see this symbol on the unit and in instructions or

manuals, be alert to the potential for personal injury. Understand these signal words; DANGER, WARNING, and

CAUTION. These words are used with the safety=alert symbol.

DANGER identifies the most serious hazards which will result in

severe personal injury or death. WARNING signifies hazards which could result in personal inju V or death. CAUTION is used

to identify unsaf_ practices which would result in minor personal

injury or product and property damage. NOTE is used to highlight

suggestions which will result in enhanced instalhion, reliability, or

operation.

Befbre installing, modil_-ing, 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.

Puron_R: systems operate at higher pressures than standard R=22 systems. To avoid danmge to the unit or possible

personal inju_', do not use R-22 sen-ice equipment or

components on Puronta equipment.

mNSTALLATmON RECOMMENDATBONS

NOTE: In some cases noise in the living area has been traced to

gas pulsations fi'om 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 robe diameters are appropriate for unit capacity.

38TPA, TZA, TXA, TSA

11, 12, 13, t4 SEER SpMit-System

Air Conditioners with Puron®

A98516

Fig. 1--Models 38TPA, 38TZA, 38TXA, and 38TSA

3 Run refrigerant tubes as directly as possible by avoiding

unnecessary rams and bends

4. Leave some slack between structure and unit to absorb vibration.

5. When passing refi'igerant robes through the wall, seal opening with RTV or other pliable silicon-based caulk. (See Fig. 2.)

6. Avoid direct robing contact with water pipes, duct work, floor

joists, wall studs, floors, and walls.

7. Do not suspend refrigerant tubing fi'om joists and studs with a rigid wire or strap which comes in direct contact with tubing.

(See Fig. 2.)

8 Ensure that robing insulation is pliable and completely sur-

rounds vapor mbe.

9. When necessary, use hanger snaps which are 1 in. wide and confbnn to shape of robing insulation. (See Fig. 2.)

10. Isolate hanger straps from insulation by using metal sleeves bent to confbrm to shape of insulation.

When outdoor unit is connected to factory-approved indoor unit, outdoor unit contains system refrigerant charge fbr operation with ARI rated indoor unit when connected by 15 [_of field-supplied or factor?" accessory tubing. For proper unit operation, check refrig- erant charge using charging in_bnnation located on control box cover and/or in the Check Charge section of this instructiom

IMPORTANT: Maximum liquid-line size is 3/8-im OD for all residential applications including long line.

IMPORTANT: Always install the fhctoo,-supplied liquid-line fil- ter drier. If replacing the filter drier, refer to Product Data Digest for appropriate part number. Obtain replacement filter driers from your distributor or branch.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without insurring obligations,

PC 101 Catalog No 533-80105 Printed in U.S.A. Form 38T-13SI Pg 1 1%03 Replaces: 38%12SI

INSTALLATION

NOTE: Avoid contact between tubing and structure

_SULATION___VAPOR TUBE

THROUGH THE WALL

3/8-1N. DIA TIEDOWN

KNOCKOUTS IN BASEPAN

121 PLACES

VIEW FROM TOP

3/16"

HANGER STRAP-- X

(AROUND VAPOR_ --

,>__IN SULATION

TUBE_,

_,/--JOIST

VAPOR TUBE

r' MIN

SUSPENSION

Fig. 2--Connecting Tub{rig InstNtation

Specifications %1" this unit in residential new construction market require d_e outdoor unit, indoor unit, refrigerant robing sets, metering device, and tilter drier listed in presale literature The*e

can be no deviation, Consult the Application Guideline and

So*vice Manual Air Conditioners and Heat Pumps Using

Puron® Refl'igerant to obtain required unit changes for specific

applications and for R-22 retrofit.

Step 1--Check Equipment and Job Site

L NPACK LNIT

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 Locate unit rating plate on unit corner panel It contains information needed to properly install unit

(hock rating plate to be sure unit matches job specifications.

Step 2--Install on a Solid, Level Mounting Pad

If conditions or tocal 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 detem_ine base pan size and knockout hole location.

On rooftop applications, mount or* level plaffbrm or fi'ame. Place unit above a load-bearing wall and isolate unit and robing set fiom

structure. Arrange supporting members to adequately support unit

and minimize transmission of vibration to building. Consult local

codes governing rooftop applications. Roof mounted units exposed to winds above 5 mph may require

wind baffles. Consult the Application Guideline and Service Manual Residential SplitoSystem Air Conditioners and Heat

Pumps Using Puron® Refrigerant for wind baffle construction.

LIQUID TUBE

A94028

Dimensions (In.)

UNIT BASE PAN DBMENSBONS

22.5 X 27.5 2-13/16 6-15116

30.0 X 35.0 4 9-3/4

TiEDOWN KNOCKOUT LOCATIONS

Fig. 8--Clearance Requirements

NOTE: Unit must be level to within ÷2 ° (÷3/8 inift) per compressor manufhcturer specifications.

Step a--Clearance Requirements

When installing, allow sufficient space for airflow clearance, wiring, refi'igerant piping, and service. Allow 30oin. clearance m service end of unit and 48 in. above unit. For proper airflow, a 6oin. 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.

On rooftop applications, locate unit at least 6 in. above roof surface.

Step 4_Operating Ambient

)"he minimum outdoor operating ambient in cooling mode is 55°F, and the maximum outdoor operating ambient in cooling mode is

125°F.

--> Step 5--Cheek indoor AceuRater® Piston and Install Piston Ring {38TXA024o048, 060034 / 38TZA / 38TPA= =Standard)

If'unit is to be installed with a piston metering device, proceed as follows:

1. Check indoor coil piston to see if it matches the required piston shown or* outdoor unit rating plate. If it does not match, replace indoor coil piston with piston shipped with outdoor unit. The piston shipped with outdoor unit is correct fbr any approved indoor coil combination.

2. After correct piston is installed, locate neoprene piston ring shipped in piston bag. Install piston ring behind metering piston as shown in Fig. 4. The piston ring ensures that piston stays seated during all operating conditions.

---> Step g--Install TXV

NOT[[: ALL 38TSA and 38TXA060035 [NH'S MIST BE INSTALLED WITH A HARD SH[T OFF TXV

The thermostatic expansion valve is specifically designed to operate with Puron:_. Do not use an Ro22 TXV. An existing Ro22 TXV must be replaced with a factou-approved TXV specifically designed for Purona;.

A97548

NOTE: FK4 and FC4 _hn coils are equipped with an R=22 TXV If an FK4 o1"an FC4 fire coil is used with a Puron;R; air conditioner,

the R=22 TXV must be replaced with a Puron® TXV or with the accessory piston body kit and piston shipped with outdoor unit.

STRAINER

TXV, marked "IN" to liquid line Avoid excessive heat which could damage valve.

6 Install vapor elbow with equalizer adapter to suction tube of

line set and suction connection to indoor coil. Adapter has a

1/4-in. male connector fbr attaching equalizer tube

7 Connect equalizer robe of TXV to li4-in equalizer fitting on

vapor line adapter.

g Attach TXV bulb to horizontal section of suction line using

clamps provided Insulate bulb with field=supplied insulation tape See Fig. 5 for correct positioning of sensing bulb.

9 Proceed with remainder of unit installation.

SENSING

FLARE ADAPTOR

LIQUID LINE STRAINER

_APPROX 2" LONG

L STRAINER LABEL

(AFFIX TO LIQ. LINE NEAR STRAINER LOCATION)

A95615

Fig. 4--AccuRateNg) Components

(38TXA, 38TZA, 38TPA Only)

To avoid improper per%finance and possible equipment failme, remove indoor coil piston if"unit is to be installed on system with a TXV metering device,

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. Valve is more susceptible to malfunction dne to debris if inlet tube is fi_cing down. A factory=approved filter drier must be installed in the liquid line.

Installing TXV in Place of Piston

1. Pump system down to 2 psig and recover refi'igerant.

2. Remove hex nut from piston body Use backup wrench on _n

coils

3. Remove and discard _Sctory=installed piston. Be sure Teflon seal is in place.

4. Reinstall hex nut. Finger tighten nut plus 1/2 turn.

NOTE: If the piston is not removed flora the body, TXV will not function properly.

t . * j

To prevent damage to the unit, use a brazing shield and wrap TXV with wet cloth or use heat sink material

5. Install TXV on indoor coil liquid line. Sweat swivel adapter to inlet of indoor coil and attach to TXV outlet Use backup

wrench to avoid damage to robing or valve Sweat inlet of

4 O'CLOCK

7/8IN. OD & SMALLER LARGER THAN 7/8IN. OD

A81032

Fig. g--Position of Sensing Bulb

Replacing TXV on R-22 Indoor Coil

1 Pump system down to 2 psig and recover refrigerant 2 Remove coil access panel and fitting panel flora _?ont of'

cabinet.

3. Remove TXV support clamp using a 5/16-in. nut &iver. Save the clamp.

4. Remove R=22 TXV using a baclcup wrench on flare connec- tions to prevent damage to tnbing.

5. Using wire cutters, cut equalizer robe offflush with vapor robe inside cabinet.

6. Remove bulb fi'om vapor robe inside cabinet.

7. Braze equalizer stub-robe closed. Use protective battier as necessary to prevent damage to drain pan.

IMPORTANT: Route d-_e equalizer tube of Puron TXV through suction line connection opening in fitting panel prior to replacing fitting panel around tubing.

8. Install TXV with 3/8=in. copper tubing through small hole in service panel. Use wrench and backup wrench, to avoid damage to tubing or valve, to attach TXV to distributor.

9. Reinstall TXV suppolq _ clamp (removed in item 3).

10. Attach TXV bulb to vapor robe inside cabinet, in same location as original was when removed, using supplied bulb clamps (nylon or copper). See Fig. 5 for con'ect positioning of sensing bulb.

11. Route equalizer robe 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 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 robe.

Table 1--Refrigerant Connections and Recommended Liquid and Va

UNIT SIZE

0t8, 024 3/8 3/8 5/8 5/8 030, 036 3/8 3/8 3/4 3/4 042, 048 3/8 3/8 7/8 7/8

060 3/8 3/8 7/8 1-1/8

NOTES: 1 Tube diameters are for lengths up to 50 ft. For tubing lengths greater than 50 ft, consult the Application Guideline and Service Manual--Air Conditioners and Heat

Pumps Using Puron® Refrigerant

2 Do not apply capillary tube indoor coils to these units

Connection Diameter Tube Diameter Connection Diameter Tube Diameter

LIQUID VAPOR

_or Tube Diameters (In.)

VAPOR (LONG LINt=)

Connection Diameter Tube Diameter

5/8 3/4 3/4 7/8 7/8 1-1/8 7/8 1-1/8

14. (onnect equalizer robe of TXV to 1i4qn. equalizer fitting on vapor line adapter. Use backnp wrench to prevent damage to

equalizer fitting.

15. Proceed with remainder of unit installation

Step 7--Make Piping Connections

Relieve pressure and recover all refrigerant be%re system repair or final unit disposal to avoid personal inju_ or death. Use all smwice ports and open all flow°contIol devices,

including solenoid valves.

To prevent improper perfbm_ance and/or unit component

failures, do not leave system open to atmosphere any longer

than minimum required for installation POE oil in compres=

sot is extremely susceptible to moisture absorption. Always

keep ends of robing sealed during installation.

To prevent improper per_:brmance or equipment fitilure this

caution must be fPllowed. If ANY refrigerant robing is buried, provide a 6 in. vertical rise at service valve. Refrig=

erant robing lengths up to 36 in. may be buried without further

special consideration Do not bury lines longer than 36 in.

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 accesso_-

tubing package or field-supplied refrigerant grade robing of correct

size and condition. For robing requirements beyond 50 ft, substan= tia] capacity and performance losses can occur Following the recommendations in the Application Guideline and Service Manual Residential Split=System Air (onditioners and Heat

Pumps Using Puron(_-': Refrigerant will reduce these losses. Refer to Table 1 _br field robing diameters. Refer to Table 2 for

accessory requirements.

There are no buried-line applications greater than 36 in.

If refi'igerant robes 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 FA( TORY-APPROVED INDOOR UNIT

Outdoor unit contains con'ect system re_:i'igerant charge _br opera- tion with ARI rated indoor unit with highest sales volume when connected by 15 ft of []eld-supplied or _ctory-accesso_- robing. (beck refrigerant charge _br maxinmm efficiency

INSTALL LIQUID-LINE FILTER DRIER

To avoid per%finance loss and compressor _ilure, installa= tion of filter &ier in liquid line is required

Re_r to Fig. 6 and install filter drier as _bllows:

1. Braze 5-in. connector tube to liquid service valve Wrap filter &ier with damp cloth

2. Braze filter drier between connector robe and liquid tube to indoor coil. Flow arrow must point towards indoor coil.

REFRIGERANT TUBING (onnect vapor tube to fitting on outdoor unit vapor service valves.

(onnect liquid robe to filter drier (See Fig 6 and Table 1.) Use refrigerant grade robing.

SWEAT CONNECTION

To avoid valve damage while brazing, service valves must be wrapped in a heat-sinking mate*ial such as a wet cloth

Use refiigerant grade robing Service valves are closed from facto W and ready for brazing Aker wrapping service valve with a wet cloth, braze sweat connections using industry accepted meth- ods and materials. Consult local code requirements. Refrigerant robing and indoor coil are now ready for leak testing. This check should include all field and facto W joints.

EVACUATE REFRIGERANT TUBING AND INDOOR COIL

To avoid compressor damage, never use the system compres° sot as a vacmlm pump

Refiigerant robes and indoor coil should be evacuated _lsing the recommended deep vacuum method of 500 microns. The alternate triple evacuation method may be used if"the procedure outlined below is _bllowed Always break a vacuum with dW nitlogen.

Deep Vacuum Method The deep vacuum method requires a vacuum pump capable of

pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth, The deep vacuum method is the most positive way of assuring a system is _:i'eeof air and liquid water. (See Fig. 7,)

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