Carrier 38YDB060 SERIES300, 38YDB060 SERIES320, 38YDB037 SERIES310, 38YDB037 SERIES300, 38YDB036 SERIES310 Installation Guide

38YDB

HEATING & COOUNG

WeatherMaker TMTwo-Speed Split System

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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 qnalified installer, service agency, or your
distributor or branch for information or assistance. The qualified

installer or agency must use _actory-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 z_ •

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 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.

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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.

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.

i. Locate unit away from windows, patios, decks, etc. where unit

operation sound may disturb customer.

Heat Pump with Puron® Refrigerant

A98516

Fig. 1--Model 38YDB

2. Ensure that vapor and liqnid tube diameters are appropriate to
capacity of unit.

3. Run refrigerant tubes as directly as possible by avoiding
unnecessary tunas 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 are 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 tubing. 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: Maxinmm liquid-line size is 3/8 in. O.D. for all
residential applications.

IMPORTANT: Only install the factory-supplied Puron,_,P_ heat
pump (bi-flow) liquid line filter &ier. 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.

PC 101 Catatog No. 533-80088 Printed in USA Form 38YDB-5Sl Pg 1 2-03 Replaces: 38YDB-4Sl

NOTE: Avoid contact between tubing and structure

F OUTDOOR WALL_ INDOOR WALL7

CAULK

[!_/_ (---__F LIQUID TUBE

_N ON_!A VAPOR TUBE

SULATI

THROUGH THE WALL

3/8-1N DIA TIEDOWN

KNOCKOUTS IN BASEPAN

(2) PLACES

HANGER STRAP--- x

(AROUNDVAPOR '_ --

i] _--INSULATION

TUBE_,

_...,_JOIST

VAPOR TUBE

1"M,N.-----I L LIQUID TUBE

SUSPENSION

A94028

Fig. 2--Connecting Tubing Installation

INSTALLATION

Step l--Check Equipment and Job Site

UNPACK UNIT
Move to final location. Remove carton, taking care not to dmnage

unit.

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

It"conditions 02"local codes require the unit be attached to pact, tie

down bolts should be used and fastened through knockouts
provided in unit base pan. Refer to unit mounting pattern in Fig. 3
to detemfine 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 fi'om

structure. Arrange supporting members to adequately support unit

and minimize transmission of vibration to building. Consult local

codes governing rooftop applications.

VIEW FROM TOP

MINIMUM

MOUNTING PAD

UNIT SIZE DIMENSIONS LOCATIONS

Support Feet Snow Stand A B

024 19 X 24 26 X 32 2-!3/16 6-15/16

036-060 26 X 32 3! X 35 4 9-3/4

TIEDOWN KNOCKOUT

3/16"

A97548

Fig. 3--Mounting Unit to Pad

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

Step 4_Operating Ambient

The minimum outdoor operating ambient in cooling mode is 55°F,
and the maxinmm outdoor operating ambient in cooling mode is

125°F.

Step 5--Elevate Unit

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.

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.ift).
Step 3--Clearance Requirements

When installing, allow sufficient space fbr 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 nmst

be maintained. Maintain a distance of 24 in. between units.

Position so water, snow, or ice from roof or eaves cannot Pall
directly on unit.

A98533

Fig. 4_Accessory Support Feet

SENSING

BULB

EQUALIZER

THERMOSTATIC

EXPANSION

VALVE

A91277

Fig. 5--TXV Installed

Step 6--Check Indoor Expansion Device

For proper unit operation and reliability, units must be
installed with balance port hard shutoff TXV specifically

designed to operate with Puron(P_ two-speed unit. Do not
install with evaporator coils having capillary robe metering

devices.

The 38YDB037 unit includes a factory supplied TXV kit. No other
size unit includes factory supplied TXV kit.

FURNACE (:OILS

Puron'_ furnace coils come _actory equipped with bi-flow, hard
shutoff TXVs specifically designed for Puron(P_ 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 _actory-supplied or

approved filter &ier must be installed in the liquid line.
Install TXV kit to indoor coil as follows:

Installing TXV in Place of Piston

i. Ensure coil has not been exposed to atmospheric pressure for

more than 15 minutes.

2. Remove indoor coil inlet robe at piston body inlet. Use
back-up wrench to prevent damage.

3. Remove piston retainer, being careful not to damage sealing

surl_ace of O-ring.

4. Remove and discard _actory-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.

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To prevent damage to the unit, use a brazing shield and wrap
TXV with wet cloth.

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 robe.

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 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 (_an coil) comes fiactory equipped with a bi-flow
balance port hard shut-off TXV specifically designed for Puron(P_
two-speed units. Changeout is not required.

To obtain efficiency rating fbr 38YDB037 with FV4ANB006,
fancoil TXV must be replaced with factory supplied TXV.

Replacing R-22 TXV or Non-Balance Port Puron(r_" TXV

i. Remove any existing refrigerant and ensure coil has not been

exposed to atmospheric pressure fbr more than 15 minutes.

2. Remove coil access panel and fitting door fi'om cabinet.

3. Remove and save TXV support clamp using a 5/16-in. nut
driver.

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

5. Using wire cutters, cut equalizer robe off flush with vapor tube
inside cabinet.

6. Remove bulb fi'om 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(P_
TXV 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 TXV bulb to vapor tube inside cabinet in same location
as original was removed fi'om using supplied bulb strap (See
Fig. 6C). Insulate bulb with _aetory-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 robe. (See Fig. 6B.)

14. Connect eqnalizer tube of TXV to 1/4-in. equalizer fitting on
vapor line 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 reliigerant 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

SENSING BULB

BULB

INSULATION

TAPE

c

A01418

Fig. 6--TXV Kit Contents

of the Long-Line Guideline section in the Application Guideline
and Service Manual_ir Conditioners and Heat Pumps Using
Puron,_.R)Refrigerant. If required by Long-Line Application Guide-
line, install LSV kit P.N KHALS0401LLS specifically designed
for Puron(R_ 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 nmst point toward outdoor unit.

Step 7--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.

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If ANY refrigerant tubing is buried, provide a 6 in. vertical
rise at service valve. Rel_dgerant 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 refi'igerant grade tubing of correct

size and condition. Tubing diameters listed in Table 1 are adequate
for equivalent lengths up to 50 It. 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.

80ICLOCK 4 O'CLOCK

A00399

Fig. 7--Positioning of Sensing Bulb

Table 1--Refrigerant Connections and

Recommended Liquid and Vapor Tube Diameters

(In.)

UNIT

SIZE

024
036

037,048

060

Notes:

1. Tube diameters are for lengths up to 50 equivalent ft and/or 20 ft vertical

differential

2. Do not increase or decrease tubing sizes.

3. If required by local codes, Pressure Guard TM kit is available See Product
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 !EXIT CONNECTED TO FACTORY-APPROVED

INDOOR UNIT
These outdoor units are carefully evaluated and listed with specific

indoor coils for proper system perfomlanee.
IMPORTANT: Do not apply to indoor coils that are not factory

approved combinations.
IMPORTANT: For 036 size units matched with the

FV.40FKiFK005 or the FVi40FKiFK006, or lbr the 38YDB048
used with the FVi40FKiFK006, a piston change is required. Refer

to the KHAPX0201CPA Installation Instructions for details.
INSTALL ADAPTER TUBE

i. 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 fi'om bag and install on open end of
liquid service valve.

5. Remove adapter tube from bag and connect threaded nut to
liqnid service valve. Tighten nut finger tight and then with

wrench an additional i/2 tum (15 ft-lb). DO NOT OVER-
TIGHTEN!

REFRIGERANT TUBING AND FILTER DRIER

Connect vapor tubing to fittings on outdoor unit vapor service
valve. Connect liqnid tubing to filter &ier. (See Table 1 and Fig.

9.) Connect other end of filter drier to adapter tube on liquid line
smwice valve.

LIQUID VAPOR

Connection Tube Connection Tube

Diameter Diameter Diameter Diameter

3/8 3/8 5/8 5/8
3/8 3/8 3/4 3/4

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

VAPOR (LONG-LINE)

Connection Tube

Diameter Diameter

5/8 3/4
3/4 7/8

7/8 7/8
7/8 1-1/8

Table 2--Accessory Usage

ACCESSORY SEACOAST APPLICATIONS

Coastal Filter Yes

Support Feet Recommended

Puron® Balance-Port Hard Shutoff TXV Yesl-

Puron® Liquid-Line Solenoid Valve for Heating 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.

REQUIRED FOR LONG-LINE

APPLICATIONS*

(OVER 50 FT)

No
No

Yesl

KHALS0401LLS

REQUIRED FOR

(WITHIN 2 MILES)

SWEAT CONNECTION

V.,l[qAliiIg_

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 robing.
EVACUATE REFRIGERANT TUBING AND INDOOR (;OIL

M [qAli_o]3

To avoid compressor damage, never use the system compres-
sor as a vacuum pump.

Refrigerant tubes and indoor coil nmst be 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 mininmm 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 metah Pay close

attention to feeder tubes, making sure wire ties on feeder tubes are
secure and tight.

Step 8--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 con'ection 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.

NOTE: Install branch circuit disconnect of adequate size per
NEC to handle unit starting cun'ent. 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 nlininmm wire size shown in Product Data Digest.

The unit cabinet must have as uninten'upted 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 24v 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 fi'om 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 nmst be separated from
incoming power leads.

The outdoor unit requires a minimum of 27-va, 24v control power.
FINAL WIRING CHECK

IMPORTANT: Check factory wiring and wire connections to
ensure temlinations 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 diagrmn.

Step 10--Make Airflow Selections

---->AIRFLOW SELECTION FOR 58CVA 58CVX FURNACES
The 58CVAi58CVX Non-Condensing Variable Speed Furnaces

provide high- and low-speed blower operation to match the