CARRIER Air Conditioner/heat Pump(outside Unit) Manual L0211024

User Manual: CARRIER CARRIER Air conditioner/heat pump(outside unit) Manual CARRIER Air conditioner/heat pump(outside unit) Owner's Manual, CARRIER Air conditioner/heat pump(outside unit) installation guides

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HEATING & COOLING

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38EZA, 38ETA, 38ESA

12, 13, 14 SEER Split-System

Air Conditioner with Puron®

Installation and Start-Up Instructions

NOTE: Read the entire instruction manual before starting the

instanmion.

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 factoty-authorized kits or accessories

when modifying this product. Refer to the individual instructions

packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,

and work gloves. Use quenching cloth for brazing operations.

Have fire extinguisher available. Read these instructions thor-

oughly and follow all warnings or cautions included in literature

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

Electrical Code (NEC) for special requirements.

Recognize safety information. This is the safety-alert symbol ,_.

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

manuals, be alert to the potential for personal injury.

Understand these signal words; DANGER, WARNING, 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 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 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.

IRSTALLATION RECOMMENDATIONS

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

gas pulsations from improper installatinn 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 for

unit capacity.

A99327

Fig. 1--Models 38EZA, 38ETA, 38ESA

3. Run refrigerant tubes as directly as possible by avoiding

unnecessary turns and bends+

4. Leave some slack between structure and unit to absorb

vibration.

5. When passing refrigerant tubesthrough the wall, seal opening

with RTV or other pliable silicon-based caulk. (See Fig. 2.)

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

joists, wall studs, floors, and walls.

10.

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.)

Ensure that tubing insulation is pliable and completely sur-

rounds vapor tube,

When necessary, use hanger straps which are 1 in. wide and

conform to shape of tubing insulation. (See Fig. 2.)

Isolate hanger sWaps from insulation by using metal sleeves

bent to conform to shape of insulation.

When outdoor unit is connected to factory-approved indoor uniL

outdoor unit contains system refrigerant charge for operation with

indoor unit of the same size when connected by 15 fl of

field-supplied or factory accessory tubing. For proper unit opera-

tion, check refrigerant charge using charging information located

on control box cover and/or in the Check Charge section of thLs

instruction.

IMPORTANT: Maximum liqnid-line size is 3/8-in. O.D. for all

residential applications including long line.

IMPORTANT: Always install the factory-supplied liquid-line ill-

ter drier. If replacing the f'dter drier, refer to Product Data Digest

for appropriate part number. Obtain replacement falter driers from

your distributor or branch.

Manufacturer _the right to diseontintm, or change at any time, specifications or designs without notice and without incurring obligations,

PC 101 Catalog No. 533-80056 Printed in U.S.A. Form 38ESA-3SI Pg 19-O2 Replaces: 38ESA-2SI

O'CLOCK SWEAT CONNECTION

SENSING

SUCTION TU_

8 O'CLOCK 4 O'CLOCK

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

A81032

Fig. 5--Position of Sensing Bulb

11'.,_["T_T_T_,_j

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.

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. For tubing requirements beyond 50 ft, substan-

tial capacity and performance losses can occur. Following the

recommendations in the Application Guideline and Service

Manual -- Residential Split-System Air Conditioners and Heat

Pumps Using Puron® Refrigerant will reduce these losses. Refer

to Table 1 for field tubing diameters. Refer to Table 2 for

accessory requirements.

No buried-line applications greater than 36 in.

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

Outdoor unit contains correct system refrigerant charge for opera-

tion with ARI rated indoor unit with highest sales volume when

connected by 15 ft of field-supplied or factory-accessory tubing.

Check refrigerant charge for maximum efficiency.

INSTALL LIQUID-LINE FILTER DRIER

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.

Consult local code requh-ements. Refrigerant tubing and indoor

coil are now ready for leak testing. This check should include all

field and factory joints.

EVACUATE REFRIGERANT TUBING AND INDOOR COIL

Never use the system compressor as a vacuum pump.

Refrigerant tubes and indoor coil should be evacuated using the

recommended deep vacuum method of 500 microns. The alternate

triple evacuation method may be used if the procedure outlined

below is followed. Always break a vacuum with dry nitrogen.

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 free of air

and liquid water. (See Fig. 7.)

Triple Evacuation Method

The triple evacuation method should only be used when vacuum

pump is only capable of pumping down to 28 in. of mercury

vacuum and system does not contain any liquid water. Refer to

Fig. 8 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 1hr. During

this time, dry nitrogen will be able to diffuse throughout the

system absorbing moisture.

5. Repeat this procedure as indicated in Fig. 8. System will then

be free of any 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 axe

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

Refer to Fig. 6 and install filter drier as follows:

1, Braze 5-in. connector tube to liquid 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 towards indoor coil.

REFRIGERANT TUBING

Connect vapor tube to fitting on outdoor unit vapor service valves.

Connect liquid tube to filter drier. (See Fig. 6 and Table 1.) Use

refrigerant grade tubing.

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 unitrating plate. Do not

CONNECTOR

TUBE

Fig. 6--Liquid-Line Filter Drier

A99331

Tabl, 1--Refrigerant Connections and Recommended Liquid Line and Vapor Tube Diameters (In.)

UNIT

SIZE

018, 024

030, 036

042, 048

060

NOTES:

LIQUID

Connection Diameter

3/8

Tube Diameter

3/8

VAPOR

Connection Diameter Tube Diameter

5/8 5/8

3/4 3/4

7/8 7/8

7/8 1-1/8

VAPOR (LONG LINE)

Connection Diameter Tube Diameter

5/8 3/4

3/4 7/8

7/8 1-1/8

f, Tube diamefers are for lengths up to 50 tt. For tubing lengths greater than 50 ft horizontal, or greater than 20 fl vertical differential, consult the Application Guideline

and Service Manual -- Air Conditioners and Heat Pumps Using Puron_ Refrigerant.

2, DO not apply capillaw tube indoor coils to these units.

ACCESSORY

Crankcase Heater

Evaporator Freeze Thermostat

Winter Start Control

Accumulator

Compressor Start Assist

Capacitor and Relay

MotorMastarO Control,

Low-Ambient Pressure Switch

Wind Baffle

Coastal Filter

Liquid-Line Solenoid Valve

Hard Shutoff TXV

Ball Bearing Fan Motor

Table 2--Accessory Usage

REQUIRED FOR

LOW-AMBIENT

APPLICATIONS

(BELOW 55°F)

Yes

Yeet

Yes

See low-ambientinstructions

Yee$

REQUIRED FOR

LONG-MNE

APPLICATIONS*

(OVER 5OFT)

Yes

See Long-Line

Application

Guideline

REQUIRED FOR

SEA COAST

APPLICATIONS

(WITHIN 2 MILES)

Yes

• For tubing line sets between 50 and 175 ft, refer to Application Guideline and Service Manual -- Air COnditioners and Heat Pump= Using Puron_ Reffigerant.

_-Only when low-pressure switch is used.

:_ Required for low-ambient controller (full modulation feature) and MotorMaste_ Control only.

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 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

cont,'o[ box.

The unit cabinet must have an 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 contactor as shown in Fig. 9.

5000

4500

4000

3500

aooo

_ 2500

i2ooo

1500

1000

50O

f SYSTEM

l r_:_ ................... _VAC;U UM TIGHT

I,_ TOO WET

FTIGHT

DRY SYSTEM

DISCONNECT

PER N.E.C. AND/OR

LOCAL CODES

CONTACTOR

FIELD POWER /W,R,NG '1 OC>

P.ASEONLY S

FIELD GROUND

WIRING @

II[

1 ; ; ; 7 __ J GROUNO

LUG

MINUTES A94025

A95424

Fig. 7--Deep Vacuum Graph

A9_25

EVACUATE]

IBREAK VACUUM WITH DRY NITROGEN]

[EVACUATE]

IBREAK VACUUM WITH DRY NITROGEN I

[EVACUATE]

CHECK FOR TIGHT, DRY SYSTEM I

( F IT HOLDS DEEP VACUUM) I

} CHARGE SYSTEM I

Fig. 8---Triple Evacuation Method

CONNECT CONTROL WIRING

Route 24v control wires through control wiring grommet and

connect leads to control wiring. (See Fig. lI.)

Use No. |8 AWG color-coded, insulated (35°C minimum) wire. If

thermostat is located more than I00 ft from uint, 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 l and must be separated from

incoming power leads.

Use furnace U'ansformer, fan coil transformer, or accessory tram-

former for control power, 24v/40va minimum.

NOTE: Use of available 24v accessories may exceed the mini-

mum 40va power requirement. Determine total transformer load-

ing and increase the transformer capacity or split the load with an

accessory transformer as required.

FINAL WIRING CHECK

IMPORTANT: Check factory wiring and field wire connections

to ensure terminations are secm'ed properly. Check wire routing to

ensure wires are not in contact with tubing, sheet metal, etc.

Step 9---Compressor Crankcase Heater

When equipped with a crankcase heater, furnish power to heater a

minimum of 24 hr before starting unit. To furnish power to heater

only, set thermostat to OFF and close elecuical disconnect to

outdoor unit.

Fig. 9_Line Power Connections

A crankcase heater is required if refrigerant tubing is longer than

50 ft. Refer to Application Guideline and Service Manual --

Residential Split-System Air Conditioners and Heat Pumps using

Puron@ Refrigerant.

Step 10---Install Electrical Accessories

Refer to the individual instructions packaged with kits or acces-

sories when installing.

Step 11--Start-Up

To prevent compressor damage or personal injury, observe

the following:

•Do not overcharge system with refrigerant.

•Do not operate unit in a vacuum or at negative pressure.

•Do not vent refrigerant to atmosphere. Recover during

system repair or final unit disposal.

•Do not disable low-pressure switch.

In scroll-compressor applications:

•Dome temperatures may be hot.

To prevent personal injury wear safety glasses, protective

clothing, and gloves when handling refrigerant and observe

the following:

•Back-seaimg service valves are not equipped with Schrader

valves. Fully back seat (counterclockwise) valve stem before

removing gage-port cap.

•Front-seating service valves are equipped with Schrader

valves.

• 3-phase scroll compressors are rotation sensitive.

• A flashing LED on phas,e monitor indicates reverse rotation.

(See Fig. 10 and Table 3.)

• This will not allow contactur to be energized.

•Disconnect power to unit and interchange 2 field wiring

leads on unit contactor.

Follow these steps to properly start up the system.

I. After system is evacuated, fully back seat (open) liquid and

vapor service valves.

2. Unit is shipped with valve stem(s) front seated (closed) and

caps installed, replace stem caps after system is opened to

refrigerant flow. Replace caps finger-tight and tighten with

wrench an additional 1/12 turn.

3. Close electrical disconnects to energize system.

4. Set room thermostat at desired temperature. Be sure set point

is below indoor ambient temperature.

5. Set room thermostat to COOL and fan control to ON or AUTO

mode, as desired. Operate unit for 15 minutes Check system

refrigerant charge.

SEQUENCE OF OPERATION

Turn on power to indoor and outdoor units. Transformer is

energized.

On a call for cooling, thermostat makes circuits R-Y and R-G. On

three phase models witb scroll compressors, the units are equipped

with a phase monitor to detect in the incoming power is correctly

phased for compressor operation. If the phasing is correct, circuit

R-Y energizes contactor, starting outdoor fan motor and compres-

sor circuit. R-G energizes indoor unit blower relay, starting indoor

blower motor on high speed.

NOTE: If the phasing is incorrect, the contactor will not be

energized. To correct the pha,(mg, interchange any two of the three

power connections on the field side.

When thermostat is satisfied, its contacts open, de-energizing

contactor and blower relay. Compressor and motors stop.

If indoor unit is equipped with a time-delay relay circuit, the

indoor blower runs an additional 90 sec to increase system

efficiency.

CONTACTOR 24VAC COn

(

OFF;NO 24VAC

ON:OK

FLASH:PHASE PROBLEM L2

Fig. lO--Phase Monitor Control

A00010

Table 3--Phase Monitor Led Indicators

LED STATUS

OFF No call for compressor operation

FLASHING Reversed phase

ON Normal

Step 12_heck Charge

UNIT CHARGE

Factory charge and charging method are shown on unit informa-

tion plate. Charge Puron® units using a commercial-type metering

device in manifold hose. Charge refrigerant into suction line.

NOTE: If superheat or subcooling charging conditions are not

favorable, charge must be weighed in accordance with unit rating

plate -+ 0.6 oTJft of 3/8-in. liquid line above or below 15 ft

respectively.

Table 4---Required Liquid-Line Temperature (°F)

REQUIRED SUBCOQLING

LIQUID TEMPERATURE

PRESSURE AT (QF)

SERVICE VALVE 810 12 14 16 18

189 58 56 54 52 50 48

195 60 58 56 54 52 50

202 62 60 58 56 54 52

208 64 62 60 58 56 54

215 66 64 62 60 58 56

222 68 66 64 62 60 58

229 70 68 66 64 62 60

236 72 70 68 66 64 62

243 74 72 70 68 66 64

251 76 74 72 70 68 66

259 78 76 74 72 70 68

266 80 78 76 74 72 70

274 82 80 78 76 74 72

283 84 82 80 78 76 74

291 86 84 82 80 78 76

299 88 86 84 82 80 78

308 90 88 86 84 82 80

317 92 90 88 86 84 82

326 94 92 90 88 86 84

335 96 g4 92 90 88 86

345 98 96 94 92 90 88

354 100 98 96 g4 92 90

364 102 100 98 96 94 92

374 104 102 100 98 96 94

384 106 104 102 100 98 96

395 108 106 104 102 100 98

406 110 108 106 104 102 100

416 112 110 108 106 104 102

427 114 112 110 108 106 104

439 116 114 112 110 108 106

450 118 116 114 112 110 108

462 120 118 116 114 112 110

474 122 120 118 116 114 112

486 124 122 120 118 116 114

499 126 124 122 120 118 116

511 128 126 124 122 120 118

OUTDOOR

TE:MP

(°F) 0 52 54

55 9 12 14

60 710 12

65 -- 6 10

70 -- -- 7

75 -- -- --

80 -- -- --

85 -- -- --

90 -- __ --

95 -- -- --

100 -- -- --

105 -- -- --

110 -- -- --

115 -- -- --

Table 5_Superheat Charging

EVAPORATOR ENTERING AIR TEMPERATURE (_FWB)

56 58 60 62 64 66

17 20 23 26 29 32

15 18 21 24 27 30

13 16 19 21 24 27

10 13 16 19 21 24

6 9 12 15- 18 21

-- 58 12 15 18

-- -- -- 811 15

-- -- -- 59 13

.... 6 10

68 70 72 74 76

35 37 40 42 45

33 35 38 40 43

30 33 36 38 41

27 30 33 36 39

24 28 31 34 37

21 25 28 31 35

19 22 26 30 33

16 20 24 27 31

14 18 22 25 29

12 15 20 23 27

9 13 17 22 26

6 11 15 20 25

-- 814 18 23

EXAMPLE:

To calculate additional charge required for a 25-ft line set:

25 ft - 15 ft = 10 ft X 0.6 ovJft = 6 oz of additional charge

COOLING ONLY PROCEDURE

Units with Cooling Mode Puron® TXV

Units installed with cooling mode TXV require charging by the

subcooling method.

I. Operate unit a nfinimum of 10 minutes before checking

charge.

2. Measure liquid service valve pressure by attaching an accurate

gage to service port.

3. Measure liquid line temperature by attaching an accurate

thermistor type or electronic thermometer to liquid near

outdoor coil.

4. Refer to unit rating plate for required subcooling temperature.

5. Refer to Table 4. Find the point where required subcooling

temperature intersects measured liquid service valve pressure.

6. To obtain required subeooling 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.

Units with Indoor Pistons

Units installed with indoor pistons require charging by the super-

heat method.

The following procedure is valid when indoor airflow is within _

21 percent of its rated CFM.

1. Operate unit a minimum of 10 minutes before checking

charge.

2. Measure suction pressure by attaching an accurate gage to

suction valve service port.

3. Measure suction temperature by attaching an accurate ther-

mistor type or electronic thermometer to suction line at service

valve.

4. Measure outdoor air dry-bulb temperature with thermometer.

5. Measure indoor air (entering indoor coil) wet-bulb tempera-

ture with a sling psychrometer.

10.

II.

Refer to Table 5. Find outdoor temperature and evaporator

entering air wet-bulb temperature. At this intersection, note

superheat.

Refer to Table 6. Find superheat temperature located in item 6

and suction pressure. At this intersection, note suction line

temperature.

If a unit has a higher suction line temperature than charted

temperature, add refrigerant until charted temperature is

reached.

[f unit has a lower suction line temperature than charted

temperature, reclaim refrigerant until charted temperature is

reached.

When adding refrigerant, charge in liquid form into suction

service port using a flow-restricting device.

If outdoor air temperature or pressure at suction valve

changes, charge to new suction line temperature indicated on

chart.

Step 13_Final Cheeks

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 t'tnger tight.

3. Leave User's Manual with owner. Explain system operation

and periofftc 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. See User's Manual for infor-

mation.

SUPERHEAT

TEMP

(°F)

Table 6--Required Suction-Line Temperature (°F WB)

107.8

112.2

4"7

SUCTION PRESSURE AT SERVICE PORT (PSIG)

116.8

121.2

126.0

130.8

138.8

140.8

145,8

LEGEND

24-v FACTORY WIRING

-- 24-V FIELD WIRING

FIELD SPLICE CONNECTION

CONTACTOR

A97368

PURON® (R-410A) QUICK REFERENCE GUIDE

• Puron® refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and

replacement compenents are designed to operate with Puron_.

• Puren_ refrigerant cylinders are rose colored.

• Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400.

•Puron_ systems should be charged with liquid refrigerant. Use acommercial type metedng device in the

manifold hose when charging into suction line with compressor operating.

• Manifold sets shoutd be at least 700 psig high side and 180 psig low side with 550 psig low-side retard.

• Use hoses with 700 psig service pressure rating.

• Leak detectors shouk:l be designed to detect HFC refdgerent.

• Puroo_, as with other HFCs, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from oil.

• Do not leave Puror_ suction line filter doers in line longer than 72 hrs.

• Do not use liquid-line filter dders with rated working pressures less than 60(3 psig.

• Do not install a suction-lLnefilter drier in liquid line.

• POE oils absorb moisture rapidly. Do not expose oil to atmosphere,

• Poe oils may cause damage to certain plastics and roofing materials.

• Wrap all filter dders and service valves with wet cloth when brazing.

• A tactory-appreved liquid-line filter drier is required on every unit.

•Do not use an R-22 TXV.

• If indoor unit is equipped with an R-22 TXV, it must be changed to a Puron_ TXV.

• Never open system to atmosphere while if is under a vacuum.

• When system must be opened for service, recover refrigerant, break vacuum with dry nitrogen prior to

opening to atmosphere. Evacuate to 500 microns pdor to recharging.

• Always replace filter drier after opening system for service.

• Do not vent Purer_ into the atmosphere.

• Do not use cepUlary tube coils.

• Observe all warnings, cautions, and bold text.

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

._ PC 101 Catalog No. 533-80066 printed in U.S,A, Form 381=SA*3SI 12 9_2 38ESA-2SI

Pg Replaces:

CARRIER Air Conditioner/heat Pump(outside Unit) Manual L0211024

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