Carrier 38TDB037300 User Manual SPLIT SYSTEM Manuals And Guides L0211023

CARRIER Air conditioner/heat pump(outside unit) Manual L0211023 CARRIER Air conditioner/heat pump(outside unit) Owner's Manual, CARRIER Air conditioner/heat pump(outside unit) installation guides

User Manual: Carrier 38TDB037300 38TDB037300 CARRIER SPLIT SYSTEM - Manuals and Guides View the owners manual for your CARRIER SPLIT SYSTEM #38TDB037300. Home:Heating & Cooling Parts:Carrier Parts:Carrier SPLIT SYSTEM Manual

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HEAI1NG & COOLING
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38TDB
WeatherMaker TMTwo-Speed
Air Conditioning Unit with Puron®
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
hnproper 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 safe_ 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 these signal words: DANGER, WARNING, CAU-
TION, 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
haz,'u'ds which could result in personal injury or death. CAUTION
is used to identify unsat_ practices which would result in minor
personal injury or product and property damage. NOTE is used to
highlight suggestions which wUl result in enhanced installation.
reliability, or operation.
V_I
Before installing, modifying, or servicing system, main elec-
trical disconnect switch must be in the OPT 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.
INSTALLATION RECOMMENDATIONS
NOTE: In some cases noise in the living m'ea 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.
2. Ensure that vapor and liquid tube diameters are appropriate to
capacity of unit.
A98516
Fig. 1reModel 38TDB
3. Run refrigerant tubes as directly as possible by avoiding
unnecessary, turnsand 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 sur-
rounds 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 fl of
field-supplied or factory accessory tubing. For proper unit opera-
tion, 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-
410At air conditioner liquid line filter drier. Obtain replacement
filter driers from your local distributor.
INSTALLATION
Step l_heck Equipment and Job Site
UNPACK UNIT
Move to final location. Remove carton, taking care not to damage
unit.
Manufacturer recycles the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 101 Catalog No. 533-80059 Pdnted in U.S.A. Form 38TDB-4SI 18-02
Pg Replaces: 38TDB-3SI
-VAPOR TUBE
INSU L/_TION
THROUGH THE WALL
I IJ_-J°'sT
(A_AONTU(NEB_
STRAP----, _
._ 0 _VAPOF1 TUBE
1 IQUID 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 pat_m 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.
NOTE: Unit must be level to within _+2° (-+3/8 in.fit).
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 l side of unit and i2 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 specifi-
cally 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
3/8-1N.DIA TIEDOWN
KNOCKOUTS IN BASEPAN
_L_ _ __ __ --2:_
8 3/16"
Dimensions (In.)
A97548
UNIT SIZE MINIMUM MOUNTING
PAD DIMENSIONS
024 19 X 24
036-060 26 X 32
TIEDOWN KNOCKOUT
LOCATIONS
AB
2-13/16 6-15/16
4 9-3/4
Fig. 3---Mounting Unit to Pad
conditioner, the R-22 TXV must be replaced with a factory-
approved Puron® TXV.
--_ 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
---) I. 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 inieL 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.
2
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
BULB
TUBE
EXPANSION
VALVE
A91277
Fig. 4--TXV Installed
8. Install vapor elbow (see Fig. 5B) with equalizer adapter to
suction tube of line set and suction connection to indoor coil.
Adapter has a l/4-in, male connector or attaching equalizer
tube.
9. Connect equalizer tube of TXV to l/4-in, equalizer fitting on
vapor line adapter.
I0. Attach TXV bulb to horizontal section of suction line using
bulb straps provided. (See Fig. 5C.) Insulate bulb with
factory-supplied insulation tape. (See Fig. 5E.) See Fig. 6 for
correct positioning of sensing bulb.
11. Proceed with remainder of unit installation.
---)"FAN COIL
To obtain efficiency rating for 38TDB037 with FV4ANB006
fancoil TXV must be replaced with factory supplied TXV.
Replacing R-22 TXV or Non-Balance Port Puron TXV
l. 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 panel from front of
cabinet.
3. Remove and save TXV support clamp using the 5/16-in. nut
driver. Save the clamp.
D
E
Fig. _TXV Kit Contents
BULB
iNSULATION
TAPE
A01418
SENSING BULB --
8 O'CLOCK J 4O'CLOCK--
Fig. 6_Positioning of Sensing Bulb
A00399
4. Remove TXV using a backup wrench on flare connections to
prevent damagetotubing.
5. Using wirecuUers, cutequalizertubeoffflushwithvaportube
inside cabinet.
6. Remove bulb from vapor mbe inside cabinet.
7. Braze equalizer stub-tube closed. Use protective barrier as
necessary to prevent damage to drain pan.
----)IMPORTANT: Route the equalizer tubeof the approved Puron®
TXV through suction line connection opening in fitting door prior
to replacing fitting panel around tubing.
8. Install TXV (Fig. 5A) with 3/8-in. copper tubing 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 ori_nal was when removed, using supplied bulb
straps. (See Fig. 5C.) See Fig. 6 for correct positioning of
sensing bulb. Insulate bulb with factory-supplied insulation
tape. (See Fig. 5E.)
11. Route equalizer tube through suction connection opening
(large hole) in fitting panel and install fitting panel in place.
12. Sweat inlet of TXV, masked "IN" to liquid line. Avoid
excessive heat which could damage valve.
13. Install vapor elbow (see Fig. 5B) with equalizer adapter to
vapor line of line set and vapor connection to indoor coil.
Adapter has a l/4-in, male connector for attaching equalizer
tube. (See Fig. 5B.)
14. Connect equalizer tube of TXV by l/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.
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 Pu-
ron® Refrigerant.
Step 6_Make Piping Connections
including solenoid valves.
3
LIQUID-LINE
FILTER-DRIER
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 I ,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 ManualIAir 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.
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 liRefrigerant Connections and
Recommended Liquid and Vapor Tube
Diameters (In.)
LIQUID VAPOR VAPOR (LONG-LINE)
UNIT
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 opera-
tion with indoor unit of same size when connected by 15 fi 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 tow,'u-d 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
Reliigerant tubes and indoor coil should be evacuated to 500
microns. Always break a vacuum with dr3, 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 memsuring this vacuum depth. The
deep vacuum method is the most positive way of _ssuring 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
pmnp is capable of pumping down to 28 in. of mercury and system
does not contain any liquid water. Refer to Fig. 9 and proceed a.s
follows:
I. 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.
50oo--
4500 I I
4000 I • _LEAK IN
35oo I I ._" LEA
o oooll -/
,25ooI |
_: 2000 t• ....... ....
1500 I I, VACUUM TIGHT
"1--1_ _ TOO WET
1000 IIF TIGHT
500 _TEM
01234567
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 ,'ue
not nabbing 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
DISCONNECT
PER N. E. C. AND/OR
LOCAL CODES
[F,ELDPOWE.]
v3, fd A__
[
FIELD GROUND -Q
WIRING j
CONTACTOR
GROUND
LUG A91306
Fig, 10_Line Power Connections
NOTE: Install branch circuit disconnect of adequate size per
NEC to handle unit starting curtera. 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 thl_ugh 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, fee, or death.
Be sure field wiring complies with local and national fire, safety,
and electrlzzal 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
in._tall unit in system where voltage may fluctuate above or below
permissible limits.
NOTEt Use copper wire only between disconnect switch and
unit.
IEVACUATE
IBREAK VACUUM WITH DRY NITROGEN [
_ACUATE]
IBREAK VACUUM WITH DRY NITROGEN [
_ACUATE]
CHECK FOR TIGHT, DRY SYSTEM 1
(|F IT HOLDS DEEP VACUUM) /
ICHARGESYSTEMI
Fig. 9--'rriple Evacuation Method A95425
CONNECT GROUND AND POWER WIRES
Conae.ct ground _'ire to _ound connection in control box for
safety. Connect power wiring to leads provided as shown in Fig.
IO.
CONNECT CONTROL WIR[NG
Route 24v control wires through control wiring grommet and
counect 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 i 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 temainations are secured properly. Check wire muting to
ensure ,,vires are not in contact with tubing, sheet metal, etc.
Step 8_lnstall Electrical Accessories
GENERAL
Refer to the individual instructions packaged with kits or acces-
sories when installing.
Available electrical accessories include latent capacity control. See
Fig. I i 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 ax an FK4C. FV4A, or
40FK fan coil or a 58CVA or 58MVP gas furnace), no LCC is
_ERMIDISTAT
CONTROL
MODEL RH
HEAT STAGE 2_"
COOL STAGE 1 [_"
HEAT STAGE _
COOL STAGE 2
FAN 1_"
24 VAC HOT {_'
DEHUMIDIFY
24 VAC COMM [_
HUMIDIFY [[_].
OUTCOOR_[_
_.°;T,ON7E_
NON-pROGRAMMABLE
THERMOSTAT
MODEL 2S
24 VAC HOT _"
24 VAC COMM [_"
FAN _"
COOL STAGE 2
HEAT STAGE 1
HEAT STAG E2
COOL STAGE 1 {_--
ou_ooN l-i_
: .E COO.l[]
THE RMIDISTAT
CONTROL
MODEL RH
COOL ST_E 1r__,
HEAT STAGE 1 [_
COOL STAGE 2 r _]
FAN [_
24 V_ HOT [_"
24 VAC COMM [_
N_
HUMIDIFY
N_
VARIABLE SPEED
CONDENSING TWO SPEED
FURNACE AIR CONEdTIONER
.... _ "-----_-_
__',
--_-I
FK4C, FV4A
)R 40FK
FANCOIL
_ _ J, JUMPER
-[]-
-tN-
-@
_ 2REMOVE
J2 JUMPER
FOR HEAT
•_ _S,AG,NG
-t_-
[]
See notes 1, 2, 3, 6, 8, 10, and 12
A01495
I_VO-SPEED
AIR CONDITIONER
m
See notes 1, 2, 3, 4. and 7
A01496
SINGLE-STAGE 3_VC_SPEED
FURNACE AIR CONDITIONER
...... _ ......
......@......
--_-I
..... J
I_V(:_ STAG E
TH ERMIDISTAT FURNACE
CONTROL WITH PSC TWO SPEED
MOOEL RH BLOWER MOTOR AIR CONOITIONER
HEAT STAGE 2 _"
COOL STAGE 1
HEAT STAGE 1
COOL STAGE 2 @
FAN [_
24 MAC HOT _"
24 VAC COMM E_'.
bitA
HUMIDIFY
NfA
SENi%_(_ TION _[_J-
COOL STAGE 1
HEAT STAGE 2
HEAT STAGE 1
COOL STAGE 2 @
FAN
24 VAC HOT
24 MAC COM
DEHUMIDIFY
..... I........... J_
..... _ W/Wf
m
.... _ vsv2_.....
.... _- ....... _
.... _ ..... 9:_
I
See notes 1, 2, 3, 6, 8, and 10
A01498
VARIABLE SPEED
_0% NON CONDENSING FUANACE
_AFS
IN ERMIDiSTAT BOARD
CONTROL
t_OEL RH ........... 7
FURNACE 1 17_O-,_E ED
AIR CONDITIONER
BOARD I m
-4 'wql
_-10 _---7
Hu_,o,E¥ _ __I
OUTDOOR
"_NNS_RTEINS_ E _
NON-PROGRAMMABLE
THERMOSTAT
MODEL 2S
24 VAC HOT 1[_
24 VAC COMM {[_
HEAT STAGE 1
COOLSTAGE2 _
FAN {_
COOL STAGE 1 [_-
N/A []
OUTDOORr-ITq
See notes 1, 2. 3, 6. and 8
A01497
Fig. 11--Typical 24V Wiring Diagram
Seen ores 1, 2, 3, 6, 8, 10, and 11
A01499
SINGtE-STAGE TWO-SPEED
FURNACE AIR CONDITIONER
m
.....{33-....._q-[]
.....El-....._q-[]
.... -El- ..... -q --ITSl
..... ]
-q-I'TTl
See notes 1,2, 3, and 5
A01500
6
pROGRAMMABLE
"('_ERMOSTAT
MODEL 2S
IF_N
HEAT STAGS I[_
DOOL STAGE 2
NiA
24 VAC HOT
2_. VAG G'_MM [_-
NiA []
oo_oo°[-l_
NO N .pROGRAIv_t_A_LE
THERMOSTAT
MODEL 2S
24 VAC HOT
24VAt COMM [_I
HEAT STAGE 1
COOL STAGE 2
HE AT STP_3E 2
GOOL STAGE 1
N/A []
OKJTOOO_R
NON-PROGRAMMABLE
THERMOSTAT
MODEL 2S
COOL STAGE 1
FAN [_
HEAT STAGE _
COOL STAGE 2
HEAT STAGE 2
24 VAC HOT
24 VAC COMM [_-
N/A []
o Doo"
SINGLE.STAG E ]3NO_SPEE O
FUHN h,CE#,_R CONDITIONER
-q-[_
See notes 1.2, 3. and 5
A01501
]_VO STAGE
FURNACE WITH TWO.SP_E D
PSC BLOWER A_R CONDITIONER
;-_-_ --- -_-_
i---I-_-E_
See notes 1, 2, 3, 4, and 10
A01502
VARIABLE SPEED
80% NONJ3ONDENSING FUF_NAGE
AF S
NON .pRoGt_AIV, M_BL_ 8OPJ_L)
THERMOSTAT
MODEL _- ---_
F_N_E II TWO'SPEED
AIR GONDI_IONIEF_
COOL STAGE I
HEAT STAGE 2 _"
COOL STAGE 2
24 VAC HOT _*
24 VAC COM
BOARD I
IPLg- d
See note 1.2, 3. 4, and 10
A01504
TWO*STAGE TWO- PED R
F RNAC WITH
_Fs 8L(_WER AIR CON [_T_'ON E
MOTOR
.... $_1
........
....-I I....
..... .....
[_' _-
See notes 1, 2, 3. 5, arid 10
A01503
VARtABLE SPEED
80% NON-CONDENSING FURNACE
_pX3GRAk_f_UE _OA_D
THERMOSTAT
FURNAC E I _'SPEED
HEAT STAGe_ _--!_ ---
STAGE t
COOL ST,_ 2
FA N E_-" ---
24 MAC HOT [_- -- _--
pLg._d
CONNECTIONS
L
NON Jp_)GP_MM_LE
_¢_SRMOSTAT
NK)OEL 2S
,L_:AT STAGE 2 _-
COOL STAGE 1 [_}-
'_E ik_ STP,G E 1
COOL S_.AG E 2
FAN
24 VAC HOT [_
24 VAC COMM [_
Fig. 11--Typical 24V Wiring Diagram (Cont)
See n_tes 1, 2, 3, 5, and 10
A01505
VARIABLE. Sp_'I::D
CONDENSING TWO-SPEE_
FURNACE AIR CONOmONER
)EH
See notes 1.2, 3, and 4
A01506
pROgRAMMABLE
THERMOSTAT
MODEL2S
24 VAC HOT _--
FAN [_
COOL STAGE 1
COOL STAGE 2
HUT STAGE 1
HEAT STAGE 2 _"
24 VAC COMM _- -
N/A []
OUTDOOR _=[_ []
F'K4C FV4A T_V OSPEED
OR 40FK AIR CON DITIONEF_
FAN COtL
] MPER
-NI
REMOVE
J2 JUMPER
_'STAGIN G
._ _FOR HEAT
See notes 1, 2, 3, 5, and 7
A01493
PROGRAMMABLE
THERMOSTAT
MODEL2S
; HEATSTAGE2 r_-].
cool STAGE 1
HEAT STAGE 1 [_
CooL STAGE 2
24 VAC HOT [_
24 VAC COMM
N/A
THERMIDISTAT
CONTROL
MODEL RH
HEAT STAGE 2
HEAT STAGE 1
COOL STAGE 1 @
COOL STAGE 2
rAN [_
24 VAC HOT r_"
DEHUMIDIFY
24 MAC COMM
HUMIOIFV
OUTOOOR_]_Tt
VARIABLE-SPEED
CONOENSING TWO_PEED
FURNACE AIR CONDITIONER
m
.....
.... JilHUMI I
FK4C. FV4A TWO-OpEL D
OR 40FK AIR CONDITIONER
FAN COIL
m
' °ELVEJ2 U2PER
..... _] "FOR HEAT STAGING
......°
.....
...... _]
] , REMOVE
• J1 JUMPER
See notes 1,2, 3, 6, 7, 8, and 9
A01494
See notes1, 2, 3, and 5
A01507
Fig. 11--Typical 24V Wiring Diagram (Cont)
required. The LCC for standard PSC blower products consists of a
standard humidistat which opens contacts on humidity rise and a
pilot duty relay with 24v coil.
NOTE: If an LCC is desired, low-speed airflow must be main-
tained so that a minimum of 300 CFM/ton can be supplied during
high speed LCC operation,
Step 9---Make Airflow Selections
AIRFLOW SELECTION FOR 58CVA/58MVP FURNACES
The 58CVA/58MVP Non-Condensing Variable Speed Furnaces
provide high- and low-speed blower operation to match the
capacities of the compressor at high and low speeds. To select the
recommended airflow and for adjustments to the manual switches
labeled SWI, A/C and CF on the control board refer to the furnace
Installation, Start-Up. and Operating lnsWuctions. The 315AAV
utilizes a control center that allows the installing technician to
select the proper airflows. The A/C switch determines the airflow
during high speed compressor operation. Airflow for hight and low
speed can be calculated at either 350 CFM per ton or 400 CFM per
ton based on the positions of SWl 5.
AIRFLOW SELECTION FOR FK4C, FV4A, OR 40FK FAN
COILS
The FK4C and FV4A 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 FK4C, FV4A,
or 40FK Installation Instructions. The FK4C. FV4A, and 40FK
utilize an EASY SELECT control board that allows the installing
technician to select proper airflows. For adjustments to control
board and recommended A/C SIZE and CFM ADJUST selections.
This fan coil has an adjustable blower off delay factory set at 90
sec for high- and low-speed blower operation.
For other combinations of equipment consult the Product Data
Digest.
AFS
LEGEND
24 VOLT FACTORY WIRING
24 VOLT FIELD WIRING
FIELD SPLICE CONNECTfON
RELAY SPDT, PILOT DUTY
24-V COIL (HN61 KK324)
OR EQUIVALENT
HUMIDISTAT, OPENS ON
HUMIDITY RISE (HL38MG026
AIRFLOW SELECTOR
A01222
WIRING DIAGRAM NOTES:
1. WIRING MUST CONFORM TO NEC OR LOCAL CODES.
2. UNDERLINED LETTER ON THERMOSTAT TERMINAL INDICATES USAGE. FOR EXAMPLE: O/W2 MEANS O IS ENERGIZED
IN COOLING MODE.
3. REFER TO INDOOR UNIT INSTALLATION INSTRUCTIONS FOR ANY ADDITIONAL FEATURES AND WIRING INFORMA-
TION.
4. NON-PROGRAMMABLE MODEL 2S0 I-B, WHEN USED IN AIR CONDITIONING INSTALLATION THE R 19 JUMPER MUST BE
CUT AND REMOVED.
5. PROGRAMMABLE MODEL 2S01-B MUST HAVE DIP SWITCH C ON WHEN USED IN AIR CONDITIONER APPLICATIONS.
6. THERMIDISTAT DIP SWITCH NO. 1 SHOULD BE SET IN OFF POSITION FOR AIR CONDITIONER APPLICATIONS
(FACTORY DEFAULT).
7. AS AN OPTION O/W22CAN CONTROL SECOND-STAGE HEAT.
8. THERMIDISTAT DIP SWITCH NO. 2 SHOULD BE SET IN THE ON POSITION FOR DUAL CAPACITY COMPRESSOR
OPERATION.
9. TO ACTIVATE DEHUMIDIFY FUNCTION ON FK4 OR FV4. REMOVE Jl JUMPER AT FAN COIL CONTROL BOARD.
10. AS AN OPTION, LOCK FURNACE INTO LOW-FIRE OPERATION AND LET O/W2 CONTROL HIGH FIRE OPERATION. REFER
TO FURNACE INSTALLATION INSTRUCTIONS FOR PROPER SETUP.
11. TO ACTIVATE DEHUMIDIFY FEATURE ON CURRENT STYLE, VARIABLE-SPEED, 80 PERCENT NON-CONDENSING,
FURNACE DISCONNECT GREEN (DEHUM) WIRE FROM G ON FURNACE CONTROL BOARD AND CONNECT TO
DEHUMIDIFY TERMINAL DHUM ON THERMIDISTAT.
12. THE DE JUMPERS MUST BE REMOVED TO ENABLE THE DEHUMIDIFICATION FEATURE ON FURNACE.
Table 2--Accessory Usage
REQUIRED FOR REQUIRED FOR
ACCESSORY LONG-MNE SEACOAST
APPUCATIONS* APPUCATIONS
(50-175 FT.) (WITHIN 2 MILES)
Coastal Filter No Yes
Support Feet No Recommended
Puron_ Balance-Port Hard
Shut-off TXV Yest Yes'i"
•For tubing line sets between 50 and 175 ;1horizontal or 20 It 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 twc_speed units.
1"Required for all applications.
9
(D nO
>cD
DO _O
Defrost Time ,.*_' _7 "_"
Selectors r'_J',_- "-'
z
age HJ_=
Low Volt
Connector E-- _ _
Reserved tor
Future Use
F_ [,-IZIIj_]]Z.YJ
Fig. 12_ontrol Board
THERMISTOR CURVE
Low Pressure
€-Switch Connector
_-High Pressure
Switch Connector
4-Thermistor
Connection
] CT°apRaUcnto r
O.D.R Connection
Crankcase Heater
Connection
A01192
90 , I i I I
80_ _ _ I _ I
IIIII
70 -I -_ I _ T -'I-
I\ I I _ 1
40 _----_-- • I • I
I\ i I I I
'
,•,
= I I
n,........
020 40 60 80 100 120
TEMPERATURE(DEG. F)
A91431
Fig. 13--Resistance Values Versus Temperature
Step lO--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 disable low-pressure switch.
Control Box
Side of Unit
-- THERMISTOR PLACED
UNDERNEATH BASE PAN
(ATTACHED TO BASE PAN
WITH ADHESIVE)
A00430
Fig. 14-_View from Top of Base Pan
To prevent personal injury wear safety glasses, protective
clothing, and gloves when handling lefrigerant and observe
the following:
• Back seating service valves are not equipped with Schrader
valves. Fully back seat (counterclockwise) valve stem before
removing gage port cap.
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
crankc:kse heat prior to initial start-up, may result in a compressor
chattering noise 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. Replace stem caps after system is opened to refrig-
erant flow (back seated). Replace caps finger tight and ti_aten
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 set point
is be]ow 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 two-speed system
from operating at high speed until unit has been operating in low
speed for 15 minutes unless there is at least a 5°F difference
between room temperature and themtostat set point. To force high
speed (after a minimum of 2 minutes in low speed), adjust the set
point at least 5° below room ambient.
6. Set room thez_ostat to COOL and fan control to AUTO or ON
as desired. Walt for appropriate time delay(_). Operate unit for
15 minutes. Check refrigerant ch,'trge.
NOTE: If unit has not operated within the past 12 hr or following
a unit power-up, upon the next tbem_ostat high- or low-speed
demand, unit operates for a minimum of 5 minutes in high speed.
10
Step 11_Check Charge
r!_l_1]_
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
Facto_ charge and charging method are shown on pink charging
label. With unit operating, charge Puron® units with liquid using
a commercial type metering device in manifold hose. Charge
refrigerant into suction line.
NOTE: Unit is to be charged in high capacity only. Ch_ging in
low capacity may cause compressor chattering and possible
damage to the compressor.
NOTE: If subcooling charging conditions are not favorable,
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 X 0.6 oz/ft = 6 oz of additional charge.
COOLING ONLY PROCEDURE
1. Operate unit a minimum of 15 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 line near
outdoor coil.
4. Refer to Table 4 for required subcooling temperature.
5. Refer to Table 3. Find the point where required subcooling
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 ff temperature is
lower. Allow a tolerance of ± 3°F.
UNIT CHARGE
Factory. charge ,and charging method are shown on pink charging
label. Puron® refrigerant cylinders contain a dip tube which
allows liquid refrigerant to flow from cylinder in upright
position. Charge Puron units with cylinder in upright position and
acommercial type metering device in manifold hose. Charge
refrigerant into suction line.
NOTE: Unit is to be charged in high capacity only. Charging in
low capacity may cause compressor chartering and possible
damage to the compressor.
NOTE: If subcooling charging conditions are not favorable.
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 fi line
set: 25 ft - 15 ft =IO fi x 0.6 oz/ft =6oz of additional charge.
Step 12--Systern 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 (YI and Y2 or Y2 only) by the
second stage of indoor thermostat. After second stage is satisfied,
Table 3--Required Liquid-Line Temperature (°F)
LIQUID
PRESSURE AT
SERVICE VALVE
(PSIG)
189
195
202
2O8
215
222
229
236
243
251
259
266
274
283
291
299
3O8
317
326
335
345
354
364
374
384
395
406
416
427
439
450
462
474
486
499
511
REQUIRED SUBCOOLING
TEMPERATURE
(°F)
8 12 14 16 18 18
58 56 54 52 50 48
60 58 56 54 52404 50
62 60 58 56 54 52
64 62 60 58 56 54
66 64 62 60 58 56
68 66 64 62 60 58
70 68 66 64 62 60
72 70 68 66 64 62
74 72 70 68 66 64
76 74 72 70 68 66
78 76 74 72 70 68
80 78 76 74 72 70
82 80 78 76 74 72
84 82 80 78 76 74
86 84 82 80 78 76
88 86 84 82 80 78
90 88 86 84 82 80
92 gO 88 86 84 82
94 92 90 88 86 84
96 94 92 90 88 86
98 96 94 92 90 88
100 98 96 94 92 90
102 1O0 98 96 94 92
104 102 100 98 96 94
106 104 102 1O0 98 96
108 106 104 102 100 98
110 108 106 104 102 100
112 110 108 106 104 102
114 112 110 108 106 104
116 114 112 110 108 106
118 116 114 112 110 108
120 118 116 114 112 110
122 120 118 116 114 112
124 122 120 118 116 114
126 124 122 120 118 116
128 126 124 122 120 118
11
the unit returns to low-speed 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 wig 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: When two-speed unit is operating at low speed, system
vapor (suction) pressure will be higher than a standard single-
speed system or high-speed operation.
NOTE: Outdoor fan motor will continue to operate for one
minute after compressor shuts off. when outdoor ambient is greater
than or equal to 100°F.
STATUS FUNCTION LIGHTS
A system control STATUS function light is located on the outdoor
unit control board. (See Fig. 12.) The STATUS light provides
indication signals for several system operations. See Table 5 for
codes and definitions. Table 5 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).
Table 4--High Capacity Only Subcooling
TXV TYPE EXPANSION DEVICE
UNIT HIGH CAPACITY ONLY
SUBCOOLING AT SERVICE VALVE
024 t4°F
036 15°F
037 11°F
048 12°F
060 16°F
Table 5--Control Function LED Code
SIGNAL
CODE DEFINITION IMPORTANCE*
Constant flash NO demand 10
NO pause Stand by
1 flash Low-speed operation 9
w/pause
2 flashes High-speed operation 8
w/pause
3flashes Outdoor thermistor failure 7
w/pause
4 flashes Outdoor coil thermistor failure 6
w/pause
3 flashes
pause Thermistor out of range 5
4flashes
5 flashes
pause Low pressure switch trip 4
1 flash
5 flashes
pause High pressure switch trip 3
2 flashes
6 flashes
w/pause Compressor VJV. trip 2
Constant light
No pause Board failure 1
No flash
*Function light signal order of importance in case of multiple signal request; 1
is most impodant.
FACTORY DEFAULTS
Factory defaults have been provided in the event of failure of
outdoor air thermistor, coil thermistor, and/or furnace interface
jumper.
ONE MINUTE SPEED CHANGE TIME DELAY
When compressor changes speeds from high to low or low to high,
there is a l-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 refriger-
ant. When the compressor operates in single stage operation the
motor reverses direction (rotates counterclockwise). The lower
piston becomes idle and the upper piston compresses refrigerant.
The start and run windings are reversed.
CRANKCASE HEATER OPERATION
The two-speed control board energizes the cr,-mkcase heater during
unit off cycle.
OUTDOOR FAN MOTOR OPERATION
The outdoor unit control energizes outdoor fan any time compres-
sor is operating. The outdoor fan remains energized during the
I-minute compressor speed change time delay and if a pressure
12
switch or compressor overload should open. Outdoor fall motor
will continue to operate lbr one minute after the compressor shuts
off when the outdoor ambient is greater th,'m or equal to 100°F.
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, conlrol shuts compressor off for
15 minutes with outdoor fan nmning. After 15 minutes (provided
there is a call for Y 1 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 limes during a YI request, then low
capacity operation is locked out and control responds to Y2
requests until a reset occurs. If 3 consecutive trips occur in a
combination of YI and Y2 or all Y2 requests, then both low and
high capacity operation will be locked out. The compressor voltage
failure (6 flashes) can be caused by:
•compressor internal overload trip (refer to Table 6 for correct
winding resistance)
•no 240 volt power supply to outdoor unit
• failed compressor contactor(s!
• failure of start relay to pick-up properly
• improper wiring
PRESSURE SWITCH PROTECTION
The outdoor unit is equipped with high- and low-pressure
switches, If the control senses the opening of a high or low
pressure switch, it will respond as follows:
De-energize the compressor low or high speed contactor.
2. Keep the outdoor fan operating for 15 minutes,
3. Display the appropriate error code on the status ligbt. ISee
Table 5)
4. After a 15 minute delay, if Y1 or Y2 inputs are 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 a 15 minute delay, the
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
2-Speed Control
The two-speed control beard controls the following functions:
Low- and high-compressor contactor operation
Outdoor fan motor operation
Crankcase heater operation
Compressor protection
Pressure switch monitoring
Time delays
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 2-pele (3500 RPM ) operation. Refer to Table 6 for correct
winding resistance.
Compressor lnternai 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.
Table 6_Two-Speed Compressor
(Winding Resistance at 70°F ±20 °)
WINDING 024 036-037 048
Start (S-C) 2.280 1.8500.5521.459
Run (R-C) 0.770 0.745
060
0.740
0.356
Compressor Control Contactors
Low and high capacity contactor coils are 24 volts. The electr_mic
control board controls the operation of the low speed tC-L_ and the
high speed (C-H) contactors.
TEMPERATURE THERMISTORS
Thermistors are electronic devices which sense temperature. As
the temperature increases, the resistance decre,x_es. Tbemtistors
are used to sense outdoor ambient and coil temperature. Refer to
Fig. 13 tbe resistance values versus temperature.
If the outdoor ambient or coil thermistor should fail. a fault code
appears at two-speed control.
IMPORTANT: Outdoor Air Thermistor Placement
Mount outdoor air thermistor underneath unit base pan lip on
control box side of the unit as shown in Fig. 14. Attach to base pan
with adhesive tape. A small piece of TXV bulb insulation tape may
be used.
IMPORTANT: If outdoor air thermistor is not properly placed
underneath bose pan, unit may see nuisance thermistor out of
frame faults.
Step 1a--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 co\ers. Securely fasten all panels and
covers.
2. Tighten service valve stem caps to 1/12-turn past finger tight.
3. Leave Owner'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.
13
DU___TY _,
CONNECTION DIAGRAM u eLK
208/230- 1- 60 L2..... _ Ye_ _aLK
BJ
RE]) I BU--
LL22
PLll _1 21 _141 51[_
HP/AC C SEV RVS C HI LO 9[,2 !
LPS
b'lA_r N_I
i
Fig. 15---Wiring Diagram--024, 036, 048
A01513
14
,_u,,2,a,,15,C:L:nt_ I ] I_
I-IP/ACC EXV ri_ CFI LO_ t _
u'slaw j F-,_ k_ _ \
"_-II_' 14q0_
Y'I_7r-- • lvc _ •
,wl_] - ..... , ABC D Cl2f _tu
CLV,OJ----_ ,, , _ _'
__ , ,,, _ t2 _
RI_-7', l,,',, ' CCH_
I i ' I_P Ooi
L ' i
7
10 ImOORtiNT
RR)
NoIrEWI0
BRN
i
Fig. 16---Wiring Diagrams037
A01439
15
CONNECTION DIAGRAM El....... eLK
PUI 1 k 21 3 L 41 51_ I
HP/AC C S_ RVS C HI LO P[2
OAT
COMM STA]IJG OCT
vc
VH
A B C 0 ODF_
_ L2
,1 CCH :
L 1
F
TO INDOOR UNIT
--> Fig. 17--Wiring Diagram-_060
A02212
Copyright 2002 CARRIER Coq_. ° 7310 W. Morris St. °Indianapolis, IN 46231 38tdb4si
Manufacturer rescues the right to discontinue, or change at any time, specifications or dq_slgns without notice and without ihcurring Obligations.
PC 101 Catalog No. 533-80059 Printed in U.S.A. Form 38TDB-4SI 16 8-02 38TDB-3Sl
Pg Replaces:

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