38TDB
WeatherMaker™ Two-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
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory-authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions 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.
A98516
Fig. 1—Model 38TDB
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.
3. Run refrigerant tubes as directly as possible by avoiding
unnecessary turns and bends.
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
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.
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.)
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.
9. Isolate hanger straps from insulation by using metal sleeves
bent to conform to shape of insulation.
Outdoor unit contains system refrigerant charge for operation with
indoor unit of the same size when connected by 15 ft of
field-supplied or factory accessory tubing. For proper unit opera-
tion, check refrigerant charge using charging information located
on control box cover.
Puron® (R-410A) systems operate at higher pressures than
standard R-22 systems. Be certain that service equipment is
rated for Puron®. Some R-22 service equipment may not be
acceptable. Check with your distributor.
IMPORTANT: Maximum liquid-line size is 3/8 in. O.D. for all
residential applications.
IMPORTANT: Only install the factory-supplied Puron® (R-
410A) air conditioner liquid line filter drier. Obtain replacement
filter driers from your local distributor.
INSTALLATION RECOMMENDATIONS
NOTE: In some cases noise in the living area has been traced to
gas pulsations from improper installation of equipment.
INSTALLATION
Step 1—Check Equipment and Job Site
1. Locate unit away from windows, patios, decks, etc. where unit
operation sound may disturb customer.
UNPACK UNIT
2. Ensure that vapor and liquid tube diameters are appropriate to
capacity of unit.
Move to final location. Remove carton, taking care not to damage
unit.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book
Tab 3a 2a
1
4
PC 101
Catalog No. 533-80059
Printed in U.S.A.
Form 38TDB-4SI
Pg 1
8-02
Replaces: 38TDB-3SI
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SENSING BULB
COIL
STRAP
SENSING
BULB
EQUALIZER
TUBE
8 O'CLOCK
4 O'CLOCK
A00399
Fig. 6—Positioning of Sensing Bulb
THERMOSTATIC
EXPANSION
VALVE
4. Remove TXV using a backup wrench on flare connections to
prevent damage to tubing.
A91277
5. Using wire cutters, cut equalizer tube off flush with vapor tube
inside cabinet.
→
Fig. 4—TXV Installed
6. Remove bulb from vapor tube inside cabinet.
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 1/4-in. male connector or attaching equalizer
tube.
7. Braze equalizer stub-tube closed. Use protective barrier as
necessary to prevent damage to drain pan.
→ IMPORTANT: Route the equalizer tube of the approved Puron®
TXV through suction line connection opening in fitting door prior
to replacing fitting panel around tubing.
9. Connect equalizer tube of TXV to 1/4-in. equalizer fitting on
vapor line adapter.
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.
10. 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.
9. Reinstall TXV support clamp (removed in item 3).
11. Proceed with remainder of unit installation.
10. Attach TXV bulb to vapor tube inside cabinet, in same
location as original 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.)
→ 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
11. Route equalizer tube through suction connection opening
(large hole) in fitting panel and install fitting panel in place.
→ 1. Remove any existing refrigerant and ensure coil has not been
exposed to atmospheric pressure for more than 15 minutes.
12. Sweat inlet of TXV, marked “IN” to liquid line. Avoid
excessive heat which could damage valve.
2. Remove coil access panel and fitting panel from front of
cabinet.
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 1/4-in. male connector for attaching equalizer
tube. (See Fig. 5B.)
3. Remove and save TXV support clamp using the 5/16-in. nut
driver. Save the clamp.
14. Connect equalizer tube of TXV by 1/4-in. equalizer fitting, on
vapor line adapter. Use backup wrench to prevent damage to
equalizer fitting.
B
15. Proceed with the remainder of unit installation.
INLET
LONG-LINE APPLICATIONS
A
D
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.
COIL
E
Step 6—Make Piping Connections
BULB
INSULATION
TAPE
C
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.
A01418
Fig. 5—TXV Kit Contents
3
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LIQUID-LINE
FILTER-DRIER
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.
LIQUID
SERVICE
VALVE
If ANY refrigerant tubing is buried, provide 6–in. vertical rise
at service valve. Refrigerant tubing lengths up to 36 in. may
be buried without further special consideration. Do not bury
lines for lengths over 36 in.
A01215
To prevent damage to unit or service valves, observe the
following:
• Use a brazing shield.
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.
• Wrap service valves with wet cloth or use a heat sink
material.
2. Braze filter drier between connector tube and liquid tube to
indoor coil. Flow arrow must point toward indoor coil.
Outdoor units may be connected to indoor section using accessory
tubing package or field-supplied refrigerant grade tubing of correct
size and condition. Tubing diameters listed in Table 1 are adequate
for equivalent lengths up to 50 ft. For tubing requirements beyond
50 ft, substantial capacity and performance losses will occur.
Follow the recommendations in the Application Guideline and
Service Manual—Air Conditioners and Heat Pumps Using Pu-
ron® Refrigerant to minimize losses.
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.
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.
LEAK CHECKING
Leak test all joints in indoor, outdoor, and refrigerant tubing.
EVACUATE REFRIGERANT TUBING AND INDOOR COIL
Table 1—Refrigerant Connections and
Recommended Liquid and Vapor Tube
Diameters (In.)
Never use the system compressor as a vacuum pump.
LIQUID
Connection
Diameter Diameter Diameter Diameter Diameter Diameter
VAPOR
VAPOR (LONG-LINE)
UNIT
SIZE
Tube
Connection
Tube
Connection Tube
Refrigerant tubes and indoor coil should be evacuated to 500
microns. Always break a vacuum with dry nitrogen.
024
036
3/8
3/8
3/8
3/8
3/8
3/8
3/8
3/8
5/8
3/4
7/8
7/8
5/8
3/4
5/8
3/4
7/8
7/8
3/4
7/8
Deep Vacuum Method
037, 048
060
7/8
7/8
The deep vacuum method requires a vacuum pump capable of
pulling a minimum vacuum of 500 microns and a vacuum gage or
thermistor capable of accurately measuring this vacuum depth. The
deep vacuum method is the most positive way of assuring a system
is free of air and liquid water. (See Fig. 8.)
1-1/8
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.
Triple Evacuation Method
OUTDOOR UNIT CONNECTED TO FACTORY-APPROVED
INDOOR UNIT
The triple evacuation method should only be used when vacuum
pump is capable of pumping down to 28 in. of mercury and system
does not contain any liquid water. Refer to Fig. 9 and proceed as
follows:
Outdoor unit contains correct system refrigerant charge for opera-
tion with indoor unit of same size when connected by 15 ft of
field-supplied or factory-accessory tubing. Check refrigerant
charge for maximum efficiency
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.
Installation of filter drier in liquid line is required.
INSTALL LIQUID-LINE FILTER DRIER
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.
Installation of filter drier in liquid line is required. Refer to Fig. 7
and install filter drier as follows:
4
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DISCONNECT
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
PER N. E. C. AND/ OR
LOCAL CODES
CONTACTOR
LEAK IN
SYSTEM
FIELD POWER
WIRING
VACUUM TIGHT
TOO WET
FIELD GROUND
WIRING
GROUND
LUG
TIGHT
DRY SYSTEM
A91306
A95424
0
1
2
3
4
5
6
7
Fig. 10—Line Power Connections
MINUTES
A95424
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.
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.
ROUTE GROUND AND POWER WIRES
Remove access panel to gain access to unit wiring. Extend wires
from disconnect through power wiring hole provided and into unit
control box. Size wires per NEC but not smaller than minimum
wire size shown in Product Data Digest.
FINAL TUBING CHECK
IMPORTANT: Check to be certain factory tubing on both indoor
and outdoor unit has not shifted during shipment. Ensure tubes are
not rubbing against each other or any sheet metal. Pay close
attention to feeder tubes, making sure wire ties on feeder tubes are
secure and tight.
The unit cabinet must have as uninterrupted or unbroken
ground to minimize personal injury if an electrical fault
should occur. The ground may consist of electrical wire or
metal conduit when installed in accordance with existing
electrical codes. Failure to follow this warning can result in an
electric shock, fire, or death.
Step 7—Make Electrical Connections
To avoid personal injury or death, do not supply power to unit
with compressor terminal box cover removed.
CONNECT GROUND AND POWER WIRES
Be sure field wiring complies with local and national fire, safety,
and electrical codes, and voltage to system is within limits shown
on unit rating plate. Contact local power company for correction of
improper voltage. See unit rating plate for recommended circuit
protection device.
NOTE: Operation of unit on improper line voltage constitutes
abuse and could affect unit reliability. See unit rating plate. Do not
install unit in system where voltage may fluctuate above or below
permissible limits.
Connect ground wire to ground connection in control box for
safety. Connect power wiring to leads provided as shown in Fig.
10.
CONNECT CONTROL WIRING
Route 24v control wires through control wiring grommet and
connect to leads provided in control box. (See Fig. 11.)
Use No. 18 AWG color-coded, insulated (35°C minimum) wire. If
thermostat is located more than 100 ft from unit, as measured
along the control voltage wires, use No. 16 AWG color-coded wire
to avoid excessive voltage drop.
NOTE: Use copper wire only between disconnect switch and
unit.
EVACUATE
All wiring must be NEC Class 1 and must be separated from
incoming power leads.
BREAK VACUUM WITH DRY NITROGEN
The outdoor unit requires a minimum of 27va, 24vac control
power.
WAIT
IMPORTANT: Check factory wiring and wire connections to
ensure terminations are secured properly. Check wire routing to
ensure wires are not in contact with tubing, sheet metal, etc.
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
Step 8—Install Electrical Accessories
GENERAL
Refer to the individual instructions packaged with kits or acces-
sories when installing.
EVACUATE
Available electrical accessories include latent capacity control. See
Fig. 11 for typical accessory wiring diagrams.
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
LATENT CAPACITY CONTROL (LCC)
The purpose of an LCC is to provide a dehumidification mode to
assure a 75 percent or less system sensible heat ratio. If indoor unit
installed contains an ECM blower (such as an FK4C, FV4A, or
40FK fan coil or a 58CVA or 58MVP gas furnace), no LCC is
CHARGE SYSTEM
A95425
Fig. 9—Triple Evacuation Method
5
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VARIABLE-SPEED
CONDENSING
FURNACE
THERMIDISTAT
CONTROL
MODEL RH
TWO-STAGE
FURNACE
THERMIDISTAT
CONTROL
MODEL RH
TWO-SPEED
AIR CONDITIONER
WITH PSC
TWO-SPEED
AIR CONDITIONER
BLOWER MOTOR
O/W2
HEAT STAGE 2
COOL STAGE 1
W2
O/W2
W2
Y1
Y2
R
Y1/W2
Y1
Y2
Y1/W2
W/W1
W/W1
Y/Y2
HEAT STAGE 1
COOL STAGE 2
W/W1
Y/Y2
W/W1
Y/Y2
G
R
FAN
G
R
G
R
G
R
24 VAC HOT
R
C
DEHUM
DE JUMPER
C
DHUM
C
DEHUMIDIFY
C
HUM
24 VAC COMM
HUMIDIFY
N/A
C
DHUM
HUM
HUM
HUMIDIFIER
(24 VAC)
B
B
OUTDOOR
SENSOR
S1
S2
OUTDOOR
SENSOR
CONNECTION
S1
S2
See notes 1, 2, 3, 6, 8, 10, and 12
A01495
NON-PROGRAMMABLE
THERMOSTAT
FK4C, FV4A
OR 40FK
FAN COIL
TWO-SPEED
AIR CONDITIONER
MODEL 2S
DH
J1 JUMPER
24 VAC HOT
24 VAC COMM
FAN
R
C
R
C
R
C
G
G
COOL STAGE 2
HEAT STAGE 1
Y/Y2
W/W1
Y/Y2
W1
Y2
REMOVE
J2 JUMPER
FOR HEAT
STAGING
HEAT STAGE 2
COOL STAGE 1
O/W2
Y1
W2
Y1
Y1
O
N/A
B
OUTDOOR
SENSOR
S1
CONNECTION
S2
See notes 1, 2, 3, 4, and 7
A01496
THERMIDISTAT
CONTROL
MODEL RH
TWO-SPEED
AIR CONDITIONER
SINGLE-STAGE
FURNACE
N/A
O/W2
Y1
Y2
Y1/ W2
COOL STAGE 1
W/W1
Y/Y2
HEAT STAGE 1
COOL STAGE 2
W
Y
FAN
G
R
G
R
R
C
24 VAC HOT
C
24 VAC COMM
C
DHUM
HUM
N/A
HUMIDIFIER
(24 VAC)
HUMIDIFY
N/A
B
OUTDOOR
SENSOR
S1
S2
OUTDOOR
SENSOR
CONNECTION
See notes 1, 2, 3, 6, and 8
A01497
VARIABLE SPEED
PROGRAMMABLE
THERMOSTAT
MODEL 2S
SINGLE-STAGE
FURNACE
TWO-SPEED
80% NON-CONDENSING FURNACE
AIR CONDITIONER
O
AFS
BOARD
NON-PROGRAMMABLE
THERMOSTAT
Y1
COOL STAGE 1
FAN
Y1/W2
G
Y1
MODEL 2S
G
W
Y
TWO-SPEED
AIR CONDITIONER
FURNACE
BOARD
COOL STAGE 1 Y1/W2
HEAT STAGE 1 W/W1
COOL STAGE 2 Y/Y2
O/W2
W2
HEAT STAGE 2
Y1
Y2
Y2
R
HEAT STAGE 1
COOL STAGE 2
FAN
W/W1
Y/Y2
W/W1
Y/Y2
N/A
O/W2
R
R
C
24 VAC HOT
G
R
G
R
R
C
24 VAC HOT
24 VAC COMM
N/A
C
B
C
COM
HUM
24 VAC COM
C
OUTDOOR
SENSOR
S1
DEHUM
PL9-10
S2
CONNECTION
N/A
B
See notes 1, 2, 3, and 5
A01501
S1
S2
OUTDOOR
SENSOR
CONNECTIONS
TWO-STAGE
FURNACE WITH
PSC BLOWER
MOTOR
NON-PROGRAMMABLE
THERMOSTAT
TWO-SPEED
MODEL 2S
AIR CONDITIONER
See note 1, 2, 3, 4, and 10
A01504
24 VAC HOT
R
C
R
C
R
C
VARIABLE SPEED
80% NON-CONDENSING FURNACE
24 VAC COMM
O
AFS
BOARD
PROGRAMMABLE
THERMOSTAT
MODEL 2S
HEAT STAGE 1 W/W1
W/W1
Y1
COOL STAGE 2
FAN
Y/Y2
G
Y2
Y/Y2
G
TWO-SPEED
AIR CONDITIONER
FURNACE
BOARD
COOL STAGE 1 Y1/W2
O/W2
W2
HEAT STAGE 2
Y1
Y2
HEAT STAGE 1
COOL STAGE 2
FAN
W/W1
Y/Y2
W/W1
Y/Y2
HEAT STAGE 2
COOL STAGE 1
N/A
W2
O/W2
Y1
Y1
G
R
G
R
R
C
HUM
B
24 VAC HOT
S1
S2
OUTDOOR
SENSOR
COM
HUM
24 VAC COM
C
CONNECTION
DEHUM
PL9-10
See notes 1, 2, 3, 4, and 10
A01502
TWO-STAGE
N/A
B
NON-PROGRAMMABLE
THERMOSTAT
TWO-SPEED
FURNACE WITH
PSC BLOWER
MOTOR
AIR CONDITIONER
S1
S2
MODEL 2S
OUTDOOR
SENSOR
CONNECTIONS
COOL STAGE 1
FAN
Y1/W2
G
Y1
See notes 1, 2, 3, 5, and 10
A01505
G
W/W1
VARIABLE-SPEED
NON-PROGRAMMABLE
THERMOSTAT
HEAT STAGE 1 W/W1
COOL STAGE 2 Y/Y2
HEAT STAGE 2 O/W2
CONDENSING
FURNACE
TWO-SPEED
MODEL 2S
AIR CONDITIONER
Y2
R
Y/Y2
W2
R
O/W2
Y1
HEAT STAGE 2
COOL STAGE 1
W2
Y1
Y2
R
R
24 VAC HOT
W/W1
Y/Y2
HEAT STAGE 1
COOL STAGE 2
W/W1
Y/Y2
G
R
24 VAC COMM
N/A
C
B
C
C
FAN
G
R
24 VAC HOT
HUM
DEHUM
DE JUMPER
OUTDOOR
SENSOR
S1
C
C
S2
HUM
CONNECTION
24 VAC COMM
N/A
C
See notes 1, 2, 3, 5, and 10
A01503
B
S1
S2
OUTDOOR
SENSOR
CONNECTION
See notes 1, 2, 3, and 4
A01506
Fig. 11—Typical 24V Wiring Diagram (Cont)
7
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PROGRAMMABLE
THERMOSTAT
MODEL 2S
THERMIDISTAT
CONTROL
MODEL RH
FK4C, FV4A
OR 40FK
FAN COIL
TWO-SPEED
AIR CONDITIONER
FK4C, FV4A
OR 40FK
FAN COIL
TWO-SPEED
AIR CONDITIONER
HEAT STAGE 2 O/W2
HEAT STAGE 1 W/W1
W2
W1
DH
R
REMOVE J2 JUMPER
FOR HEAT STAGING
J1
JUMPER
24 VAC HOT
FAN
R
R
Y1/W2
Y/Y2
COOL STAGE 1
COOL STAGE 2
Y1
Y2
Y1
Y/Y2
G
G
G
Y1
Y/Y2
COOL STAGE 1
COOL STAGE 2
HEAT STAGE 1
HEAT STAGE 2
Y1
Y2
Y1/W2
Y/Y2
G
R
FAN
R
R
O
REMOVE
24 VAC HOT
W1
W2
W/W1
O/W2
J2 JUMPER
FOR HEAT
STAGING
REMOVE
J1 JUMPER
DH
C
DHUM
DEHUMIDIFY
C
C
24 VAC COMM
HUMIDIFY
N/A
24 VAC COMM
N/A
C
O
C
C
B
HUM
HUMIDIFIER
(24 VAC)
B
OUTDOOR
SENSOR
S1
OUTDOOR
SENSOR
S1
S2
OUTDOOR
SENSOR
CONNECTION
CONNECTION
S2
See notes 1, 2, 3, 5, and 7
A01493
See notes 1, 2, 3, 6, 7, 8, and 9
A01494
VARIABLE-SPEED
CONDENSING
FURNACE
PROGRAMMABLE
THERMOSTAT
MODEL 2S
TWO-SPEED
AIR CONDITIONER
O/W2
HEAT STAGE 2
COOL STAGE 1
W2
Y1
Y2
R
Y1/W2
W/W1
Y/Y2
HEAT STAGE 1
COOL STAGE 2
W/W1
Y/Y2
G
R
FAN
G
R
24 VAC HOT
DEHUM
DE JUMPER
C
C
HUM
24 VAC COMM
N/A
C
B
S1
S2
OUTDOOR
SENSOR
CONNECTION
See notes 1, 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.
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.
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 SW1, A/C and CF on the control board refer to the furnace
Installation, Start-Up, and Operating Instructions. 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 SW1-5.
For other combinations of equipment consult the Product Data
Digest.
8
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LEGEND
24 VOLT FACTORY WIRING
24 VOLT FIELD WIRING
FIELD SPLICE CONNECTION
RELAY SPDT, PILOT DUTY
24-V COIL (HN61KK324)
OR EQUIVALENT
R1
H
HUMIDISTAT, OPENS ON
HUMIDITY RISE (HL38MG026)
AIRFLOW SELECTOR
AFS
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 2S01–B, WHEN USED IN AIR CONDITIONING INSTALLATION THE R19 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/W2CAN 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 J1 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
LONG-LINE
REQUIRED FOR
SEACOAST
APPLICATIONS
(WITHIN 2 MILES)
ACCESSORY
APPLICATIONS*
(50-175 FT.)
Coastal Filter
Support Feet
No
No
Yes
Recommended
Puron® Balance-Port Hard
Shut-off TXV
Yes†
Yes†
* 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.
† Required for all applications.
9
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Control Box
Side of Unit
THERMISTOR PLACED
UNDERNEATH BASE PAN
(ATTACHED TO BASE PAN
WITH ADHESIVE)
CEBD430439-03A
SS0ID
C2
R38
R33
R9
J1
Low Pressure
Switch Connector
High Pressure
Switch Connector
Thermistor
A00430
1
PL1
PL2
PL3
PL4
C31
R61
1
1
Fig. 14—View from Top of Base Pan
R65
PL5
Connection
PWM2
PWM1
DEFROST
TIME (MIN)
R39
To prevent personal injury wear safety glasses, protective
clothing, and gloves when handling refrigerant 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.
S1
120
R44
R42
Defrost Time
Selectors
30
60
C18
C16
BRN
1
2
60
30
R36
90
To Run
Capacitor
BLU
0
Y2
Y1
W1
C
BLK
YEL
RED
Thermostat
Low Voltage
Connector
C O M M S TAT U S
D52
CEPL130439-01
K1
O.D.F. Connection
Crankcase Heater
Connection
D51
R
R89
R85
R91
R86
R87
HK38EA001
A
B
C
D
Reserved for
Future Use
Do not vent refrigerant to atmosphere. Recover during system
repair or final unit disposal.
A01192
Fig. 12—Control Board
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.
THERMISTOR CURVE
90
80
NOTE: Starting the compressor without a minimum of 12 hr of
crankcase heat prior to initial start-up, may result in a compressor
chattering noise and possible damage to the compressor.
70
60
50
40
30
20
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 tighten
additional 1/12 turn (20 ft-lb torque) with wrench.
10
4. Close electrical disconnects to energize system.
0
0
5. Set room thermostat at desired temperature. Be sure set point
is below indoor ambient and is set low enough to energize
desired speed.
20
40
60
80
100
120
TEMPERATURE (DEG. F)
A91431
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 thermostat 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.
Fig. 13—Resistance Values Versus Temperature
Step 10—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.
6. Set room thermostat to COOL and fan control to AUTO or ON
as desired. Wait for appropriate time delay(s). Operate unit for
15 minutes. Check refrigerant charge.
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 in high speed.
10
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Step 11—Check Charge
Table 3—Required Liquid-Line Temperature (°F)
REQUIRED SUBCOOLING
TEMPERATURE
(°F)
LIQUID
PRESSURE AT
SERVICE VALVE
(PSIG)
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.
8
12
56
14
54
16
52
18
50
18
48
189
195
202
208
215
222
229
236
243
251
259
266
274
283
291
299
308
317
326
335
345
354
364
374
384
395
406
416
427
439
450
462
474
486
499
511
58
60
58
56
54
52404
54
50
62
60
58
56
52
64
62
60
58
56
54
UNIT CHARGE
66
64
62
60
58
56
Factory 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.
68
66
64
62
60
58
70
68
66
64
62
60
72
70
68
66
64
62
74
72
70
68
66
64
NOTE: Unit is to be charged in high capacity only. Charging in
low capacity may cause compressor chattering and possible
damage to the compressor.
76
74
72
70
68
66
78
76
74
72
70
68
80
78
76
74
72
70
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.
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
90
88
86
84
82
COOLING ONLY PROCEDURE
94
92
90
88
86
84
1. Operate unit a minimum of 15 minutes before checking
charge.
96
94
92
90
88
86
98
96
94
92
90
88
2. Measure liquid service valve pressure by attaching an accurate
gage to service port.
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
98
96
94
92
90
100
102
104
106
108
110
112
114
116
118
120
122
124
126
98
96
94
92
3. Measure liquid line temperature by attaching an accurate
thermistor type or electronic thermometer to liquid line near
outdoor coil.
100
102
104
106
108
110
112
114
116
118
120
122
124
98
96
94
100
102
104
106
108
110
112
114
116
118
120
122
98
96
100
102
104
106
108
110
112
114
116
118
120
98
4. Refer to Table 4 for required subcooling temperature.
100
102
104
106
108
110
112
114
116
118
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 if 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
a commercial type metering device in manifold hose. Charge
refrigerant into suction line.
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 will 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: Unit is to be charged in high capacity only. Charging in
low capacity may cause compressor chattering and possible
damage to the compressor.
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: 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.
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.
Step 12—System Functions and Sequence of Operation
STATUS FUNCTION LIGHTS
The outdoor unit control system has special functions. The
following is an overview of the two-speed control functions:
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.
COOLING OPERATION
This product utilizes a 2-stage cooling indoor thermostat. With a
call for first stage cooling (Yl), the outdoor fan and low capacity
compressor are energized. If low capacity cannot satisfy cooling
demand, high capacity is energized (Yl and Y2 or Y2 only) by the
second stage of indoor thermostat. After second stage is satisfied,
NOTE: Only one code will be displayed on the outdoor unit
control board (the most recent, with the highest priority).
11
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switch or compressor overload should open. Outdoor fan motor
will continue to operate for one minute after the compressor shuts
off when the outdoor ambient is greater than or equal to 100°F.
Table 4—High Capacity Only Subcooling
TXV TYPE EXPANSION DEVICE
UNIT
HIGH CAPACITY ONLY
COMPRESSOR VOLTAGE FAILURE (6 FLASHES)
SUBCOOLING AT SERVICE VALVE
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, control shuts compressor off for
15 minutes with outdoor fan running. After 15 minutes (provided
there is a call for Y1 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 times during a Y1 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 Yl 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:
024
036
037
048
060
14°F
15°F
11°F
12°F
16°F
Table 5—Control Function LED Code
SIGNAL
IMPORTANCE*
CODE
DEFINITION
Constant flash
No pause
No demand
Stand by
10
1 flash
w/pause
•
compressor internal overload trip (refer to Table 6 for correct
winding resistance)
Low-speed operation
High-speed operation
Outdoor thermistor failure
9
8
7
2 flashes
w/pause
•
•
•
•
no 240 volt power supply to outdoor unit
failed compressor contactor(s)
failure of start relay to pick-up properly
improper wiring
3 flashes
w/pause
4 flashes
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:
1. 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 light. (See
Table 5)
4. After a 15 minute delay, if Yl 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.
FACTORY DEFAULTS
MAJOR COMPONENTS
Factory defaults have been provided in the event of failure of
outdoor air thermistor, coil thermistor, and/or furnace interface
jumper.
2-Speed Control
The two-speed control board controls the following functions:
- Low- and high-compressor contactor operation
- Outdoor fan motor operation
- Crankcase heater operation
- Compressor protection
- Pressure switch monitoring
- Time delays
ONE MINUTE SPEED CHANGE TIME DELAY
When compressor changes speeds from high to low or low to high,
there is a 1-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.
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-pole (3500 RPM) operation. Refer to Table 6 for correct
winding resistance.
CRANKCASE HEATER OPERATION
The two-speed control board energizes the crankcase heater during
unit off cycle.
Compressor Internal 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.
OUTDOOR FAN MOTOR OPERATION
The outdoor unit control energizes outdoor fan any time compres-
sor is operating. The outdoor fan remains energized during the
1-minute compressor speed change time delay and if a pressure
with adhesive tape. A small piece of TXV bulb insulation tape may
be used.
Table 6—Two-Speed Compressor
(Winding Resistance at 70°F ± 20°)
IMPORTANT: If outdoor air thermistor is not properly placed
underneath base pan, unit may see nuisance thermistor out of
frame faults.
WINDING
Start (S-C)
Run (R-C)
024
036–037
1.850
048
060
2.280
0.770
1.459
0.552
0.740
0.356
0.745
Step 13—Final Checks
IMPORTANT: Before leaving job, be sure to do the following:
Compressor Control Contactors
1. Ensure that all wiring and tubing is secure in unit before
adding panels and covers. Securely fasten all panels and
covers.
Low and high capacity contactor coils are 24 volts. The electronic
control board controls the operation of the low speed (C-L) and the
high speed (C-H) contactors.
2. Tighten service valve stem caps to 1/12-turn past finger tight.
TEMPERATURE THERMISTORS
3. Leave Owner’s Manual with owner. Explain system operation
and periodic maintenance requirements outlined in manual.
Thermistors are electronic devices which sense temperature. As
the temperature increases, the resistance decreases. Thermistors
are used to sense outdoor ambient and coil temperature. Refer to
Fig. 13 for resistance values versus temperature.
4. Fill out Dealer Installation Checklist and place in customer
file.
CARE AND MAINTENANCE
If the outdoor ambient or coil thermistor should fail, a fault code
appears at two-speed control.
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.
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
13
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DUAL CAPACITY
CONNECTION DIAGRAM L1
BLK
BLK
RED
L2
YEL
208 / 230 - 1 - 60
BLK
POWER SUPPLY
CH
11
C L
11
23
23
EQUIP GND
21
21
YEL
BLU
NOTE #11
COMP
BRN
BLK
R
S
C
RED
BLU
BRN
BRN
1
2
3
4
5
1
2
PL1
HP/AC
C
SEV RVS
C
HI LO PL2
BRN
START
CAP
LPS
LPS
1
2
3
YEL/PNK
YEL/PNK
PL3
C
H
COMP
CAP
FORCED
DEFROST
HPS
OAT
OCT
BRN
HPS
PL4
BLU/PNK
BLU/PNK
1
2
YEL
DEFROST
TIME (MIN)
5
1
-t°
-t°
BLU
OAT
PL5
BLK
BLK
BRN
BRN
1
2
2
BLU
START
RELAY
BRN
4
5
OCT
O
COMM STATUS
Y
2
VC
VH
BRN
BLU
OFM
RED
YEL
Y
1
YEL
FAN CAP
W
BLK
1
A
B
C
D
ODF
L 2
BLK
YEL
RED
BRN
BLK
C
R
CCH
CCH
TO INDOOR UNIT
Fig. 15—Wiring Diagram—024, 036, 048
A01513
14
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DUAL CAPACITY
CONNECTION DIAGRAM L1
BLK
BRN
BLK
L2
YEL
208 / 230 - 1 - 60
RED
BLU
POWER SUPPLY
CH
11
11
21
23
23
23
23
C L
EQUIP GND
21
YEL
BLU
NOTE #10
COMP
BRN
BLK
R
BLU
BLU
C
RED
BLU
BRN
S
BRN
1
2
3
4
5
1
2
PL1
HP/AC
C
EXV RVS
C
HI LO PL2
BRN
LPS
LPS
START
CAP
1
2
3
YEL/PNK
YEL/PNK
PL3
FORCED
DEFROST
C
H
COMP
CAP
HPS
OAT
OCT
BRN
HPS
PL4
BLU/PNK
BLU/PNK
1
2
BLU
YEL
PWM 2
PWM 1
DEFROST
TIME (MIN)
5
1
-t°
-t°
BLU
BLK
BLK
BRN
BRN
YEL
OAT
PL5
1
2
2
BLU
START RELAY
BRN
4
5
COMM STATUS
OCT
O
Y
2
GRN/YEL
BRN
BLU
VC
Y
YEL
1
BRN
VH
ODF
L 2
W
BLU
BLK
YEL
RED
1
A
B
C
D
C
R
OFM
CCH
RED
CCH
TO INDOOR UNIT
Fig. 16—Wiring Diagram—037
A01439
15
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DUAL CAPACITY
CONNECTION DIAGRAM L1
BLK
L2
YEL
208 / 230 - 1 - 60
POWER SUPPLY
BLK
BLK
CH
CL
13
11
21
11
21
RED
EQUIP GND
23
YEL
BLU
NOTE #11
COMP
BRN
BLK
R
S
C
RED
1
BLU
2
BRN
BRN
1
2
3
4
5
PL1
HP/AC
C
SEV RVS
C
HI LO PL2
BRN
LPS
START
CAP
LPS
PL3
1
2
3
YEL/PNK
YEL/PNK
C
H
COMP
CAP
FORCED
DEFROST
HPS
OAT
OCT
BRN
BLU/PNK
BLU/PNK
HPS
PL4
1
2
YEL
5
1
DEFROST
TIME(MIN)
-t∞
-t∞
BLU
BLK
BLK
BRN
BRN
OA T
PL5
1
2
2
BLU
START
RELAY
BRN
4
5
COMM STATUS
OC T
O
Y
2
1
VC
OFM
RED
Y
BRN
BLU
BLK
YEL
YEL
FA N CAP
VH
ODF
L 2
W
BLK
1
A
B
C
D
BLK
BRN
C
R
YEL
CCH
RED
CCH
TO INDOORUNIT
→ Fig. 17—Wiring Diagram—060
A02212
Copyright 2002 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231
38tdb4si
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book
Tab 3a 2a
1
4
PC 101
Catalog No. 533-80059
Printed in U.S.A.
Form 38TDB-4SI
Pg 16
8-02
Replaces: 38TDB-3SI
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