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Installation and Start-Up Instructions
NOTE: Read the entire instruction manual before starting the
installation.
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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 thoroughly 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 electrical disconnect switch must be in the OFF position. There
may be more than 1 disconnect switch. Lock out and tag
switch with a suitable warning label. Electrical shock can
cause personal injury or death.
Puron® systems operate at higher pressures than standard
R-22 systems. Do not use R-22 service equipment or components on Puron® equipment.
INSTALLATION RECOMMENDATIONS
NOTE: In some cases noise in the living area has been traced to
gas pulsations from improper installation of equipment.
1. Locate unit away from windows, patios, decks, etc. where unit
operation sound may disturb customer.
2. Ensure that vapor and liquid tube diametersareappropriate for
unit capacity.
38EZG, 38ETG, 38ESG
12, 13, 14 SEER Split-System
Air Conditioner with Puron®
A98525
Fig. 1—Models 38EZG, 38ETG, 38ESG
.
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 tubes through 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.
7. 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.)
8. Ensure that tubing insulation is pliable and completely surrounds vapor tube.
9. When necessary, use hanger straps which are 1 in. wide and
conform to shape of tubing insulation. (See Fig. 2.)
10. Isolate hanger straps from insulation by using metal sleeves
bent to conform to shape of insulation.
When outdoor unit is connected to factory-approved indoor unit,
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 operation, check refrigerant charge using charging information located
on control box cover and/or in the Check Charge section of this
instruction.
IMPORTANT: Maximum liquid-line size is 3/8-in. O.D. for all
residential applications including long line.
IMPORTANT: Always install the factory-supplied liquid-line filter drier. If replacing the filter drier, refer to Product Data Digest
for appropriate part number. Obtain replacement filter driers from
your distributor or branch.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 3a 2a
PC 101 Catalog No. 533-80079 Printed in U.S.A. Form 38ESG-1SI Pg 1 11-02 Replaces: New
Avoid contact between tubing and structureNOTE:
OUTDOOR WALL INDOOR WALL
CAULK
LIQUID TUBE
C
INSULATION
THROUGH THE WALL
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
1″ MIN.
SUSPENSION
VAPOR TUBE
JOIST
INSULATION
VAPOR TUBE
LIQUID TUBE
A01383
Fig. 2—Connecting Tubing Installation
INSTALLATION
Specifications for this unit in residential new construction market
require the outdoor unit, indoor unit, refrigerant tubing sets,
metering device, and filter drier listed in presale literature. There
can be no deviation. Consult the Application Guideline and
Service Manual — Residential Split-System Air Conditioners and
Heat Pumps using Puron® Refrigerant to obtain required unit
changes for specific applications and for R-22 retrofit.
Step 1—Check Equipment and Job Site
UNPACK UNIT
Move to final location. Remove carton taking care not to damage
unit.
INSPECT EQUIPMENT
File claim with shipping company prior to installation if shipment
is damaged or incomplete. Locate unit rating plate on unit corner
panel. It contains information needed to properly install unit.
Check rating plate to be sure unit matches job specifications.
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 pattern 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.
Roof mounted units exposed to winds above 5 mph may require
wind baffles. Consult the Application Guideline and Service
Manual — Residential Split-System Air Conditioners and Heat
Pumps using Puron® Refrigerant for wind baffle construction.
NOTE: Unit must be level to within ± 2° (± 3/8 in./ft) per
compressor manufacturer specifications.
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 1 side of unit and 12 in. on all remaining sides must
3
⁄8″D. (9.53) TIEDOWN
A
KNOCKOUTS (2) PLACES
B
DIMENSIONS (IN.)
UNIT BASE PAN
DIMENSIONS
22-1/2 X 22-1/2 3-11/16 18-1/8 14-3/8
30X30 6-1/2 23-1/2 20
TIEDOWN KNOCKOUT LOCATIONS
ABC
Fig. 3—Mounting Unit to Pad
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 Ambients
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—Check Indoor AccuRater® Piston and
Install Piston Ring (38EZG Standard)
If unit is to be installed with a piston metering device, proceed as
follows:
1. Check indoor coil piston to see if it matches the required
piston shown on outdoor unit rating plate. If it does not match,
replace indoor coil piston with piston shipped with outdoor
unit. The piston shipped with outdoor unit is correct for any
approved indoor coil combination.
2. After correct piston is installed, locate Teflon piston ring
shipped in piston bag. Install piston ring behind metering
piston as shown in Fig. 4. The piston ring ensures that piston
stays seated during all operating conditions.
NOTE: If a Puron TXV is used with a Puron reciprocating
compressor, an appropriate accessory hard start kit (capacitor and
relay) must be used. For the appropriate accessory hard start kit see
the Product Data Digest.
Step 6—TXV Installation (38ETG and 38ESG Required)
NOTE: All 38ETG and 38ESG units MUST be installed with a
hard shut off Puron® TXV.
The thermostatic expansion valve is specifically designed to
operate with Puron®. Do not use an R-22 TXV. An existing R-22
TXV must be replaced with a factory-approved TXV specifically
designed for Puron®. To replace an R-22 TXV, refer to Installation Instructions packaged with accessory kit.
NOTE: FK4 and FC4 fan coils are equipped with an R-22 TXV.
If an FK4 or an FC4 fan coil is used with a Puron® air conditioner,
the R-22 TXV must be replaced with a Puron® TXV.
2
A94199
13
⁄16–IN.
BRASS HEX
NUT
STRAINER
PISTON
DISTRIBUTOR
TEFLON SEAL
PISTON RETAINER
Fig. 4—AccuRater® Components (38EZG Use)
Remove indoor coil piston if unit is to be installed on system
with a TXV metering device.
IMPORTANT: The TXV should be mounted as close to the
indoor coil as possible and in a vertical, upright position. Avoid
mounting the inlet tube vertically down. Valve is more susceptible
to malfunction due to debris if inlet tube is facing down. A factory
approved filter-drier must be installed in the liquid line.
INSTALLING TXV IN PLACE OF PISTON
1. Pump system down to 2 psig and recover refrigerant.
2. Remove hex nut from piston body. Use backup wrench on fan
coils.
3. Remove and discard factory-installed piston. Be sure Teflon
seal is in place.
4. Reinstall hex nut. Finger tighten nut plus 1/2 turn.
NOTE: If the piston is not removed from the body, TXV will not
function properly.
To prevent damage to the unit, use a brazing shield and wrap
TXV with wet cloth or use heat sink material.
5. Install TXV on indoor coil liquid line. Sweat swivel adapter to
inlet of indoor coil and attach to TXV outlet. Use backup
wrench to avoid damage to tubing or valve. Sweat inlet of
TXV, marked “IN” to liquid line. Avoid excessive heat which
could damage valve.
6. Install vapor elbow with equalizer adapter to suction tube of
line set and suction connection to indoor coil. Adapter has a
1/4–in. male connector for attaching equalizer tube.
7. Connect equalizer tube of TXV to 1/4–in. equalizer fitting on
vapor line adapter.
8. Attach TXV bulb to horizontal section of suction line using
clamps provided. Insulate bulb with field-supplied insulation
tape. See Fig. 5 for correct positioning of sensing bulb.
9. Proceed with remainder of unit installation.
REPLACING TXV ON R-22 INDOOR COIL
1. Pump system down to 2 psig and recover refrigerant.
2. Remove coil access panel and fitting panel from front of
cabinet.
3. Remove TXV support clamp using a 5/16-in. nut driver. Save
the clamp.
4. Remove R-22 TXV using a backup wrench on flare connections to prevent damage to tubing.
5. Using wire cutters, cut equalizer tube off flush with vapor tube
inside cabinet.
PISTON
RING
3
⁄4–IN. BRASS
HEX BODY
COPPER TUBE
A01164
6. Remove bulb from vapor tube inside cabinet.
7. Braze equalizer stub-tube closed. Use protective barrier as
necessary to prevent damage to drain pan.
IMPORTANT: Route the equalizer tube of Puron® TXV through
suction line connection opening in fitting panel prior to replacing
fitting panel around tubing.
8. Install TXV with 3/8-in. copper tubing through small hole in
service panel. Use wrench and backup wrench, to avoid
damage to tubing or valve, to attach TXV to distributor.
9. Reinstall TXV support clamp (removed in item 3).
10. Attach TXV bulb to vapor tube inside cabinet, in same
location as original was when removed, using supplied bulb
clamps (nylon or copper). See Fig. 5 for correct positioning of
sensing bulb.
11. Route equalizer tube through suction connection opening
(large hole) in fitting panel and install fitting panel in place.
12. Sweat inlet of TXV, marked IN, to liquid line. Avoid
excessive heat which could damage valve.
13. Install vapor elbow 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.
14. Connect equalizer tube of TXV to 1/4–in. equalizer fitting on
vapor line adapter. Use backup wrench to prevent damage to
equalizer fitting.
15. Proceed with remainder of unit installation.
Remove indoor coil piston if unit is to be installed on system
with a TXV metering device.
Step 7—Making Piping Connections
Relieve pressure and recover all refrigerant before system
repair or final unit disposal to avoid personal injury or death.
Use all service ports and open all flow-control devices,
including solenoid valves.
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.
3
10 O'CLOCK
2 O'CLOCK
STRAP
SENSING BULB
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.
SWEAT CONNECTION
SUCTION TUBE
4 O'CLOCK
7⁄
8
IN. OD
A81032
7
⁄
IN. OD & SMALLER
8
8 O'CLOCK
LARGER THAN
Fig. 5—Position of Sensing Bulb
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, substantial 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 operation 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
To avoid compressor damage and performance loss due to
plugged circuits and expansion device, installation of filter
drier in liquid line is required.
To avoid valve damage while brazing, service valves must be
wrapped in a heat-sink material such as a wet cloth.
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 requirements. 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
To avoid compressor damage, 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 1 hr. 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 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.
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.
To avoid personal injury or death, do not supply power to unit
with compressor terminal box cover removed.
Be sure field wiring complies with local and national fire, safety,
and electrical codes, and voltage to system is within limits shown
4
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