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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
LIQUID-LINE
FILTER-DRYER
CONNECTOR
TUBE
A99331
Fig. 6—Liquid-Line Filter Drier
Table 1—Refrigerant Connections and Recommended Liquid Line and Vapor Tube Diameters (In.)
UNIT
SIZE
018, 024 3/8 3/8 5/8 5/8 5/8 3/4
030, 036 3/8 3/8 3/4 3/4 3/4 7/8
042, 048 3/8 3/8 7/8 7/8 7/8 1-1/8
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 ft. For tubing lengths greater than 50 ft horizontal, or greater than 20 ft vertical differential, consult the Application Guideline
and Service Manual — Air Conditioners and Heat Pumps Using Puron® Refrigerant.
2. Do not apply capillary tube indoor coils to these units.
Connection Diameter Tube Diameter Connection Diameter Tube Diameter Connection Diameter Tube Diameter
LIQUID VAPOR VAPOR (LONG LINE)
Table 2—Accessory Usage
REQUIRED FOR
ACCESSORY
Crankcase Heater Yes Yes No
Evaporator Freeze Thermostat Yes No No
Winter Start Control Yes† No No
Accumulator No No No
Compressor Start Assist
Capacitor and Relay
MotorMaster® Control,
Low-Ambient Pressure Switch
Liquid-Line Solenoid Valve
Ball Bearing Fan Motor Yes‡ No No
* For tubing line sets between 50 and 175 ft, refer to Application Guideline and Service Manual — Air Conditioners and Heat Pumps Using Puron® Refrigerant.
† Only when low-pressure switch is used.
‡ Required for low-ambient controller (full modulation feature) and MotorMaster® Control only.
or
Wind Baffle See low-ambient instructions No No
Coastal Filter No No Yes
or
Hard Shutoff TXV
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.
NOTE: Use copper wire only between disconnect switch and
LOW-AMBIENT
APPLICATIONS
(BELOW 55°F)
Yes Yes No
Yes No No
No
NOTE: Install branch circuit disconnect of adequate size per
NEC to handle unit starting current. Locate disconnect within sight
from and readily accessible from unit, per Section 440-14 of NEC.
ROUTE GROUND AND POWER WIRES
Remove access panel to gain access to unit wiring. Extend wires
from disconnect through power wiring hole provided and into unit
control box.
unit.
REQUIRED FOR
LONG-LINE
APPLICATIONS*
(OVER 50 FT)
See Long-Line
Application
Guideline
REQUIRED FOR
SEA COAST
APPLICATIONS
(WITHIN 2 MILES)
No
5
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
01234567
MINUTES
Fig. 7—Deep Vacuum Graph
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
A95424
A95424
DISCONNECT
PER N.E.C. AND/OR
LOCAL CODES
CONTACTOR
FIELD POWER
WIRING
3 PHASE ONLY
FIELD GROUND
WIRING
BLUE
GROUND
LUG
A94025
Fig. 9—Line Power Connections
NOTE: Use of available 24v accessories may exceed the mini-
mum 40va power requirement. Determine total transformer loading and increase the transformer capacity or split the load with an
accessory transformer as required.
WAIT
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
CHARGE SYSTEM
A95425
Fig. 8—Triple Evacuation Method
The unit cabinet must have an uninterrupted or unbroken
ground to minimize personal injury if an electrical fault
should occur. The ground may consist of electrical wire or
metal conduit when installed in accordance with existing
electrical codes. Failure to follow this warning can result in an
electric shock, fire, or death.
CONNECT GROUND AND POWER WIRES
Connect ground wire to ground connection in control box for
safety. Connect power wiring to contactor as shown in Fig. 9.
CONNECT CONTROL WIRING
Route 24v control wires through control wiring grommet and
connect leads to control wiring. (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 1 and must be separated from
incoming power leads.
Use furnace transformer, fan coil transformer, or accessory transformer for control power, 24v/40va minimum.
FINAL WIRING CHECK
IMPORTANT: Check factory wiring and field wire connections
to ensure terminations are secured properly. Check wire routing to
ensure wires are not in contact with tubing, sheet metal, etc.
Step 9—Compressor Crankcase Heater
When equipped with a crankcase heater, furnish power to heater a
minimum of 24 hr before starting unit. To furnish power to heater
only, set thermostat to OFF and close electrical disconnect to
outdoor unit.
A crankcase heater is required if refrigerant tubing is longer than
50 ft. Refer to Application Guideline and Service Manual —
Residential Split-System Air Conditioners and Heat Pumps using
Puron® Refrigerant.
Step 10—Install Electrical Accessories
Refer to the individual instructions packaged with kits or accessories when installing.
Step 11—Start-Up
To prevent compressor damage or personal injury, observe
the following:
•Do not overcharge system with refrigerant.
•Do not operate unit in a vacuum or at negative pressure.
•Do not vent refrigerant to atmosphere. Recover during
system repair or final unit disposal.
•Do not disable low-pressure switch.
In scroll-compressor applications:
•Dome temperatures may be hot.
To prevent personal injury wear safety glasses, protective
clothing, and gloves when handling refrigerant and observe
the following:
•Back-seating service valves are not equipped with Schrader
valves. Fully back seat (counterclockwise) valve stem before
removing gage-port cap.
•Front-seating service valves are equipped with Schrader
valves.
6
• 3-phase scroll compressors are rotation sensitive.
• A flashing LED on phase monitor indicates reverse rotation.
(See Fig. 10 and Table 3.)
• This will not allow contactor to be energized.
• Disconnect power to unit and interchange 2 field wiring
leads on unit contactor.
Follow these steps to properly start up the system.
1. After system is evacuated, fully back seat (open) liquid and
vapor service valves.
2. Unit is shipped with valve stem(s) front seated (closed) and
caps installed. replace stem caps after system is opened to
refrigerant flow. Replace caps finger-tight and tighten with
wrench an additional 1/12 turn.
3. Close electrical disconnects to energize system.
4. Set room thermostat at desired temperature. Be sure set point
is below indoor ambient temperature.
5. Set room thermostat to COOL and fan control to ON or AUTO
mode, as desired. Operate unit for 15 minutes Check system
refrigerant charge.
SEQUENCE OF OPERATION
Turn on power to indoor and outdoor units. Transformer is
energized.
On a call for cooling, thermostat makes circuits R-Y and R-G. On
three phase models with scroll compressors, the units are equipped
with a phase monitor to detect in the incoming power is correctly
phased for compressor operation. If the phasing is correct, circuit
R-Y energizes contactor, starting outdoor fan motor and compressor circuit. R-G energizes indoor unit blower relay, starting indoor
blower motor on high speed.
NOTE: If the phasing is incorrect, the contactor will not be
energized. To correct the phasing, interchange any two of the three
power connections on the field side.
When thermostat is satisfied, its contacts open, de-energizing
contactor and blower relay. Compressor and motors stop.
If indoor unit is equipped with a time-delay relay circuit, the
indoor blower runs an additional 90 sec to increase system
efficiency.
A00010
Fig. 10—Phase Monitor Control
Table 3—Phase Monitor Led Indicators
LED STATUS
OFF No call for compressor operation
FLASHING Reversed phase
ON Normal
Step 12—Check Charge
UNIT CHARGE
Factory charge and charging method are shown on unit informa-
tion plate. Charge Puron® units using a commercial-type metering
device in manifold hose. Charge refrigerant into suction line.
NOTE: If superheat or subcooling charging conditions are not
favorable, charge must be weighed in accordance with unit rating
plate ± 0.6 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=6ozofadditional charge
COOLING ONLY PROCEDURE
Units with Cooling Mode Puron® TXV
Units installed with cooling mode TXV require charging by the
subcooling method.
1. Operate unit a minimum of 10 minutes before checking
charge.
2. Measure liquid service valve pressure by attaching an accurate
gage to service port.
3. Measure liquid line temperature by attaching an accurate
thermistor type or electronic thermometer to liquid near
outdoor coil.
4. Refer to unit rating plate for required subcooling temperature.
5. Refer to Table 4. Find the point where required subcooling
temperature intersects measured liquid service valve pressure.
6. To obtain required 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.
Units with Indoor Pistons
Units installed with indoor pistons require charging by the super-
heat method.
The following procedure is valid when indoor airflow is within ±
21 percent of its rated CFM.
1. Operate unit a minimum of 10 minutes before checking
charge.
2. Measure suction pressure by attaching an accurate gage to
suction valve service port.
3. Measure suction temperature by attaching an accurate thermistor type or electronic thermometer to suction line at service
valve.
4. Measure outdoor air dry-bulb temperature with thermometer.
5. Measure indoor air (entering indoor coil) wet-bulb temperature with a sling psychrometer.
6. Refer to Table 5. Find outdoor temperature and evaporator
entering air wet-bulb temperature. At this intersection, note
superheat.
7. Refer to Table 6. Find superheat temperature located in item 6
and suction pressure. At this intersection, note suction line
temperature.
7
Table 4—Required Liquid-Line Temperature (°F)
LIQUID
PRESSURE AT
SERVICE VALVE
189 58 56 54 52 50 48
195 60 58 56 54 52 50
202 62 60 58 56 54 52
208 64 62 60 58 56 54
215 66 64 62 60 58 56
222 68 66 64 62 60 58
229 70 68 66 64 62 60
236 72 70 68 66 64 62
243 74 72 70 68 66 64
251 76 74 72 70 68 66
259 78 76 74 72 70 68
266 80 78 76 74 72 70
274 82 80 78 76 74 72
283 84 82 80 78 76 74
291 86 84 82 80 78 76
299 88 86 84 82 80 78
308 90 88 86 84 82 80
317 92 90 88 86 84 82
326 94 92 90 88 86 84
335 96 94 92 90 88 86
345 98 96 94 92 90 88
354 100 98 96 94 92 90
364 102 100 98 96 94 92
374 104 102 100 98 96 94
384 106 104 102 100 98 96
395 108 106 104 102 100 98
406 110 108 106 104 102 100
416 112 110 108 106 104 102
427 114 112 110 108 106 104
439 116 114 112 110 108 106
450 118 116 114 112 110 108
462 120 118 116 114 112 110
474 122 120 118 116 114 112
486 124 122 120 118 116 114
499 126 124 122 120 118 116
511 128 126 124 122 120 118
REQUIRED SUBCOOLING
TEMPERATURE
(°F)
8 1012141618
1. Ensure that all wiring and tubing is secure in unit before
adding panels and covers. Securely fasten all panels and
covers.
2. Tighten service valve stem caps to 1/12-turn past finger tight.
3. Leave User’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 equipment failure, periodic maintenance must be performed on this
equipment.
Frequency of maintenance may vary depending upon geographic
areas, such as coastal applications. See User’s Manual for information.
8. If a unit has a higher suction line temperature than charted
temperature, add refrigerant until charted temperature is
reached.
9. If unit has a lower suction line temperature than charted
temperature, reclaim refrigerant until charted temperature is
reached.
10. When adding refrigerant, charge in liquid form into suction
service port using a flow-restricting device.
11. If outdoor air temperature or pressure at suction valve
changes, charge to new suction line temperature indicated on
chart.
Step 13—Final Checks
IMPORTANT: Before leaving job, be sure to do the following:
8
Table 5—Superheat Charging
OUTDOOR
TEMP
(°F)
55 9 12141720232629323537404245
60 7 10121518212427303335384043
65 — 6 10 13 16 19 21 24 27 30 33 36 38 41
70 —— 7 1013161921242730333639
75 — — — 6 9 12 15 18 21 24 28 31 34 37
80 ———— 5 81215182125283135
85 —————— 811151922263033
90 —————— 5 9131620242731
95 ——————— 6101418222529
100 ———————— 81215202327
105 ———————— 5 913172226
110 ————————— 611152025
115 —————————— 8141823
50 52 54 56 58 60 62 64 66 68 70 72 74 76
EVAPORATOR ENTERING AIR TEMPERATURE (°F WB)
Table 6—Required Suction-Line Temperature (°F WB)
SUPERHEAT
TEMP
(°F)
0 35 37 39 41 43 45 47 49 51
2 37 39 41 43 45 47 49 51 53
4 39 41 43 45 47 49 51 53 55
6 41 43 45 47 49 51 53 55 57
8 43 45 47 49 51 53 55 57 59
10 45 47 49 51 53 55 57 59 61
12 47 49 51 53 55 57 59 61 63
14 49 51 53 55 57 59 61 63 65
16 51 53 55 57 59 61 63 65 67
18 53 55 57 59 61 63 65 67 69
20 55 57 59 61 63 65 67 69 71
22 57 59 61 63 65 67 69 71 73
24 59 61 63 65 67 69 71 73 75
26 61 63 65 67 69 71 73 75 77
28 63 65 67 69 71 73 75 77 79
30 65 67 69 71 73 75 77 79 81
32 67 69 71 73 75 77 79 81 83
34 69 71 73 75 77 79 81 83 85
36 71 73 75 77 79 81 83 85 87
38 73 75 77 79 81 83 85 87 89
40 75 77 79 81 83 85 87 89 91
107.8 112.2 116.8 121.2 126.0 130.8 138.8 140.8 145.8
SUCTION PRESSURE AT SERVICE PORT (PSIG)
9
A/C
THERMOSTAT
Typical
FURNACE
AIR
CONDITIONER
A/C
THERMOSTAT
Typical
FAN COIL
AIR
CONDITIONER
24 VAC HOT
24 VAC COM
HEAT STAGE 1
COOL STAGE 1
INDOOR FAN
R
C
W/W1
Y/Y2
G
R
C
W
Y
G
C
24 VAC HOT
24 VAC COM
HEAT STAGE 1
COOL STAGE 1
INDOOR FAN
R
C
W/W1
Y/Y2
G
Fig. 11—Generic Wiring Diagram
(See Thermostat Installation Instructions for wiring specific unit combinations)
LEGEND
24-V FACTORY WIRING
24-V FIELD WIRING
FIELD SPLICE CONNECTION
C
CONTACTOR
W2
R
C
C
G
A02326
A97368
10
11
PURON® (R-410A) QUICK REFERENCE GUIDE
• Puron® refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and
replacement components are designed to operate with Puron®.
• Puron® refrigerant cylinders are rose colored.
• Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400.
• Puron® systems should be charged with liquid refrigerant. Use a commercial type metering device in the
manifold hose when charging into suction line with compressor operating.
• Manifold sets should be at least 700 psig high side and 180 psig low side with 550 psig low-side retard.
• Use hoses with 700 psig service pressure rating.
• Leak detectors should be designed to detect HFC refrigerant.
• Puron®, as with other HFCs, is only compatible with POE oils.
• Vacuum pumps will not remove moisture from oil.
• Do not leave Puron® suction line filter driers in line longer than 72 hrs.
• Do not use liquid-line filter driers with rated working pressures less than 600 psig.
• Do not install a suction-line filter drier in liquid line.
• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.
• Poe oils may cause damage to certain plastics and roofing materials.
• Wrap all filter driers and service valves with wet cloth when brazing.
• A factory-approved liquid-line filter drier is required on every unit.
• Do not use an R-22 TXV.
• If indoor unit is equipped with an R-22 TXV, it must be changed to a Puron® TXV.
• Never open system to atmosphere while it is under a vacuum.
• When system must be opened for service, recover refrigerant, break vacuum with dry nitrogen prior to
opening to atmosphere. Evacuate to 500 microns prior to recharging.
• Always replace filter drier after opening system for service.
• Do not vent Puron® into the atmosphere.
• Do not use capillary tube coils.
• Observe all warnings, cautions, and bold text.
Copyright 2002 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 38esg1si
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 12 11-02 Replaces: New
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