38EYA
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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 the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which willresultinsevere
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.
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® (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.
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 diameters are appropriate to
capacity of unit.
3. Run refrigerant tubes as directly as possible by avoiding
unnecessary turns and bends.
38EYA
12 SEER Split-System
Heat Pump with Puron®
.
Fig. 1—Model 38EYA
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 same size when connected by 15 ft of field-supplied
or factory accessory tubing. Add (or subtract) 0.6 oz/ft of 3/8
liquid line for lengths greater (or less) than 15 ft. For proper unit
operation, check refrigerant charge using charging information
located on control box cover and/or in theCheckChargesection 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 Puron® heat
pump (bi-flow) 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.
A99327
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 5a 5a
PC 101 Catalog No. 533-80006 Printed in U.S.A. Form 38EYA-3SI Pg 1 4-01 Replaces: 38EYA-2SI
Avoid contact between tubing and structureNOTE:
OUTDOOR WALL INDOOR WALL
CAULK
INSULATION
THROUGH THE WALL
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
1″ MIN.
SUSPENSION
LIQUID TUBE
VAPOR TUBE
JOIST
INSULATION
VAPOR TUBE
LIQUID TUBE
A94028
Fig. 2—Connecting Tubing Installation
INSTALLATION
IMPORTANT: Specifications for this unit in residential new
construction market require using 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 for 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.
C
3
⁄8″D. (9.53) TIEDOWN
A
B
KNOCKOUTS (2) PLACES
A94199
DIMENSIONS (IN.)
UNIT
SIZE
018, 024, 030 22-1/2 X 22-1/2 3-11/16 18-1/8 14-3/8
036–060 30 X 30 6-1/2 23-1/2 20
MINIMUM
MOUNTING PAD
DIMENSIONS
TIEDOWN KNOCKOUT
LOCATIONS
ABC
Fig. 3—Mounting Unit to Pad
Do not allow POE lubricant to come into contact with roofing
material. POE may determine certain types of synthetic
roofing.
Roof mounted units exposed to winds above 5 mph may require
wind baffles. Consult the Application Guideline and Service
Manual for 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
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.
On rooftop applications, locate unit at least 6 in. above roof
surface.
Step 4—Operating Ambients
The minimum outdoor operating ambient in cooling mode without
additional accessories is 55°F, and the maximum outdoor operating ambient in cooling mode is 125°F. The maximum outdoor
operating ambient in heating mode is 66°F.
2
Step 5—Elevate Unit
Accumulation of water and ice in base pan may cause
equipment damage.
Elevate unit per local climate and code requirements to provide
clearance above estimated snowfall level and ensure adequate
drainage of unit.
and feeder tube going into outdoor coil. At the end of 1 of the
feeder tubes, there is a 3/8-in. OD stub tube approximately 3 in.
long. (See Fig. 6.) The defrost thermostat should be located on stub
tube. Note that there is only 1 stub tube used with liquid header,
and on most units it is the bottom circuit.
Step 8—In Long-Line Applications, Install Liquid-Line
Solenoid Valve (LSV)
For refrigerant piping arrangements with equivalent lengths
greater than 50 ft or when elevation difference between indoor and
outdoor unit is greater than ± 20 ft, follow all requirements of the
Long-Line Guideline section in the Application Guideline and
COIL
THERMOSTATIC
EXPANSION
VALVE
SENSING
BULB
EQUALIZER
TUBE
A88382
Fig. 4—Typical TXV Installation
Step 6—Check Indoor Expansion Device
For proper unit operation and reliability, units must be
installed with hard shutoff TXV specifically designed to
operate with Puron®. Do not use R-22 TXV. Do not install
with evaporator coils having capillary tube metering devices
or pistons.
For TXV kit part number and charging instructions, refer to TXV
label in outdoor unit.
FURNACE COILS
If TXV installation is required, remove existing AccuRater® from
indoor coil. Refer to Fig. 4 and 5 and install TXV kit (specifically
designed for Puron®) as follows:
1. Install suction tube adapter.
2. Install liquid flare-to-sweat adapter.
3. Connect external equalizer tube to fitting on suction tube
adapter.
4. Position sensing bulb on horizontal portion of suction tube
adapter. Secure using supplied hardware.
5. Insulate bulb after installation. (See Fig. 5.)
6. Leak check all connections.
FAN COILS
If indoor unit (fan coil) comes factory equipped with a bi-flow
hard shutoff TXV specifically designed for Puron®,noTXV
change is required.
If fan coil is not designed for Puron®, a Puron® TXV installation
is required. Refer to TXV kit Installation Instructions for details on
TXV installation.
Step 7—Check Defrost Thermostat
Check defrost thermostat to ensure it is properly located and
securely attached. There is a liquid header with a brass distributor
SENSING BULB
STRAP
8 O'CLOCK
4 O'CLOCK
A00399
Fig. 5—Positioning of Sensing Bulb
FEEDER TUBE
STUB TUBE
DEFROST
THERMOSTAT
A97517
Fig. 6—Defrost Thermostat Location
Service Manual for Residential Split-System Air Conditioners and
Heat Pumps Using Puron® Refrigerant.
If required by Long-Line Application Guideline, install LSV kit
part No. KHALS0401LLS specifically designed for Puron® Heat
Pump. LSV should be installed between filter drier and indoor coil,
as close as possible to filter drier. Follow the Installation Instructions included with accessory kit.
IMPORTANT: Flow arrow must point toward outdoor unit.
Step 9—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.
3
Table 1—Refrigerant Connections and Recommended Liquid Line and Vapor Tube Diameters (In.)
UNIT
SIZE
018, 024 3/8 5/8 3/8 5/8 3/4 ACR 3/4
030 3/8 3/4 3/8 3/4 7/8 1-1/8
036 3/8 3/4 3/8 3/4 7/8 1-1/8
042, 048 3/8 7/8 3/8 7/8 7/8 3/4 and 1-1/8
060 3/8 1-1/8 3/8 1-1/8 7/8 3/4
NOTES:
1. Tube diameters are for lengths up to 50 ft. For tubing lengths greater than 50 ft, consult the Application Guideline and Service Manual — Residential Split-System
Air Conditioners and Heat Pumps Using Puron® Refrigerant.
2. Refrigerant tubes and indoor coils must be evacuated to 500 microns to minimize contamination and moisture in the system.
CONNECTION DIAMETER TUBE DIAMETER
Liquid Vapor Liquid Vapor Vapor Vapor
TUBE DIAMETER
(ALTERNATE)
SWEAT/FLARE
ADAPTER
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
TEFLON
SEAL
ends of tubing sealed during installation.
RST TUBE
DIAMETERS
NOT PERMITTED
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.
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 for Residential Split-System Air Conditioners and Heat
Pumps using Puron® Refrigerant to minimize losses. Refer to
Table 1 for field tubing diameters. Refer to Table 2 for accessory
requirements.
Refrigerant tubes and indoor coil must be evacuated to 500
microns to minimize contamination and moisture in the system.
OUTDOOR UNIT CONNECTED TO FACTORY-APPROVED
INDOOR UNIT
These outdoor units are carefully evaluated and listed with specific
indoor coils for proper system performance.
IMPORTANT: Do not apply indoor coils which are not factory
approved to these units.
INSTALL ADAPTER TUBE
1. Remove plastic retainer holding outdoor piston in liquid
service valve.
2. Check outdoor piston size with matching number listed on unit
rating plate.
3. Locate plastic bag taped to unit containing adapter tube.
4. Remove teflon washer from bag and install on open end of
liquid service valve. (See Fig. 7.)
5. Remove adapter tube from bag and connect threaded nut to
liquid service valve. Tighten nut finger tight and then with
PISTON
PISTON BODY
LIQUID SERVICE VALVE
A99441
Fig. 7—Liquid Service Valve with Sweat Adapter
Tube
LIQUID-LINE
FILTER-DRIER
LIQUID
SERVICE
VALVE
A00431
Fig. 8—Filter Drier with Sweat Adapter Tube and
Liquid Tube
4
Table 2—Accessory Usage
ACCESSORY
Crankcase Heater Yes Yes
Evaporator Freeze Thermostat Yes No
Compressor Start Assist—Capacitor and Relay Yes Yes
Puron® Low-Ambient Pressure Switch Yes No
Wind Baffle See Low-Ambient Instructions No
Support Feet Recommended No
Hard Shutoff TXV Yes† Yes†
Liquid-Line Solenoid Valve for Heating No
* For tubing line sets between 50 and 175 ft, or when vertical difference is greater than 20 ft, refer to Application Guideline and Service Manual — Residential Split-System
Air Conditioners and Heat Pumps Using Puron®.
† Required for all applications.
REQUIRED FOR LOW-AMBIENT
APPLICATIONS
(BELOW 55°F)
REQUIRED FOR LONG-LINE
APPLICATIONS*
(OVER 50 FT)
See Long-Line
Application Guideline
wrench an additional 1/12 turn (15 ft-lb). DO NOT OVERTIGHTEN.
REFRIGERANT TUBING AND FILTER DRIER
Installation of filter drier in liquid line is required.
Connect vapor tubing to fittings on outdoor unit vapor service
valves. Connect liquid tube to filter drier. (See Table 1 and Fig. 8.)
Use refrigerant grade tubing. Connect other end of filter drier to
adapter tube on liquid service valve.
SWEAT CONNECTION
To avoid valve damage while brazing, service valves must be
wrapped in a heat-sink material such as a wet cloth.
Wrap service valves and filter drier with a wet cloth or heatsinking material. Braze connections using either silver bearing or
non-silver bearing brazing material. Do not use soft solder
(materials which melt below 800°F.) Consult local code requirements.
LEAK CHECKING
Leak test all joints in indoor, outdoor, and refrigerant tubing.
EVACUATE REFRIGERANT TUBING AND INDOOR COIL
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
01234567
MINUTES
Fig. 9—Deep Vacuum Graph
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
A95424
A95424
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.
IMPORTANT: Never open system under vacuum to atmosphere
without first breaking it open with 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. 9.)
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. 10 and proceed as follows:
WAIT
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
CHARGE SYSTEM
A95425
Fig. 10—Triple Evacuation Method
5
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