Carrier 38EYG060 SERIES300, 38EYG048 SERIES300, 38EYG042 SERIES300, 38EYG036 SERIES300, 38EYG024 SERIES300 Owner’s Manual

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HEATING & COOUNG

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Heat

38EYG

12 SEER Split-System

Pump with Puron® Refrigerant

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 fiactory-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.

Recognize safety information. This is the safety-alert symbol Z_ •

When you see this symbol on the unit and in instructions or

manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAU-

TION. These words are used with the safety-alert symbol. DAN-

GER 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, reliablitily,

or operation.

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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.

r;_[Rr21lii_] iq

Puron_; (R-410A) systems operate at higher pressures than

standard R-22 systems. Be certain that service eqnipment is

rated for Puron:,P¢. 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.

i. Locate unit away from windows, patios, decks, etc. where unit

operation sound may disturb customer.

2. Ensure that vapor and liquid tube diameters are appropriate to

capacity of unit.

A98525

Fig. 1--Model 38EYG

3. Run refrigerant tubes as directly as possible by avoiding

unnecessary tunas 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 sur-

rounds 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 fiactory-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 ozift 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 the Check Charge section of

this instruction.

IMPORTANT: Maxinmm liquid-line size is 3/8-in. O.D. for all

residential applications including long line.

IMPORTANT: Always install the factory-supplied Puron:R; 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.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 101 Catalog No. 533-80094 Printed in USA Form 38EYG-2SI Pg 1 2-03 Replaces: 38EYG-1SI

NOTE: Avoid contact between tubing and structure

--OUTDOOR WALL_ INDOOR WAL_

_"CAULK--_ _ F LIQUID TUBE

_/_ VAPOR TUBE

t.--INSULATION --J

THROUGH THE WALL

HANGER STRAP-- k

(AROUND VAPOR _ --

TUBE_,

.,_--JOIST

i] _ INSULATION

#VAPOR TUBE

r' MIN.----II_ L LIQUIDTUBE

SUSPENSION

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 robing sets, metering device, and filter &ier listed in

presale literature. There can be no deviation. Consult the Appli-

cation Guideline and Service Manual for Residential Split-System

Air Conditioners and Heat Pumps using Puron:R; 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 05"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 patteru 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 fi'om

structure. Arrange supporting members to adequately support unit

and minimize transmission of vibration to building. Consult local

codes goveruing rooftop applications.

3/8"D (953) TIEDOWN

KNOCKOUTS (2) PLACES

A94199

DIMENSIONS (IN.)

UNIT

SIZE

018, 024, 030

038-080

MINIMUM

MOUNTING PAD

DIMENSIONS

22-1/2 X 22-1t2

30 X 30

TIEDOWN KNOCKOUT

LOCATIONS

A B C

3-11/16 18-1/8 14-3/8

6-1/2 23-1/2 20

Fig. 3--Mounting Unit to Pad

F.,I[_

Do not allow POE lubricant to come into contact with roofing

materiah POE may deteriorate 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'K Refrigerant for wind baffle construction.

NOTE: Unit must be level to within ± 2 ° (± 3/8 in.ift) per

compressor manufacturer specifications.

Step a--Clearance Requirements

When installing, allow sufficient space for airflow clearance,

wiring, refrigerant piping, and service. Allow 30-in. clearance to

smwice 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 l'rom roof or eaves cannot fall

directly on unit.

On rooftop applications, locate unit at least 6 in. above roof

surface.

Step 4--Operating Ambient

The mininmm outdoor operating ambient in cooling mode without

additional accessories is 55°F, and the maximum outdoor operat-

ing ambient in cooling mode is 125°F. The maxinmm outdoor

operating ambient in heating mode is 66°F.

SENSING BULB

SENSING

BULB

EQUALIZER

THERMOSTATIC

EXPANSION

VALVE

Fig. 4_Typical TXV Installation

Step 5--Elevate Unit

A81277

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.

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:RL 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 (:OILS

If TXV installation is required, remove existing AccuRateffK" from

indoor coi!. Refer to Fig. 4 and 5 and install TXV kit (specifically

designed for PuronJ_0 as follows:

i. 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,:P_, no TXV

change is required.

If _an coil is not designed for Puron_, a Puron(P_ TXV installation

is required. Refer to TXV kit Installation Instructions for details on

TXV installation.

r_ |','!:I-']," 11_

Step 7--Check Defrost Thermostat

Check defrost thermostat to ensure it is properly located and

secnrely attached. There is a liquid header with a brass distributor

8 O'CLOCK 4 O'CLOCK

A00399

Fig. 5--Positioning of Sensing Bulb

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 themlostat 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 refiigerant piping an'angements with equivalent lengths

greater than 50 fl and.or when elevation difference between indoor

and outdoor unit is greater than ± 20 fl, follow all requirements of

the Long-Line Guideline section in the Application Guideline and

Service Manual for Residential Split-System Air Conditioners and

Heat Pumps Using Puron® Refrigerant.

FEEDER TUBE

TUBE

DEFROST

THERMOSTAT

A97517

Fig. 6--Defrost Thermostat Location

If required by Long-Line Application Guideline, install LSV kit

part No. KHALS0401LLS specifically designed for Puron_K Heat

Pump. LSV should be installed within 2 ft of the outdoor unit with

flow an'ow pointing toward outdoor unit, 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 selwice ports and open all flow-control devices,

including solenoid valves.

Table 1--Refrigerant Connections and Recommended Liquid Line and Vapor Tube Diameters (In.)

TUBE DIAMETER

UNIT CONNECTION DIAMETER TUBE DIAMETER (ALTERNATE)

SIZE

Liquid Vapor Liquid Vapor Vapor

018, 024 3/8 5t8 3/8 5/8 3/4

030 3/8 3t4 3/8 3/4 5/8, 7/8

036 3/8 3/4 3/8 3/4 5/8, 7/8

042, 048 3/8 7/8 3/8 7/8 3/4

060 3/8 1-!/8 3/8 1- 1/8 7/8

NOTES:

1 Tube diameters are for lengths up to 50 ft For tubing iengths greater than 50 ft horizontal and/or 20 ft vertical differential, consutt 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.

3 If requried by local codes, Pressur Guard TM kit is availaNe. See Product Data Digest for part numbers

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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.

¥:I [_o1]1

If ANY refrigerant tubing is buried, provide a 6 in. vertical

rise at service valve. Refi'igerant tubing lengths up to 36 in.

may be buried. Do NOT bury tubing lengths over 36 in.

Iv.,l[_

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 refi'igerant grade tubing of correct

size and condition. For tubing requirements beyond 50 ft, substan-

tial capacity and performance losses can occur. Following the

recommendations in the Application Guideline and Selwice

Manual for Residential Split-System Air Conditioners and Heat

Pumps using Puron,_.P_ 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 lbr proper system performance.

IMPORTANT: Do not apply indoor coils which are not factory

approved to these units.

INSTALL ADAPTER TUBE

i. 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 robe.

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 smwice valve. Tighten nut finger tight and then with

/_ SWEAT/FLARE

ADAPTER

,STON

LIQUID SERVICE VALVE

A01214

Fig. 7--Liquid Service Valve with Sweat Adapter

Tube

A01215

Fig. 8--Filter Drier with Sweat Adapter Tube and

Liquid Tube

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