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Carrier 38AU manual

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Table of contents for the manual

  • Page 1

    1 38AU Air Cooled Con dens ing U nits 60 Hz W ith P uron R (R - - - 410A) Refrig erant S i z e s 1 6 --- 2 5 Installation, Start - - - Up and Service Instructions CONTENTS SAFET Y CONSIDE RA TIONS 2 .................... INST ALLA TION GUI DEL INE S 2 .................. Replacemen t/Retrofit — R- - 22 to Puro n 2 ........... INS T ALLA TION 1 1 - [...]

  • Page 2

    2 SAF ETY CONSIDERA TIONS Impro per ins tallation, ad justment, alteration, s ervice, maintenance, o r us e can caus e explo sion , fire, electrical shock or other c onditions whic h may c ause personal injury or property dam age. Consult a qua lifi ed insta lle r , service agenc y , or your distributor or branch for infor mation or as sis tance. T[...]

  • Page 3

    3 Same tub e sizes are capable o f handlin g higher flowrates (expressed as tons of cooli ng capa cit y) w it h Puron refrigera nt com pared t o R - - 22 at consta nt pressure drops. For examp le, a 1 / 2 - - inch O D liquid line is rated at 33% higher tons with Puron R than with R- - 22 (at 5 _ F pressure drop). A 1 1 / 8 - - inch OD s uction line[...]

  • Page 4

    4 C10942 UNI T Standar d Wei g h t Corner A Corner B Corner C Corner D Cent er of Gravi ty Unit Heig ht lbs. kg . lbs. kg . lb s. kg. lb s. kg. lb s. kg. X Y Z H 38AUZ*16 (MC HX ) 633 288 220 100 134 61 135 61 144 65.5 38 [965.2] 19 [482.6] 15 [381] 50 3 / 8 [1279.2] 38AUD *16 (MC HX ) 633 288 220 100 134 61 135 61 144 65.5 38 [965.2] 19 [482.6] 15[...]

  • Page 5

    5 C10943 UNI T Standar d Wei g h t Corner A Corner B Corner C Corner D Cent er of Gravi ty Unit Heig ht lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. X Y Z H 38AUZ*25 (RT PF) 978 444 360 163 188 85 147 67 283 128 38 [965.2] 23 [584.2] 17 [431.8] 50 3 / 8 [1279.2] 38AUD *25 (RT PF) 978 444 360 163 188 85 147 67 283 128 38 [965.2] 23 [584.2] 17 [431.8[...]

  • Page 6

    6 Tab le 1A — Ph ysical Data — 38AUZ*16-25 Un i ts — 60 Hz En gl i sh UNI T SIZE 38A U Z*16 Z*25 NOM INA L C APAC IT Y ( ton s) 15 20 OPERA TING WEI GHTS (lb ) NOVAT IO N ™ Coil ( Al T ube) 633 --- Round T ube/P late Fin Coil ( Cu/Al ) 731 900 REFRIGERAN T TYPE ‡ R-410A NOVA TION Opera ting C har ge, T ypica l (lb) † 24.6 --- NOVATION S[...]

  • Page 7

    7 Tab le 1B — Ph ysical Data — 38AUZ*16-25 Un i ts — 60 Hz SI UNI T SIZE 38A U Z*16 Z*25 NOM INA L C APACI T Y (k W) 52.7 70.3 OPERA TING W EIGHT (k g) NOVAT IO N ™ Coil ( Al T ube) 288 --- Round T ube/P late Fin Coil ( Cu/Al ) 332 409 REFRIGERAN T TYPE ‡ R-410A NOVA TION Opera ting C har ge, T ypica l (kg) † 11.1 --- NOVA TION Shippin [...]

  • Page 8

    8 Tab le 2A — Ph ysical Data — 38AUD*16-25 Uni ts — 60 Hz En g li sh UNI T SIZE 38A U D*16 D* 25 NOM INA L C APAC IT Y ( ton s) 15 20 OPERA TING WEI GHTS (lb ) NOVAT IO N ™ Coil ( Al T ube) 633 --- Round T ube/P late Fin Coil ( Cu/Al ) 731 900 REFRIGERAN T TYPE ‡ R-410A NOVA TION Opera ting Cha rge A/B, T ypical (lb) † 12.0 / 12.0 --- N[...]

  • Page 9

    9 Tab le 2B — Ph ysical Data — 38AUD*16-25 Uni ts — 60 Hz SI UNI T SIZE 38A U D*16 D* 25 NOM INA L C APACI T Y (k W) 52.7 70.3 OPERA TING W EIGHT (k g) NOVAT IO N ™ Coil ( Al T ube) 288 --- Round T ube/P late Fin Coil ( Cu/Al ) 332 409 REFRIGERAN T TYPE ‡ R-410A R-410A NOVA TION Opera ting Ch arge A /B, T y pical (kg) † 5.4 / 5.4 --- NO[...]

  • Page 10

    10 Model T ype 3 8 A U = Ca rr i e r Condensing Unit Puron ® R - - - 410A Refrigerant Ty p e o f C o i l D = Dual Circuit, A/C Scroll Compressor Z = Single Circuit, A/C Scroll Compressor Refr igera nt Options A = None B = Low Ambient No minal T onnage 16 = 15 T ons 25 = 20 T ons Not U se d A = Not Used Not U se d 0 = Not Used 38 A U Z A 25A 0 G 6A[...]

  • Page 11

    11 Matching 38AU Model T o Evaporator Coil The Model 38AUZ is a single-circ uit unit design, requiring one set of re frigera tion pi ping. T his mode l ca n be connected to an ev aporato r coil with one circuit or with two circ uits (by mani folding the eva porator connec tions into a sing le piping s ystem). The Model 38AUD is a dua l-ci rcuit uni[...]

  • Page 12

    12 Ste p 3 — Pr epar e Unit M ount ing Support Sla b Mo unt — Pro vide a level co ncrete s lab that extend s a minimu m of 6 in. (150 m m) beyond uni t ca binet . Insta ll a grave l a pron in front of condenser c oil a ir inl et to prevent grass and foliage from obstruct ing ai rflow . Ste p 4 — Rig and Mo unt the U nit UNIT DAMAG E HAZ ARD F[...]

  • Page 13

    13 Enter the appr opriate table to select the recommended line sizes . Model : Line Sizes T a ble Qu a nti ty of L in e Se ts 38AU Z 5 1 38AU D 6 2 Liqui d Li ft — A liquid lift condition exi sts when the outdoor unit is loca ted be low the indoor (evaporat or) unit a nd liquid flow s vertically u p in a portion of th e liquid line. The vertic al[...]

  • Page 14

    14 T abl e 6 – 38 AUD 16- 25 P ipi ng Rec o mme ndat io ns (T wo-Ci rcui t Uni t) NOT E : 38AUD requires TWO set s of ref rigeration pip ing R - 410A Equival ent Length Ft 0-38 38-75 75-113 113-150 150-188 m 0-12 12-23 23-34 34-46 46-57 Model Linea r Length Ft 0-25 25-50 50-75 75-100 100-125 m 0-8 8-15 15-23 23-30 30-38 38AUD *16 Liquid Li ne 1 /[...]

  • Page 15

    15 Circuit 1 Connections Circuit 2 Connections CKT 1 CKT 1 CKT 2 CKT 2 C10355 Fig. 6 - - 38AUD S ervi ce V alve Locati ons Plan the Ci rcuit 1 and Circ uit 2 t ubing segme nts care fully , mark each seg ment and check cons tantly as piping sys tems are assembled to av oid pipin g errors . 38AUD uni t cannot be fi eld-pi ped as a sing le-circuit/tan[...]

  • Page 16

    16 INDOOR COIL CKT 2 AIRFLOW INDOOR COIL CKT 1 AIRFLOW 15 DIAMS MIN 10 DIAMS 8 DIAMS MIN TXV SENSING BULB EQUALIZER LINE SIGHT GLASS A LOCATION SIGHT GLASSES B LOCA TION TXV CKT 2 FIL TER DRIER A LOCATION FIL TER DRIERS B LOCA TION FLOW TXV SENSING BULB TXV CKT 1 8 DIAMS MIN 15 DIAMS MIN 10 DIAMS Single Circuit Coil Piping Configuration For single [...]

  • Page 17

    17 The stub tube connec tions incl ude 1 / 4 -in SAE service fittings with S chrader valve cor es (see F ig. 10). Bef ore making any brazed connections to the unit service valves, remove bot h Schrader va lve c aps and core s and save for re-instal lat ion. Conne ct a source for ni trogen to one of these s ervice fittings during tube brazin g to pr[...]

  • Page 18

    18 Step 7 — Co mpl ete El ectrica l Co nn ecti on s ELECTRIC AL SHOCK HAZARD Failure t o follow thi s warning could result in personal injury or dea th. Do not use ga s pi ping as an e lec tric al ground. Unit cabine t m ust have an unint errupte d, unbroke n ele ctri cal ground to minimize the poss ib ility of pers onal i njury if an ele ctri ca[...]

  • Page 19

    19 11 1 3 L1 L2 L3 CT B 1 208/230-3-60 460-3-60 575-3-60 Units Without Disconnect Option Units With Disconnect Option 2 4 6 1 3 5 L1 L2 L3 Optional Disconnect Switch Disconnect factory test leads; discard. Factory Wiring Disconnect per NEC C10204 Fig. 12 - - Power W iring Con nectio ns Af fix the crankc ase hea ter warni ng sticke r to the unit dis[...]

  • Page 20

    20 B 50HJ542739 Maximum Continuous use : 8 A mps 24/7 Conv enience Outlet Utilization NOTICE C10207 Fig. 15 - - Conv enien ce Outlet Utilizat ion N otice La bel T est the GFC I receptacle by press ing the TEST button on the face of the r eceptacle to trip and open the receptacle. Check for prope r grounding wires and power line phasing if the GFCI [...]

  • Page 21

    21 Th ermost at — Ins tall a Carrier -approv ed access ory thermos tat according to installatio n instr uctions included w ith the accessor y . Locate the thermostat accesso ry on a solid wall in the conditi oned space to sense average te mpera ture in accordan ce with the thermo stat installatio n instr uctions . The 38A UZ is a s ingle-circu it[...]

  • Page 22

    22 T ab le 10 – U nit W ire/Fus e or HAC R Brea ker S izing D ata UNIT SIZE 38AU NOMI NAL POWE R SUPPL Y VOL TAGE RANGE COMP RESSOR N O C.O . or UNPW RD C.O . No. 1 No. 2 OFM POWER SU PPL Y DISC ONNE CT SI ZE V --- P h --- H z Min Max RLA LRA RLA LRA Qty FLA (ea) MCA FUSE o r HACR BRKR FLA LRA D*16 Z*16 208/230 - - - 3 - - - 60 187 253 25.0 164 2[...]

  • Page 23

    23 PRE- ST AR T -UP IMP ORT ANT : Before be ginning Pre-Start-Up or Star t-Up, rev iew Start- Up Ch ecklist at the b ack of th is book. The Checkl ist assures proper start-up of a unit and provides a record of unit condi tion, appli cat ion requirem ents, system inform ati on, and operati on at initial star t-up. UNIT DAMAG E HAZ ARD Failur e to fo[...]

  • Page 24

    24 Compr essor Ove rload — This overl oad i nterrupt s power to the compre ssor when either the curren t or internal moto r wind ing temperatu re becomes ex cess ive, and automatically res ets when the interna l tem perat ure drops to a safe level. T his ove rload may requi re up to 60 m inute s (or l onger) t o reset. If the interna l overl oad [...]

  • Page 25

    25 38AUZ* 25 Chec k Compre ssor Oi l Le ve l — After adjusting the re frigera nt charge, al low the uni t t o run fully loaded for 20 minutes . Stop th e compres so rs and chec k the oil le vel. Oil l evel should be 1 / 3 to 1 / 2 up on the sight gla ss (see Fig. 22). 1 / 3 (MIN) 1 / 2 (MAX) C01377 Fig. 22 - - Recomme nded Oil Level — 38AUZ*25 [...]

  • Page 26

    26 (CIRCUIT 1) (CIRCUIT 2) C10946 Fig. 24 - - 38AUD*16 Charging Ch art (Novation) 38AU[...]

  • Page 27

    27 C10947 Fig. 25 - - 38AUZ*16 Charging Chart (R TP F) C10948 Fig. 26 - - 38AUZ*25 Charging Chart (R TP F) 38AU[...]

  • Page 28

    28 C10949 Fig. 27 - - 38AUD*16 Charging Ch art (RTPF) 38AU[...]

  • Page 29

    29 (CIRCUIT 1) (CIRCUIT 2) C10950 Fig. 28 - - 38AUD*25 Charging Ch art (RTPF) 38AU[...]

  • Page 30

    30 C10212A Fig. 29 - - T ypical 38AUZ W i ring Diagram - (15 T on 230V T andem Unit Sh own) 38AU[...]

  • Page 31

    31 C10213A Fig. 30 - - T ypical 38AUD Wiring Diagram - (15 T on 230V Dual Un it Shown) 38AU[...]

  • Page 32

    32 OPERA T ING SEQUENCE Base Unit Controls Indoor (Suppl y) F an — The indoor fa n conta ctor (IFC) is rem otel y loca ted at the fan coil or fan s ection. If the thermo stat fan op eration is selected as Continuous, the IFC i s energized and the indoor (supply) fan motor runs continuously . If the the rmostat fan ope rati on is selected as Au to[...]

  • Page 33

    33 ROUTINE SYSTEM MAINTENANCE These ite ms should be part of a routine mai ntena nce prog ram, to be checked ever y month or tw o, until a specific sched ule for each can be iden tified for this installation: Quarterl y Inspection (and 30 days after i nitial start) — Ind oor secti on S Condenser c oil clea nline ss checke d. S Return air f ilter [...]

  • Page 34

    34 Liq uid L ine Filter D rier — The factory -pro vided filter dr ier is sp ecifically designed to operate w ith Puro n ® . Replace the filter drier with factory-authori zed components onl y with a filter drier with desiccant made from 100% molecular sieve grade XH -1 1. Filter dr ier must be replaced whenever th e refrigera nt system is opened.[...]

  • Page 35

    35 Comfort Alert Diagnostic Module The Comfort Alert Diagnostic Module (CAD M) moni tors and anal yzes data from the Cope land Scroll ® three-ph ase compressor and t he t hermosta t de mand. The CADM also prov ides a 3 -minute anti- recycle time delay to comp ress or cycli ng. Ea ch c ompressor has a separat e CADM module . The CAD M detects caus [...]

  • Page 36

    36 T abl e 11 – LED Status Code s Status LED Status LE D Descr iption S tat us LED T roub lesho oti ng Informat ion Green “PO WER” Mo du le h as p ow er Supp ly voltage is present a t module terminals Red “TRIP” LED On Sol id The rmostat d ema nd sign al Y is prese nt, but the com - pres sor is n ot running. 1. Compressor protect or is op[...]

  • Page 37

    37 T abl e 12 – CADM T ro uble shoo ti ng Miswi red Module Indic ation Recommended T r oublesho oting Act ion Green L ED is not on, mo dule does no t power up Determi ne if b oth R and C module terminal s are connected. Veri fy v oltage in present at module’s R and C termi nals. NOT E : The CADM r equires a cons tant nom inal 2 4V AC power s up[...]

  • Page 38

    38 Condenser Fans/Motors Service V alves Access Panel - Control Box & Compressors C10087 Fig. 34 - - 38AUD S iz e 16 Cabinet C10095 Fig. 35 - - 38AUD*16 Piping 38AU[...]

  • Page 39

    39 Equalization LPS Oil Equalizer Line C10079 Fig. 36 - - 38AUZ*16 Compr essor Assembly (Rear V iew) C10214 Fig. 37 - - 38AUD*16 Compr essor Ass embly (Rear V iew) 38AU[...]

  • Page 40

    40 Condenser Fans/Motors Service V alves Access Panel - Control Box & Compressors C10089 Fig. 38 - - 38AUZ,D Size 25 Cabinet CKT 2 CKT 2 CKT 1 CKT 1 HPS LPS HPS LPS C10090 Fig. 39 - - 38AUD*25 Piping 38AU[...]

  • Page 41

    41 C10215 Fig. 40 - - 38AUZ*25 Compr essor Assembly (Rear V iew) C10091 Fig. 41 - - 38AUD*25 Compr essor Ass embly (Rear V iew) 38AU[...]

  • Page 42

    42 Coil T ype Identifica tion 38AU units are ava ila ble with different coil types. Cl eani ng methods dif fer for each type so identifying the coil type is importa nt. Unit m odel number a nd appea rance ca n ident ify the coi l type. NOV A TIO N t Ty p e — The ne w NOV A TION Heat Exchange r T ec hnology is a n all - - a luminum construc tion w[...]

  • Page 43

    43 oxyacety lene fuel an d torch . While the flame temperature for M AP P is low er than that of oxyacety lene (and thus prov ides mor e flexibility wh en work ing on aluminum), the flame temperatu re is s till higher than the melting temperatur e of aluminum, so u ser cautio n is required. Fo llow inst ructions carefully . Use the h eat shield . R[...]

  • Page 44

    44 7. Hold garden spraye r nozzl e cl ose to finned are as and apply c lea ner with a verti cal , up-and-down motion. A void sp raying in h orizontal patter n to min imize po- tential for fin d amage. 8. Ensure cle aner thoroughly pene trat es deep i nto finne d areas . 9. Interior a nd exteri or finned area s must be thoroughly cleaned. 10. Finned[...]

  • Page 45

    45 TROUBLESHOOTING (cont ) PROBLEM SOLUTION COMP RESSOR CYCLES ON L OW- PRESSURE SWITCH Indoor-Air Fan Running 1. Li q u i d l in e so le n o i d v a l v e ( s) f a i l s to op e n . 1. C heck li qu id line s olenoid valve(s) for proper operation. Replace if necessary . 2. Fil te r drie r plugged. 2 . Repl ace fi lter dr ier . 3. Expan sion valve p[...]

  • Page 46

    46 APP ENDIX A Air Conditioner & Hea t P ump with PURON ® — Quick Reference Gui de S Puro n ® (R-410A) refrigera nt operat es at 50 percent t o 70 perce nt higher pre ssures than R-22. Be sure tha t servicing equipment and replacement c omponents are designed to ope rate with Puron ® . S Puro n ® refri gerant c ylinders are rose colore d.[...]

  • Page 47

    47 APP ENDIX C Low Ambie nt Option — F actory I nstalled Units with th e factory ins talled low ambient option are equippe d with a Motorma ster R sol i d - - sta te h ea d pr essu re contr ol which reg ulates fan s peed. A temper ature sen sor , mounted on c ircui t 1 of the outdoor coi l (see Figs. 44 and 45) controls the speed of approved outd[...]

  • Page 48

    48 Motormaster Sensor - Attach to Circuit 1 coil only . 508 mm (20 in) for Single Circuit 254 mm (10 in) for Dual Circuit C10093 Fig. 44 - - Motor master Sensor Location: 38AUZ*16 & 38AU D*16 (Novation) Motormaster Sensor - Must be positioned on V apor Stub of Circuit 1 coil only . C10094 Fig. 45 - - Motor master Sensor Location: 38AUZ*16/25 &a[...]

  • Page 49

    49 T a b l e1 4–W i n dB a f f l eD i m e n s i o n DIM E NSI ONS - - - INC H E S UNI T BAFFLE A B C D E F G H J 38AU Z* 16 38AU D*16 (MCHX) LEFT SI DE 19 3 / 4 20 1 / 2 21 1 / 4 43 1 / 8 8 3 / 8 18 27 1 / 4 40 --- BACK 80 1 / 4 81 81 3 / 4 43 1 / 8 8 3 / 8 18 27 1 / 4 40 --- RIGHT S IDE 38 3 / 4 39 1 / 2 40 1 / 4 43 1 / 8 8 3 / 8 18 27 1 / 4 40 [...]

  • Page 50

    50 C10363A Fig. 46 - - Wind Baffles - - Fabrication 38AU[...]

  • Page 51

    51 C10366 Fig. 47 - - 15 T on Wind Baffle Brackets - - Fabrication 38AU[...]

  • Page 52

    52 RIGHT BACK LEFT FRONT BOTTOM BRACKET TOP BRACKETS C10367 Fig. 48 - - Wind Baffle Installation — 15 T on Unit s 38AU[...]

  • Page 53

    53 RIGHT BACK LEFT FRONT C10368 Fig. 49 - - Wind Baffle Installation — 20 T on Unit s 38AU[...]

  • Page 54

    54 Copyright 2010 Carrier Corp. D 7310 W . Morris St. D I ndianapolis, I N 46231 Pr inted in U. S.A. Edition Date: 11/10 Manufacturer reser ves the right to change, at any time, specifications and d esigns without notice and without oblig ations. Catal og No : 38AU - - - 09SI Replaces : 38AU - - - 07SI 38AU[...]

  • Page 55

    55 ST AR T -UP CHECKLIST I. P RELIMINAR Y INFORMA TION OUTDOOR: MODEL NO. SERI AL NO. INDOOR: AIRHANDLE R MANUF ACTUR ER MODEL NO. SERIAL NO. ADDITI ONAL ACCE SSORI ES II. PRE-ST AR T -UP OUTDOOR UNIT IS THE RE ANY SHIPPI NG DAMAGE? (Y/N) IF SO, WHERE: WI LL T HIS DAMAGE PREVE NT UNIT ST AR T - UP? (Y/N) CHEC K POWE R SUPPL Y . DOE S IT AGREE W IT [...]

  • Page 56

    56 CHECK VOL T AGE IMBALANCE LINE -TO-L INE VOL T S: AB V AC V B C V (AB + AC + BC)/ 3 = A VE RAGE VOL T AGE = V MAXIMUM DEVI A T ION FR OM A VE RAGE VOL T AGE = V VOL T AGE IMBAL ANCE = 10 0 X (MAX DE VIA TION) /( A VE RAGE VOL T AGE ) = IF O VER 2% V OL T AGE IM BALAN CE, DO NO T A TTEMP T TO ST AR T SYS TEM! CALL L OCAL POW E R COMP ANY FOR ASSI[...]