Carrier 38AUQ Installation, Start-Up And Service Instructions Manual
Heat pump condensing units 60 hz with puron (r-410a) refrigerant
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38AUQ
Heat Pump Condensing Units
60 Hz
®
with Puron
(R-410A) Refrigerant
Sizes 07, 08, and 12
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . . . . 7
Step 2 - Complete Pre-Installation Checks. . . . . . . . . . 7
Step 3 - Prepare Unit Mounting Support . . . . . . . . . . 7
Step 4 - Rig and Mount the Unit . . . . . . . . . . . . . . . . . . 7
Step 6 - Install Accessories. . . . . . . . . . . . . . . . . . . . . . 10
Step 7 - Complete Electrical Connections . . . . . . . . . 10
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Turn On Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . 15
Preliminary Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 -18
38AUQ Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATING SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . 19
Indoor (Supply) Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cooling Unit Without Economizer . . . . . . . . . . . . . . . . . 19
Cooling, Unit With Economizer . . . . . . . . . . . . . . . . . . . 19
Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Supplemental Heating/Emergency Heating . . . . . . . . 19
Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cooling and Heating Shutdown. . . . . . . . . . . . . . . . . 19
ROUTINE SYSTEM MAINTENANCE. . . . . . . . . . . . . . . 20
SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 31
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 20
Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Synthetic Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Liquid Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . 21
Filed Refrigerant Access Ports . . . . . . . . . . . . . . . . . 21
Outdoor Coil Metering Devices. . . . . . . . . . . . . . . . . 21
Refrigerant System Pressure Access Ports . . . . . . . . 21
Heat Pump Controls. . . . . . . . . . . . . . . . . . . . . . . . . . 22
Commercial Defrost Board . . . . . . . . . . . . . . . . . . . . . . 22
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Compressor Protection. . . . . . . . . . . . . . . . . . . . . . . . . . 22
Low-Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation, Start-Up and
Service Instructions
Comfort Alert Diagnostic Module . . . . . . . . . . . . . . 28
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . 31
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
APPENDIX A
Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . 33
APPENDIX B
Wiring Diagram List. . . . . . . . . . . . . . . . . . . . . . . . . 33
Motormaster Sensor Locations. . . . . . . . . . . . . . . . . 34
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . .CL-1, CL-2
SAFETY CONSIDERATIONS
Improper
installation,
adjustment,
maintenance, or use can cause explosion, fire, electrical shock
or other conditions which may cause 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 package
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloths for brazing operations and have a fire
extinguisher available. Read these instructions thoroughly and
follow all warnings or cautions attached to the unit. Consult
local building codes and appropriate national electrical codes
(in USA, ANSI/NFPA70, National Electrical Code (NEC); in
Canada, CSA C22.1) for special requirements.
It is important to 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,
CAUTION, and NOTE. 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 may 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.
®
-
alteration,
service,
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Related Manuals for Carrier 38AUQ
Summary of Contents for Carrier 38AUQ
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Page 1: Table Of Contents
START-UP........15 -18 38AUQ Units ....... . . 15 OPERATING SEQUENCE. -
Page 2: Installation Guidelines
Replacement /Retrofit – R22 to Puron Split system heat pumps are intended to be installed with matching indoor sections only. The 38AUQ heat pump outdoor units are matched only with same-size 40RUQ indoor sections. Existing R-22 indoor coils cannot be converted to R-410A heat pump duty. - Page 3 Standard Corner Weight UNIT lbs. lbs. lbs. 38AUQ*07 38AUQ*08 38AUQ*12 Fig. 1 — 38AUQ*07-12 Unit Dimensions Corner Corner Corner lbs. lbs. [584] [508] [533] Center of Gravity Unit Height 42-3/8 [660] [330] [1076] 42-3/8 [610] [330] [1076] 50-3/8 [610] [584]...
- Page 4 Table 1A — Physical Data — 38AUQ*07-12 Units — 60 Hz English UNIT SIZE 38AUQ NOMINAL CAPACITY (tons) OPERATING WEIGHTS (lb) Aluminum-Fin Coils ‡ REFRIGERANT TYPE † Operating Charge, Typical (lb) Shipping Charge (lb) COMPRESSOR Qty...Type OUTDOOR FANS Qty...Rpm Motor Hp...
- Page 5 Table 1B — Physical Data — 38AUQ*07-12 Units — 60 Hz SI UNIT SIZE 38AUQ NOMINAL CAPACITY (kW) OPERATING WEIGHT (kg) Aluminum-Fin Coils ‡ REFRIGERANT TYPE † Operating Charge, Typical (kg) Shipping Charge (kg) COMPRESSOR Qty...Type CONDENSER FANS Qty...r/s Motor Hp NEMA...
- Page 6 3 8 A U Q A 1 2 A 0 C 6 _____________ Model Type 38AU= Carrier Condensing Unit Puronr R--- 410A Refrigerant Type of Coil Q = Heat Pump Scroll Compressor Refrigerant Options A = None B = Low Ambient...
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Page 7: Step 1 - Plan For Unit Location
INSTALLATION Jobsite Survey Complete the following checks before installation. 1. Consult local building codes and the NEC (National Electrical Code) ANSI/NFPA 70 for special installation requirements. 2. Determine unit location (from project plans) or select unit location. 3. Check for possible overhead obstructions which may in- terfere with unit lifting or rigging. - Page 8 (where applicable) NOTE: For applications with linear length greater than 100 ft (30.5 m), contact your local Carrier representative. CHECK VERTICAL SEPARATION — If there is any vertical separation between the indoor and outdoor units, check to ensure that the separation is within allowable limits.
- Page 9 15 DIAMS AIRFLOW DIAMS 8 DIAMS LEGEND TXV — Thermostatic Expansion Valve Fig.5 — Location of Sight Glass(es) and Filter Driers (typical 38AUQ/40RUQ size 07 & 08 systems) Table 5 — Refrigerant Specialties Part Numbers. LIQUID LINE LLSV COIL ALC-066208 AMG-24/50-60 †...
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Page 10: Step 6 - Install Accessories
MAKE PIPING CONNECTIONS — Piping connections at the 38AUQ unit are ball valves with stub tube extensions. Do not open the unit service valves until all interconnecting tube brazing as been completed. The stub tube connections include ¼-in SAE service fittings with Schrader valve cores (see Fig. -
Page 11: Convenience Outlets
Locate its disconnect switch, if appropriate, and open it. Tag-out this switch, if necessary. Two types of convenience outlets are offered on 38AUQ models: Non-powered and unit-powered. Both types provide a 125-volt GFCI (ground-fault circuit-interrupter) duplex receptacle rated at 15-A behind a hinged waterproof access cover, located on the end panel of the unit. - Page 12 Convenience Outlet GFCI Pwd-CO Fuse Switch Control Box Access Panel Fig. 10 — Convenience Outlet Location Non-powered type: This type requires the field installation of a general-purpose 125-volt 15-A circuit powered from a source elsewhere in the building. Observe national and local codes when selecting wire size, fuse or breaker requirements and disconnect switch size and location.
- Page 13 Carrier warranty. Field Control Wiring — 38AUQ unit control voltage is 24 v. See Fig. 19 for typical field control connections and the unit’s label diagram for field- supplied wiring details. Route control wires to the 38AUQ unit through the opening in unit’s end panel to the connections...
- Page 14 Table 8 — Electrical Data — 38AUQ*07-12 60 Hz Units UNIT FACTORY- SIZE INSTALLED 38AUQ OPTION NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET...
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Page 15: Pre-Start-Up
On 3-phase units with scroll compressors, it is important to be certain that the compressor is rotating in the proper direction. 38AUQ units are equipped with a Comfort Alert Diagnostic Module (CADM). Alert Code 7 indicates reverse power phas- ing. - Page 16 The unit must be charged in Cooling mode only. Refer to Cool- ing Charging Charts, Fig. 16 through Fig. 18. For applications with line lengths greater than 100 ft, contact Carrier representa- tive. Vary refrigerant until the conditions of the chart are met.
- Page 17 Fig. 16 — 38AUQ*07 Charging Chart Fig. 17 — 38AUQ*08 Charging Chart Fig. 18 — 38AUQ*12 Charging Chart...
- Page 18 Fig. 19 — 38AUQ Wiring Diagram (208/230-3-60 shown)
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Page 19: Operating Sequence
Cooling, Unit Without Economizer When thermostat calls for Cooling, terminal Y1 is energized. The 38AUQ’s Defrost Board (DFB) receives this input at P2-5. DFB issues 24-v outputs at OF, P3-7 (RVS1) and P3-10 (COMP1). The OF output energizes outdoor fan relay (OFR);... -
Page 20: Routine System Maintenance
ROUTINE SYSTEM MAINTENANCE These items should be part of a routine maintenance program, to be checked every month or two, until a specific schedule for each can be identified for this installation: Quarterly Inspection (and 30 days after initial start) Indoor section •... -
Page 21: Liquid Line Filter Drier
Liquid Line Filter Drier The factory-provided reversible filter drier is specifically de- signed to operate with Puron®. Replace the filter drier with factory-authorized components only with a filter drier with desiccant made from 100% molecular sieve grade XH-11. Fil- ter drier must be replaced whenever the refrigerant system is opened. -
Page 22: Heat Pump Controls
1 or 2 stage heating, emergency heating and defrost control with unit operating sequences. See Fig. 22 for board arrangement. The DFB is located in the 38AUQ's main control box (see Fig. 21). All connections are factory-wired. Refer to Table 12 for details of DFB Inputs and Outputs. -
Page 23: Compressor Control
Fig. 22 — Defrost Control Board (DFB) Arrangement Reversing valve control The DFB has two outputs for unit reversing valve control. Op- eration of the reversing valves is based on internal logic; this application does not use an “O” or “B” signal to determine re- versing valve position. - Page 24 Defrost Thermostats These are temperature switches that monitor the surface tem- perature of the outdoor coil circuits. These switches are mount- ed on the liquid tube exiting the outdoor coil heating circuits. These switches close on temperature drop at 30°F (-1°C) and reset open on temperature rise at 80°F (27°C).
- Page 25 Fans Fig. 24 — 38AUQ*07 Exterior Defrost Thermostat (DFT) High Flow Access Ports Fig. 25 — 38AUQ*07 Interior Service Valves Outdoor Coil...
- Page 26 Fans Fig. 26 — 38AUQ*08 Exterior Defrost Thermostat (DFT) High Flow Access Ports Fig.27 — 38AUQ*08 Interior Service Valves Outdoor Coil...
- Page 27 Fans Fig. 28 — 38AUQ*12 Exterior Defrost Thermostat (DFT) High Flow Access Ports Fig. 29 — 38AUQ*12 Interior Service Valves Outdoor Coil...
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Page 28: Comfort Alert Diagnostic Module
Manual reset for lockouts requires that main power to the 38AUQ unit be recycled after the cause for the Alert condition has been detected and corrected. The TRIP LED indicates either a time-delay period is currently active (RED LED is blinking) or the module has locked out the compressor (RED LED is on steady). - Page 29 Table 14 — LED Status Codes Status LED Status LED Description Green “POWER” Module has power Red “TRIP” Thermostat demand signal Y LED On Solid is present, but the compressor is not running. Red “TRIP” LED The anti-short cycle timer (3 minutes), in module is preventing compressor Flashing restart.
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Page 30: Lubrication
R and C terminals have a constant source. See “NOTE” above for details on R and C wiring. Verify Y terminal is wired properly per the 38AUQ wiring diagram (see Fig. 19). Verify voltage at contactor coil falls below 0.5VAC when off. Verify 24VAQC is present across Y and C when thermostat demand signal is present. -
Page 31: Service Parts
Clean coil as follows: 1. Turn off unit power, tag disconnect. 2. Remove top panel screws on outdoor coil end of unit. 3. Remove coil corner post. To hold top panel open, place coil corner post between top panel and center post. 4. -
Page 32: Start-Up
PROBLEM Compressor and Power failure. Outdoor Fan Fuse blown or circuit breaker tripped. Will Not Start. Defective thermostat, contactor, transformer, control relay, or capacitor. Insufficient line voltage. Incorrect or faulty wiring. Thermostat setting too high. High pressure switch tripped. Low pressure switch tripped. Freeze-up protection thermostat tripped. -
Page 33: Low-Pressure Switches
• Vacuum pumps will not remove moisture from oil. • Use only factory specified liquid-line filter driers with rated working pressures greater than 600 psig. 38AUQ Size • Do not install a suction-line filter drier in liquid-line. • POE oils absorb moisture rapidly. Do not expose oil to atmosphere. -
Page 34: Motormaster Sensor Locations
10T HEAT PUMP Fig. 31 Motormaster Sensor Locations per Unit Size Catalog No: 38AUQ-01SI Copyright 2009 Carrier Corp • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 09/09 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. -
Page 35: Start-Up Checklist
I. PRELIMINARY INFORMATION OUTDOOR: MODEL NO. INDOOR: AIR HANDLER MANUFACTURER MODEL NO. ADDITIONAL ACCESSORIES II. PRE-START-UP OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE? IF SO, WHERE: WILL THIS DAMAGE PREVENT UNIT START-UP? CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT? HAS THE GROUND WIRE BEEN CONNECTED? HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? - Page 36 INDOOR UNIT LEAVING-AIR WB TEMP COMPRESSOR AMPS (L1/L2/L3) NOTES: Copyright 2009 Carrier Corp • 7310 W. Morris St. • Indianapolis, IN 46231 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Printed in U.S.A.