Carrier 38AU Installation, Start-Up And Service Instructions Manual
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Carrier 38AU Installation, Start-Up And Service Instructions Manual

Carrier 38AU Installation, Start-Up And Service Instructions Manual

Air-cooled condensing units 60 hz with puron (r-410a) refrigerant sizes 07 – 14
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38AU
Air-Cooled Condensing Units
60 Hz
®
with Puron
(R-410A) Refrigerant
Sizes 07 - 14
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . . . . 9
Step 4 - Rig and Mount the Unit . . . . . . . . . . . . . . . . . . 9
Step 6 - Install Accessories. . . . . . . . . . . . . . . . . . . . . . 11
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Turn On Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . 17
Preliminary Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 -23
38AU Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATING SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . 24
Indoor (Supply) Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cooling, Unit Without Economizer . . . . . . . . . . . . . . . . 24
Cooling, Unit With Economizer . . . . . . . . . . . . . . . . . . . 24
Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
ROUTINE SYSTEM MAINTENANCE. . . . . . . . . . . . . . . 24
Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 24
SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 - 30
Comfort Alert Diagnostic Module. . . . . . . . . . . . . . . 25
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Compressor Protection. . . . . . . . . . . . . . . . . . . . . . . . . . 27
Low-Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . 27
High-Pressure Switches. . . . . . . . . . . . . . . . . . . . . . . . . 27
Outdoor Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replacing NOVATION Condenser Coil . . . . . . . . . . 28
Field Refrigerant Access Ports . . . . . . . . . . . . . . . . . 28
Factory High-Flow Access Ports . . . . . . . . . . . . . . . . 28
Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . 29
Installation, Start-Up and
Service Instructions
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 30 -31
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . 32
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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Summary of Contents for Carrier 38AU

  • Page 1: Table Of Contents

    Follow all safety codes. Wear safety glasses and work gloves. 38AU Units ........19 Use quenching cloths for brazing operations and have a fire OPERATING SEQUENCE.

  • Page 2: Installation Guidelines

    6. If a suction line filter drier is also to be installed, install gloves when handling parts and servicing 38AU units. suction line drier downstream of suction line service valve at condensing unit.
  • Page 3 15.00 50.36 38AUZ*12 [584.2] [508.0] [381.0] [1279.2] 19.00 23.00 15.00 50.36 38AUZ*14 [482.6] [584.2] [381.0] [1279.2] 20.000 23.00 15.00 50.36 38AUD*12 [508.0] [584.2] [381.0] [1279.2] 20.000 24.00 15.00 50.36 38AUD*14 [508.0] [609.6] [381.0] [1279.2] Fig. 1 — 38AU**07-14 Unit Dimensions...
  • Page 4 Table 1A — Physical Data — 38AUZ*07-14 Units — 60 Hz English UNIT SIZE 38AU Z*07 Z*08 Z*12 Z*14 12.5 NOMINAL CAPACITY (tons) OPERATING WEIGHTS (lb) Aluminum-Fin Coils R-410A ‡ REFRIGERANT TYPE † Operating Charge, Typical (lb) 10.2 13.8 18.0...
  • Page 5 Table 1B — Physical Data — 38AUZ*07-14 Units — 60 Hz SI UNIT SIZE 38AU Z*07 Z*08 Z*12 Z*14 21.1 26.4 35.1 NOMINAL CAPACITY (kW) OPERATING WEIGHT (kg) Aluminum-Fin Coils R-410A ‡ REFRIGERANT TYPE † Operating Charge, Typical (kg) Shipping Charge (kg)
  • Page 6 Table 2A — Physical Data — 38AUD*12-14 Units — 60 Hz English UNIT SIZE 38AU D*12 D*14 12.5 NOMINAL CAPACITY (tons) OPERATING WEIGHTS (lb) Aluminum-Fin Coils R-410A ‡ REFRIGERANT TYPE † Operating Charge A/B, Typical (lb) 7.4/7.3 10.8/10.9 Shipping Charge A/B (lb) 3.0/3.0...
  • Page 7 Table 2B — Physical Data — 38AUD*12-14 Units — 60 Hz SI UNIT SIZE 38AU D*12 D*14 35.1 NOMINAL CAPACITY (kW) OPERATING WEIGHT (kg) Aluminum-Fin Coils R-410A ‡ REFRIGERANT TYPE † Operating Charge A/B, Typical (kg) 3.4/3.3 4.8/4.9 Shipping Charge A/B (kg) 1.3/1.3...
  • Page 8 3 8 A U Z A 1 4 A 0 G 6 – 0 A 0 A 0 _____________ ____ Model Type Packaging 38AU= Carrier Condensing Unit 0 = Standard Puronr R--- 410A Refrigerant 1 = LTL Type of Coil...

  • Page 9: Step 1 - Plan For Unit Location

    Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree PROVIDE SAFETY RELIEF — The 38AU unit is provided with power supply provided. with a fusible joint in the suction line in accordance with UNCRATE UNIT —...
  • Page 10 3. Charge unit with R-410A and verify that subcooled liquid exists at TXV by checking for a full liquid line sight glass or by calcu- the 38AU unit are ball valves with stub tube extensions. Do not lating subcooling at TXV.

  • Page 11: Step 6 - Install Accessories

    INDOOR SENSING to 500 microns using a two-stage vacuum pump attached to the COIL CKT 2 BULB service ports outside the 38AU service valves, following de- SIGHT GLASS A LOCATION scription in GTAC II, Module 4, System Dehydration. FILTER DRIER...

  • Page 12: Step 7 - Complete Electrical Connections

    Step 7 — Complete Electrical Connections ELECTRICAL SHOCK HAZARD ELECTRIC DISCONNECT Failure to follow this warning could result in personal SWITCH injury or death. COPPER Do not use gas piping as an electrical ground. Unit cabinet WIRE ONLY must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical ALUMINUM fault should occur.
  • Page 13 Locate its disconnect switch, if appropriate, and open it. Tag-out this switch, if necessary. Two types of convenience outlets are offered on 38AU 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 14 “230” and move it to the connection labelled “208”. box. See Fig. 13. The 38AU unit requires an external temperature control device. This device can be a thermostat (field-supplied) or a PremierLink controller (available as factory-installed option or as field-installed accessory, for use on a Carrier Comfort Network or as a stand alone control).
  • Page 15 Table 6 — Electrical Data — 38AUZ*07-14 60 Hz Units NOMINAL VOLTAGE POWER UNIT FACTORY- COMPRESSOR FAN MOTORS ‡ VOLTAGE RANGE SUPPLY SIZE INSTALLED 38AU OPTION V-Ph-Hz FLA (ea) LRA (ea) MOCP NONE OR DISCONNECT 208/230-3-60 25.2 CONVENIENCE OUTLET NONE OR DISCONNECT 460-3-60 12.9 Z*07...
  • Page 16 Table 7 — Electrical Data — 38AUD*12-14 60 Hz Units NOMINAL VOLTAGE COMPRESSOR COMPRESSOR POWER UNIT FACTORY- FAN MOTORS ‡ VOLTAGE RANGE SUPPLY SIZE INSTALLED 38AU OPTION V-Ph-Hz FLA (ea) LRA (ea) QTY MOCP NONE OR DISCONNECT 40.6 208/230-3-60 CONVENIENCE OUTLET 43.8 NONE OR DISCONNECT 22.5 460-3-60 D*12 CONVENIENCE OUTLET 21.3...

  • Page 17: Pre-Start-Up

    3. Check tightness of all electrical connections. NOTE: The 38AU units are factory charged with the 4. Open the liquid line and suction line service valves. required amount of oil. If recharging in required, use Emka- 5.
  • Page 18 Only the 38AU**12 and 38AU**14 units, that unloads the scroll com- crankcase heater will be energized. pressor when the internal temperature reaches approximately Reset the space thermostat below ambient so that a call for 300°F.
  • Page 19 Fig. 16 — 38AUZ*07 Charging Chart Fig. 17 — 38AUZ*08 Charging Chart...
  • Page 20 Fig. 18 — 38AUZ*12 Charging Chart Fig. 19 — 38AUZ*14 Charging Chart...
  • Page 21 Fig. 20 — 38AUD*12 Charging Chart...
  • Page 22 Fig. 21 — 38AUD*14 Charging Chart...
  • Page 23 Fig. 22 — 38AU Wiring Diagram...

  • Page 24: Operating Sequence

    (supply) fan motor runs. Thermostat contact TC1 • Pulley alignment checked closes; terminal Y1 at 38AU unit receives 24-v. 24-v received • Fan shaft bearing locking collar tightness checked at CADM terminal Y. If anti-recycle time delay period has not •...

  • Page 25: Service

    Line C Line normally. Manual reset requires that main power to the 38AU unit be recycled after the cause for the Alert condition has been Control of the compressor contactor coil is through a detected and corrected.
  • Page 26 Table 8 — LED Status Codes Status LED Status LED Description Status LED Troubleshooting Information Green “POWER” Module has power Supply voltage is present at module terminals Red “TRIP” Thermostat demand signal Y 1. Compressor protector is open LED On Solid is present, but the 2.

  • Page 27: Crankcase Heater

    “NOTE” above for details on R and C wiring. TRIP LED is on but system Verify Y terminal is wired properly per the 38AU wiring and compressor check OK diagram (see Fig. 21). Verify voltage at contactor coil falls below 0.5VAC when off.

  • Page 28: Novation™ Coil Cleaning And Maintenance

    NOVATION™ Coil Cleaning and Maintenance — Repairing NOVATION Condenser Tube Leaks To clean the NOVATION condenser coil, chemicals are NOT RCD offers service repair kit Part Number 50TJ660007 for to be used; only water is approved as the cleaning solution. repairing tube leaks in the NOVATION coil crosstubes.

  • Page 29: Fastener Torque Values

    SEAT CORE (Part No. EC39EZ067) 1/2-20 UNF RH 0.596 45° 30° WASHER DEPRESSOR PER ARI 720 O-RING 1/2" HEX +.01/-.035 5/8” HEX FROM FACE OF BODY This surface provides a metal to metal seal when 7/16-20 UNF RH torqued into the seat. Appropriate handling is required to not scratch or dent the surface.

  • Page 30: Troubleshooting

    TROUBLESHOOTING PROBLEM SOLUTION COMPRESSOR DOES NOT RUN Contactor Open 1. Power off. 1. Restore power. 2. Fuses blown in field power circuit. 2. After finding cause and correcting, replace with correct size fuse. 3. No control power. 3. Check control transformer primary connections and circuit breaker. 4.
  • Page 31 TROUBLESHOOTING (cont) PROBLEM SOLUTION COMPRESSOR RUNNING BUT COOLING INSUFFICIENT Suction Pressure Low 1. Refrigerant charge low. 1. Add refrigerant. 2. Head pressure low. 2. Check refrigerant charge. Check outdoor-air fan thermostat settings. 3. Air filters dirty. 3. Clean or replace filters. 4.

  • Page 32: Appendix

    APPENDIX • Do not install a suction-line filter drier in liquid-line. • POE oils absorb moisture rapidly. Do not expose oil to AIR CONDITIONER AND HEAT PUMP WITH atmosphere. — ® PURON QUICK REFERENCE GUIDE • POE oils may cause damage to certain plastics and roofing materials.
  • Page 34 Catalog No: 38AU-02SI 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. Replaces: 38AU-01SI...

  • Page 35: Start-Up Checklist

    III. START UP START-UP CHECKLIST I. PRELIMINARY INFORMATION OUTDOOR: MODEL NO. SERIAL NO. INDOOR: AIR HANDLER MANUFACTURER MODEL NO. SERIAL NO. ADDITIONAL ACCESSORIES II. PRE-START-UP OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE? (Y/N) IF SO, WHERE: WILL THIS DAMAGE PREVENT UNIT START-UP? (Y/N) CHECK POWER SUPPLY.
  • Page 36 COMPRESSOR AMPS (L1/L2/L3) NOTES: Catalog No: 38AU-02SI 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.

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