Carrier Gemini 38AU07 Series Installation Instructions Manual
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Carrier Gemini 38AU07 Series Installation Instructions Manual

Air-cooled condensing units with puron (r-410a) refrigerant
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CONTENTS
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION GUIDELINES. . . . . . . . . . . . . . . . . . . . . 2
Replacement/Retrofit - R-22 to Puron . . . . . . . . . . . 2
Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . . . 3
Identify Factory Options . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . . . 6
Step 4 - Rig and Mount the Unit . . . . . . . . . . . . . . . . . 7
Suction Riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 7 - Install Accessories . . . . . . . . . . . . . . . . . . . . 14
Step 9 - Wind Baffles for Low Ambient
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Turn on Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . 23
Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Start Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . 32
Base Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
38AUDC with SVR Relays . . . . . . . . . . . . . . . . . . . . . . . 33
All Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Quarterly Inspection (and 30 Days After
Initial Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Comfort Alert Diagnostic Module . . . . . . . . . . . . . . . 36
Compressor Protection . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . 39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Appendix B - Wiring Diagram List . . . . . . . . . . . . . 42
Appendix B - Low Ambient-Option,
Factory Installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, main-
tenance, or use can cause explosion, fire, electrical shock or
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53380020-01
Installation Instructions
Page
Printed in U.S.A.
Form 38AU-7-14-03SI
Air-Cooled Condensing Units
®
with Puron
(R-410A) Refrigerant
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 quali-
fied installer or agency must use factory-authorized kits or ac-
cessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when
installing.
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. Con-
sult local building codes and appropriate national electrical
codes (in USA, ANSI/NFPA 70, 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 per-
sonal injury.
Understand the signal words DANGER, WARNING, CAU-
TION, 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 signi-
fies hazards which could result in personal injury or death.
CAUTION is used to identify unsafe practices, which may re-
sult in minor personal injury or product and property damage.
NOTE is used to highlight suggestions which will result in en-
hanced installation, reliability, or operation.
FIRE, EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury or death.
Disconnect gas piping from unit when leak testing at pres-
sure greater than 0.5 psig (3450 Pa). Pressures greater than
0.5 psig (3450 Pa) will cause gas valve damage resulting in
hazardous condition. If gas valve is subjected to pressure
greater than 0.5 psig (3450 Pa), it must be replaced before
use. When pressure testing field-supplied gas piping at
pressures of 0.5 psig (3450 Pa) or less, a unit connected to
such piping must be isolated by closing the manual gas
valve.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could cause personal injury
or death.
Before performing service or maintenance operations on
unit, always turn off main power switch to unit and install
lock(s) and lockout tag(s). Unit may have more than one
power switch.
Pg 1
Gemini™
38AU07-14
WARNING
WARNING
1-19
Replaces: 38AU-7-14-02SI

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  • Page 1: Table Of Contents

    Gemini™ 38AU07-14 Air-Cooled Condensing Units ® with Puron (R-410A) Refrigerant Installation Instructions other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your CONTENTS distributor or branch for information or assistance. The quali- Page fied installer or agency must use factory-authorized kits or ac- cessories when modifying this product.

  • Page 2: Installation Guidelines

    INSTALLATION GUIDELINES WARNING Replacement/Retrofit — R-22 Puron® Refrigerant UNIT OPERATION AND SAFETY HAZARD Replacement/retrofit installations require change-out of Failure to follow this warning could cause personal injury, outdoor unit, metering device, and filter driers. Change-out death and/or equipment damage. of indoor coil (evaporator) and interconnecting tubing is Puron (R-410A) refrigerant systems operate at higher pres- recommended.

  • Page 3: Rated Indoor Airflow (Cfm)

    Evacuate and charge the system according to the instruc- Table 2 — Equivalent Lengths for Common Fittings tions in this installation manual. (ft) Operate the system for 10 hr. Monitor the pressure drop ELBOWS NOMINAL across the suction line filter drier. If pressure drop TUBE OD 90°...
  • Page 4 10 11 12 13 14 15 16 17 18 3 8 A U D C 1 2 A 0 A 6 A 0 A 0 A 0 Model Type Packaging 38AU = Carrier Condensing Unit 0 = Standard ® Puron R--- 410A Refrigerant...
  • Page 5 Fig. 3 — 38AUD/Z 07-14 Base Unit Dimensions...

  • Page 6: Installation

    Table 5 — 38AU Corner Weights STD. UNIT UNIT CORNER A CORNER B CORNER C CORNER D CENTER OF GRAVITY HEIGHT UNIT lbs. lbs. lbs. lbs. lbs. 42 3/8 38AUZ*07 (RTPF) [457.2] [609.6] [533.4] [1076.0] 38AUZ*08 42 3/8 (RTPF) [457.2] [609.6] [533.4] [1076.0]...

  • Page 7: Step 2 - Complete Pre-Installation Checks

    Equivalent Lengths for Common Fittings, for usual fitting types. Also identify adjustments for refrigeration specialties. INSPECT SHIPMENT Refer to Part 3 of the Carrier System Design Manual for addi- File a claim with shipping company if the shipment is tional data and information on equivalent lengths.
  • Page 8 Table 7 — 38AUZ Piping Recommendations (Single-Circuit) MODEL & LINEAR LINE (FT) 0 - 25 25 - 50 50 - 75 75 - 100 100 - 125 125 - 150 150 - 175 175 - 200 NOMINAL EQUIV. LINE (FT) 0 - 38 38 - 75 75 - 113...
  • Page 9 22.0 Charge (lb) 1/2 NOTES: 1. 38AUDC units require TWO sets of refrigeration piping. 2. For applications with equivalent length greater than 188 ft. (57 m.) and/or linear length greater than 125 ft. (38 m.), contact your local Carrier representative.

  • Page 10: Suction Riser

    Suction Riser lines data under VAPOR RISER GREATER Suction Riser THAN 20 FT (6.1 M). See Fig. 6. Tube S is the horizontal A suction riser condition exists when the outdoor unit is line size. Tube A is the reduced diameter riser size without located above the indoor (evaporator) unit and suction vapor bottom trap;...
  • Page 11 38AUD PIPING CONNECTIONS The 38AUD unit’s two circuits are designated Circuit 1 and Circuit 2. Circuit 1 is controlled by the thermostat’s Y1 (or TC1) contact and will be the first circuit on and last circuit off. Circuit 2 is controlled by the thermostat’s Y2 (or TC2) contact and this circuit is always the “lag”...
  • Page 12 Select the filter drier for maximum unit capacity and mini- mum pressure drop. Complete the refrigerant piping from the EQUALIZER LINE indoor unit to the outdoor unit before opening the liquid and SENSING BULB suction lines at the outdoor unit. AIRFLOW INSTALL LIQUID LINE SOLENOID VALVE 15 DIAMS...
  • Page 13 Factory Shipping Charge: 9 lbs SWEAT CONNECTION Field-Charge quantity: 18.5 - 9.0 = 9.5 lbs For linear line lengths longer than 125 ft (38 m), contact Fig. 11 — Typical Piping Connection Assembly your local Carrier representative for system charge value.

  • Page 14: Step 7 - Install Accessories

    Step 7 — Install Accessories WARNING Accessories requiring modifications to unit wiring should be completed now. These accessories may include Winter FIRE HAZARD Start controls and Low Ambient controls. Refer to the in- Failure to follow this warning could result in personal injury, structions shipped with the accessory.
  • Page 15 mounted non-fused disconnect or HACR breaker switch; this will provide service power to the unit when the unit disconnect Units Without Disconnect Option switch or HACR switch is open. Other connection methods will result in the convenience outlet circuit being de-energized when the unit disconnect or HACR switch is open.
  • Page 16 (air handler or packaged fan coil). Fig. 20 (38AUZ) and 21 shown in Fig. 16. Remove two slot fillers in the bottom of the (38AUD) depict typical connections to a Carrier 40RU fan coil cover to permit service tool cords to exit the cover. Check for unit.
  • Page 17 Table 13 — 38AUZ 07-14 Cooling without Powered Convenience Outlet COMPRESSOR VOLTAGE RANGE POWER SUPPLY DISCONNECT SIZE NO. 1 UNIT STAGE V-Ph-Hz SIZE Fuse or COOLING FLA (ea) HACR Breaker 575-3-60 208/230-3-60 17.5 25/25 30/30 24/24 142/142 460-3-60 575-3-60 208/230-3-60 19.6 28/28 45/45...
  • Page 18 Table 15 — 38AUD 12, 14 Cooling without Powered Convenience Outlet NOMINAL COMPRESSOR COMPRESSOR DISCONNECT POWER VOLTAGE RANGE POWER SUPPLY No. 1 No. 2 SIZE SUPPLY UNIT SIZE Fuse or Volts HACR (ea) Brkr 208/230-3-60 15.9 15.9 39/39 50/50 40/40 226/226 460-3-60 575-3-60...
  • Page 19 Fig. 17 — Typical Single Circuit/Single Stage 38AUZ Wiring Diagrams...
  • Page 20 Fig. 18 — Typical Single Circuit/Two-Stage 38AUZ Wiring Diagram...
  • Page 21 Fig. 19 — Typical Dual Circuit/Two-Stage 38AUD Wiring Diagram...
  • Page 22 THERMOSTAT 38AUZ UNIT Install a Carrier-approved accessory thermostat according 38AUZ(A,B) unit is a single-stage cooling unit. If no to installation instructions included with the accessory. For economizer function is required, select a single-stage cooling typical thermostat connections see Fig. 20 (38AUZ) and 21 thermostat.

  • Page 23: Control

    Charging, Recover, Recycling, and Reclamation for liquid Step 9 — Wind Baffles for Low Ambient Control charging procedures. Models 38AZB and 38AUDB include the factory installed 32LT Motormaster Low Ambient Control. Model 38AUDC (with hot gas bypass option) also includes the 32LT Motormaster CAUTION Low Ambient Control as a standard feature.

  • Page 24: Start Unit

    ADJUST REFRIGERANT CHARGE Refer to Cooling Charging Charts, Fig. 25-32. For applica- tions with line lengths greater than 125 ft (38 m), contact Carrier representative. Vary refrigerant until the conditions of the chart are met. Note that the charging charts are different from the type normally used.
  • Page 25 6 Ton Charging Chart R-410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve 1050 1400 1750 2100 2450 2800 3150 3500 3850 Pressure at Liquid Valve (PSIG / Kpa) 38AU501045 Fig. 25 — 38AUZA/B07 Charging Chart (RTPF)
  • Page 26 7.5 Ton Charging Chart R-410A Refrigerant Add Charge if Add Charge if Above the Curve Above the Curve Remove Charge if Remove Charge if Below the Curve Below the Curve 1050 1400 1750 2100 2450 2800 3150 3500 3850 Pressure at Liquid Valve (PSIG / Kpa) 38AU501046 Fig.
  • Page 27 10 Ton Charging Chart R-410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve 1050 1400 1750 2100 2450 2800 3150 3500 3850 Pressure at Liquid Valve (PSIG / Kpa) 38AU501047 Fig. 27 — 38AUZA/B12 Charging Chart (RTPF)
  • Page 28 12.5 Ton Charging Chart R-410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve 1050 1400 1750 2100 2450 2800 3150 3500 3850 Pressure at Liquid Valve (PSIG / Kpa) 38AU501048 Fig. 28 — 38AUZA/B14 Charging Chart (RTPF)
  • Page 29 6 TON DUAL STAGE CHARGING CHART PURON (COMPRESSOR FULL LOAD, ALL CONDENSER FANS OPERATING) Add Charge if Above the Curve Remove Charge if Below the Curve 1050 1400 1750 2100 2450 2800 3150 3500 3850 Pressure at Liquid Valve (PSIG / Kpa) PN: 38AU000484 REV - Fig.
  • Page 30 7.5 Ton Dual Stage Charging Chart R-410A Refrigerant Fig. 30 — 38AUZD/E08 Charging Chart (RTPF)
  • Page 31 10 Ton Circuit A Charging Chart R-410A Refrigerant 10 Ton Circuit B Charging Chart R-410A Refrigerant Add Charge if Add Charge if Above the Curve Above the Curve Remove Charge if Remove Charge if Below the Curve Below the Curve 100 150 200 250 300 350 400 450 500 550 600 100 150 200 250 300 350 400 450 500 550 600 350 700 1050 1400 1750 2100 2450 2800 3150 3500 3850...

  • Page 32: Operating Sequence

    38AUD (Two Circuit) OPERATING SEQUENCE On a thermostat call for Cooling, IFC will be energized Base Unit Controls and indoor (supply) fan motor runs. Thermostat output Y1 is energized; terminal Y1 at 38AUD unit receives 24-v. 24-v re- INDOOR (SUPPLY) FAN ceived at CADM1 terminal Y.

  • Page 33: 38Audc With Svr Relays

    EVAPORATOR COIL WATCH YOUR SUCTION RISERS SUCTION LINE HOT GAS DE-SUPERHEAT HOT GAS LINE CHAMBER CONDENSER LIQ INJ BULB COIL TO SUCTION LINE HOT GAS BULB TO SUCTION LINE SOLENOID AND INSULATE VALVE SCHRADER VALVE AT BOTTOM COMPRESSOR Fig. 33 — Hot Gas Bypass Option 38AUDC with SVR Relays With no thermostat demand, there will be no voltage at LVTB-A1;...

  • Page 34: Maintenance

    CADM terminal Y but no current is measured at T1, T2, T3 SERVICE motor sensors); CADM relay opens and RED LED is illumi- Refrigeration System nated. TRIP condition maintains lockout of compressor oper- ation until CADM is manually reset. Reset CADM by cycling unit main power.
  • Page 35 These ports are -in. SAE Flare couplings with Schrader (see Fig. 37 and 38). These are brass fittings with black plas- check valves and service caps. Use these ports to admit nitro- tic caps. The hose connection fittings are standard -in.

  • Page 36: Comfort Alert Diagnostic Module

    if necessary. Service tools are available from RCD that allow Table 18 — Comfort Alert Diagnostic Module Inputs the replacement of the check valve core without having to re- INPUT TERMINAL VOLTAGE cover the entire system refrigerant charge. Apply compressor Control Power 24-v refrigerant oil to the check valve core’s bottom o-ring.
  • Page 37 TROUBLESHOOTING THE CADM WIRING Flashing LEDs also indicate wiring problems to the CADM. See Tables 19 and 20 for discussion of additional LED flash codes and troubleshooting instructions. Table 19 — LED Status Codes STATUS LED STATUS LED STATUS LED TROUBLESHOOTING INFORMATION DESCRIPTION Green “POWER”...

  • Page 38: Compressor Protection

    RTPF coils. This A thermostat installed on the compressor motor winding cleaner is available from Carrier Replacement parts division reacts to excessively high winding temperatures and shuts off as part number P902-0301 for a one gallon container, and part the compressor.

  • Page 39: Fastener Torque Values

    Thoroughly apply Totaline environmentally sound coil cleaner solution to all coil surfaces including the finned area, tube sheets and coil headers. Hold garden sprayer nozzle close to finned areas and RIGID apply cleaner with a vertical, up-and-down motion. SUPPORT COVER Avoid spraying in horizontal pattern to minimize poten- tial for fin damage.

  • Page 40: Troubleshooting

    TROUBLESHOOTING See Table 22 for troubleshooting. Table 22 — 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.

  • Page 41: Appendix A - Air Conditioner And Heat Pump With Puron Quick Reference Guide

    ® APPENDIX A — AIR CONDITIONER AND HEAT PUMP WITH PURON QUICK REFERENCE GUIDE • Puron (R-410A) refrigerant operates at 50 percent to 70 • POE oils may cause damage to certain plastics and roof- percent higher pressures than R-22. Be sure that servic- ing materials.

  • Page 42: Appendix B - Wiring Diagram List

    APPENDIX B — WIRING DIAGRAM LIST ELECTRICAL DIAGRAM UNIT CHARACTERISTICS NUMBER 208/230-3-60 38AU500320 460-3-60 38AU500432 38AUZA/B07 575-3-60 38AU500337 208/230-3-60 38AU000441 460-3-60 38AU000441 38AUZD/E07 575-3-60 38AU000442 208/230-3-60 38AU000759 460-3-60 38AU000760 38AUZ(D,E)08 575-3-60 38AU000758 208/230-3-60 38AU500320 460-3-60 38AU500432 38AUZ*07 575-3-60 38AU500337 208/230-3-60 38AU500320 460-3-60 38AU500432...

  • Page 43: Factory Installed

    APPENDIX C — LOW AMBIENT OPTION, FACTORY INSTALLED Units with the factory installed low ambient option are Troubleshooting equipped with a Motormaster ® solid-state head pressure con- OBSERVATION POSSIBLE REMEDY trol which regulates fan speed. A temperature sensor, mount- All fans: ed on either circuit 1 (38AUZ units) or circuit 2 (38AUD Check power and wiring units) of the outdoor coil controls the speed of approved out-...
  • Page 44 APPENDIX C — LOW AMBIENT OPTION, FACTORY INSTALLED (CONT) 38AUZ*07-08 38AUZ*12 38AUZ*14 Fig. A — 38AUZ*07-14 Motormaster Sensor Locations (RTPF)
  • Page 45 APPENDIX C — LOW AMBIENT OPTION, FACTORY INSTALLED (CONT) 38AUD*12 38AUD*14 Fig. B — 38AUD*12-14 Motormaster Sensor Locations (RTPF)
  • Page 46 APPENDIX C — LOW AMBIENT OPTION, FACTORY INSTALLED (CONT) Fig. C — Wind Baffles...
  • Page 47 APPENDIX C — LOW AMBIENT OPTION, FACTORY INSTALLED (CONT) Table A — Wind Baffle Dimension DIMENSIONS - INCHES UNIT BAFFLE LEFT SIDE — 38AUZ 07 (RTPF) BACK — LEFT SIDE — 38AUZ 08 (RTPF) BACK — LEFT SIDE 38AUZ 12 / 38AUD 12 (RTPF) BACK LEFT SIDE...
  • Page 50 © Carrier Corporation 2019 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53380020-01 Printed in U.S.A. Form 38AU-7-14-03SI Pg 50 1-19 Replaces: 38AU-7-14-02SI...

  • Page 51: Start-Up Checklist

    START-UP CHECKLIST (Remove and use for Job File) NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preced- ing sections of this Controls, Start-Up, Operation, Service, and Troubleshooting document.
  • Page 52 ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ © Carrier Corporation 2019 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53380020-01 Printed in U.S.A. Form 38AU-7-14-03SI Pg CL-2...

This manual is also suitable for:

Gemini 38au08 seriesGemini 38au12 seriesGemini 38au14 series

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