Carrier GEMINI 38APD025-100 Operating And Service Manual
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Carrier GEMINI 38APD025-100 Operating And Service Manual

Commercial air-cooled condensing units with comfortlink controls 50/60 hz
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See also: Instruction and Installation Manual
Controls, Start-Up, Operation,
Service, and Troubleshooting
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .1,2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conventions Used in This Manual . . . . . . . . . . . . . . . . 2
Display Module Usage . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . 18
Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . . . 18
Energy Management Module (EMM) . . . . . . . . . . . . . 18
Compressor Expansion Module (CXB) . . . . . . . . . . 19
AUX Board (AUX). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Enable/Off/Remote Contact Switch . . . . . . . . . . . . . . 19
Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . 19
Board Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Module Communication. . . . . . . . . . . . . . . . . 19
OPERATING DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan Status Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Thermostat Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure Transducer Inputs . . . . . . . . . . . . . . . . . . . . . 23
Energy Management Module . . . . . . . . . . . . . . . . . . . . 23
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Set Point Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
(4 to 20 mA Controlled)
Cooling Set Point (4 to 20 mA) . . . . . . . . . . . . . . . . . . 32
Digital Scroll Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-49
Preliminary Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjust Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 34
Check Compressor Oil Level . . . . . . . . . . . . . . . . . . . . 47
Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53380003-01
Page
(CCN) Interface. . . . . . . 20
®
Printed in U.S.A.
38APS025-050,38APD025-100
Commercial Air-Cooled Condensing Units
with COMFORTLINK™ Controls
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• AMBIENT LIMITATIONS
Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-59
Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . 49
• CONTROL COMPONENTS
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pressure Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Condenser Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
V Controller . . . . . . . . . . . . . . . . . . . . . . 54
®
Motormaster
• GENERAL OPERATION
• CONFIGURATION
• EPM CHIP
• TROUBLESHOOTING
• REPLACING DEFECTIVE MODULES
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59,60
Recommended Maintenance Schedule . . . . . . . . . . 59
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 60-66
Complete Unit Stoppage and Restart. . . . . . . . . . . . 60
• GENERAL POWER FAILURE
• FAN STATUS INPUT OPEN
• COOLING LOAD SATISFIED
• THERMISTOR FAILURE
• COMPRESSOR SAFETIES
Alarms and Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
APPENDIX A - DISPLAY TABLES . . . . . . . . . . . 67-78
APPENDIX B - CCN TABLES . . . . . . . . . . . . . . . . 79-84
START-UP CHECKLIST FOR 38AP SPLIT SYSTEM
CONDENSING UNIT . . . . . . . . . . . . . . . . . . . . CL-1-CL-5

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be
hazardous due to system pressures, electrical components, and
equipment location (roof, elevated structures, mechanical
rooms, etc.). Only trained, qualified installers and service
mechanics should install, start up, and service this equipment.
Form 38AP-1T
GEMINI™ SELECT
50/60 Hz
Pg 1
210
11-09
Page
Replaces: New

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Summary of Contents for Carrier GEMINI 38APD025-100

  • Page 1: Table Of Contents

    Control Module Communication....19 (CCN) Interface..20 Carrier Comfort Network ® OPERATING DATA......20-33 Sensors .

  • Page 2: General

    The CCN (Carrier Comfort Network referenced in the local display tables for users configuring the unit with CCN software instead of the local display. The CCN tables are located in Appendix B of the manual.
  • Page 3 LEGEND — Auxiliary — Contactor — Circuit Breaker CCHR — Crankcase Heater Relay — Current Sensor Board — Energy Management Module EQUIP GND — Equipment Ground — Fuse Block — Fan Contactor — Local Operating Network — Main Base Board —...
  • Page 4 LEGEND — Auxiliary — Contactor — Circuit Breaker — Crankcase Heater Relay — Current Sensor Board — Energy Management Module EQUIP GND — Equipment Ground — Fan Contactor — Fan Circuit Breaker — Local Operating Network — Main Base Board —...
  • Page 5 LEGEND — Auxiliary — Contactor — Circuit Breaker — Crankcase Heater Relay — Current Sensor Board — Compressor Expansion Board — Energy Management Module EQUIP GND — Equipment Ground — Fan Contactor — Fan Circuit Breaker — Local Operating Network —...
  • Page 6 Fig. 4 — Power Wiring Schematic — 38APS,APD025-030...
  • Page 7 Fig. 5 — Power Wiring Schematic — 38APS040,050...
  • Page 8 Fig. 6 — Power Wiring Schematic — 38APD040-060...
  • Page 9 Fig. 7 — Power Wiring Schematic — 38APD070-100...
  • Page 10 Fig. 8 — Control Wiring Schematic — 38APS025-050...
  • Page 11 Fig. 9 — Control Wiring Schematic — 38APD025-060...
  • Page 12 Fig. 10 — Control Wiring Schematic — 38APD070-100...
  • Page 13 LEGEND ACCSY — Accessory — Alarm AMPS — Amperes — Auxiliary — Contactor — Circuit Breaker — Compressor Circuit Breaker — Crankcase Heater Relay — Crankcase Heater COMP — Compressor — Current Sensor Board — Compressor Expansion Module — Digital Scroll —...
  • Page 14 LEGEND EQUIP GND — Equipment Ground — National Electrical Code NOTES: 1. Factory wiring is in accordance with UL 1995 standards. Field modifications or additions must be in compliance with all applicable codes. 2. All units or modules have single point primary power connection. Main power must be supplied from a field or factory-supplied disconnect.
  • Page 15 a38-7125 *Not required for single circuit units. Fig. 13 — Constant Volume Application Wiring Diagram 2-Stage Thermostat Control, Sizes 025-030 — *See Fig. 12 for MAT/RAT and SAT location. †Not required for single circuit units. Fig. 14 — Constant Volume Application Wiring Diagram 2-Stage Thermostat Control — with Digital Scroll Option, Sizes 025-030 or All Sizes 040-100 a38-7127 *See Fig.
  • Page 16 a38-7128 *See Fig. 12 for MAT/RAT and SAT location. †Not required for single circuit units. Fig. 16 — Variable Air Volume Application Wiring Diagram, Sizes 025-100 Fig. 17 — Optional Energy Management Module Wiring LEGEND ALM R — Alarm Relay (24-v), 5-va Maximum COOL1 —...

  • Page 17: Display Module Usage

    Display Module Usage SCROLLING MARQUEE DISPLAY — This device is the keypad interface used for accessing unit information, reading sensor values, and testing the unit. See Fig. 18. The scrolling marquee display is a 4-key, 4-character, 16-segment LED (light-emitting diode) display. Eleven mode LEDs are located on the display as well as an Alarm Status LED.

  • Page 18: Main Base Board (Mbb)

    Adjusting the Contrast — The contrast of the display can be adjusted to suit ambient conditions. To adjust the contrast of the Navigator module, press the ESCAPE play reads, “Select a menu item.” Using the arrow keys move to the Configuration mode. Press ENTER this mode.

  • Page 19: Compressor Expansion Module (Cxb)

    The J4 connector on the MBB provides both power and communication directly to the marquee display only. YELLOW LED — The MBB has one yellow LED. The Carrier Comfort Network (CCN) LED will blink during times of network communication. INSTANCE JUMPER The Emergency On/Off...

  • Page 20: Carrier Comfort Network (Ccn) Interface

    CONTACT SWITCH Fig. 21 — Scrolling Marquee, Enable/Off/Remote Contact Switch, and Emergency On/Off Switch Locations ® Carrier Comfort Network (CCN) Interface — The 38AP units can be connected to the CCN if desired. The communication bus wiring is a shielded, 3-conductor cable with drain wire and is supplied and installed in the field.

  • Page 21: Supply Air Temperature (Sat) Accessory

    3.90 3.00 .175 DIA x .600 FOAM GASKET .40'' O.D. PLENUM RATED CABLE 114'' ±6 Fig. 22 — 33ZCSENSAT Sensor SUPPLY AIR TEMPERATURE (SAT) ACCESSORY (33ZCSENSAT) — A supply air temperature sensor is required for unit sizes 040-100 and all units equipped with the digital scroll option.
  • Page 22 Units on the CCN can be monitored from the space using the RJ11 connector provided with the space sensor, if desired. To wire the RJ11 connector into the CCN (Fig. 26): IMPORTANT: The cable selected for the RJ11 connector wiring MUST be identical to the CCN communication bus wire used for the entire network.

  • Page 23: Fan Status Input

    A proof-of-fan operation is recom- Fan Status Input — mended and needs to be field installed in the indoor unit. Sev- eral different types of switches can be utilized, such as a differ- ential pressure switch located across the indoor fan or auxiliary contacts on an indoor fan contactor.
  • Page 24 • C.TYP = 3 (TSTAT-MULTI) configuration will force the MBB to monitor the thermostat inputs to make a determination of mode. Unlike traditional 2-stage ther- mostat control, the unit is allowed to use multiple stages of cooling control and perform VAV style operation. The control will be able to call out a low set point or a high set point to maintain supply air temperature.
  • Page 25 the return temperature, space, or outdoor-air temperature reset features. It can also be reset from an external 4 to 20 mA signal (requires energy management module factory-installed option or field-installed accessory). The control has an automatic lead-lag feature built in which determines the wear factor (combination of starts and run hours) for each compressor.

  • Page 26: Head Pressure Control

    MINUTES LEFT FOR START — This value is displayed only in the network display tables (using Service Tool, ComfortVIEW™ or ComfortWORKS represents the amount of time to elapse before the unit will start its initialization routine. This value can be zero without the machine running in many situations.
  • Page 27 Outdoor Fan Layout – Top View OFM1 OFM1 OFM2 OFM2 Sizes 025-030 Sizes 040, 050 OFM1 OFM5 OFM3 OFM2 OFM6 Size 080 Compressor Layout Dual Circuit – Top View Sizes 025-030 Sizes 040-060 Sizes 090, 100 Compressor Layout Single Circuit – Top View Sizes 025-030 Sizes 040, 050 Fig.

  • Page 28: Service Test

    This is a 1 to 4 hour temporary override of the programmed schedule, forcing unit to Occupied mode. Over- ride can be implemented with unit under Local (Enable) or CCN (Carrier Comfort Network ® ) control. Override expires af- ter each use.

  • Page 29: Set Point Adjustment

    CHIL_S_S variable is 'Stop.' Similarly, the control mode will be 6 when the CHIL_S_S variable is 'Start.' Set Point Adjustment CV SET POINT ADJUSTMENT — If the unit is configured for control type SPT MULTI (C.TYP =5) and the Space Tem- perature Offset Sensor is enabled.
  • Page 30 KEYPAD SUB-MODE ITEM ENTRY RSET CRST ENTER MA.DG NOTE: The example above shows how to configure the unit for 4 to 20 mA reset. No reset will occur at 4.0 mA input, and a 5.0 F reset will occur at 20.0 mA. An energy management module is required. Table 11 —...

  • Page 31: Demand Limit

    Demand Limit is a feature that allows Demand Limit — the unit capacity to be limited during periods of peak energy usage. There are 3 types of demand limiting that can be configured. The first type is through 2-stage switch control, which will reduce the maximum capacity to 2 user-configu- rable percentages.

  • Page 32: Demand Limit (Ccn Loadshed Controlled)

    100% CAPACITY AT 4mA Fig. 33 — 4 to 20 mA Demand Limiting — Demand Limit Select (DMDC = 2) DEMAND LIMIT (CCN Loadshed Controlled) — To con- figure Demand Limit for CCN Loadshed control, set the De-  mand Limit Select (Configuration RSET Then configure the Loadshed Group Number (Configura- ...

  • Page 33: Pre-Start-Up

    24 hours. See Add Oil section on page 47, for Carrier-approved oils. 5. Electrical power source must agree with unit nameplate. 6. Crankcase heaters must be firmly attached to compres- sors, and must be on for 24 hours prior to start-up.

  • Page 34: Adjust Refrigerant Charge

    Table 15 — Preliminary Puron Refrigerant (R-410A) Charge, lb (kg) 38AP UNIT SIZE CIRCUIT A 38APS025 24 (10.9) 38APD025 12 (5.6) 38APS027 26 (11.6) 38APD027 13 (6.0) 38APS030 29 (12.9) 38APD030 14 (6.5) 38APS040 39 (17.7) 38APD040 21 (9.5) 38APS050 48 (21.5) 38APD050 22 (9.9)
  • Page 35 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb increments until complete.
  • Page 36 a38-7171 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb increments until complete.
  • Page 37 a38-7173 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb increments until complete.
  • Page 38 a38-7175 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb increments until complete.
  • Page 39 130.0 130.0 120.0 120.0 110.0 110.0 100.0 100.0 90.0 90.0 80.0 70.0 a38-7177 60.0 200.0 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met.
  • Page 40 a38-7179 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb increments until complete.
  • Page 41 130.0 130.0 120.0 120.0 110.0 110.0 100.0 100.0 90.0 90.0 80.0 70.0 60.0 a38-7181 200.0 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met.
  • Page 42 a38-7183 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb increments until complete.
  • Page 43 a38-7185 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb increments until complete.
  • Page 44 a38-7187 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb increments until complete.
  • Page 45 a38-7189 1500 LEGEND SST — Saturated Suction Temperature NOTE: Charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refrigerant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb increments until complete.
  • Page 46 a38-7117 LEGEND LLS — Liquid Line Solenoid TXV — Thermostatic Expansion Valve *Field-supplied. †Field-supplied when required. Must be controlled by 38AP unit control. Fig. 57 — Required Location of Solenoid Valves and Recommended Filter Drier and Sight Glass Locations for 38APD025-100 Dual-Circuit Units LIQUID LINE LIQUID...

  • Page 47: Check Compressor Oil Level

    20 minutes then shut off to check oil level. Repeat procedure until acceptable oil level is present. NOTE: Use only Carrier approved compressor oil. Approved sources are: Totaline ..... . .3MAF POE P903-1601 Mobil.

  • Page 48: Operation

    2. Fan status switch input should close. Note the unit will not start unless the fan status input is closed. 3. Close Y1 input unit will stage up to 50 % capacity with 1 minute between stages. 4. Close Y2 input the unit will stage up to 100% capacity with 1 minute between stages.

  • Page 49: Service

    For all units, if temperature reset is used, the unit controls to a higher leaving temperature as the building load reduces. If demand limit is used, the unit may temporarily be unable to maintain the desired leaving-air temperature because of im- posed power limitations.
  • Page 50 Table 17 — 5K Thermistor Temperatures (°F) vs. Resistance/Voltage Drop VOLTAGE TEMP RESISTANCE DROP (Ohms) –25 3.699 98,010 –24 3.689 94,707 –23 3.679 91,522 –22 3.668 88,449 –21 3.658 85,486 –20 3.647 82,627 –19 3.636 79,871 –18 3.624 77,212 –17 3.613 74,648 –16...
  • Page 51 Table 18 — 5K Thermistor Temperatures (°C) vs. Resistance/Voltage Drop VOLTAGE TEMP RESISTANCE DROP (Ohms) –32 3.705 100,260 –31 3.687 94,165 –30 3.668 88,480 –29 3.649 83,170 –28 3.629 78,125 –27 3.608 73,580 –26 3.586 69,250 –25 3.563 65,205 –24 3.539 61,420 –23...
  • Page 52 Table 19 — 10K Thermistor Temperature (°F) vs. Resistance/Voltage Drop VOLTAGE TEMP RESISTANCE DROP (Ohms) –25 4.758 196,453 –24 4.750 189,692 –23 4.741 183,300 –22 4.733 177,000 –21 4.724 171,079 –20 4.715 165,238 –19 4.705 159,717 –18 4.696 154,344 –17 4.686 149,194 –16...
  • Page 53 Table 20 — 10K Thermistor Temperature (°C) vs. Resistance/Voltage Drop VOLTAGE TEMP RESISTANCE DROP (Ohms) –32 4.762 200,510 –31 4.748 188,340 –30 4.733 177,000 –29 4.716 166,342 –28 4.700 156,404 –27 4.682 147,134 –26 4.663 138,482 –25 4.644 130,402 –24 4.624 122,807 –23...

  • Page 54: Pressure Transducers

    The suction and discharge Pressure Transducers — transducers are different part numbers and can be distinguished by the color of the transducer body, suction (yellow) and dis- charge (red). Figures 59 and 60 shows typical location of pres- sure transducers on each circuit. No pressure transducer cali- bration is required.

  • Page 55: Drive Programming

    (EPM) chip to store the program parameters. This is an EEPROM memory chip and is accessible from the front of the VFD. It should not be removed with power applied to the VFD. LOSS OF CCN COMMUNICATIONS — Carrier Comfort Network ® (CCN) communications with external control systems can be affected by high frequency electrical noise gen- erated by the Motormaster V control.
  • Page 56 LEGEND — Motormaster V Control BUTTONS Mode Fig. 63 — Motormaster FAULT CODE High Temperature Fault: Ambient temperature is too high; Cooling fan has failed (if equipped). Control Fault: A blank EPM, or an EPM with corrupted data has been installed. Incompatibility Fault: An EPM with an incompatible parameter ver- sion has been installed.
  • Page 57 208/230, 460, 575 VOLT ONLY 208 VOLT ONLY LEGEND AUX — Auxiliary — Fuse Block MODE — Fan Relay — Motormaster OFM — Outdoor Fan Motor — Terminal Block *208-v can run in mode 5 or 6. Fig. 64 — Typical Motormaster MOTORMASTER V TERMINAL BLOCK Configuration Table NOMINAL VOLTAGE...
  • Page 58 Table 23 — Motormaster PARAMETER Line Voltage: 01 = low line, 02 = high line Carrier Freq: 01 = 4 kHz, 02 = 6 kHz, 03=8 kHz Start-up mode: flying restart Stop mode: coast to stop Standard Speed source: 04=4-20 mA, 05=R22, 06=R134a...

  • Page 59: Compressors

    NOTE: Handle boards by mounting standoffs only to avoid electrostatic discharge. 4. Package the defective module in the carton of the new module for return to Carrier. 5. Mount the new module in the unit’s control box using a Phillips screwdriver and the screws saved in Step 2.

  • Page 60: Microchannel Heat Exchanger (Mchx) Condenser Coil Maintenance And Cleaning

    Every month: • Check condenser coils for debris, clean as necessary. • Check moisture indicating sight glass for possible refrig- erant loss and presence of moisture. Every 3 months: • Check refrigerant charge. • Check all refrigerant joints and valves for refrigerant leaks, repair as necessary.

  • Page 61: Alarms And Alerts

    Fig. 65 — Advanced Scroll Temperature Protection Label Advanced scroll temperature protection is a form of internal discharge temperature protection that unloads the scroll com- pressor when the internal temperature reaches approximately 300 F. At this temperature, an internal bi-metal disk valve opens and causes the scroll elements to separate, which stops compression.
  • Page 62 Wiring Error — A wiring error might not allow the compres- sor to start. To check out alerts T051-T057: 1. Turn on the compressor in question using Service Test mode. If the compressor does not start, then most likely the problem is one of the following: HPS open, open in- ternal protection, circuit breaker trip, incorrect safety wir- ing, or incorrect compressor wiring.
  • Page 63 T114 (Circuit A Low Superheat) T115 (Circuit B Low Superheat) — Alert codes 114 and 115 occur when the superheat of a circuit is less than 5 F (2.8 C) for 5 continuous minutes. The low superheat alert is generated and the circuit is shut down.

  • Page 64: Alarm And Alert Codes

    Transducer Failure Discharge Gas T094 Alert Thermistor Failure LEGEND ® — Carrier Comfort Network — Current Sensor Board — Compressor Expansion Module — Discharge Temperature Thermistor EEPROM — Electrically Erasable Programmable Read-Only Memory — Energy Management Module greater than 22 mA. The reset function will be disabled when this occurs.
  • Page 65 A151 Alarm Illegal Configuration A152 Alarm Unit Down Due to Failure LEGEND — Carrier Comfort Network ® — Current Sensor Board — Compressor Expansion Module — Discharge Temperature Thermistor EEPROM — Electrically Erasable Programmable Read-Only Memory — Energy Management Module Table 26 —...

  • Page 66: Example Of Reading And Clearing Alarms

    B2 Failure Current Sensor Board T505 Alert B3 Failure LEGEND ® — Carrier Comfort Network — Current Sensor Board — Compressor Expansion Module — Discharge Temperature Thermistor EEPROM — Electrically Erasable Programmable Read-Only Memory — Energy Management Module Table 27 — Example of Reading and Clearing Alarms...

  • Page 67: Appendix A - Display Tables

    APPENDIX A — DISPLAY TABLES Run Status Mode and Sub-Mode Directory SUB-MODE ITEM VIEW SETP CTPT LOD.F STAT SPT.M MODE STGE ALRM TIME MNTH DATE YEAR HRS.U STR.U HRS.A HRS.B HR.A1 HOUR HR.A2 HR.A3 HR.B1 HR.B2 HR.B3 DISPLAY ITEM DESCRIPTION xxx.x ºF Return Air Temperature xxx.x ºF...
  • Page 68 APPENDIX A — DISPLAY TABLES (cont) Run Status Mode and Sub-Mode Directory (cont) SUB-MODE ITEM ST.A1 ST.A2 STRT ST.A3 ST.B1 ST.B2 ST.B3 COIL SI.CL C.L.DN C.L.MN CL.DT C.L.M0 C.L.M1 C.L.M2 C.L.M3 C.L.M4 VERS MARQ NAVI Service Test Mode and Sub-Mode Directory SUB-MODE ITEM TEST...
  • Page 69 APPENDIX A — DISPLAY TABLES (cont) Temperature Mode and Sub-Mode Directory SUB-MODE ITEM UNIT SCT.D SCT.A SST.A CIR.A RGT.A D.GAS SH.A SCT.B CIR.B SST.B RGT.B SH.B Pressures Mode and Sub-Mode Directory SUB-MODE ITEM PRC.A DP.A SP.A PRC.B DP.B SP.B Set Points Mode and Sub-Mode Directory SUB-MODE ITEM CSP.1...
  • Page 70 APPENDIX A — DISPLAY TABLES (cont) Inputs Mode and Sub-Mode Directory SUB-MODE ITEM STST IDFA GEN.I IDFB DLS1 DLS2 FKA1 FKA2 FKA3 CRCT HPSA FKB1 FKB2 FKB3 HPSB DMND 4-20 RSET CL.MA Outputs Mode and Sub-Mode Directory SUB-MODE ITEM FAN1 FAN2 FAN3 GEN.O...
  • Page 71 APPENDIX A — DISPLAY TABLES (cont) Configuration Mode and Sub-Mode Directory SUB-MODE ITEM TEST METR DISP LANG PAS.E PASS SIZE NCKT SZ.A1 SZ.A2 SZ.A3 UNIT SZ.B1 SZ.B2 SZ.B3 FAN.S A1.TY MAX.T CCNA CCNB BAUD MLV.S CSB.E SPT.S SPOS SPOR OPT1 RAT.T SAT.T C.TYP...
  • Page 72 APPENDIX A — DISPLAY TABLES (cont) Configuration Mode and Sub-Mode Directory (cont) SUB-MODE ITEM MMR.S P.GAN M.MST I.GAN D.GAN MIN.S CRST MA.DG RM.NO RM.F RM.DG RT.NO RT.F RSET RT.DG DMDC DM20 SHNM SHDL SHTM DLS1 DLS2 RL.S CRMP SLCT SCHD Z.GN EN.A1 EN.A2...
  • Page 73 APPENDIX A — DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory SUB-MODE ITEM TIME HH.MM MNTH DATE YEAR STR.M STR.W STR.D MIN.A STP.M STP.W STP.D MIN.S HOL.L HD.01 HD.02 HD.03 HD.04 HD.05 HD.06 HD.07 HD.08 DISPLAY ITEM DESCRIPTION TIME OF DAY XX.XX Hour and Minute MONTH, DATE, DAY, AND YEAR...
  • Page 74 APPENDIX A — DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory (cont) SUB-MODE ITEM HD.09 HD.10 HD.11 HD.12 HD.13 HD.14 HD.15 HD.16 HD.17 HD.18 HD.19 DISPLAY ITEM DESCRIPTION HOLIDAY SCHEDULE 09 Holiday Start Month Start Day Duration (days) HOLIDAY SCHEDULE 10 Holiday Start Month Start Day Duration (days)
  • Page 75 APPENDIX A — DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory (cont) SUB-MODE ITEM HD.20 HD.21 HD.22 HD.23 HD.24 HD.25 HD.26 HD.27 HD.28 HD.29 HD.30 DISPLAY ITEM DESCRIPTION HOLIDAY SCHEDULE 20 Holiday Start Month Start Day Duration (days) HOLIDAY SCHEDULE 21 Holiday Start Month Start Day Duration (days)
  • Page 76 APPENDIX A — DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory (cont) SUB-MODE ITEM SCH.N SCH.L OCC.1 UNC.1 MON.1 TUE.1 PER.1 WED.1 THU.1 FRI.1 SAT.1 SUN.1 HOL.1 OCC.2 UNC.2 MON.2 TUE.2 PER.2 WED.2 THU.2 FRI.2 SAT.2 SUN.2 HOL.2 OCC.3 UNC.3 MON.3 TUE.3...
  • Page 77 APPENDIX A — DISPLAY TABLES (cont) Time Clock Mode and Sub-Mode Directory (cont) SUB-MODE ITEM OCC.6 UNC.6 MON.6 TUE.6 PER.6 WED.6 THU.6 FRI.6 SAT.6 SUN.6 HOL.6 OCC.7 UNC.7 MON.7 TUE.7 PER.7 WED.7 THU.7 FRI.7 SAT.7 SUN.7 HOL.7 OCC.8 UNC.8 MON.8 TUE.8 PER.8 WED.8...
  • Page 78 APPENDIX A — DISPLAY TABLES (cont) Operating Mode and Sub-Mode Directory SUB-MODE ITEM MD05 MD06 MD09 MD10 MD14 MD15 MODE MD17 MD18 MDTG MD21 MD22 MD23 MD25 TKCA TKCB TSKS TKFA TKFB Alarms Mode and Sub-Mode Directory SUB-MODE ITEM AXXX CRNT TXXX PXXX...

  • Page 79: Appendix B - Ccn Tables

    DESCRIPTION TSTAT_IN (Thermostat Input) Indoor Fan Status-CIRA Y1 Thermostat Input Y2 Thermostat Input Indoor Fan Status-CIRB Y3 Thermostat Input Y4 Thermostat Input A_UNIT (General Unit Parameters) Control Mode Space Temp Control Mode Occupied CCN Chiller Alarm State 4-20 Cooling Demand Active Demand Limit Override Modes in Effect Percent Total Capacity...
  • Page 80 DESCRIPTION CIRCB_AN (Circuit B Analog Parameters) Percent Total Capacity Percent Available Capacity Discharge Pressure Suction Pressure Saturated Condensing Temperature Saturated Suction Temperature Variable Head Press Out Circuit B Compressor Return Gas Temperature Suction Superheat Temperature CIRCBDIO (Circuit B Discrete Inputs/Outputs) CIRC.B DISCRETE OUTPUTS Compressor B1 Relay Compressor B2 Relay...
  • Page 81 DESCRIPTION UNIT (Unit Configuration) Unit Size Number of Refrig Ckts Compressor A1 Size Compressor A2 Size Compressor A3 Size Compressor B1 Size Compressor B2 Size Compressor B3 Size Fan Sequence Number Compressor A1 Digital Maximum A1 Unload Time OPTIONS1 (Options 1 Configuration) Motormaster Select Minimum Load Valve Select CSB Boards Enable...
  • Page 82 DESCRIPTION DISPLAY (Marquee Display Set Up) Service Password Password Enable Metric Display Language Selection HPA (Head Pressure) SCT Delta for Compressor A1 SCT Delta for Compressor A2 HPB (Head Pressure) SCT Delta for Comp B1 SCT Delta for Comp B2 SERVICE Enable Compressor A1 Enable Compressor A2...
  • Page 83 DESCRIPTION CURRMODS (Maintenance Display) Ramp Load Limited Timed Override in effect Slow Change Override Minimum OFF time active Temperature Reset Demand Limited Low Temperature Cooling High Temperature Cooling High SCT Circuit A High SCT Circuit B Minimum Comp. On Time Low Sound Mode Time Guard Active Alarms (Maintenance Display)
  • Page 84 DESCRIPTION PM-COIL (Maintenance Display) Coil Cleaning Srvc Inter Coil Service Countdown Coil Cleaning Maint.Done Coil Cleaning Maint.Date Coil Cleaning Maint.Date Coil Cleaning Maint.Date Coil Cleaning Maint.Date Coil Cleaning Maint.Date TESTMODE (Maintenance Display) Service Test Mode Compressor A1 Relay Compressor A2 Relay Compressor A3 Relay Compressor B1 Relay Compressor B2 Relay...
  • Page 86 Copyright 2009 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53380003-01 Printed in U.S.A. Form 38AP-1T Pg 86 11-09 Replaces: New...

  • Page 87: Condensing Unit

    START-UP CHECKLIST FOR 38AP SPLIT SYSTEM CONDENSING UNIT I. Project Information JOB NAME ______________________________________________________________________________ ADDRESS _______________________________________________________________________________ CITY ____________________________________________ STATE _______________ ZIP______________ INSTALLING CONTRACTOR ________________________________________________________________ SALES OFFICE ___________________________________________________________________________ START-UP PERFORMED BY ________________________________________________________________ Design Information CAPACITY SUCTION LINE LIQUID LINE DIAMETER DIAMETER UNIT MODEL ______________________________ SERIAL ________________________________ II.
  • Page 88 Refrigeration System Check 1. ALL SERVICE VALVES ARE OPEN. 2. ONLY BLEED TXV(S) ARE INSTALLED. 3. ALL PIPING IS CONNECTED PROPERLY. 4. FILTER DRIERS AND SIGHT GLASSES ARE INSTALLED NEAR THE TXV(S). 5. THE SYSTEM HAS BEEN EVACUATED. 6. THE SYSTEM HAS BEEN CHARGED WITH THE APPROPRIATE INITIAL CHARGE. 7.
  • Page 89 Start and Operate Machine. Complete the Following: 1. COMPLETE COMPONENT TEST. 2. CHECK REFRIGERANT AND OIL CHARGE. 3. FINISH CHARGING ACCORDING TO THE CHARGING CHART PROVIDED. 4. RECORD COMPRESSOR MOTOR CURRENT. 5. RECORD CONFIGURATION SETTINGS. 6. RECORD OPERATING TEMPERATURES AND PRESSURES. 7.
  • Page 90 Compressor Running Current — All readings taken at full load. COMPRESSOR MOTOR CURRENT COMPRESSOR A1 COMPRESSOR A2 COMPRESSOR A3 COMPRESSOR B1 COMPRESSOR B2 COMPRESSOR B3 CONDENSER FAN MOTOR CURRENT FAN MOTOR 1 FAN MOTOR 2 FAN MOTOR 3 FAN MOTOR 4 FAN MOTOR 5 FAN MOTOR 6 EVAPORATOR MOTOR CURRENT...
  • Page 91 COMMENTS: _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ SIGNATURES: START-UP TECHNICIAN ____________________________ DATE ___________________________________ CUSTOMER REPRESENTATIVE ____________________________ DATE ________________________________________ CL-5...
  • Page 92 Copyright 2009 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53380003-01 Printed in U.S.A. Form 38AP-1T Pg CL-6 11-09 Replaces: New...

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