Carrier Gemini 38AU 07 Series Installation, Start-Up And Service Instructions Manual
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Carrier Gemini 38AU 07 Series Installation, Start-Up And Service Instructions Manual

Carrier Gemini 38AU 07 Series Installation, Start-Up And Service Instructions Manual

Air-cooled condensing units with puron r-410a refrigerant
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Installation, Start-Up and Service Instructions
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . 2
R-22 to Puron Refrigerant . . . . . . . . . . . . . . . . . . . 2
Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . 2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Step 7 - Install Accessories . . . . . . . . . . . . . . . . . . 14
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Turn On Crankcase Heater . . . . . . . . . . . . . . . . . . . . 20
Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . . . . . 20
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATING SEQUENCE . . . . . . . . . . . . . . . . . . . . . 29
Base Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 29
38AUDC with SVR Relays . . . . . . . . . . . . . . . . . . . . . 30
All Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
(and 30 days after initial start) . . . . . . . . . . . . . . . 31
Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . . 31
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . 31
Comfort Alert Diagnostic Module . . . . . . . . . . . . . . 33
Compressor Protection . . . . . . . . . . . . . . . . . . . . . . 35
Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . 36
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 36
APPENDIX B - WIRING DIAGRAMS . . . . . . . . . . . . 38
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53380041-01
Page
Printed in U.S.A.
Form 38AU-7-14-05SI
Air-Cooled Condensing Units
with Puron
(R-410A) Refrigerant
®

SAFETY CONSIDERATIONS

Improper
installation,
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
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. 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.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning will result in personal injury or
death.
Before performing service or maintenance operations on unit,
turn off main power switch to unit and install lock(s) and lock-
out tag(s). Ensure electrical service to rooftop unit agrees with
voltage and amperage listed on the unit rating plate. Unit may
have more than one power switch.
WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal injury,
death and/or equipment damage.
R-410A refrigerant systems operate at higher pressures than
standard R-22 systems. Do not use R-22 service equipment or
components on R-410A refrigerant equipment.
Pg 1
Gemini™
38AU**07-14
adjustment,
alteration,
DANGER
2-2020
Replaces: 38AU-7-14-04SI
service,

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  • Page 1: Table Of Contents

    Gemini™ 38AU**07-14 Air-Cooled Condensing Units with Puron (R-410A) Refrigerant ® Installation, Start-Up and Service Instructions CONTENTS SAFETY CONSIDERATIONS Page Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or SAFETY CONSIDERATIONS ....1 other conditions which may cause personal injury or property INSTALLATION GUIDELINES .

  • Page 2: Installation Guidelines

    sizing data in Table 8 , 9 or 10; replace with smaller lines when feasible. WARNING INSTALLATION PERSONAL INJURY AND ENVIRONMENTAL Remove the existing evaporator coil or fan coil and install the HAZARD replacement coil when appropriate. Failure to follow this warning could cause personal injury or Drain oil from low points and traps in suction line tubing (and death.

  • Page 3: Identify Factory Options

    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 4 Fig. 3 — 38AUD/Z 07-14 Base Unit Dimensions...
  • Page 5 Table 4 — 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(A/B/D/E)07 [457.2] [609.6] [533.4] [1076.0] 42 3/8 38AUZ(A/B)08 [457.2] [609.6] [533.4] [1076.0] 42 3/8 38AUZ(D/E)08...

  • Page 6: Installation

    Table 6 — 38AUD*12-14 Physical Data TWO CIRCUIT MODELS with RTPF – ROUND TUBE/PLATE FIN COIL DESIGN 38AUD*12 38AUD*14 Refrigeration System # Circuits / # Comp. / Type 2 / 2 / Scroll 2 / 2 / Scroll Refrigerant Type Puron R-410A Puron R-410A...

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

    Step 2 — Complete Pre-Installation Checks Step 5 — Determine Refrigerant Line Sizes Select the recommended line sizes for 38AUZ and 38AUD unit CHECK UNIT ELECTRICAL CHARACTERISTICS from the appropriate tables. Confirm before installation of unit that voltage, amperage and cir- Determine the linear length of interconnecting piping required cuit protection requirements listed on unit data plate agree with between the outdoor unit and indoor unit (evaporator).
  • Page 8 Table 8 — 38AUZ Piping Recommendations (Single-Circuit) MODEL & LINEAR LINE (FT) 0 - 24 25 - 49 50 - 74 75 - 99 100 - 124 125 - 149 150 - 174 175 - 200 NOMINAL EQUIV. LINE (FT) 0 - 37 38 - 74 75 - 112...
  • Page 9 Table 9 — 38AUD Piping Recommendations (Dual-Circuit) MODEL & LINEAR LINE (FT) 0 - 24 25 - 49 50 - 74 75 - 99 100 - 124 125 - 149 150 - 174 175 - 200 NOMINAL EQUIV. LINE (FT) 0 - 37 38 - 74 75 - 112 113 - 149...

  • Page 10: Suction Riser

    22.0 NOTES: 2. For applications with equivalent length greater than 188 ft and/or linear length greater than 125 ft (38 m), contact your local Carrier 1. 38AUDC units require TWO sets of refrigeration piping. representative. Table 10 includes liquid line size selections based on use of RTPF Suction Riser coil option only.

  • Page 11: Step 6 - Complete Refrigerant Piping

    See Fig. 7 for location of Circuit 1 and Circuit 2 service valves and field piping connections. Circuit 1 is on the right-hand side of the service valve compartment; Circuit 2 is on the left. When a single piece evaporator coil with two separate circuits is connected to a 38AUD, the lower coil circuit should be connected to the 38AUD unit’s Circuit 1 so that the evaporator’s lower coil segment is first-on/last-off (to avoid re-evaporation of condensate...
  • Page 12 In some applications, depending on space and convenience re- quirements, it may be desirable to install 2 filter driers and sight glasses in a single circuit application. One filter drier and sight glass may be installed at A locations (see Fig. 9) or 2 filter driers and sight glasses may be installed at B locations (see Fig.
  • Page 13 Evaporator Capacity Control Liquid Line Solenoid Valve EQUALIZER LINE Many older unit designs included automatic capacity controls SENSING that sensed changes in suction pressure and could increase or BULB decrease compressor capacity automatically as the evaporator load changed. Control systems were used on these units that AIRFLOW had the thermostat’s second stage contacts control a capacity 15 DIAMS...

  • Page 14: Step 7 - Install Accessories

    EVACUATION/DEHYDRATION Step 7 — Install Accessories Evacuate and dehydrate the connected refrigeration system(s) (ex- Accessories requiring modifications to unit wiring should be com- cluding the 38AU unit) to 500 microns using a two-stage vacuum pleted now. These accessories may include Winter Start controls pump attached to the service ports outside the 38AU service and Low Ambient controls.
  • Page 15 Units Without Disconnect Option ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY Disconnect ALUMINUM WIRE 208/230-3-60 Fig. 12 — Disconnect Switch and Unit 460-3-60 575-3-60 UNITS WITH FACTORY-INSTALLED NON-FUSED DIS- CONNECT The factory-installed option disconnect switch is located in a Units With Disconnect Option weatherproof enclosure located under the main control box.
  • Page 16 Figures 17 (38AUZ) and 18 Observe National Electrical Code Article 210, Branch Cir- (38AUD) depict typical connections to a Carrier 40RU fan coil cuits, for use of convenience outlets. unit. Plan for field connections carefully and install control wir- ing correctly per the project plan.
  • Page 17 38AUZ(A,B) unit is a single-stage cooling unit. If no economizer function is required, select a single-stage cooling thermostat. If an Install a Carrier-approved accessory thermostat according to in- integrated economizer function is required, select a two-stage stallation instructions included with the accessory. For typical cooling thermostat.
  • Page 18 Table 14 — 38AUZ 07-14 Electrical Data without Powered Convenience Outlet VOLTAGE RANGE COMPRESSOR POWER SUPPLY DISCONNECT SIZE UNIT Fuse or STAGE V-Ph-Hz SIZE FLA (ea) HACR COOLING 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 26/26...
  • Page 19 Table 16 — 38AUD 12, 14 Electrical Data without Powered Convenience Outlet VOLTAGE COMPRESSOR COMPRESSOR DISCONNECT POWER SUPPLY RANGE* No. 1 No. 2 SIZE UNIT V-Ph-Hz Fuse or SIZE HACR (ea) Brkr 575-3-60 208/230-3-60 15.9 15.9 39/39 50/50 40/40 226/226 460-3-60 575-3-60 208/230-3-60...

  • Page 20: Step 9 - Wind Baffles For Low Ambient Control

    Step 9 — Wind Baffles for Low Ambient Control Models 38AZB and 38AUDB include the factory installed 32LT CAUTION Motormaster Low Ambient Control. Model 38AUDC (with hot gas bypass option) also includes the 32LT Motormaster Low UNIT DAMAGE HAZARD Ambient Control as a standard feature. Failure to follow this caution may result in equipment damage.

  • Page 21: Start Unit

    ADVANCED SCROLL TEMPERATURE PROTECTION Start Unit (ASTP) Set the space thermostat to a set point above space temperature so that there is no demand for cooling. Close the 38AU disconnect A label located above the terminal box identifies Copeland switch. Only the crankcase heater will be energized. Scroll compressor models that contain this technology.
  • Page 22 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. 22 — 38AUZA/B07 Charging Chart (RTPF)
  • Page 23 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 24 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. 24 — 38AUZA/B12 Charging Chart (RTPF)
  • Page 25 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. 25 — 38AUZA/B14 Charging Chart (RTPF)
  • Page 26 6 TON DUAL STAGE CHARGING CHART R-410A (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 27 7.5 Ton 2-Stage Charging Chart R-410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve –6 1050 1400 1750 2100 2450 2800 3150 3500 3850 Pressure at Liquid Valve (PSIG/Kpa) 38AU000761 Fig. 27 — 38AUZD/E08 Charging Chart (RTPF)
  • Page 28 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 29: Operating Sequence

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

  • Page 30: 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. 30 — Hot Gas Bypass Option 38AUDC with SVR Relays With no thermostat demand, there will be no voltage at LVTB-A1;...

  • Page 31: Maintenance

    of compressor operation until CADM is manually reset. Reset SERVICE CADM by cycling unit main power. Refrigeration System Complete system shutdown may be caused by loss of main pow- er, open compressor internal overload, open low-pressure or high-pressure switch, or a fault detected by the CADM logic. WARNING Compressor operation without cooling may indicate the com- pressor’s ASTP feature is active;...
  • Page 32 FIELD REFRIGERANT ACCESS PORTS FACTORY HIGH-FLOW ACCESS PORTS Field service access to refrigerant pressures is through the access There are two additional access ports in the system - on the suction ports located at the service valves (see Fig. 32 and 33). These ports tube between the compressor and the suction service valve and on -in.

  • Page 33: Comfort Alert Diagnostic Module

    of the check valve core without having to recover the entire sys- Table 19 — Comfort Alert Diagnostic Module Inputs tem refrigerant charge. Apply compressor refrigerant oil to the INPUT TERMINAL VOLTAGE check valve core’s bottom o-ring. Install the fitting body with 96 Control Power 24-v ±10 in-lbs (1085 ±23 N-cm) of torque;...
  • Page 34 Table 20 — LED Status Codes STATUS LED STATUS LED STATUS LED TROUBLESHOOTING INFORMATION DESCRIPTION Green “POWER” Module has power Supply voltage is present at module terminals 1. Compressor protector is open 2. Condensing unit power disconnect is open Thermostat demand signal 3.

  • Page 35: Compressor Protection

    RTPF coils. This cleaner is to excessively high winding temperatures and shuts off the available from Carrier Replacement parts division as part number compressor. P902-0301 for a one gallon container, and part number P902-0305 for a 5 gallon container.

  • Page 36: Fastener Torque Values

    Thoroughly apply Totaline environmentally balanced 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 apply cleaner with a vertical, up-and-down motion. Avoid spraying RIGID SUPPORT in horizontal pattern to minimize potential for fin damage.
  • Page 37 Table 23 — 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.

  • Page 38: 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 roofing ® percent higher pressures than R-22. Be sure that servicing materials.
  • Page 39 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. A — Single Circuit/Single Stage Wiring Diagram, 6 - 10 Ton — 208/230-3-60 Units...
  • Page 40 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. B — Single Circuit/Single Stage Wiring Diagram, 6 - 10 Ton — 460-3-60 Units...
  • Page 41 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. C — Single Circuit/Single Stage Wiring Diagram, 6 - 10 Ton — 575-3-60 Units...
  • Page 42 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. D — Single Circuit/Two-Stage Wiring Diagram, 6 Ton — 208/230-3-60 and 460-3-60 Units...
  • Page 43 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. E — Single Circuit/Two-Stage Wiring Diagram, 6 Ton — 575-3-60 Units...
  • Page 44 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. F — Single Circuit/Two-Stage Wiring Diagram, 7.5 Ton — 208/230-3-60 Units...
  • Page 45 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. G — Single Circuit/Two-Stage Wiring Diagram, 7.5 Ton — 460-3-60 Units...
  • Page 46 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. H — Single Circuit/Two-Stage Wiring Diagram, 7.5 Ton — 575-3-60 Units...
  • Page 47 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. I — Dual Circuit/Two Stage Wiring Diagram, 10 - 12.5 Ton — 208/230-3-60 Units...
  • Page 48 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. J — Dual Circuit/Two Stage Wiring Diagram, 10 - 12.5 Ton — 460-3-60 Units...
  • Page 49 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. K — Dual Circuit/Two Stage Wiring Diagram, 10 - 12.5 Ton — 575-3-60 Units...

  • Page 50: Appendix C - Low Ambient Option

    APPENDIX C — LOW AMBIENT OPTION Units with the factory installed low ambient option are equipped Troubleshooting with a Motormaster solid-state head pressure control which regu- ® OBSERVATION POSSIBLE REMEDY lates fan speed. A temperature sensor, mounted on either circuit 1 (38AUZ units) or circuit 2 (38AUD units) of the outdoor coil con- All fans: Check power and wiring...
  • Page 51 APPENDIX C — LOW AMBIENT OPTION (CONT) 38AUZ*07-08 38AUZ*12 38AUZ*14 Fig. L — 38AUZ*07-14 Motormaster Sensor Locations (RTPF)
  • Page 52 APPENDIX C — LOW AMBIENT OPTION (CONT) 38AUD*12 38AUD*14 Fig. M — 38AUD*12-14 Motormaster Sensor Locations (RTPF)
  • Page 53 APPENDIX C — LOW AMBIENT OPTION (CONT) Fig. N — Wind Baffles...
  • Page 54 1054 1095 38AUD 14 RIGHT SIDE 1095 © 2020 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53380041-01 Printed in U.S.A. Form 38AU-7-14-05SI Pg 54...

  • Page 55: 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 preceding sections of this Installation, Start-Up, and Service document.
  • Page 56 ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ © 2020 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53380041-01 Printed in U.S.A. Form 38AU-7-14-05SI Pg CL-2...

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