Table of Contents
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38AU
Air-Cooled Condensing Units
50 Hz
®
with Puron
(R-410A) Refrigerant
Sizes 07 - 14
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Step 1 – Plan for Unit Location . . . . . . . . . . . . . . . . . . . 9
Step 2 – Complete Pre-Installation Checks. . . . . . . . . . 9
Step 3 – Prepare Unit Mounting Support . . . . . . . . . . 9
Step 4 – Rig and Mount the Unit . . . . . . . . . . . . . . . . . . 9
Step 5 – Complete Refrigerant Piping Connections . . 10
Step 6 – Install Accessories. . . . . . . . . . . . . . . . . . . . . . 14
Step 7 – Complete Electrical Connections . . . . . . . . . 14
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Turn On Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . 19
Preliminary Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 -25
38AU Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATING SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . 26
Indoor (Supply) Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cooling, Unit Without Economizer . . . . . . . . . . . . . . . . 26
Cooling, Unit With Economizer . . . . . . . . . . . . . . . . . . . 26
Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ROUTINE SYSTEM MAINTENANCE. . . . . . . . . . . . . . . 26
Quarterly Inspection (and 30 days after initial start) . . 26
Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 26
SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 - 33
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 27
Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Servicing Systems on Roofs with
Synthetic Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Liquid Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . 27
Filed Refrigerant Access Ports . . . . . . . . . . . . . . . . . 27
Factory High-flow Access Ports . . . . . . . . . . . . . . . . 27
Comfort Alert Diagnostic Module. . . . . . . . . . . . . . . 28
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Compressor Protection. . . . . . . . . . . . . . . . . . . . . . . . . . 30
Low-Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . 30
High-Pressure Switches. . . . . . . . . . . . . . . . . . . . . . . . . 30
Outdoor Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
NOVATION™ Coil Cleaning and Maintenance . . . . 33
Installation, Start-Up and
Service Instructions
Repairing NOVATION Condenser Tube Leaks . . . . 33
Replacing NOVATION Condenser Coil . . . . . . . . . . 33
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3
Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . 33 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 34 -35
APPENDIX A
Air Conditioner and Heat Pump with Puron
Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . 36
APPENDIX B
Wiring Diagram List. . . . . . . . . . . . . . . . . . . . . . . . . 36
APPENDIX C
Motormaster Sensor Locations. . . . . . . . . . . . . . . . . 37
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 for special requirements. In absence of
local codes, it is recommended that the (USA standard ANSI/
NFPA70, National Electrical Code (NEC), be followed.
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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Table of Contents
Related Manuals for Carrier 38AUZ*08 Series
Summarization of Contents
INSTALLATION GUIDELINES
Retrofit R22 to Puron®
Guidelines for replacing R22 systems with Puron® systems.
Existing Evaporator Coil Checks
Checks for existing evaporator coil suitability for Puron® systems.
Acid Test and Filter Drier Installation
Procedure for acid testing and installing filter driers if acid is detected.
INSTALLATION
Jobsite Survey
Checks to complete before installation.
Plan Unit Location
Selecting unit location considering clearances and safety.
Pre-Installation Checks
Verifying electrical characteristics and inspecting shipment.
Mounting Support Preparation
Preparing a level concrete slab for unit mounting.
Rigging and Mounting
Procedures for rigging and mounting the unit safely.
Refrigerant Piping
Connecting refrigerant piping, including safety and line sizing.
Suction Line Insulation
Applying insulation to suction lines for proper operation.
PRE-START-UP
System Checks
Verifying all system components are correctly installed and connected.
Crankcase Heater Activation
Energizing crankcase heater for 24 hours before compressor start.
Preliminary Charge
Adding initial refrigerant charge to the system.
START-UP
38AU Unit Specifics
Specific start-up requirements for 38AU units.
Start-Up Preliminary Checks
Final checks before energizing the unit.
Compressor Rotation
Ensuring correct compressor rotation direction.
ASTP Operation
Explains ASTP and its behavior during operation.
Refrigerant Charge Adjustment
Adjusting refrigerant charge based on charging charts.
ROUTINE SYSTEM MAINTENANCE
Quarterly Inspection
Scheduled inspection items for indoor section.
Seasonal Maintenance
Maintenance tasks for air conditioning and heating seasons.
Economizer/Damper Maintenance
Maintenance checks for economizer components.
SERVICE
Refrigeration System
System considerations for Puron® refrigerant.
Compressor Oil
Information on POE oil and its properties.
Synthetic Roof Servicing Precautions
Precautions for servicing units on synthetic roofing materials.
Liquid Line Filter Drier
Replacement guidelines for Puron® filter driers.
Field Refrigerant Access Ports
Using access ports for pressure checks and charging.
Factory High-Flow Access Ports
Location and use of factory high-flow access ports.
Comfort Alert Diagnostic Module (CADM)
Monitors compressor and system failures, provides diagnostic codes.
CADM Troubleshooting
Troubleshooting guide for CADM LED status codes.
Compressor Protection
Covers overtemperature protection and ASTP features.
System Components
Details on Low-Pressure Switch, High-Pressure Switch, Outdoor Fans, and Lubrication.
Coil Maintenance and Repair
NOVATION™ Coil Cleaning
Water-only cleaning procedure for NOVATION condenser coils.
NOVATION Tube Leak Repair
Procedure for repairing leaks in NOVATION condenser coils.
NOVATION Coil Replacement
Steps for replacing the NOVATION condenser coil.
RTPF Coil Cleaning
Cleaning procedures for RTPF coils using specific cleaners.
Service Parts
Information on obtaining service parts through EPIC.
Fastener Torque Values
Table of torque values for fasteners.
TROUBLESHOOTING
Compressor Not Running
Common problems and solutions when the compressor does not run.
High-Pressure Switch Operation
Troubleshooting when the compressor stops due to high pressure.
Low-Pressure Switch Cycling
Issues related to the compressor cycling on low-pressure switch.
Insufficient Cooling
Causes for insufficient cooling while compressor is running.
System Noise and Oil Loss
Diagnosing and resolving noisy system operation and oil loss.
Line Frosting Issues
Troubleshooting frosted suction and liquid lines.
APPENDIX A: Puron® Quick Reference
Puron® System Information
Key information for Puron® refrigerant systems.
Wiring Diagram List
List of available wiring diagrams for different units.
START-UP CHECKLIST
Preliminary Information
Recording unit model and serial numbers.
Outdoor Unit Pre-Start Checks
Verifying shipping damage, power supply, and wiring.
Controls Checks
Verifying thermostat wiring, terminals, and crankcase heater.
Indoor Unit Checks
Verifying drain pan, air filters, pulleys, and fan rotation.
Piping Checks
Verifying solenoid valves, leak checks, and service valve status.
Voltage Imbalance Check
Calculating and verifying voltage imbalance before start-up.
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