Carrier 38AUD Installation Manual PDF

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Summary of Content for Carrier 38AUD Installation Manual PDF

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38AUD Air Cooled Condensing Units 50 Hz With PuronR (R---410A) Refrigerant Sizes 07 --- 14

Installation, Start---Up and Service Instructions

CONTENTS SAFETY CONSIDERATIONS 2. . . . . . . . . . . . . . . . . . . .

INSTALLATION GUIDELINES 2. . . . . . . . . . . . . . . . . .

Replacement/Retrofit R-22 to Puron 2. . . . . . . . . . .

INSTALLATION 10 - 21. . . . . . . . . . . . . . . . . . . . . . . . .

Jobsite Survey 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 1 - Plan for Unit Location 10. . . . . . . . . . . . . . . . .

Step 2 - Complete Pre- Installation Checks 10. . . . . . . .

Step 3 - Prepare Unit Mounting Support 10. . . . . . . . . .

Step 4 - Rig and Mount the Unit 10. . . . . . . . . . . . . . . .

Step 5 - Complete Refrigerant Piping Connections 11. . .

Step 6 - Install Accessories 18. . . . . . . . . . . . . . . . . . . .

Step 7 - Complete Electrical Connections 18. . . . . . . . .

PRE-START-UP 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Check 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turn On Crankcase Heater 22. . . . . . . . . . . . . . . . . . . . .

Preliminary Charge 22. . . . . . . . . . . . . . . . . . . . . . . . . . .

START-UP 22 - 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preliminary Checks 22. . . . . . . . . . . . . . . . . . . . . . . . . . .

Start Unit 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING SEQUENCE 31. . . . . . . . . . . . . . . . . . . . . .

Indoor (Supply) Fan 31. . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling, Unit Without Economizer 31. . . . . . . . . . . . . .

Cooling, Unit With Economizer 31. . . . . . . . . . . . . . . . .

Heating 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROUTINE SYSTEM MAINTENANCE 32. . . . . . . . . . . .

Quarterly Inspection (and 30 days after initial start) 32. . .

Seasonal Maintenance 32. . . . . . . . . . . . . . . . . . . . . . . .

SERVICE 32 - 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigeration System 32. . . . . . . . . . . . . . . . . . . . . . . . .

Compressor Oil 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing Systems on Roofs with Synthetic Materials 32. . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Line Filter Drier 33. . . . . . . . . . . . . . . . . . . . . . .

Filed Refrigerant Access Ports 33. . . . . . . . . . . . . . . . . .

Factory High-Flow Access Ports 33. . . . . . . . . . . . . . . .

Comfort Alert Diagnostic Module 34. . . . . . . . . . . . . . .

Compressor Protection 36. . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Heater 36. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low-Pressure Switch 36. . . . . . . . . . . . . . . . . . . . . . . . .

High-Pressure Switch 36. . . . . . . . . . . . . . . . . . . . . . . . .

Outdoor Fans 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coil Type Identification 39. . . . . . . . . . . . . . . . . . . . . . .

NOVATIONt Coil Cleaning and Maintenance 39. . . . .

Repairing NOVATION Condenser Tube Leaks 39. . . . .

Replacing NOVATION Condenser Coil 39. . . . . . . . . . .

Routine Cleaning of Round-Tube Plate Fin (RTPF) Coils 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fastener Torque Values 41. . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 41 - 42. . . . . . . . . . . . . . . . . . . . .

APPENDIX A Air Conditioner & Heat Pump with PuronR Quick Reference Guide 43. . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX B Wiring Diagram List 43. . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX C Low Ambient Option Factory Installed 44. . . . . . . . . .

START-UP CHECKLIST 49 - 50. . . . . . . . . . . . . . . . . . .

2

SAFETY CONSIDERATIONS Improper installation, adjustment, alteration, service, 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/NFPA 70, 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.

ELECTRICAL SHOCK HAZARD Failure to follow this warning could cause in personal injury or death.

Before performing service or maintenance operations on unit, always turn off main power switch to unit and install lockout tag. Unit may have more than one power switch.

! WARNING

UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause in personal injury,death and/or equipment damage.

PuronR (R- 410A) refrigerant systems operate at higher pressures than standard R- 22 systems. Do not use R- 22 service equipment or components on Puron refrigerant equipment.

! WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD Failure to follow this warning could cause in personal injury or death.

Relieve pressure and recover all refrigerant before system repair or final unit disposal.

Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils.

! WARNING

CUT HAZARD Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing 38AU units.

CAUTION!

INSTALLATION GUIDELINE

Replacement/Retrofit R-22 to PuronR

Replacement/retrofit installations require change-out of outdoor unit, metering device, and filter driers. Change-out of indoor coil (evaporator) and interconnecting tubing is recommended.

Existing evaporator coil If the existing evaporator coil may be re-used, check with the coil manufacturer to verify the coil construction is suitable for operation with the higher pressures of PuronR (R-410A). Also determine if the existing TXV valve is compatible with R-410A, replace if necessary. The minimum factory test pressure rating must be 1725 kPa (250 psig). Existing coil will need to be purged with Nitrogen to remove as much mineral oil as possible to eliminate cross contamination of oils.

Acid test If the existing system is being replaced because of a compressor electrical failure, assume acid is in system. If system is being replaced for any other reason, use an approved acid test kit to determine acid level. If even low levels of acid are detected, install a 100 percent activated alumina suction-line filter drier in addition to the replacement liquid-line filter drier. Remove the suction line filter drier as soon as possible, with a maximum of 72 hr of operation. Recommendation: Install a ball valve in the liquid line at the filter drier location when installing a suction filter in the suction line.

Existing refrigeration piping Reuse of existing refrigerant piping involves three issues: quality (strength) of existing tubing, cleanliness and tube size. Inspect all tube segments and joints for signs of damage, corrosion or poor brazing. Flush the interconnecting piping system with dry Nitrogen to eliminate as much trace of mineral oil as possible.

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Same tube sizes are capable of handling higher flowrates (expressed as tons of cooling capacity) with Puron refrigerant compared to R-22 at constant pressure drops. For example, a 1/2- inch OD liquid line is rated at 33% higher tons with PuronR than with R-22 (at 5_F pressure drop). A 1 1/8- inch OD suction line is rated at 53% higher tons with Puron than with R-22 (at 2_F pressure drop). Refrigeration lines selected for R-22 use are typically oversized for Puron applications. Carefully check the existing suction line size against the table for maximum size (see Table 7); replace vertical riser segments if necessary. Check existing liquid line size against sizing data in Table 5 or 6; replace with smaller lines when feasible.

Installation

1. Remove the existing evaporator coil or fan coil and install the replacement coil when appropriate.

2. Drain oil from low points and traps in suction line tubing (and hot gas bypass tubing if appropriate) and evaporator if they were not replaced. Removing oil from evaporator coil may require purging of the tubing with dry nitrogen.

3. Unless indoor unit is equipped with a Puron approved metering device, change the metering device to a thermal expansion valve (TXV) designed for PuronR (R-410A).

4. Remove the existing outdoor unit. Install the new out- door unit according to these installation instructions.

5. Install a new field-supplied liquid-line filter drier at the indoor coil just upstream of the TXV or fix orifice metering device.

6. If a suction line filter drier is also to be installed, in- stall suction line drier downstream of suction line ser- vice valve at condensing unit.

UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation.

Never install suction- line filter drier in the liquid- line of a PuronR system.

CAUTION!

7. If required, install a 100% activated alumina suction line filter drier at the outdoor unit.

8. Evacuate and charge the system according to the in- structions in this installation manual.

9. Operate the system for 10 hr. Monitor the pressure drop across the suction line filter drier. If pressure drop exceeds 21kPa (3 psig), replace suction-line and liquid-line filter driers. Be sure to purge system with dry nitrogen and evacuate when replacing filter driers. Continue to monitor the pressure drop across suction-line filter drier. Repeat filter changes is neces- sary. Never leave suction-line filter drier in system longer than 72 hr (actual time).

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C101015

UNIT STD. UNIT WT. CORNER A CORNER B CORNER C CORNER D CENTER OF GRAVITY UNIT HEIGHT

kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. X Y Z H 38AUZ*07 (MCHX) 149 328 58 128 31 68 28 62 32 70 533.2 mm

21 in 482.6 mm 19 in

330.2 mm 13 in

1076.0 mm 42 3/8 in

38AUZ*08 (MCHX) 160 353 63 138 33 72 29 65 35 78 482.6 mm

19 in 584.2 mm 23 in

330.2 mm 13 in

1076.0 mm 42 3/8 in

38AUD*12 (MCHX) 226 499 88 193 50 111 38 72 56 123 508.0 mm

20 in 584.2 mm 23 in

381.0 mm 15 in

1279.2 mm 50 3/8 in

38AUD*14 (MCHX) 229 505 86 190 40 88 34 76 68 151 508.0 mm

20 in 609.6 mm 24 in

381.0 mm 15 in

1279.2 mm 50 3/8 in

38AUZ*07 (RTPF) 176 389 64 141 44 96 28 62 41 91 457.2 mm

18 in 609.6 mm 24 in

533.4 mm 21 in

1076.0 mm 42 3/8 in

38AUZ*08 (RTPF) 177 391 64 142 44 96 28 62 41 91 457.2 mm

18 in 609.6 mm 24 in

533.4 mm 21 in

1076.0 mm 42 3/8 in

38AUD*12 (RTPF) 234 516 84 185 53 117 38 83 59 131 482.6 mm

19 in 584.2 mm 23 in

609.6 mm 24 in

1279.2 mm 50 3/8 in

LEGEND: MCXH = Novation coil RTPF = Round Tube/Plate Fin coil

Fig. 1 - 38AU Unit Dimensions

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Table 1A Physical Data 38AUZ*07-08 Units 50 Hz SI

UNIT SIZE 38AU Z*07 Z*08

NOMINAL CAPACITY (kW) 18 22

OPERATING WEIGHTS (kg)

NOVATION Coil (Al Tube) 149 160

Round Tube/Plate Fin Coil (Cu/Al) 176 176

REFRIGERANT TYPE R-410A

NOVATION Operating Charge, Typical (kg) 3.8 4.6

NOVATION Shipping Charge (kg) 2.0 2.2

RTPF Operating Charge, Typical (kg) 6.4 7.7

RTPF Shipping Charge (kg) 5.0 5.9

COMPRESSOR

Qty...Type 1...Scroll 1...Scroll

Oil Charge (L) 1.7 1.8

CONDENSER FANS

Qty...r/s 2...15.3

Motor kW 0.43 0.40

Diameter (mm) 560

Nominal Airflow (L/s) 1950 3000

RTPF CONDENSER COIL

Material (Tube/Fin) Cu / Al

Coil Type 3/8--- in RTPF

Rows/Fins per Meter (Fins/m) 2 / 670

Face Area (sq m total) 1.6 1.6

NOVATION CONDENSER COIL

Material (Tube/Fin) Al / Al

Coil Type Novation

Rows/Fins per Meter (Fins/m) 1 / 670

Face Area (sq m total) 1.6 1.9

CONTROLS

Pressurestat Settings (kPa)

High Cutout 4347 70

Cut-in 3482 138

Low Cutout 372 21

Cut-in 807 34

PIPING CONNECTIONS (in. ODS)

Qty...Suction 1...11/8 1...11/8

Qty...Liquid 1...3/8 1...1/2 LEGEND RTPF Round Tube/Plate Fin ODS Outside Diameter Sweat (socket)

Unit is factory-supplied with partial charge only. Typical operating charge with 7.6 m (25 ft) of interconnecting piping.

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Table 1B Physical Data 38AUZ*07-08 Units 50 Hz English

UNIT SIZE 38AU Z*07 Z*08

NOMINAL CAPACITY (tons) 6 7.5

OPERATING WEIGHTS (lb)

NOVATION Coil (Al Tube) 328 353

Round Tube/Plate Fin Coil (Cu/Al) 389 389

REFRIGERANT TYPE R-410A

NOVATION Operating Charge, Typical (lb) 8.4 10.2

NOVATION Shipping Charge (lb) 4.4 4.9

RTPF Operating Charge, Typical (lb) 14.0 17.0

RTPF Shipping Charge (lb) 11.0 13.0

COMPRESSOR

Qty...Type 1...Scroll 1...Scroll

Oil Charge (oz) 56 60

CONDENSER FANS

Qty...Rpm 2...920

Motor Watts 430 400

Diameter 22

Nominal Airflow (Cfm Total) 4150 6300

RTPF CONDENSER COIL

Material (Tube/Fin) Cu / Al

Coil Type 3/8--- in RTPF

Rows/Fins per inch (FPI) 2/ 17

Face Area (sq ft total) 17.5 17.5

NOVATION CONDENSER COIL

Material (Tube/Fin) Al / Al

Coil Type Novation

Rows/Fins per inch (FPI) 1 / 17

Face Area (sq ft total) 17.5 20.5

CONTROLS

Pressurestat Settings (psig)

High Cutout 630 10

Cut-in 505 20

Low Cutout 54 3

Cut-in 117 5

PIPING CONNECTIONS (in. ODS)

Qty...Suction 1...11/8 1...11/8

Qty...Liquid 1...3/8 1...1/2 LEGEND RTPF Round Tube/Plate Fin ODS Outside Diameter Sweat (socket)

Unit is factory-supplied with partial charge only. Typical operating charge with 25 ft (7.6 m) of interconnecting piping.

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Table 2A Physical Data 38AUD*12-14 Units 50 Hz SI

UNIT SIZE 38AU D*12 D*14

NOMINAL CAPACITY (kW) 28 34

OPERATING WEIGHTS (kg)

NOVATION Coil (Al Tube) 226 229

Round Tube/Plate Fin Coil (Cu/Al) 234 ---

REFRIGERANT TYPE R-410A

NOVATION Operating Charge A/B, Typical (kg) 3.4 / 3.3 4.8 / 4.9

NOVATION Shipping Charge A/B (kg) 1.3 / 1.3 1.5 / 1.5

RTPF Operating Charge A/B, Typical (kg) 5.0 / 5.0 ---

RTPF Shipping Charge A/B (kg) 3.6 / 3.6 ---

COMPRESSOR

Qty...Type 2...Scroll 2...Scroll

Oil Charge A/B (L) 1.2 1.7

CONDENSER FANS

Qty...r/s 2...15.3

Motor kW 0.40

Diameter (mm) 560

Nominal Airflow (l/s Total) 3000 2450

RTPF CONDENSER COIL

Material (Tube/Fin) Cu / Al ---

Coil Type 3/8--- in RTPF ---

Rows/Fins per Meter (Fins/m) 2 / 670 ---

Face Area (sq m total) 2.3 ---

NOVATION CONDENSER COIL

Material (Tube/Fin) Al / Al

Coil Type Novation

Rows/Fins per Meter (Fins/m) 1 / 670

Face Area (sq m total) 2.3 3.0

CONTROLS

Pressurestat Settings (kPa)

High Cutout 4347 70

Cut-in 3482 138

Low Cutout 372 21

Cut-in 807 34

PIPING CONNECTIONS (in. ODS)

Qty...Suction A/B 1...11/8 / 1...11/8 1...13/8 / 1...13/8

Qty...Liquid A/B 1...3/8 / 1...3/8 1...1/2 / 1...1/2 LEGEND RTPF Round Tube/Plate Fin ODS Outside Diameter Sweat (socket)

Unit is factory-supplied with partial charge only. Typical operating charge with 7.6 m (25 ft) of interconnecting piping.

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Table 2B Physical Data 38AUD*12-14 Units 50 Hz English

UNIT SIZE 38AU D*12 D*14

NOMINAL CAPACITY (tons) 10 12.5

OPERATING WEIGHTS (lb)

NOVATION Coil (Al Tube) 499 505

Round Tube/Plate Fin Coil (Cu/Al) 516 ---

REFRIGERANT TYPE R-410A

NOVATION Operating Charge A/B, Typical (lb) 7.4 / 7.3 10.8 / 10.9

NOVATION Shipping Charge A/B (lb) 3.0 / 3.0 3.5 / 3.5

RTPF Operating Charge A/B, Typical (lb) 11.0 / 11.0 ---

RTPF Shipping Charge A/B (lb) 8.0 / 8.0 ---

COMPRESSOR

Qty...Type 2...Scroll 2...Scroll

Oil Charge A/B (oz) 42 60

CONDENSER FANS

Qty...Rpm 2...920

Motor Watts 400

Diameter 22

Nominal Airflow (Cfm Total) 6300 5200

RTPF CONDENSER COIL

Material (Tube/Fin) Cu / Al ---

Coil Type 3/8--- in RTPF ---

Rows/Fins per inch (FPI) 2 / 17 ---

Face Area (sq ft total) 25.1 ---

NOVATION CONDENSER COIL

Material (Tube/Fin) Al / Al

Coil Type Novation

Rows/Fins per inch (FPI) 1 / 17

Face Area (sq ft total) 25.0 31.8

CONTROLS

Pressurestat Settings (psig)

High Cutout 630 10

Cut-in 505 20

Low Cutout 54 3

Cut-in 117 5

PIPING CONNECTIONS (in. ODS)

Qty...Suction A/B 1...11/8 / 1...11/8 1...13/8 / 1...13/8

Qty...Liquid A/B 1...3/8 / 1...3/8 1...1/2 / ...11/2 LEGEND RTPF Round Tube/Plate Fin ODS Outside Diameter Sweat (socket)

Unit is factory-supplied with partial charge only. Typical operating charge with 25 ft (7.6 m) of interconnecting piping.

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

3 8 A U D A 1 4 A 0 G 9 A 0 A 0 A 0

Model Type Packaging 38AU = Carrier Condensing Unit 0 = Standard

Type of Coil Electrical Options

D = Dual Circuit, A/C Scroll Compressor Z = Single Circuit, A/C Scroll Compressor A = None

C = Non-Fused Disconnect

1 = LTL

Service Options 0 = None

Nominal Capacity 07 = 18 kW (6 Tons) 08 = 22 kW (7.5 Tons)

Not Used

12 = 28 kW (10 Tons)

A = Place Holder

14 = 34 kW (12.5 Tons)

Base Unit Controls 0 = Electro-Mechanical Controls

Not Used A = Not Used

Design Revision

Voltage 9 = 400/3/60

Refrigerant Options A = None B = Low Ambient

Not Used 0 = Not Used

Coil Options

Puron R410A Refrigerant

A = Initial Rev (Discrete Model Number)

NOVATION G = Al/Al K = E-Coat Al/Al T = Al/Al with Hail Guard W = E-Coat Al/Al with Hail Guard

RTPF A = Cu/Al B = Precoat (Cu/Al) C = E-Coat (Cu/Al)

N = Precoat (Cu/Al) with Hail Guard P = E-Coat (Cu/Al) with Hail Guard

M = Cu/Al with Hail Guard

C101016

Fig. 2 - Model Number Nomenclature

SETANGISEDNOITISOP )radnelac lacsif( erutcafunam fo keeW12

)ASU ,saxeT ,PTE = G( noitacol gnirutcafunaM5 rebmun laitneuqeS610

1 2 3 4 5 6 7 8 9 10 0 5 1 0 G 1 2 3 4 5

POSITION NUMBER TYPICAL

Year of manufacture (10 = 2010)34

C10068

Fig. 3 - Serial Number Nomenclature

Matching 38AU Model To Evaporator Coil

The Model 38AUZ is a single-circuit unit design, requiring one set of refrigeration piping. This model can be connected to an evaporator coil with one circuit or with two circuits (by manifolding the evaporator connections into a single piping system).

The Model 38AUD is a dual-circuit unit design that requires two sets of refrigeration piping between the outdoor unit and the evaporator coil (or coils). This model can only be connected to an evaporator coil that has two refrigeration circuits (or to two separate evaporator coils). The Model 38AUD CANNOT be connected to a single-circuit evaporator coil. The Model 38AUD CANNOT be field-converted to a single-circuit design.

Table 3 Evaporator Coil Connections

Evaporator Coil has Connect to Model Notes

Single Circuit 38AUZ ONLY

Two Circuits

38AUZ Manifold evaporator circuits into single piping system

Or

38AUD Use two separate piping systems

Before unpacking this new 38AU model, compare the evaporator coil design to the 38AU model.

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.INSTALLATION

Jobsite Survey

Complete the following checks before installation.

1. Consult local building codes or the U.S.A. National Electrical Code (Ref: ANSI/NFPA 70, [American Na- tional Standards Institute/National Fire Protection As- sociation], latest revision) for special installation re- quirements

2. Determine unit location (from project plans) or select unit location.

3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.

Step 1 Plan for Unit Location

Select a location for the unit and its support system (pad, rails or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings. See Fig.4.

NOTE: Local codes may require different clearances than specified in Fig. 4. It is the responsibility of installers to be knowledgeable in local codes and to modify the recommended clearances to satisfy local codes. NOTE: Consider also the effect of adjacent units on airflow performance and control box safety clearance.

REAR: Min 18 (457 mm) requried for service

Note: Observe requirements for 39 (914 mm) operating clearance on either Left or Rear coil opening.

RIGHT: Min 18 (457 mm) requried for service

LEFT: Min 18 (457 mm) requried for service FRONT:

42 (1067 mm)

C110201

Fig. 4 - Service Clearance Dimensional Drawing

Do not install the outdoor unit in an area where fresh air supply to the outdoor coil may be restricted or when recirculation from the condenser fan discharge is possible. Do not locate the unit in a well or next to high walls.

Evaluate the path and required line length for interconnecting refrigeration piping, including suction riser requirements (outdoor unit above indoor unit), liquid line lift (outdoor unit below indoor unit) and hot gas bypass line. Relocate sections to minimize the length of interconnecting tubing.

DO NOT BURY REFRIGERATION LINES.

Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit.

Step 2 Complete Pre-Installation Checks

Check Unit Electrical Characteristics: Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.

Un- crate Unit: Remove unit packaging except for the top skid assembly, which should be left in place until after the unit is rigged into its final location.

Inspect Shipment: File a claim with shipping company if the shipment is damaged or incomplete.

Consider System Requirements:

S Consult local building codes or the U.S.A. National Electrical Code (Ref: ANSI/NFPA 70, [American National Standards Institute/National Fire Protection Association], latest revision) for special installation requirements.

S Allow sufficient space for airflow clearance, wiring, refrigerant piping, and servicing unit. See Fig. 1 for unit dimensions and weight distribution data.

S Locate the unit so that the outdoor coil (condenser) airflow is unrestricted on all sides and above.

S The unit may be mounted on a level pad directly on the base channels or mounted on raised pads at support points. See Tables 1A through 2B for unit operating weights. See Fig. 1 for weight distribution based on recommended support points.

NOTE: If vibration isolators are required for a particular installation, use the data in Fig. 1 to make the proper selection.

Step 3 Prepare Unit Mounting Support

Slab Mount

Provide a level concrete slab that extends a minimum of 150 mm (6 in.) beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow.

Step 4 Rig and Mount the Unit

UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage.

All panels must be in place when rigging. Unit is not designed for handling by fork truck.

CAUTION!

Rigging: These units are designed for overhead rigging. Refer to the rigging label for preferred rigging method. Spreader bars are not required if top crating is left on the unit. All panels must be in place when rigging. As further protection for coil faces, plywood sheets may be placed against the sides of the unit, behind cables. Run cables to a central suspension point so that the angle from the

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horizontal is not less than 45 degrees. Raise and set the unit down carefully.

If it is necessary to roll the unit into position, mount the unit on longitudinal rails, using a minimum of 3 rollers. Apply force to the rails, not the unit. If the unit is to be skidded into position, place it on a large pad and drag it by the pad. Do not apply any force to the unit.

Raise from above to lift the unit from the rails or pad when unit is in its final position.

After the unit is in position, remove all shipping materials and top crating.

Step 5 Complete Refrigerant Piping Connections

IMPORTANT: Do not bury refrigerant piping underground.

IMPORTANT: A refrigerant receiver is not provided with the unit. Do not install a receiver.

Provide Safety Relief

If local codes dictate an additional safety relief device, purchase locally and install locally. Installation will require the recovery of the factory shipping charge before the factory tubing can be cut and the supplemental relief device is installed.

Model 38AUD has two separate refrigeration systems. If required, each circuit will require a field-supplied/installed supplemental relief device.

Check 38AU Model with Evaporator Coil Connections

Confirm before installation of unit that the evaporator coil connections are consistent with this 38AU model. See Table 3 on page 9.

Determine Refrigerant Line Sizes

Select the recommended line sizes for 38AUZ and 38AUD unit from the appropriate tables.

Determine the linear length of interconnecting piping required between the outdoor unit and indoor unit (evaporator). Consider and identify also the arrangement of the tubing path (quantity and type of elbows in both lines), liquid line solenoid size, filter drier and any other refrigeration specialties located in the liquid line. Refer to the indoor unit installation instructions for additional details on refrigeration specialties devices.

Determine equivalent line length adjustments for path and components and add to linear line lengths. See Table 4, Equivalent Lengths for Common Fittings, for usual fitting types. Also identify adjustments for refrigeration specialties. Refer to Part 3 of the Carrier System Design Manual for additional data and information on equivalent lengths.

Table 4 Equivalent Lengths for Common Fittings (EN units)

mm Ref

Nominal Tube OD (in)

Elbows 90 Std

90 Lrad

90 Street

45 Std

45 Street

9.5 3/8 0.40 0.24 0.67 0.18 0.30

12.7 1/2 0.43 0.27 0.70 0.21 0.34

15.9 5/8 0.49 0.30 0.76 0.24 0.40

19.1 3/4 0.55 0.37 0.88 0.27 0.46

22.2 7/8 0.61 0.43 0.98 0.27 0.49

28.6 11/8 0.79 0.52 1.25 0.40 0.64

34.9 13/8 1.01 0.70 1.71 0.52 0.91

41.3 15/8 1.22 0.79 1.92 0.64 1.04

54.0 21/8 1.52 1.01 2.50 0.79 1.37

mm Ref

Nominal Tube OD (in)

Tees

Branch Flow

Straight-Thru

No Reduct

Reduce 25%

Reduce 50%

9.5 3/8 0.79 0.24 0.34 0.40

12.7 1/2 0.82 0.27 0.37 0.43

15.9 5/8 0.91 0.30 0.43 0.49

19.1 3/4 1.07 0.37 0.52 0.55

22.2 7/8 1.22 0.43 0.58 0.61

28.6 11/8 1.52 0.52 0.70 0.79

34.9 13/8 2.13 0.70 0.94 1.01

41.3 15/8 2.44 0.79 1.13 1.22

54.0 21/8 3.05 1.01 1.43 1.52

NOTE: Equivalent line lengths will vary based on tube diameter. Calculate equivalent line length for each pipe by adding equivalent length adjustments to linear lengths for each pipe.

Enter the appropriate table to select the recommended line sizes.

Model: Line Sizes Table Quantity of Line Sets

38AUZ 5 1

38AUD 6 2

Liquid Lift

A liquid lift condition exists when the outdoor unit is located below the indoor (evaporator) unit and liquid flows vertically up in a portion of the liquid line. The vertical column of liquid reduces the available state point subcooling at the evaporator coils thermal expansion valve. This effect reduces the length of liquid lift (feet of elevation) that a liquid line size can accommodate. Longer linear tube lengths will also reduce the amount of liquid lift possible.

Check Tables 5 (38AUZ) and 6 (38AUD) for maximum liquid lift capabilities for line sizes. Reselect the liquid line tube size if necessary. If maximum available tube size cannot provide the required lift distance on this installation, relocate the outdoor unit to reduce the equivalent line length or the lift requirement.

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Table 5 38AUZ 07-08 50Hz Piping Recommendations (Single-Circuit Unit)

R---410A Equivalent Length meter 0---12 12---23 23---34 34---46 46---57 feet 0---38 38---75 75---113 113---150 150---188

Model

Linear Length meter 0---7.5 7.5---15 15---23 23---30 30---38 feet 0---25 25---50 50---75 75---100 100---125

38AUZ*07 Liquid Line 3/8 3/8 1/2 3/8 1/2 3/8 1/2 3/8 1/2 Max Lift SI (m) Novation 7.5 15 16 23 9 29 10 34 RTPF 7.5 15 19 23 12 30 11 38 EN (ft) Novation 25 50 53 75 34 97 33 112 RTPF 25 50 63 75 42 100 38 125 Suction Line 7/8 7/8 7/8 7/8 7/8 1---1/8 Charge SI (kg) Novation 3.8 4.4 4.9 5.9 5.4 6.8 6.1 7.9 RTPF 6.4 7.0 7.4 8.5 7.9 9.3 8.7 10.4 EN (lbs) Novation 8.4 9.8 10.8 13.1 11.8 14.9 13.5 17.4 RTPF 14.0 15.4 16.4 18.7 17.4 20.5 19.1 23.0

38AUZ*08 Liquid Line 1/2 1/2 5/8 1/2 5/8 1/2 5/8 1/2 5/8 Max Lift SI (m) Novation 7.5 9 11 7 10 DNU 10 10 16 RTPF 7.5 15 NR 23 NR 27 30 18 38 EN (ft) Novation 25 30 38 24 36 DNU 35 33 53 RTPF 25 50 NR 75 NR 89 100 62 125 Suction Line 7/8 7/8 1---1/8 1---1/8 1---1/8 Charge SI (kg) Novation 5.5 6.3 7.2 7.4 8.6 DNU 9.9 9.1 11.2 RTPF 8.6 9.4 NR 10.4 NR 11.3 13.0 12.2 14.3 EN (lbs) Novation 12.2 13.9 15.8 16.2 19.0 DNU 21.9 20.0 24.8 RTPF 19.0 20.7 NR 23.0 NR 24.9 28.7 26.8 31.6

Legend:

Equivalent Length Equivalent tubing length, including effects of refrigeration specialties devices

Linear Length Linear tubing length, feet

Liquid Line Tubing size, inches OD.

Max Lift Maximum liquid lift (indoor unit ABOVE outdoor unit only), at maximum permitted liquid line pressure drop S Linear Length Less than 30 m (100 ft): Minimum 1.1 C (2.0 F) subcooling entering TXV S Linear Length Greater than 30 m (100 ft): Minimum 0.3 C (0.5 F) subcooling entering TXV

Suction Line Tube size, inches OD

Charge Charge Quantity, lbs. Calculated for both liquid line sizes (where applicable), but only with larger suction line size (where applicable)

DNU Do Not Use (pressure drop exceeds available subcooling in this model)

NR Not Recommended (use smaller liquid tube size)

SI Metric units of measure

EN English units of measure (I---P)

NOTE: For applications with equivalent length greater than 57 m (188 ft) and/or linear length greater than 38 m (125 ft), contact your local Carrier representative.

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Table 6 38AUD 12-14 50Hz Piping Recommendations (Two-Circuit Unit)

NOTE: 38AUD requires TWO sets of refrigeration piping R---410A Equivalent Length

meter 0---12 12---23 23---34 34---46 46---57 feet 0---38 38---75 75---113 113---150 150---188

Model

Linear Length meter 0---7.5 7.5---15 15---23 23---30 30---38 feet 0---25 25---50 50---75 75---100 100---125

38AUD*12 Liquid Line 3/8 3/8 3/8 1/2 3/8 1/2 3/8 1/2 Max Lift SI (m)

Novation 7.5 15 15 23 10 24 13 29 RTPF 7.5 15 15 23 10 27 11 32 EN (ft)

Novation 25 50 50 75 36 79 44 96 RTPF 25 50 50 75 36 89 39 106 Suction Line 7/8 7/8 7/8 7/8 1---1/8 Charge SI (kg)

Novation 3.3 3.8 4.2 5.3 4.7 6.1 5.1 6.9 RTPF 4.9 5.4 5.8 6.9 6.3 7.7 6.8 8.6 EN (lbs)

Novation 7.3 8.3 9.3 11.6 10.3 13.4 11.3 15.2 RTPF 10.9 11.9 12.9 15.2 13.9 17.0 14.9 18.8

38AUD*14 Liquid Line 3/8 1/2 5/8 1/2 5/8 1/2 5/8 1/2 5/8 Max Lift SI (m)

Novation 7.5 13 15 12 14 11 14 17 20 EN (ft)

Novation 25 45 50 42 49 39 48 56 68 Suction Line 7/8 7/8 7/8 1---1/8 1---1/8 Charge SI (kg)

Novation 4.6 5.8 6.6 6.6 7.8 7.6 10.7 9.4 12.0 EN (lbs)

Novation 10.1 12.7 14.6 14.5 17.3 16.8 23.5 20.7 26.4 Legend:

Equivalent Length Equivalent tubing length, including effects of refrigeration specialties devices

Linear Length Linear tubing length, feet

Liquid Line Tubing size, inches OD.

Max Lift Maximum liquid lift (indoor unit ABOVE outdoor unit only), at maximum permitted liquid line pressure drop S Linear Length Less than 30 m (100 ft): Minimum 1.1 C (2.0 F) subcooling entering TXV S Linear Length Greater than 30 m (100 ft): Minimum 0.3 C (0.5 F) subcooling entering TXV

Suction Line Tube size, inches OD

Charge Charge Quantity, lbs. Calculated for both liquid line sizes (where applicable), but only with larger suction line size (where applicable)

DNU Do Not Use (pressure drop exceeds available subcooling in this model)

NR Not Recommended (use smaller liquid tube size)

SI Metric units of measure

EN English units of measure (I---P)

NOTE: For applications with equivalent length greater than 57 m (188 ft) and/or linear length greater than 38 m (125 ft), contact your local Carrier representative.

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Suction Riser

A suction riser condition exists when the outdoor unit is located above the indoor (evaporator) unit and suction vapor must flow vertically up to return to the compressor. Oil return is a concern when the suction tube size is too large to produce the minimum refrigerant velocity to ensure oil return at minimum load conditions.

Check Table 7 for maximum suction tube size for 38AU units at minimum load conditions. Consider suction speed riser (reduced tube size for vertical segment only) or double suction riser arrangement if the proposed suction tube size does not provide necessary minimum flowrates for this riser.

Table 7 38AU Maximum Suction Pipe Size

Model: Unit Size Maximum Tube Size

38AUZ 07 13/8

08 15/8

38AUD 12 13/8

14 13/8

Vertical Separation (outdoor unit above indoor unit)

Vertical elevation difference of 60 m (200 ft) is permitted when the outdoor unit (38AUZ or 38AUD) is located above the indoor unit.

Insulate Suction Lines

Apply closed-cell tubular insulation to all suction lines between evaporator coil connection and 38AU units suction service valve.

Hot Gas Bypass

Hot gas bypass, if used, should be introduced before the evaporator. (A bypass route that also bypasses the evaporator circuit may lead to oil trapping in the evaporator circuit during low load conditions and then to oil slugging as evaporator load increases.) Model 38AU units do not include a hot gas stub connection; a tee must be field-supplied and installed in the compressor discharge line. Run a 1/2-in OD line between outdoor unit and evaporator coil inlet. Install an Auxiliary Side Connector at the evaporator between TXV and distributor (follow instructions for the side connector part). Insulate the hot gas line.

38AUD: Generally only one hot gas bypass system will be applied on a two-circuit unit. Connect the hot gas bypass system to Circuit 1 (first-on/last-off, connected to the evaporator coils bottom circuit).

38AUD Piping Connections

The 38AUDs two circuits are designated Circuit 1 and Circuit 2. Circuit 1 is controlled by the thermostats Y1 (or TC1) contact and will be the first circuit on and last circuit off. Circuit 2 is controlled by the thermostats Y2

(or TC2) contact and this circuit is always the lag circuit.

See Fig. 5 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 38AUDs Circuit 1 so that the evaporators lower coil segment is first-on/last-off (to avoid re-evaporation of condensate on dry lower coil segments).

Circuit 1 Connections

Circuit 2 Connections

CKT 2 CKT

1

C10912

Fig. 5 - 38AUD Service Valve Locations

Plan the Circuit 1 and Circuit 2 tubing segments carefully, mark each segment and check constantly as piping systems are assembled to avoid piping errors.

38AUD unit cannot be field-piped as a single-circuit/tandem system.

Connecting 40RU to 38AUD: The 40RU fan coil in sizes 12, 14 and 16 is a face-split coil design that also has its circuits designated as 1 and 2. See Fig. 6. Note that the lower coil segment changes as the arrangement of the 40RU changes. In a vertical arrangement, the 40RUs lower coil segment is segment 2; this segment should be connected to the 38AUDs Circuit 1. In a horizontal arrangement, the 40RUs lower segment is now segment 1; this segment should be connected to the 38AUDs Circuit 1.

Note that refrigerant suction piping should be insulated.

40RU Arrangement

Cooling Stage

40RU Coil Segment

Connect to 38AUD

Vertical Y1 Y2

2 1

Circuit 1 Circuit 2

Horizontal Y1 Y2

1 2

Circuit 1 Circuit 2

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FIRST ON/LAST OFF = 2 VERTICAL INSTALLATION

FIRST ON/LAST OFF = 1 HORIZONTAL INSTALLATION

1

2

2

1

C10071

Fig. 6 - Typical Evaporator Coil Connections (40RU)

Install Filter Drier(s) and Moisture Indicator(s)

Every unit MUST have a filter drier in the liquid line. 38AUD models require two filter driers (one in each liquid line). Locate the filter drier(s) at the indoor unit, close to the evaporator coils thermal expansion valve (TXV) inlets.

38AU units include one (38AUZ) or two (38AUD) Puron-duty filter drier(s), shipped in cartons attached to the unit basepan. Remove the filter drier(s) and prepare to install in the liquid line(s) at the evaporator coil. Do not remove connection fitting plugs until ready to connect and braze the filter drier into the liquid line position.

Table 8 Puron-duty Filter Drier(s)

Model-Size Qty Liquid Line OD

Desiccant Volume

Part Number Ref

38AUZ*07 1 3/8-in 8 cu. in. KH43LS091

38AUZ*08 1 1/2-in 16 cu. in. KH43LS085

38AUD*12 2 3/8-in 8 cu. in. KH43LS091

38AUD*14 2 1/2-in 16 cu. in. KH43LS085

Installation of liquid line moisture indicating sightglass in each circuit is recommended. Locate the sightglass(es) between the outlet of the filter drier and the TXV inlet.

Refer to Table 9 for recommendations on refrigeration specialties.

In some applications, depending on space and convenience requirements, 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. 7) or 2 filter driers and sight glasses may be installed at B locations (see Figs. 7 and 8).

Select the filter drier for maximum unit capacity and minimum pressure drop. Complete the refrigerant piping from the indoor unit to the outdoor unit before opening the liquid and suction lines at the outdoor unit.

INDOOR COIL CKT 2

AIRFLOW

INDOOR COIL CKT 1

AIRFLOW

15 DIAMS MIN 10

DIAMS 8 DIAMS

MIN

TXV SENSING BULB

EQUALIZER LINE

SIGHT GLASS A LOCATION

SIGHT GLASSES B LOCATION

TXV CKT 2

FILTER DRIER A LOCATION

FILTER DRIERS B LOCATION

FLOWTXV SENSING BULB

TXV CKT 1

8 DIAMS MIN

15 DIAMS MIN 10

DIAMS

Single Circuit Coil Piping Configuration For single compressor condensing units

Dual Circuit Coil Piping Configuration For single compressor condensing units

15 DIAMS MIN 10

DIAMS 8 DIAMS

MIN

INDOOR COIL CKT

AIRFLOW

TXV SENSING BULB

EQUALIZER LINE

SIGHT GLASS A LOCATION

TXV

FILTER DRIER A LOCATION

LIQUID LINE SOLENOID VALVE

FLOW

LIQUID LINE SOLENOID VALVE

C10202

Fig. 7 - Location of Sight Glass(es) and Filter Driers Typical 38AUZ Systems

Table 9 Refrigerant Specialties Part Numbers

LIQUID LINE SIZE (in.)

LIQUID LINE SOLENOID VALVE (LLSV)

LLSV COIL

SIGHT GLASS

FILTER DRIER

3/8 EF680033 EF680037 KM680008 provided with unit see Table 81/2 EF680035 EF680037 KM680004

38AUD units require TWO sets of parts.

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AIRFLOW

SUCTION CIRCUIT 2

SUCTION CIRCUIT 1

AIRFLOW

15 DIAMS MIN 10

DIAMS 8 DIAMS

MIN

TXV SENSING BULB

EQUALIZER LINE

SIGHT GLASSES

TXV CKT 2

FILTER DRIERS

LIQUID LINE SOLENOID VALVE CIRCUIT 2

FLOW

LIQUID LINE SOLENOID VALVE CIRCUIT 1

FLOW

TXV SENSING BULB

TXV CKT 1

8 DIAMS MIN

15 DIAMS MIN 10

DIAMS

Dual Circuit Coil Piping Configuration For two circuit condensing units

C10072

Fig. 8 - Location of Sight Glasses and Filter Driers Typical 38AUD Systems

Install Liquid Line Solenoid Valve

It is recommended that a solenoid valve be placed in the main liquid line (see Figs. 7 & 8) between the condensing unit and the evaporator coil. Locate the solenoid valve at the outlet end of the liquid line, near the evaporator coil connections, with flow direction arrow pointed at the evaporator coil. Refer to Table 9. (A liquid line solenoid valve is required when the liquid line length exceeds 23 m [75 ft].) This valve prevents refrigerant migration (which causes oil dilution) to the compressor during the off cycle, at low outdoor ambient temperatures.

Solenoid drop control wiring: control the power to the liquid line solenoid through a Solenoid Valve Relay (SVR) in all units. Use part number HN61PC005 (field- supplied, installed). 38AUZ unit requires one SVR; 38AUD unit requires two relays.

38AUD units also require a separate control power transformer for the liquid solenoid valve loads. Use transformer part number HT01BD602, according to unit power supply.

Mount the SVR (and transformer TRAN3 when used) in unit control box. Connect per wiring schematic label on unit or per Fig. 24 (38AUZ) or Fig. 25 (38AUD).

Capacity Control Liquid Line Solenoid Valve: Evaporator capacity staging control via direct thermostat control of a liquid solenoid valve on the evaporators second stage circuit is not possible with 38AU models. If this installation is a retrofit for a unit that included automatic pressure- operated unloading, check the existing thermostat and liquid solenoid valve wiring for possible direct thermostat control of a solenoid valve; re-wire per Figs. 12 or 13 and 24 or 25.

Selecting an Accumulator

Because all 38AU models use scroll compressors, an accumulator is not required. If an accumulator is to be added, check the accumulator manufacturers literature

carefully for indication of its suitability for use with R-410A; look for minimum working pressure of 1380 kPa (200 psig). Select the accumulator first on the basis of its cataloged minimum capacity (tons) to ensure oil return from the accumulator, then on tube size or holding capacity.

Make Piping Connections

Piping connections at the 38AU unit are ball valves with stub tube extensions. Do not open the unit service valves until all interconnecting tube brazing has been completed.

The stub tube connections include 1/4-in SAE service fittings with Schrader valve cores (see Fig. 9). Before making any brazed connections to the unit service valves, remove both Schrader valve caps and cores and save for re-installation. Connect a source for nitrogen to one of these service fittings during tube brazing to prevent the formation of copper oxides inside the tubes at brazed joints.

Factory High-Flow Access Port

Service Valve with Stem Cap

Field Service Access Port (Schrader core)

Sweat Connection

C10203

Fig. 9 - Typical Piping Connection Assembly

When connecting the field tubing to the 38AU service valves, wrap the valves in wet rags to prevent overheating

Pressure-test all joints from outdoor unit connections over to the evaporator coil, using nitrogen as pressure and with soap-and-bubbles.

When pressure-testing is completed, remove the nitrogen source at the outdoor unit service valves and re-install the two Schrader valve cores. Torque the cores to 23-34 N-cm (2-3 in-lbs).

Evacuation/Dehydration

Evacuate and dehydrate the connected refrigeration system(s) (excluding the 38AU unit) to 500 microns using a two-stage vacuum pump attached to the service ports outside the 38AU service valves, following description in GTAC II, Module 4, System Dehydration.

UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause personal injury, death and/or equipment damage.

PuronR (R- 410A) refrigerant systems operate at higher pressure than standard R- 22 systems. Do not use R- 22 service equipment or components on Puron refrigerant equipment.

! WARNING

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This unit is designed for use with Puron (R- 410A) refrigerant. Do not use any other refrigerant in this system.

Puron (R- 410A) refrigerant is provided in pink (rose) colored cylinders. These cylinders are available with and without dip tubes; cylinders with dip tubes will have a label indicating this feature. For a cylinder with a dip tube, place the cylinder in the upright position (access valve at the top) when removing liquid refrigerant for charging. For a cylinder without a dip tube, invert the cylinder (access valve on the bottom) when removing liquid refrigerant.

Because Puron (R- 410A) refrigerant is a blend, it is strongly recommended that refrigerant always be removed from the cylinder as a liquid. Admit liquid refrigerant into the system in the discharge line. If adding refrigerant into the suction line, use a commercial metering/expansion device at the gauge manifold; remove liquid from the cylinder, pass it through the metering device at the gauge set and then pass it into the suction line as a vapor. Do not remove Puron (R- 410A) refrigerant from the cylinder as a vapor.

Preliminary Charge

Before starting the unit, charge R-410A liquid refrigerant into the high side of each 38AU circuit through the liquid service valve(s). The amount of refrigerant added must be at least 80% of the operating charge listed in Tables 5 or 6 for LINEAR line length LESS the factory charge quantity (if factory shipping charge has not been removed). See example below.

Allow high and low side pressures to equalize. If pressures do not equalize readily, charge R-410A vapor (using special service manifold with expansion device) into the suction line service port for the low side of system to assure charge in the evaporator. Refer to GTAC II, Module 5, Charging, Recover, Recycling, and Reclamation for liquid charging procedures.

Example (using Tables 5 and 6):

Unit 38AUZA08 with Novation coil Linear line length 25 m Estimated equivalent line length 37 m (add 50% to linear length) Liquid lift 8 m (indoor unit above outdoor unit)

See Table 5, 38AUZ models, for line sizes and system operating charge. Enter table in Equivalent Length column for 34-46 m.

Liquid line size: Note that a DNU code (Do Not Use) applies to 1/2-in. OD tube with Novation coil option for unit 38AUZ*08. Check liquid lift capability of 5/8-in OD tube against project requirements. Table 5 indicates 5/8-in tube allows 10 m lift which exceeds job requirements. (Note: If maximum liquid lift value is not greater than project requirements, STOP. Select a new location for the outdoor unit that reduces lift and/or length requirements or select a unit model with RTPF coil option.)

Suction line size: Select 1-1/8-in. OD tube for this line length.

Note Operating Charge quantity: 9.9 kg.

Start-up Charge Calculation

Target start-up charge quantity is 80% of Operating Charge quantity: Start-up Charge = 0.80 x 9.9 = 7.9 kg (use for recharge situation)

Deduct Shipping Charge if still available (new unit installation): Shipping Charge (from Table 1A): 2.2 kg Field-Add for Start-up: 7.9 2.2 = 5.7 kg (use for new unit installation)

EN Units:

38AUZA08 with Novation coil Linear length 82 ft Equivalent length 123 ft Liquid lift 25 ft

Select liquid line as 5/8-in OD, suction line as 1-1/8-in OD. Note Operating Charge quantity: 21.9 lbs

Start-up Charge Calculation

Target start-up charge quantity is 80% of Operating Charge quantity: Start-up Charge = 0.80 x 21.9 = 17.5 lbs (use for recharge situation)

Deduct Shipping Charge if still available (new unit installation): Shipping Charge (from Table 2A): 4.6 lbs Field-Add for Start-up: 17.5 4.6 = 12.9 lbs (use for new unit installation)

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Step 6 Install Accessories

Accessories requiring modifications to unit wiring should be completed now. These accessories may include Winter Start controls and Low Ambient controls. Refer to the instructions shipped with the accessory.

Step 7 Complete Electrical Connections

ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death.

Do not use gas piping as an electrical ground. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with local electrical codes or in absence of local codes, it is recommended that the U.S.A. standard ANSI/NFPA 70, National Electrical Code (NEC), be followed.

! WARNING

NOTE: Check all factory and field electrical connections for tightness. Field-supplied wiring shall conform with the limitations of 33C (63F) rise.

Field Power Supply

Field power wires are connected to the unit at line-side pressure lugs on compressor contactor C and TB1 (see wiring diagram label for control box component arrangement) or at factory-installed option non-fused disconnect switch. Max wire size is #4 AWG (copper only).

NOTE: TEST LEADS - Unit may be equipped with short leads (pigtails) on the field line connection points on contactor C or optional disconnect switch. These leads are for factory run-test purposes only; remove and discard before connecting field power wires to unit connection points. Make field power connections directly to line connection pressure lugs only.

FIRE HAZARD Failure to follow this warning could cause in personal injury, death and/or equipment damage.

Do not connect aluminum wire between disconnect switch and condensing unit. Use only copper wire. (See Fig. 10.)

! WARNING

COPPER

WIRE ONLY

ELECTRIC DISCONNECT

SWITCH

ALUMINUM WIRE

A93033

Fig. 10 - Disconnect Switch and Unit

Units Without Factory-Installed Disconnect

When installing units, provide a disconnect switch of adequate size per local or national wiring code. Disconnect sizing data is provided on the unit informative plate. Locate on unit cabinet or within sight of the unit per national or local codes. Do not cover unit informative plate if mounting the disconnect on the unit cabinet.

Units with Factory-Installed Disconnect

The factory-installed option disconnect switch is located in a weatherproof enclosure located under the main control box. The manual switch handle is accessible through an opening in the access panel.

All Units

All field wiring must comply with all local codes. Size wire based on MCA (Minimum Circuit Amps) on the unit informative plate. See Fig. 11 for power wiring connections to the unit load terminals and equipment ground.

Provide a ground- fault and short- circuit over- current protection device (fuse or breaker) per local code (or in absence of local code, is is recommended that U.S.A. standard, NEC Article 440, be followed). Refer to unit informative data plate for MOCP (Maximum Over- current Protection) device size.

All field wiring must comply with the appropriate national electrical codes and local requirements.

Affix the crankcase heater warning sticker to the unit disconnect switch.

Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate. See Tables 11 and 12. On 3-phase units, voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown in the legend for Tables 11 and 12 Note 3 (see page 21) to determine the percent of voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty.

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Units Without Disconnect Option

Units With Disconnect Option

2

4

6

1

3

5

L1

L2

L3

Optional Disconnect

Switch

Disconnect factory test leads; discard.

Factory Wiring

11 13

L1 L2 L3

C1 TB1

Disconnect

C10074 Fig. 11 - Power Wiring Connections

Table 10 American/European Wire Conversions AMERICAN EUROPEAN

Industry Standard Size

American Conversion Size (mm2)

Industry Standard Size (mm2)

20 AWG 0.52 0.5 18 AWG 0.82 1.0 16 AWG 1.30 1.5 14 AWG 2.08 2.5 12 AWG 3.30 4.0 10 AWG 5.25 6.0 8 AWG 6.36 10.0 6 AWG 13.29 16.0 4 AWG 21.14 25.0 3 AWG 26.65 2 AWG 33.61 35.0 1 AWG 42.39 50.0 1/0 AWG 53.49 2/0 AWG 67.42 70.0 3/0 AWG 85.00 95.0 4/0 AWG 107.9 120.0

Field Control Wiring

38AU unit control voltage is 24 v. See Fig. 24 (38AUZ) and Fig. 25 (38AUD) for typical field control connections and the units label diagram for field-supplied wiring details. Route control wires to the 38AU unit through the opening in units end panel to the connections terminal board in the units control box.

Remainder of the system controls connection will vary according to the specific construction details of the indoor section (air handler or packaged fan coil). Fig. 12 (38AUZ) and Fig. 13 (38AUD) depict typical connections to a Carrier 40RU fan coil unit. Plan for field connections carefully and install control wiring correctly per the project plan. Additional components and supplemental transformer accessory may be required.

The 38AU unit requires an external temperature control device. This device can be a thermostat (field-supplied) or a PremierLink controller (available as a field-installed accessory, for use on a Carrier Comfort Network or as a stand alone control).

Note 1: Connect only if thermostat requires 24-vac power source. Note 2: Connect W1 and W2 if supplemental heaters are installed Field Wiring

(Note 1)

(Note 2)

(Note 2)

C10985

Fig. 12 - Typical Remote Thermostat Connections 38AUZ

Note 1: Typical multi-function marking. Follow manufacturers configuration instructions to select Y2. Note 2: Connect only if thermostat requires 24-vac power source. Note 3: Connect W1 and W2 if supplemental heaters are installed Field Wiring

(Note 1)

(Note 2)

(Note 3)

(Note 3)

C10078

Fig. 13 - Typical Remote Thermostat Connections 38AUD

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Thermostat

Install a Carrier-approved accessory thermostat according to installation instructions included with the accessory. Locate the thermostat accessory on a solid wall in the conditioned space to sense average temperature in accordance with the thermostat installation instructions.

38AUZ Unit - 38AUZ unit is a single- stage cooling unit. If no economizer function is required, select a single- stage cooling thermostat. If an integrated economizer function is required, select a two-stage cooling thermostat.

The 38AUD is a dual- circuit, two-stage cooling unit. Select a twostage cooling thermostat.

Select a thermostat cable or equivalent single leads of different colors with minimum of four leads for 38AUZ or five leads for 38AUD unit. Check the thermostat installation instructions for additional features which might require additional conductors in the cable.

For wire runs up to 15 m (50 ft.), use no. 18 AWG (American Wire Gage) insulated wire (35C minimum). For 15 to 23 m (50 to 75 ft.), use no. 16 AWG insulated wire (35C minimum). For over 23 m (75 ft.), use no. 14 AWG insulated wire (35C minimum). All wire sizes larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat.

PremierLink (accessory installation) Refer to Form 33CS-58SI for details on connecting the PremierLink controller and its various sensors.

Control Circuit Wiring

Control voltage is 24 v. See Fig. 24 and Fig. 25 and the units label diagram for field- supplied wiring details. Route control wires through the opening in units end panel to the connection in the units control box.

Control Transformer Wiring

On multi voltage units, check the transformer primary wiring connections. See Fig. 14 or refer to the units label diagram.

C10079

Fig. 14 - Control Transformer Wiring

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Table 11 Electrical Data 38AUZ*07- 14 50 Hz Units

UNIT V---Ph---Hz

VOLTAGE RANGE} COMPRESSOR 1 OFM POWER

SUPPLY DISCONNECT

SIZE

MIN MAX RLA LRA OTY FLA MCA Fuse FLA LRA

38AUZ*07 400---3---50 360 440 9.7 64 2 .07 13.5 20 13 68

38AUZ*08 400---3---50 360 440 12.2 100 2 .07 16.7 25 16 104

NOTE: See Legend and Notes for Tables 11 & 12

Table 12 Electrical Data 38AUD*12- 14 50 Hz Units

UNIT V---Ph---Hz

VOLTAGE RANGE}

COMPRESSOR 1

COMPRESSOR 2 OFM (ea) POWER

SUPPLY DISCONNECT

SIZE

MIN MAX RLA LRA RLA LRA QTY FLA MCA Fuse FLA LRA

38AUD*12 400---3---50 360 440 7.8 52 7.8 52 2 0.7 19.0 25 20 108

38AUD*14 400---3---50 360 440 10.6 74 10.6 74 2 0.7 25.3 30 26 152

NOTE: See Legend and Notes for Tables 11 & 12

Legend and Notes for Tables 11 and 12

LEGEND: FLA --- Full Load Amps LRA --- Locked Rotor Amps MCA --- Minimum Circuit Amps

Protection NEC --- National Electrical Code RLA --- Rated Load Amps

} Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed limits.

NOTES: 1. The MCA and Fuse values are calculated in accordance with The NEC. Article 440.

2. Motor RLA and LRA values are established in accordance with Underwriters Laboratories (UL). Standard 1995.

3. Unbalanced 3-Phase Supply Voltage Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to de- termine the percentage of voltage imbalance.

Example: Supply voltage is 400-3-50

% Voltage Imbalance = 100 x max voltage deviation from average voltage

average voltage

AB = 394 v BC = 401 v AC = 396 v

Average Voltage = (394 + 401 + 396)

= 1191

3 3

= 397

Determine maximum deviation from average voltage. (AB) 397 394 = 3 v (BC) 401 397 = 4 v (AC) 397 396 = 1 v Maximum deviation is 4 v. Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x 4

397

= 1.00%

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%. IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

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PRE-START-UP

IMPORTANT: Before beginning Pre-Start-Up or Start-Up, review Start-Up Checklist at the back of this book. The Checklist assures proper start-up of a unit and provides a record of unit condition, application requirements, system information, and operation at initial start-up.

UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage.

Do not attempt to start the condensing unit, even momentarily, until the following steps have been completed. Compressor damage may result.

CAUTION!

System Check 1. The electrical power source must agree with the units nameplate rating.

2. Check all air handler(s) and other equipment auxiliary components. Consult the manufacturers instructions re- garding any other equipment connected to the condens- ing unit. If the unit has field-installed accessories, be sure all are properly installed and correctly wired. If used, the airflow switch must be properly installed.

3. Check tightness of all electrical connections. 4. Be sure liquid line and low side of the system are properly leak checked and dehydrated.

5. Be sure the unit is properly charged. See Preliminary Charge, below.

6. Open the liquid line and suction line service valves. 7. The crankcase heater must be firmly attached to the compressor crankcase. Be sure the crankcase is warm (heater must be on for 24 hours before starting com- pressor).

Turn On Crankcase Heater

Turn on the crankcase heater for 24 hours before starting the unit to be sure all the refrigerant is out of the oil. To energize the crankcase heater, proceed as follows:

1. Set the space thermostat set point above the space temperature so there is no demand for cooling.

2. Close the field disconnect.

Preliminary Charge

Before starting the unit, charge liquid refrigerant into the high side of the system through the liquid service valve. The amount of refrigerant added must be at least 80% of the operating charge listed in the Physical Data table (Tables 1A through 2B, pages 5 through 8). Allow high and low side pressures to equalize before starting compressor. If pressures do not equalize readily, charge vapor on low side of system to assure charge in the evaporator. Refer to GTAC II, Module 5, Charging, Recover, Recycling, and Reclamation for liquid charging procedures.

UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage.

Prior to starting compressor, a preliminary charge of refrigerant must be added to avoid possible compressor damage.

CAUTION!

START-UP 38AU Units: The compressor crankcase heater must be on for 24 hours before start-up. After the heater has been on for 24 hours, the unit can be started. If no time elapsed since the preliminary charge step was completed, it is unnecessary to wait the 24-hour period.

Preliminary Checks 1. Check that electric power supply agrees with unit nameplate data.

2. Verify that the compressor crankcase heater is se- curely in place.

3. Check that the compressor crankcase heater has been on at least 24 hours.

4. Recheck for leaks using the procedure outlined in the Pre-Start-Up section, Leak Test and Dehydration. If any leaks are detected, repair as required. Evacuate and dehydrate as described in the Leak Test and De- hydration section.

5. Ensure that the preliminary charge has been added as described in the Pre-Start-Up section, Preliminary Charge.

6. All internal wiring connections must be tight, and all barriers and covers must be in place.

NOTE: The 38AU units are factory charged with the required amount of oil. If recharging in required, use Emkarate RL 32-3MAF for the 38AU units.

Compressor Rotation

On 3-phase units with scroll compressors, it is important to be certain that the compressor is rotating in the proper direction. 38AU units are equipped with a Comfort Alert Diagnostic Module (CADM). Alert Code 7 indicates reverse power phasing.

To correct phase order:

1. Turn off power to the unit, tag disconnect. 2. Reverse any two of the unit power leads. 3. Reapply power to the compressor, verify correct pres- sures.

To verify the compressor is rotating in the proper direction:

1. Connect service gages to the suction and liquid pres- sure fittings.

2. Energize the compressor. 3. The suction pressure should drop and the liquid pres- sure should rise, as is normal on any start- up.

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Compressor Overload

This overload interrupts power to the compressor when either the current or internal motor winding temperature becomes excessive, and automatically resets when the internal temperature drops to a safe level. This overload may require up to 60 minutes (or longer) to reset. If the internal overload is suspected of being open, disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester.

Advanced Scroll Temperature Protection (ASTP)

A label located above the terminal box identifies Copeland Scroll compressor models that contain this technology. See Fig. 15. Advanced Scroll Temperature Protection (ASTP) is a form of internal discharge temperature protection, that unloads the scroll compressor when the internal temperature reaches approximately 149_C (300_F). At this temperature, an internal bi-metal disk valve opens and causes the scroll elements to separate, which stops compression. Suction and discharge pressures balance while the motor continues to run. The longer the compressor runs unloaded, the longer it must cool before the bi-metal disk resets. See Fig. 16.

C10080

Fig. 15 - Advanced Scroll Temperature Protection Label

0 10 20 30 40 50 60 70 80 90

100 110 120

0 10 20 30 40 60 70 80 9050

Compressor Unloaded Run Time (Minutes)*

*Times are approximate. NOTE: Various factors, including high humidity, high ambient temperature, and the presence of a sound blanket will increase cool-down times.

R ec

om m

en de

d C

oo lin

g Ti

m e*

(M in

ut es

)

C10081

Fig. 16 - Recommended Minimum Cool-Down Time After Compressor is Stopped

To manually reset ASTP, the compressor should be stopped and allowed to cool. If the compressor is not stopped, the motor will run until the motor protector trips, which occurs up to 90 minutes later. Advanced Scroll Temperature Protection will reset automatically before the motor protector resets, which may take up to 2 hours.

Start Unit

Set the space thermostat to a set point above space temperature so that there is no demand for cooling. Close the 38AU disconnect switch. Only the crankcase heater will be energized.

Reset the space thermostat below ambient so that a call for cooling is ensured.

UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage.

Never charge liquid into the low-pressure side of system. Do not overcharge. During charging or removal of refrigerant, be sure indoor-fan system is operating. Ensure both outdoor fan motors are running; bypass any Motormaster function.

CAUTION!

Adjust Refrigerant Charge

Refer to Cooling Charging Charts, Fig. 17 through Fig. 23. For applications 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. The charts are based on charging the units to the correct subcooling for the various operating conditions. Accurate pressure gage and temperature sensing device are required. Connect the pressure gage to the service port on the liquid line service valve. Mount the temperature sensing device on the liquid line close to the liquid line service valve, and insulate it so that outdoor ambient temperature does not affect the reading. Indoor airflow must be within the units normal operating range. Operate the unit for a minimum of 15 minutes. Ensure that pressure and temperature readings have stabilized. Plot the liquid pressure and temperature on chart and add or reduce the charge to meet the curve. Adjust the charge to conform with the charging chart, using the liquid pressure and temperature to read the chart.

Using plotted operating point:

If plotted operating condition is - Adjust charge by -

BELOW the curve REDUCE charge

ABOVE the curve ADD charge

Final Checks

Ensure that all safety controls are operating, control panel covers are on, and the service panels are in place.

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C101050

Fig. 17 - 38AUZ*07 Charging Chart (Novation)

C101051

Fig. 18 - 38AUZ*08 Charging Chart (Novation)

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C101052

Fig. 19 - 38AUD*12 Charging Chart (Novation)

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C101053

Fig. 20 - 38AUD*14 Charging Chart (Novation)

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C101054

Fig. 21 - 38AUZ*07 Charging Chart (RTPF)

20

40

60

80

100

120

140

160

50 150 250 350 450 550 650

7.5 TON CHARGING CHART PURON ALL CONDENSER FANS OPERATING

7.5 TONNE TABLEAU DE CHARGE PURON

TOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT

PRESSURE AT LIQUID VALVE (PSIG) PRESSION LA VANNE DE LIQUIDE (PSIG)

TE M

P E

R A

TU R

E A

T LI

Q U

ID V

A LV

E (

F) TE

M P

R

A TU

R E

L

A V

A N

N E

D E

L IQ

U ID

E (

F)

C101055

Fig. 22 - 38AUZ*08 Charging Chart (RTPF)

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C101056

Fig. 23 - 38AUD*12 Charging Chart (RTPF)

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C101013

Fig. 24 - Typical 38AUZ Wiring Diagram

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C101014

Fig. 25 - Typical 38AUD Wiring Diagram

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OPERATING SEQUENCE

Base Unit Controls

Indoor (Supply) Fan

The indoor fan contactor (IFC) is remotely located at the fan coil or fan section. If the thermostat fan operation is selected as Continuous, the IFC is energized and the indoor (supply) fan motor runs continuously. If the thermostat fan operation is selected as Automatic, the IFC will be energized on a call for Cooling; indoor (supply) fan motor runs. When thermostat call for Cooling is satisfied, the IFC is de-energized and indoor (supply) fan motor stops.

Cooling, Unit Without Economizer

38AUZ (Single Circuit)

On a thermostat call for Cooling, IFC will be energized and indoor (supply) fan motor runs. Thermostat output Y1 is energized; terminal Y1 at 38AUZ unit receives 24-v. 24-v received at CADM1 terminal Y. If anti-recycle time delay period has not expired, CADM1 relay will remain open, de-energizing Solenoid Valve Relay (SVR) and preventing compressor start. When safety pressure switches are closed and CADM1 time delay expires, CADM1 relay closes, SVR and compressor contactor C are energized; liquid line solenoid valve LLSV opens, all outdoor fan motors start and Compressor starts.

As space cooling load is satisfied, thermostat output Y1 is de- energized, removing 24-v at 38AUZ terminal Y1. On Y1 opening, Compressor stops, all outdoor fan motors stop and SVR relay is de-energized. Liquid line solenoid valve is de-energized and valve closes. CADM1 begins its three-minute anti-recycle time delay.

38AUD (Two Circuit)

On a thermostat call for Cooling, IFC will be energized and indoor (supply) fan motor runs. Thermostat output Y1 is energized; terminal Y1 at 38AUD unit receives 24-v. 24-v received at CADM1 terminal Y. If anti-recycle time delay period has not expired, CADM1 relay will remain open, de-energizing Solenoid Valve Relay 1 (SVR1) and preventing compressor start. When safety pressure switches are closed and CADM1 time delay expires, CADM1 relay closes, SVR1 and compressor contactor C1 are energized; liquid line solenoid valve LLSV1 opens, all outdoor fan motors start and Circuit 1 compressor starts.

On a thermostat calling for Stage 2 Cooling, thermostat output Y2 is energized; terminal Y2 at 38AUD unit receives 24-v. 24-v received at CADM2 terminal Y. If anti-recycle time delay period has not expired, CADM2 relay will remain open, de-energizing Solenoid Valve Relay 2 (SVR2) and preventing compressor start. When safety pressure switches are closed and CADM2 time delay expires, CADM2 relay closes, SVR2 and compressor contactor C2 are energized; liquid line solenoid valve LLSV2 opens and Circuit 2 compressor starts.

As space cooling load is satisfied, thermostat outputs Y2 and Y1 are de- energized, removing 24-v at 38AUD terminals Y2 and Y1. Circuit 2 compressor stops on Y2 opening; SVR2 is de-energized and LLSV2 closes. CADM2 begins its three-minute anti-recycle time delay. On Y1 opening, Circuit 1 compressor stops, all outdoor fan motors stop and SVR1 relay is de-energized. Liquid line solenoid valve LLSV1 is de-energized and valve closes. CADM1 begins its three-minute anti-recycle time delay.

All Units

If either the Low Pressure Switch or High Pressure Switch opens while thermostat output Y1 or Y2 remain energized, the compressor contactor is de-energized, the compressor stops and liquid line solenoid is de-energized (valve closes). CADM initiates a TRIP event (cooling demand sensed at CADM terminal Y but no current is measured at T1, T2, T3 motor sensors); CADM relay opens and RED LED is illuminated. TRIP condition maintains lockout of compressor operation until CADM is manually reset. Reset CADM by cycling unit main power.

Complete system shutdown may be caused by loss of main power, open compressor internal overload, open low-pressure or high-pressure switch, or a fault detected by the CADM logic. Compressor operation without cooling may indicate the compressors ASTP feature is active; disconnect unit power and allow compressor to cool. See Service section for further details.

Cooling, Unit With Economizer

Refer to fan coil unit installation instructions and economizer accessory installation instructions for operating sequences when system is equipped with accessory economizer.

Heating

Refer to fan coil unit installation instructions and accessory heating device installation instructions for operating sequences in heating mode.

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ROUTINE SYSTEM MAINTENANCE These items should be part of a routine maintenance program, to be checked every month or two, until a specific schedule for each can be identified for this installation:

Quarterly Inspection (and 30 days after initial start)

Indoor section

S Condenser coil cleanliness checked.

S Return air filter replacement

S Outdoor hood inlet filters cleaned

S Belt tension checked

S Belt condition checked

S Pulley alignment checked

S Fan shaft bearing locking collar tightness checked

S Condensate drain checked

Seasonal Maintenance

These items should be checked at the beginning of each season (or more often if local conditions and usage patterns dictate):

Air Conditioning

S Condenser fan motor mounting bolts tightness

S Compressor mounting bolts

S Condenser fan blade positioning

S Control box cleanliness and wiring condition

S Wire terminal tightness

S Refrigerant charge level

S Evaporator coil cleaning

S Evaporator blower motor amperage

Heating

S Power wire connections

S Fuses ready

S Manual-reset limit switch is closed

Economizer or Outside Air Damper

S Inlet filters condition

S Check damper travel (economizer)

S Check gear and dampers for debris and dirt

SERVICE

Refrigeration System

EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in damage to equipment.

This system uses PuronR refrigerant which has higher pressures than R-22 and other refrigerants. No other refrigerant may be used in this system. Gage set, hoses, and recovery system must be designed to handle Puron. If you are unsure consult the equipment manufacturer.

CAUTION!

Compressor Oil

EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in damage to equipment.

The compressor in a Puron system uses a polyolester (POE) oil. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere.

CAUTION!

Servicing Systems on Roofs With Synthetic Materials

POE (polyolester) compressor lubricants are known to cause long term damage to some synthetic roofing materials. Exposure, even if immediately cleaned up, may cause embrittlement (leading to cracking) to occur in one year or more. When performing any service which may risk exposure of compressor oil to the roof, take appropriate precautions to protect roofing. Procedures which risk oil leakage include but are not limited to compressor replacement, repairing refrigerants leaks, replacing refrigerant components such as filter drier, pressure switch, metering device, coil, accumulator, or reversing valve.

Synthetic Roof Precautionary Procedure:

1. Cover extended roof working area with an imper- meable polyethylene (plastic) drop cloth or tarp. Cover an approximate 3.3 x 3.3 m (10 x 10 ft ) area.

2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run-offs, and protect drop cloth from tears caused by tools or components.

3. Place terry cloth shop towel inside unit immediately un- der component(s) to be serviced and prevent lubricant run-offs through the louvered openings in the base pan.

4. Perform required service. 5. Remove and dispose of any oil contaminated material per local codes.

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Liquid Line Filter Drier

The factory-provided filter drier is specifically designed to operate with Puron. Replace the filter drier with factory-authorized components only with a filter drier with desiccant made from 100% molecular sieve grade XH-11. Filter drier must be replaced whenever the refrigerant system is opened.

When removing a filter drier, use a tubing cutter to cut the drier from the system. Do not unsweat a filter drier from the system. Heat from unsweating will release moisture and contaminants from drier into system.

Field Refrigerant Access Ports

Field service access to refrigerant pressures is through the access ports located at the service valves (see Figs 29 and 31). These ports are -in SAE Flare couplings with Schrader check valves and service caps. Use these ports to admit nitrogen to the field tubing during brazing, to evacuate the tubing and evaporator coil, to admit initial refrigerant charge into the low-side of the system and when checking and adjusting the system refrigerant charge. When service activities are completed, ensure the service caps are in place and secure; check for leaks. If the Schrader check valve must be removed and re-installed, tighten to 2-3 in-lbs (23-34 N-cm).

Factory High-Flow Access Ports

There are two additional access ports in the system - on the suction tube between the compressor and the suction service valve and on the liquid tube near the liquid service valve (see Figs 30 and 32). These are brass fittings with black plastic caps. The hose connection fittings are standard -in SAE Male Flare couplings.

The brass fittings are two-piece High Flow valves, with a receptacle base brazed to the tubing and an integral spring-closed check valve core screwed into the base. (See Fig. 26) This check valve is permanently assembled into this core body and cannot be serviced separately; replace the entire core body if necessary. Service tools are available from RCD that allow the replacement of the check valve core without having to recover the entire system refrigerant charge. Apply compressor refrigerant oil to the check valve cores bottom o-ring. Install the fitting body with 96 -10 in-lbs (1085 23 N-cm) of torque; do not overtighten.

1/2-20 UNF RH

30

0.596

.475/8 HEX

SEAT CORE

WASHER DEPRESSOR PER ARI 720 +.01/-.035 FROM FACE OF BODY

7/16-20 UNF RH

O-RING

45

1/2" HEX

This surface provides a metal to metal seal when torqued into the seat. Appropriate handling is required to not scratch or dent the surface.

(Part No. EC39EZ067)

C08453

Fig. 26 - CoreMax Access Port Assembly

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Comfort Alert Diagnostic Module

The Comfort Alert Diagnostic Module (CADM) monitors and analyzes data from the Copeland Scroll three-phase compressor and the thermostat demand. The CADM also provides a 3-minute anti-recycle time delay to compressor cycling. Each compressor has a separate CADM module.

The CADM detects causes for electrical and system related failures without any sensors. Flashing LEDs communicate the Alert codes to guide service technicians in accurately and quickly troubleshooting the system and determining root cause for the failure.

Inputs to the CADM include 24-vac power, thermostat Y1 or Y2, compressor contactor coil (common side) and compressor power leads (from the compressor contactor).

Input Terminal Voltage

Control Power R 24-V

Control Common C 24-V

Cooling Y 24-V

Contactor Coil P 24-V

Line A T1 Line

Line B T2 Line

Line C T3 Line

Control of the compressor contactor coil is through a normally-closed (power on the module) contact between terminals P and C.

Communications of status and alert conditions is through three LEDs located on the top edge of the module housing (see Fig. 27): POWER (green), ALERT (yellow), and TRIP (red).

The POWER LED indicates the presence of control power to the CADM.

The ALERT LED indicates an abnormal condition exists in the system through a flash code. The ALERT LED will blink a number of times consecutively, pause and the repeat the process. The number of blinks, defined in Table 13, correlates to a particular abnormal condition; troubleshooting tips are provided for each Alert code. Reset of the ALERT may be automatic or manual. If the fault condition causing the Alert is self-corrected, the Alert code will be removed and the CADM will automatically reset and allow the system to restart normally. Manual reset requires that main power to the 38AU unit be recycled after the cause for the Alert condition has been detected and corrected.

POWER (GRN)

ALERT (YEL)

TRIP (RED)

C10086

Fig. 27 - CADM Housing/LED Locations

The TRIP LED indicates either a time-delay period is currently active (RED LED is blinking) or the module has locked out the compressor (RED LED is on steady). A lockout condition will occur when the CADM detects a thermostat demand at input Y but there is no power at the compressor line terminals T1 or T2 or T3. This lockout can occur due to a safety switch (LPS or HPS) opening and de-energizing the compressor contactor, the compressor-motor internal overload opens, or other internal power interruption has occurred. Reset of the TRIP LED requires that unit main power be recycled after the loss of power to the compressor condition has been detected and corrected.

Simultaneous Blinking of YELLOW and RED LEDs indicates control power input to the CADM is low. Check control circuit transformer and wiring.

Troubleshooting the CADM Wiring Flashing LEDs also indicate wiring problems to the CADM. See Table 14 for discussion of additional LED flash codes and troubleshooting instructions.

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Table 13 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 LED On Solid

Thermostat demand signal Y is present, but the com- pressor is not running.

1. Compressor protector is open

2. Condensing unit power disconnect is open

3. Compressor circuit breaker or fuse(s) is open

4. Broken supply wires or connector is not making contact

5. Compressor power wires not routed through Comfort Alert

6. Compressor contactor has failed open

Red TRIP LED Flashing

The anti-short cycle timer (3 minutes) in module is preventing compressor restart.

Module locks out compressor when compressor damaging ALERT code appears. Lockout ALERT codes are noted in the Status LED Description. During a compressor lock out, 24VAC power must be removed from module to manually reset.

Yellow ALERT LED On Solid

A short circuit or over cur- rent condition exists on PROT terminal.

1. Compressor contactor coil shorted

2. Electrical load too high for PROT circuit (maximum 1 Amp)

3. 24 V AC wired directly to PROT terminal

Yellow ALERT Flash Code 2

System Pressure Trip Discharge pressure out of limits or compressor over- load (if no high pressure switch in system) LOCKOUT

1. High head pressure

2. Condenser coil poor air circulation (dirty, blocked, damaged)

3. Condenser fan is not running

4. If low pressure switch is open: Refer to Code 3 for troubleshooting

Yellow ALERT Flash Code 3

Short Cycling Compressor is running only briefly (four consecutive cycles of less than three minutes each) LOCKOUT

1. If low pressure switch is open:

a. Low refrigerant charge

b. Evaporator blower is not running

c. Evaporator coil is frozen

d. Faulty metering device

e. Condenser coil is dirty

f. Liquid line restriction (filter drier blocked if present)

2. If high pressure switch is open, go to Flash Code 2 information

3. Intermittent thermostat demand signal

4. System or control board defective

Yellow ALERT Flash Code 4

Locked Rotor LOCKOUT

1. Low line voltage to compressor

2. Excessive liquid refrigerant in compressor

3. Compressor bearings are seized

Yellow ALERT Flash Code 5

Open Circuit 1. Condensing unit power disconnect is open

2. Compressor circuit breaker or fuses are open

3. Compressor contactor has failed open

4. High pressure switch is open and requires manual reset

5. Broken supply wires or connector is not making contact

6. Unusually long compressor protector reset time due to extreme ambient temperature

7. Compressor windings are damaged

Yellow ALERT Flash Code 6

Missing Phase LOCKOUT

1. Compressor fuse is open on one phase

2. Broken wire or connector on one phase

3. Compressor motor winding is damaged

4. Utility supply has dropped one phase

Yellow ALERT Flash Code 7

Reverse Phase LOCKOUT

1. Compressor running backward due to supply phase reversal

Yellow ALERT Flash Code 8

Welded Contactor Compressor always runs

1. Compressor contactor has failed closed

2. Thermostat demand signal not connected to module

Yellow ALERT Flash Code 9

Low Voltage Control circuit < 18VAC

1. Control circuit transformer is overloaded

2. Low line voltage to compressor

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Table 14 CADM Troubleshooting

Miswired Module Indication Recommended Troubleshooting Action

Green LED is not on, module does not power up

Determine if both R and C module terminals are connected. Verify voltage in present at modules R and C terminals. NOTE: The CADM requires a constant nominal 24VAC power supply. The wiring to the modules R and C terminals must be directly from the control transformer. The module cannot receive its power from another device that will interrupt the 24VAC power supply. See the 38AU Wiring Diagram(s) (Fig. 24 and Fig. 25).

Green LED Intermittent, module powers up only when compressor runs

Determine if R and Y terminals are wired in reverse. Verify modules R and C terminals have a con- stant source. See NOTE above for details on R and C wiring.

TRIP LED is on but system and compressor check OK

Verify Y terminal is wired properly per the 38AU wiring diagram (see Fig. 24 and Fig. 25). Verify voltage at contactor coil falls below 0.5VAC when off. Verify 24VAQC is present across Y and C when thermostat demand signal is present. If not, R and C are reverse wired.

TRIP LED and ALERT LED flashing together

Verify R and C terminals are supplied with 19-28VAC.

ALERT Flash Code 3 (Compressor Short Cycling) displayed incorrectly

Verify Y terminal is connected to 24VAC at contactor coil. Verify voltage at contactor coil falls below 0.5VAC when off.

ALERT Flash Code 5 or 6 (Open Circuit, Missing Phase) displayed incorrectly

Check that compressor T1 and T3 wires are through modules current sensing holes. Verify Y ter- minal is connected to 24VAC at contactor coil. Verify voltage at contactor coil falls below 0.5VAC when off.

Alert Flash Code * (Welded Contactor) displayed incorrectly

Determine if modules Y terminal is connected. Verify Y terminal is connected to 24VAC at contactor coil. Verify 24VAC is present across Y and C when thermostat demand signal is present. If not, R and C are reverse wired. Verify voltage at contactor coil falls below 0.5VAC when off.

Compressor Protection

Compressor Overtemperature Protection (IP)

A thermostat installed on the compressor motor winding reacts to excessively high winding temperatures and shuts off the compressor.

Crankcase Heater

The heater minimizes absorption of liquid refrigerant by oil in the crankcase during brief or extended shutdown periods. The heater is wired to cycle with the compressor; the heater is off when compressor is running, and on when compressor is off.

The crankcase heater will operate as long as the power circuit is energized. The main disconnect must be on to energize the crankcase heater.

IMPORTANT: Never open any switch or disconnect that energizes the crankcase heater unless unit is being serviced or is to be shut down for a prolonged period. After a prolonged shutdown on a service job, energize the crankcase heater for 24 hours before starting the compressor.

Advanced Scroll Temperature Protection (ASTP)

See Advanced Scroll Temperature Protection (ASTP) on page 23.

Low-Pressure Switch

The 38AU low-pressure switch is stem-mounted on the suction line. Switches are all fixed, non-adjustable type.

High-Pressure Switch

The high- pressure switch is stem mounted on the discharge line. The switch is a fixed, non-adjustable type.

Outdoor Fans

Each fan is supported by a formed-wire mount bolted to the fan deck and covered with a wire guard. Fan motors have permanently lubricated bearings.

1. Shut off unit power supply. Install lockout tag. 2. Remove outdoor fan assembly (grille, motor, and fan). 3. Loosen fan hub setscrews. 4. Adjust fan height as shown in Fig. 28. 5. Tighten setscrews to 949 N-cm (84 in- lbs). 6. Replace outdoor fan assembly.

3.6 mm +0/0/-0.8

C10103

Fig. 28 - Outdoor Fan Blade Position

Lubrication

Fan Motors: The fan motors have sealed bearings. No provisions are made for lubrication.

Compressor: The compressor has its own oil supply. Loss of oil due to a leak in the system should be the only reason for adding oil after the system has been in operation.

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Condenser Fans

Service Valves

C10927

Fig. 29 - Typical Exterior, Single-Circuit Unit (38AUZ*08 shown)

HPS

LPS

High Flow Access Port

32LT Sensor Typical Location

Outdoor Coil

C10928

Fig. 30 - Typical Interior, Single-Circuit Unit (38AUZ*08 shown)

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Condenser Fans

Service Valves

C10929

Fig. 31 - Typical Exterior, Two-Circuit Unit (38AUD*14 shown)

HPS

LPS

High Flow Access Ports

Motormaster Sensor Location

Outdoor Coil

CKT 2 CKT

1

C10930

Fig. 32 - Typical Interior, Two-Circuit Unit (38AUD*14 shown)

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Coil Type Identification

38AU units are available with different coil types. Cleaning methods differ for each type so identifying the coil type is important. Unit model number and appearance can identify the coil type.

NOVATIONt Type

The new NOVATION Heat Exchanger Technology is an all- aluminum construction with louvered serpentine fins over single-depth crosstubes. The horizontal crosstubes have large diameter aluminum headers on each end. Various optional coatings are also available.

38AU units use two- row segmented coils.

TUBES

FINS

MICROCHANNELS

MANIFOLD

C07273

Fig. 33 - NOVATION Heat Exchanger Coil

Model number designation: See Fig. 2 for general unit model number format. Position 11 indicates the coil type and coating. Position 11 values of G, K, T and W indicate NOVATION coil type is on this unit.

Round-Tube Plate-Fin (RTPF) Type

This construction uses a series of small diameter copper hairpin tubes running horizontally with vertical plate fins. The plate fins may be aluminum (standard) or copper (optional). Various optional coatings are also available. 38AU units use two- row segmented coils.

Model number designation: See Fig. 2 for general unit model number format. Position 11 indicates the coil type and coating. Position 11 values of A, B, C, M, N and P indicate RTPF coil type is on this unit.

NOVATION Coil Cleaning and Maintenance

To clean the NOVATION condenser coil, chemicals are NOT to be used; only water is approved as the cleaning solution. Only clean potable water is authorized for cleaning NOVATION condensers.

Clean the coil as follows:

1. Turn off unit power. 2. Remove screws holding rear corner posts and top cover in place. Pivot top cover up 305 to 457 mm (12 to 18 in.) and support with a rigid support. See Fig. 34.

C10216

Fig. 34 - Pivot and Support Top Cover

3. Carefully remove any foreign objects or debris at- tached to the coil face or trapped within the mounting frame and brackets.

4. Using a high pressure water sprayer, purge any soap or industrial cleaners from hose and/or dilution tank prior to wetting the coil. Clean condenser face by spraying the coil core steadily and uniformly from top to bottom, directing the spray straight into or toward the coil face. Do not exceed 6205 kPa (900 psig) or a 45 degree angle; nozzle must be at least 30 cm (12 in.) from the coil face. Reduce pressure and use caution to prevent damage to air centers (fins). Do not fracture the braze between air centers and refrigerant tubes. Allow water to drain from the coil core and check for refrigerant leaks prior to start up.

5. Replace top cover and rear corner posts.

EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in equipment damage.

Chemical cleaning should NOT be used on the aluminum microchannel (NOVATION) condenser. Damage to the coil may occur. Only approved cleaning is recommended.

CAUTION!

Repairing NOVATION Condenser Tube Leaks

RCD offers service repair kit Part Number 50TJ660007 for repairing tube leaks in the NOVATION coil crosstubes. This kit includes approved braze materials (aluminum fluxcore braze rods), a heat shield, a stainless steel brush, replacement fin segments, adhesive for replacing fin segments, and instructions specific to the NOVATION aluminum coil. See EPIC for instruction sheet 99TA526379.

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The repair procedure requires the use of MAPP gas and torch (must be supplied by servicer) instead of conventional oxyacetylene fuel and torch. While the flame temperature for MAPP is lower than that of oxyacetylene (and thus provides more flexibility when working on aluminum), the flame temperature is still higher than the melting temperature of aluminum, so user caution is required. Follow instructions carefully. Use the heat shield.

Replacing NOVATIONt Condenser Coil

The service replacement coil is preformed and is equipped with transition joints with copper stub tubes. When brazing the connection joints to the unit tubing, use a wet cloth around the aluminum tube at the transition joint. Avoid applying torch flame directly onto the aluminum tubing.

Routine Cleaning of Round-Tube Plate Fin (RTPF) Coils

Periodic cleaning with Totaline environmentally sound coil cleaner is essential to extend the life of RTPF coils. This cleaner is available from Carrier Replacement parts division as part number P902-0301 for a 3.8 liter (1 gallon) container, and part number P902-0305 for a 19 liter (5 gallon) container. It is recommended that all RTPF coils be cleaned with the Totaline environmentally sound coil cleaner as described below.

NOTE: Do NOT use Totaline environmentally sound coil cleaner, or any other coil cleaner on NOVATION coils. See NOVATION Coil Cleaning and Maintenance for instructions on cleaning NOVATION coils.

Coil cleaning should be part of the units regularly scheduled maintenance procedures to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment.

Avoid the use of:

S coil brighteners

S acid cleaning prior to painting

S high pressure washers

S poor quality water for cleaning

Totaline environmentally sound coil cleaner is non-flammable, hypoallergenic, non-bacterial, and a USDA accepted biodegradable agent that will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces, or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected.

Totaline Environmentally Sound Coil Cleaner Application Equipment

S 91/2 liter (21/2 gallon) garden sprayer

S water rinse with low velocity spray nozzle

UNIT DAMAGE HAZARD Failure to follow this caution may result in corrosion and damage to the unit.

Harsh chemicals, household bleach or acid or basic cleaners should not be used to clean outdoor or indoor coils or any kind. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin/tube interface where dissimilar materials are in contact. If there is dirt below the surface of the coil use the Totaline environmentally sound coil cleaner as described above.

CAUTION!

UNIT RELIABILITY HAZARD Failure to follow this caution may result in reduced unit performance.

High velocity water from a pressure washer, garden hose, or compressed air should never be used to clean a coil. The force of the water or air jet will bend the fin edges and increase airside pressure drop.

CAUTION!

Totaline Environmentally Sound Coil Cleaner Application Instructions:

NOTE: Proper eye protection such as safety glasses is recommended during mixing and application. 1. Turn off unit power. 2. Remove screws holding rear corner post and top cover in place. Pivot top cover up 305 to 457 mm (12 to 18 inches) and support with a rigid support. See Fig. 34.

3. Remove all surface loaded fibers and dirt with a vacu- um cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges can be easily bent over and damage to the coating of a protected coil) if the tool is applied across the fins.

NOTE: Use of a water stream, such as a garden hose, against surface loaded coil will drive the fibers and dirt into the coil, making cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse. 4. Using a low velocity garden hose thoroughly wet finned surfaces with clean water. Be careful not to bend the fins.

5. Mix Totaline environmentally sound coil cleaner in a 91/2 liter (21/2 gallon) garden sprayer according to the instructions included with the cleaner. The optimum solution temperature is 38C (100F).

NOTE: Do NOT USE water in excess of 54C (130F), as the enzymatic activity will be destroyed. 6. Thoroughly apply Totaline environmentally sound coil cleaner solution to all coil surfaces including the finned area, tube sheets and coil headers.

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7. Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical, up-and-down motion. Avoid spraying in horizontal pattern to minimize po- tential for fin damage.

8. Ensure cleaner thoroughly penetrates deep into finned areas.

9. Interior and exterior finned areas must be thoroughly cleaned.

10. Finned surfaces should remain wet with cleaning solution for 10 minutes.

11. Ensure surfaces are not allowed to dry before rinsing. Reapply cleaner as needed to ensure 10-minute satur- ation is achieved.

12. Thoroughly rinse all surfaces with low velocity clean water using downward rinsing motion of water spray nozzle. Protect fins from damage from the spray nozzle.

13. Replace top cover and rear corner posts.

FASTENER TORQUE VALUES Table 15 Torque Values

Compressor mounting bolts 734847 Ncm (65---75 inlbs)

Condenser fan motor mounting bolts 226 23 Ncm (20 2 inlbs)

Condenser fan hub setscrew 949 136 Ncm (84 2 inlbs)

High-flow service port 1085 23 Ncm (96 10 inlbs)

Schrader-type service check valve 2334 Ncm (23 inlbs)

Compressor oil sightglass thread 2334 Ncm (330 31 inlbs)

Compressor to Compressor rail torque 13561898 Ncm (120168 inlbs)

Compressor rail to base pan torque 791 57 Ncm (70 5 inlbs)

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. Thermostat circuit open. 4. Check thermostat setting.

5. Safety device lockout circuit active. 5. Reset lockout circuit.

6. Low-pressure switch open. 6. Check for refrigerant undercharge, obstruction of indoor airflow. Make sure liquid line solenoid valve(s) is open.

7. High-pressure switch open. 7. Check for refrigerant overcharge, obstruction of outdoor airflow, air in system. Be sure outdoor fans are operating correctly.

8. Compressor overtemperature switch open. 8. Check for open condition. Allow for reset. Replace compressor if necessary.

9. Loose electrical connections. 9. Tighten all connections.

10. Compressor stuck. 10. See compressor service literature.

Contactor Closed

1. Compressor leads loose. 1. Check connections.

2. Motor windings open. 2. See compressor service literature.

3. Single phasing. 3. Check for blown fuse. Check for loose connection at compressor terminal.

COMPRESSOR STOPS ON HIGH-PRESSURE SWITCH

Outdoor Fan On

1. High-pressure switch faulty. 1. Replace switch.

2. Reversed fan rotation. 2. Confirm rotation, correct if necessary.

3. Airflow restricted. 3. Remove obstruction.

4. Air recirculating. 4. Clear airflow area.

5. Noncondensables in system. 5. Recover refrigerant and recharge as required.

6. Refrigerant overcharge. 6. Recover refrigerant as required.

7. Line voltage incorrect. 7. Consult power company.

8. Refrigerant system restrictions. 8. Check or replace filter drier, expansion valve, etc.

Outdoor Fan Off

1. Fan slips on shaft. 1. Tighten fan hub setscrews.

2. Motor not running. 2. Check power and capacitor.

3. Motor bearings stuck. 3. Replace bearings.

4. Motor overload open. 4. Check overload rating. Check for fan blade obstruction.

5. Motor burned out. 5. Replace motor.

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TROUBLESHOOTING (cont)

PROBLEM SOLUTION

COMPRESSOR CYCLES ON LOW-PRESSURE SWITCH

Indoor-Air Fan Running

1. Liquid line solenoid valve(s) fails to open. 1. Check liquid line solenoid valve(s) for proper operation. Replace if necessary.

2. Filter drier plugged. 2. Replace filter drier.

3. Expansion valve power head defective. 3. Replace power head.

4. Low refrigerant charge. 4. Add charge. Check low-pressure switch setting.

Airflow Restricted

1. Coil iced up. 1. Check refrigerant charge.

2. Coil dirty. 2. Clean coil fins.

3. Air filters dirty. 3. Clean or replace filters.

4. Dampers closed. 4. Check damper operation and position.

Indoor-Air Fan Stopped

1. Electrical connections loose. 1. Tighten all connections.

2. Fan relay defective. 2. Replace relay.

3. Motor overload open. 3. Power supply.

4. Motor defective. 4. Replace motor.

5. Fan belt broken or slipping. 5. Replace or tighten belt.

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. Expansion valve power head defective. 4. Replace power head.

5. Indoor coil partially iced. 5. Check low-pressure setting.

6. Indoor airflow restricted. 6. Remove obstruction.

Suction Pressure High

1. Heat load excessive. 1. Check for open doors or windows in vicinity of fan coil.

UNIT OPERATES TOO LONG OR CONTINUOUSLY

1. Low refrigerant charge. 1. Add refrigerant.

2. Control contacts fused. 2. Replace control.

3. Air in system. 3. Purge and evacuate system.

4. Partially plugged expansion valve or filter drier. 4. Clean or replace.

SYSTEM IS NOISY

1. Piping vibration. 1. Support piping as required.

2. Compressor noisy. 2. Replace compressor if bearings are worn.

COMPRESSOR LOSES OIL

1. Leak in system. 1. Repair leak.

2. Crankcase heaters not energized during shutdown. 2. Check wiring and relays. Check heater and replace if defective.

3. Improper interconnecting piping design. 3. Check piping for oil return. Replace if necessary.

FROSTED SUCTION LINE

Expansion valve admitting excess refrigerant. Adjust expansion valve.

HOT LIQUID LINE

1. Shortage of refrigerant due to leak. 1. Repair leak and recharge.

2. Expansion valve opens too wide. 2. Adjust expansion valve.

FROSTED LIQUID LINE

1. Restricted filter drier. 1. Remove restriction or replace.

2. Liquid line solenoid valve partially closed. 2. Replace valve.

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APPENDIX A

Air Conditioner & Heat Pump with PURON

Quick Reference Guide S Puron (R-410A) refrigerant operates at 50 percent to 70 percent higher pressures than R-22. Be sure that servicing equipment and replacement components are designed to operate with Puron.

S Puron refrigerant cylinders are rose colored.

S Recovery cylinder service pressure rating must be 2758 kPa (400 psig), DOT 4BA400 or DOT BW400.

S Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose when charging into suction line with compressor operating.

S Manifold sets should be 4826 kPa (700 psig) high side and 1241 kPa (180 psig) low side with 3290 kPa (550 psig) low-side retard.

S Use hoses with 4826 kPa (700 psig) service pressure rating.

S Leak detectors should be designed to detect HFC refrigerant.

S Puron, as with other HFCs, is only compatible with POE oils.

S Vacuum pumps will not remove moisture from oil.

S Use only factory specified liquid-line filter driers with rated working pressures greater than 4137kPa (600 psig).

S Do not install a suction-line filter drier in liquid-line.

S POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

S POE oils may cause damage to certain plastics and roofing materials.

S Wrap all filter driers and service valves with wet cloth when brazing.

S A factory approved, liquid-line filter drier is required on every unit.

S Do not use an R-22 TXV.

S If indoor unit is equipped with a TXV, it must be changed to a Puron TXV.

S Never open system to atmosphere while it is under a vacuum.

S When system must be opened for service, recover refrigerant, break vacuum with dry nitrogen before opening system.

S Always replace filter drier after opening system for service.

S Do not vent Puron into the atmosphere.

S Do not use capillary tube coils.

S Observe all warnings, cautions, and bold text.

S All Puron heat pumps must have indoor TXV.

S Do not leave Puron suction line driers in place for more than 72 hours.

APPENDIX B

Wiring Diagram List 38AU Size Electrical Characteristics Diagram Number Z*07 400---3---50 38AU500495 Z*08 400---3---50 38AU500495 D*12 400---3---50 38AU500496 D*14 400---3---50 38AU500496

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APPENDIX C

Low Ambient Option Factory Installed

Units with the factory installed low ambient option are equipped with a MotormasterR solid- state head pressure control which regulates fan speed. A temperature sensor, mounted on circuit 1 of the outdoor coil (see Figs. 35 through 38) controls the speed of approved outdoor fan motors in order to maintain a constant head pressure in the outdoor coil. The control maintains the appropriate head pressure at low ambient temperatures down to - 28_C (- 20_F).

Wind baffles are required to prevent wind cross currents from causing abnormally low condensing temperatures.

Use 20- gauge sheet metal to fabricate wind baffles (see Fig. 39 and Table 16).

Operation

Fan on/off control in cooling- only units (38AUZ, 38AUD) is provided by an outdoor fan relay (OFR).

In cooling mode, fan motor speed of outdoor motors OFM1 and OFM3 is regulated by the speed control temperature sensor on outdoor coil 1 for a minimum coil condensing temperature of approximately 38_C (100_F) at higher outdoor ambient temperature and 27_C (80_F) at lower ambient. Additionally, outdoor fan motor OFM2 and OFM4 are turned on/off by the low ambient temperature switch, LAS, operating the low ambient relay (LAR). The LAS control temperatures are open open 5.5_C +/- 2.8_C, close 13.9_C +/- 2.8_C (42_F +/- 5_F, close 57_F +/- 5_F).

To override the speed control for full fan speed operation during service or maintenance, either:

a. remove sensor and place in hot water >49_C (>120_F), or

b. rewire to bypass control by connecting speed control input and output power wires.

Troubleshooting

OBSERVATION POSSIBLE REMEDY Fans wont start All fans:

Check power & wiring Check outdoor fan relay (OFR) OFM1, OFM3 only: Check speed control sensor location Check speed sensor resistance OFM2, OFM4 only: Check low ambient switch (LAS) Check low ambient relay (LAR)

Cooling --- Center outdoor fans (OFM2, OFM4) off below approximately 16_C (60_F) outdoor am- bient.

Normal operation

Cooling --- Center outdoor fans (OFM2, OFM4) not on above approximately 16_C (60_F) outdoor ambient

Check low ambient switch (LAS) Check low ambient relay (LAR)

Cooling --- Slow fan speed for outer fans (OFM1, OFM3) at start or during low outdoor ambient

Normal operation

Cooling --- Slow fan speed for outer fans (OFM1, OFM3) above 85_F (29_F) outdoor ambient (should be full speed)

Check speed control sensor location Check speed control sensor resistance Check fan motor capacitor

Cooling --- motor current into speed control is greater than motor name- plate FLA

Normal operation Up to 30% higher A at partial speed at low ambient

Speed Control Sensor Resistance

TEMPERATURE RESISTANCE _C +/---1_C _F +/---2_F_ Ohms, nominal ---30 ---22 88350 ---20 ---4 48485 ---10 14 27650 0 32 16325 10 50 9950 20 68 6245 25 77 5000 30 86 4028 40 104 2663 50 122 1801 60 140 1244 70 158 876

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20 in (508 mm)

Sensor

C10931

Fig. 35 - 38AUZ Motormaster Sensor Location (All Sizes - Novation)

10 in (254 mm)

Sensor

C10932

Fig. 36 - 38AUD*12-14 Motormaster Sensor Location (Novation)

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C10986

Fig. 37 - 38AUZ*07- 08 Motormaster Sensor Location (RTPF)

C109XX

Fig. 38 - 38AUZ*12 Motormaster Sensor Location (RTPF)

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D

K J

H G

F

E

C B A

7 m

m DR

ILL (B

OT H

SI DE

S OF

B AF

FL E)

22 m

m (T

YP )

12 m

m (T

YP )

25 4 m

m MI

N 25 m

m MI

NI MU

M (T

YP )

C101017

Fig. 39 - Wind Baffles

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Table 16 Wind Baffle Dimension

DIMENSIONS --- MM

UNIT BAFFLE A B C D E F G H J K

38AUZ 07 (MCHX) LEFT SIDE 826 845 864 895 151 457 865 --- --- ---

BACK 1029 1048 1067 895 113 457 827 --- --- ---

38AUZ 08 (MCHX) LEFT SIDE 1130 1149 1168 895 151 457 865 --- --- ---

BACK 1029 1048 1067 895 113 457 827 --- --- ---

38AUD 12 (MCHX) LEFT SIDE 1130 1149 1168 1095 212 539 737 1015 --- ---

BACK 1029 1048 1067 1095 180 507 737 983 --- ---

38AUD 14 (MCHX)

LEFT SIDE 1130 1149 1168 1095 212 539 737 1015 --- ---

BACK 1016 1035 1054 1095 180 507 737 983 --- ---

RIGHT SIDE 616 635 654 1095 174 501 737 977 --- ---

38AUZ 07 (RTPF) LEFT SIDE 718.7 737.8 756.8 895.4 32.9 236.1 439.3 642.5 845.7 ---

BACK 1023.0 1042.1 1061.1 895.4 105.8 283.6 461.4 639.2 817.0 ---

38AUZ 08 (RTPF) LEFT SIDE 718.7 737.8 756.8 895.4 32.9 236.1 439.3 642.5 845.7 ---

BACK 1023.0 1042.1 1061.1 895.4 105.8 283.6 461.4 639.2 817.0 ---

38AUZ 12 38AUD 12 (RTPF)

LEFT SIDE 1022.7 1041.8 1060.8 1095.4 32.9 236.1 439.3 642.5 845.7 1048.9

BACK 1023.0 1042.1 1061.1 895.4 105.8 283.6 461.4 639.2 817.0 994.8

DIMENSIONS --- INCHES

UNIT BAFFLE A B C D E F G H J K

38AUZ 07 (MCHX) LEFT SIDE 32 1/2 33 1/4 34 35 1/4 6 18 34 1/8 --- --- ---

BACK 40 1/2 41 1/4 42 35 1/4 4 1/2 18 32 5/8 --- --- ---

38AUZ 08 (MCHX) LEFT SIDE 44 1/2 45 1/4 46 35 1/4 6 18 34 1/8 --- --- ---

BACK 40 1/2 41 1/4 42 35 1/4 4 1/2 18 32 5/8 --- --- ---

38AUD 12 (MCHX) LEFT SIDE 44 1/2 45 1/4 46 43 1/8 8 3/8 21 1/4 29 40 --- ---

BACK 40 1/2 41 1/4 42 43 1/8 7 1/8 20 29 38 3/4 --- ---

38AUD 14 (MCHX)

LEFT SIDE 44 1/2 45 1/4 46 43 1/8 8 3/8 21 1/4 29 40 --- ---

BACK 40 40 3/4 41 1/2 43 1/8 7 1/8 20 29 38 3/4 --- ---

RIGHT SIDE 24 1/2 25 25 3/4 43 1/8 6 7/8 19 3/4 29 38 1/2 --- ---

38AUZ 07 (RTPF) LEFT SIDE 28 1/4 29 29 3/4 35 1/4 1 1/4 9 1/4 17 1/4 25 1/4 33 1/4 ---

BACK 40 1/4 41 41 3/4 35 1/4 4 1/8 11 1/8 18 1/8 25 1/8 32 1/8 ---

38AUZ 08 (RTPF) LEFT SIDE 28 1/4 29 29 3/4 35 1/4 1 1/4 9 1/4 17 1/4 25 1/4 33 1/4 ---

BACK 40 1/4 41 41 3/4 35 1/4 4 1/8 11 1/8 18 1/8 25 1/8 32 1/8 ---

38AUZ 12 38AUD 12 (RTPF)

LEFT SIDE 40 1/4 41 41 3/4 43 1/8 1 1/4 9 1/4 17 1/4 25 1/4 33 1/4 41 1/4 BACK 40 1/4 41 41 3/4 35 1/4 4 1/8 11 1/8 18 1/8 25 1/8 32 1/8 39 1/8

MCHX: NOVATION coil model

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E 2019 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---53380037---01 Printed in U.S.A. Form 38AU---7---14---C01SI 9---19 Replaces 38AU---C05SI

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START-UP CHECKLIST I. PRELIMINARY INFORMATION

OUTDOOR: MODEL NO. SERIAL NO.

INDOOR: AIRHANDLER 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. DOES IT AGREE WITH UNIT? (Y/N)

HAS THE GROUND WIRE BEEN CONNECTED? (Y/N)

HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (Y/N)

ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (Y/N)

CONTROLS ARE THERMOSTAT AND INDOOR FAN CONTROL WIRING CONNECTIONS MADE AND CHECKED?

(Y/N)

ARE ALL WIRING TERMINALS (including main power supply) TIGHT? (Y/N)

HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS? (Y/N)

INDOOR UNIT HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE? (Y/N)

ARE PROPER AIR FILTERS IN PLACE? (Y/N)

HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT? (Y/N)

DO THE FAN BELTS HAVE PROPER TENSION? (Y/N)

HAS CORRECT FAN ROTATION BEEN CONFIRMED? (Y/N)

PIPING ARE LIQUID LINE SOLENOID VALVES LOCATED AT THE INDOOR COILS AS REQUIRED? (Y/N)

HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR, OUTDOOR AND INDOOR COILS, TXVs (Thermostatic Expansion Valves), SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE PLUGS WITH A LEAK DETECTOR? (Y/N)

LOCATE, REPAIR, AND REPORT ANY LEAKS.

HAVE LIQUID LINE SERVICE VALVES BEEN OPENED? (Y/N)

HAVE SUCTION LINE SERVICE VALVES BEEN OPENED? (Y/N)

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CHECK VOLTAGE IMBALANCE

LINE-TO-LINE VOLTS: AB V AC V BC V

(AB + AC + BC)/3 = AVERAGE VOLTAGE = V

MAXIMUM DEVIATION FROM AVERAGE VOLTAGE = V

VOLTAGE IMBALANCE = 100 X (MAX DEVIATION)/(AVERAGE VOLTAGE) =

IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START SYSTEM! CALL LOCAL POWER COMPANY FOR ASSISTANCE.

CHECK INDOOR UNIT FAN SPEED AND RECORD.

CHECK OUTDOOR UNIT FAN SPEED AND RECORD.

AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:

SUCTION PRESSURE CIR 1: CIR 2:

SUCTION LINE TEMP CIR 1: CIR 2:

LIQUID PRESSURE CIR 1: CIR 2:

LIQUID LINE TEMP CIR 1: CIR 2:

ENTERING OUTDOOR UNIT AIR TEMP

LEAVING OUTDOOR UNIT AIR TEMP

INDOOR UNIT ENTERING-AIR DB (dry bulb) TEMP

INDOOR UNIT ENTERING-AIR WB (wet bulb) TEMP

INDOOR UNIT LEAVING-AIR DB TEMP

INDOOR UNIT LEAVING-AIR WB TEMP

COMPRESSOR 1 AMPS (L1/L2/L3) / /

COMPRESSOR 2 AMPS (L1/L2/L3) / /

NOTES:

E 2019 Carrier Corporation

Manufacturer reserves the right to discontinue, or change at any time, spe

Manualsnet FAQs

If you want to find out how the 38AUD Carrier works, you can view and download the Carrier 38AUD Installation Manual on the Manualsnet website.

Yes, we have the Installation Manual for Carrier 38AUD as well as other Carrier manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Installation Manual should include all the details that are needed to use a Carrier 38AUD. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Carrier 38AUD Installation Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Carrier 38AUD Installation Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Carrier 38AUD Installation Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Carrier 38AUD Installation Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the Carrier 38AUD Installation Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.