Carrier 38AD028 Unit installation

Concepcion-Carrier
Air conditioning
Company
Philippines
CONTENTS
38AKS016 - 044 AIR-COOLED
CONDENSING UNITS - 60 Hz
INSTALLATION, OPERATING MANUAL & SERVICE
INSTRUCTIONS
Page
Page
SAFETY CONSIDERATIONS
2
INSTALLATION
Step 1 – Complete Pre-Installation Checks
Step 2 – Rig and Mount the Unit
Step 3 – Complete Refrigerant Piping Connections
Step 4 – Complete Electrical Connections
2
2
2
8
10
PRE-START-UP
System Check-up
Leak Test and Dehydration
Turn on Crankcase Heater
Preliminary Charge
12
12
13
13
13
START-UP
Preliminary Checks
Preliminary Oil Charge
Start Unit
Adjust Refrigerant Charge
13
13
13
13
14
38AKS016/024
Check Compressor Oil Level
Final Checks
14
14
OPERATING SEQUENCE
Cooling
14
14
SERVICE
Capacity Control
Time Guard Circuit
Crankcase Heater
Compressor Protection
High Pressure Switches
Low Pressure Switches
Outdoor Fans
Lubrication
Cleaning Coils
20
20
20
20
21
21
21
21
21
21
TROUBLESHOOTING
START-UP CHECKLIST
23
25
38AKS028/034 (044 - 3 Fans)
SAFETY CONSIDERATIONS
•
Installing, starting up, and servicing air-conditioning
equipment can be hazardous due to system pressures,
electrical components, and equipment location (roofs, elevated
structures, etc.).
Unit may be mounted on a level pad directly on the base
channels or mounted on raised pads at support points. See
Tables 2A-2B for unit operating weights. See Table 1 for
weight distribution based on recommended support points.
NOTE: If vibration isolators are required for a particular
installation, use the data in Table 1 to make the proper
selection.
Only trained, qualified installers and service mechanics
should install, start-up, and service this equipment (Fig. 1 to Fig.
4).
Untrained personnel can perform basic maintenance
functions such as cleaning coils. Trained service personnel
should perform all other operations.
Table 1 - Weight Distribution
UNIT
38AKS
When working on the equipment, observe precautions in the
literature and on tags, stickers, and labels attached to the
equipment.
016
024
028
034
044
Follow all safety codes. Wear safety glasses and work
gloves. Keep quenching cloth and fire extinguisher nearby when
brazing. Use care in handling, rigging, and setting bulky
equipment.
Total
Operating
789 (359)
900 (408)
1650 (748)
1803 (818)
2347 (1105)
WEIGHT - lb (kg)
Support Point
A
B
C
143 (65)
143 (65)
250 (114)
178 (81)
168 (76)
269 (122)
418 (190)
626 (284)
242 (110)
459 (208)
673 (305)
272 (124)
864 (392)
1077 (488) 221 (100)
D
253 (115)
285 (129)
364 (165)
399 (181)
275 (125)
ELECTRIC SHOCK HAZARD
Separate power sources (main and control
power circuits) are used for these units. Be
sure both main and control power circuits are
disconnected before servicing.
38AKS016 and 024
38AKS028 and 034
INSTALLATION
CAUTION
Step 1 – Complete Pre-Installation Checks
Be sure unit panels are securely in place prior to rigging.
UNCRATE UNIT – Remove plastic cover, which should be left
in place until after the unit is rigged into its final location.
Step 2 – Rig and Mount the Unit
INSPECT SHIPMENT – File claim with shipping company if
shipment is damaged or incomplete.
RIGGING – These units are designed for overhead rigging only.
For this purpose, the transverse base channels extend beyond the
sides of the unit, with holes provided in the end plates to attach
cables or hooks. Rig with top skid packaging assembly in place to
prevent unit damage by the rigging cable. As further protection for
the coil faces, plywood sheets can be placed against the sides of
the unit, behind the cables. Run the cables to a central position
point so that the angle from the horizontal is not less than 45
degrees. Raise and set the unit down carefully.
CONSIDER SYSTEM REQUIREMENTS
• Consult local building codes and National Electrical
Code (NEC) for special installation requirements.
• Allow sufficient space for airflow clearance, wiring,
refrigerant piping, and servicing unit. See Fig. 1 to Fig. 3 for
unit component locations.
• Locate unit so that outdoor coil (condenser) airflow is
unrestricted on all sides and above.
2
3
Fig. 2 – Dimensions (38AKS028/034)
4
Fig. 3 – Dimensions (38AKS044)
5
Table 2A - Physical Data (English, 60 Hz)
UNIT 38AKS
NOMINAL CAPACITY (tons)
016
15
OPERATING WEIGHT ( lb)
REFRIGERANT*
Operating Charge, Typical ( lb)**
COMPRESSOR
Speed (Rpm)
789
No. Cylinders
Model No.
Oil (pt)
Crankcase Heater Watts
Unloader Setting (psig)
024
20
900
R-22
23
28
Reciprocating, Semi-Hermetic
1750
6
06DD537
8
125
Load
Unload
OUTDOOR-AIR FANS
No. …Rpm
Diameter (in.)
Motor Hp
Nominal Total Airflow ( Cfm)
OUTDOOR COIL
Face Area (sq ft)
Storage Capacity (lb)^
70+/-1
60+/-2
Axial Flow, Direct Drive
2 …900
26
1/2
9210
29.2
39.8
39.8
CONTROLS
Pressurestat Settings (psig)
High Cutout
Cut-in
Low Cutout
Cut-in
FUSIBLE PLUG (F)
PIPING CONNECTIONS (in. ODM)
Suction
Liquid
4
06E--50
14
395+/-10
295+/-10
29+/-4
60 +15/-0
200
1 3/8
1 5/8
5/8
*Unit is factory supplied with holding charge only.
**With 25 ft of interconnecting piping. Operating charge is approximate for maximum system capacity.
^Storage capacity is measured at liquid saturated temperatures of 130 F for 38AKS016 and 024.
6
Table 2B - Physical Data (English, 60 Hz)
UNIT 38AKS
028
034
044
NOMINAL CAPACITY (tons)
25
30
40
OPERATING WEIGHTS (lb)
1650
1803
2437
COMPRESSOR
Reciprocating, Semi-Hermetic
Model
06E-265
06E-275
Oil (pt)
19
No. Cylinders (ea)…Speed (rpm)
06E-299
19
6… 1750
Capacity Steps
100%, 66%
Unloader Setting (psig)
No. 1 Load
76
Unload
58
REFRIGERANT
R-22
Operating Charge, Typical (lb)
30.5
43.5
CONDENSER FANS
65
Propeller Type - Direct Drive
Quantity…Diameter (in.)
2…30
3…30
Nominal Airflow (cfm)
15,700
23,700
Speed (rpm)
1140
Power Consumption (Watts, each)
1492
CONDENSER COIL
Enhanced Copper Tubes, Lanced Aluminum Fins
Rows…Fins/in.
3… 17
Total Face Area (sq ft)
39.2
58.4
Coil Storage Cap. (lb) - 80% Full at 125 F
56.6
84.4
ELECTRIC CONTROLS
Time Guard Device
HIGH PRESSURE SWITCH (psig)
Cutout
364 +/-7
Cut-in
200 +/-20
LOW PRESSURE SWITCH (psig)
Cutout
29 +/-3
Cut-in
44+/-5
OIL PRESSURE SWITCH (psig)
Close on Rise
7.0
Open on Fall
5.0
PRESSURE RELIEF
Fusible Plug
PIPING CONNECTIONS
Suction
- in. OD
1 5/8
Liquid
- in. OD
7/8
Hot Gas Stub - in. OD
5/8
7
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.
Hot gas bypass, if used, should be introduced before the
evaporator.
Note that refrigerant suction piping should be insulated.
Table 3A - Liquid Line Data
Raise from above to lift unit from the rails or pad when unit is
in final position.
MAXIMUM
ALLOWABLE
COMPRESSOR MOUNTING – As shipped, the compressor is
held tightly in place by self-locking bolts. Before starting unit,
loosen self-locking bolts until the snubber washer can be
moved sideways with the finger pressure. Do not remove
shipping bolts. See Fig. 4.
LIQUID LINE
LIQUID LIFT
UNIT
38AKS
ft (m)
60 Hz
Maximum
Maximum
Allowable
Allowable
Filter Drier and
Sight Glass
Pressure Drop
Temp. Loss
Flare Conn. *
psig (kPa)
F (C)
in. (mm)
016
82 (25)
7 (48.3)
2 (1.1)
5/8
024
87 (26.5)
7 (48.3)
2 (1.1)
5/8
*Inlet and outlet
NOTE: Data shown is for units operating at 45 F (7.2 C) saturated
suction and 95 F (35 C) entering air.
Table 3B - Maximum
Liquid Lift (028/034/044)
Fig. 4 – Compressor Mounting
Step 3 – Complete Refrigerant Piping Connections
IMPORTANT: A refrigerant receiver is not provided
with the unit. Do not install a receiver.
SIZE REFRIGERANT LINES – Consider the length of piping
required between outdoor unit and indoor unit (evaporator), the
amount of liquid lift, and compressor oil return. See Tables 3A4B for design details and line sizing. Refer to indoor unit
installation instructions for additional information.
NOTE: Use the piping data in Tables 3A-4B as a general guide
only.
8
UNIT 38AKS
FT
028
034
044
76
67
76
Table 4A - Refrigerant Piping Sizes
0-15
(0-4.5)
UNIT
38AKS
016
024
L
1/2
5/8
S
1 3/8
1 5/8
LENGTH OF INTERCONNECTING PIPING, FT (M)
15-25
25-50
50-75
(4.5-7.5)
(7.5-15)
(15-23)
Line Size (in. OD)
L
S
L
S
L
S
5/8
1 3/8
5/8
1 5/8
7/8
1 5/8
5/8
1 5/8
7/8
1 5/8
7/8
2 1/8
75-100
(23-30)
L
7/8
7/8
S
2 1/8
2 1/8
LEGEND
L - Liquid
S - Suction
Close-coupled.
NOTES:
1. Pipe sizes are based on a 2 F (1.1 C) loss for liquid lines and a 1.5 F (0.8 C) loss for suction
lines.
2. Pipe sizes are based on an equivalent length equal to the maximum length of interconnecting
piping plus 50% for fittings.
A more accurate estimate may result in smaller sizes.
3. Line size conversion to mm:
in.
mm.
1/2
12.7
5/8
15.9
7/8
22.2
1 1/8
28.6
1 3/8
34.9
1 5/8
41.3
2 1/8
54
Table 4B - Refrigerant Piping Sizes
SINGLE SUCTION RISERS
UNIT
38AKS
028
L
7/8
S
1 5/8
LENGTH OF INTERCONNECTING PIPING, FT
26-50
51-75
76-100
L
S
L
S
L
S
7/8
1 5/8
7/8
2 1/8
7/8
2 1/8
034
044
7/8
7/8
1 5/8
1 5/8
7/8
7/8
16-25
1 5/8
1 5/8
7/8
7/8
LEGEND
L - Liquid Line
S - Suction Line
NOTE: Liquid and suction line sizes are OD (in.)
9
2 1/8
2 1/8
1 1/8
1 1/8
2 1/8
2 1/8
101-200
L
S
7/8
2 1/8
1 1/8
1 1/8
2 5/8
2 5/8
INSTALL FILTER DRIER(S), MOISTURE INDICATOR(S) AND
SOLENOID VALVE(S) – The illustrations below are the
standard piping connections.
INSTALL LIQUID LINE SOLENOID VALVE – CAPACITY
CONTROL - For 2-step cooling , place a solenoid valve in the
location shown in Fig. 5 and Fig. 6 , upper circuit (ckt. 2). Circuit
(ckt.) 2 shall be controlled by Thermostat 2 (T2).
Complete the refrigerant piping from indoor unit to outdoor unit
before opening the liquid and suction lines at the outdoor unit.
MAKE PIPING CONNECTIONS – Do not remove runaround loop
from suction and liquid line stubs in the compressor compartment
until piping connections are ready to be made. Pass nitrogen or
other inert gas through piping while brazing to prevent formation of
copper oxide.
FOR 38 AKS 016/024
WARNING
Recover holding charge prior to removal of runaround
piping loop (R-22).
FOR
38AKS 024
ONLY
1. Open service valves:
a. Discharge service valve on compressor.
b. Suction service valve on compressor.
c. Liquid line valve.
2. Remove ¼ in. flare cap from liquid valve Schrader port.
3. Attach refrigerant recovery device and recover holding charge.
4.Remove runaround loop.
Fig. 5– Location of Sight Glass,
Filter Drier and Solenoid Valve(s)
for 38 AKS 016/024
5. Install the field-supplied filter drier(s), liquid moisture
indicator(s)and solenoid valve(s) in the piping based on the
given illustrations.
PROVIDE SAFETY RELIEF – A fusible plug is located on the
compressor crankcase or in the liquid line (Fig.7). Do not cap
this plug.
Step 4 – Complete Electrical Connections
POWER WIRING – Unit is factory wired for voltage shown on
nameplate. Provide adequate fused disconnect switch within
sight from unit and readily accessible from unit, but out of the
reach of children. Lock switch open (off) to prevent power from
being turned on while unit is being serviced. Disconnect switch,
fuses, and field wiring must comply with national and local code
requirements. See Tables 5A and 5B.
Fig. 6 – Location of Sight Glasses,
Filter Driers and Solenoid Valves
for 38AKS 028/034/044
10
NOTE: 38AKS024, 034 & 044 has a fusible plug in the liquid line.
Fig. 8 – Main power Supply Wiring
Fig. 7 – Location of Fusible Plug (38AKS)
Table 5A - Electrical Data (3 Ph/60 Hz)
UNIT
UNIT
38AKS
016
024
COMPR
Volts
Model
501
601
501
601
Nameplate
208-230
460
208-230
460
Supplied*
Min
Max
187
253
414
528
187
253
414
528
MCA
ICF
MOCP
C.B.
87.5
40.7
93.4
48.1
274
124
353
177
125
60
150
80
LEGEND
RLA
LRA
63.6
29.3
67.9
34.7
266
120
345
173
FAN MOTORS (Single Phase)
FLA(ea)
Total
Fan No.
HP
Fans
1
2
3.6
2
1/2
1.8
3.6
2
1/2
1.8
*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 MOCP values are calculated in accordance with
the National Electrical Code (NEC) article 440 (U.S.A.
standard).
2. Motor RLA and LRA values are established in accordance with
Underwriters' Laboratories (UL) Standard 1995 (U.S.A.
standard).
FLA - Full Load Amps (Fan Motors)
ICF - Maximum Instantaneous Current Flow during start-up
(LRA of compressor plus total FLA of fan motors)
kW - Total Fan Motor Input (kilowatts)
LRA - Locked Rotor Amps
MCA - Minimum Circuit Amps per NEC (U.S.A.), Section 430-24
MOCP- Maximum Overcurrent Protection (amps)
RLA - Rated Load Amps (Compressor)
CB - Circuit Breaker (Amps)
11
Table 5B - Electrical Data (3 Ph/60 Hz)
UNIT
38AKS
028
034
044
FLA
ICF
-
LRA MCA -
Nominal
Voltage
UNIT
Voltage
Range*
Min
Max
208-230
460
208-230
460
208-230
460
187
414
187
414
187
414
254
508
254
508
254
508
COMPRESSOR
FAN MOTORS
FLA
RLA
LRA
Qty
102.2
49.8
118.4
56.2
165.6
74.7
89.8
43.6
106.5
50
147.5
65.4
446
223
506
253
690
345
LEGEND
Full Load Amps
Maximum Instantaneous Current Flow during starting.
(The point in the starting sequence where the sum of
the LRA for the starting compressor, plus the total RLA
for all running compressors, plus the total FLA for all
running motors is maximum).
Locked Rotor Amps
Minimum Circuit Amps
3
MOCP
OFM
RLA
C.B.
-
FLA
(ea)
MCA
ICF
MOCP
(C.B.)
5.5
2.75
5.5
2.75
5.5
2.75
124.6
60.7
145.5
68.7
203
91
452.2
226.1
512.2
256.1
702.4
351.2
200
100
250
110
350
150
Maximum Overcurrent Protection
Outdoor (Condenser) Fan Motor
Rated Load Amps
Circuit Breaker (Amps)
*Units are suitable for use on electrical systems
where voltage supplied to the unit terminals
is not below or above the listed minimum and
maximum limits.
Route power wires through opening in unit end panel to
connection in unit control box as shown on unit label diagram
and in Fig. 8. Unit must be grounded.
If unit has field-installed accessories, be sure all are properly
installed and correctly wired. If used, airflow switch must be
properly installed.
Affix crankcase heater warning sticker to unit disconnect
switch. See accessories with unit.
2. Backseat (open) compressor suction and
discharge valves. Now close valves one turn to allow
refrigerant pressure to reach test gages.
PRE-START-UP
3. Open liquid line service valve.
IMPORTANT: Before beginning Pre-Start-up or Startup, 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.
4. Check tightness of all electrical connections.
CAUTION
Do not attempt to start the condensing unit, even
momentarily, until the following steps have been
completed. Compressor damage may result.
5.
Compressor oil level should be visible in sight
glass. See Fig. 9. Adjust the oil level as required. Refer to
Preliminary Oil Charge section. No oil should be removed
unless the crankcase heater has been energized for at least
24 hours.
6.
Be sure unit is properly leak checked, dehydrated, and
charged. See Preliminary Charge.
7.
Electrical power source must agree with nameplate rating.
8.
Crankcase heater must be firmly locked into compressor
crankcase. Be sure crankcase is warm (heater must be on
for 24 hours before starting compressor).
9.
Be sure compressor floats freely on the mounting springs
and that snubber washers can be moved with finger
pressure. See Compressor Mounting, page 9, and Fig. 5 for
loosening compressor bolts.
System Check
1.
2
POWER SUPPLY
Check all air handler(s) and other equipment auxiliary
components. Consult the manufacturer’s instructions
regarding any other equipment connected to the
condensing unit.
12
Leak Test and Dehydration – Leak test the entire refrigerant
system using soap bubbles and/or an electronic leak detector.
section, Leak Test and Dehydration.
9. All internal wiring connections must be re-tightened, and all
barriers and covers must be in place.
Turn On Crankcase Heater – Turn on 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:
Preliminary Oil Charge – Compressor is factory charged with oil
(see Tables 2A-2B). When oil is checked at start-up, it may be
necessary to add or remove oil to bring it to the proper level. One
recommended oil level adjustment method follows:
1. Set the space thermostat set point above the space
temperature so there is no demand for cooling.
2. Close the field disconnect.
ADD OIL – Close suction service valve and pump down
crankcase to 2 psig (14 kPag). (Low-pressure switch must be
jumpered). Wait a few minutes and repeat until pressure remains
steady at 2 psig (14 kPag). Remove oil fill plug above the oil level
sight glass, add oil through plug hole, and replace plug. Run
compressor for 20 minutes and check oil level. See Fig. 9.
3. Turn the fan circuit breaker on. Leave the compressor circuit
breakers off. The crankcase heater is now energized
Preliminary Charge – Charge each system with R-22 by the
liquid charging method (through liquid service valve) on the high
side when the system has not yet been started. Charge
according to the values in the Charging Chart, Fig. 10 to 14 via
the suction service valve when the system has started.
NOTE: Use only Carrier approved compressor oil. Approved
sources are:
Totaline. ……………………………………150 SUS
Texas, Inc. ………………………………...Capella WF-32
Witco Chemical Co. ………………………Suniso 3GS
START-UP
Do not use oil that has been drained out, or oil that has been
exposed to atmosphere, due to moisture content.
Compressor crankcase heater must be on 24 hours before
start-up. After the heater has been on for 24 hours, the unit can
be started. However, if start-up is done immediately after
charging, the 24 hours wait is NOT necessary.
REMOVE OIL – Pump down compressor to 2 psig (14 kPag).
Loosen the ¼ in. (6.4 mm) pipe plug at the compressor base and
allow the oil to seep out past the threads of the plug.
Preliminary Checks
1.
Ensure that compressor service valves are back seated.
NOTE: The crankcase will be slightly pressurized. Do not remove
the plug, or the entire oil charge will be lost.
2.
Verify that each compressor floats freely on its mounting
springs, snug fit on washer.
Small amounts of oil can be removed through the oil pump
discharge connection while the compressor is running.
3.
Check that electric power supply agrees with the unit
nameplate data.
4.
Verify that compressor crankcase heater is securely in place.
5.
Check that compressor crankcase heater has been on at
least 24 hours.
6.
Note that compressor oil level is visible in the sight glass.
Next, close the compressor circuit breaker and then reset
space thermostat below ambient so that a call for cooling is
ensured. If compressor does not start, set thermostat lower.
7.
Recheck for leaks using same procedure as previously
outlined in Pre-Start-Up section, Leak Test and
Dehydration.
NOTE: Do not use circuit breaker to start and stop the compressor
except in an emergency.
8.
If any leaks are detected, evacuate, repair and dehydrate as
previously outlined in Pre-Start-Up
Start Unit – The field disconnect is closed, the fan circuit breaker
is closed, and the space thermostat is set above ambient so that
there is no demand for cooling. Only the crankcase heater will be
energized.
13
If the initial check shows too much oil (too high in the sight glass)
remove oil to proper level. See Preliminary Oil Charge, for proper
procedure for adding and removing oil. See Fig. 9.
CAUTION
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.
When the above checks are complete, repeat the procedure
with the unit operating at minimum load conditions.
Adjust Refrigerant Charge
MAX.
3/4 OF
SIGHT GLASS
NOTE: Actual start-up and all refrigerant charge modifications
should be done only under supervision of a qualified refrigerant
mechanic.
1/8 OF SIGHT GLASS
With all fans operating, adjust the refrigerant charge.
MIN.
1/4 OF SIGHT GLASS
3/8 OR 1/3 OF SIGHT GLASS
Measure pressure at the liquid line service valve, being sure
Schrader depressor is used if required. Also, measure liquid line
temperature as close to the liquid service valve as possible. Add
charge until the pressure and temperature conditions of the
charging chart curve are met. If liquid pressure and temperature
point fall above curve, add charge. If liquid pressure and
temperature point fall below curve, reduce the charge until the
conditions match the curve. (± 3 ºF allowable range)
38AKS024 – 044
(06E COMPRESSOR)
38AKS016
(06D COMPRESSOR)
Fig. 9 – Operating Oil Levels
Final Checks – Ensure all safety controls are operating, control
panel covers are on, and the service panels are in place.
If the sight glass is cloudy, check refrigerant charge again.
Ensure all fans are operating. Also ensure maximum allowable
liquid lift has not been exceeded. If charge per chart and if the
sight glass is still cloudy, check for a plugged filter drier or a
partially closed solenoid valve. Replace or repair, as needed.
OPERATING SEQUENCE
Cooling - When the first stage (TC1) of the cooling thermostat
closes, timer starts. After 3 minutes, the timer expires, energizing
the compressor.
Check Compressor Oil Level – After adjusting the refrigerant
charge, allow the compressor to run fully loaded for 20 minutes.
Running oil level should be within view of the crankcase sight
glass. Stop the compressor at the field power supply disconnect
and check the crankcase oil level. Add oil only if necessary to
bring the oil into view in the sight glass. If oil is added, run the
compressor for an additional 10 minutes; then stop and check
oil level. If the level remains low, check the piping system for
proper design for oil return; also, check the system for leaks.
On demand for additional cooling capacity, the second stage (TC2)
of the cooling thermostat closes, energizing field supplied liquid
line solenoid (LLS) valve, which opens.
At shutdown, the Time Guard timer prevents the compressor from
re-starting for approximately 3 minutes.
14
15
FIG. 10 – 38AKS016 CHARGING CHART
16
FIG. 11 – 38AKS024 CHARGING CHART
17
FIG. 12 – 38AKS028 CHARGING CHART
18
FIG. 13 – 38AKS034 CHARGING CHART
19
FIG. 14 – 38AKS044 CHARGING CHART
When installed, a field supplied solenoid shuts of the liquid line
to prevent refrigerant migration back to the compressor during
the off cycle.
SERVICE
Capacity Control – For compressors equipped with an
unloader, 2 cylinders are unloaded to provide capacity control.
The unloader maybe suction-pressure actuated or electrically
operated.
Suction pressure-actuated unloader as shown in Fig 15, is
controlled by suction pressure that automatically unloads when
system load is low and loads up when system load increases.
Factory setting is 10 turns from bottom stop (CCW) before R-22
charging (control set point) (see Tables 2A-2B).
CONTROL SET POINT (cylinder load point) is adjustable from 0
to 85 psig (586 kPa). To adjust, turn control set point adjustment
nut (Fig. 15) clockwise to its bottom stop. In this position, set
point is 85 psig (586 kPa). Next, turn adjustment
counterclockwise to desired control set point. Every full turn
counterclockwise decreases set point by 7.5 psig (51.7 kPa).
For 38AKS016 & 024: 2 turns CCW. For 38AKS028, 034 & 044:
1 ½ turns CCW.
Fig. 15 – Suction Pressure Unloader
Electric unloader as shown in Figure 16, needs an electric
solenoid coil wired in the control circuit, usually controlled by the
thermostat.
Time Guard Circuit – Circuit prevents short cycling by
providing a delay of 3 minutes before restarting compressor
after shutdown from safety device action.
On start-up, the Time Guard timer causes a delay of
approximately 3 minutes seconds after thermostat closes. Refer
to label diagram of the unit.
Crankcase Heater – The heater prevents refrigerant migration
and compressor oil dilution during shutdown whenever
compressor is not operating. It is wired to cycle with the
compressor; the heater is off when compressor is running, and
on when compressor is off.
Both compressor service valves must be closed (front seated)
whenever the crankcase heater is de-energized for more than 6
hours. The crankcase heater is operable as long as the control
circuit is energized.
Fig. 16 – Electric Solenoid Coil Unloader
20
COMPRESSOR OVERTEMPERATURE PROTECTION (IP) – A
thermostat installed in compressor motor winding reacts to
excessively high winding temperatures and shuts off the
compressor. (This is applicable only for 06D Compressor, not on
06E.) Discharge Temp. Sensor is on Cylinder Head for 06E,
externally.
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. See Preliminary Oil Charge
section.
Cleaning Coils – The coils can be cleaned with a vacuum
cleaner, washed out with water, blown out with low pressure
compressed air, or brushed (do not use wire brush). Fan motors
are drip-proof but not waterproof. Therefore wrap motors in plastic
bags, to be sure.
TIME GUARD CONTROL – Control prevents compressor from
short cycling. See Operating Sequence.
CRANKCASE HEATER – Heater minimizes absorption of liquid
refrigerant by oil in crankcase during brief or extended shutdown
periods. The control circuit is maintained if compressor fan
motor circuit breakers are turned off. The main disconnect must
be on to energize crankcase heater.
Clean outdoor coil annually or as required by location or
outdoor air conditions. Inspect coil monthly, and clean as required.
For 38AKS016 AND 024 fins are not continuous through coil
sections; dirt and debris may pass through first section, become
trapped between 3 rows of fins and restrict outdoor airflow. Use a
flashlight to determine if dirt or debris has collected between coil
sections. Cleaning coil of 38AKS028 to 044 is not as hard as
cleaning the coil of 38AKS016 and 024 because it has a
continuous coil section (3 rows). Clean coil as follows:
IMPORTANT: Never open any switch or disconnect that
energizes the crankcase heater unless unit is being
serviced or is to be shutdown for a prolonged period. After
a prolonged shutdown on a service job, energize the
crankcase heater for 24 hours before starting the
compressor.
1.
Turn of unit power.
2.
Remove screws holding rear corner posts and top cover in
place. Pivot top cover up 12 to 18 in. (305 to 457 mm) and
support with a rigid support. See Fig. 18.
3.
Remove clips securing tube sheets together at the return
bend end of the coil. Carefully spread the ends of the coil
rows apart by moving the outer sections. See Fig. 19.
4.
Using a water hose, or other suitable equipment, flush down
between the sections of coil to remove dirt and debris.
5.
Clean the remaining surfaces in the normal manner.
6.
Reposition outer coil sections.
7.
Reinstall clips which secure tube sheets.
8.
Replace top cover and rear corner posts.
High Pressure Switches – Switches have fixed, nonadjustable
settings. Switches are mounted on the compressors.
Low Pressure Switches – Switches have fixed, nonadjustable
settings. Switches are mounted on the compressors.
TO CHECK – Slowly close liquid shutoff valve and allow
compressor to pump down. Do not allow compressor pumpdown below 2 psig (13.8 kPa). Compressor should shut down
when suction pressure drops to cutout pressure in Tables 2A2B, and should restart when pressure builds up to cut-in
pressure shown.
Outdoor Fans – Each fan is supported by a formed wire mount
bolted to the fan deck and covered with a wire guard. The
exposed end of the motor shaft is covered with sealing gum. In
case a fan motor must be repaired or replaced, be sure to put a
new sealing gum when the fan is reinstalled and be sure the fan
guard is in place before starting the unit. Fig. 17 shows the
proper position of the mounted fan. Fan motors have
permanently lubricated bearings.
Lubrication
FAN MOTORS have sealed bearings. No provisions are made
for lubrication.
21
Fig. 17 – Outdoor Fan – 38AKS016 & 024
Fig. 18 – Pivot and Support Top Cover – 38AKS016 & 024
Fig. 19 – Coil Cleaning Typical – 38AKS016 & 024
22
TROUBLESHOOTING
PROBLEM
SOLUTION
COMPRESSOR DOES NOT RUN
Contactor Open
1. Power off.
1. Restore power.
2. Fuses blown in field power circuit.
2. After finding cause and correcting, replace with correct size fuse.
3. No control power.
3. Check control circuit breaker; reset if tripped or replace if defective.
4. Thermostat circuit open.
4. Check thermostat setting.
5. Time Guard II device not operating.
5. Check Time Guard II devices.
6. Compressor circuit breaker tripped.
6. Check for excessive compressor current draw. Reset breaker;
replace if defective.
7. Safety device lock-out circuit active.
7. Reset lock-out circuit at thermostat or circuit breaker.
8. Low-pressure switch open.
8. Check for refrigerant undercharge, obstruction of indoor airflow, or
whether compressor suction shutoff valve is fully open. Make sure
liquid line solenoid valve(s) is open.
9. High-pressure switch open.
9. Check for refrigerant overcharge, obstruction or outdoor airflow,
air in system, or whether compressor discharge valve is fully open.
Be sure outdoor fans are operating correctly.
10. Compressor overtemperature switch open.
10. Check for open condition. Allow for reset. Replace if defective.
11. Loose electrical connections.
11. Tighten all connections.
12. Compressor stuck.
12. See compressor service literature.
Contactor Closed
1. Compressor leads loose.
1. Check connections and tighten.
2. Motor windings open.
2. See compressor service literature.
3. Single phasing.
3. Check for blown fuse. Check for loose connection at compressor
terminal. Contact power company.
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 re-circulating.
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. Check that
compressor discharge service valve is fully open.
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.
COMPRESSOR CYCLES ON LOW PRESSURE SWITCH
Indoor-Air Fan Running
1. Compressor suction service valve partially closed.
1. Open valve fully.
2. Liquid line solenoid valve(s) fails to open.
2. Check liquid line solenoid valve(s) for proper operation. Replace if
3. Filter drier plugged.
3. Replace filter drier.
4. Expansion valve power head defective.
4. Replace power head.
5. Low refrigerant charge.
5. Add charge. Check low-pressure switch setting. Check system for leaks.
necessary.
23
TROUBLESHOOTING (cont)
PROBLEM
COMPRESSOR CYCLES ON LOW PRESSURE SWITCH
Airflow Restricted
1. Coil iced up.
2. Coil dirty.
3. Air filters dirty.
4. Dampers closed.
Indoor-Air Fan Stopped
1. Electrical connections loose.
2. Fan relay defective.
3. Motor overload open.
4. Motor defective.
5. Fan belt broken or slipping.
SOLUTION
1. Check refrigerant charge.
2. Clean coil fins.
3. Clean or replace filters.
4. Check damper operation and position.
1. Tighten all connections.
2. Replace relay.
3. Power supply.
4. Replace motor.
5. Replace or tighten belt.
COMPRESSOR RUNNING BUT COOLING INSUFFICIENT
Suction Pressure Low
1. Refrigerant charge low.
2. Head pressure low.
3. Air filters dirty.
4. Expansion valve power head defective.
5. Indoor coil partially iced.
6. Indoor airflow restricted.
Suction Pressure High
1. Unloaders not functioning.
2. Compressor valve defective.
3. Heat load excessive.
1. Check unloader adjustments. Check unloader setting.
2. See compressor service literature.
3. Check for open doors or windows in vicinity of fan coil.
UNIT OPERATES TOO LONG OR CONTINUOUSLY.
1. Low refrigerant charge.
2. Control contacts fused.
3. Air in system.
4. Partially plugged expansion valve or filter drier.
1. Add refrigerant.
2. Replace control.
3. Purge and evacuate system.
4. Clean or replace.
SYSTEM IS NOISY
1. Piping vibration.
2. Compressor noisy.
1. Add refrigerant. Check system for leaks and fix.
2. Check refrigerant charge. Check outdoor-air fan thermostat settings.
3. Clean or replace filters.
4. Replace power head.
5. Check low pressure setting.
6. Remove obstruction.
1. Support piping as required.
2. Check valve plates for valve noise. Re-pipe compressor if
bearings are worn.
COMPRESSOR LOSES OIL
1. Leak in system.
2. Crankcase heaters not energized during shutdown.
3. Improper interconnecting piping design.
1. Repair leak.
2. Check wiring and delays. Check heater and replace if defective.
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.
2. Expansion valve opens too wide.
1. Repair leak and recharge.
2. Adjust expansion valve.
FROSTED LIQUID LINE
1. Restricted filter drier.
2. Liquid line solenoid partially closed.
1. Remove restriction or replace.
2. Replace valve.
COMPRESSOR WILL NOT UNLOAD
1. Defective unloader.
2. Defective capacity control solenoid valve (if used).
3. Miswired capacity control liquid line solenoid (if used).
4. Weak, broken, or wrong valve body spring.
1. Replace unloader.
2. Replace valve.
3. Rewire correctly.
4. Replace spring.
COMPRESSOR WILL NOT LOAD.
1. Miswired capacity control liquid line solenoid (if used).
2. Defective capacity control solenoid valve (if used).
3. Plugged strainer (high side).
4. Stuck or damaged unloader piston or piston ring(s).
1. Rewire correctly.
2. Replace valve.
3. Clean or replace strainer.
4. Clean or replace the necessary parts.
24
25
START-UP CHECKLIST FOR 38AKS CONDENSING UNIT
(MUST BE SENT TO CCAC UPON COMPLETION)
A.
PRELIMINARY INFORMATION
Job Name
:
Location
:
Installing Contractor
:
Distributor
:
Start-up performed by :
Start-up Date
:
EQUIPMENT:
Model :
Serial No. :
COMPRESSOR:
Model :
Serial No. :
Motor No. :
Volts :
INDOOR UNIT:
B.
RLA :
Manufacturer :
Model :
Serial No. :
Volts :
RLA/KW :
PRELIMINARY EQUIPMENT CHECK (Yes or No)
Is there any shipping damage?
If so, where?
Will this damage prevent unit start-up?
Check power supply. Does it agree with unit?
Has the circuit protection been sized and installed properly?
Are the supply wires sized as per requirement?
Are the refrigerant lines sized as per requirement?
Have the electrical components been checked for tightness?
Check Air Systems (Yes or No)
Is air handler operational?
Correct rotation?
V-belts tension normal?
Record motor amperage
L1
A,
L2
A,
L3
A
Check for possible leak caused by shipment
Leak check thoroughly compressor, fusible plugs, thermostatic expansion valve (TXV), filter drier and other parts
with electronic leak detector of soap bubbles.
Check voltage imbalance
AB
.
V,
AB + AC + BC (divided by 3) = AVERAGE VOLTAGE =
25
AC
V,
BC
V
V
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =
VOLTAGE IMBALANCE = (Max. deviation) x 100 =
Average Voltage
V
%VOLTAGE IMBALANCE
If over 2% Voltage Imbalance, do not attempt to start the unit!
Call local power company for assistance.
Assure that incoming power supply voltage to unit is within the range of PLUS or MINUS 10% rated voltage.
C.
UNIT START-UP (insert check mark as each item is completed)
q
Ensure crankcase heaters have been energized for a minimum of 24 hours prior to start-up.
q
Ensure compressor oil level is correct.
q
Ensure liquid line service valve is backseated.
q
Ensure compressor suction service valve is backseated.
q
Ensure compressor discharge service valve is backseated.
q
Loosen compressor shipping holddown bolts.
§
Check operation of the following:
q
Crankcase Heater.
q
Time Guard II Control.
q
Head Pressure Control.
q
Capacity Control.
q
Low Pressure Switch Control.
q
Oil Pressure Switch (for AKS024, AKS028, AKS034 & AKS044 only)
q
Be sure temperature controller is set properly.
q
Set point should be adjusted to the desired room/space temperature.
§
Does machine start at first attempt?
If not, explain why
§
Measure the following while machine is in stable operation.
Suction Pressure / Saturated Temperature
°F
PSIG
°F
°F
Discharge Line Temperature
°F
Liquid Line Pressure / Saturated Temperature
°F
Liquid Line Temperature
Liquid Subcooling
PSIG
°F
Discharge Pressure / Saturated Temperature
Discharge Superheat
°F
°F
Suction Line Temperature
Suction Superheat
PSIG
°F
26
§
Record motor amperage
Compressor
L1
A,
Fan Motor
1
A
2
A
L2
A,
L3
A
Remarks / Comments:
Signature Technician
Date
Signature Customer
27
Date