Carrier start-up and Installation manual

38AUQ
Heat Pump Condensing Units
60 Hz
With PuronR (R---410A) Refrigerant
Sizes 16 --- 25
Installation, Start---Up and
Service Instructions
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 2
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 36
INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . 2
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Servicing Systems on Roofs
with Synthetic Materials . . . . . . . . . . . . . . . . . . . . . . . 25
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . . . 7
Step 2 - Complete Pre-- Installation Checks . . . . . . . . . 8
Liquid Line Filter Driers . . . . . . . . . . . . . . . . . . . . . . . 26
Step 3 – Prepare Unit Mounting Support . . . . . . . . . . . 8
Filed Refrigerant Access Ports . . . . . . . . . . . . . . . . . . 26
Step 4 - Rig and Mount the Unit . . . . . . . . . . . . . . . . . 8
Outdoor Coil Metering Devices . . . . . . . . . . . . . . . . . 26
Step 5 - Complete Refrigerant Piping Connections . . . 8
Refrigerant System Pressure Access Ports . . . . . . . . . 26
Step 6 - Install Accessories . . . . . . . . . . . . . . . . . . . . 12
Compressor Protection . . . . . . . . . . . . . . . . . . . . . . . . 27
Step 7 - Complete Electrical Connections . . . . . . . . . 12
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Commercial Defrost Board . . . . . . . . . . . . . . . . . . . . . 27
System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Comfort Alert Diagnostic Module . . . . . . . . . . . . . . . 32
Turn On Crankcase Heaters . . . . . . . . . . . . . . . . . . . . 17
Outdoor Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
START-- UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 23
Outdoor Coil Maintenance and
Cleaning Recommendations . . . . . . . . . . . . . . . . . . . . 34
38AUQ Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . 24
Indoor (Supply) Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cooling Unit Without Economizer . . . . . . . . . . . . . . . 24
Cooling Unit With Economizer . . . . . . . . . . . . . . . . . 24
Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 36
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 37
APPENDIX A
Air Conditioner and Heat Pump with PuronR –
Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . 38
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Supplemental Heating/Emergency Heating . . . . . . . . 25
APPENDIX B
Wiring Diagram List . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cooling and Heating Shutdown . . . . . . . . . . . . . . . . . 25
ROUTINE SYSTEM MAINTENANCE . . . . . . . . . . . . 25
Quarterly Inspection
(and 30 days after initial start) . . . . . . . . . . . . . . . . . . 25
APPENDIX C
Low Ambient Option — Factory Installed . . . . . . . . . 39
START-- UP CHECKLIST . . . . . . . . . . . . . . . . . . . 47 - 48
1
SAFETY CONSIDERATIONS
!
38AUQ
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
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to follow this warning could cause 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 ignitions sources
away from refrigerants and oils.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloths for brazing operations and
have a fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions attached to
the unit. Consult local building codes and appropriate
national electrical codes (in USA, ANSI/NFPA70,
National Electrical Code (NEC); in Canada, CSA C22.1)
for special requirements.
!
!
WARNING
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 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.
CAUTION
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
38AUQ units.
It is important to recognize safety information. This is the
. When you see this symbol on the
safety-- alert symbol
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.
WARNING
INSTALLATION GUIDELINE
Replacement /Retrofit – R22 to Puron®
Split system heat pumps are intended to be installed with
matching indoor sections only. The 38AUQ heat pump
outdoor units are matched only with same-size 40RUQ
indoor sections. Existing R-22 indoor coils cannot be
converted to R-410A heat pump duty. Only the existing
refrigerant piping is a candidate for retrofit use.
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. Operate
this system in COOLING ONLY. 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.
Installation –
1. Remove the existing evaporator coil or fan coil and
install the replacement coil.
2. Drain oil from low points and traps in suction line
tubing if they were not replaced.
3. Remove the existing outdoor unit. Install the new outdoor unit according to these installation instructions.
4. Install the factory-supplied liquid-line filter drier at
the indoor coil just upstream of the TXV.
2
!
7. Operate the system for 10 hr. Monitor the pressure
drop across the suction line filter drier. If pressure
drop exceeds 3 psig (21kPa), 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 necessary. Never leave suction-line filter drier in system
longer than 72 hr (actual time).
CAUTION
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.
38AUQ
5. If required, install a 100% activated alumina suction
line filter drier at the outdoor unit.
6. Evacuate and charge the system according to the instructions in this installation manual.
Fig. 1 - 38AUQ*16 Unit Dimensions
3
C10674
38AUQ
Fig. 2 - 38AUQ*25 Unit Dimensions
4
C10675
Table 1A — Physical Data — 38AUQ*16-25 Units — 60 Hz English
UNIT SIZE 38AUQ*
16
25
NOMINAL CAPACITY (tons)
15
20
REFRIGERANT
SYSTEM‡
Refrigerant
PuronR (R--- 410A)
# Circuits / # Compressor / Type
2 / 2 / Scroll
2 / 2 / Scroll
9.0/9.0
9.0/9.0
21/21
27/27
Acutrol
Acutrol
High---Pressure Trip / Reset (psig)
630 / 505
630 / 505
Low---Pressure Trip / Reset (psig)
27 / 44
27 / 44
ZP83 (2)
ZP103 (2)
60
110
3500
3500
Shipping Charge A/B (lb)
Operating Charge w/Fan
Coil†
A/B (lbs)
Metering Device
Model
Oil Charge A/B (oz)
Speed (RPM)
OUTDOOR COIL
Material
Al/Cu
Coil Type
Round Tube/Plate Fin (RTPF)
Rows/Fins Per Inch (FPI)
Total Face Area
2/17
(ft2)
47.1
50.1
Qty / Motor Drive Type
3 / Direct
4 / Direct
Motor HP / RPM
¼ / 1100
¼ / 1100
22
22
10,000
14,000
970
1150
44 ±5
44 ±5
Qty...Vapor
2...13/8
2...13/8
Qty...Liquid
2...1/2
2...1/2
OUTDOOR FAN / MOTOR
Diameter (in)
Nominal Airflow (Cfm)
Watts (Total)
Cut-in
PIPING CONNECTIONS (in. ODS)
LEGEND
ODS — Outside Diameter Sweat (socket)
† Approximate system charge with 25 ft piping of sizes indicated with matched 40RUQ
5
38AUQ
COMPRESSOR
Table 1B — Physical Data — 38AUQ*16-25 Units — 60 Hz SI
UNIT SIZE 38AUQ*
16
25
NOMINAL CAPACITY (kW)
15
20
REFRIGERANT
SYSTEM‡
Refrigerant
PuronR (R--- 410A)
# Circuits / # Compressor / Type
2 / 2 / Scroll
2 / 2 / Scroll
4.1/4.1
4.1/4.1
9.5/9.5
12.2/12.2
Acutrol
Acutrol
High---Pressure Trip / Reset (kPa)
4344 / 3482
4344 / 3482
Low---Pressure Trip / Reset (kPa)
372 / 807
372 / 807
ZP83 (2)
ZP103 (2)
Oil Charge A/B (L)
1.7
3.2
Speed (r/s)
58
58
Shipping Charge A/B (kg)
Operating Charge w/Fan
Coil†
A/B (kg)
Metering Device
38AUQ
COMPRESSOR
Model
OUTDOOR COIL
Material
Al/Cu
Coil Type
Round Tube/Plate Fin (RTPF)
Rows/Fins Per Meter (Fins/m)
Total Face Area
2/17
(m2)
4.4
4.6
3 / Direct
4 / Direct
Motor HP / r/s
¼ / 18
¼ / 18
Diameter (mm)
559
559
Nominal Airflow (L/s)
4719
6607
Watts (Total)
970
1150
44 ±5
44 ±5
Qty / Vapor
2 / 34.9
2 / 34.9
Qty / Liquid
2 / 12.7
2 / 12.7
OUTDOOR FAN / MOTOR
Qty / Motor Drive Type
Cut-in
PIPING CONNECTIONS (mm ODS)
LEGEND
NEMA — National Electrical Manufacturers Association
ODS — Outside Diameter Sweat (socket)
† Approximate system charge with 7.6 m piping of sizes indicated with matched 40RUQ
6
1
2
3
8 A U Q A 2
3
4
5
6
_____________
7
8
9
10 11 12 13 14 15 16 17 18
5 A 0 C 6
– 0 A 0 A 0
____
Model Type
Packaging
38AU= Carrier Condensing Unit
Puronr R--- 410A Refrigerant
1 = LTL
0 = Standard
Type of Coil
Q = Heat Pump Scroll Compressor
Electrical Options
A = None
C = Non-Fused Disconnect
Refrigerant Options
A = None
B = Low Ambient
Service Options
0 = None
1 = Un-powered Convenience Outlet
2 = Powered Convenience Outlet
Nominal Tonnage
16 = 15 Tons
25 = 20 Tons
Not Used
A = Not Used
38AUQ
Not Used
A = Place Holder
Base Unit Controls
0 = Electro-Mechanical Controls
Not Used
0 = Not Used
Design Revision
A = Initial Rev (Discrete Model Number)
Coil Options
A = Al/Cu
B = Precoat Al/Cu
C = E-Coat Al/Cu
E= Cu/Cu
M = Al/Cu with Hail Guard
N = Precoat Al/Cu with Hail Guard
P = E-Coat Al/Cu with Hail Guard
R = Cu/Cu with Hail Guard
Voltage
1 = 575/3/60
5 = 208/230/3/60
6 = 460/3/60
C10676
Fig. 3 - Model Number Nomenclature
POSITION NUMBER
TYPICAL
1
4
2
8
3
1
POSITION
1−2
3−4
5
6−10
4
0
5
G
6
1
7
2
8
3
INSTALLATION
Jobsite Survey
Complete the following checks before installation.
1. Consult local building codes and the NEC (National
Electrical Code) ANSI/NFPA 70 for special installation requirements.
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.
10
5
DESIGNATES
Week of manufacture (fiscal calend ar)
Year of manufacture (”10” = 2010)
Manufacturing location (G = ETP, Texas, USA)
Seq uential numb er
Fig. 4 - Serial Number Nomenclature
.
9
4
C10799
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. 5.
Select a unit mounting system that provides adequate
height to allow for removal and disposal of frost and ice
that will form during the heating-defrost mode.
NOTE: Consider also the effect of adjacent units on
airflow performance and control box safety clearance.
7
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.
38AUQ
Although unit is weatherproof, avoid locations that permit
water from higher level runoff and overhangs to fall onto
the unit.
LEFT:
Min 18” (457 mm)
requried for service
NOTE: If vibration isolators are required for a particular
installation, use the data in Figs. 1 and 2 to make the
proper selection.
Step 3 — Prepare Unit Mounting Support
Slab Mount —
DO NOT BURY REFRIGERATION LINES.
REAR:
Min 18” (457 mm)
requried for service
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 and 1B for unit operating
weights. See Figs. 1 and 2 for weight distribution based
on recommended support points.
RIGHT:
Min 18” (457 mm)
requried for service
FRONT:
42” (1067 mm)
Note: Observe requirements for 39” (914 mm) operating clearance
on either Left or Rear coil opening.
C10201
Fig. 5 - Service Clearance Dimensional Drawing
Step 2 — Complete Pre-Installation Checks
Check Unit Electric Characteristic —
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.
Provide a level concrete slab that extends a minimum of 6
in. (150 mm) 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
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
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
Refrigerant lines must be carefully designed and
constructed to ensure equipment reliability and efficiency.
Line length, pressure drop, compressor oil return, and
vertical separation are several of the design criteria that
must be evaluated. See Table 2.
Consider System Requirements —
IMPORTANT: Do not bury refrigerant piping
underground.
S Consult local building codes and National Electrical
Code (NEC, U.S.A.) for special installation
requirements.
IMPORTANT: A refrigerant receiver is not
provided with the unit. Do not install a receiver.
S Allow sufficient space for airflow clearance, wiring,
refrigerant piping, and servicing unit. See Figs. 1 and 2
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.
8
Table 2 – 38AUQ*16-- 25 Piping Recommendations (Two-Circuit Unit)
R-410A
Model
Nominal Capacity
38AUQ*16
Equivalent Length
Length Equiv
0-38
38-75
75-113
113-150
150-188
Length Lin
0-25
25-50
50-75
75-100
100-125
Liquid Line
1/
1/
1/
1/
1/
2
2
2
2
2
Max Lift
38AUQ*25
Cool
25
50
75
100
125
Heat
25
50
60
60
60
Vapor Line
11/
11/
11/
11/
Charge ea. (lbs)
20.9
22.8
Liquid Line
1/
1/
8
2
8
24.8
5/
2
8
1/
8
5/
2
8
8
11/8
26.6
28.6
5/
5/
8
8
Max Lift
25
37
50
24
51
48
Heat
25
50
50
60
60
60
Vapor Line
11/
11/
Charge ea. (lbs)
26.9
8
11/
8
28.8
30.7
11/
8
30.7
33.6
63
60
8
13/
8
37.1
13/8
40.2
Legend:
Length Equiv
Equivalent tubing length, including effects of refrigeration specialties devices
Linear Lin
Typical linear tubing length, Feet (50% added to linear to define Equivalent Length for this table)
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 100 ft: Minimum 2.0°F subcooling entering TXV
S Linear Length Greater than 100 ft: Minimum 0.5°F subcooling entering TXV
Vapor 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)
NOTE:
For applications with equivalent length greater than 188 ft (57 m) and/0r linear length greater than 125 ft (38 m),
contact your local Carrier representative.
Check Vertical Separation —
If there is any vertical separation between the indoor and
outdoor units, check to ensure that the separation is within
allowable limits. Relocate equipment if necessary.
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.
Refrigerant Line Sizing —
Consider the length of the piping required between the
outdoor and indoor units. The maximum allowable line
length is 100 ft (30.5 m). See Table 2. Refrigerant vapor
piping should be insulated.
Install Filter Driers and Moisture Indicators —
38AUQ units include two Puron-duty filter driers, shipped
in cartons attached to the unit basepan. Remove the filter
driers and prepare to install in the liquid lines at the
evaporator coil. Do not remove connection fitting plugs
until ready to connect and braze the filter driers into the
liquid line positions See Table 3.
IMPORTANT: A refrigerant receiver is not
provided with the unit. Do not install a receiver.
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 4 for recommendations on refrigeration
specialties.
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.
Every unit MUST have bi-directional filter driers in the
liquid lines. Locate the filter driers at the indoor unit,
close to the evaporator coil’s thermal expansion valve
(TXV) inlets.
9
38AUQ
Cool
Table 3 – Puron-duty Filter Drier(s)
Liquid
Line OD
Model-Size
Qty
38AUQ*16
2
1/
2
1/
38AUQ*25
Desiccant
Volume
Part
Number Ref
2-in
16 cu. in.
KH43LG089
2-in
16 cu. in.
KH43LG089
Table 4 – Refrigerant Specialties Part Numbers
LIQUID LINE
SIZE (in.)
LIQUID LINE
SOLENOID VALVE (LLSV)
SOLENOID
COIL
SIGHT
GLASS
FILTER
DRIER
1/
2
EF680035 plus EF680039 biflow kit
EF680037
KM680004
5/
8
EF680036 plus EF680039 biflow kit
EF680037
KM680005
Provided with unit
See Table 4
38AUQ
Install Liquid Line Solenoid Valves —
It is recommended that bi-directional solenoid valves be
placed in the main liquids line for circuits 1 and 2 (see
Fig. 6) between the outdoor unit and the indoor coil.
Locate the solenoid valves at the end of the liquid lines,
near the outdoor unit connections, with flow direction
arrow pointed at the outdoor unit. Refer to Table 4. (A
liquid line solenoid valve is required when the liquid line
length exceeds 75 ft [23 m].) This valve prevents
refrigerant migration (which causes oil dilution) to the
compressor during the off cycle, at low outdoor ambient
temperatures. Wire the solenoid according to the unit label
diagram.
!
EQUALIZER LINE
TXV
SENSING
BULB
AIRFLOW
15 DIAMS
MIN
10
DIAMS
TXV
CKT 2
8 DIAMS
MIN
TXV
SENSING
BULB
AIRFLOW
15 DIAMS
MIN
CAUTION
10
DIAMS
SIGHT
GLASSES
FILTER
DRIERS
TXV
CKT 1
8 DIAMS
MIN
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage.
Failure to use a solenoid valve relay (SUR) accessory
may cause overload of Comfort Alert Diagnostic
Module (CADM) and compressor alarm lock out.
SUCTION
CIRCUIT 2
SUCTION
CIRCUIT 1
Dual Circuit Coil Piping Configuration
C10830
Fig. 6 - Location of Sight Glasses and Filter Driers
Table 5 – Minimum Outdoor Air Operating Temperature
Capacity Control Liquid Line Solenoid Valve —
Evaporator capacity control via liquid solenoid valve is
not recommended for use with 38AUQ models.
UNIT
38AUQ16
38AUQ25
*
†
10
%
COMPRESSOR
CAPACITY
100
MINIMUM OUTDOOR
TEMP — F (C)*
Standard Unit
Head Pressure
Control†
35 (1.7)
–20 (–28.9)
35 (1.7)
–20 (–28.9)
Applies to Cooling mode of operation only.
Wind baffles (field-supplied and field-installed) are recommended for all
units with low ambient head pressure control. Refer to Low Ambient
Control Installation Instructions (shipped with accessory) for details.
Make Piping Connections —
Evacuation/Dehydration —
Piping connections at the 38AUQ unit are ball valves with
stub tube extensions. Do not open the unit service valves
until all interconnecting tube brazing as been completed.
Evacuate and dehydrate the connected refrigeration
system(s) (excluding the 38AUQ unit) to 500 microns
using a two-stage vacuum pump attached to the service
ports outside the 38AUQ service valves, following
description in GTAC II, Module 4, System Dehydration.
!
WARNING
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 pressures than standard R-- 22 systems. Do not
use R-- 22 service equipment or components on Puron
refrigerant equipment.
Field Service
Access Port
(Schrader core)
Factory
High-Flow
Access Port
IMPORTANT: Charge in Cooling mode only!
Preliminary Charge —
Service Valve
with Stem Cap
Sweat
Connection
Fig. 7 - Typical Piping Connection Assembly
C10203
When connecting the field tubing to the 38AUQ service
valves, wrap the valves in wet rags to prevent overheating
Pressure-test all joints from outdoor unit connections over
to the indoor coil, using nitrogen as pressure and with
soap-and-bubbles.
Before starting the unit, charge R-410A liquid refrigerant
into the high side of each 38AUQ circuit through the
liquid service valve(s). The amount of refrigerant added
must be at least 80% of the operating charge listed in
Table 2 for LINEAR line length LESS the factory charge
quantity (if factory shipping charge has not been
removed). See the following example.
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 2-3 in-lbs
(23-34 N-cm).
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.
Where vapor line is exposed to outdoor air, line must be
insulated. See Table 6 for insulation requirements.
Example:
38AUQ*25
Table 6 – Insulation for Vapor Line Exposed
to Outdoor Conditions
LENGTH OF EXPOSED
VAPOR LINE*
*
†
ft
m
10
INSULATION THICKNESS†
in.
mm
3
3/
8
10
25
8
1/
2
13
50
15
3/
4
19
Recommended vapor line insulation for piping exposed to outdoor
conditions to prevent loss of heating during heating cycle. When vapor
line goes through interior spaces, insulation should be selected to prevent condensation on cooling cycle. Heating capacity should be reduced 1000 Btuh (295 W) if over 35 ft (11 m) of vapor line with 3/4 in. (19
mm) insulation is exposed to outdoor conditions.
Closed cell foam insulation with a thermal conductivity of: 0.28 Btu S
in./ft2 S h S °F (0.04 W/m S °C).
60-ft (18.3 m) linear line length
Equivalent line length 90-ft (27.4 m)
Cooling Liquid Lift: 20-ft (6.1 m)
Select line sizes from Table 2 (38AUQ):
Liquid 1/2 - in (provides liquid lift to 24-- ft (7.3 m))
Vapor 1-1/8 in.
Charge (each circuit):
1/ - in liquid line: 30.7 lbs (at 75-ft linear length)
2
80% of Operating Charge:
0.80 x 30.7 = 24.6 lbs
Factory Shipping Charge: 9 lbs
Field-Charge (each circuit):
24.6 - 9.0 = 15.6 lbs
For linear line lengths longer than 125 ft (38.1 m), contact
your local Carrier representative for system charge value.
11
38AUQ
The stub tube connections include π-in SAE service
fittings with Schrader valve cores (see Fig. 7). 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.
Step 6 — Install Accessories
Accessories requiring modifications to unit wiring should
be completed now. These accessories may include Winter
Start controls, Low Ambient controls, phase monitor,
Compressor LOCout. Refer to the instructions shipped
with the accessory.
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.
Step 7 — Complete Electrical Connections
38AUQ
!
!
WARNING
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 NEC (National
Electrical Code); ANSI/NFPA 70, latest edition (in
Canada, Canadian Electrical Code CSA [Canadian
Standards Association] C22.1), and local electrical
codes.
FIRE HAZARD
Failure to follow this warning could result in
intermittent operation or performance satisfaction.
Do not connect aluminum wire between disconnect
switch and condensing unit. Use only copper wire.
(See Fig. 8.)
ELECTRIC
DISCONNECT
SWITCH
COPPER
WIRE ONLY
NOTE: Check all factory and field electrical connections
for tightness. Field-supplied wiring shall conform with the
limitations of 63°F (33°C) rise.
ALUMINUM
WIRE
Field Power Supply —
If equipped with optional Powered Convenience Outlet:
The power source leads to the convenience outlet’s
transformer primary are not factory connected. Installer
must connect these leads according to required operation
of the convenience outlet. If an always-energized
convenience outlet operation is desired, connect the
source leads to the line side of the unit-mounted
disconnect. (Check with local codes to ensure this method
is acceptable in your area.) If a de-energize via unit
disconnect switch operation of the convenience outlet is
desired, connect the source leads to the load side of the
unit disconnect. On a unit without a unit-mounted
disconnect, connect the source leads to compressor
contactor C and indoor fan contactor IFC pressure lugs
with unit field power leads.
All units except 208/230-v units are factory wired for the
voltage shown on the nameplate. If the 208/230-v unit is
to be connected to a 208-v power supply, the control
transformer must be rewired by moving the black wire
with the 1/4-in. female spade connector from the 230-v
connection and moving it to the 208-v 1/4-in. male
terminal on the primary side of the transformer. Refer to
unit label diagram for additional information.
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).
WARNING
Fig. 8 - Disconnect Switch and Unit
A93033
Units Without Factory-Installed Disconnect —
When installing units, provide a disconnect switch per
NEC (National Electrical Code) of adequate size.
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 NEC and all local codes.
Size wire based on MCA (Minimum Circuit Amps) on the
unit informative plate. See Fig. 9 for power wiring
connections to the unit power terminal block and equipment
ground. Maximum wire size is #4 ga AWG per pole.
Provide a ground-fault and short-circuit over-current
protection device (fuse or breaker) per NEC Article 440
(or local codes). Refer to unit informative data plate for
MOCP (Maximum Over-current Protection) device size.
12
Units Without Disconnect Option
C
11
Convenience
Outlet
GFCI
TB1
13
Pwd-CO
Fuse
Switch
Pwd-CO
Transformer
Disconnect
per
NEC
L2
L3
208/230-3-60
460-3-60
575-3-60
Control Box
Access Panel
Units With Disconnect Option
L1
2
L2
4
L3
6
1
Optional
Disconnect
Switch
3
Fig. 10 - Convenience Outlet Location
Factory
Wiring
5
Disconnect factory test leads; discard.
Fig. 9 - Power Wiring Connections
C10204
All field wiring must comply with the NEC and local
requirements.
Voltage and Current Balance —
Voltage to compressor terminals during operation must be
within voltage range indicated on unit nameplate. See
Table 7. 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 Table 7, Note 5 (see
page 14) 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.
Convenience Outlets
!
WARNING
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal
injury or death.
Units with convenience outlet circuits may use
multiple disconnects. Check convenience outlet for
power status before opining unit for service. Locate its
disconnect switch, if appropriate, and open it. Tag-- out
this switch, if necessary.
Two types of convenience outlets are offered on 38AUQ
models: Non-powered and unit-powered. Both types
provide a 125-volt GFCI (ground-fault circuit-interrupter)
duplex receptacle rated at 15-A behind a hinged
waterproof access cover, located on the end panel of the
unit. See Fig. 10.
C10205
Non-powered type: This type requires the field
installation of a general-purpose 125-volt 15-A circuit
powered from a source elsewhere in the building. Observe
national and local codes when selecting wire size, fuse or
breaker requirements and disconnect switch size and
location. Route 125-v power supply conductors into the
bottom of the utility box containing the duplex receptacle.
Unit-powered type: A unit-mounted transformer is
factory-installed to stepdown the main power supply
voltage to the unit to 115-v at the duplex receptacle. This
option also includes a manual switch with fuse, located in
a utility box and mounted on a bracket behind the
convenience outlet; access is through the unit’s control
box access panel. See Fig. 10.
The primary leads to the convenience outlet transformer
are not factory-connected. Selection of primary power
source is a customer-option. If local codes permit, the
transformer primary leads can be connected at the
line-side terminals on the unit-mounted non-fused
disconnect or HACR breaker switch; this will provide
service power to the unit when the unit disconnect switch
or HACR switch is open. Other connection methods will
result in the convenience outlet circuit being de-energized
when the unit disconnect or HACR switch is open. See
Fig. 11.
Duty Cycle: The unit-powered convenience outlet has a
duty cycle limitation. The transformer is intended to
provide power on an intermittent basis for service tools,
lamps, etc; it is not intended to provide 15-amps loading
for continuous duty loads (such as electric heaters for
overnight use). Observe a 50% limit on circuit loading
above 8-amps (i.e., limit loads exceeding 8-amps to 30
minutes of operation every hour).
Test the GFCI receptacle by pressing the TEST button on
the face of the receptacle to trip and open the receptacle.
Check for proper grounding wires and power line phasing
if the GFCI receptacle does not trip as required. Press the
RESET button to clear the tripped condition.
Fuse on power type: The factory fuse is a Bussman
“Fusetron” T-15, non-renewable screw-in (Edison base)
type plug fuse.
13
38AUQ
L1
Using unit-mounted convenience outlets: Units with
unit-mounded convenience outlet circuits will often
require that two disconnects be opened to de-energize all
power to the unit. Treat all units as electrically energized
until the convenience outlet power is also checked and
de-energization is confirmed. Observe National Electrical
Code Article 210, Branch Circuits, for use of convenience
outlets.
Loosen the two screws at the GFCI duplex outlet, until
approximately 1/2in (13 mm) under screw heads are
exposed. Press the gasket over the screw heads. Slip the
backing plate over the screw heads at the keyhole slots
and align with the gasket; tighten the two screws until
snug (do not overtighten).
Mount the weatherproof cover to the backing plate as
shown in Fig. 12. Remove two slot fillers in the bottom of
the cover to permit service tool cords to exit the cover.
Check for full closing and latching.
RECEPTACLE
NOT INCLUDED
38AUQ
COVER – WHILE-IN-USE
WEATHERPROOF
BASE PLATE FOR
GFCI RECEPTACLE
C10206
UNIT
VOLTAGE
CONNECT
AS
208,
230
240
PRIMARY
CONNECTIONS
TRANSFORMER
TERMINALS
L1: RED + YEL
L2: BLU + GRA
H1 + H3
H2 + H4
H1
H2 + H3
H4
460
480
L1: RED
Splice BLU +
YEL
L2: GRA
575
600
L1: RED
L2: GRA
H1
H2
Installing Weatherproof Cover
A weatherproof while-- in-- use cover for the factory
installed convenience outlets is now required by UL
standards. This cover cannot be factory mounted due its
depth; it must be installed at unit installation. For
shipment, the convenience outlet is covered with a blank
cover plate.
The weatherproof cover kit is shipped in the unit’s control
box. The kit includes the hinged cover, a backing plate
and gasket.
TO
UNIT
C09022
All Units —
Fig. 11 - Powered Convenience Outlet Wiring
DISCONNECT ALL POWER
CONVENIENCE OUTLET.
Fig. 12 - Weatherproof Cover Installation
AND
Remove the blank cover plate at the convenience outlet;
discard the blank cover.
Voltage to compressor terminals during operation must be
within voltage range indicated on unit nameplate. See
Table 7. 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 Table 7, Note 5 (see
pages 14) 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.
Field Control Wiring —
38AUQ unit control voltage is 24 v. See Fig. 20 for typical
field control connections and the unit’s label diagram for
field-supplied wiring details. Route control wires to the
38AUQ unit through the opening in unit’s end panel to the
connections terminal board in the unit’s control box.
Remainder of the system controls connection will vary
according to the specific construction details of the indoor
section. Fig. 13 depicts typical connections to a Carrier
40RUQ 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 38AUQ 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).
14
Thermostat —
Install a Carrier-approved accessory thermostat according
to installation instructions included with the accessory.
For complete economizer function, select a two—stage
cooling thermostat. Locate the thermostat accessory on a
solid wall in the conditioned space to sense average
temperature in accordance with the thermostat installation
instructions.
(Note 1)
(Note 3)
For wire runs up to 50 ft. (15 m), use no. 18 AWG
(American Wire Gage) insulated wire (35°C minimum).
For 50 to 75 ft. (15 to 23 m), use no. 16 AWG insulated
wire (35°C minimum). For over 75 ft. (23 m), use no. 14
AWG insulated wire (35°C 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.
(Note 3)
(Note 2)
38AUQ
If the thermostat contains a logic circuit requiring 24-v
power, use a thermostat cable or equivalent single leads of
different colors with minimum of five leads. If the
thermostat does not require a 24-v source (no “C”
connection required), use a thermostat cable or equivalent
with minimum of four leads. Check the thermostat
installation instructions for additional features which
might require additional conductors in the cable.
Note 1: Typical multi-function marking. Follow manufacturer’s 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
C10078
PremierLink (accessory installation) – Refer to Form
33CS-58SI for details on connecting the PremierLink
controller and its various sensors.
Fig. 13 - Typical Remote Thermostat Connections
15
Table 7 – Electrical Data — 38AUQ*15-- 25
UNIT
SIZE
38AUQ
*16
38AUQ
*25
UNIT
SIZE
38AUQ
*16
*25
NOMINAL
POWER
SUPPLY
COMPRESSOR
VOLTAGE
RANGE
No. 1
NO C.O. or UNPWRD C.O.
No. 2
OFM
POWER SUPPLY
DISCONNECT SIZE
V--- Ph--- Hz
Min
Max
RLA
LRA
RLA
LRA
Qty
FLA
(ea)
MCA
FUSE or
HACR
BRKR
208/230---3---60
187
253
25.0
164
25.0
164
3
1.5
60.8/60.8
80/80
63/63
337/337
460 ---3 ---60
414
506
12.2
100
12.2
100
3
0.8
29.9
40
31
206
575 ---3 ---60
518
633
9.7
78
9.7
78
3
0.7
23.9
30
2
162
208/230---3---60
187
253
30.1
225
30.1
225
4
1.5
73.7/73.7
100/100
76/76
462/462
460 ---3 ---60
414
506
16.7
114
16.7
114
4
0.8
40.8
50
42
236
575 ---3 ---60
518
633
12.2
80
12.2
80
4
0.7
30.3
40
31
168
NOMINAL
POWER
SUPPLY
COMPRESSOR
VOLTAGE
RANGE
No. 1
FLA
LRA
w/ PWRD C.O.
No. 2
OFM
POWER SUPPLY
DISCONNECT SIZE
V--- Ph--- Hz
Min
Max
RLA
LRA
RLA
LRA
Qty
FLA
(ea)
MCA
FUSE or
HACR
BRKR
FLA
LRA
208/230---3---60
187
253
25.0
164
25.0
164
3
1.5
65.6/65.6
90/90
68/68
342/342
460 ---3 ---60
414
506
12.2
100
12.2
100
3
0.8
32.1
40
33
208
575 ---3 ---60
518
633
9.7
78
9.7
78
3
0.7
25.6
30
27
164
208/230---3---60
187
253
30.1
225
30.1
225
4
1.5
78.5/78.5
100/100
82/82
467/467
460 ---3 ---60
414
506
16.7
114
16.7
114
4
0.8
43
50
45
238
575 ---3 ---60
518
633
12.2
80
12.2
80
4
0.7
32
40
33
170
Legend and Notes for Table 10
LEGEND:
BRKR
CO
FLA
LRA
MCA
60 Hz Units
-----------
Circuit breaker
Convenient outlet
Full Load Amps
Locked Rotor Amps
Minimum Circuit Amps
Protection
National Electrical Code
Powered convenient outlet
Rated Load Amps
Unpowered convenient outlet
NEC
--PWRD CO
--RLA
--UNPWR CO
--NOTES:
1. In compliance with NEC requirements for multimotor and
combination load equipment (refer to NEC Articles 430 and
440), the overcurrent protective device for the unit shall be
fuse or HACR breaker. Canadian units may be fuse or circuit
breaker.
2. The MCA values are calculated in accordance with The NEC.
Article 440.
3. Motor RLA and LRA values are established in accordance
with Underwriters’ Laboratories (UL). Standard 1995.
4. The 575--- v units are UL, Canada--- listed only.
5. 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 determine the percentage of voltage imbalance.
Example: Supply voltage is 230-3-60
% Voltage Imbalance
= 100 x
max voltage deviation from average voltage
average voltage
AB = 224 v
BC = 231 v
AC = 226 v
Average Voltage =
=
(224 + 231 + 226)
3
=
681
3
227
Determine maximum deviation from average voltage.
(AB) 227 – 224 = 3 v
(BC) 231 – 227 = 4 v
(AC) 227 – 226 = 1 v
Maximum deviation is 4 v.
Determine percent of voltage imbalance.
% Voltage Imbalance
= 100 x
4
227
= 1.76%
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.
16
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.
Prior to starting compressor, a preliminary charge of
refrigerant must be added to avoid possible
compressor damage.
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage.
Do not attempt to start the heat pump system, even
momentarily, until the following steps have been
completed. Compressor damage may result.
System Check
1. Check all indoor section and other equipment auxiliary components. Consult the manufacturer’s instructions regarding any other equipment connected to the
condensing 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.
2. Be sure the unit is properly leak checked and dehydrated.
3. Check tightness of all electrical connections.
4. Open the liquid line and suction line service valves.
5. Be sure the unit is properly charged. See “Preliminary
Charge”, below.
6. The electrical power source must agree with the unit’s
nameplate rating.
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 compressor).
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 and 1B on pages 4 and 5). 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.
START-UP
38AUQ 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 securely 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 Dehydration 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 units are factory charged with the required
amount of oil. If recharging in required, use Emkarate
RL 32-3MAF.
Compressor Rotation —
On 3-phase units with scroll compressors, it is important
to be certain that the compressor is rotating in the proper
direction. 38AUQ 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 pressures.
To verify the compressor is rotating in the proper direction:
1. Connect service gages to the suction and liquid pressure fittings.
2. Energize the compressor.
3. The suction pressure should drop and the liquid pressure should rise, as is normal on any start-up.
17
38AUQ
!
CAUTION
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.
A label located above the terminal box identifies
Copeland Scroll compressor models that contain this
technology. See Fig. 14. Advanced Scroll Temperature
Protection (ASTP) is a form of internal discharge
temperature protection, that unloads the scroll compressor
when the internal temperature reaches approximately
300°F. At this temperature, an internal bi-metal disk valve
opens and causes the scroll elements to separate, which
stops compression. 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. 15.
Start Unit —
Set the space thermostat to a set point above space
temperature so that there is no demand for cooling. Close
the 38 AUQ disconnect switch. Only the crankcase heater
will be energized.
Reset the space thermostat below ambient so that a call
for cooling is ensured.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage.
Never charger liquid into the low-- pressure side of the
system. Do not overcharge. During charging or
removal of refrigerant, be sure indoor-- fan system is
operating. Ensure both outdoor fan motors re running;
bypass any Motormaster function.
Adjust Refrigerant Charge —
Fig. 14 - Advanced Scroll Temperature
Protection Label
Recommended Cooling Time
(Minutes)
38AUQ
Advanced Scroll Temperature Protection (ASTP) —
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.
C10080
120
110
100
90
80
70
60
50
40
30
20
10
0
0
10
20
30
40
50
60
70
80
90
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.
The unit must be charged in Cooling mode only. Refer to
Cooling Charging Charts, Figs. 16 and 17. For
applications with line lengths greater than 100 ft, contact
Carrier representative. Vary refrigerant until the
conditions of the chart are met. 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 unit’s 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.
Final Checks —
Ensure that all safety controls are operating, control panel
covers are on, and the service panels are in place.
C10081
Fig. 15 - Recommended Minimum Cool-Down Time
After Compressor is Stopped
18
38AUQ
Fig. 16 - 38AUQ*16 Charging Chart
19
C10784
38AUQ
Fig. 17 - 38AUQ*25 Charging Chart
20
C10785
38AUQ
Fig. 18 - 38AUQ*16 Power Schematic (208/230-3-60 shown)
21
C10786
38AUQ
Fig. 19 - 38AUQ*25 Power Schematic (208/230-3-60 shown)
22
C10787
38AUQ
Fig. 20 - 38AUQ*16/25 Control Schematic
23
C10788
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 or Heating; indoor
(supply) fan motor runs. When thermostat is satisfied, the
IFC is de-energized and indoor (supply) fan motor stops.
38AUQ
Cooling, Unit Without Economizer —
When thermostat calls for Cooling, terminal Y1 is
energized. The 38AUQ’s Defrost Board (DFB) receives
this input at P2-5. DFB issues 24-v outputs at OF, P3-7
(RVS1) and P3-10 (COMP1). The OF output energizes
outdoor fan relay (OFR); both outdoor fan motors start
and run. The output RVS1 energizes the reversing valve
solenoid (RVS); Reversing valve switches to Cooling
position.
Output PL3-10 (COMP1, 24-v) is received at CADM
terminal Y. If anti-recycle time delay period has not
expired, safety pressure switches are open, and/or lockout
alarms are active, CADM relay will remain open,
preventing compressor start. When safety pressure
switches are closed and CADM time delay expires, the
CADM relay closes, energizing Solenoid Valve Relay
SVR and compressor contactor C. SVR contacts close,
energizing the external liquid line solenoid valve.
Solenoid valve LLSV opens. Compressor contactor C
closes, energizing the compressor motor. Compressor
starts and system runs in Cooling mode.
When space cooling load is satisfied, terminal Y1 is
de-energized. Compressor and outdoor fan motors stop.
Liquid line solenoid valve LLSV is de-energized and
valve closes. CADM begins its three-minute anti-recycle
time delay.
Heating —
When the thermostat calls for first stage heating, terminal
W1 is energized. The 38AUQ’s Defrost Board (DFB)
receives this input at P2-7. The DFB removes the output
at P3-7 (RVS1); the reversing valve solenoid is
de-energized and the reversing valve moves to Heating
position.
DFB issues outputs at OF and P3-10 (COMP1). Outdoor
fan relay OFR is energized; both outdoor fan motors run.
Output PL3-10 (COMP1, 24-v) is received at CADM
terminal Y. If anti-recycle time delay period has not expired
and/or safety pressure switches are open, outdoor lockout
alarms are active, CADM relay will remain open, preventing
compressor start. When safety pressure switches are closed
and CADM time delay expires, the CADM relay closes,
energizing Solenoid Valve Relay SVR and compressor
contactor C.SVR contacts close, energizing the external
liquid line solenoid valve. Solenoid valve LLSV opens.
Compressor contactor C closes, energizing the compressor
motor. Compressor starts and system runs in Heating mode,
providing Stage 1 Heat.
When the space heating load is satisfied terminal W1 is
de-energized. Compressor and outdoor fan operations stop.
Liquid line solenoid LLSV is de-energized and valve closes.
CADM begins its three-minute anti-recycle time delay.
If either the Loss of Charge (LOC) Switch or High
Pressure Switch (HPS) opens while, the compressor
contactor C and relay SVR are de-energized; compressor
stops and liquid line solenoid is de-energized (valve
closes). CADM initiates a TRIP event (compressor
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.
Reversing valve solenoid remains de-energized until the
next Cooling cycle is initiated.
Defrost Cycle —
If either the Loss of Charge (LOC) Switch or High
Pressure Switch (HPS) opens while Y1 remains energized,
the compressor contactor C and relay SVR are
de-energized; 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.
During the Heating Mode, frost and ice can develop on
the outdoor coil. Defrost sequence will clear the frost and
ice from the coil by briefly reversing the Heating
sequence periodically.
Reversing valve solenoid (RVS) is energized in Cooling
modes. This solenoid will remain energized until the next
Heating mode is initiated.
If the outdoor coil’s Defrost Thermostat switch (DFT) is
closed (shorting DFB terminals DFT1 and DFT1), the
Defrost cycle will start. Output at OF is removed; outdoor
fans stop during the Defrost cycle. Output P3–7 (RVS1) is
energized; reversing valve solenoid RVS is energized and
reversing valve changes position, placing the circuit in a
Cooling mode flow, directing hot gas into the outdoor coil
where its heat melts the frost and loosens the ice on the
coil face.
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.
A window to test for a need to run the Defrost cycle opens
at a fixed period after the end of the last Defrost cycle or
the previous test window closed. The window period is
determined by the configuration settings on the DFB’s
DIP switches (see unit wiring diagram).
24
Defrost cycle is fixed at a maximum 10 minute duration
limit. The period to test and initiate a Defrost cycle can be
configured for 30, 60, 90 or 120 minutes.
S Wire terminal tightness
S Refrigerant charge level
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
!
Supplemental Heat/Emergency Heat —
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 PuronR. If you are unsure consult the
equipment manufacturer.
Supplemental heat type is determined by 40RUQ indoor
unit options and accessories. This heat is initiated when
the indoor unit W2 terminal is energized by the
thermostat. (Or as detailed in “Defrost Cycle” on page
19.) The thermostat may energizes W2 as supplemental
(2nd stage) heat at larger space heating demand, or when
selected as emergency heat mode. When the space heating
demand decreases below the 2nd stage limit, or
emergency heat is turned off, W2 is de-energized, and
supplemental heat is turned off.
Cooling and Heating Shutdown —
Compressor Oil —
!
Partial or complete cooling or heating functions may
shutdown caused by loss of main power, open pressure
switches, diagnostic alarms, or open internal compressor
protections. See Service section for further details.
CAUTION
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.
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
CAUTION
S Coil cleanliness checked.
Servicing Systems on Roofs with Synthetic Materials —
S Return air filter replacement
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.
S Belt tension checked
S Belt condition checked
S Pulley alignment checked
S Fan shaft bearing locking collar tightness checked
S Condensate drain checked
S Blower motor amperage
Outdoor Section
S Fan motor mounting bolts tightness
S Compressor mounting bolts
Synthetic Roof Precautionary Procedure:
1. Cover extended roof working area with an impermeable polyethylene (plastic) drop cloth or tarp.
Cover an approximate 10 x 10 ft (3.3 x 3.3 m) area.
S Fan blade positioning
S Control box cleanliness and wiring condition
25
38AUQ
During the Defrost cycle, output EHEAT is also energized
(if not already energized by a thermostat W2 demand);
supplemental heater will be energized. During the Defrost
Cycle, LED1 on the DFB will be illuminated. The Defrost
cycle ends when DFT opens (as liquid temperature exiting
the coil rises above DFT setpoint) or the defrost cycle runs
for 10 minutes. Output at EHEAT is removed;
supplemental heater will be de-energized (unless
thermostat has a W2 demand). Output at OF is restored;
outdoor fans start again. Output P3–7 (RVS1) is removed;
reversing valve returns to Heating position.
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
under 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.
38AUQ
Liquid Line Filter Drier —
The factory-provided reversible 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.
Outdoor Coil Metering Devices —
The metering devices are multiple fixed–bore devices
(Acutrol™) swaged into the horizontal outlet tubes from
the liquid header, located at the entrance to each
evaporator coil circuit path. These are non–adjustable.
Service requires replacing the entire liquid header
assembly.
To check the indoor coil, disconnect the supply fan signal
(A04-A06 direct-drive fans) or contactor (IFC) coil, then
start the circuit in a Cooling Mode (jumper R to Y1 or
Y2) and observe the frosting pattern on the face of the
indoor coil. A frost pattern should develop uniformly
across the face of the indoor coil starting at each tube at
the Acutrol nipple locations.
To check the outdoor coil, disconnect the outdoor fan
motor. Start the circuit in a Heating Mode (jumper R to
W1 or W2) and observe the frost pattern on the face of the
outdoor coil.
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.
Failure to develop frost at an outlet tube can indicate a
plugged or a missing orifice.
Field Refrigerant Access Ports —
There are two access ports in each circuit - on the suction
tube near the compressor and on the discharge tube near
the compressor. These are brass fittings with black plastic
caps. The hose connection fittings are standard 1/4 SAE
Male Flare couplings.
Field service access to refrigerant pressures is through the
access ports located at the service valves (see Figs 25 and
27). These ports are 1/4-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).
Refrigerant System Pressure Access Ports —
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. 21.) 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 core’s bottom o-ring. Install the
fitting body with 96 ±10 in-lbs (1085 ±23 N-- cm) of
torque; do not overtighten.
SEAT
CORE
(Part No. EC39EZ067)
1/2-20 UNF RH
0.596
45°
30°
WASHER
O-RING
5/8” HEX
.47
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.
Fig. 21 - CoreMax Access Port Assembly
26
DEPRESSOR PER ARI 720
+.01/-.035
FROM FACE OF BODY
7/16-20 UNF RH
C08453
Compressor Protection
Charge Switch trip setting is 27 psig ± 3 psig (186 ±21 kPa).
Reset is automatic at 44 ±5 psig (303 ± 35 kPa).
The compressor has internal limbered motor protection.
Compressor Overtemperature Protection (IP) —
The compressor has an internal protector to protect it
against excessively high discharge gas temperatures.
Crankcase Heater —
The heater prevents refrigerant migration and compressor oil
dilution during shutdown whenever compressor is not
operating. 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.
High Pressure Switch —
The system is provided with a high pressure switch
mounted on the discharge line. The switch is
stem-mounted and brazed into the discharge tube. Trip
setting is 630 ± 10 psig (4344 ± 69 kPa) when hot. Reset
is automatic at 505 ± 20 psig (3482 ± 140 kPa).
Loss of Charge Switch —
The system is protected against a loss of charge and low
evaporator coil loading condition by a loss of charge switch
located on the liquid line and a freeze protection thermostat
on the indoor coil. The switch is stem-mounted. Loss of
HPS1
LOC1
or
LPS1
The factory installed loss of charge pressure switch (LOC)
has open/close settings which do not provide indoor coil
freeze protection. The control provides a location on
terminal board TB2 to add a field supplied indoor coil freeze
protection switch, if additional protection is wanted. The
freeze protection switch can be wired into the 24VAC
control circuit in series with the high pressure switch and
loss of charge switch as shown in Fig. 22. Note that the wire
to the compressor contactor must be moved from the LPS
terminal to the FPT terminal, as shown.
A recommended indoor coil freeze protection switch is part
# HH18HB015 (30_ ± 5_F open, 45_ ± 5_F close) which
can be mounted on a return bend of the indoor coil. For
dual--circuits, a separate switch si used for each half of the
indoor coil. And are wired as shown in Fig. 22
Outdoor Fan Motor Protection —
The outdoor fan motor is internally protected against
overtemperature.
Control Circuit, 24-V —
The control circuit is protected against overcurrent
conditions by a circuit breaker mounted on control
transformer TRAN. Reset is manual.
Commercial Defrost Control
The Commercial Defrost Control Board (DFB)
coordinates thermostat demands for supply fan control, 1
or 2 stage cooling, 1 or 2 stage heating, emergency
heating and defrost control with unit operating sequences.
See Fig. 23 for board arrangement.
The DFB is located in the 38AUQ’s main control box (see
Fig. 24). All connections are factory-wired. Refer to
Table 8 for details of DFB Inputs and Outputs.
FPT1
C1
CIRCUIT 1
HPS
LPS
FPT
NOTE: Move compressor contactor wire
from right-side LPS terminal
to right-side FPT terminal
CIRCUIT 2
HPS
LPS
FPT
C2
HPS2
LOC2
or
LPS2
FPT2
Fig. 22 - Field Wiring of Indoor Coil Freeze Protection Switch (FPT)(Dual Circuit Shown)
27
C10822
38AUQ
Compressor Overcurrent —
Reversing Valve Control —
The DFB has two outputs for unit reversing valve control.
Operation of the reversing valves is based on internal logic;
this application does not use an “O” or “B” signal to
determine reversing valve position. Reversing valves are
energized during the Cooling stages and de-energized during
Heating cycles. Once energized at the start of a Cooling
stage, the reversing valve will remain energized until the
next Heating cycle demand is received. Once de-energized
at the start of a Heating cycle, the reversing valves will
remain de-energized until the next Cooling stage is initiated.
Compressor Control —
38AUQ
DIP
Switches
Speed-Up
Jumpers
The DFB receives inputs indicating Stage 1 Cooling and
Stage 1 Heating from the space thermostat or unit control
system (PremierLink); it generates commands to start
compressors with or without reversing valve operation to
produce Stage 1 Cooling (one compressor), or Stage 1
Heating (both compressors run).
C09275
Fig. 23 - Defrost Control Board (DFB) Arrangement
Table 8 – 38AUQ Defrost Board I/O and Jumper Configurations
Inputs
Point Name
Type of I/O
Connection Pin Number
G Fan
DI, 24-vac
P2-3
Unit Connection
Note
Y1 Cool 1
DI, 24-vac
P2-5
TB-Y1
Wi Heat 1
DI, 24-vac
P2-7
TB-W1
R Power
24-vac
P3-1
TRAN2
C Common
24-vac, ground
P3-3
TRAN2
DFT1 Defrost Switch
DI, 24-vac
DFT-1 to DFT-1
DFB
DFT2 Defrost Switch
DI, 24-vac
DFT-2 to DFT-2
DFB
Point Name
Type of I/O
Connection Pin Number
Unit Connection
OF OD Fan
DO, 24-vac
OF
OFR
RVS1
DO, 24-vac
P3-7 to P3-5
RVS1
Energize in COOL
RVS2
DO, 24-vac
P3-6 to P3-4
RVS2
Energize in COOL
COMP 1
DO, 24-vac
P3-10
CADM1-Y
TB--- W2
DO, 24-vac
E-HEAT
HR
Point Name
Type of I/O
Connection Pin Number
Unit Connection
Note
Select Jumper
24-vac
P1-1
1 Compressor
24-vac
P1-2
Type of I/O
Connection Pin Number
Unit Connection
Note
Not used
Outputs
Note
Configuration
Speed-Up Configuration
Point Name
Speed-Up Jumper
JMP17
Speed-Up Jumper
JMP18
Jumper for 1-3 secs: Factory Test, defrost runs for 12 seconds or less
Jumper for 5-20 secs: Forced Defrost, defrost runs for 30 secs if DFT2 is open
Fig. 24 - Defrost Control Board (DFB) Location
28
C10789
Defrost —
If the space heating load is satisfied and compressor
operation is terminated, the defrost control will remember
where the run period was interrupted. On restart in Heating,
the defrost control will resume unit operation at the point in
the run period where it was last operating.
The defrost control mode is a time/temperature sequence.
There are two time components: The continuous run
period and the test/defrost cycle period. The temperature
component is provided by the defrost thermostats (DFT1
and DFT2) mounted on the outdoor coil.
Defrost Thermostats —
The continuous run period is a fixed time period between the
end of the last defrost cycle (or start of the current Heating
cycle) during which no defrost will be permitted. This period
can be set at 30, 60, 90 or 120 minutes by changing the
positions of DIP switches SW1 and SW2 (see Fig. 25 and
Table 9). The default run period is 60 minutes.
These are temperature switches that monitor the surface
temperature of the outdoor coil circuits. These switches
are mounted on the liquid tube exiting the outdoor coil
heating circuits. These switches close on temperature drop
at 30°F (-1°C) and reset open on temperature rise at 80°F
(27°C).
The DFB can provide a 30 sec delay on Indoor Fan Off if
the thermostat’s fan selector switch is set on AUTO
control. DIP Switch SW3 on the DFB selects use of the
fan off time delay feature. Setting SW3 in the OPEN
position turns the Fan Off Delay feature on; setting SW3
in the CLOSED position disables this feature. The delay
period begins when Y1 demand or W1 demand by the
space thermostat is removed.
C10790
Defrost Speedup Functions —
Fig. 25 - DIP Switch Settings — Defrost Board
The DFB permits the servicer to speed-up the defrost
cycle. There are two speed-up sequences: relative
speed-up and an immediate forced defrost. Speed-up
sequences are initiated by shorting jumper wires JMP17
and JMP18 together (see Fig. 23); use a straight-edge
screwdriver.
At the end of the continuous run period, the defrost control
will test for a need to defrost. DFT2 (located on the bottom
circuit of the outdoor coil) controls the start and termination
of the defrost cycle. If DFT2 is still open, the defrost test/run
window is closed and the control repeats the continuous run
period. If DFT2 is closed, the defrost cycle is initiated in
Circuit 2. The defrost period will end when DFT2 opens
(indicating the outdoor coil has been cleared of frost and ice)
or a 10 minute elapsed period expires, whichever comes
first.
Shorting the jumpers for a period of 1 to 3 secs reduces
the defrost timer periods by a factor of 0.1 sec/minute.
(For example, the 90 min run period is reduced to 9 secs.)
The DFB will step the unit through a Heating cycle and a
Defrost cycle using these reduced time periods. This mode
ends after the Defrost cycle.
Circuit 1’s defrost thermostat DFT1 (located on the upper
circuit of the outdoor coil) cannot initiate a unit defrost
cycle; only DFT2 may do this. But once Circuit 2 is in
defrost, the DFB will monitor the status of DFT1. If DFT1
closes during a Circuit 2 defrost cycle, Circuit 1 will also
enter a defrost cycle. Circuit 1’s defrost cycle will end
when DFT1 opens (indicating the upper portion of the
outdoor coil is cleared of frost and ice) or the Circuit 2
defrost cycle is terminated.
Shorting the jumpers for a period of 5 to 20 secs bypasses
the remaining continuous run period and places the unit in
a Forced Defrost mode. If the controlling DFT is closed
when this mode is initiated, the unit will complete a
normal defrost period that will terminate when the
controlling DFT opens or the 10 minute defrost cycle limit
is reached. If the controlling DFT is open when this mode
is initiated, the Defrost cycle will run for 30 secs. Both
modes end at the end of the Defrost cycle.
At the end of the unit defrost cycle, the unit will be
returned to Heating cycle for a full continuous run period.
Table 9 – Dip Switch Position
Switch No.
1
1
0
2
1
1
J
J
30 minutes
0
2
J
J
60 minutes
1
2
J
J
1
0
1
90 minutes
29
1
2
J
J
0
3
1
0
120 minutes
On
J
Fan Delay
Off
38AUQ
Indoor Fan Off Delay —
38AUQ
Fans
Service
Valves
C10791
Fig. 26 - 38AUQ*16 Exterior
Outdoor Coil
Outdoor Coil
Defrost
Thermostat
(DFT)
High Flow
Access Ports
Defrost
Thermostat
(DFT)
HPS
LOC
LOC
HPS
Fig. 27 - 38AUQ*16 Interior
30
C10792
38AUQ
Fans
Service
Valves
C10793
Fig. 28 - 38AUQ*25 Exterior
Outdoor Coil
Outdoor Coil
High Flow
Access Port
High Flow
Access Port
Defrost
Thermostat
(DFT)
HPS
Defrost
Thermostat
(DFT)
LOC
HPS
LOC
Fig. 29 - 38AUQ*25 Interior
31
C10794
Comfort Alert Diagnostic Module
POWER
(GRN)
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.
The CADM detects causes for electrical and system
related failures. Flashing LEDs communicate the Alert
codes to guide service technicians in accurately and
quickly troubleshooting the system and determining root
cause for the failure.
ALERT
(YEL)
38AUQ
Inputs to the CADM include 24-vac power, demand signal
Y, 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
Demand
Y
24-V
Contactor Coil
P
24-V
Compressor T1
T1
Line
Compressor T2
T2
Line
Compressor T3
T3
Line
Control of the compressor contactor coil is through a
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. 30): POWER (green), ALERT (yellow), and
TRIP (red).
The POWER LED indicates the presence of control power
to the CADM.
TRIP
(RED)
Fig. 30 - CADM Housing/LED Locations
C10086
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 10, 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 for lockouts requires that main
power to the 38AUQ unit be recycled after the cause for
the Alert condition has been detected and corrected.
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 for some faults as identified
in Table 10. 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 11 for
discussion of additional LED flash codes and
troubleshooting instructions.
32
Table 10 – 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
compressor 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.
Yellow “ALERT” LED On Solid
Yellow “ALERT” Flash Code 2
Yellow “ALERT” Flash Code 3
Yellow “ALERT” Flash Code 4
Yellow “ALERT” Flash Code 5
Yellow “ALERT” Flash Code 6
A short circuit or over
current 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
System Pressure Trip
Discharge pressure out of
limits or compressor overload (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
Short Cycling
Compressor is running only
briefly LOCKOUT
1.
If low pressure switch is open:
Locked Rotor
LOCKOUT
Open Circuit
Missing Phase
LOCKOUT
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
1.
Low line voltage to compressor
2.
Excessive liquid refrigerant in compressor
3.
Compressor bearings are seized
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
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
Low Voltage
Control circuit < 18VAC
1.
Control circuit transformer is overloaded
2.
Low line voltage to compressor
Yellow “ALERT” Flash Code 9
33
38AUQ
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.
38AUQ
Table 11 – 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 module’s R and C terminals.
NOTE: The CADM requires a constant nominal 24VAC power supply. The
wiring to the module’s 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 Figs. 18 and 19, the 38AUQ Wiring
Diagram.
Green LED Intermittent,
module powers up only
when compressor runs
Determine if R and Y terminals are wired in reverse. Verify module’s R and C
terminals have a constant 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 38AUQ wiring diagram (see Figs. 18
and 19). 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 module’s current sensing
holes. Verify Y terminal 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 module’s 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.
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.
2.
3.
4.
5.
6.
Shut off unit power supply. Install lockout tag.
Remove outdoor fan assembly (grille, motor, and fan).
Loosen fan hub setscrews.
Adjust fan height as shown in Fig. 31.
Tighten setscrews to 84 in--lbs (949 N--cm).
Replace outdoor fan assembly.
Routine cleaning of coil surfaces is essential to maintain
proper operation of the unit. Elimination of contamination
and removal of harmful residues will greatly increase the
life of the coil and extend the life of the unit. The
following maintenance and cleaning procedures are
recommended as part of the routine maintenance activities
to extend the life of the coil.
Remove Surface Loaded Fibers —
Surface loaded fibers or dirt should be removed with a
vacuum 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 the coating of a protected coil) if
the tool is applied across the fins.
3.6 mm +0/0/-0.8
Fig. 31 - Outdoor Fan Blade Position
Outdoor Coil Maintenance and Cleaning
Recommendation
C10103
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.
NOTE: Use of a water stream, such as a garden hose,
against a surface loaded coil will drive the fibers and dirt
into the coil. This will make cleaning efforts more
difficult. Surface loaded fibers must be completely
removed prior to using low velocity clean water rinse.
Periodic Clean Water Rinse —
A periodic clean water rinse is very beneficial for coils
that are applied in coastal or industrial environments.
However, it is very important that the water rinse is made
with very low velocity water stream to avoid damaging
the fin edges. Periodic cleaning as described below is
recommended.
34
CAUTION
!
PERSONAL INJURY AND UNIT DAMAGE
HAZARD
Failure to follow this caution may result in personal
injury or equipment damage.
Only approved cleaning is recommended.
UNIT RELIABILTY 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.
Routine Cleaning of Indoor Coil Surfaces —
Periodic cleaning with Totaline® environmentally sound
coil cleaner is essential to extend the life of coils. This
cleaner is available from Carrier Replacement
Components Division as part number P902-0301 for one
gallon container, and part number P902-0305 for a 5
gallon container. It is recommended that all coils,
including standard aluminum, pre-coated, copper/copper
or E-coated coils be cleaned with the Totaline
environmentally sound coil cleaner as described below.
Coil cleaning should be part of the unit’s regularly
scheduled maintenance procedures to ensure long life of
the coil. Failure to clean the coils may result in reduced
durability in the environment.
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 12 to 18 inches (305 to 457
mm) and support with a rigid support. See Fig. 32.
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
nonflammable, 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 21/2 gallon garden sprayer
S Water rinse with low velocity spray nozzle
!
CAUTION
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 of 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 ot the coil,
use the Totaline environmentally sound coil cleaner as
described above.
Fig. 32 - Pivot and Support Top Cover
C10216
3. Remove all surface loaded fibers and dirt with a vacuum 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.
35
38AUQ
!
38AUQ
5. Mix Totaline environmentally sound coil cleaner in a
21/2 gallon garden sprayer according to the instructions included with the cleaner. The optimum solution
temperature is 100°F (38°C).
NOTE: Do NOT USE water in excess of 130°F (54°C),
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.
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 potential 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 saturation 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.
Service Parts
Listings of service parts for all units are available from the
Replacement Components Division’s Electronic Parts
Information Catalog (EPIC). EPIC is available at Totaline
stores, distributor and service office parts departments and
on-line at HVACPartners.com.
When entering EPIC, the full unit model number is
required. The model number includes the Design Revision
reference value (see Fig. 3, Position 13). The unit model
number is available from the unit’s information data plate.
(Do not use the “catalog number” when using EPIC. The
“catalog number” suppresses the Design Revision value;
failure to include Design Revision value may cause an
incorrect unit parts list to be displayed.) When using
EPIC, enter first four digits of the model number only.
Find appropriate model from sales packages listed. Be
sure to choose correct voltage and Design Revision.
EPIC is a product of RCD. To comment of the EPIC
program, use the “Comment” button inside the EPIC
program.
FASTENER TORQUE VALUES
Table 12 – Torque Values
Compressor mounting bolts
65--- 75 in–lbs
(734–847 N–cm)
Condenser fan motor mounting bolts
20 ±2 in–lbs
(226 ±23 N–cm)
Condenser fan hub setscrew
84 ±2 in–lbs
(949 ±136 N–cm)
High-flow service port
96 ±10 in–lbs
(1085 ±23 N–cm)
Schrader-type service check valve
2–3 in–lbs
(23–34 N–cm)
Compressor oil sightglass thread
330 ±31 in–lbs
(23–34 N–cm)
Compressor to Compressor rail torque
120–168 in–lbs
(1356–1898 N–cm)
Compressor rail to base pan torque
70 ±5 in–lbs
(791 ±57 N–cm)
36
PROBLEM
CAUSE
REMEDY
Compressor and
Outdoor Fan
Will Not Start.
Power failure.
Call power company.
Fuse blown or circuit breaker tripped.
Replace fuse or reset circuit breaker. Determine root cause.
Defective thermostat, contactor, transformer,
control relay, or capacitor.
Replace component.
Insufficient line voltage.
Determine cause and correct.
Incorrect or faulty wiring.
Check wiring diagram and rewire correctly.
Thermostat setting too high.
Lower thermostat setting below room temperature.
High pressure switch tripped.
See problem ‘‘Excessive head pressure.’’
Low pressure switch tripped.
Check system for leaks. Repair as necessary.
Freeze-up protection thermostat tripped.
See problem ‘‘Suction pressure too low.’’
Faulty wiring or loose connections in
compressor circuit.
Check wiring and repair or replace.
Compressor motor burned out, seized, or
internal overload open.
Determine cause. Replace compressor or allow enough time
for internal overload to cool and reset.
Defective run/start capacitor, overload, start relay.
Determine cause and replace compressor.
One leg of 3-phase power dead.
Replace fuse or reset circuit breaker. Determine cause.
Refrigerant overcharge or undercharge.
Recover refrigerant, evacuate system, and recharge to nameplate.
Defective compressor.
Replace and determine cause.
Insufficient line voltage.
Determine cause and correct.
Blocked outdoor coil or dirty air filter.
Determine cause and correct.
Defective run/start capacitor, overload, or start relay.
Determine cause and replace.
Defective thermostat.
Replace thermostat.
Faulty outdoor-fan (cooling) or indoor-fan
(heating) motor or capacitor.
Replace.
Restriction in refrigerant system.
Locate restriction and remove.
Dirty air filter.
Replace filter.
Unit undersized for load.
Decrease load or increase unit size.
Thermostat set too low (cooling).
Reset thermostat.
Low refrigerant charge.
Locate leak; repair and recharge.
Air in system.
Recover refrigerant, evacuate system, and recharge.
Compressor Will Not
Start But Outdoor
Fan Runs.
Compressor Cycles
(Other Than
Normally Satisfying
Thermostat).
Compressor Operates
Continuously.
Outdoor coil dirty or restricted.
Clean coil or remove restriction.
Compressor Makes
Excessive Noise.
Compressor rotating in the wrong direction.
Reverse the 3-phase power leads as described in Start-Up.
Excessive Head
Pressure.
Dirty outside air or return air filter (heating).
Replace filter.
Dirty outdoor coil (cooling).
Clean coil.
Refrigerant overcharged.
Recover excess refrigerant.
Air in system.
Recover refrigerant, evacuate system, and recharge.
Condensing air restricted or air short-cycling.
Determine cause and correct.
Low refrigerant charge.
Check for leaks; repair and recharge.
Compressor scroll plates defective.
Replace compressor.
Restriction in liquid tube.
Remove restriction.
High heat load.
Check for source and eliminate.
Compressor scroll plates defective.
Replace compressor.
Refrigerant overcharged.
Recover excess refrigerant.
Dirty air filter (cooling).
Replace filter.
Dirty or heavily iced outdoor coil (heating).
Clean outdoor coil. Check defrost cycle operation.
Low refrigerant charge.
Check for leaks; repair and recharge.
Metering device or low side restricted.
Remove source of restriction.
Insufficient indoor airflow (cooling mode).
Increase air quantity. Check filter and replace if necessary.
Temperature too low in conditioned area.
Reset thermostat.
Field-installed filter drier restricted.
Replace.
Outdoor ambient below 25°F (cooling).
Install low--- ambient kit.
Outdoor fan motor(s) not operating (heating).
Check fan motor operation.
Head Pressure
Too Low.
Excessive Suction
Pressure.
Suction Pressure
Too Low.
37
38AUQ
TROUBLESHOOTING
APPENDIX A
S Do not install a suction-line filter drier in liquid-line.
S POE oils absorb moisture rapidly. Do not expose oil to
atmosphere.
AIR CONDITIONER AND HEAT PUMP
WITH PURON® — QUICK REFERENCE
GUIDE
S POE oils may cause damage to certain plastics and
roofing materials.
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 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 Puron® refrigerant cylinders are rose colored.
S Do not use an R-22 TXV.
38AUQ
S Recovery cylinder service pressure rating must be 400
psig, DOT 4BA400 or DOT BW400.
S If indoor unit is equipped with a TXV, it must be
changed to a Puron® TXV.
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 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 Manifold sets should be 700 psig high side and 180 psig
low side with 550 psig low-side retard.
S Always replace filter drier after opening system for
service.
S Use hoses with 700 psig service pressure rating.
S Leak detectors should be designed to detect HFC
refrigerant.
S Do not vent Puron® into the atmosphere.
S Puron®, as with other HFCs, is only compatible with
POE oils.
S Do not use capillary tube coils.
S Vacuum pumps will not remove moisture from oil.
S All Puron® heat pumps must have indoor TXV.
S Use only factory specified liquid-line filter driers with
rated working pressures greater than 600 psig.
S Do not leave Puron® suction line driers in place for
more than 72 hours.
S Observe all warnings, cautions, and bold text.
APPENDIX B
WIRING DIAGRAM LIST
38AUQ
Size
*16
*25
Electrical Characteristics
Diagram Number
208/230-3-60
Power: 38AU500571
Control: 38AU500890
460-3-60
Power: 38AU500572
Control: 38AU500890
575-3-60
Power: 38AU500573
Control: 38AU500890
208/230-3-60
Power: 38AU500172
Control: 38AU500890
460-3-60
Power: 38AU500173
Control: 38AU500890
575-3-60
Power: 38AU500174
Control: 38AU500890
38
APPENDIX C
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. 32 and
33) 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 - 20_F (-- 28_C).
Wind baffles are required to prevent wind cross currents
from causing abnormally low condensing temperatures.
S Use 20-- gauge sheet metal to fabricate wind baffles (see
Fig. 35 and Table 13) and mounting brackets (see Fig.
36).
NOTE: Mounting brackets are for use on 15 ton model
units only.
S Install the wind baffles as show in Fig. 37, for 15 ton
units and Fig. 38, for 20 ton units .
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 100_F (38_C)
at higher outdoor ambient temperature and 80_F (27_C) 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 42_F +/-5_F, close 57_F +/-- 5_F (open 5.5_C +/-- 2.8_C, close
13.9_C +/-- 2.8_C).
Troubleshooting —
OBSERVATION
POSSIBLE REMEDY
Fans won’t 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 60_F
(16_C) outdoor ambient.
Normal operation
Cooling --- Center outdoor
fans (OFM2, OFM4) not on
above approximately 60_F
(16_C) 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 nameplate FLA
Normal operation
Up to 30% higher A at partial speed
at low ambient
38AUQ
Low Ambient Option — Factory Installed
Speed Control Sensor Resistance —
TEMPERATURE
To override the speed control for full fan speed operation
during service or maintenance, either:
a. remove sensor and place in hot water >120_F
(>49_C), or
b. rewire to bypass control by connecting speed
control input and output power wires.
39
RESISTANCE
_F +/---2_F_
_C +/---1C
Ohms, nominal
--- 22
--- 30
88350
--- 4
--- 20
48485
14
--- 10
27650
32
0
16325
50
10
9950
68
20
6245
77
25
5000
86
30
4028
104
40
2663
122
50
1801
140
60
1244
158
70
876
Motormaster Sensor Must be positioned
on Vapor Stub
(Fourth from Top)
38AUQ
Motormaster Sensor Must be positioned
on Vapor Stub
(Fourth from Top)
C10795
Fig. 33 - Motormaster Sensor Location:
38AUQ*16
Fig. 34 - Motormaster Sensor Location:
38AUQ**25
Table 13 – Wind Baffle Dimension
DIMENSIONS --- INCHES
UNIT
38AUQ*16
38SUQ*25
BAFFLE
A
B
C
D
E
F
G
H
J
LEFT SIDE
19 3/4
20 1/2
21 1/4
43 1/8
8 3 /8
18
27 1/4
40
---
BACK
80 1/4
81
81 3/4
43 1/8
8 3 /8
18
27 1/4
40
---
RIGHT SIDE
38 3/4
39 1/2
40 1/4
43 1/8
8 3 /8
18
27 1/4
40
---
FRONT
34 1/8
34 7/8
35 5/8
43 1/8
6 7 /8
16 1/2
25 3/4
38 1/2
---
LEFT SIDE
32 7/8
33 5/8
34 3/8
43 1/8
4 1 /4
13 1/4
22 1/4
31 1/4
40 1/4
BACK
47 3/4
48 1/2
49 1/4
43 1/8
4 1 /4
13 1/4
22 1/4
31 1/4
40 1/4
61 7/
62 5/
RIGHT SIDE
FRONT
61
1/
20
1/
8
8
20 7/
8
8
21 5/
8
43
1/
8
43
1/
8
3
3/
8
3
3/
4
12
3/
4
12
3/
4
21
3/
4
21
3/
4
30
3/
4
30
3/
4
4
39 3/4
39 3/4
DIMENSIONS --- MM
UNIT
38AUQ*16
38AUQ*16
BAFFLE
A
B
C
D
E
F
G
H
J
LEFT SIDE
501
520
539
1095
212
457
694
1015
---
BACK
2037
2056
2075
1095
212
457
694
1015
---
RIGHT SIDE
983
1002
1021
1095
212
457
694
1015
---
FRONT
866
885
904
1095
174
419
656
977
---
LEFT SIDE
834
853
872
1095
108
337
565
794
1022
BACK
1214
1233
1252
1095
108
337
565
794
1022
RIGHT SIDE
1551
1570
1589
1095
95
324
552
781
1010
FRONT
510
530
549
1095
95
324
552
781
1010
40
C10796
41
Fig. 35 -- Wind Baffles -- Fabrication
38AUQ
C10363
42
Fig. 36 -- 15 Ton Wind Baffle Brackets -- Fabrication
38AUQ
C10366
43
LEFT
RIGHT
Fig. 37 -- Wind Baffle Installation — 15 Ton Units
FRONT
TOP BRACKETS
38AUQ
BACK
BOTTOM
BRACKET
C10367
44
LEFT
RIGHT
Fig. 38 -- Wind Baffle Installation — 20 Ton Units
FRONT
38AUQ
BACK
C10368
45
38AUQ
38AUQ
Copyright 2010 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231
Printed in U.S.A.
Edition Date: 08/10
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
46
Catalog No: 38AUQ---03SI
Replaces: New
START UP CHECKLIST
I. PRELIMINARY INFORMATION
OUTDOOR: MODEL NO.
INDOOR:
SERIAL NO.
AIRHANDLER MANUFACTURER
MODEL NO.
SERIAL NO.
ADDITIONAL ACCESSORIES
II. PRE-START-UP
OUTDOOR UNIT
IS THERE ANY SHIPPING DAMAGE?
(Y/N)
WILL THIS DAMAGE PREVENT UNIT START-UP?
(Y/N)
CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT?
HAS THE GROUND WIRE BEEN CONNECTED?
38AUQ
IF SO, WHERE:
(Y/N)
(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?
HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS?
(Y/N)
(Y/N)
INDOOR UNIT
HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE?
ARE PROPER AIR FILTERS IN PLACE?
(Y/N)
(Y/N)
HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT?
DO THE FAN BELTS HAVE PROPER TENSION?
(Y/N)
(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?
HAVE SUCTION SERVICE VALVES BEEN OPENED?
(Y/N)
(Y/N)
47
CHECK VOLTAGE IMBALANCE
LINE-TO-LINE VOLTS:
AB
V
AC
V
(AB + AC + BC)/3 = AVERAGE VOLTAGE =
BC
V
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.
38AUQ
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:
Copyright 2010 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231
Printed in U.S.A.
Edition Date: 08/10
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
48
Catalog No: 38AUQ---03SI
Replaces: New