advertisement
GEMINI
TM
38AQ007
38ARQ008,012
38AQS016
Split System Heat Pumps
50/60 Hz
Installation, Start-Up and Service Instructions
CONTENTS
SAFETY CONSIDERATIONS ......................
Page
1
INSTALLATION ................................
General ..........................................
1-17 l
Step 1 -- Complete Pre-lnstallation Checks ......
1
Step 2 -- Rig and Mount Unit .....................
1
Step 3 -- Complete Refrigerant Piping
Connections ..................................
10
Step 4 -- Complete Electrical Connections ......
11
PRE-START-UP ...............................
START-UP ....................................
18, 19
19-21
SEQUENCE OF OPERATION .................
SERVICE .....................................
TROUBLESHOOTING .........................
START-UP CHECKLIST ..................
21,22
22-27
28, 29
CL-I, CL-2
SAFETY CONSIDERATIONS
Installing, stalling up, and servicing air-conditioning equipment can be hazardous due to system pressures, electric;d components, and equipment location (roofs, elevated structures, etc.).
Only tnuned, qualified installers and service mechanics should install, start-up, and service this equipment.
Untrained pel_onnel can perforru basic maintenance functions such as cleaning coils. All other operations should be performed by trained service pel_onnel.
When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment.
Follow all safety codes.
Wear safety glasses and work gloves.
Keep quenching cloth and fire extinguisher nem_y when brazing.
Use care in handling, rigging, and setting bulky equipment.
Before installing or servicing system, ¢flways turn off main power to system and inst_fll lockout tag on disconnect.
There may be more than one disconnect switch. Electric_d shock can cause personal injury.
INSTALLATION
General -The split systeln heat pump units described in this book should only be used with fire 40RMQ indoor packaged air handler sections.
Step 1 -Complete Pre-lnstallation Checks
UNCRATE UNITRemove 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 claim with shipping company if shipment is damaged or incomplete.
CONSIDER SYSTEM REQUIREMENTS
• Consult local building codes and National Electrical
Code (NEC, U.S.A.) for special installation requirements.
• Allow sufficient space for airflow clearance, wiring, refi'igerant piping, and servicing unit. See Fig. 1-3 for unit dimensions. Figure 4 shows typical component locations for 38AQS016 units.
• Locate unit so that outdoor coil airflow is unrestricted on all sides and above.
• Unit may be mounted on a level pad directly on the base channels or mounted on raised pads at support points.
See Tables IA-ID for unit operating weights.
Step 2 -- Rig and Mount Unit
Be sure unit panels are securely in place prior to rigging.
Be cgueful rigging, handling, and installing unit. Improper unit location can cause system malfunction and material damage. Inspect base rails for any shipping damage and make sum they are fastened securely to unit before rigging.
RIGGING -- These units are designed for overhead rigging.
Refer to rigging label for preferred rigging method. Spreader bars am not required if top crating is left on unit. All panels must be in place when rigging. As lin-ther protection for coil faces, plywood sheets may be placed against sides of unit, behind cables. Run cables to a centrtd suspension point so that angle from the horizontal is not less than 45 degrees. Raise and set unit down careliflly.
If it is necessary to roll the unit into position, mount the unit on field-supplied rails placed lengthwise under the unit using a minimum of 3 rollers. Apply force to the rails, not the unit. ff the unit is to be skidded into position, place it on a large pad and di'ag it by the pad. Do not apply any force to fire unit.
Raise from above to lift unit from the mils or pad when unit is in final position.
After unit in position, remove all shipping materials and top crating.
LOCATE UNITFor service access and unrestricted airflow, provide clearance on each end and side of unit. Position unit so that there is unrestricted airflow above unit.
NOTE: Before mounting unit, remove holddown brackets and release skid.
If conditions or local codes require unit to be fastened to pad, use the mounting holes in the base rails.
MOUNT UNIT -The unit may be mounted on a solid, level concrete pad, on accessory mounting legs, or on field-supplied raised supports at each mounting position.
(Note that mounting hardware is field supplied.)
Bolt unit securely to pad or supports after unit is in position and is level. Be sure to mount unit level to ensure proper oil return to compressors.
Mounting holes on unit can be used to secure unit to vibration isolators, if required.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 111 Catalog No. 533-80118 Printed in U.S,A, 38A-19SI Pg 1 9-04 Replaces: 38A-16SI
19 3/8
FRONT
4 PLACES
BOTTOM
B CONTROL BOX f
\
_
35 /
Line & Low
Voltage Wiring
Entrances _
5-3
D
2 / 1/2 1-;/2 t2-1/8
@ 9-3/4t
rTTTT_TTTT
J
2-1/2
4-1/4
REAR
11/2
1-1/2
38-1/2
33
35 i iii
33
TOP FRONT
NOTES:
1, All dimensions are in inches,
2, Recommended clearance for proper airflow (local codes or jurisdictions may prevail):
Top -- 60 in,
Sides -- 24 in, on 3 sides; one side may have 6-in. clearance.
(Control box side should have
24qn, clearance for service access.)
3. Corner Weights (Ib): A = 86
B =84
C=92
D=90
Fig. 1 -- 38AQ007 Unit Dimensions
1-1/2
38-1/2
CORNER _ COIL IlXll
OUTDOORCOIL COMPRESSOR
ACCESSPANEL
11627
[4578]
REARVIEW
COIL
ACCESS
TOP VIEW
//
CORNER "Z
ELECTRICAL
LOCATION
CONTROL
LOCATION
(SEE CHART FOR SIZE)
CONNECTION
{SEE CHART FOR SIZE)
OUTDOORCOIL i _
5825
[2293]
OUTLET
2268
[8983
(3 SIDESONLY)
LEFT SIDE VIEW
111.7
E440]
FIELD
ENTRYSERVICEPORT
6456
[2542]
15093
[5942]
FRONTVIEW
SERVICE VALVE CONNECTIONS
Unit
38ARQO08
38ARQ012
Vapor
1V 8
13/8
Liquid
V2
V2 t_
/
Center of Gravity,
Direction of airflow,
Dimensions in [ ] are in inches.
NOTES:
1.
Minimum clearance (local codes or jurisdiction may prevail): a.
Bottom to combustible surfaces: 0 inches.
b, Outdoor coil, for proper airflow: 36 inches one side, 12 inches the other. The side getting the greater clearance is optional.
c.
Overhead: 60 inches, to assure proper outdoor fan operation.
d.
Between units: Control box side, 42 inches per NEC.
e.
Between unit and ungrounded surfaces: Control box side, 36 inches per NEC.
f, Between unit and block or concrete walls and other grounded surfaces, control box side, 42 inches per NEC.
2.
With exception of the clearance for the outdoor coil as stated in Note 1B, a removable fence or barricade requires no clearance,
3.
Units may be installed on combustible floors made from wood or Class A, B or C roof covering material,
OUTDOOR COIL ACCESS
PANEL
872
[34
RIGHT SIDE VIEW
UNIT
38ARQ008
38ARQ012
ALUMINUM COIL COPPER COILS
ELECTRICAL
CHARACTERISTICS
Std.
Unit
Wt.
Corner Corner Corner Corner
W X Y Z
Center of
Gravity
[mm (in.)]
Std.
Unit
Wt.
Corner Corner Corner Corner
W X Y Z
Center of
Gravity
[mm (in,)]
208/230-3-60, 460-3-60
Ib kg Ib kg Ib kg Ib kg Ib kg
464210120541426410849
X Y Ib kg Ib kg Ib kg Ib kg Ib kg
94 43
812.8
[32,00]
660,4
[26,00] 58525613561 173791446511351
889.0
666,8
91 42 [35,00] [26,25] 60727513059203921667510849
X Y
850,9 635.0
[33.50] [25.00]
927,1 641.4
[36.50] [25.25]
Fig. 238ARQO08,012 Unit Dimensions
REHOVASLE
L
LJ
1 5/8"
ODM VAPOR t/2 ° DIA.
(4) MTG. HOLES
{13 meO
--(972
38 1/4" mm)--_
243
2
158
(72)
26 11116"
(678 mm)
_1_
(S?
u)
4
1
158
(72}
38AQS016
3
244
(111)
WEIGHT DISTRIBUTION
UNIT Total
38AQS Operating
Weight
WEIGHT -- Ib (kg)
Support Point
1 2 3
016
803
(364)
4
158 243 244 158
(72) (110) (111) (72)
5°-9 311G*
(1757 r_)
BETWEEN ROUNTI_ HOLES
(1016 ram)
BETWEEN MOUNTING HOLES
SEE DETAIL "A" FOR
HOUNTIN6LEG5 ACCESSORY
2*_7°
(1118 mm)
(51 m) K,0.
HAIH PONER 5bPPLY m
OUTDOOR
/
COIL (1 81DEU)
8
• 13"
2 -41- 0
(732 N) IS"
2"-3
(710 m)
CONTROLPOWER
(12 ram)
0'
3"i_°
(916 m_
3"-_ Z"
B
(1013 mm)
(O_ALL)
4
(171 mm} r 0' -2*
¥
(5t
I 3" DIA. K.O.
(SUCTION LINE)
4
(44 ram)
1 1" DIA* K,O.
(LIGUID LINE}
(32 ram)
END VIEW
Fig. 3 --38AQS016 Unit Dimensions
NOTE: Recommended service clearances are as follows (local codes or jurisdictions may prevail):
Side (compressor) --31/2 ft (1067 ram)
Side (opposite compressor) -- 3 ft (914 mm)
Ends-2 ft (616 mm)
Top -- 5 ft (1524 mm)
1 2 3 4 5 6 7 8 9 10 11 12
28
16
26
© ©
25 24 23 22 21 20
1 -Defrost Board/Time Guard II Control
2Fuse
3 -Fan No. 1
4 -Compressor Lockout Device (CLO)
5 -Outdoor-Fan Relay
6 -Outdoor-Fan Contactor
7 -Compressor Contactor
8 -Fan Motor Capacitors
9 -Circuit Breaker
10 -Fan No. 2
Fig. 4--
LEGEND
11 -Power Terminal Block
12 -Control Terminal Block
13 -Compressor Lockout (CLO2 for Crankcase Heater)
14 -Control Relay (CR3)
15 -Liquid Line Solenoid
16 -Control Relay (CR2)
17 -No Dump Relay (NDR)
18 -Oil Pressure Switch
19 -Fusible Plug (hidden)
20 -High-Pressure Switch
Component Locations -- 38AQS016 Shown
21Compressor
22 -Capacity Control Solenoid
23 -Filter Drier
24Muffler
25 -Oil Solenoid
26 -Reversing Valve
27-
28-
Accumulator
Coil
14
15
Table 1APhysical Data38AQ007, 38ARQ008,012, 38AQS016 Units60 Hz English
UNIT
NOMINAL CAPACITY (tons)
OPERATING WEIGHTS (Ib)
Aluminum-Fin Coils (standard)
REFRIGERANT*
Operating Charge, Typical (Ib)'l"
Shipping Charge (Ib)
COMPRESSOR
Qty._Model
Oil Charge (oz)
No. Cylinders
Speed (rpm)
OUTDOOR FANS
Qty...Rpm
Diameter (in.)
Nominal Hp
Nominal Airflow (cfm total)
Watts (total)
OUTDOOR COILS (Oty)
Face Area (sq ft total)
Rows...Fins/in.
Storage Capacity (Ib)**
CONTROLS
Pressurestat Settings (psig)
High Pressure
Open
Close
Low Pressure
Open
Close
PIPING CONNECTIONS (in. ODM)
Vapor
Liquid
38AQ007
6
20
1
1 ...1100
26
3/4
6300
750
1
24
2...18
17.3
I
I
I
I
I
38ARQ008
7.5
565
20
9
Scroll
1""ZR-94
N/A
3500
I
I
I
2...1100
22
'/4
6500
570
2
29.2
2...17
34.2
I
I
I 38AR0012
*Unit is factory supplied with holding charge only.
tTypical operating charge with 25 ft of interconnecting pipe.
**Storage capacity of condenser coil with 80% full of liquid at 95 R
1-tEquipped with an electric solenoid unloader, capacity steps 100% and 67%.
I10
R-22
607
22
9
110
I
I
I
I
I 38AOS016
15
37
3
Semi-hermetic reciprocating
1...06DF537tl-128
6
1750
2...1075
26
'/2
11,OO0
1460
1
29.2
3...15
40.1
Table 1 B -- Physical Data -- 38AQ007, 38ARQ008,012, 38AQS016 Units -- 60 Hz Sl
UNIT
NOMINAL CAPACITY (kW)
OPERATING WEIGHTS (kg)
Aluminum-Fin Coils (standard)
REFRIGERANT*
Operating Charge, Typical (kg)l"
Shipping Charge (kg)
COMPRESSOR
Qty._Model
Oil Charge (L)
No. Cylinders
Speed (r/s)
OUTDOOR FANS
Qty...r/s
Diameter (mm)
Nominal kW
Nominal Airflow (L/s total)
Watts (total)
OUTDOOR COILS (Qty)
Face Area (sq m total)
Rows...Fins/m
Storage Capacity (kg)**
CONTROLS
Pressurestat Settings (kPag)
High Pressure
Open
Close
Low Pressure
Open
Close
PIPING CONNECTIONS (in. ODM)
Vapor
Liquid
38AQ007
21.1
9
.5
1...18
660
.56
3000
750
1
2.2
2,..708
7.9
I
I
I
I
I
38ARQ008
26.4
256
9
4.1
Scroll
1""ZR-94
N/A
58
I
I
I
2,,,18
560
.19
3070
570
2
2.7
2.,,670
15.5
I
I
I 38ARQ012
R-22
2950_+ 70
*Unit is factory supplied with holding charge only.
1-Typical operating charge with 7.6 m of interconnecting pipe.
**Storage capacity of condenser coil with 80% full of liquid at 36 C.
1-1-Equipped with an electric solenoid unloader, capacity steps 100% and 67%.
35.1
275
10
4.1
3.3
I
I
I
I
I
I 38AOS016
52.7
17
1.3
Semi-hermetic reciprocating
1...06DF5371-1-3.8
6
29
2,,,18
660
.37
5190
1460
1
2.7
3...590
18.2
Table lC -- Physical Data -- 38ARQ008,012 and 38AQS016 Units -- 50 Hz English
UNIT 38ARQ008 38ARQ012 I 38AQS016
OPERATING WEIGHTS (Ib)
NOMINAL
Coils (standard)
Copper-Fin Coils (optional)
REFRIGERANT*
Operating Charge, Typical (Ib)t
Shipping Charge (Ib)
COMPRESSOR
Qty._Model
Oil Charge (oz)
No. Cylinders
Speed (rpm)
OUTDOOR FANS
Qty...Rpm
Diameter (in.)
Nominal Hp
Nominal Airflow (cfm total)
OUTDOOR COILS (Qty)
Face Area (sq ft total)
Rows...Fins/in.
Storage Capacity (Ib)**
CONTROLS
Pressurestat Settings (psig)
High Pressure
Open
Close
Low Pressure
Open
Close
PIPING CONNECTIONS (in. ODM)
Vapor
Liquid
6.3
565
20
9
1...ZR_94
90
2900
I
I
Scroll
I
2...920
22
1/4
5800
2
29.2
2...17
34.2
607
22
9
| 1...ZR125
428 _+10
320 _+20
22_+5
110
2900
R-22
I
I
I
11/8
1/2
7_+3 13/8
1/2
I
*Unit is factory supplied with holding charge only.
tTypical operating charge with 25 ft of interconnecting pipe.
**Storage capacity of condenser coil with 80% full of liquid at 95 R
1-tEquipped with an electric solenoid unloader, capacity steps 100% and 67%.
945
37
3
Semi-hermetic reciprocating
1...06DF5371-t
1450
2...900
28
1/2
7400
1
29.2
3...15
40.1
395 _+20
295 _+20
22_+5
5/8
Table 1D -- Physical Data -- 38ARQ008,012 and 38AQS016 Units -- 50 Hz Sl
UNIT
NOMINAL CAPACITY (kW)
OPERATING WEIGHTS (kg)
Aluminum-Fin Coils (standard)
Copper-Fin Coils (optional)
REFRIGERANT*
Operating Charge, Typical (kg)t
Shipping Charge (kg)
COMPRESSOR
Qty._Model
Oil Charge (L)
No. Cylinders
Speed (r/s)
OUTDOOR FANS
Qty...r/s
Diameter (ram)
Nominal kW
Nominal Airflow (L/s total)
OUTDOOR COILS (Qty)
Face Area (sq m total)
Rows...Fins/m
Storage Capacity (kg)**
CONTROLS
Pressurestat Settings (kPag)
High Pressure
Open
Close
Low Pressure
Open
Close
PIPING CONNECTIONS (in. ODM)
Vapor
Liquid
38ARQ008
22.1
210
256
9
4.1
1...ZR
2.7-
58
94
Scroll
/
2...15
560
.19
2740
2
I
I
I
2.7
2...670
15.5
2950_+
38ARQ012
29.2
230
275
10
4.1
1...ZR125
70
2200 _+138
48 _+20
150 _+35
3.3
58
R-22
I
I
I
I
11/8
1/2
13/8
1/2
I
I
*Unit is factory supplied with holding charge only.
tTypical operating charge with 7.6 m of interconnecting pipe.
**Storage capacity of condenser coil with 80% full of liquid at 36 C.
1-tEquipped with an electric solenoid unloader, capacity steps 100% and 67%.
38AOS016
43.9
365
430
17
1.3
Semi-hermetic reciprocating
1...06DF537tt
29
2...15
660
.37
3500
1
2.7
3...590
18.2
2725_+135
2035 _+135
48 _+20
150 _+35
1s/8
5/8
Step 3 -Complete Refrigerant Piping ConnectionsRefi'igerant lines nmst be cm'efully designed and constructed to ensure equipment reliability and efficiency.
Line length, pressure drop, compressor oil leturn, and vertical separation ;u'e several of the design criteria that must be evaluatedi See Table 2.
IMPORTANT: underground.
Do not bury refrigerant piping
IMPORTANT: Piping must be properly sized and ] installed for the system to operate efficiently.
I
CHECK VERTICAL SEPARATION -- If there is any vertic_d separation between the indoor and outdoor units, check to ensure that the separation is within allowable limits. Relocate equipment if necesstuy.
See Table 3.
REFRIGERANT LINE SIZING -Consider the length of the piping required between the outdoor and indoor units. The maximum _dlowable line length is 100 ft (30.5 m). See Table 2.
Refiigerant vapor piping should be insulated.
I
]
I
IMPORTANT: A refrigerant receiver is not provided ] with the unit. Do not install a receiver.
I
IMPORTANT: For 38AR0008,012
Maximum lift is 60 ft (18 m).
applications with ] liquid lift greater than 20 ft (6 m), use 5/s-in. liquid line.
I
Table 2 -Refrigerant Piping Sizes
OUTDOOR
UNIT
38AQ007
38ARQ008
38ARQ012
38AQS016
1_
3/8
V2
5/8
L
LENGTH OF PIPING ft (m)
0-25
(0-7,5)
26-60
(7,8-18.0)
61-100
(18.3-30)
V
Line Size (in.
OD)
L V L V
1 l&
1 l&
13/8
18&
5/8
1_
1_
3/4
1 l&
1 l&
13&
18&
5&
1_
1_
3/4
11½
1 l&
13&
18&
MAXIMUM
LIQUID
LINE*
(in. OD)
%
%
%
3/4
LEGEND
L -Liquid Line
V -Vapor Line
*if there is a vertical separation between indoor and outdoor units, see
Table 3 -- Maximum Vertical Separation.
NOTE: Approximately 4 elbows assumed in determining pipe sizes.
Maximum length of interconnecting piping is 100 ft (30.5
m).
Table 3 -- Maximum Vertical Separation*
UNIT 38 UNIT 40RMQ
AQ007
ARQ008
ARQ012
AQS016
008
008
012
016
*Vertical distance between indoor and outdoor units.
DISTANCE FT (M)
Unit 38
Above Unit 40RMQ
50 (15.2)
60 (18.3)
60 (18.3)
80 (24.4)
INSTALL FILTER DRIER(S) AND MOISTURE INDICA-
TOR(S)Every unit should have a filter drier and liquidmoisture indicator (sight glass).
In some applications, depending on space and convenience requirements, it may be desirable to install 2 tilter driers and sight glasses.
One filter drier and sight glass may be installed at A locations in Fig. 5. If desired, 2 filter driers and sight glasses may be installed at
13 locations in Fig. 5.
Select the filter drier for maximum unit capacity and minimum pressure drop.
Complete the refrigerant piping fi'om indoor unit to outdoor unit before opening the liquid and vapor lines at the outdoor unit.
Refer to Table 4 for specific filter driers.
LIQUID LINE PIPING PROCEDURE -Pipe the system liquid line as follows:
Unit is pressurized with a holding charge of refi'igerant.
Recover R-22 holding charge before removing runaround liquid piping loop. Failure to recover holding charge before removing piping loop could result in equipment &_mage and sevele pel.sonal injury.
1. Open service valves in sequence: a.
Discharge service valve on compressoc b.
Vapor service valve on compressor.
c.
Liquid line valve.
2.
Remove l/4-in, flare cap from liquid vCdve Schmder port.
3.
Attach refi'igerant recovery device and recover holding charge.
4.
Remove runaround loop (38AQS016 only).
5.
Connect system liquid line from liquid connection of outdoor unit (38AQ, 38ARQ, 38AQS) to indoor unit
(40RMQ) liquid line connections.
Select proper fieldsupplied bi-flow filter driers and install in the liquid line.
See Fig. 5. Install a field-supplied liquid moisture indicator between the filter drier(s) and the liquid connections on the indoor unit. Braze or silver ¢flloy solder all connections.
Pass nitrogen or other inert gas through piping while making connections to prevent formation of copper oxide.
(Copper oxides me extremely active under high temperature and pressure.
Failure to prevent collection of copper oxides may lesult in system component failures.)
LIQUID LINE SOLENOID VALVE -Addition of a liquid solenoid valve (LLSV) is required (except for 38AQS016 units that aheady have LLSV factory-installed).
The LLSV must be a bi-flow type suited for use in heat pump systems.
Refer to
Table 4 for specific refrigerant specialty p_uts. Wire the solenoid valve in pargfllel with the complessor contactor coil.
The LLSV must be installed at the outdoor unit with the flow mTOW pointed toward the outdoor unit (in-flow direction for the Heating mode).
INDOOR
COIL CKT 2
¢
AIRFLOW
INDOOR
COIL CKT 1
TXV
SENSING
BULB
MIN 10
EQUALIZER LINE
TXV
CAPACITY CONTROL
SOLENOID VALVE
SIGHT GLASS
A LOCATION
FILTER DRIER
A LOCATION
,FILTER
CRIERS
B LOCATION
DIAMS
MIN
INDOOR
COIL VAPOR AND LIQUID LINE
PIPING FOR SPLWFACE COIL
LEGEND
TXV -Thermostatic Expansion Valve
Fig. 5 -Location of Sight Glass(es) and Filter Driers
10
Table 4 -- Refrigerant Specialties Part Numbers
UNIT LIQUID LINE
SIZE
38AQ007
38ARQ008
38ARQ012
1/2"
5/8"
3/8"
1/2"
1/2"
38AQS016 5/8......
3/4......
*A filter drier is shipped loose with the 38AQ007.
1-Bushings required.
**Factory Installed.
LIQUID LINE
SOLENOID VALVE (LLSV)
200RB GS-1928 5T4
200RB GS-1929 5T5
200RB GS-1928 5T41-
200RB GS-1928 5T4
200RB GS-1928 5T4
LLSV COIL
AMG-24/50-60
AMG-24/50-60
AMG-24/50-60
AMG-24/50-60
AMG-24/50-60
SIGHT GLASS
AMI-1TT4
AMI-1TT5
AMI-1TT3
AMI-1TT4
AMI-1TT4
AM I- 1TT5
AMI-1TT5
PROVIDE SAFETY RELIEF -- A lusible plug is located on the compressor crankcase or in the liquid line. See Fig. 6. Do not cap this plug. If local code requires additional safety devices, install them as directed.
Head Pressure Control (38AOS016 Only) -- Fan cycling for head pressure control is a stan&ud offering but is functional in the cooling cycle only. Number 2 fan cycles as a function of liquid pressure. Fan cycling pressure switch cycles the fan off at 160 _+10 psig (1103 _+69 kPag) as pressure decreases and cycles back on at 255 _+10 psig (1758 _+69). Switch is automatically bypassed in heating cycle. Table 5 shows minimum outdoor air temperature for full cooling capacity without low ambient controls.
FUSIBLE PLUG
FILTER DRIER
P504-8083S
P504-8084S
P504-8164S
P504-8085S
P504-8085S
Qty 2
Qty 2
Table 6 -- Insulation for Vapor Line Exposed to Outdoor Conditions
LENGTH OF EXPOSED
VAPOR LINE* ft
10
25
35
50 m
3
8
11
15
INSULATION THICKNESS1in.
mm a/8
1/2
10
13 s/4 s/4
19
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) ef vapor line with 3/4 in. (19 mm) insulation is exposed to outdoor conditions.
1-Closed cell foam insulation with a thermal conductivity of: 0.28 Btu
• in./ft 2 • h • °F (0.04 W/m • °C).
Fig. 6 -- Location of Fusible Plug --
38AQS016 Unit
Table 5 -- Minimum Outdoor Air
Operating Temperature
UNIT
AQ
AQS
38
007
O08
ARQ --
012
016
%
COMPRESSOR
CAPACITY
10o
100
67
MINIMUM OUTDOOR
TEMP -- F (C)*
Standard Unit Head Pressure
Control1-
0 (-17.8)
35 (1.7)
35 (1.7)
23 (-5)
36 (2.2)
0 (-17.8)
-20 (-28.9)
-20 (-28.9)
-20 (-28.9)
-20 (-28.9)
*Applies to Cooling mode of operation only.
1-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.
VAPOR LINE PIPING PROCEDURE -- Connect system vapor line to the vapor line stub on the outdoor unit and the vapor stubs on the indoor unit. At the indoor unit, construct vapor piping branches as shown in Fig. 7 for good mixing of the refrigerant leaving the indoor coil during cooling. This will ensure proper TXV (thermostatic expansion valve) bulb sensing.
Where vapor line is exposed to outdoor air. line must be insulated. See Table 6 for insulation requirements.
TXV
BULB CAPILLARY
TUBES
TUBE DIAMETERS
40RMQ012 = 7/8" OD
40RMQ016 = 1 1/8" OD
40RMQ
UNIT
15" (381 mm)
MIN
_
10" (254 ram)
MIN
VAPORLINE
LEGEND
TXV -Thermostatic Expansion Valve
8" (208 mm)
MIN
Fig. 7 -- Vapor Line Branch Piping Details
Step 4 -- Complete Electrical Connections
POWER SUPPLY -- Electric_d ch_u'actedstics of available power supply must agree with nameplate rating. Supply voltage must be within tolerances shown in Table 7. Phase imbalance must not exceed 2%. Operation qfunit on improper
SUl)l)@ voltage or with excessive phase imbalance constituWs abuse and is not corered by Carrier warran O"
11
Perloc_fl connect
Provision power disconnect switchopen(off)isadvisable frombeingturned switch,luses, localrequilements.
WIRING- All powerwilingmustcomplywith applicable disconnect terminal through blockinside
UNBALANCED operate than2%.Usethefollowing
percentage hnbalance:
= 100x
max voltage deviation from average voltage average voltage
EXAMPLE: Supply voltage is 460-3-60.
AB = 452 v h
BC = 464 v
AC = 455 v
B ¢
@
3
Average Voltage = 452 + 464 + 455
Determine maximum deviation from average voltage:
(AB) 457 - 452 = 5 v
(BC) 464 - 457 = 7 v
(AC) 457 - 455 = 2 v
Maximum deviation is 7 v. Determine percentage of voltage imbahmce:
7
% Voltage hnbalance = 100 x
= 1.53%
This amount of phase imbalance is satisfactory as it is below the maximum allowable of 2%.
IMPORTANT: Contact your local electric utility company immediately if the supply voltage phase imbalance is more than 2%.
Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occm: This ground may consist of electrical wire connected to unit ground lug in control comp_utment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical
Code) (U.S.A.), ANSI/NFPA (American National Standards Institute/National Fire Protection Association)
(U.S.A.), and loc_d electric_d codes.
Failure to follow this w_u'ning could result in the installer being liable for personal injury of others.
IMPORTANT: Operation of unit on improper power ] supply voltage or with excessive phase imbahmce constitutes abuse and is not covered by Carrier warranty.
I
GENERAL WIRING NOTES (See Fig. 8-13)
I.
A crankcase heater is wired in the control circuit so it is always operable as long as power supply disconnect is on, even if any safety device is open or unit stop/stmt switch is off.
2.
The power-cimuit field supply disconnect should never be
open except when unit is being seia'iced or is to be down fi_r a prolonged period When operation is resumed, crunkcase heater should be eneqked fi_r 24 hours b@re start-up.
[_ s3_tem is to be shut down fi_r a prolonged
t)eiqod, it is recommended Nat the suction and dischaiig, e vah'es be closed m prevent an (_rcessive accumulation of re fiqgerant in the conq)ressor oil.
3.
Terminals for field power supply tue suitable for copper.
copper-clad Numinum, or aluminum conductors.
4.
Cturier recommends an indoor airflow switch (field supplied) be installed and interlocked with the outdoor unit. This prevents the outdoor unit fi_)m operating if indoor airflow Nils (broken Nn belt, etc.). Operafion of the compressor in vacuum can damage bearing surfaces.
Install indoor airflow switch in a convenient location at the indoor supply air duct and wire per Fig. 14.
CONTROL CIRCUIT WIRING -Control voltage is 24 v.
See unit label diagram for field-supplied wiring detNls. Route control wires through opening in unit end panel to connection in unit control box.
CONTROL TRANSFORMER WIRING -On multivoltage units, check the transformer primary wiring connections.
See
Fig. 9 or refer to unit label diagram.
For 38AO.ARO
Units -If unit will be operating at 400-3-50 power, remove the black wire (BLK) from the transformer primtuy connection labelled "460" and move it to the connection labelled "400".
See Fig. 9.
If unit will be operating at 208-3-60 power, remove black wire (BLK) from the transformer primtuy connection labelled
"230" and move it to the connection labelled "208". See Fig. 9.
For 38AQS Units -- Transformers no. 1 and 2 are wired for a
230-v unit. |fa 208/230-v unit is to be mn with a 208-v power supply, the transformers must be rewiled as follows:
1. Remove cap from red (208 v) wire.
2.
Remove cap from orange (230 v) spliced wile.
3.
Replace orange wire with red wile.
4.
Recap both wires.
IMPORTANT: BE CERTAIN UNUSED WIRES ARE ]
CAPPED.
Failure to do so may damage the transforlner.
I
Duplex 38AQS.ARQ
with 40RMQ024 or 40RMQ028 -In order to properly connect two heat pump condensing units to a single 40RMQ packaged air handler, it is necessary to add field-supplied Fan Coil Relay Board(s), P/N 33ZCRLYBRD.
Relay botud(s) no. 1 and no. 2 should be installed in the control box of condensing unit.
IMPORTANT: The common (COM) terminals from the fan coil relay board(s) must be connected to the 'C' terminal in condensing unit 'A'.
Route thermostat cable or equiwdent single leads of no. 18
AWG (American Wire Gage) colored wire from subbase terminals through conduit in unit to low-voltage connections as shown on unit wiring diagram and Fig. 12 and 13.
NOTE: For wire runs up to 50 ft, use no. 18 AWG insulated wire (35 C minimum).
For 51 to 75 ft, use no. 16 AWG insulated wire (35 C minimum).
For over 75 ft, use no. 14 AWG insulated wire (35 C minimum).
All wire huger than no. 18
AWG c_mnot be directly connected to the thermostat and will require a junction box and a splice at the thermostat.
12
Table 7 -- Electrical Data
UNIT
38
AQ007
FACTORY-INSTALLED
OPTION
NONE
NOMINAL VOLTAGE
(V-Ph-Hz)
208/230-3-60
460-3-60
575-3-60
ARQ008
ARQ012
NONE OR DISCONNECT
CONVENIENCE OUTLET
NONE OR DISCONNECT
CONVENIENCE OUTLET
NONE OR DISCONNECT
NONE OR DISCONNECT
CONVENIENCE OUTLET
NONE OR DISCONNECT
CONVENIENCE OUTLET
NONE OR DISCONNECT
CONVENIENCE OUTLET
NONE OR DISCONNECT
208/230-3-60
460-3-60
400-3-50
208/230-3-60
460-3-60
575-3-60
AQS016
NONE
NONE
LEGEND
FLA
LRA
--
--
Full Load Amps
Locked Rotor Amps
MCA -Minimum Circuit Amps
MOCP -Maximum Overcurrent Protection
NEC
RLA
-National Electrical Code (U.S.A. Standard)
-Rated Load Amps
400-3-50
208/230-3-60
460-3-60
575-3-60
230-3-50
400-3-50
*Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed limits.
360
187
414
518
198
342
VOLTAGE RANGE*
Min Max
187
414
517
187
418
360
187
418
523
253
506
633
254
506
440
254
506
632
440
253
528
660
264
457
COMPRESSOR
RLA
18.9
9.5
7.6
29.0
15.0
15.0
34.0
17.0
14.0
17.2
63.6
29.3
23.8
47.9
29.3
LRA
146
73
58
190
95
95
225
114
80
125
266
120
96
200
115
FAN MOTORS
FLA
5.1
2.6
1.2
1.5
0.7
0.7
1.5
0.7
0.7
0.7
4.3
2.3
1.8
3.5
3.5
19.8
21.9
19.8
45.0
50.0
23.0
25.0
18.0
POWER SUPPLY
MCA MOCP
28.7
45
14.5
10.7
39.0
43.8
20
15
60
60
70
30
30
25
30
30
30
60
20.0
22.9
87.5
40.7
33.0
66.9
43.0
25
30
125
60
50
100
60
NOTES:
1. The MCA and MOCP values are calculated in accordance with the
NEC, Article 440.
2.
Motor RLA and LRA values are established in accordance
Underwriters' Laboratories (UL), Standard 1995.
with
3. The 575-v units are UL Canada-listed only.
4.
Convenience outlet is available as factory-installed is 115-v, 1 ph, 60 Hz.
option only and
"[ DEFROSTr_T_V- _
q;ArCONTRO __ __
J
-BL 4
LEGEND
DF -Defrost Relay
LP/HP -Low- or High-Pressure Switch (Optional)
PS -Pressure Switch
RV -Reversing Valve
SEN -Outdoor Coil Temperature Sensor
TSTAT -Thermostat
Line Voltage Factory Wiring
Low Voltage Factory Wiring
Low Voltage Field Wiring
- Y
-
#'LP/HP
R i i_ i
i
I
_- i
_------4---BL-----_---i
L R
-¥ -(_
R C O Y W
COLOR CODE
BK Black
BL Blue
O
R
Orange
Red
W White
Y Yellow
I LW._____DEFROSTHEAT
_
--COMPRESSOR
-O----It---HEAT/COOL J
COMMON
24 VAC _--
NOTES:
1. All electrical work must be done in conformance with the
National Electrical Code (NFPA No. 70) and in conformance with local codes and authorities having jurisdiction.
2, For use with copper conductors only.
Not suitable for use on systems exceeding 150 volts to ground,
Fig. 8 -- Wiring Diagram -- 38AQ007 208/230-3-60 Units
13
_ I
!
I
460V TRAN CONFIG
!
i !
,
!
I
_{_ TRf, N
Fig. 9 -- Wiring Diagram -- 38ARQ008,012 -- Control Transformer
TO ELECTRIC
HEATER
ACCESSORY
IF EQUIPPED
THERMOSTAT
(3-
(3-
(3-
C)-
-q
@
(3-
C)-
I
I I
I r
CONNECTION
BOARD (TB)
C)
.C)
.C)
Q
G
-©
4Z)
Q
LEGEND
IFC -Indoor Fan Contactor
LLSV -Liquid Line Solenoid Valve
TB -Terminal Block
NOTES:
1. For thermostat and subbase part no. see price pages.
2, Use copper conductors only.
Fig. 10 -- Wiring Diagram -- 38ARQ008,012 230-3-60 Units
14
4ORMQ ELECTRIC
HEAT ACCESSORY
....
REMOVE
JUMPER
-J
THERMOSTAT
38AQS TERMINAl
TB2
BLOCK
40RMQ UNiT WIRING
]FM
L
EQUIP --
GND
HC
--
--
IFC --
IFM
NEC
TB
--
--
--
LEGEND
Equipment
Ground
Heater Contactor
Indoor Fan Contactor
Indoor Fan Motor
National Electrical Code (U.S.A.)
Terminal Block
Fig. 11 -- Wiring Diagram -- 38AQS016 Unit With Standard Thermostat and Electric Heat
15
TB1 o_lHCl_
BISCONNECT__P_OW_E_R _ _]| _ I c 4 HTR1 __?_UP_PL_y _ _HCI_
3-PhONLY
EQUIP
__-rr'_
GND I I I r j i i CIRCUlTBREAKER
(5 HPAND LARGER)
]
I ' %" IFC I
I II4 d_II_-BLK_ )IFM; 40RMQ024
TERMINALBLOCKTB1 _] -_@I_-BLK-_____j/ !
E
E
E
E
E
F;-
-WHT_]
--WHT
WIRINGEIELDPOWER
40RMQ
HEAT ACCESSORY
J
._/
E r_
E
I
I I
I I
I
I
UNITWIRING J
'
I
I
I
11
I -i
HEATPUMP"A"
TB2
[]
CA
I
, ,___
_ _ _.
I_
-
RELAY BOARD
/33ZORLYBRD/
[] /VALVE/q---
_1_1
TSTAT
I
I
1
I i i_i_
I
I
I
HEAT PUMP "B"
LEGEND
CR
EQUIP-
GND
-Control Relay (Field-Supplied)
Equipment
-Ground
HC
HTR
IFC
IFM
--
--
--
--
Heating Contactor
Electric Heater
Indoor-Fan
Indoor-Fan
Contactor
Motor
TB -Terminal Block
TSTAT -Thermostat
Factory Wiring
Field Control Wiring
NOTE: Use copper conductors only.
TB2
D
D
52}
[]
[]
[]
[]
[]
Fig. 12 -- Wiring Diagram -- Duplex 38ARQ012 With 40RMQ024 and Electric Heat
HI(COOL)
MED(HEAT)----_
I ILO-/' '
-I-
_1
I
16
DISCONNECT
TB1
_-I
P_OW_ERp_pL_y_IIL21_ I l--a
HCI_ HTR1
S-PhONLY 1---,
I
BREAKER
I I 5HPANDLARGER
I I 11 _____ _IFC _ -"
.ORMOO28
' _} - - PCfl_@-BLK-_€_ ),FM!
TERMINALTB1BLOCK
--
R-_
FIELD POWER
WIRING
_ _ _- _ _p__.___
_It_3)-BLK_
I UNIT WIRING
Y'_ 48RMQ
HEAT ACCESSORY
,
I
I
I
--4-
I_ I _
I
G_ -WHT
_ -_T_ x--I x
HEAT PUMP A
38AQSO16
I i I li I
II
II
I
TB2
[]
[]
RELAY BOARD
I g
(33ZCRLYBRD)
I
- - - _
_,'
' _ l i " '
G
, _
, ,I
_ i __I_LO_
FAN
(VALVE>
I
I _ !__q,,
J I
MED(REAT)--I--'
LI_ -
_ H'(O°°L/--I , -
/ ,--
TSTAT*
I
I
; ,_ i_
I
I
I r
I
[]
[]
[]
[]
G FAN --
B
t
_
[]
H'/C°°L>--I
I _
__: I--o I_LO--
MED(HEAT)--
/
LEGEND
CR
EQUIP-
GND
-Control Relay (Field-Supplied)
Equipment
-Ground
HC
HTR
IFC
IFM
--
--
--
--
Heating Contactor
Electric Heater
Indoor-Fan
Indoor-Fan
Contactor
Motor
TB -Terminal Block
TSTAT -Thermostat
Factory Wiring
Field Control Wiring
*Do not configure TSTAT for heat pump.
NOTE: Use copper conductors only.
HEAT PUMP B
38ARQO12
TB2
[]
[]
[]
[]
[]
[]
CR
Fig. 13 -- Wiring Diagram -- Duplex 38ARQ012 and 38AQS016 With 40RMQ028 and Electric Heat
CR
- -II- -
-I
I I
DB
[_-YEL _
SPLICE
I
I
I
I
I
I
1
L------I I-....
AFS
SPLICE
YEL
_ CR3 ,.i,
LEGEND
AFS -Airflow Switch (Sail Switch)
CR -Control Relay
DB -Defrost Board
--
....
Factory Wiring
Field Control Wiring
NOTES:
1. Locate YEL wire between [] and cut.
on DB and terminal 5 of CR3
2. Splice airflow switch (AFS) (field supplied) contact wires (field provided) to two ends of cut YEL wire as depicted.
Fig. 14 -- Typical Field Wiring for Airflow Switch --
38AQS016/40RMQ (Shown)
17
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 the system and provides a record of unit condition, application requirements, system information, and operation at initial start-up.
Do not attempt to sttut tile heat pump system, even momentmily, until the following steps have been completed. Compressor damage may result.
Preliminary Checks
1. Check all air handler and other equipment auxiliary components.
Consult manufacturer's instructions regmding any other equipment attached to unit. If unit has fieldinstalled accessories, be sine _dl are properly installed and correctly wiled.
If used, airflow switch must be properly installed. See Fig. 14 for typical field wiring.
2.
As shipped, compressor is held down by 4 bolts.
After unit is installed, loosen each bolt using locknut until flat washer or snubber (3/8 in.) can be moved with finger pressure.
Be sure complessor floats freely on the mounting springs and that upper flat washers can be moved with finger pressure.
See Fig.
15A and 15B for compressor mounting.
3.
Check tightness of all electrical connections.
4.
Ensme electrical power source agrees with nameplate rating.
5.
Turn on crankcase heater for 24 hours before starting the unit to be sine all refiigemnt is out of the oil. To energize crankcase heatel, perform the following steps: a.
Set the space thermostat system switch to OFF.
or adjust the temperature so there is no demand for cooling.
b.
Close the field disconnect.
c.
Leave the compressor circuit breaker off. The crankcase heater is now energized.
6.
Leak test the field lefrigemnt piping, connections and joints, and the indoor coil. To perform leak test, complete the following steps: a.
Pressurize refrigerant piping; do not exceed 150 psi.
b.
Using soap bubbles and/or an electronic leak detector, test refrigerant piping, connections and joints, and the indoor coil. See Fig. 16.
150 PSI MAX
DRY
NITROGEN
7.
c.
Check for leaks.
Evacuate and dehydiate entire refrigerant system by use of methods described in GTAC II, Module 4, System
Dehydiation.
38AQS016 only -- compressor oil level should be visible
in sight glass. Adjust the oil level as required.
No oil should be removed unless the crankcase heater has been energized for at least 24 hours.
See Start-Up section,
Preliminary Oil Charge.
NOTE: The 38AQ and 38ARQ units do not have a compressor oil level sight glass.
These units are factory chtu'ged with the required amount of oil.
If required, use the following oil for replacement:
For 38AQ007 use Zerol 150, part number tx)03-2001.
For 38ARQ008,012 use RCD part number P903-0101.
SELF-LOCKING
BOLT
-____
_
_ _SNUBBER WASHER
_ NEOPRENE
COMPRESSOR
Fig. 15A -Compressor Mounting --
38AQ007 and 38ARQ008,012 Units
FOOT
3/8"-16
LOCKNU_
m 03'X; 'IAGE
3/8"-16
BOLT
CARRIAGE
BOLT_
3/8" FLAT
_ 3/8"-16
LOCKNUT
' FOOT
COMPRESSOR
FOOT
COMPRESSOR
SPRING
1/2" FLAT
_SPACER
_f NUTS
SPRIN
WASHER_
FRONT VIEW
NUTS _WASHER
REAR VIEW
Fig. 15B -- Compressor Mounting --
38AQS016 Units
LIQUID
SOLENOID
LINE
VALVE
INDOOR
COIL
OUTDOOR
UNIT
Fig. 16 -Recommended
W
Process for Checking for Leaks
18
8. Backseat (open) compressor vapor and discharge valves.
Now close valves one turn to _dlowrefiigerant pressure to reach test gages.
Preliminary Charge
The 38ARQ008 and 38ARQ012 units contain a 9 lb
(4.1 kg) charge of refrigerant.
Add remainder of preliminary charge and allow pressure to equalize before starting compressoc Failure to do so WILL cause the compressor to oveltleat in a few minutes, possibly causing permanent compressor &_mage. The amount of refrigerant added
must be at least 80% of the operating charge listed in
the Physical Data table (Tables 1A-1D).
Before starting the unit, charge liquid refrigerant into the high side of the system through the liquid service valve. Allow high and low side pressures to equalize before stm-ting compressol: If pressures do not equalize readily, charge vapor on low side of system to assure charge in the evapomtol: Refer to
GTAC II, Module 5, Charging, Recovery.
Recycling, and Reclamation for liquid charging procedures.
Liquid Line Solenoid -To minimize refrigerant migration to the compressor during the heat pump OFF cycle, the
38AQ,ARQ unit must have a bi-flow liquid line solenoid v;dve
(field supplied).
The valve opens when the compressor is energized, and closes when the compressor is deenergized.
This reduces compressor flooded st_u-ts,thus significantly increasing compressor life.
Accumulator -qn_e unit accumulator controls the rate of liquid ret]igemnt to the compressor during heat pump operation.
The 38AQS accumulator features a unique method for returning oil to the compressor The oil return mechanism is external to the accumulatol: The mixture of oil and refrigerant is metered to the compressor by a brass orifice which is removable and cleanable.
The oil return mechanism also contains a solenoid valve that opens when the compressor is ON and closes when the compressor is OFF.
This keeps the liquid refrigerant stored in the accumulator from di'aining to the compressor during the heat pump OFF cycle, which further protects the compressor against flooded starts.
START-UP
2.
Turn off power to the unit, tag disconnect.
3.
Reverse any two of the unit power leads.
4.
Reapply power to the compressol: verily correct pressures.
The vapor and dischtuge pressure levels should now move to their norln¢fl start-up levels.
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 intern;d temperature drops to a safe level.
This overload usually resets within 60 minutes (or longer). If the intermfl 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 testel:
Advanced Scroll Temperature
(ASTP)
-Advanced Scroll Temperature
Protection
Protection
(ASTP) is a form of internal discharge temperature protection that unloads the scroll compressor when the internal temperature reaches approximately 300 IF.At this temperatme, an internal bi-metal disk valve opens and causes the scroll elements to sepm'ate, 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 befole the bi-metal disk resets. See Fig. 17.
To manually reset ASTP. the complessor should be stopped and allowed to cool. If the compressor is not stopped, the motor will mn until the motor protector trips, which occurs up to
90 minutes latel: Advanced Scroll Temperatme Protection will reset automatically before the motor protector resets, which may take up to 2 hours. A label located above the terlninal box identities Copeland Scroll compressor models (ZR94, 108 and
125) that contain this technology.
See Fig. 18.
Compressor crankcase heater must be on for 24 hom:s before st_ul-up.
After the heater has been on for 24 hours, the unit can be started.
Prior to starting compressol: a preliminary ch_uge of refrigerant must be added to avoid possible compressor dmnage.
Compressor Rotation (38AQ,ARQ Units) -On
3-phase units with scroll compressors, it is important to be certain compressor is rotating in the proper direction.
To determine whether or not compressor is rotating in the proper direction:
1. Connect service gages to suction and discharge pressure fittings.
2.
Energize the compressol:
3.
The vapor pressure should &up and the discharge pressure should rise, as is normal on any start-up.
If the vapor pressure does not drop and the discharge pressure does not rise to normal levels:
1. Note that the condenser fan is probably also rotating in the wrong direction.
19
J J
J jJ
J jJ
J
0 10 20
Compressor
30 40
Unloaded
50
Run
60
Time
70
(Minutes)
80 90
*Times are approximate.
Various factors, including high humidity, high ambient temperature, and the presence of a sound blanket will increase cool-down times.
Fig. 17Recommended Minimum Cool-Down
Time After Compressor is Stopped*
Fig. 18 -- Advanced Scroll Temperature
Protection Label
Compressor Lockout (CLO) Device-Tile Compressor lockout (CLO) device prevents the compressor fiom stariing or running in a high pressure, loss-of-chmge or fieezestat open situation.
Reset the CLO device by setting the
thermostat to eliminate cooling demand and return it to the ong_ inal set point, ff the system shuts down again for the stone fault, determine the possible cause before attempting to _eset the CLO device.
Preliminary Oil Charge (38AQS) -Tile compressor is factory chm'ged with oil (see N_bles IA-ID).
When oil is checked at stml-up, it may be necess;uy to add or remove oil to bring it to the proper level.
Add oil only if necessary to bring oil into view in sight glass. Use only Carrier-al)l)nn'ed
¢Xm_l)ressor oil. One recommended method is as follows: oil level adjustment
ADD OIL--Close vapor service valve and pump down crankcase to 2 psig. Wait a few minutes and repeat until pressure remains steady at 2 psig. Remove oil fill plug above the sight glass, add oil through plug hole, and replace plug. Run compressor for 20 minutes and check oil level.
NOTE: Use only Carrier approved compressor oil. Approved sources are;
Petroleum Specialties, Inc .....................
Texaco, Inc ...............................
Witco Chemical Co ..........................
Cryol 150A
Capella WF32
Suniso 3GS
Do not use oil that has been &'ained out, or oil that has been exposed to atmosphere.
REMOVE OIL -Pump down compressor to 2 psig. Loosen the l/4-in, pipe plug at the compressor base and allow the oil to seep out past the threads of the plug. RetigNen plug when level is correct.
NOTE: The crankcase is slightly pressurized.
Do not remove the plug, or the entire oil charge will be lost.
Small amounts of oil can be removed through the oil pump discharge connection while the compressor is running.
Start Unit
-Tile field disconnect is closed, the fan circuit bleaker is closed, and the space thermostat is set above ambient so that there is no demand for cooling.
Only the crankcase heater will be energized.
Next, close the compressor circuit breaker and then reset space thermostat below ambient so that a call for cooling is ensured.
NOTE: Do not use circuit bleaker to start and stop the complessor except in an emergency.
After starting, there is a delay of at least 3 seconds before compressor starts.
Adjust Refrigerant Charge
-Refer to Charging Charts
Fig. 19A-19C and Table 8. Do not exceed maximum refrigerant charge. Vmy refrigerant until the conditions of the chart are met. Note that chmging charts are different from type normally used.
Chmls are based on chmging the units to the correct subcooling for the various operating conditions.
Accurate pressure gage and temperature sensing device me 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 normal operating range of the unit. Operate unit a minimum of 15 minutes.
Ensure pressure and temperature readings have stabilized.
Plot liquid pressure and temperature on chm't and add or reduce charge to meet curve.
Adjust charge to conform with charging chmt, using the liquid pressure and temperature to read chart.
If the sight glass is cloudy, check refrigerant charge again.
EiIsure all fims arc ol)erating. Also ensme maximum allowable liquid lift has not been exceeded.
If charged per chmt and if the sight glass is still cloudy, check for a plugged filter drier or a pmtially closed solenoid v¢flve. Replace or repair, as needed.
45-
-_ 40-
'_ 35w
30-
25-
20"
70-
65*
0_60.
_J
>,55-
<
> 50-
O_DOOR FAN MUST BE OPE_TING
!
_45"
,<
_'5¢-
E0,
55-
_o
iiiiIlilllll ,lllJl Jtllilii
I_
,lO
liilllill
.............
iiiiiii
IlllllYiil
iiiiiliii iili
,oo iliili lllllllH'lllll!
_illlll,rllltlill
1 illllHIIIIllll!
illi,I/lllltiillli
_111111 il_lL!o!ltllllll
_111111111 illllllllllll
III11111 illllllllllllllllllll
°o!illl!lli
lll!llil!llll!ltll!ll
50 1_ 1_ 2_ 250 _0
LIQUID PRE_URE AT LIQUID VALVE (PSIG)
I
I_
ii
I
I
I
1
IIII
_0
1
1
1
1
400
Fig, 19A-
LIQUID PRE_URE AT _QUID VALVE (kPa)
38AQ007 Charging Chart
6O
54 ku
> 49
¢
4_
38
32
27
21
16
10
50
344
/
ADD CHARGE IF ABOVE CURVE /
/
/
/
/
/
/
/
/
/ REDUCE CHARGE IF BELOW CURVE
100
6;9
/
/
150 200 250 300
LIQUID PRESSURE
1034 1;79
LIQUID PRESSURE
AT LIQUID
AT LIQUID
1724
VALVE
VALVE
(PSIG)
2089
(Kilopascals)
350
2414
Fig. 19B38ARQ008,012 Charging Chart
400
5t00 150
LIQUID
200 250
PRESSURE
300 350 400
AT LIQUID VALVE (PSIG)
7;0 _doo_so' _oo' roB' _oo_2ao' _soo'2z;o '
LIQUID PRESSURE AT LIQUID VALVE (kPa)
450
Fig.
19C -38AQS016 Charging Chart
2O
Never charge liquid into the low-pressure
Do not ovemharge.
During charging side or removed of system.
of refrigerant, be sum indoor-fan system is operating.
Chmge unit on cooling cycle only. If unit is charged on heating cycle, overch;uging may occm:
Checking Heating Cycle Operation -Place thermostat selector switch at HEAT and reset the space set point above mnbient temperature so that a call for heating is ensured.
Compressor will start within 5 minutes.
Observe system operation.
Check Compressor Oil Level (38AQS) --After adjusting the refngerant charge, allow the systeln to run fully loaded for 20 minutes.
Running oil level should be within view in the crankcase sign glass. Stop compressor at the field power supply disconnect and check the crankcase oil level. Add oil only if necessary to bring the oil into view in the sight glass. If oil is added, mn the system for an additional 10 minutes, then stop and check oil level. If the level lemains low, check the piping system for proper design for oil return; _dso check the system for leaks.
If the initial check shows too much oil (too high in the sight glass) lemove oil to proper level. See Preliminary Oil Charge section for proper procedme for adding and removing oil.
When the above checks me complete, repeat the procedure with the unit operating at minimum load conditions.
Unload the com_sor at TB2 _.
by disconnecting the field-control circuit lead
Reconnect the field-control circuit lead when checks are complete.
Final Checks
-Ensure ;ill safety controls are operating, control panel covers me on, and the service panels are in place.
Table 8 -Maximum Refrigerant Charge
R-22
UNIT 38
AQ007
ARQ008,012
AQS016
(Ib)
27.0
34.2
34.2
62.0
(kg)
12.2
15.5
15.5
28.1
SEQUENCE OF OPERATION
38AQ007 UnitsWhen power is supplied to unit, the transformer (TRAN) and crankcase heater (CCH) ale energized.
COOLING -- On a call for cooling, the thermostat completes the following circuits: R-G. R-Y. and R-O. If the compressor recycle delay of 3 minutes is complete, the compressor ;rod outdoor fan start. The reversing valve is energized for cooling and the indoor-fan motor starts.
When the thermostat is satisfied, the circuits are opened, and the compressol: outdoor-fan motol: and indoor-fan motor stop. The reversing valve is deenergized.
HEATING -On a c;dl for heating, the thermostat completes the following circuits: R-G and R-Y. If the compressor recycle delay of 3 minutes is complete, the compressor and outdoor fan st_u't. The indoor-fan motor will also staff.
If room temperature continues to fall, the thermostat completes circuit R-W. If the optional electric heat package is used, the heat relay is energized, and the electric heaters are energized.
When the thermostat is satisfied, the circuits me opened, and the compressor, outdoor-fan motor, heatel_, and indoor-fan motor stop.
DEFROST -Defrost board (DB) is a time and temperature control, which includes a field-selectable time period between checks for frost (30, 50, and 90 minutes).
Electronic timer and defrost cycle start only when contactor is energized and defrost thermostat (DFT) is closed (below 28 F [-2.2 C]).
Defrost mode is identical to Cooling mode, except outdoorfan motor (OFM) stops and a bank of supplemental electric heat turns on to wmm air supplying the conditioned space.
Defrost mode is terminated when the DFT reaches 65 F
(l 8.3 C).
AIR CIRCULATION -When the fan switch is at FAN ON, the indoor-air fans operate continuously to provide ventilation.
The thermostat operates the other components as described above.
EMERGENCY HEAT CYCLE -- If the compressor is inoperative due to a tripped safety device, the second stage of the thermostat automatically energizes the indoor-air fan and the electric resistance heaters (if equipped).
38ARQ008,012 Units--When power is supplied to unit, the mmsformer (TRAN) is energized.
The crankcase heater is also energized.
COOLING--With the thermostat subbase in the cooling position, and when the space temperature comes within 2° F
(1 ° C) of the cooling set point, the thermostat makes circuit
R-O. This energizes the reversing valve solenoid (RVS) and places the unit in standby condition for cooling.
As the space temperature continues to rise, the second stage of the thermostat makes, closing circuit R-Y. When compressor time delay (5 _+2 minutes) is completed, a circuit is made to contactor (C), staffing the compressor (COMP) and outdoorfan motor (OFM).
Circuit R-G is made at the same time, energizing the indoor-fan contactor (IFC) and starting the indoor-fan motor (IFM) after one-second delay.
When the thermostat is satisfied, contacts open, deenergizing C. The COMR IFM, and OFM stop.
HEATINGOn a call for heat, thermostat makes circuits
R-Y and R-G When compressor time delay (5 _+2 minutes) is completed, a circuit is made to C, starting COMP and OFM.
Circuit R-G also energizes lFC and starts IFM after a 1-second delay.
38AQS016 Units
HEATING -Place therlnostat selector at HEAT and set temperature selector above room ambient.
COOLING -Place thermostat selector at COOL and set temperature selector below room mnbient.
When thermostat c_dls for unit operation (either heating or cooling), the indoor-fan motor starts immediately.
The outdoor-fan motors and compressor start within 3 seconds to
5 minutes depending on when unit was last shut off by thermostat, because unit contains a compressor time delay circuit.
When first-stage cooling is required, thermostat (TCI) closes, causing the heat pump to stmt with an unloaded compressol:
When TC2 closes, demanding additional cooling, the compressor loads to full load operation.
During heating, compressor is always fully loaded. When
THI demands first-stage heating, the heat pump starts within
3 seconds to 5 minutes depending on when unit was last shut off by thermostat, because unit contains a compressor time delay circuit. (The defrost bomd has speed terminals to shorten this cycle.) When TH2 of the thermostat closes, auxilimy heat supply (electric strip heat) is energized in 1 or 2 stages depending on number of stages available and whether outdoor thermostats are closed.
21
is achieved cycleanddeenergization outdoor a timersetto initiatedefrost coil.Defrost
every30,50,or 90minutes
Defrost outdoor theoutdoor sensed ambient bythedefiost temperature
Defrost rises ontheliquidline;ortherefrigerant
280psig(1931 thedefiost attheHPS2 timercompletes
Duplex Units
DUPLEX 38ARQ012
Fig. 12)
UNITS WITH 40RMQ024 (See
Cooling -When the thermostat is set for cooling, and the space temperature comes within 2 ° F (1 o C) of the cooling set point, the thermostat completes the circuit from R to O and the reversing valves in both units are energized.
If the space temperature continues to rise, the circuit from R to YI is completed. If the time delays and safeties are satisfied, the compressor contactor closes, starting the compressor and outdoor-fan motors of Heat Pump A. At the same time the circuit is completed from R to G. starting the indoor-fan motor. If the space temperature continues to rise, the circuit is completed from R to Y2 and the Cooling mode is initiated in Heat Pump
B in a similar mannec
When the thermostat is satisfied, the contacts open, deenergizing first the Heat Pump B and then Heat Pump A.
Heating -When the thermostat c_dls for heating, the circuit fiom R to YI is completed.
If the time delays and safeties are satisfied, the compressor contactor closes, sttuting the compressor and outdoor-fan motors of Heat Pump A and Heat
Pump B. At the same time the circuit is completed from R to G.
st_uting the indoor-fan motol: If the second stage of heating is required, the circuit from R to W2 will be completed and the electric resistance heaters will be energized.
When the thermostat is satisfied, the contacts open, deenergizing Heat Pump A and Heat Pump B.
DUPLEX 38AQS016 AND
40RMQ028 (See Fig.
13)
38ARQ012 UNITS WITH
Cooling -When the thermostat calls for cooling, the circuit from R to YI is completed.
If the time delays and safeties are satisfied, the compressor contactor closes, sttuting the compressor and outdoor-fan motors of Heat Pump A (38AQS016).
At the same time the circuit is completed form R to G. stmling the indoor-fan motol: If the space temperature continues to rise, the circuit is completed from R to Y2 and the Cooling mode is initiated in Heat Pump B (38ARQ012).
When the thermostat is satisfied, the contacts open, deenergizing first the Heat Pump B and then Heat Pump A.
Heating -When the thermostat c_dls for heating, the circuit from R to WI is completed.
If the time delays and safeties are satisfied, the compressor contactor closes, st_uting the complessor and outdoor-fan motors of Heat Pump A and Heat
Pump B. At the same time the circuit is completed from R to G.
st_uting the indoor-fan motol: If the second stage of heating is required, the circuit from R to W2 will be completed and the electric lesistance heaters will be energized.
When the thermostat is satisfied, the contacts open, deenergizing Heat Pump A and Heat Pump B.
SAFETIESThe high-plessure switch, loss-of-charge switch, oil pressure safety switch, and compressor overtemperature safety are located in a CLO that prevents heat pump operation if these safety devices are activated.
The lockout
22 system can be reset by adjusting the thermostat to open the contacts (down for Heating mode, up for Cooling mode), deenergizing the CLO.
Compressor overcurrent protection is achieved with a circuit breaker which requires manual resetting at the outdoor unit control box (38AQS only).
The 38AQS unit is equipped with an oil pressure safety switch that protects the compressor if oil pressure does not develop on start-up or is lost during operation.
The oil pressure switch is of the manual reset type and therefore must be reset at the outdoor unit. DO NOT RESET MORE THAN ONCE.
If oil pressure switch trips, determine cause and correct. DO
NOT JUMPER OIL PRESSURE SAFETY SWITCH.
To reset the oil pressure switch:
1. Disconnect power to the unit.
2.
Press the RESET button on the oil pressure switch.
3.
Reconnect power to the unit.
Unit is equipped with a no-dump reversing valve circuit.
When unit is in Cooling mode, reversing valve remains in cooling position until a call for heating is requested by themlostat.
When unit is in Heating mode, reversing valve remains in heating position until there is a call for cooling.
CHECK OPERATION -Ensure operation of all safety controis. Replace zfll service panels.
Be sure that control panel cover is dosed tigh@
Restart --Manu_fl reset of the 24-v control circuit is necessa q if unit shutdown is caused by automatic reset devices
(including IP [internal compressor overcurrent protectionl,
HPS [high-pressure switchl, LCS [loss-of-charge switchl), or if shutdown is caused by manual reset devices (including OPS
[oil pressure switchl and compressor circuit breaker protection). To restart the unit when IR HPS, or LCS has tripped (@
Wr device has reset automati_zd@), open and then close the thermostat contacts.
Opening and then closing thermostat contacts interrupts and restores 24-v power to the CLO, which resets the circuit.
It is necessary to manu_dly reset the compressor cimuit breaker and OPS at the unit if either of these safeties should shut down the unit.
IMPORTANT: If OPS trips, it must be reset fi_t before making and b_eaking the thermostat contacts to reset
CLO. If this procedure is not followed, the CLO cannot
_eset.
Causes of Complete Unit Shutdown:
•
• interruption of supplied power open compressor overtemperature protection (IP)
• compressor electrical overload protection (CB)
• open high-pressure or loss-of-charge safety switches
• open oil pressure switch
• open crankcase heater lockout (CLO2)
• open control circuit fuse (FUI or FU2)
• open discharge gas thermostat (38ARQ only)
SERVICE
Compressor Removal -See Tables IA-ID for compressor information.
Follow safety codes and wear safety glasses and work gloves.
1. Shut off power to unit. Remove unit access panel.
2.
Recover refrigerant from system using refrigerant recovery methods described in C;urier Training booklet GTAC |I,
Module 5, and in accordance with loc:d and national stan&_rds.
3.
Disconnect compressor wiring at compressor termimd box.
4.
Disconnect refrigerant lines from compressol:
5. Remove screws fiom compressor mounting plate.
Excessive movement of copper lines at compressor may cause higher levels of vibration when unit is restored to service.
6.
Remove or disconnect crankcase heater from compressor base.
7.
Remove compressor from unit.
8.
On 38AQS016 unit remove compressor holddown bolts and lift compressor off mounting plate.
9.
Clean system. Add new liquid line filter &ier
10.
Install new compressor on compressor mounting plate and position in unit. Connect vapor and discharge lines to compressor.
Secure mounting plate with compressor to unit. Ensure that compressor holddown bolts are in place.
Connect wiring. Install crankcase heatel:
11. Evacuate and rechmge unit.
12.
Restore unit powel:
38ARQ008, 012 Cooling Mode Operation
(See Fig. 20)
1. High pressure, high temperature refrigerant vapor from the compressor flows through the reversing v_flve and is directed to the vapor headel:s of both outdoor coils.
2.
At the outdoor coil vapor header, the high pressure, high temperature refrigerant vapor flows up to check valve
"A" that blocks the flow.
All the refrigerant is then directed to flow into the coil circuits.
3.
Subcooled refrigerant liquid leaves the coil circuits through the side outlet on the liquid headers.
The liquid refrigerant from each coil flows through check valves
"B" which are open, enters the liquid line and goes to the indoor coil.
4.
The liquid refrigerant is expanded and evaporated in the indoor coil resulting in low pressure vapol: This low pressure vapor returns to the outdoor unit through the system vapor line, reversing valve, and accumulatol: reentering the compressor at the suction connection.
38ARQ008, 012 Heating Mode Operation
(See Fig. 21)
1. High pressure, high temperature refrigerant vapor from the compressor flows through the reversing valve and is directed through the system vapor line to the indoor coil.
Refrigerant is condensed and subcooled in the indoor coil and returns to the outdoor unit through the system liquid line.
2.
Check valve "B" blocks the flow of liquid and the liquid refrigerant must flow through the filter driers, through check v_dve "C", and into the liquid header assembly.
3.
The liquid refrigenmt is expanded as it passes through the fixed orifice metering devices into outdoor coil circuits.
The refrigerant evaporates as it passes through the coil circuits resulting in low plessure vapol:
4.
The low pressure vapor leaves the coil circuits and enters the vapor headers, check valves "A" are open, and returns to the compressor through the vapor line, revelling valve, and accumulator, reentering the compressor at the suction connection.
COMPRESSOR
_M
vel
_
_
REVERSING VALVE
VAPO_'_RLINE
[_]ZZZ1
BALL
VALVE
FROM
INDOOR
UNIT
FILTER
DRIER
LIQUID LINE
METERING DEVICE
FIXED ORIFICE
Fig. 20 -- 38ARQ008, 012 Cooling Mode (Size 008 Shown)
23
[_INDOOR
BALL
VALVE
TO
UNIT
COMPRESSOR
?M
CK VALVE B f
CK VALVE A
CK VALVE C
II
1]
_
UL R _
REVERSING VALVE
VAPOR-_LINE
BALL
VALVE
TO
INDOOR
UNIT
?
d&
FILTER
DRIER
LIQUID LINE
FIXED ORIFICE
METERING DEVICE
Fig. 21 -- 38ARQ008, 012 Heating Mode (Size 008 Shown)
[_
BALL
VALVE
FROM
INDOOR
UNIT
38AQS016 Cooling Mode Operation
(See Fig. 22)
I.
High pressure, high temperature lefrigemnt vapor froln the compressor flows through the reversing valve and is directed to the outdoor coil vapor headel:
2.
At the outdoor coil vapor headel: the high pressure, high temperature refrigerant vapor flows up to check valve
"A" that blocks the flow.
All the refrigerant is then directed to flow into the coil circuits.
Subcooled refrigerant liquid leaves the coil circuits entering the portion of the vapor header which is above check valve "A". Check valve "C" is closed, therefore, the liquid refrigerant passes through check valve "B," which is open, and enters the liquid line and goes to the indoor coil.
4.
The liquid refrigerant is expanded and evaporated in the indoor coil resulting in low pressure vapor This low plessure vapor returns to the outdoor unit through the system vapor line, reversing valve, and accumulator.
reentering the compressor at the suction connection.
38AQ8016 Heating Mode Operation
(See Fig. 23)
I.
High pressure, high temperature lefrigemnt vapor froln the compressor flows through the reversing valve and is directed through the system vapor line to the indoor coil.
Refrigerant is condensed and subcooled in the indoor coil and returns to the outdoor unit through the system liquid line.
2.
Check valve "B" blocks the flow of liquid and the refiigerant is then directed to flow through check wtlve "C"
(which is open), through the filter drier, and into the liquid header assembly.
3.
The liquid refrigerant is expanded as it passes through the capillary tubes into outdoor coil circuits.
The refrigerant evaporates as it passes through the coil circuits resulting in low plessure vapol:
4.
The low pressme vapor leaves the coil circuits and enters the vapor headek check valve "A" is open, and returns to the compressor through the vapor line, leversing v;dve, and accumulator.
_eentering the compressor at the suction connection.
Crankcase Heater--The crankcase heater prevents refrigerant migration and compressor oil dilution during shutdown when compressor is not operating.
Close both compressor service valves when crankcase heater is deenergized for more than 6 houL's.
Outdoor Unit
Fans--Each fan is supported by a formed-wire mount bolted to the fan deck and covered with a wire guard. On the 38AQS016, the exposed end of the motor shaft is covered with a rubber boot. In case a fan motor must be repaired or leplaced, be sure the rubber boot is put back on when the fan is reinstalled and be sure the fan guard is in place before stmting the unit.
Lubrication--Fan motors have permanently bemings.
No further lubrication is required.
sealed
24
ACCUMULATOR
CN
GAS AND OIL _[J
./
REVERSING
VALVE
REFRIGERANT MIXTURE
f
FROM INDOOR
COiL
TO INDOOR
COIL
LLSV
LIQUID
ANGLE
VALVE
WITH SCHRADER
PORT
HOT GAS j
COIL RETURN
BEND END
CK VALVE B
-CK VALVE A
CK VALVE C
Fig. 22 --38AQS016 Cooling Mode
REVERSING
VALVE
REFRIGERANT MIXTURE
GAS AND OIL
_
_ _
J
DOlL
_
LLSV
TO INDOO_R
INDOOR
/
COIL
LIOUID
ANGLE
VALVE
WITH SCHRADER
PORT
HOTGAS j
/
COIL RETURN
BEND END
CK VALVE C
Fig. 23 -- 38AQS016 Heating Mode
25
Coil Cleaning and Maintenance--This section discusses the cleaning and the maintenance of standard coils and
E-Coated coils. Routine cleaning of coil surfaces is essential to minimize contamination build-up and remove harmful residue.
Inspect coils monthly and clean as required.
CLEANING STANDARD COILS -- Standard coils can be cleaned with a vacuum cleaner, washed out with low velocity water, blown out with compressed ail; or blushed (do not use wire brush).
Fan motors _u'e dripproof but not waterproof.
Do not use acid cleaners.
Clean coil annually or as required by location or outdoor air conditions.
Inspect coil monthly and clean as required.
Fins are not continuous through coil sections.
Dirt and debris may pass through first section and become trapped, restricting condenser airflow.
Use a flashlight to determine if dirt or debris has collected between coil sections.
Clean coils as follows:
1. Turn off unit powel:
2.
Remove screws holding rear corner posts and top cover
in place. Pivot top cover up 12 to 18 in. (300 to 450 mm) and support with a board or other adequate rigid support.
See Fig. 24.
3.
Remove clips securing tube sheets together at the return bend end of the coil. Carefully spread the ends of the coil rows apart by moving the outer sections. See Fig. 25.
4.
Using a water hose or other suitable equipment, flush down between the sections of coil to remove dirt and debris.
5.
Clean the lemaining surfaces in the normal mannel:
6.
Reposition outer coil sections.
Reinstall clips which secure tube sheets, and replace top cover and rear corner posts.
7.
Restore unit powel:
CLEANING AND MAINTAINING E-COATED CO[LS --
Routine cleaning of condenser coil surfaces is essential to maintain proper operation of the unit. Elimination of contamination and removal of harmlul residue will greatly increase the life of the coil and extend the life of the unit. The following maintenance and cleaning procedures gue recommended as Dul of the routine maintenance activities to extend the life of the coil.
TOP
COVER
RIGID
SUPPORT
SPREAD
OUTER COIL
SECTIONS
OLFi3NARD
3
Fig. 25 -- Coil Cleaning (Typical)
Remove Surface Loaded Fibers -Debris such as dirt and fibel;s on the surface of the coil should be removed with a vacuum cleanel: If a vacuum cleaner is not available, a soil brash may be used. The cleaning tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins.
NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibel.'s and dirt into the coil.
This will make cleaning efforts more difficult.
Surface debris 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 industri_fl environments.
Howevek it is very important that the water rinse is made with very low velocity water stream to avoid damaging the tin edges. Monthly cleaning is recommended.
Routine Cleaning of E-Coated Coil Surfaces -Monthly cleaning with Environmentally Sound Coil Cleaner is essential to extend the life of coils. It is recommended that all coils including stan&trd aluminum, pre-coated, copper/coppek or E-coated coils be cleaned with the Environmentally Sound Coil Cleaner as described below. Coil cleaning should be Du-t of the regularly scheduled maintenance procedures of the unit to ensure long life of the coil. Failure to clean the coils may result in reduced durability in the environment.
Environmentally Sound Coil Cleaner is non-bacterial, biodegra&tble and will not harm the coil or sunounding components such as electric_d wiring, painted metal surfaces or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected.
The following field supplied equipment is required for coil cleaning:
• 21/2 gallon (9.5 liter) garden sprayer
• water rinse with low velocity spray nozzle
Environmentally Sound Coil Cleaner Application Instructions
-Perform the following procedure to clean the coil.
NOTE: Wear proper eye protection such as safety glasses during mixing and application.
1. Remove all surface debris and dirt from the coil with a vacuum cleaner
2.
Thoroughly wet finned surfaces with clean water _md a low velocity garden hose, being careful not to bend tins.
3.
Mix Environment_dly Sound Coil Cleaner in a 21/2 g_dlon
(9.5
liter) garden sprayer according to the instructions included with file cleaner. The optimum solution temperature is 100 F (37.8 C).
Fig. 24 -- Pivot and Support Top Cover
26
DO NOT USE water in excess of 130 F (54.4
C).
Enzymes in coil cleaner will be destroyed and coil cleaner will not be effective.
4.
Thoroughly apply Environmentally Sound Coil Cleaner solution to all coil surfaces including finned _uea, tube sheets, and coil headers.
Hold gmden sprayer nozzle close to finned areas and apply cleaner with a vertic_d, up-and-down motion.
Avoid spraying in horizontal pattern to minimize potential for fin dmnage.
Ensure cleaner thoroughly penetrates deep into finned _ueas.
Interior and exterior finned areas must be thoroughly cleaned.
5.
Allow finned surfaces to remain wet with cleaning solution for 10 minutes.
Ensure surfaces are not _dlowed to dry before rinsing.
Reapply cleaner as needed to ensure
10-minute saturation is achieved.
6.
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.
Do not use bleach, harsh chemicals, or acid cleaneLs on outdoor or indoor coils of any kind. These types of cleaneLs me difficult to rinse, and they promote rapid corrosion of the tin collar -copper tube connection.
Only use the Environmentally Sound Coil Cleanel:
Never use high pressure air or liquids to clean coils. High pressures damage coils and increase the airside pressure
&op. To promote unit integrity, follow cleaning and maintenance procedures in this document.
27
Do
BREAKER
1
POWER CIRCUIT
F
I
CONTACTOR
OPEN
._
t
WILLNOTRUN
COMPRESSOR
I
1
COILORCONTACTS
1
._
_,_
VALVE RELAY
._
COIL
CYCLE=LOC
TM
I i[
BREAKER
I
CHART-HEATING CYCLE TROUBLESHOOTING
I
SWITCH
__{HIGH-PRESSURE
I
1
1
RUNSBUT
I
I
INSUFFICIENT
I NO HEATING
I
OR
I
DISCHARGE
GAS
THERMOSTAT
I
LOW VAPOR
LOW HEAD
PRESSURE
I
COMPRESSOR
VALVES
DEFECTIVE
STOPPED
OUTDOOR FAN
OR
____[ DIRTY t
OUTDOOR
RUNNING
FAN
I
COMPRESSOR
RUNS, tNSUPFt-
CIENTttEATING
I
I
I
COMPRESSOR
FLOODING
__[
CYCLING ON
FANS
_{
AT
LOOSE LEADS
._
BURNED OUT
FAN MOTOR I
VOLTAGE OR UN
LOW LINE
3-PHASE LINE
1
COMPR ESSO R
BEARINGS
REVERSING
,._
I
._
DISCHARGE
RESTRICTtONIN
LINE
I
I
SABLES
NONCONDEN
I
VALVE JAMMED
REVERSING
POSITION
I
OUTDOOR FAN
CONDITION
HIGH LOAD 1 "_
BURNED OUT
PAN MOTOR
N.C.
CONTACTS
UNDERCHARGED
SYMPTOMS
I
INDOOR COIL
HEADERCHECK
VALVESTUCK
OPEN
1
CHECK VALVE
1
OUTDOOR
DIRTY
COIL
OUTDOOR
HEAVILY
FROSTED
COIL
HIGH VAPOR
LOW HEAD
PRESSURE
I
CHECK
(C)
VALVE
OPEN
VOLTAGE
LOW-
I
SWITCH CYCUNG
LOSS-OF_CHARGE I
DISCHALGE GAS I
T H_ _cMLIONS_AT I
...{
THERMOSTAT
DEFROST
WITH LINE
IN
_{
DEFROST RELAY
1
LEGEND
CCH -Crankcase Heater
N.C.
-Normally Closed
-_ CCH DEFECTIVE 1
I
L
HIGit HEAD
I
LIQUID LINE
1
METERING
RESTRICTED
DEVICE
OR iCE CLOGGED t
SYSTEM
OVERCHARGED
I
]
RESTRICTED
__.[
VALVE
___
SWITCH OPEN
OIL PRESSURE
'F
1
I
I
OPEN
I
I I
t +N+_c_o_
I
_t °NTA++o_
t t t
VOLTAGE
IN t
COIL OR CONTACTS
1 ,_ !
POWER SUPPLY
COMPRESSOR
O;EN
I __
BREAKER
LEADS l ""f OPEN COMPR ESSQ R I
J
AI FAN MOTOR I
I
I
DEFROST RELAY
CONTACTS I ++++1
I ,._
--
BREAKER
OR COIL
CONTACTOE
DEFECTIVE
I __[ q
TROUBLESHOOTING
I __[
RESTRICTED OR
AIR ] "--t
I
RUNS BUT
1
GAS
COMPRESSOR
NOT
I
COMPRESSOR
VALVES OR
HEADGASKETS
I
REVERSING
VALVEIN
MID POSITION
VOLiAGE
BEARINGS
COMPRESSOR
I
CHART -- COOLING CYCLE
INSUFFICIENT
COOLING
I
OR
1
I
,
J-t
INDOOR
FREEZE
COIL
UP
FAN
STOPPED
I
I '_'_i_
J
4
1
[
AIR
DIR/Y
I
INSUFFICIENT
GGOUNG
I
RUNS
I
LOW HEAD
I
PRESSURE
_
.,GR_RORJ
PRESSU_IE t
LOW
.,OHV_,+.I
LOW_,'OR
PRESSURE
++°+'_
I
+°°,.+
INTERNAL LE_,K
I
I I +++
RESTRICTED
J
I 1 I
COMPRESSOR
]
VALVE LEAKING
OR Ba, CKWARDS
R ESTRICTED
FILTER
+t,+
DRIER
S
I°+L+,_I_
REFRIGERANT
OPEN
I
SYMPTOM
I i _A.MOTOR1
_
NOT
CONTROLLING
CHECK VALVE SY+ASS J
NOT
CONTROLLING
VAI VE "JOT
EUI t YOPEN
I
TXV NOT ,.°°o_oo,_
REVERSING
VALVE
REMOTECONTEOL
CENTER [
ELECIRIC&L
I
LINE I
FAN
GREATLY
RESTRICTED
!NDOOR
AIR
J
'_E°lc°'L ] CYCLE LOG
TM t
I
J
SWITCH
CYCLING
LOS_OI
I
DIIAli_!
SWI ICII CYCLING
NO DI iA_GE
I
DISCHARGE GAS
IRERMOSIAI
CYCLING
I
I
NONCO_DENSABLER
]
REFRIGERANT
LOW l
TXV
I
LINE l
I
I
LIONID LINECHECK
I
J
I l
LEGEND
CCH -Crankcase Heater
TXV -Thermostatic Expansion Valve t CCH OE F ECq-IME ]
Copyright 2004 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PC 111 Catalog No. 533-80118 Printed in U.S.A.
38A-19SI Pg 30 9-04 Replaces: 38A-16SI
START-UP CHECKLIST
I. PRELIMINARY INFORMATION
OUTDOOR UNIT: MODEL NO.
INDOOR UNIT: MODEL NO.
ADDITIONAL ACCESSORIES
II. PRE-START-UP
OUTDOOR UNIT
IS THERE ANY SHIPPING DAMAGE'?
IF SO, WHERE:
(Y/N)
SERIAL NO.:
SERIAL NO.:
WILL THIS DAMAGE PREVENT UNIT START-UP?
(Y/N)
CHECK POWER SUPPLY.
DOES IT AGREE WITH UNIT'?
(Y/N)
HAS THE GROUND WIRE BEEN CONNECTED'?
(Y/N)
HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY'?
(Y/N)_
ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY'?
HAVE COMPRESSOR
(Y/N)
(Y/N)
HOLDDOWN BOLTS BEEN LOOSENED (Snubber washers are snug, but not tight)'?
CONTROLS
ARE THERMOSTAT AND INDOOR FAN CONTROL WIRING
CONNECTIONS MADE AND CHECKED'? (Y/N)
ARE ALL WIRING TERMINALS (including main power supply) TIGHT'?
(Y/N)
HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS'?
(Y/N)
INDOOR UNIT
HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE'?
ARE PROPER AIR FILTERS IN PLACE'?
(Y/N)
HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT'?
DO THE FAN BELTS HAVE PROPER TENSION'?
(Y/N)
HAS CORRECT FAN ROTATION BEEN CONFIRMED'?
(Y/N).
(Y/N)
(Y/N)
PIPING
HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR, OUTDOOR UNIT. INDOOR UNIT.
TXVs (Thermostatic Expansion Valves), SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE
PLUGS WITH A LEAK DETECTOR'?
(Y/N)
LOCATE, REPAIR, AND REPORT ANY LEAKS.
HAVE ALL COMPRESSOR SERVICE VALVES BEEN FULLY OPENED (BACKSEATED)?
HAS LIQUID LINE SERVICE VALVE BEEN OPENED'?
IS THE OIL LEVEL
(Y/N)
IN COMPRESSOR
(Y/N)
CRANKCASE VISIBLE IN THE COMPRESSOR
(Y/N)
SIGHT GLASS'?
CHECK VOLTAGE IMBALANCE
LINE-TO-LINE VOLTS: AB V
(AB + AC + BC)/3 = AVERAGE VOLTAGE =
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =
AC
V
V BC
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.
V
%
CL-l
III. START-UP
CHECK INDOOR FAN SPEED AND RECORD.
CHECK OUTDOOR FAN SPEED AND RECORD.
AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:
COOLING HEATING
OIL PRESSURE
VAPOR PRESSURE
VAPOR LINE TEMP
DISCHARGE PRESSURE
DISCHARGE LINE TEMP
ENTERING OUTDOOR AIR
LEAVING OUTDOOR AIR TEMP
INDOOR ENTERING-AIR DB (dry bulb) TEMP
INDOOR ENTERING-AIR WB (wet bulb) TEMP
INDOOR LEAVING-AIR DB TEMP
INDOOR LEAVING-AIR WB TEMP
COMPRESSOR AMPS (LI/L2/L3) / / /
CHECK THE COMPRESSOR OIL LEVEL SIGHT GLASSES; ARE THE SIGHT GLASSES SHOWING
OIL LEVEL IN VIEW'?
(Y/N)
/
NOTES:
LU c_
LU
I-rm o
I-
<
Z o,
LU rm
LU
Ic_ o
I-
Z
< o,
Copyright 2004 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 14 PC 111 Catalog No. 533-80118 Printed in U.S,A.
38A-19SI Pg CL-2 8-05A 9-04 Replaces: 38A-16SI
Tab 5a 15a
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project