38AUQ Heat Pump Condensing Units 60 Hz with Puron® (R-410A) Refrigerant Sizes 07, 08, and 12 Installation, Start-Up and Service Instructions CONTENTS SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Step 1 – Plan for Unit Location . . . . . . . . . . . . . . . . . . . 7 Step 2 – Complete Pre-Installation Checks. . . . . . . . . . 7 Step 3 – Prepare Unit Mounting Support . . . . . . . . . . 7 Step 4 – Rig and Mount the Unit . . . . . . . . . . . . . . . . . . 7 Step 5 – Complete Refrigerant Piping Connections . . . 7 Step 6 – Install Accessories. . . . . . . . . . . . . . . . . . . . . . 10 Step 7 – Complete Electrical Connections . . . . . . . . . 10 PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Turn On Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . 15 Preliminary Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 -18 38AUQ Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 OPERATING SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . 19 Indoor (Supply) Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cooling Unit Without Economizer . . . . . . . . . . . . . . . . . 19 Cooling, Unit With Economizer . . . . . . . . . . . . . . . . . . . 19 Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Supplemental Heating/Emergency Heating . . . . . . . . 19 Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cooling and Heating Shutdown. . . . . . . . . . . . . . . . . 19 ROUTINE SYSTEM MAINTENANCE. . . . . . . . . . . . . . . 20 Quarterly Inspection (and 30 days after initial start) . . 20 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 31 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 20 Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Servicing Systems on Roofs with Synthetic Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Liquid Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . 21 Filed Refrigerant Access Ports . . . . . . . . . . . . . . . . . 21 Outdoor Coil Metering Devices. . . . . . . . . . . . . . . . . 21 Refrigerant System Pressure Access Ports . . . . . . . . 21 Heat Pump Controls. . . . . . . . . . . . . . . . . . . . . . . . . . 22 Commercial Defrost Board . . . . . . . . . . . . . . . . . . . . . . 22 Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Compressor Protection. . . . . . . . . . . . . . . . . . . . . . . . . . 22 Low-Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . 33 Comfort Alert Diagnostic Module . . . . . . . . . . . . . . 28 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Outdoor Coil Maintenance and Cleaning Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . 31 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 APPENDIX A Air Conditioner and Heat Pump with Puron® – Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . 33 APPENDIX B Wiring Diagram List. . . . . . . . . . . . . . . . . . . . . . . . . 33 APPENDIX C Motormaster Sensor Locations. . . . . . . . . . . . . . . . . 34 START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . .CL-1, CL-2 SAFETY CONSIDERATIONS Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions package Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloths for brazing operations and have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and appropriate national electrical codes (in USA, ANSI/NFPA70, National Electrical Code (NEC); in Canada, CSA C22.1) for special requirements. It is important to recognize safety information. This is the safety-alert symbol . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safetyalert 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. INSTALLATION GUIDELINE Replacement /Retrofit – R22 to Puron® ELECTRICAL SHOCK HAZARD Failure to follow this warning could cause 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. 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. UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause personal injury, death and/or equipment damage. Puron® (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. 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. 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 ignition sources away from refrigerants and oils. 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 Puron® system. 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. 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. 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 suctionline filter drier in system longer than 72 hr (actual time). 2 UNIT Standard Weight Corner A Corner B Corner C Corner D lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. 38AUQ*07 444 201 134 61 97 44 90 41 123 56 38AUQ*08 483 219 162 74 110 50 85 39 125 57 38AUQ*12 575 261 186 84 126 57 106 48 157 71 Center of Gravity X 23  20  21  Fig. 1 — 38AUQ*07-12 Unit Dimensions 3 Y 26  24  24  Unit Height Z 13  13  23  H 42-3/8  42-3/8  50-3/8  Table 1A — Physical Data — 38AUQ*07-12 Units — 60 Hz English UNIT SIZE 38AUQ NOMINAL CAPACITY (tons) *07 6 OPERATING WEIGHTS (lb) Aluminum-Fin Coils 444 *08 7.5 *12 10 483 575 R-410A TYPE‡ REFRIGERANT Operating Charge, Typical (lb)† 18.0 21.0 27.0 10.0 12.0 15.0 COMPRESSOR Qty...Type 1...Scroll 1...Scroll 1...Scroll OUTDOOR FANS Qty...Rpm Shipping Charge (lb) 2...1100 2...1100 2...1100 Motor Hp 1/ 1/ 1/ Diameter (in) 22 22 22 6,000 6,000 6,000 610 610 610 Nominal Airflow (Cfm Total) Watts (Total) 4 4 4 1...Round Tube/Plate Fin (RTPF) OUTDOOR COIL (Qty) Face Area (sq ft total) 17.5 23.0 28.1 2/17 2/17 2/17 630 ±10 630 ±10 630 ±10 505 ±20 505 ±20 505 ±20 Low Cutout 27 ±3 27 ±3 27 ±3 Cut-in 44 ±5 44 ±5 44 ±5 1...11/8 1...11/8 1...13/8 1...3/ 1...1/ 1...1/2 Rows/Fins per inch (FPI) CONTROLS Pressurestat Settings (psig) High Cutout Cut-in PIPING CONNECTIONS (in. ODS) Qty...Vapor Qty...Liquid 8 LEGEND ODS — Outside Diameter Sweat (socket) ‡ Unit is factory-supplied with partial charge only. † Typical operating charge with 25 ft of interconnecting piping. 4 2 Table 1B — Physical Data — 38AUQ*07-12 Units — 60 Hz SI UNIT SIZE 38AUQ NOMINAL CAPACITY (kW) *07 21.1 OPERATING WEIGHT (kg) Aluminum-Fin Coils 201 *08 26.4 *12 35.1 219 261 R-410A TYPE‡ REFRIGERANT Operating Charge, Typical (kg)† Shipping Charge (kg) COMPRESSOR Qty...Type 8.2 9.5 12.2 4.5 5.9 6.8 1...Scroll 1...Scroll 1...Scroll CONDENSER FANS Qty...r/s 2...18 2...18 2...18 Motor Hp NEMA 1/ 1/ 1/ 4 4 4 Diameter (mm) 560 560 560 Nominal Airflow (L/s) 2832 2832 2832 Watts (Total) 610 610 610 1...Round Tube/Plate Fin (RTPF) CONDENSER COIL (Qty) Face Area (sq m total) Rows/Fins per Meter (Fins/m) 1.6 2.1 2.6 2/670 2/670 2/670 CONTROLS Pressurestat Settings (kPa) High Cutout 4344 ±70 4344 ±70 4344 ±70 3482 ±138 3482 ±138 3482 ±138 Low Cutout 186 ±21 186 ±21 186 ±21 Cut-in 303 ±35 303 ±35 303 ±35 1...11/8 1...11/8 1...13/8 1...3/ 1...1/ 1...1/2 Cut-in PIPING CONNECTIONS (in. ODS) Qty...Vapor Qty...Liquid 8 2 LEGEND NEMA — National Electrical Manufacturers Association ODS — Outside Diameter Sweat (socket) ‡ Unit is factory-supplied with partial charge only. † Typical operating charge with 7.62 m of interconnecting piping. 5 1 2 3 4 5 6 3 8 A U Q A 1 _____________ 7 8 9 10 11 12 13 14 15 16 17 18 2 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 07 = 6 Tons 08 = 7.5 Tons 12 = 10 Tons Not Used A = Place Holder Not Used A = Not Used Base Unit Controls 0 = Electro-Mechanical Controls Not Used 0 = Not Used Design Revision A = Initial Rev (Discrete Model Number) Voltage 1 = 575/3/60 5 = 208/230/3/60 6 = 460/3/60 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 Fig. 2 — Model Number Nomenclature POSITION NUMBER TYPICAL 1 4 2 8 3 0 4 9 POSITION 1−2 3−4 5 6−10 5 G 6 1 7 2 8 3 DESIGNATES Week of manufacture (fiscal calend ar) Year of manufacture (”09” = 2009) Manufacturing location (G = ETP, Texas, USA) Seq uential numb er Fig. 3 — Serial Number Nomenclature 6 9 4 10 5 . INSTALLATION 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, refrigerant piping, and servicing unit. See Fig.1 for unit dimensions and weight distribution data. • Locate the unit so that the outdoor coil (condenser) airflow is unrestricted on all sides and above. • 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 Fig. 1 for weight distribution based on recommended support points. NOTE: If vibration isolators are required for a particular installation, use the data in Fig. 1 to make the proper selection. 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. Step 1 — Plan for Unit Location Select a location for the unit and its support system (pad, rails or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings. See Fig. 4. 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. 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. Step 3 — Prepare Unit Mounting Support Slab Mount 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 UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage. All panels must be in place when rigging. Unit is not designed for handling by fork truck. . DO NOT BURY REFRIGERATION LINES. 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. Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit. REAR: Min 18” (457 mm) requried for service LEFT: Min 18” (457 mm) requried for service 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. Step 5 — Complete Connections Fig. 4 — Service Clearance Dimensional Drawing Step 2 — Complete Pre-Installation Checks Refrigerant Piping 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. CHECK UNIT ELECTRICAL CHARACTERISTIC — Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided. UNCRATE 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. IMPORTANT: Do not bury refrigerant piping underground. IMPORTANT: A refrigerant receiver is not provided with the unit. Do not install a receiver. 7 Table 2 — 38AUQ*07-12 Piping Recommendations (Single-Circuit Unit) R-410A Equivalent Length Ft 0-38 38-75 75-113 113-150 Model Length Linear Nominal Capacity Length Equiiv 0-25 0-38 25-50 38-75 50-75 75-113 75-100 113-115 38AUQ*07 Liquid Line 3/ 3/ 3/ Max Lift Cool Heat 25 25 50 50 48 46 Suction Line 7/ 7/ 8 1-1/8 Charge (lbs) 17.8 18.8 20.3 Liquid Line 1/ 1/ 1/ Max Lift Cool Heat 25 25 Suction Line 7/ Charge (lbs) Liquid Line Max Lift Cool Heat 25 25 Suction Line 7/ Charge (lbs) 26.8 38AUQ*08 38AUQ*12 8 8 2 8 2 1/ 8 3/ 2 75 60 39 31 22.6 1-1/8 1-1/8 1-1/8 20.9 23.0 24.9 26.8 1/ 1/ 1/ 1/ 8 1-1/8 2 2 24.5 2 100 60 2 100 60 21.4 1/ 2 75 60 1-1/8 2 1-1/8 50 50 8 1/ 8 5/ 2 8 50 50 75 60 85 60 100 60 1-1/8 1-1/8 1-1/8 1-3/8 28.8 30.7 33.4 37.2 Legend: Length Equiv Equivalent tubing length, including effects of refrigeration specialties devices Liquid Line Tubing size, inches OD. Max Lift Cooling Heating Maximum liquid lift at maximum permitted liquid line pressure drop • Indoor unit ABOVE outdoor unit • Indoor unit BELOW outdoor unit Suction Line Tube size, inches OD Charge Charge Quantity, lbs. Calculated for both liquid line sizes (where applicable), but only with larger suction line size (where applicable) NOTE: For applications with linear length greater than 100 ft (30.5 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 DRIER(S) AND MOISTURE INDICATOR(S) — Every unit MUST have a bi-directional filter drier in the liquid line. Locate the filter drier at the indoor unit, close to the evaporator coil’s thermal expansion valve (TXV) inlets. 38AUQ units include one Puron-duty filter drier, shipped in cartons attached to the unit basepan. Remove the filter drier and prepare to install in the liquid line at the evaporator coil. Do not remove connection fitting plugs until ready to connect and braze the filter drier into the liquid line position. Table 4 — Puron-duty Filter Drier(s) IMPORTANT: A refrigerant receiver is not provided with the unit. Do not install a receiver. UNIT 40RUQ 07 08 12 07 08 12 Desiccant Volume Part Number Ref Qty 38AUQ*07 1 3/ 8-in 8 cu. in. KH43LG091 38AUQ*08 1 1/ 2-in 16 cu. in. KH43LG085 38AUQ*12 1 1/ 2-in 16 cu. in. KH43LG085 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 5 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. Table 3 — Maximum Vertical Separation* UNIT 38AUQ Liquid Line OD Model-Size DISTANCE FT (M) Unit 38AUQ Above Unit 40RMQ 50 (15.2) 60 (18.3) 60 (18.3) *Vertical distance between indoor and outdoor units. 8 Table 5 — Refrigerant Specialties Part Numbers. LIQUID LINE SIZE (in.) † LIQUID LINE SOLENOID VALVE (LLSV) LLSV COIL SIGHT GLASS 3/ 8 ALC-066208 AMG-24/50-60 HMI-1TT3 1/ 2 ALC-066209† AMG-24/50-60 HMI-1TT4 5/ 8 ALC-066212 AMG-24/50-60 HMI-1TT5 AIRFLOW 15 DIAMS MIN 8 DIAMS MIN FILTER DRIER LOCATION 8 DIAMS MIN FLO W TXV SENSING BULB 15 DIAMS MIN LIQUID LINE SOLENOID VALVE TXV CKT 1 10 DIAMS Fig.6 — Location of Sight Glass(es) and Filter Driers (typical 38AUQ/40RUQ size 12 system) Table 6 — Minimum Outdoor Air Operating Temperature FILTER DRIER A LOCATION TXV 10 DIAMS 10 DIAMS LEGEND TXV — Thermostatic Expansion Valve EQUALIZER LINE SIGHT GLASS A LOCATION SIGHT GLASS LOCATION TXV CKT 2 8 DIAMS MIN CAPACITY CONTROL LIQUID LINE SOLENOID VALVE Evaporator capacity control via liquid solenoid valve is not recommended for use with 38AUQ models. TXV SENSING BULB 15 DIAMS MIN INDOOR COIL CKT 1 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. EQUALIZER LINE TXV SENSING BULB INDOOR COIL CKT 2 AIRFLOW AIRFLOW Provided with unit See Table 4 38AUD units require TWO sets of parts. INSTALL LIQUID LINE SOLENOID VALVE — It is recommended that a bi-directional solenoid valve be placed in the main liquid line (see Figs. 5 & 6) between the outdoor unit and the indoor coil. Locate the solenoid valve at the end of the liquid line, near the outdoor unit connections, with flow direction arrow pointed at the outdoor unit. Refer to Table 5. (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. INDOOR COIL CKT FILTER DRIER FLO W LIQUID LINE SOLENOID VALVE UNIT % COMPRESSOR CAPACITY 38AUQ07 38AUQ08 38AUQ12 100 MINIMUM OUTDOOR TEMP — F (C)* Standard Unit Head Pressure Control† 35 (1.7) –20 (–28.9) 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. LEGEND TXV — Thermostatic Expansion Valve Table 7 — Insulation for Vapor Line Exposed to Outdoor Conditions Fig.5 — Location of Sight Glass(es) and Filter Driers (typical 38AUQ/40RUQ size 07 & 08 systems) LENGTH OF EXPOSED VAPOR LINE* ft m 10 3 INSULATION THICKNESS† in. 3/ 8 mm 10 25 8 1/ 2 13 35 11 3/ 4 19 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 • in./ft2 • h • °F (0.04 W/m • °C). 9 Example: 38AUQ*08 60-ft (18.3 m) linear line length Equivalent line length 90-ft (27.4 m) Liquid Lift: 20-ft (6.1 m) Select line sizes from Table 2 (38AUQ): Liquid 1/2 in Suction 1-1/8 in. Charge 23.0 lbs (at 75-ft linear length) MAKE PIPING CONNECTIONS — 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. The stub tube connections include ¼-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. 80% of Operating Charge: 0.80 x 23.0 = 17.6 lbs Field Service Access Port (Schrader core) Factory High-Flow Access Port Service Valve with Stem Cap Factory Shipping Charge: 12 lbs Field-charge quantity: 17.6 lbs –12.0 lbs = 5.6 lbs For linear line lengths longer than 100 ft (30.5 m), contact your local Carrier representative for system charge value. Step 6 — Install Accessories Sweat Connection 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. Fig. 7 — Typical Piping Connection Assembly 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-andbubbles. 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). Where vapor line is exposed to outdoor air, line must be insulated. See Table 7 for insulation requirements. EVACUATION/DEHYDRATION — 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. Step 7 — Complete Electrical Connections ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Do not use gas piping as an electrical ground. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code); ANSI/ NFPA 70, latest edition (in Canada, Canadian Electrical Code CSA [Canadian Standards Association] C22.1), and local electrical codes. NOTE: Check all factory and field electrical connections for tightness. Field-supplied wiring shall conform with the limitations of 63°F (33°C) rise. 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. UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause personal injury, death and/or equipment damage. Puron® (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. IMPORTANT: Charge in Cooling mode only! PRELIMINARY CHARGE — 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. 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. 10 Field power wires are connected to the unit at line-side pressure lugs on compressor contactor C and TB1 (see wiring diagram label for control box component arrangement) or at factory-installed option non-fused disconnect switch. Max wire size is #4 AWG (copper only). NOTE: TEST LEADS - Unit may be equipped with short leads (pigtails) on the field line connection points on contactor C or optional disconnect switch. These leads are for factory run-test purposes only; remove and discard before connecting field power wires to unit connection points. Make field power connections directly to line connection pressure lugs only. Units Without Disconnect Option C 11 TB1 13 Disconnect per NEC L1 L2 L3 208/230-3-60 460-3-60 575-3-60 Units With Disconnect Option 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.) L1 2 L2 4 L3 6 1 Optional Disconnect Switch 3 Factory Wiring 5 Disconnect factory test leads; discard. Fig. 9 — Power Wiring Connections ELECTRIC DISCONNECT SWITCH 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 10. 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 8, 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. COPPER WIRE ONLY ALUMINUM WIRE Fig. 8 — Disconnect Switch and Unit 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. Convenience Outlets 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 opening 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. 11 Convenience Outlet GFCI Pwd-CO Fuse Switch Pwd-CO Transformer UNIT CONNECT VOLTAGE AS PRIMARY CONNECTIONS TRANSFORMER TERMINALS 240 L1: RED + YEL L2: BLU + GRA H1 + H3 H2 + H4 460 480 L1: RED Splice BLU + YEL L2: GRA H1 H2 + H3 H4 575 600 L1: RED L2: GRA 208, 230 Control Box Access Panel H1 H2 UNIT CONNECT PRIMARY TRANSFORMER VOLTAGE AS CONNECTIONS TERMINALS Fig. 10 — Convenience Outlet Location 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 factoryinstalled 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 unitmounted 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. 208, 230 240 L1: RED + YEL L2: BLU + GRA H1 + H3 H2 + H4 460 480 L1: RED Splice BLU + YEL L2: GRA H1 H2 + H3 H4 575 600 L1: RED L2: GRA H1 H2 Fig. 11 - Powered Convenience Outlet Wiring 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. Using unit-mounted convenience outlets: Units with unitmounded 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. 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. DISCONNECT ALL POWER TO UNIT AND CONVENIENCE OUTLET. Remove the blank cover plate at the convenience outlet; discard the blank cover. Loosen the two screws at the GFCI duplex outlet, until approximately 1/2-in (13 mm) under screw heads are exposed. 12 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. 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. 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. PremierLink (accessory installation) – Refer to Form 33CS58SI for details on connecting the PremierLink controller and its various sensors. 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 over-tighten). 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. COVER – WHILE-IN-USE WEATHERPROOF RECEPTACLE NOT INCLUDED BASE PLATE FOR GFCI RECEPTACLE Fig. 12 — Weatherproof Cover Installation All Units — Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate. See Table 8. 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 8, 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. 19 for typical field control connections and the unit’s label diagram for fieldsupplied 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). R G Y1 O/B/Y2 (Notes 1, 2) W1 W2 (Note 4) C (Note 3) Note 1: Typical multi-function marking. Follow manufacturer’s configuration instructions to select Y2. Note 2: Y2 to economizer required on single-stage cooling units when integrated economizer function is desired Note 3: Connect only if thermostat requires 24-vac power source. Note 4: Connect W2 if supplemental heater installed Field Wiring Fig. 13 — Typical Remote Thermostat Connections 13 Table 8 — Electrical Data — 38AUQ*07-12 60 Hz Units UNIT SIZE 38AUQ FACTORYINSTALLED OPTION NONE OR DISCONNECT CONVENIENCE OUTLET *07 NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET *08 NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET *12 NONE OR DISCONNECT CONVENIENCE OUTLET NONE OR DISCONNECT CONVENIENCE OUTLET NOMINAL VOLTAGE V-Ph-Hz 208/230-3-60 460-3-60 575-3-60 208/230-3-60 460-3-60 575-3-60 208/230-3-60 460-3-60 575-3-60 VOLTAGE RANGE‡ MIN 187 414 518 187 414 518 187 414 518 LEGEND — Full Load Amps LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection NEC — National Electrical Code RLA — Rated Load Amps FLA MAX 253 506 633 253 506 633 253 506 633 COMPRESSOR FAN MOTORS RLA FLA (ea) 19.0 9.7 7.4 25.0 12.2 9.0 30.1 16.7 12.2 LRA 123 1.5 62 2 0.6 164 2 1.5 100 2 0.9 78 2 0.6 225 2 1.5 114 2 0.8 80 QTY 2 0.9 50 POWER SUPPLY 2 0.6 2 MCA MOCP 26.8 45 31.6 50 13.9 20 16.1 25 10.5 15 12.2 15 34.3 50 39.1 60 17.1 25 19.3 30 12.5 20 14.2 20 40.6 60 45.4 60 22.5 30 24.7 30 16.5 25 18.2 30 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. max voltage deviation from average voltage % Voltage Imbalance = 100 x average voltage Example: Supply voltage is 208/230-3-60 AB = 224 v BC = 231 v AC = 226 v ‡ Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed limits. NOTES: 1. The MCA and MOCP values are calculated in accordance with the NEC, Article 440. 2. Motor RLA and LRA values are established in accordance with Underwriters’ Laboratories (UL), Standard 1995. 3. The 575-v units are UL, Canada-listed only. 4. Convenience outlet is available as a factory-installed option and is 115-v, 1 ph, 60 Hz. 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. 14 PRE-START-UP START-UP 38AUQ Units 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. 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 24hour 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. UNIT DAMAGE HAZARD 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). 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. 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. 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. 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. 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. UNIT DAMAGE HAZARD Prior to starting compressor, a preliminary charge of refrigerant must be added to avoid possible compressor damage. 15 Advanced Scroll Temperature Protection (ASTP) Reset the space thermostat below ambient so that a call for cooling is ensured. 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. Never charge liquid into the low-pressure side of system. Do not overcharge. During charging or removal of refrigerant, be sure indoor-fan system is operating. Ensure both outdoor fan motors are running; bypass any Motormaster function. Adjust Refrigerant Charge The unit must be charged in Cooling mode only. Refer to Cooling Charging Charts, Fig. 16 through Fig. 18. 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. Recommended Cooling Time (Minutes) Fig. 14 — Advanced Scroll Temperature Protection Label Final Checks 120 110 100 90 80 70 60 50 40 30 20 10 0 Ensure that all safety controls are operating, control panel covers are on, and the service panels are in place. 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. *Times are approximate. NOTE: Various factors, including high humidity, high ambient temperature, and the presence of a sound blanket will increase cool-down times. Fig. 15 — Recommended Minimum Cool-Down Time After Compressor is Stopped To manually reset ASTP, the compressor should be stopped and allowed to cool. If the compressor is not stopped, the motor will run until the motor protector trips, which occurs up to 90 minutes later. Advanced Scroll Temperature Protection will reset automatically before the motor protector resets, which may take up to 2 hours. Start Unit Set the space thermostat to a set point above space temperature so that there is no demand for cooling. Close the 38 AUQ disconnect switch. Only the crankcase heater will be energized. 16 Fig. 16 — 38AUQ*07 Charging Chart Fig. 17 — 38AUQ*08 Charging Chart Fig. 18 — 38AUQ*12 Charging Chart 17 Fig. 19 — 38AUQ Wiring Diagram (208/230-3-60 shown) 18 OPERATING SEQUENCE 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. 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. 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-engerized. 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. 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. Reversing valve solenoid (RVS) is energized in Cooling modes. This solenoid will remain energized until the next Heating mode is initiated. Defrost Cycle 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. 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). 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. 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. 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. 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. Supplemental Heat/Emergency Heat 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. 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 Cooling and Heating Shutdown 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. 19 ROUTINE SYSTEM MAINTENANCE SERVICE 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: Refrigeration System Quarterly Inspection (and 30 days after initial start) EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in damage to equipment. This system uses Puron® refrigerant which has higher pressures than R-22 and other refrigerants. No other refrigerant may be used in this system. Gage set, hoses, and recovery system must be designed to handle Puron®. If you are unsure consult the equipment manufacturer. Indoor section • Coil cleanliness checked. • Return air filter replacement • Belt tension checked • Belt condition checked • Pulley alignment checked • Fan shaft bearing locking collar tightness checked • Condensate drain checked • Blower motor amperage Compressor Oil Outdoor Section • Fan motor mounting bolts tightness • Compressor mounting bolts • Fan blade positioning • Control box cleanliness and wiring condition • Wire terminal tightness • Refrigerant charge level 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. Economizer or Outside Air Damper • Inlet filters condition • Check damper travel (economizer) • Check gear and dampers for debris and dirt Servicing Systems on Roofs With Synthetic Materials — POE (polyolester) compressor lubricants are known to cause long term damage to some synthetic roofing materials. Exposure, even if immediately cleaned up, may cause embrittlement (leading to cracking) to occur in one year or more. When performing any service which may risk exposure of compressor oil to the roof, take appropriate precautions to protect roofing. Procedures which risk oil leakage include but are not limited to compressor replacement, repairing refrigerants leaks, replacing refrigerant components such as filter drier, pressure switch, metering device, coil, accumulator, or reversing valve. SYNTHETIC ROOF PRECAUTIONARY PROCEDURE 1. Cover extended roof working area with an impermeable polyethylene (plastic) drop cloth or tarp. Cover an approximate 10 x 10 ft (3.3 x 3.3 m) area. 2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run-offs, and protect drop cloth from tears caused by tools or components. 3. Place terry cloth shop towel inside unit immediately 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. 20 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. 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. 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. Failure to develop frost at an outlet tube can indicate a plugged or a missing orifice. Field Refrigerant Access Ports Refrigerant System Pressure Access Ports Field service access to refrigerant pressures is through the access ports located at the service valves (see Figs 24, 26 and 28). These ports are ¼-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). 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. 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. 20.) 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 of torque; do not overtighten. 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. 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. 20 — CoreMax Access Port Assembly 21 DEPRESSOR PER ARI 720 +.01/-.035 FROM FACE OF BODY 7/16-20 UNF RH Heat Pump Controls Compressor Protection Control Circuit, 24-V The control circuit is protected against overcurrent conditions by a circuit breaker mounted on control transformer TRAN. Reset is manual. Compressor Overcurrent The compressor has internal limbered motor protection. Compressor Overtemperature The compressor has an internal protector to protect it against excessively high discharge gas temperatures. 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 Charge Switch trip setting is 27 psig ± 3 psig (186 ±21 kPa). Reset is automatic at 44 ±5 psig (303 ± 35 kPa). Outdoor Fan Motor Protection The outdoor fan motor is internally protected against overtemperature. 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. 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. 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. 22 for board arrangement. The DFB is located in the 38AUQ's main control box (see Fig. 21). All connections are factory-wired. Refer to Table 12 for details of DFB Inputs and Outputs. Table 12 —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 Y1 Cool 1 DI, 24-vac P2-5 Wi Heat 1 DI, 24-vac P2-7 TB-W1 R Power 24-vac P3-1 TRAN2 24-vac, ground P3-3 TRAN2 DI, 24-vac DFT-1 to DFT-1 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 HEAT 2 DO, 24-vac E-HEAT HC-1 (TB4-1) Unit Connection Note Unit Connection Note C Common DFT1 Defrost Switch Unit Connection Note Not used TB-Y1 Outputs Note Configuration Point Name Type of I/O Connection Pin Number Select Jumper 24-vac P1-1 1 Compressor 24-vac P1-2 Type of I/O Connection Pin Number 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 22 Fig. 21 — Defrost Control Board (DFB) Location Defrost 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 thermostat (DFT1) mounted on the outdoor coil. 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. 23 and Table 13). The default run period is 60 minutes. DIP Switches Speed-Up Jumpers Fig. 22 — Defrost Control Board (DFB) Arrangement Fig. 23 — DIP Switch Settings — Defrost Board Reversing valve control At the end of the continuous run period, the defrost control will test for a need to defrost. On unit sizes 04-07 (single compressor designs), DFT1 controls the start and termination of the defrost cycle. If DFT1 is still open, the defrost test/run window is closed and the control repeats the continuous run period. If DFT1 is closed, the defrost cycle is initiated. The defrost period will end when DFT1 opens (indicating the outdoor coil has been cleared of frost and ice) or a 10 minute elapsed period expires, whichever comes first. At the end of the unit defrost cycle, the unit will be returned to Heating cycle for a full continuous run period. 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 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 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). Table 13 —Dip Switch Position Switch No. 1 1 0 ■ 2 ■ 30 minutes 1 1 0 ■ 2 ■ 60 minutes 1 1 0 ■ 2 ■ 90 minutes 23 1 1 ■ 2 ■ 0 3 1 0 120 minutes ■ Fan Delay On Off Defrost Thermostats Defrost Speedup Functions 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 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. 22); use a straight-edge screwdriver. 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. 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. Indoor Fan Off Delay 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. 24 Fans Service Valves Fig. 24 — 38AUQ*07 Exterior Outdoor Coil Defrost Thermostat (DFT) LOC HPS High Flow Access Ports Fig. 25 — 38AUQ*07 Interior 25 Fans Service Valves Fig. 26 — 38AUQ*08 Exterior Outdoor Coil Defrost Thermostat (DFT) LOC HPS High Flow Access Ports Fig.27 — 38AUQ*08 Interior 26 Fans Service Valves Fig. 28 — 38AUQ*12 Exterior Outdoor Coil Defrost Thermostat (DFT) LOC HPS High Flow Access Ports Fig. 29 — 38AUQ*12 Interior 27 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. 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 Control Power Control Common Demand Contactor Coil Compressor T1 Compressor T2 Compressor T3 ALERT (YEL) Terminal Voltage R 24-V C 24-V Y P T1 T2 T3 24-V 24-V Line Line Line TRIP (RED) Fig. 30 — CADM Housing/LED Locations 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 14, 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 14. 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 15 for discussion of additional LED flash codes and troubleshooting instructions. 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. 28 Table 14 — LED Status Codes Status LED Green “POWER” Red “TRIP” LED On Solid Status LED Description Module has power Thermostat demand signal Y is present, but the compressor is not running. Status LED Troubleshooting Information Supply voltage is present at module terminals 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 The anti-short cycle timer (3 minutes), in module is preventing compressor Flashing restart. Module locks out compressor when compressor damaging ALERT code appears. Lockout ALERT codes are noted in the Status LED Description. During a compressor lock out, 24VAC power must be removed from module to manually reset. Yellow “ALERT” A short circuit or over current 1. Compressor contactor coil shorted LED On Solid condition exists on PROT 2. Electrical load too high for PROT circuit terminal. (maximum 1 Amp) 3. 24 V AC wired directly to PROT terminal Yellow “ALERT” System Pressure Trip 1. High head pressure Flash Code 2 Discharge pressure out of 2. Condenser coil poor air circulation (dirty, limits or compressor blocked, damaged) overload (if no high pressure 3. Condenser fan is not running switch in system) LOCKOUT 4. If low pressure switch is open: Refer to Code 3 for troubleshooting Yellow “ALERT” Short Cycling 1. If low pressure switch is open: Flash Code 3 Compressor is running only a. Low refrigerant charge briefly LOCKOUT b. Evaporator blower is not running c. Evaporator coil is frozen d. Faulty metering device e. Condenser coil is dirty f. Liquid line restriction (filter drier blocked if present) 2. If high pressure switch is open, go to Flash Code 2 information 3. Intermittent thermostat demand signal 4. System or control board defective Yellow “ALERT” Locked Rotor 1. Low line voltage to compressor Flash Code 4 LOCKOUT 2. Excessive liquid refrigerant in compressor 3. Compressor bearings are seized Yellow “ALERT” Open Circuit 1. Condensing unit power disconnect is open Flash Code 5 2. Compressor circuit breaker or fuses are open 3. Compressor contactor has failed open 4. High pressure switch is open and requires manual reset 5. Broken supply wires or connector is not making contact 6. Unusually long compressor protector reset time due to extreme ambient temperature 7. Compressor windings are damaged Yellow “ALERT” Missing Phase 1. Compressor fuse is open on one phase Flash Code 6 LOCKOUT 2. Broken wire or connector on one phase 3. Compressor motor winding is damaged 4. Utility supply has dropped one phase Yellow “ALERT” Reverse Phase 1. Compressor running backward due to supply Flash Code 7 LOCKOUT phase reversal Yellow “ALERT” Welded Contactor 1. Compressor contactor has failed closed Flash Code 8 Compressor always runs 2. Thermostat demand signal not connected to module Yellow “ALERT” Low Voltage 1. Control circuit transformer is overloaded Flash Code 9 Control circuit < 18VAC 2. Low line voltage to compressor 29 Table 15 — 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 Fig. 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 Fig. 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. Lubrication FAN MOTORS have sealed bearings. No provisions are made for lubrication. 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. PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this caution may result in personal injury or equipment damage. Only approved cleaning is recommended. Outdoor Coil Maintenance and Cleaning Recommendation Routine Cleaning of Indoor Coil Surfaces 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. 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. Avoid the use of • coil brighteners • acid cleaning prior to painting • high pressure washers • poor quality water for cleaning 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. 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 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. 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. Monthly cleaning as described below is recommended. 30 Totaline Environmentally Sound Coil Cleaner Application Instructions Clean coil as follows: 1. Turn off unit power, tag disconnect. 2. Remove top panel screws on outdoor coil end of unit. 3. Remove coil corner post. To hold top panel open, place coil corner post between top panel and center post. 4. Remove screws securing coil to compressor plate and compressor access panel. 5. Use a water hose or other suitable equipment to flush down the coil to remove dirt and debris. Clean the outer surfaces with a stiff brush in the normal manner. 6. Remove the coil corner post from between the top panel and center post. Reinstall the coil corner post and replace all screws. 1. Proper eye protection such as safety glasses is recommended during mixing and application. 2. Remove all surface loaded fibers and dirt with a vacuum cleaner as described above. 3. Thoroughly wet finned surfaces with clean water and a low velocity garden hose, being careful not to bend fins. 4. Mix Totaline environmentally sound coil cleaner in a 21/2 gallon garden spryer 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. 5. Thoroughly apply Totaline environmentally sound coil cleaner solution to all coil surfaces including finned area, tube sheets and coil headers. 6. 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. 7. Ensure cleaner thoroughly penetrates deep into finned areas. 8. Interior and exterior finned areas must be thoroughly cleaned. 9. Finned surfaces should remain wet with cleaning solution for 10 minutes. 10. Ensure surfaces are not allowed to dry before rinsing. Reapply cleaner as needed to ensure 10-minute saturation is achieved. 11. 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. Totaline Environmentally Sound Coil Cleaner Application Equipment • 2-1/2 gallon garden sprayer • Water rinse with low velocity spray nozzle UNIT DAMAGE HAZARD Failure to follow this caution may result in corrosion and damage to the unit. Harsh chemicals, household bleach or acid or basic cleaners should not be used to clean outdoor or indoor coils 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 of the coil, use the Totaline environmentally sound coil cleaner as described above. UNIT DAMAGE 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. 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. 2, 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 16 — 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) 31 TROUBLESHOOTING PROBLEM Compressor and Outdoor Fan Will Not Start. Compressor Will Not Start But Outdoor Fan Runs. Compressor Cycles (Other Than Normally Satisfying Thermostat). Compressor Operates Continuously. CAUSE REMEDY 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. 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. Head Pressure Too Low. Excessive Suction Pressure. Suction Pressure Too Low. 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. 32 APPENDIX A • Do not install a suction-line filter drier in liquid-line. • POE oils absorb moisture rapidly. Do not expose oil to atmosphere. • POE oils may cause damage to certain plastics and roofing materials. • Wrap all filter driers and service valves with wet cloth when brazing. • A factory approved, liquid-line filter drier is required on every unit. • Do not use an R-22 TXV. • If indoor unit is equipped with a TXV, it must be changed to a Puron® TXV. • Never open system to atmosphere while it is under a vacuum. • When system must be opened for service, recover refrigerant, break vacuum with dry nitrogen before opening system. • Always replace filter drier after opening system for service. • Do not vent Puron® into the atmosphere. • Do not use capillary tube coils. • Observe all warnings, cautions, and bold text. • All Puron® heat pumps must have indoor TXV. • Do not leave Puron® suction line driers in place for more than 72 hours. AIR CONDITIONER AND HEAT PUMP WITH PURON® — QUICK REFERENCE GUIDE • 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®. • Puron® refrigerant cylinders are rose colored. • Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400. • 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. • Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low-side retard. • Use hoses with 700 psig service pressure rating. • Leak detectors should be designed to detect HFC refirgerant. • Puron®, as with other HFCs, is only compatible with POE oils. • Vacuum pumps will not remove moisture from oil. • Use only factory specified liquid-line filter driers with rated working pressures greater than 600 psig. APPENDIX B WIRING DIAGRAM LIST 38AUQ Size *07 *08 *12 Electrical Characteristics 208/230-3-60 460-3-60 575-3-60 208/230-3-60 460-3-60 575-3-60 208/230-3-60 460-3-60 575-3-60 33 Diagram Number 38AU500363 38AU500362 38AU500435 38AU500363 38AU500362 38AU500435 38AU500363 38AU500362 38AU500435 APPENDIX C MOTORMASTER SENSOR LOCATIONS MOTOR MASTER SENSOR MUST BE POSITIONED ON VAPOR STUB (FOURTH FROM TOP) MOTOR MASTER SENSOR MUST BE POSITIONED BETWEEN METERING DEVICE (SECOND FROM TOP) AND TUBE SHEET 6T HEAT PUMP MOTOR MASTER SENSOR MUST BE POSITIONED ON VAPOR STUB (FOURTH FROM TOP) 7.5T HEAT PUMP 10T HEAT PUMP Fig. 31 Motormaster Sensor Locations per Unit Size Copyright 2009 Carrier Corp • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 09/09 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 34 Catalog No: 38AUQ-01SI Replaces: New III. START UP START-UP CHECKLIST I. PRELIMINARY INFORMATION OUTDOOR: MODEL NO. SERIAL NO. INDOOR: AIR HANDLER MANUFACTURER MODEL NO. SERIAL NO. ADDITIONAL ACCESSORIES II. PRE-START-UP OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE? (Y/N) IF SO, WHERE: WILL THIS DAMAGE PREVENT UNIT START-UP? (Y/N) CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT? HAS THE GROUND WIRE BEEN CONNECTED? (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? 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) CHECK VOLTAGE IMBALANCE LINE-TO-LINE VOLTS: AB V AC (AB + AC + BC)/3 = AVERAGE VOLTAGE = V BC 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. CL-1 V (Y/N) CHECK OUTDOOR UNIT FAN SPEED AND RECORD. AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS: SUCTION PRESSURE SUCTION LINE TEMP LIQUID PRESSURE LIQUID LINE TEMP 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 AMPS (L1/L2/L3) / / NOTES: Copyright 2009 Carrier Corp • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 11/09 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Catalog No: 38AUQ-01SI Pg CL-2 Replaces: New - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE CHECK INDOOR UNIT FAN SPEED AND RECORD.