Carrier 38AK007 User's Manual
Contents
1. MAX LIQUID LINE ALLOWABLE Max Allowabie Max Allowable UNIT SBARIO LIQUID Pressure Drop Temp Loss LIFT ft psi NOTE Values shown are for units operating at 45 F saturated suc tion and 95 F entering air Step 4 Make Electrical Connections A WARNING Unit cabinet must have an uninterrupted unbroken elec trical ground to minimize the possibility of personal in jury 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 elec trical ground when installed in accordance with NEC ANSI American National Standards Institute NFPA National Fire Protection Association 70 1987 and lo cal electrical codes Failure to follow this warning could result in the installer being liable for personal injury of others NOTES 1 2 3 4 nes 1 4 5 16 CONTROL BOX 6 16 414 5 COMPRESSOR ACCESS PANEL CONNECTION SIZES 1 DIA 35 FIELD POWER SUPPLY HOLE 2 DIA 51 POWER SUPPLY KNOCK OUT 212 DIA 64 POWER SUPPLY KNOCK OUT 7 DIA 22 FIELD CONTROL WIRING HOLE Dimensions in are in millimeters a Center of gravity Direction of air flow Minimum clearance focal codes or jurisdiction may prevail a Bottom to combustible surfaces 0 in b Condenser coil for proper air flow 36 in one side 12 in the other The side getting the greater clear ance is optional Overhea2. Contactor Factory Wiring NEC National Electrical Code AO Gage Suain Field Wiring Fig 3 Power Wiring Connections Table 4 Electrical Data UNIT V Ph Hz NOMINAL VOLTAGE _ VOLTAGE RANGE compr orm MN Max RLA LRA FLA MCA 208 230 3 60 187 254 190 142 19 256 460 360 aa 5o 95 72 10 129 1 9 POWER SUPPLY 38AK007 575 3 60 58 62 76 5 19 114 220 3 50 198 242 190 142 19 2356 400 3 50 o mo os z 10o io LEGEND Example Supply voltage is 460 3 60 CSA Canadian Standards Association aR E AB 452 v FLA Full Load Amps BC 464 v HACR Heating Air Conditioning and Refrigeration AC 455 v LRA Locked Rotor Amps 452 464 455 MCA Minimum Circuit Amps Average Voltage _ _ MOCP Maximum Overcurrent Protection 3 NEC National Electrical Code 1371 OFM Outdoor Condenser Fan Motor 457 RLA Rated Load Amps NOTES NOTE The 575 v units are CSA only 1 In compliance with NEC requirements for multimotor and combi nation load equipment refer to NEC Articles 430 and 440 the overcurrent protective device for the unit shall be fuse or HACR breaker 2 Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply volt age is greater than 2 Use the following formula to determine the voltage imbalance 460 max vol
3. Fig 9 5 Use a water hose or other suitable equipment to flush down between the 2 coil sections to remove dirt and de bris Clean the outer surfaces with a stiff brush in the normal manner 6 Reposition the outer coil section and remove the coil corner post from between the top panel and side panel Secure the sections together Install the coil corner post and replace all screws Lubrication COMPRESSORS Each compressor is charged with cor rect amount of oil at the factory FAN MOTOR BEARINGS Fan motor bearings are of the permanently lubricated type No further lubrication is required Condenser Fan Adjustment Fig 10 Shut off unit power supply Remove condenser fan assembly grille motor motor cover and fan Loosen fan hub setscrews Adjust fan height as shown in Fig 10 Tighten setscrews Replace condenser fan assembly MOTOR COVER OUTLET GRILLE CONDENSER FAN MOTOR CONDENSER FAN Fig 10 Condenser Fan Adjustment TROUBLESHOOTING GUIDE COMPRESSOR DOES NOT RUN Contactor Open Power off restore power Fuses blown replace with correct fuses after finding cause and correcting Transformer dead replace transformer if primary wind ings are receiving power Thermostat circuit open check thermostat setting Low pressure switch open check for refrigerant under charge or obstruction of indoor airflow High pressure switch open check for refrigerant ove
4. check damper operation and position Evaporator Air Fan Stopped Electrical connections loose tighten all connections Fan relay defective replace relay Motor overload open check power supply Motor defective replace motor Fan belt broken or slipping replace or tighten belt COMPRESSOR RUNS BUT COOLING INSUFFICIENT Suction Pressure Low Refrigerant charge low check charge Head pressure low check refrigerant charge Indoor air filters dirty clean or replace filters Expansion valve power head defective replace power head Evaporator coil partially iced check low pressure setting Evaporator airflow restricted remove obstruction Suction Pressure High Heat load excessive check for open doors or windows Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 533 809 Book 1 4 PC 111 Tab 3a 2a Printed in USA Form 38AK 2S Pg 8 6 92 Replaces New
5. in the corner post 3 Feed wire through the raceway built into the corner post to the 24 v barrier located on the left side of the control box See Fig 5 The raceway provides the UL required clearance between the high and low voltage wiring THERMOSTAT CONNECTIONS FOR STANDARD ant THERMOSTAT CONNECTION BOARD WIRING CONNECTIONS UNIT CONNECTION BOARD Fig 4 Control Wiring Connections LOW VOLTAGE LEADS RACEWAY HOLE IN END PANEL HIDDEN Fig 5 Field Control Wiring Raceway START UP Preliminary Checks 1 Check that all internal wiring connections are tight and that all barriers covers and panels are in place 2 Field electrical power source must agree with unit name plate rating 3 All service valves must be open Leak Test Test entire refrigerant system by using soap bubbles and or an electronic leak detector Evacuate and Dehydrate Evacuate and dehy drate entire refrigerant system by use of the methods de scribed in GTAC II Module 4 System Dehydration Refrigerant Charge Refer to GTAC II Module 5 Charging Recovery Recycling and Reclamation Unit panels must be in place when unit is operating dur ing charging procedure Unit is shipped with holding charge only Weigh in 7 lbs R 22 to start unit NO CHARGE Use standard evacuating techniques Af ter evacuating system weigh in the specified amount of re frigerant Refer to Table 1 LOW CHA
6. 30 v unit is to be connected to a 208 v power supply the transformer must be rewired by moving the black wire from the 230 v orange wire on the trans former and connecting it to the 200 v red wire from the transformer The end of the orange wire must then be insulated Refer to unit label diagram for additional information Pigtails are provided for field wire connections Use factory supplied splices or UL Underwriters Laborato ries approved copper aluminum connector When installing units provide a disconnect per NEC All field wiring must comply with NEC and local requirements Install field wiring as follows 1 Install conduit through side panel openings 2 Install power lines to connections as shown in Fig 3 Wrap connections with electrical tape Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate also see Table 4 On 3 phase units voltages between phases must be balanced within 2 and the current within 10 Use the formula shown in Table 4 Note 2 to determine the voltage imbalance Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components Such operation would in validate any applicable Carrier warranty YEL E I l 230 3 50 400 3 50 FIELD POWER SUPPLY 208 230 3 60 PaaS EN pat Ceara te 460 3 60 i DISCONNECT 575 3 60 PER NEC LEGEND c
7. RGE COOLING Use Cooling Charging Chart Fig 6 Vary refrigerant until the conditions of the chart are met Note the charging chart is different from type nor mally used Chart is based on charging the units to the cor rect subcooling for the various operating conditions Accu rate 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 af fect the reading Indoor air cfm must be within the normal operating range of the unit Operate unit and adjust charge to conform with charging chart using liquid pressure and temperature to read chart TO USE COOLING CHARGING CHART Initially charge with 7 lbs R 22 Place pressure gage at liquid line service valve Install thermocouple to liquid line near the liquid line service valve Operate unit Plot liquid pressure and tem perature on chart and add or reduce charge to meet curve CHARGING CHART 38AK007 OUTDOOR FAN MUST BE OPERATING m u re hy Q tw gt a lt x gt cs 3 ad lt w a gt E lt x iw Q ly H Q gt O LIQUID PRESSURE AT LIQUIO VALVE PSIG Fig 6 Cooling Charging Chart 38AK007 Unit Preparation Make sure that unit has been in stalled in accordance with installatio
8. are based on a 2 F loss for liquid and suction lines 5 Pipe sizes are based on an equivalent length equal to the max imum length of interconnecting piping plus 50 percent for fittings 3 Charge units with R 22 in accordance with unit installation instructions SIZE REFRIGERANT LINES Consider length of pip ing required between condensing unit and evaporator amount of liquid lift and compressor oil return See Table 3 and also refer to Part 3 of Carrier System Design Manual for design details and line sizing Refer to evaporator installa tion instructions for additional information INSTALL FILTER DRIER AND MOISTURE INDICA TOR The filter drier is factory supplied and field in stalled Moisture indicator is a field installed option and should be installed just after liquid line shutoff valve Do not use a receiver there is none provided with unit and one should not be used NOTE Unit is shipped with R 22 holding charge System pressure must be relieved before removing caps Pass nitrogen or other inert gas through piping while braz ing to prevent formation of copper oxide Install field supplied thermostatic expansion valve to evap orator section It is recommended that a field supplied liq uid line solenoid be positioned in the main liquid line close to the evaporator coil and wired to close when compressor stops to minimize refrigerant migration during the OFF cycle Table 3 Liquid Line Data
9. d 60 in to assure proper condenser fan op eration Between units control box side 42 in per NEC Between unit and ungrounded surfaces control box side 36 in per NEC 3 9 Between unit and block or concrete walls and other t1144 grounded surfaces control box side 42 in per NEC With the exception of the clearance for the condenser coil as stated in notes 5a b and c a removable fence or barricade requires no clearance Units may be installed on combustible floors made from wood or class A B or C roof covering material oa 0 an CORNER C ELECTRICAL 1 21 DISCONNECT f 1362 c se LOCATION i is 197 eee 1 11716 322 3 3 5 3 16 RUCK vist TP 1O46 FORK TRIC a 0 2 1 4 DIA 573 1185 0 ed vie TYP 8 PLACES LEFT SIDE mee RIGHT SIDE FRONT Fig 1 Dimensions ft in NOTICE TO RIGGERS HOOK RIGGING SHACKLES THROUGH HOLES IN BASE RAIL ON ALL FOUR SIDES HOLES IN BASE RAILS ARE CENTERED AROUND THE UNIT CENTER OF GRAVITY eA omt TOP SKID WHEN RIGGING TO PREVENT RIGGING STRAPS FROM CAUTION ALL PANELS MUST BE IN PLACE WHEN RIGGING TYP 4 PLACES SEE DETAIL A ouy TMAXWEIGHT A B Pb ko in mm in mm in 3BAKOO7 390 177 26 7 1186 30 6 1006 35 5 Fig 2 Rigging Label mm 904 3 FIELD POWER SUPPLY All units except 208 230 v units are factory wired for the voltage shown on the name plate If the 208 2
10. g tbs ko bs kos raao 154 see 30 53 38AK007 CORNER B CORNER C FRONT CORNER D Step 2 Rig and Mount the Unit A CAUTION Be sure unit panels are securely in place prior to rigging RIGGING These units are designed for overhead rig ging Refer to rigging label for preferred rigging method Spreader bars are not required if top crating is left on unit All panels must be in place when rigging See Fig 2 As further protection for coil faces plywood sheets may be placed against sides of unit behind cables Run cables to a central suspension point so that angle from the horizontal is not less than 45 degrees Raise and set unit down carefully If it is necessary to roll unit into position mount unit on rails using a minimum of 3 rollers Apply force to rails not unit If 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 unit Raise from above to lift unit from rails or pad when unit is in final position After unit is in position remove all shipping wrapping and top crating Step 3 Complete Refrigerant Piping Connec tions Suction connection is 1 1 8 in sweat with plas tic cap liquid connection is 1 2 in sweat with plastic cap Follow standard piping practices Se A REFRIGERANT PIPING SIZES EQUIVALENT LENGTH OF PIPING FT L Liquid Line S Suction Line oe S Pipe sizes
11. i gt HEATING amp COOLING 38AK007 Air Cooled Condensing Unit Installation Start Up and Service Instructions SAFETY CONSIDERATIONS Installing and servicing air conditioning equipment can be hazardous due to system pressure and electrical compo nents Only trained and qualified service personnel should install or service air conditioning equipment When working on air conditioning equipment observe precautions in literature and on tags and labels attached to unit Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for brazing operations Have fire extinguisher available Read these instructions thor oughly Consult local building codes and National Electri cal Code NEC for special installation requirements A WARNING Before installing or servicing system always turn off main power to system There may be more than one disconnect switch Electrical shock can cause personal injury INSTALLATION Step 1 Complete Pre Installation Checks UNCRATE UNIT Remove unit packaging except for the top skid assembly and wood bumpers which should be left in place until after unit is rigged into place INSPECT SHIPMENT File claim with shipping com pany if shipment is damaged or incomplete CONSIDER SYSTEM REQUIREMENTS Consult local building codes and NEC for special instal lation requirements Allow sufficient space for airflow clearance wiring refrigerant
12. it shuts down on any safety trip and remains off an indicator light on thermostat comes on Check reason for safety trip Compressor restart is accomplished by manual reset at the thermostat by turning the selector switch to OFF posi tion and then to ON position Sequence of Operation At start up the thermo stat calls for cooling and with all safety devices satisfied the compressor contactor and fan contactor will energize causing the compressor and outdoor fan motor to operate Contacts on TB1 terminals 1 and 2 are also energized al lowing the field supplied and installed indoor fan contactor to function A field supplied and installed liquid line valve connect to TB1 terminals 3 and 4 will also open allowing the system to function in cooling As cooling demand is satisfied the thermostat contacts break deenergizing the contactor causing the system to shut off The liquid line shutoff valve closes minimizing the potential for refrigerant migration at this time The compressor does not restart un til the thermostat again calls for cooling If a demand for cooling occurs within 5 minutes after the thermostat is sat isfied the system will not restart due to the feature of Time Guard II After the 5 minute time period the system will restart as normal upon thermostat demand The system is protected with Cycle Loc device so that the compressor will not start if a high pressure or low pressure fault occurs Merely turn down the
13. n instructions and ap plicable codes Compressor Mounting Compressors are inter nally spring mounted Do not loosen or remove compressor holddown bolts Internal Wiring Check all electrical connections in unit control boxes tighten as required Time Guard Il Device Time Guard II Circuit pro vides for a delay of approximately 5 minutes before restart ing compressor after shutdown from safety device action On start up the Time Guard timer causes a delay of ap proximately 15 seconds after thermostat closes Refrigerant Service Ports Each unit system may have Schrader type service ports one on the suction line one on the liquid line and one on the compressor discharge line Be sure that caps on the ports are tight Cooling Set space thermostat to OFF position Set sys tem selector switch at COOL position and fan switch at AUTO position Adjust thermostat to a setting below room tem perature Compressor starts on closure of contactor Check cooling effects at a setting below room tempera ture Check unit charge Refer to Refrigerant Charge sec tion on page 5 Reset thermostat at a position above room temperature Compressor will shut off TO SHUT OFF UNIT Set system selector switch at OFF position Resetting thermostat at a position above room tem perature shuts unit off temporarily until space temperature exceeds thermostat setting Units are equipped with Cycle LOC protection device Un
14. piping and servicing unit See Fig 1 and Table 1 Locate unit so that condenser airflow is unrestricted on all sides and above Refer to Fig 1 Unit may be mounted on a level pad directly on base rails or mounted on raised pads at support points See Table 2 for weight distribution based on recommended support points NOTE If vibration isolators are required for a particular in stallation use data in Table 2 to make proper selection Table 1 Physical Data UNIT 38AK 007 OPER WEIGHT ib 340 REFRIGERANT 22 COMPRESSOR Oil 0z 65 CONDENSER AIR FAN Propeller Direct Drive Number Rpm 60 Hz 1 850 50 Hz 1 708 Diameter in 26 Motor Hp NEMA ve Nominal Cfm Total 3800 CONDENSER COIL Face Area sq ft 12 24 Storage Capacity Ib t 11 264 CONNECTIONS sweat Suction in 1 Liquid in Y2 CONTROLS Pressurestat Settings High Cutout 426 7 psig Cut in 320 20 psig Low Cutout 7 3psig Cut in 22 5 psig FUSIBLE PLUG 200 F Unit is factory supplied with holding charge only tStorage capacity of condenser coil with coil 80 full of liquid R 22 at 124 F Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 4 PC 111 Tab 3a 2a Catalog No 533 809 Printed in U S A Form 38AK 2Si Pg 1 6 92 Replaces New oo aA Table 2 Weight Distribution STD UNIT CORNER WEIGHT CORNER WEIGHT Weight fa ibs k
15. r charge or obstruction of outdoor airflow Connections loose tighten all connections Compressor motor thermostat open check for excessive motor temperature Contactor Closed Compressor leads loose check connections Single phasing replace blown fuse COMPRESSOR CYCLES ON HIGH PRESSURE SWITCH Condenser Fan On High pressure switch faulty replace switch Airflow restricted remove obstruction Air recirculating clear airflow area Noncondensables in system purge and recharge as re quired Refrigerant overcharge purge as required Refrigerant system restrictions check or replace filter drier expansion valve etc Condenser Fan Off Fan slips on shaft tighten fan hub setscrews Motor not running check power and capacitor Motor bearings stuck replace bearings Motor overload open check overload rating Check for fan blade obstruction Motor burned out replace motor Copyright 1992 Carrier Corporation COMPRESSOR CYCLES ON LOW PRESSURE SWITCH Evaporator Air Fan Running Filter drier plugged replace filter drier Expansion valve power head defective replace power head Low refrigerant charge add charge Check low pressure switch setting Airflow Restricted Evaporator coil iced up check refrigerant charge Evaporator coil dirty clean coil fins Indoor air filter dirty clean or replace filters Indoor air dampers closed
16. tage deviation from average voltage xX eaa ee average voltage AB 457 452 5v BC 464 457 7v AC 457 455 2v Maximum deviation is 7 v Determine voltage imbalance 7 Voltage Imbalance 100 x ie 158 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 immedi ately cos FIELD CONTROL WIRING Install a Carrier approved accessory thermostat assembly according to installation in structions included with the accessory Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature in accordance with thermostat instal lation instructions Route thermostat cable or equivalent single leads of col ored wire from subbase terminals to low voltage connec tions on unit shown in Fig 4 as described in Steps 1 through 3 below NOTE For wire runs up to 50 ft use no 18 AWG Amer ican Wire Gage insulated wire 35 C minimum For 50 to 75 ft use no 16 AWG insulated wire 35 C minimum For over 75 ft use no 14 AWG insulated wire 35 C min imum All wire larger than no 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat 1 Connect thermostat wires to screw terminals of low voltage connection board 2 Pass the control wires through the hole provided
17. thermostat to eliminate the cooling demand to reset the Cycle Loc device This should be done only once and if system shuts down due to the same fault de termine the problem before attempting to reset the Cycle Loc device The 38AK007 unit does not require a crank case heater SERVICE A CAUTION When servicing unit shut off all electrical power to unit to avoid shock hazard or injury from rotating parts Cleaning Inspect unit interior at the beginning of each cooling season and as operating conditions require CONDENSER COIL Inspect coil monthly Clean con denser coil annually and as required by location or outdoor air conditions Clean coil as follows 1 Turn off unit power 2 Remove top panel screws on condensing unit 3 Remove condenser coil corner post See Fig 7 To hold top panel open place coil corner post between top panel and side panel See Fig 8 CONTROL BOX CORNER POST REMOVE SCREWS CONDENSER REMOVE COIL COIL CORNER POST Fig 7 Cleaning Condenser Coil COIL CORNER POST TOP PANEL CONDENSER COIL Fig 8 Propping Up Top Panel iu il TOP VIEW PARET CONDENSER COIL INNER COIL SECTION 4 MAX OUTER COIL CLEAN SECTION RETURN END Fig 9 Separating Coil Sections 4 Remove device holding coil sections together at return end of condenser coil Carefully separate the outer coil section 3 to 4 in from the inner coil section See
Download Pdf Manuals
Related Search