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Carrier 30GN040-420 Refrigerator User Manual

1. SCHEMATIC COIL TEMP re 208 230V 6 1 5 10 SNGL HP p SPEED SENSOR I 115V MOTORMASTER FIELD SUPPLY RED 1 BLK FIOP ACCESSORY CONVENIENCE OUTLET BLK dE oe i ccu i BLK 1 m 4 BLK BLK FIOP CONVENIENCE OUTLET 115V 1 m 4 C CADM RED NOTES FIELD 4 n 1 CONNECT PER I BLK BLK TAL D4 lt gm BLK 2 FOR 40V SUPPLY T PONER F r BLK 12 BLU f CONNECT BLU TO GRA BLU n YEL 13 23 YEL nmm BLU G2 COMP aay GRA RED TO YEL sent YEL TB1 gt amp RED YEL BLU GRA GFI CO kA YEL BLU e BLU gm YELLE pon Yt ed 49 J EQUIP GR 4 d i i Lei _oFR BLK H2 8LK BLK 0 4 P d BLK HC 8LK YEL OFM 1 SECOS SWITCH FUSE YEL BUSSMAN T 15 HKO HOO BRN pU BLK SS CAP 1 DEFROST BOAR
2. 4 5 8 168 45 1 8 STU veer view UU M FRONT VIEW OUTDOOR COIL REAR VIEW Standard UNIT Weight Ibs 38AUQ 07 444 SOMO Cee 38AUQ 12 Fig 1 38AUQ 07 12 Unit Dimensions NO TES 1 SUCTION CONNECTION SEE CHART FOR SIZE LIQUID CONNECTION SEE CHART FOR SIZE MINIMUM CLEARANCE LOCAL CODES OR JURISDICTION MAY PREVAIL A BOTTOM TO COMBUSTIBLE SURFACES 0 INCHES B OUTDOOR COIL FOR PROPER AIR FLOW 36 INCHES 914 ONE SIDE 12 INCHES 305 THE OTHER THE SIDE GETTING THE GREATER CLEARANCE 15 OPTIONAL C OVERHEAD 60 INCHES 1524 TO ASSURE PROPER OUTDOOR FAN OPERATION D BETWEEN UNITS CONTROL BOX SIDE 42 INCHES 1067 PER NEC E BETWEEN UNIT AND UNGROUNDED SURFACES CONTROL BOX SIDE 36 INCHES 914 PER NEC F BETWEEN UNIT AND BLOCK OR CONCRETE WALLS AND OTHER GROUNDED SURFACES CONTROL BOX SIDE 42 INCHES 1067 PER NEC WITH EXCEPTION OF THE CLEARANCE FOR THE OUTDOOR COIL AS STATED IN NOTE 1B 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 COVERTNG MATERTAL SERVICE VALVE CONNECTIONS UNIT SUCTION LIQUID 3841007 1 1 8 128 61 3 8 19 5 3841008 1 1 8 28 6 1 2 12 71 3841012 1 3 8 134 91 1 2 12 71 e CENTER OF GRAVITY CG B DIRECTION OF AIR FLOW DIMENSIONS IN 1 ARE IN MILLIMETERS 21 24 23 50 3 8
3. e o os L s 12051 RIGHT SIDE VIEW Unit Height 42 3 8 1076 42 3 8 1076 Table 1A Physical Data 38AUQ 07 12 Units 60 Hz English UNIT SIZE 38AUQ 07 08 12 NOMINAL CAPACITY tons 6 75 210 OPERATING WEIGHTS Ib Aluminum Fin Coils 444 483 575 REFRIGERANT R 410A Operating Charge Typical Ib t 18 0 21 0 27 0 Shipping Charge Ib 10 0 12 0 15 0 COMPRESSOR Qty Type 1 Scroll 1 Scroll 1 Scroll OUTDOOR FANS Qty Rpm 2 1100 Motor Hp 1 4 Diameter in 22 Nominal Airflow Cfm Total 6 000 Watts Total 610 OUTDOOR COIL Qty 1 Round Tube Plate Fin RTPF Face Area sq ft total 17 5 23 0 28 1 Rows Fins per inch FPI 2 17 2 17 2 17 CONTROLS Pressurestat Settings psig High Cutout 630 10 630 10 630 10 Cut in 505 20 505 20 505 20 Low Cutout 27 3 27 3 27 3 Cut in 44 5 44 5 44 5 PIPING CONNECTIONS in ODS Qty Vapor 1 11 8 1 11 g 1 13 g Qty Liquid 1 3 g 1 1 2 1 1 2 LEGEND ODS Outside Diameter Sweat socket t Unit is factory supplied with partial charge only T Typical operating charge with 25 ft of interconnecting piping Table 1B Physical Data 38AUQ 07 12 Units 60 Hz SI NOMINAL CAPACITY kW 35 1 OPERATING WEIGHT kg Aluminum Fin Coils 201 219 261 REFRIGERANT R 410A Operating Charge Typical kg t 8 2 9 5 12 2 Shipping Charge kg 4 5 5 9 6 8 COMPRESSOR Qty Type 1 Scroll 1 Scroll 1
4. ARE PROPER AIR FILTERS IN PLACE YIN _ HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT Y N DO THE FAN BELTS HAVE PROPER TENSION Y N HAS CORRECT FAN ROTATION BEEN CONFIRMED Y N _ PIPING ARE LIQUID LINE SOLENOID VALVES LOCATED AT THE INDOOR COILS AS REQUIRED YIN 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 CHECK VOLTAGE IMBALANCE LINE TO LINE VOLTS AB V AC V BC V AB AC 3 AVERAGE VOLTAGE 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 CHECK INDOOR UNIT FAN SPEED AND RECORD 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 Copy
5. 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 1s equipped with a TXV it must be changed to a 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 Do not leave Puron suction line driers in place for more than 72 hours APPENDIX B WIRING DIAGRAM LIST 38AUQ Electrical Characteristics 460 3 60 575 3 60 Diagram Number 38AU500362 38AU500435 208 230 3 60 38AU500363 208 230 3 60 460 3 60 575 3 60 460 3 60 575 3 60 208 230 3 60 33 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 ON VAPOR STUB F
6. 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 33CS 58SI for details on connecting the PremierLink controller and its various sensors THERMOSTAT ONE E BOARD CTB BOARD CTB eee kn EE LEN hr op e he Notes 1 2 INN S MEM 5 Q J te Note 4 g d 0 Note 3 a o 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 Table 8 Electrical Data 38AUQ 07 12 60 Hz Units UNIT FACTORY VOLTAGE NOMINAL VOLTAGE RANGE t POWER COMPRESSOR SUPPLY FAN MOTORS SIZE INSTALLED NONE OR DISCONNECT 45 208 230 3 60 187 253 1 5 CONVENIENCE OUTLET 316 6 50 NONE OR DISCONNECT 13 9 20 07 460 3 60 414 506 CONVENIENCE OUTLET 16 1 1 25 NONE OR DISCONNECT 10 5 15 575 3 60 518 633 pur CONVENIENCE OUTLET 12 2 2 15 NONE DISCONNECT 34 3 50 208 230 3 60 187 253 A C
7. High pressure switch is open and requires manual reset 5 Broken supply wires or connector is not making contact 6 Unusually long compressor protector reset time due to extreme ambient temperature 7 Compressor windings are damaged 1 Compressor fuse is open on one phase 2 Broken wire or connector on one phase 3 Compressor motor winding is damaged 4 Utility supply has dropped one phase Compressor running backward due to supply phase reversal 1 Compressor contactor has failed closed 2 Thermostat demand signal not connected to module 1 Control circuit transformer is overloaded 2 Low line voltage to compressor 2 29 Table 15 Troubleshooting Recommended Troubleshooting Action 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 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 and C wiring Miswired Module Indication Green LED is not on module does not power up Green LED Intermittent module powers up only when compressor runs T
8. Preliminary Charge below 6 The electrical power source must agree with the unit s nameplate rating Q UC 7 The crankcase heater must be firmly attached to the com pressor crankcase Be sure the crankcase is warm heater must be on for 24 hours before starting compressor Turn On Crankcase Heater Turn on the crankcase heater for 24 hours before starting the unit to be sure all the refrigerant is out of the oil To energize the crankcase heater proceed as follows 1 Set the space thermostat set point above the space tem perature so there is no demand for cooling 2 Close the field disconnect Preliminary Charge Before starting the unit charge liquid refrigerant into the high side of the system through the liquid service valve The amount of refrigerant added must be at least 80 of the operating charge listed in the Physical Data table Tables 1A and 1B on pages 4 and 5 Allow high and low side pressures to equalize before starting compressor If pressures do not equalize readily charge vapor on low side of system to assure charge in the evaporator Refer to GTAC II Module 5 Charging Recover Recycling and Reclamation for liquid charging procedures A CAUTION UNIT DAMAGE HAZARD Prior to starting compressor a preliminary charge of refrigerant must be added to avoid possible compressor damage 15 START UP 38AUQ Units The compressor crankcase heater must be on for 24 hours before start
9. discard Fig 9 Power Wiring Connections 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 Convenience Outlets WARNING ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death Units with convenience outlet circuits may use multiple disconnects Check convenience outlet for power status before opening unit for service Locate its disconnect switch 1f 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 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 Convenience Outlet GFCI aco Fuse Switch W Pwd CO Control Box Access Panel Fig
10. A CAUTION PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this caution may result in personal injury or equipment damage Only approved cleaning is recommended Routine Cleaning of Indoor Coil Surfaces Periodic cleaning with Totaline environmentally sound coil cleaner is essential to extend the life of coils This cleaner is available from Carrier Replacement Components Division as part number P902 0301 for one gallon container and part num ber P902 0305 for a 5 gallon container It is recommended that all coils including standard aluminum pre coated copper cop per or E coated coils be cleaned with the Totaline environmen tally 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 Totaline environmentally sound coil cleaner is nonflammable hypoallergenic non bacterial and a USDA accepted biode gradable agent that will not harm the coil or surrounding com ponents such as electrical wiring painted metal surfaces or in sulation Use of non recommended coil cleaners is strongly discouraged since coil and unit durability could be affected Clean coil as follows 1 Turn offunit power tag disco
11. EE i s 0 BRN ONTROL BOX COMPONENT ARRANGEMENT CO 1 2 g1 QNVOB NOII23NNOO BRN 20098599 FIELD CONTROL WIRING lt FIELD SPLICE CONTACTOR COMPRESSOR CAPACITOR OO MARKED WIRE CH CRANKCASE HEATER CADM COMFORT ALERT DIAGNOSTICS MODULE TD TERMINAL MARKED COMP COMPRESSOR MOTOR DFB DEFROST BOARD TERMINAL UNMARKED DFT DEFROST THERMOSTAT EQUIP EQUIPMENT X TERMINAL BLOCK FPT FREEZE PROTECTION THERMOSTAT FU FUSE SPLICE GR_ GROUND HPS HIGH PRESSURE SWITCH FACTORY WIRING WS gs ULSV LIQUID LINE SOLENOID VALVE CONTROL WIRING LOC LOSS OF CHARGE SWITCH OFM OUTDOOR FAN MOTOR mm FIELD PORE B WIRING OFR OUTDOOR FAN RELAY oe RVS REVERSING VALVE SOLENOID ACCESSORY OR OPTIONAL WIRING 5 REVERSI Ne VALE IND TCATE COMMON SVR SOLENOID VALVE RELAY POTENTIAL ONLY NOT TERMINAL BLOCK TO REPRESENT WIRING TRAN TRANSEORMER NOTES CREARE Z Torn fang 2 DEFROST BOARD DFB DISCONNECT PER NEC wn IF ANY OF THE ORIGINAL WIRE FURNISHED MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 90 C WIRE OR ITS EQUIVALENT USE COPPER CONDUCTORS ONLY COMPRESSORS AND FAN MOTORS ARE THERMALLY PROTECTED THREE PHASE MOTORS ARE PROTECTED AGAINST PRIMARY SINGLE PHA
12. Not Used Base Unit Controls A Not Used 0 Electro Mechanical Controls Not Used Design Revision 0 Not Used A Initial Rev Discrete Model Number Coil Options Voltage A Al Cu 1 575 3 60 B Precoat Al Cu 5 208 230 3 60 C E Coat Al Cu 6 460 3 60 Cu Cu M Al Cu with Hail Guard Precoat Al Cu with Hail Guard P E Coat Al Cu with Hail Guard Cu Cu with Hail Guard Fig 2 Model Number Nomenclature POSITION NUMBER 1 2 3 4 5 6 7 8 9 10 TYPICAL 4 8 0 9 G 1 2 3 4 5 POSITION DESIGNATES 1 2 Week of manufacture fiscal calendar 3 4 Year of manufacture 09 2009 5 Manufacturing location Texas USA 6 10 Sequential number Fig 3 Serial Number Nomenclature INSTALLATION Jobsite Survey Complete the following checks before installation 1 Consult local building codes and the NEC National Electrical Code ANSI NFPA 70 for special installation requirements 2 Determine unit location from project plans or select unit location 3 Check for possible overhead obstructions which may in terfere 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 draw
13. Protection Compressor May Stop Pumping With Motor Running Turn Off And Wait Until Cool May Need More Than 1 Hour To Reset 052 1272 00 www EmersonClimateContractor com ASTP Fig 14 Advanced Scroll Temperature Protection Label Recommended Cooling Time Minutes 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 dis connect switch Only the crankcase heater will be energized 16 Reset the space thermostat below ambient so that a call for cooling is ensured A CAUT
14. RESET button to clear the tripped condition Fuse on power type The factory fuse is a Bussman Fusetron 1 15 non renewable screw in Edison base type plug fuse Using unit mounted convenience outlets Units with unit mounded convenience outlet circuits will often require that two disconnects be opened to de energize all power to the unit Treat all units as electrically energized until the convenience outlet power is also checked and de energization is confirmed Observe National Electrical Code Article 210 Branch Circuits for use of convenience outlets 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 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 13 mm under screw heads are exposed Press the gasket over the screw heads Slip the backing plate over the screw heads at the keyhole slots and align with the gasket tighten the two screws until snug do not over tighten M
15. from tears caused by tools or components 3 Place terry cloth shop towel inside unit immediately un der 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 Liquid Line Filter Drier The factory provided reversible filter drier is specifically de signed 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 Fil ter 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 sys tem Heat from unsweating will release moisture and contami nants from drier into system Field Refrigerant 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 4 in SAE Flare couplings with Schrader check valves and service caps Use these ports to admit nitrogen to the field tubing during brazing to evacuate the tubing and evaporator coil to admit initial refrigerant charge into the low side of the system and when checking and adjusting the system refrigerant charge When service activities are completed ensure the service caps are in place and secure c
16. installation instructions and economizer accessory installation instructions for operating sequences when system is equipped with accessory economizer Heating When the thermostat calls for first stage heating terminal W1 is energized The 33AUQ s Defrost Board DFB receives this input at P2 7 The DFB removes the output at P3 7 RVS 1 the reversing valve solenoid is de energized and the reversing valve moves to Heating position DFB issues outputs at OF and P3 10 Outdoor fan relay OFR is energized both outdoor fan motors run Output PL3 10 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 19 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 Charg
17. is closed the defrost cycle is initiated The defrost period will end when opens indicating the outdoor coil has been cleared of frost and ice or a 10 minute elapsed period ex pires 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 con trol will resume unit operation at the point in the run period where it was last operating Table 13 Dip Switch Position Switch No 1 2 1 2 1 2 1 2 3 Dr I qup im L w vw v mj w Tor w 3ommues oms SUmmues aons Fan Day 23 Defrost Thermostats These are temperature switches that monitor the surface tem perature of the outdoor coil circuits These switches are mount ed 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 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 dis ables this feat
18. the unit label diagram CAUTION 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 CAPACITY CONTROL LIQUID LINE SOLENOID VALVE Evaporator capacity control via liquid solenoid valve is not rec ommended for use with 38AUQ models EQUALIZER LINE TXV INDOOR SENSING COIL CKT BULB AIRFLOW SIGHT GLASS A LOCATION FILTER DRIER A LOCATION SOLENOID VALVE LEGEND TXV Thermostatic Expansion Valve Fig 5 Location of Sight Glass es and Filter Driers typical 38AUQ 40RUQ size 07 amp 08 systems INDOOR COIL CKT 2 AIRFLOW FILTER DRIER LOCATION INDOOR COIL CKT 1 AIRFLOW LIQUID LINE SOLENOID VALVE L LEGEND TXV Thermostatic Expansion Valve Fig 6 Location of Sight Glass es and Filter Driers typical 38AUQ 40RUQ size 12 system Table 6 Minimum Outdoor Air Operating Temperature MINIMUM OUTDOOR UNIT COMPRESSOR Standard Unit Head Pressure Controlt 20 28 9 20 28 9 20 28 9 Applies to Cooling mode of operation only TWind baffles field supplied and field installed are recommended for all units with low ambient head pressure control Refer to Low Ambient Control Installation Instructio
19. 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 13 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
20. 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 factory installed to stepdown the main power supply voltage to the unit to 115 v at the duplex receptacle This option also includes a manual switch with fuse located in a utility box and mounted on a bracket behind the convenience outlet access is through the unit s control box access panel See Fig 10 The primary leads to the convenience outlet transformer are not factory connected Selection of primary power source is a customer option If local codes permit the transformer primary leads can be connected at the line side terminals on the unit mounted non fused disconnect or HACR breaker switch this will provide service power to the unit when the unit disconnect switch or HACR switch is open Other connection methods will result in the convenience outlet circuit being de energized when the unit disconnect or HACR switch is open See Fig 11 12 SCHEMATIC CONVENIENCE OUTLET pe
21. 12 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 inlet Refer to Table 5 for recommendations 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 5 Refrigerant Specialties Part Numbers LIQUID LINE LIQUID LINE LLSV SIGHT FILTER SIZE in SOLENOID VALVE LLSV COIL GLASS DRIER 3 8 ALC 066208 AMG 24 50 60 HMI 1TT3 Ti ALC 066209t AMG 24 50 60 HMI 1TT4 rovicec See Table 4 5 8 066212 AMG 24 50 60 HMI 1TT5 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 amp 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
22. 38AUQ Heat Pump Condensing Units 60 Hz with R 410A Refrigerant Sizes 07 08 and 12 Turn to the Experts Installation Start Up and Service Instructions CONTENTS SAFETY CONSIDERATIONS 1 INSTALLATION GUIDELINES 2 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 10 Step 7 Complete Electrical Connections 10 8 15 System 15 Turn On Crankcase 15 Preliminary 15 STARI UP ots hoes ETEEN 15 18 38AUQ Uns L ZL ee ERI PR UAR OF TEE t 15 OPERATING SEQUENCE 19 Indoor Supply 19 Cooling Unit Without Economizer 19 Cooling Unit With 19 Heating s ade s 2 19 Supplemental Heating Emergency Heating 19 Defrost Cycle con remp uu 19 Cooling and Heati
23. 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 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 5 in Suction 1 1 s in Charge 23 0 165 at 75 ft linear length 80 of Operating Charge 0 80 x 23 0 17 6 165 Factory Shipping Charge 12 lbs Field charge quantity 17 6 Ibs 12 0 lbs 5 6 Ibs For linear line lengths longer than 100 ft 30 5 m contact your local Carrier representative for system charge value Step 6 Install Accessories Accessories requiring modifications to unit wiring should be completed now These accessories may include Winter Start controls Low Ambient controls phase monitor Compressor LOCout Refer to the instructions shipped with the accessory Step 7 Complete Electrical Connections A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal i
24. D LC RED K2 me BLK DIP SWITCH SETTINGS Go BETWEEN duro SCB Na WIRES U Y eS EAT PACTIS ETOP accEssoRy L MES EL OFM 2 1491 irr 123 SHORT FOR 5 SEC AND RELEASE FOR firm BRN Lp FORCED YEL o or PERMANENT SHORT WILL BE IGNORED BLK TRANT L L LE DEFROST WILL TERMINATE IN 30 SEC IF 30 555 sss 558 ss DEFROST WILL TERMINATE NORMALLY DFT S CLOSED CB CONN QN BRN GRN YEL YEL DEFROST BOARD BLK TRAN2 90 110 9 Goo DS BLU pavac i 24 24V BRN COHN gt BOARD GRN YEL so RED s VIO 1 Morn 07 orn RED CR CH eRN bel RED YEL Y CL P ORN CADM BRN CONNECTION 2070009 oy a CONNECTION THERMOSTAT BOARD TB BOARD TB 1 S R 2 HPS Loc por al BLU 8 55 Mises BLK BLU 3 12 1 5 5 O 22 erur 82 Fop 1 Don 2 O 5 O O T O ACCESSORY CONN Pe t 4 E ORN BOARD BLU 1 KS am C BOARD 1 BRN SVR 1 BRN HR BRN rep GH 2 wr qp 8 E j BBN O GO N eh pr 19 BRN O NHT PNK 2 PAD M BRN 2 4 TRANI 0 WH m a m 22 2 2 BRN C CADM BRN BRN 0 5 08 s 2 eem BRN s
25. Flare cou plings The brass fittings are two piece High Flow valves with a re ceptacle 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 refrig erant oil to the check valve core s bottom o ring Install the fit ting body with 96 10 in Ibs of torque do not overtighten CORE Part No EC39EZ067 f DEPRESSOR PERARI 720 01 035 FROM FACE OF BODY This surface provides a metal to metal seal when torqued into the seat Appropriate handling is required to not scratch or dent the surface 7 16 20 UNF RH Fig 20 CoreMax Access Port Assembly 21 Heat Pump Controls Compressor Protection 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 mount ed on the discharge line The switch is stem mounted and brazed into the discharge tube Trip setting is 630 10 psig 4344 69 kPa wh
26. HECKLIST 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 N 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 safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices
27. ION Never charge liquid into the low pressure side of system Do not overcharge During charging or removal of refriger ant 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 Cool ing Charging Charts Fig 16 through Fig 18 For applications with line lengths greater than 100 ft contact Carrier representa tive Vary refrigerant until the conditions of the chart are met The charts are based on charging the units to the correct sub cooling 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 out door ambient temperature does not affect the reading Indoor airflow must be within the unit s normal operating range Oper ate the unit for a minimum of 15 minutes Ensure that pressure and temperature readings have stabilized Plot the liquid pres sure and temperature on chart and add or reduce the charge to meet the curve Adjust the charge to conform with the charging chart using the liquid pressure and temperature to read the chart Final Checks Ensure that all safety controls are operating control panel covers are on and the servi
28. IT 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 RIGGING These units are designed for overhead rigging Refer to the rigging label for preferred rigging method Spread er bars are not required if top crating is left on the unit All pan els must be in place when rigging As further protection for coil faces plywood sheets may be placed against the sides of the unit behind cables Run cables to a central suspension point so that the angle from the horizontal is not less than 45 degrees Raise and set the unit down carefully If it is necessary to roll the unit into position mount the unit on longitudinal rails using a minimum of 3 rollers Apply force to the rails not the unit If the unit is to be skidded into position place it on a large pad and drag it by the pad Do not apply any force to the unit Raise from above to lift the unit from the rails or pad when unit is in its final position After the unit is in position remove all shipping materials and top crating Step 5 Complete Refrigerant Piping Connections Refrigerant lines must be carefully designed and constructed to ensure equipment reliability and efficiency Line length pres sure drop compressor oil return and vertical separation are several of the design criteria that must be evaluated See Table 2 IMPORTANT Do not bury re
29. ONVENIENCE OUTLET 39 1 1 60 OR DISCONNECT 17 1 25 08 460 3 60 414 506 EL CONVENIENCE OUTLET 193 3 30 NONE OR DISCONNECT 12 5 20 575 3 60 518 633 CONVENIENCE OUTLET 142 2 20 NONE OR DISCONNECT 60 208 230 3 60 187 CONVENIENCE OUTLET 60 NONE OR DISCONNECT 30 12 460 3 60 CONVENIENCE OUTLET 30 NONE OR DISCONNECT 25 CONVENIENCE OUTLET 30 LEGEND 5 Unbalanced 3 Phase Supply Voltage FLA Full Load Amps Never operate a motor where a phase imbalance in supply voltage is greater than 2 Use the following formula to determine the percentage LRA Locked Rotor Amps of voltage imbalance MCA Minimum Circuit Amps max voltage deviation from average voltage MOCP Maximum Overcurrent C US usc dd average voltage Protection National Electrical Code Example Supply voltage is 208 230 3 60 RLA Rated Load Amps LAM AB 224 v BC 231 v t Units are suitable for use on electrical systems where voltage supplied to AC 226v 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 224 231 226 3 681 Average Voltage 227 Determine ma
30. OURTH FROM TOP MOTOR MASTER SENSOR MUST BE POSITIONED BETWEEN METERING DEVICE SECOND FROM TOP AND TUBE SHEET 6T HEAT PUMP 75T HEAT PUMP 10T HEAT PUMP Fig 31 Motormaster Sensor Locations per Unit Size Copyright 2009 Carrier Corp 7310 W Morris St gt Indianapolis 46231 Printed in U S A Edition Date 09 09 Catalog No 38AUQ 01SI Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces New 34 II START UP START UP CHECKLIST PRELIMINARY INFORMATION OUTDOOR MODEL NO SERIAL NO INDOOR AIR HANDLER MANUFACTURER MODEL NO SERIAL NO ADDITIONAL ACCESSORIES PRE START UP OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE Y N IF SO WHERE WILL THIS DAMAGE PREVENT UNIT START UP YIN CHECK POWER SUPPLY DOES IT AGREE WITH UNIT Y N _ HAS THE GROUND WIRE BEEN CONNECTED Y N HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY Y N _ _ ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY Y N _ _ CONTROLS ARE THERMOSTAT AND INDOOR FAN CONTROL WIRING CONNECTIONS MADE AND CHECKED VN ___ ARE ALL WIRING TERMINALS including main power supply TIGHT Y N _ HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS YN INDOOR UNIT HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE Y N
31. RIP 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 24 VAQC 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 Verify R and C terminals are supplied with 19 28VAC flashing together Verify Y terminal is connected to 24VAC at contactor coil Compressor Short Cycling Verify voltage at contactor coil falls below 0 5VAC when displayed incorrectly off ALERT Flash Code 3 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 be
32. SING CONDITIONS TRANSFORMER IS WIRED FOR 230V UNIT IF UNIT IS TO BE RUN WITH 208V POWER SUPPLY DISCONNECT BLK WIRE FROM 230V TAP AND CONNECT TO 208V TAP ON UNITS WITH SPEED CONTROL REMOVE BLACK WIRE BETWEEN CONTACTOR TERMINAL 11 AND OFR TERMINAL 4 AT CONTACTOR TERMINAL 11 AND CONNECT TO SCB TERMINAL 2 Fig 19 38AUQ Wiring Diagram 208 230 3 60 shown 18 OPERATING SEQUENCE Base Unit Controls Indoor Supply Fan The indoor fan contactor 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 15 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 The OF output energizes outdoor fan relay both outdoor fan motors start and run The output 1 ener gizes the reversing valve solenoid RVS Reversing valve switches to Cooling position Output PL3 10 24 v is received at CADM terminal Y If anti recycle time delay period has not expired safety pre
33. Scroll CONDENSER FANS Qty r s 2 18 2 18 2 18 Motor Hp NEMA 1 4 1 4 1 4 Diameter mm 560 560 560 Nominal Airflow L s 2832 2832 2832 Watts Total 610 610 610 CONDENSER COIL Qty 1 Round Tube Plate Fin RTPF Face Area sq m total 1 6 2 1 2 6 Rows Fins per Meter Fins m 2 670 2 670 2 670 CONTROLS Pressurestat Settings kPa High Cutout 4344 70 4344 70 4344 70 Cut in 3482 138 3482 138 3482 138 Low Cutout 186 21 186 21 186 21 Cut in 303 35 303 35 303 35 PIPING CONNECTIONS in ODS Qty Vapor 1 11 8 1 11 8 1 13 Qty Liquid 1 3 g 1 1 2 1 1 2 LEGEND NEMA National Electrical Manufacturers Association ODS Outside Diameter Sweat socket Unit is factory supplied with partial charge only T Typical operating charge with 7 62 m of interconnecting piping 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 3 8 1 2 0 0 A O A O Model Type Packaging 38AU Carrier Condensing Unit 0 Standard Puron R 410A Refrigerant 1 LTL Type of Coil Electrical Options Q Heat Pump Scroll Compressor Non Fused Disconnect Refrigerant Options A None Service Options B Low Ambient 0 None 1 Un powered Convenience Outlet Nominal Tonnage 2 Powered Convenience Outlet 07 6 Tons 08 7 5 Tons Not Used 12 10 Tons A Place Holder
34. actor IFC pressure lugs with unit field power leads All units except 208 230 v units are factory wired for the volt age shown on the nameplate If the 208 230 v unit is to be con nected 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 trans former Refer to unit label diagram for additional information Field power wires connected to the unit at line side pres sure lugs on compressor contactor and TBI see wiring dia gram label for control box component arrangement or at facto ry 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 con tactor 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 A WARNING FIRE HAZARD Failure to follow this warning could result in intermittent operation or performance satisfaction Do not connect aluminum wire between disconnect switch and condensing unit Use only copper wire See Fig 8 ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY Fig 8 Disconnect Swit
35. 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 Table 3 Maximum Vertical Separation DISTANCE FT M UNIT 38AUQ UNIT 40RUQ Unit 38AUQ Above Unit 40RMQ 07 07 50 52 08 oo 12 A 2 60 18 3 Vertical distance between indoor and outdoor units 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 braze the filter drier into the liquid line position Table 4 Puron duty Filter Drier s Liquid Desiccant Part AUTOT KH43LG09 AUTO 4315065 38AUQ
36. ce panels are in place CF TEMPERATURE AT LIQUID VALVE TEMPERATURE A LA VANNE DE LIQUIDE F 6 TON CHARGING CHART PURON ALL CONDENSER FANS OPERATING 6 TONNE TABLEAU DE CHARGE PURON TOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT 600 500 400 300 200 100 0 20 40 60 80 100 120 140 PRESSURE AT LIQUID VALVE PSIG PRESSION A LA VANNE DE LIQUIDE PSIG Fig 16 38AUQ 07 Charging Chart F TEMPERATURE AT LIQUID VALVE LA VANNE DE LIQUIDE F 7 5 TON CHARGING CHART PURON ALL CONDENSER FANS OPERATING 7 5 TONNE TABLEAU DE CHARGE PURON TOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT 150 130 110 90 70 50 30 140 190 240 290 340 390 440 490 540 590 PRESSURE AT LIQUID VALVE PSIG PRESSION LA VANNE DE LIQUIDE PSIG F wW gt gt a4 gt euo Pu lt gt m lt EN lt 2 Fu lt c lt a gt CAES Fig 17 38AUQ 08 Charging Chart 10 TON CHARGING CHART PURON ALL CONDENSER FANS OPERATING 10 TONNE TABLEAU DE CHARGE PURON TOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT 290 340 390 440 PRESSURE AT LIQUID VALVE PSIG PRESSION LA VANNE DE LIQUIDE PSIG Fig 18 38AUQ 12 Charging Chart 17
37. ch 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 1s 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 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 11 Units Without Disconnect Option 1 ee l Disconnect 1 SAT TTT TT 1 12 L3 208 230 3 60 460 3 60 575 3 60 Units With Disconnect Option Optional M a Disconnect s Switch Wing factory test leads
38. e LOC Switch or High Pressure Switch HPS opens while the compressor contactor C and re lay SVR are de energized compressor stops and liquid line so lenoid is de energized valve closes CADM initiates a TRIP event compressor demand sensed at CADM terminal Y but no current is measured at 2 T3 motor sensors CADM relay opens and RED LED is illuminated TRIP condition maintains lockout of compressor operation until CADM is manually re set Reset CADM by cycling unit main power Reversing valve solenoid remains de energized until the next Cooling cycle is initiated Defrost Cycle During the Heating Mode frost and ice can develop on the out door 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 previ ous 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 3 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 c
39. en hot Reset is automatic at 505 20 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 overtem perature Control Circuit 24 V The control circuit is protected against overcurrent conditions by a circuit breaker mounted on control transformer TRAN Reset is manual Crankcase Heater The heater prevents refrigerant migration and compressor oil dilution during shutdown whenever compressor is not operat ing The heater is wired to cycle with the compressor the heat er 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 pro longed 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 thermo
40. en in operation Outdoor Coil Maintenance and Cleaning Recommendation Routine cleaning of coil surfaces is essential to maintain proper operation of the unit Elimination of contamination and remov al of harmful residues will greatly increase the life of the coil and extend the life of the unit The following maintenance and cleaning procedures are recommended as part of the routine maintenance activities to extend the life of the coil Remove Surface Loaded Fibers Surface loaded fibers or dirt should be removed with a vacuum cleaner Ifa 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 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 ve locity water stream to avoid damaging the fin edges Monthly cleaning as described below is recommended 30
41. faces with low velocity clean wa ter using downward rinsing motion of water spray nozzle Protect fins from damage from the spray nozzle Service Parts Listings of service parts for all units are available from the Re placement Components Division s Electronic Parts Informa tion Catalog EPIC EPIC is available at Totaline stores dis tributor and service office parts departments and on line at CPartners com When entering EPIC the full unit model number is required The model number includes the Design Revision reference val ue 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 Condenser fan motor mounting bolts 20 2 in Ibs 226 23 N cm Condenser fan hub setscrew 84 2 in lbs High flow service port 96 10 in Ibs 949 136 N cm 1085 23 N cm Schrader type serv
42. facturer Compressor Oil CAUTION EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in damage to equipment The compressor in a Puron system uses a polyolester POE oil This oil is extremely hygroscopic meaning it absorbs water readily POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC re frigerants Take all necessary precautions to avoid exposure ofthe oil to the atmosphere 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 expo sure 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 refrig erants 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 ap proximate 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
43. frigerant piping underground IMPORTANT A refrigerant receiver is not provided with the unit Do not install a receiver Table 2 38AUQ 07 12 Piping Recommendations Single Circuit Unit R 410A Equivalent Length Ft 0 38 38 75 113 150 Model Length Linear 0 25 25 50 75 100 Nominal Capacity Length Equiiv 0 38 38 75 113 115 Liquid Une h 38AUQ 07 Max Lift Cool 25 50 48 75 39 100 Heat 25 50 46 60 31 60 iT E Charge bs 2 8 4__245 Max Lift Cool 25 50 75 100 Heat 50 60 Charge Ibs 203 23 0 24 9 26 8 38AUQ 12 Liquid Line 1 1 1 1 5 Max Lift Cool 25 50 75 85 100 Heat 25 50 60 60 60 ETE Charge Ibs 26 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 Maximum liquid lift at maximum permitted liquid line pressure drop Cooling Indoor unit ABOVE outdoor unit Heating Indoor unit BELOW outdoor unit Suction Line Tube size inches OD Charge Charge Quantity Ibs 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
44. hat 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 com pany if the shipment is damaged or incomplete CONSIDER SYSTEM REQUIREMENTS Consult local building codes and National Electrical Code NEC U S A for special installation requirements Allow sufficient space for airflow clearance wiring refrigerant piping and servicing unit See Fig 1 for unit dimensions and weight distribution data Locate the unit so that the outdoor coil condenser air flow 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 1 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 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 A CAUTION UN
45. heck for leaks If the Schrader check valve must be removed and re installed tighten to 2 3 in Ibs 23 34 N cm Outdoor Coil Metering Devices The metering devices are multiple fixed bore devices Acu trol 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 I 5 8 HEX _ lt 47 gt SEAT 1 2 20 UNF RH WASHER 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 ob serve 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 to W1 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 Refrigerant System Pressure Access Ports There are two access ports in each circuit on the suction tube near the compressor and on the discharge tube near the com pressor These are brass fittings with black plastic caps The hose connection fittings are standard 1 4 SAE Male
46. his caution may result in equipment damage or improper operation Never install suction line filter drier in the liquid line of a Puron system 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 instruc tions in this installation manual 7 Operate the system for 10 hr Monitor the pressure drop across the suction line filter drier If pressure drop ex ceeds 3 psig 21kPa replace suction line and liquid line filter driers Be sure to purge system with dry nitrogen and evacuate when replacing filter driers Continue to monitor the pressure drop across suction line filter drier Repeat filter changes is necessary Never leave suction line filter drier in system longer than 72 hr actual time CORNE 59 3 8 1509 THIS SIDE ONLY FOR 38AU214 amp 38AUD14 CORNER nm x TOP VIEW 3 3 4 ELECTRICAL 1961 DISCONNECT LOCATION OPTIONAL COMPRESSOR 13 114 FACTORY ACCESS PANEL 13371 INSTALLED DISCONNECT OUTDOOR COIL 1 3 8 134 51 POWER ENTRY WITH 50 0 58 0 65 0 MM OPTIONAL FACTORY INSTALLED CONVENIENCE OUTLET LOCATION 1 3 4 144 51 GUAGE ACCESS 1 8 22 2 FIELD ENTRY SERVICE PORT D E sa L 6 5 8 HANDLE FORK TRUCK SLOTS
47. ice check valve 2 3 in lbs 31 23 34 TROUBLESHOOTING PROBLEM CAUSE REMEDY Outdoor Fan 2 Will Not Start Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Determine root cause control relay or capacitor Fan Runs Compressor motor burned out seized or Determine cause Replace compressor or allow enough time for internal overload open internal overload to cool and reset Defective run start capacitor overload start Determine cause and replace compressor relay One leg of 3 phase power dead Replace fuse or reset circuit breaker Determine cause Compressor Will Not Faulty wiring or loose connections in compressor Check wiring and repair or replace Start But Outdoor circuit Nona Satisfying Defective compressor Replace and determine cause Blocked outdoor coil or dirty air filter Determine cause and correct Defective run start capacitor overload or start Determine cause and replace relay Defective thermostat Replace thermostat Faulty outdoor fan cooling or indoor fan heating motor or capacitor Locate leak repair and recharge Outdoor coil dirty or restricted Clean coil or remove restriction Compressor Makes Compressor rotating in the wrong direction Reverse the 3 phase power leads as described in Excessive Noise Start Up Excessive Head Dirty outside air or return air filter heating Replace filter Thermostat Insufficient line voltage Deter
48. ings 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 out door unit above indoor unit liquid line lift outdoor unit below indoor unit and hot gas bypass line Relocate sections to mini mize the length of interconnecting tubing DO NOT BURY REFRIGERATION LINES Although unit is weatherproof avoid locations that permit water from higher level runoff and overhangs to fall onto the unit RIGHT Min 18 457 mm requried for service REAR Min 18 457 mm requried for service LEFT Ss Min 18 457 mm requried for servi a 1067 mm _ c Note Observe requirements for 39 914 mm operating clearance on either Left or Rear coil opening diii FRONT Fig 4 Service Clearance Dimensional Drawing Step 2 Complete Pre Installation Checks CHECK UNIT ELECTRICAL CHARACTERISTIC Confirm before installation of unit t
49. ions may shutdown caused by loss of main power open pressure switches diag nostic alarms or open internal compressor protections See Service section for further details ROUTINE SYSTEM MAINTENANCE These items should be part of a routine maintenance program to be checked every month or two until a specific schedule for each can be identified for this installation Quarterly Inspection and 30 days after initial start Indoor section 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 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 Economizer or Outside Air Damper nlet filters condition Check damper travel economizer Check gear and dampers for debris and dirt 20 SERVICE Refrigeration System CAUTION EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in damage to equipment This system uses Puron amp refrigerant which has higher pressures than R 22 and other refrigerants No other refrig erant may be used in this system Gage set hoses and re covery system must be designed to handle If you are unsure consult the equipment manu
50. less Jumper for 5 20 secs Forced Defrost defrost runs for 30 secs if DFT2 is open 22 a e Gy a eg 2 DIAC wo la LL fo E PORT 3 AAT Lp 2 B E w B TB r KG s F o ol Gl EEG 000 TB2 DEO sc x ko 9 990 200 9 BBB Fig 21 Defrost Control Board DFB Location DIP Switches Fig 22 Defrost Control Board DFB Arrangement Reversing valve control The DFB has two outputs for unit reversing valve control Op eration of the reversing valves 15 based on internal logic this application does not use an or signal to determine re versing 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 de mand 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 thermo
51. 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 voucason HHP 3 qiti ES 3 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 Simulta
52. mine cause and correct Refrigerant overcharged Recover excess refrigerant Recover refrigerant evacuate system and recharge Condensing air restricted or air short cycling Determine cause and correct Outdoor ambient below 25 F cooling Install low ambient kit Outdoor fan motor s not operating heating Check fan motor operation Head Pressure Low refrigerant charge Check for leaks repair and recharge 32 APPENDIX A 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 DOT BW400 e 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
53. neous 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 Table 14 LED Status Codes Status LED Status LED Description Status LED Troubleshooting Information Green POWER Module has power Supply voltage is present at module terminals Red TRIP Thermostat demand signal Y Compressor protector is open LED On Solid is present but the Condensing unit power disconnect is open compressor is not running EA Compressor circuit breaker or fuse s is open Broken supply wires or connector is not making contact Compressor power wires not routed through Comfort Alert Compressor contactor has failed open Red TRIP LED The anti short cycle timer 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 24 VAC power must be removed from module to manually reset Yellow ALERT short circuit or over current LED On Solid condition exists on PROT terminal Yellow ALERT Flash Code 2 System Pressure Trip Discharge pressure out of limits or compressor overload if no high pressure Switch in sys
54. ng Shutdown 19 ROUTINE SYSTEM MAINTENANCE 20 Quarterly Inspection and 30 days after initial start 20 SERVICE er ee hen PA 20 31 Refrigeration System 20 Compressor 20 Servicing Systems Roofs with Synthetic 1 20 Liquid Line Filter 21 Filed Refrigerant Access Ports 21 Outdoor Coil Metering Devices 21 Refrigerant System Pressure Access Ports 21 Heat Pump 22 Commercial Defrost 22 Crankcase 22 Compressor 22 Low Pressure 33 Comfort Alert Diagnostic Module 28 Lu briCatiot st 30 Outdoor Coil Maintenance and Cleaning 30 Service Parts 31 Fastener Torque Values 31 TROUBLESHOOTING 32 APPENDIX A Air Conditioner and Heat Pump with Puron Quick Reference 33 APPENDIX B Wiring Diagram 18 33 APPENDIX C Motormaster Sensor 34 START UP C
55. njury 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 pri mary 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 cont
56. nnect 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 Totaline Environmentally Sound Coil Cleaner Application Equipment 2 1 gallon garden sprayer Water rinse with low velocity spray nozzle CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in corrosion and damage to the unit Harsh chemicals household bleach or acid or basic clean ers 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 inter face where dissimilar materials are in contact If there is dirt below the surface of the coil use the Totaline environmen tally sound coil cleaner as described above CAUTION 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
57. ns shipped with accessory for details 38AUQ07 38AUQ08 38AUQ12 Table 7 Insulation for Vapor Line Exposed to Outdoor Conditions LENGTH OF EXPOSED VAPOR LINE INSULATION THICKNESST 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 capac ity 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 con ditions TClosed cell foam insulation with a thermal conductivity of 0 28 Btu in ft2 h F 0 04 W m 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 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 Con nect 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 Field Service Access Port Factory Schrader core High Flow Access Port Service Valve with Stem Cap S os Connec
58. oil 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 supple mental heater will be energized During the Defrost Cycle on 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 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 de mand 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 supple mental heat is turned off Cooling and Heating Shutdown Partial or complete cooling or heating funct
59. ount 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 1096 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 field supplied wiring details Route control wires to the 38AUQ unit through the opening in unit s end panel to the connections terminal board in the unit s control box Remainder of the system controls connection will vary according to the specific construction details of the indoor section Fig 13 depicts typical connections to a Carrier A0RUQ fan coil unit Plan for field connections carefully and install control
60. p alo vel diu BLU PER T Gro Supp y HEC Ps So e e Sp RED YEL BLU GRA SECONDARY OO dh L a i A SECONDARY NT GROUND FAULT TRANA ANE RUE TER CONVENTENEE Sr icto G gt GRN k T La See Lom swircu ruse E 15 AMP UNI CONNECT PRIMARY TRANSFORMER VOLTAGE AS CONNECTIONS TERMINALS 208 L1 RED YEL H1 H3 230 240 L2 BLU GRA H2 H4 L1 RED 460 480 Splice BLUE H2 H3 YEL HA L2 GRA L1 RED H1 gt L2 GRA H2 UNIT CONNECT PRIMARY TRANSFORMER VOLTAGE AS CONNECTIONS TERMINALS 208 L1 RED YEL H1 230 L2 BLU GRA H2 H4 L1 RED Splice BLU L1 RED H1 L2 GRA 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 ie 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 re ceptacle does not trip as required Press the
61. right 2009 Carrier Corp 7310 W Morris St gt Indianapolis 46231 Printed in U S A Edition Date 11 09 Catalog No 38AUQ 01SI Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Pg CL 2 Replaces New CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE
62. ron Split system heat pumps are intended to be installed with matching indoor sections only The 38AUQ heat pump outdoor units are matched only with same size 40RUQ indoor sections Existing R 22 indoor coils cannot be converted to R 410A heat pump duty Only the existing refrigerant piping is a candidate for retrofit use Acid test If the existing system is being replaced because of a compressor electrical failure assume acid is in system If system is being replaced for any other reason use an approved acid test kit to determine acid level If even low levels of acid are detected install a 100 percent activated alumina suction line filter drier in addition to the replacement liquid line filter drier Operate this system in COOLING ONLY Remove the suction line filter drier as soon as possible with a maximum of 72 hr of operation Recommendation Install a ball valve in the liquid line at the filter drier location when installing a suction filter in the suction line Installation 1 Remove the existing evaporator coil or fan coil and install the replacement coil 2 Drain oil from low points and traps in suction line tubing if they were not replaced 3 Remove the existing outdoor unit Install the new outdoor unit according to these installation instructions 4 Install the factory supplied liquid line filter drier at the in door coil just upstream of the A CAUTION UNIT DAMAGE HAZARD Failure to follow t
63. s sure 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 de lay 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 enger ized Compressor and outdoor fan motors stop Liquid line so lenoid valve LLSV 15 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 Y 1 remains energized the compres sor 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 illumi nated TRIP condition maintains lockout of compressor opera tion until CADM is manually reset Reset CADM by cycling unit main power Reversing valve solenoid RVS is energized Cooling modes This solenoid will remain energized until the next Heat ing mode is initiated Cooling Unit With Economizer Refer to fan coil unit
64. ss Ports Fig 25 38AUQ 07 Interior 25 Outdoor Coil LOC Fig 26 38AUQ 08 Exterior EU UT ATE aaa NN 3 CS e 5 7 High Flow Access Ports Defrost Thermostat DFT HPS Fig 27 38AUQ 08 Interior 26 Fig 28 38AUQ 12 Exterior Outdoor Coil Defrost Thermostat DFT High Flow Access Ports Fig 29 38AUQ 12 Interior 27 COMFORT ALERT DIAGNOSTIC MODULE The Comfort Alert Diagnostic Module CADM monitors and analyzes data from the Copeland Scroll three phase compres sor 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 24 Contacior Co P 24V 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
65. stat demands for supply fan control 1 or 2 stage cooling 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 G Fan 1 Cool 1 Wi Heat 1 R Power Type of I O DI 24 vac DI 24 vac DI 24 vac 24 vac 24 vac ground C Common Connection Pin Number Note ew TRAE TRAE Unit Connection P2 3 2 5 2 7 P3 1 P3 3 TB Y1 DETI Defrost Swich Di 24 vac o8 Outputs Point Name OF OD Fan RVS1 RVS2 COMP 1 DO 24 vac DO 24 vac DO 24 vac DO 24 vac P3 7 to P3 5 P3 6 to P3 4 Type of I O Connection Pin Number Unit Connection RVS1 RVS2 CADM1 Y Energize in COOL Energize in COOL P3 10 HEAT 2 DO 24 vac E HEAT HC 1 TB4 1 l l Configuration Point Name Select Jumper 24 vac Type of I O Connection Pin Number Unit Connection P1 1 Speed Up Configuration Point Name CS JMP17 Type of I O Connection Pin Number Unit Connection SpeedUp uumper Jj Jumper for 1 3 secs Factory Test defrost runs for 12 seconds or
66. stat 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 compres sors run 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 cy cle 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 SW 30 MINUTES 2 3 TCH SETTINGS DEFROST BD 60 MINUTES 90 MINUTES 120 MINUTES 2 3 1 2 3 12 3 ON OR OR OFF FIELD SELECTABLE OPT DEFROST CYCLES MINU Fig 23 DIP Switch Settings Defrost Board ONS FOR TIME ES PERIOD BETWEEN At the end of the continuous run period the defrost control will test for a need to defrost On unit sizes 04 07 single compres sor designs controls the start and termination of the de frost cycle If DFTI is still open the defrost test run window is closed and the control repeats the continuous run period If
67. tem LOCKOUT Yellow ALERT Flash Code 3 Short Cycling Compressor is running only briefly LOCKOUT Yellow ALERT Flash Code 4 Locked Rotor LOCKOUT Yellow ALERT Flash Code 5 Open Circuit Yellow ALERT Flash Code 6 Missing Phase LOCKOUT Yellow ALERT Reverse Phase 1 Flash Code 7 LOCKOUT Yellow ALERT Flash Code 8 Welded Contactor Compressor always runs Yellow ALERT Low Voltage Flash Code 9 Control circuit lt 18VAC 1 Compressor contactor coil shorted 2 Electrical load too high for PROT circuit maximum 1 Amp 3 24V AC wired directly to PROT terminal 1 High head pressure 2 Condenser coil poor air circulation dirty blocked damaged 3 Condenser fan is not running 4 If low pressure switch is open Refer to Code 3 for troubleshooting 1 If low pressure switch is open a Low refrigerant charge Evaporator blower is not running Evaporator coil is frozen Faulty metering device Condenser coil is dirty Liquid line restriction filter drier blocked if present If high pressure switch is open go to Flash Code 2 information 3 Intermittent thermostat demand signal 4 System or control board defective 1 Low line voltage to compressor 2 Excessive liquid refrigerant in compressor 3 Compressor bearings are seized 1 Condensing unit power disconnect is open 2 Compressor circuit breaker or fuses are open 3 Compressor contactor has failed open 4
68. 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 Compressor Overload This overload interrupts power to the compressor when either the current or internal motor winding temperature becomes ex cessive and automatically resets when the internal temperature drops to a safe level This overload may require up to 60 min utes 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 Advanced Scroll Temperature Protection ASTP 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 ap proximately 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 bal ance while the motor continues to run The longer the compres sor runs unloaded the longer it must cool before the bi metal disk resets See Fig 15 seron Advanced Scroll Temperature
69. the water or air jet will bend the fin edges and in crease airside pressure drop Totaline Environmentally Sound Coil Cleaner Application Instructions 1 Proper eye protection such as safety glasses is recom mended 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 gallon garden spryer according to the instructions includ ed with the cleaner The optimum solution temperature 1s 100 38 NOTE Do NOT USE water in excess of 130 F 54 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 ap ply 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 ar eas 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 Re apply cleaner as needed to ensure 10 minute saturation 15 achieved 11 Thoroughly rinse all sur
70. tion 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 and bubbles 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 Ibs 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 follow ing description in GTAC II Module 4 System Dehydration WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause personal injury death and or equipment damage Puron amp R 410A refrigerant systems operate at higher pressures than standard R 22 systems Do not use 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
71. up After the heater has been on for 24 hours the unit can be started If no time elapsed since the preliminary charge step was completed it is unnecessary to wait the 24 hour period Preliminary Checks 1 Check that electric power supply agrees with unit nameplate data 2 Verify that the compressor crankcase heater is securely in place 3 Check that the compressor crankcase heater has been on at least 24 hours 4 Recheck for leaks using the procedure outlined in the Pre Start Up section Leak Test and Dehydration If any leaks are detected repair as required Evacuate and dehydrate as described in the Leak Test and Dehydration section 5 Ensure that the preliminary charge has been added as described in the Pre Start Up section Preliminary Charge 6 All internal wiring connections must be tight and all barriers and covers must be in place NOTE The units are factory charged with the required amount of oil If recharging in required use Emkarate RL 32 3MAF Compressor Rotation On 3 phase units with scroll compressors it is important to be certain that the compressor is rotating in the proper direction 38AUQ units are equipped with a Comfort Alert Diagnostic Module CADM Alert Code 7 indicates reverse power phas ing 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 pres sures To verify
72. ure The delay period begins when Y 1 demand or W1 demand by the space thermostat is removed 24 Defrost Speedup Functions 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 de frost 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 Service Valves Fig 24 38AUQ 07 Exterior Outdoor Coil Defrost Thermostat or gt i LOC ni 9 E HPS High Flow Acce
73. which may result in minor personal injury or product and property damage NOTE 15 used to highlight suggestions which will result enhanced installation reliability or operation WARNING 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 A WARNING 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 A WARNING 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 A CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing 38AUQ units INSTALLATION GUIDELINE Replacement Retrofit R22 to Pu
74. ximum deviation from average voltage AB 227 224 2 BC 231 227 4v AC 227 226 1v Maximum deviation is 4 v Determine percent of voltage imbalance Voltage Imbalance 100 x 227 1 76 This amount of phase imbalance is satisfactory as it is below the maximum allowable 296 IMPORTANT If the supply voltage phase imbalance is more than 296 contact your local electric utility company immediately 14 PRE START UP IMPORTANT Before beginning Pre Start Up or Start Up review Start Up Checklist at the back of this book The Checklist assures proper start up of a unit and provides a record of unit condition application requirements system information and operation at initial start up CAUTION 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 i Check Check all indoor section and other equipment auxiliary components Consult the manufacturer s instructions regarding any other equipment connected to the con densing unit If the unit has field installed accessories be sure all are properly installed and correctly wired used the airflow switch must be properly installed Besure the unit is properly leak checked and dehydrated Check tightness of all electrical connections Open the liquid line and suction line service valves Be sure the unit is properly charged See

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