Concepcion-Carrier Air conditioning Company Philippines CONTENTS 38AKS016 - 044 AIR-COOLED CONDENSING UNITS - 60 Hz INSTALLATION, OPERATING MANUAL & SERVICE INSTRUCTIONS Page Page SAFETY CONSIDERATIONS 2 INSTALLATION Step 1 – Complete Pre-Installation Checks Step 2 – Rig and Mount the Unit Step 3 – Complete Refrigerant Piping Connections Step 4 – Complete Electrical Connections 2 2 2 8 10 PRE-START-UP System Check-up Leak Test and Dehydration Turn on Crankcase Heater Preliminary Charge 12 12 13 13
SAFETY CONSIDERATIONS • Installing, starting up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.). Unit may be mounted on a level pad directly on the base channels or mounted on raised pads at support points. See Tables 2A-2B for unit operating weights. See Table 1 for weight distribution based on recommended support points.
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Table 2A - Physical Data (English, 60 Hz) UNIT 38AKS NOMINAL CAPACITY (tons) 016 15 OPERATING WEIGHT ( lb) REFRIGERANT* Operating Charge, Typical ( lb)** COMPRESSOR Speed (Rpm) 789 No. Cylinders Model No. Oil (pt) Crankcase Heater Watts Unloader Setting (psig) 024 20 900 R-22 23 28 Reciprocating, Semi-Hermetic 1750 6 06DD537 8 125 Load Unload OUTDOOR-AIR FANS No. …Rpm Diameter (in.
Table 2B - Physical Data (English, 60 Hz) UNIT 38AKS 028 034 044 NOMINAL CAPACITY (tons) 25 30 40 OPERATING WEIGHTS (lb) 1650 1803 2437 COMPRESSOR Reciprocating, Semi-Hermetic Model 06E-265 06E-275 Oil (pt) 19 No. Cylinders (ea)…Speed (rpm) 06E-299 19 6… 1750 Capacity Steps 100%, 66% Unloader Setting (psig) No. 1 Load 76 Unload 58 REFRIGERANT R-22 Operating Charge, Typical (lb) 30.5 43.5 CONDENSER FANS 65 Propeller Type - Direct Drive Quantity…Diameter (in.
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. Hot gas bypass, if used, should be introduced before the evaporator. Note that refrigerant suction piping should be insulated.
Table 4A - Refrigerant Piping Sizes 0-15 (0-4.5) UNIT 38AKS 016 024 L 1/2 5/8 S 1 3/8 1 5/8 LENGTH OF INTERCONNECTING PIPING, FT (M) 15-25 25-50 50-75 (4.5-7.5) (7.5-15) (15-23) Line Size (in. OD) L S L S L S 5/8 1 3/8 5/8 1 5/8 7/8 1 5/8 5/8 1 5/8 7/8 1 5/8 7/8 2 1/8 75-100 (23-30) L 7/8 7/8 S 2 1/8 2 1/8 LEGEND L - Liquid S - Suction Close-coupled. NOTES: 1. Pipe sizes are based on a 2 F (1.1 C) loss for liquid lines and a 1.5 F (0.8 C) loss for suction lines. 2.
INSTALL FILTER DRIER(S), MOISTURE INDICATOR(S) AND SOLENOID VALVE(S) – The illustrations below are the standard piping connections. INSTALL LIQUID LINE SOLENOID VALVE – CAPACITY CONTROL - For 2-step cooling , place a solenoid valve in the location shown in Fig. 5 and Fig. 6 , upper circuit (ckt. 2). Circuit (ckt.) 2 shall be controlled by Thermostat 2 (T2). Complete the refrigerant piping from indoor unit to outdoor unit before opening the liquid and suction lines at the outdoor unit.
NOTE: 38AKS024, 034 & 044 has a fusible plug in the liquid line. Fig. 8 – Main power Supply Wiring Fig. 7 – Location of Fusible Plug (38AKS) Table 5A - Electrical Data (3 Ph/60 Hz) UNIT UNIT 38AKS 016 024 COMPR Volts Model 501 601 501 601 Nameplate 208-230 460 208-230 460 Supplied* Min Max 187 253 414 528 187 253 414 528 MCA ICF MOCP C.B. 87.5 40.7 93.4 48.1 274 124 353 177 125 60 150 80 LEGEND RLA LRA 63.6 29.3 67.9 34.7 266 120 345 173 FAN MOTORS (Single Phase) FLA(ea) Total Fan No.
Table 5B - Electrical Data (3 Ph/60 Hz) UNIT 38AKS 028 034 044 FLA ICF - LRA MCA - Nominal Voltage UNIT Voltage Range* Min Max 208-230 460 208-230 460 208-230 460 187 414 187 414 187 414 254 508 254 508 254 508 COMPRESSOR FAN MOTORS FLA RLA LRA Qty 102.2 49.8 118.4 56.2 165.6 74.7 89.8 43.6 106.5 50 147.5 65.4 446 223 506 253 690 345 LEGEND Full Load Amps Maximum Instantaneous Current Flow during starting.
Leak Test and Dehydration – Leak test the entire refrigerant system using soap bubbles and/or an electronic leak detector. section, Leak Test and Dehydration. 9. All internal wiring connections must be re-tightened, and all barriers and covers must be in place. Turn On Crankcase Heater – Turn on crankcase heater for 24 hours before starting the unit to be sure all the refrigerant is out of the oil.
If the initial check shows too much oil (too high in the sight glass) remove oil to proper level. See Preliminary Oil Charge, for proper procedure for adding and removing oil. See Fig. 9. CAUTION Never charge liquid into the low-pressure side of system. Do not overcharge. During charging or removal of refrigerant, be sure indoor-fan system is operating. When the above checks are complete, repeat the procedure with the unit operating at minimum load conditions. Adjust Refrigerant Charge MAX.
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When installed, a field supplied solenoid shuts of the liquid line to prevent refrigerant migration back to the compressor during the off cycle. SERVICE Capacity Control – For compressors equipped with an unloader, 2 cylinders are unloaded to provide capacity control. The unloader maybe suction-pressure actuated or electrically operated.
COMPRESSOR OVERTEMPERATURE PROTECTION (IP) – A thermostat installed in compressor motor winding reacts to excessively high winding temperatures and shuts off the compressor. (This is applicable only for 06D Compressor, not on 06E.) Discharge Temp. Sensor is on Cylinder Head for 06E, externally. COMPRESSOR has its own oil supply. Loss of oil due to a leak in the system should be the only reason for adding oil after the system has been in operation. See Preliminary Oil Charge section.
Fig. 17 – Outdoor Fan – 38AKS016 & 024 Fig. 18 – Pivot and Support Top Cover – 38AKS016 & 024 Fig.
TROUBLESHOOTING PROBLEM SOLUTION COMPRESSOR DOES NOT RUN Contactor Open 1. Power off. 1. Restore power. 2. Fuses blown in field power circuit. 2. After finding cause and correcting, replace with correct size fuse. 3. No control power. 3. Check control circuit breaker; reset if tripped or replace if defective. 4. Thermostat circuit open. 4. Check thermostat setting. 5. Time Guard II device not operating. 5. Check Time Guard II devices. 6. Compressor circuit breaker tripped. 6.
TROUBLESHOOTING (cont) PROBLEM COMPRESSOR CYCLES ON LOW PRESSURE SWITCH Airflow Restricted 1. Coil iced up. 2. Coil dirty. 3. Air filters dirty. 4. Dampers closed. Indoor-Air Fan Stopped 1. Electrical connections loose. 2. Fan relay defective. 3. Motor overload open. 4. Motor defective. 5. Fan belt broken or slipping. SOLUTION 1. Check refrigerant charge. 2. Clean coil fins. 3. Clean or replace filters. 4. Check damper operation and position. 1. Tighten all connections. 2. Replace relay. 3. Power supply.
START-UP CHECKLIST FOR 38AKS CONDENSING UNIT (MUST BE SENT TO CCAC UPON COMPLETION) A. PRELIMINARY INFORMATION Job Name : Location : Installing Contractor : Distributor : Start-up performed by : Start-up Date : EQUIPMENT: Model : Serial No. : COMPRESSOR: Model : Serial No. : Motor No. : Volts : INDOOR UNIT: B. RLA : Manufacturer : Model : Serial No.
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE = VOLTAGE IMBALANCE = (Max. deviation) x 100 = Average Voltage V %VOLTAGE IMBALANCE If over 2% Voltage Imbalance, do not attempt to start the unit! Call local power company for assistance. Assure that incoming power supply voltage to unit is within the range of PLUS or MINUS 10% rated voltage. C. UNIT START-UP (insert check mark as each item is completed) q Ensure crankcase heaters have been energized for a minimum of 24 hours prior to start-up.
§ Record motor amperage Compressor L1 A, Fan Motor 1 A 2 A L2 A, L3 A Remarks / Comments: Signature Technician Date Signature Customer 27 Date
