Specifications

ManualsBrandsCarrier ManualsHeat Pump38AQ

GEMINI TM

38AQ007

38ARQ008,012

38AQS016

Split System Heat Pumps

50/60 Hz

Installation, Start-Up and Service Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS ...................... 1

INSTALLATION ................................ 1-17

General .......................................... l

Step 1 -- Complete Pre-lnstallation Checks ...... 1

Step 2 -- Rig and Mount Unit ..................... 1

Step 3 -- Complete Refrigerant Piping

Connections .................................. 10

Step 4 -- Complete Electrical Connections ...... 11

PRE-START-UP ............................... 18, 19

START-UP .................................... 19-21

SEQUENCE OF OPERATION ................. 21,22

SERVICE ..................................... 22-27

TROUBLESHOOTING ......................... 28, 29

START-UP CHECKLIST .................. CL-I, CL-2

SAFETY CONSIDERATIONS

Installing, stalling up, and servicing air-conditioning equip-

ment can be hazardous due to system pressures, electric;d

components, and equipment location (roofs, elevated struc-

tures, etc.).

Only tnuned, qualified installers and service mechanics

should install, start-up, and service this equipment. Untrained

pel_onnel can perforru basic maintenance functions such as

cleaning coils. All other operations should be performed by

trained service pel_onnel.

When working on the equipment, observe precautions in

the literature and on tags, stickers, and labels attached to the

equipment.

Follow all safety codes. Wear safety glasses and work

gloves. Keep quenching cloth and fire extinguisher nem_y

when brazing. Use care in handling, rigging, and setting bulky

equipment.

Before installing or servicing system, ¢flways turn off main

power to system and inst_fll lockout tag on disconnect.

There may be more than one disconnect switch. Electric_d

shock can cause personal injury.

INSTALLATION

General -- The split systeln heat pump units described in

this book should only be used with fire40RMQ indoor pack-

aged air handler sections.

Step 1 -- Complete Pre-lnstallation Checks

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 claim with shipping company

if shipment is damaged or incomplete.

CONSIDER SYSTEM REQUIREMENTS

• Consult local building codes and National Electrical

Code (NEC, U.S.A.) for special installation requirements.

• Allow sufficient space for airflow clearance, wiring,

refi'igerant piping, and servicing unit. See Fig. 1-3 for

unit dimensions. Figure 4 shows typical component loca-

tions for 38AQS016 units.

• Locate unit so that outdoor coil airflow is unrestricted on

all sides and above.

• Unit may be mounted on a level pad directly on the base

channels or mounted on raised pads at support points.

See Tables IA-ID for unit operating weights.

Step 2 -- Rig and Mount Unit

Be sure unit panels are securely in place prior to rigging.

Be cgueful rigging, handling, and installing unit. Improper

unit location can cause system malfunction and material

damage. Inspect base rails for any shipping damage and

make sum they are fastened securely to unit before rigging.

RIGGING -- These units are designed for overhead rigging.

Refer to rigging label for preferred rigging method. Spreader

bars am not required if top crating is left on unit. All panels

must be in place when rigging. As lin-ther protection for coil

faces, plywood sheets may be placed against sides of unit,

behind cables. Run cables to a centrtd suspension point so that

angle from the horizontal is not less than 45 degrees. Raise and

set unit down careliflly.

If it is necessary to roll the unit into position, mount the unit

on field-supplied rails placed lengthwise under the unit using a

minimum of 3 rollers. Apply force to the rails, not the unit. ff

the unit is to be skidded into position, place it on a large pad

and di'ag it by the pad. Do not apply any force to fire unit.

Raise from above to lift unit from the mils or pad when unit

is in final position.

After unit in position, remove all shipping materials and top

crating.

LOCATE UNIT- For service access and unrestricted air-

flow, provide clearance on each end and side of unit. Position

unit so that there is unrestricted airflow above unit.

NOTE: Before mounting unit, remove holddown brackets and

release skid.

If conditions or local codes require unit to be fastened to

pad, use the mounting holes in the base rails.

MOUNT UNIT -- The unit may be mounted on a solid, level

concrete pad, on accessory mounting legs, or on field-supplied

raised supports at each mounting position. (Note that mounting

hardware is field supplied.)

Bolt unit securely to pad or supports after unit is in position

and is level. Be sure to mount unit level to ensure proper oil

return to compressors. Mounting holes on unit can be used to

secure unit to vibration isolators, if required.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

PC 111 Catalog No. 533-80118 Printed in U.S,A, 38A-19SI Pg 1 9-04 Replaces: 38A-16SI

Summary of content (32 pages)

PAGE 1
GEMINI TM 38AQ007 38ARQ008,012 38AQS016 Split System Heat Pumps 50/60 Hz Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS ...................... 1 INSTALLATION ................................ 1-17 General .......................................... l Step 1 -- Complete Pre-lnstallation Checks ...... 1 Step 2 -- Rig and Mount Unit ..................... 1 Step 3 -- Complete Refrigerant Piping Connections ..................................
PAGE 2
B CONTROL BOX f FRONT \ 4 PLACES Line & Low _ 19 3/8 Voltage Wiring 35 / 2 / 1/2 Entrances 5-3 38-1/2 _ 1-;/2 t2-1/8 @ 9-3/4t 1-I/8 rTTTT_TTTT J D 2-1/2 4-1/4 11/2 1-1/2 REAR BOTTOM 33 35 i 38-1/2 iii 33 TOP 1-1/2 FRONT NOTES: 1, All dimensions are in inches, 2, Recommended clearance for proper airflow (local codes or jurisdictions may prevail): Top -- 60 in, Sides -- 24 in, on 3 sides; one side may have 6-in. clearance.
PAGE 3
CORNER COMPRESSOR ACCESSPANEL _ COIL IlXll OUTDOORCOIL 11627 [4578] REARVIEW COIL ACCESS CORNER // "Z TOP VIEW ELECTRICAL LOCATION CONTROL ACCESS PANEL (SEE CHART {SEE CONNECTION CHART FOR SIZE) LOCATION FOR SIZE) OUTDOORCOIL i 5825 [2293] _ OUTLET 6456 [2542] 111.7 E440] FORKTRUCK SLOTS (3 SIDESONLY) LEFT 2268 [8983 1751 [6.90] [459] ,,D.
PAGE 4
t/2 ° DIA. (4) MTG. HOLES {13 meO --(972 158 38 1/4" mm)--_ (72) 2 243 26 11116" (678 mm) _1_ 38AQS016 1 158 (72} 3 244 (111) WEIGHT DISTRIBUTION LJ WEIGHT -- Ib (kg) L 4 (S? u) UNIT 38AQS Total Operating Weight 1 2 3 4 803 (364) 158 (72) 243 (110) 244 (111) 158 (72) 016 REHOVASLE Support Point 1 5/8" ODM VAPOR 5°-9 311G* (1757 r_) BETWEENROUNTI_ HOLES (1016 ram) BETWEEN MOUNTING HOLES SEE DETAIL "A" FOR HOUNTIN6LEG5 ACCESSORY 2*_7° (1118 mm) m (51 m) K,0.
PAGE 5
1 2 3 4 5 6 7 8 9 10 11 12 14 15 28 16 26 © 25 24 23 22 21 © 20 LEGEND 1 23 4 5 6 7 8 9 10 ---------- Defrost Board/Time Guard II Control Fuse Fan No. 1 Compressor Lockout Device (CLO) Outdoor-Fan Relay Outdoor-Fan Contactor Compressor Contactor Fan Motor Capacitors Circuit Breaker Fan No. 2 Fig.
PAGE 6
Table 1ANOMINAL Physical Data- 38AQ007, 38ARQ008,012, 38AQS016 Units- UNIT 38AQ007 38ARQ008 CAPACITY (tons) 6 7.5 OPERATING WEIGHTS I I I10 34514641506 N/A 15 565 607 I 20 1 I I 20 9 I I 22 9 37 3 Scroll 1""SR-75 1""ZR12588 I 1""ZR-94 90 N/A 3500 (cfm total) OUTDOOR COILS (Oty) Face Area (sq ft total) Rows...Fins/in.
PAGE 7
Table 1 B -- Physical Data -- 38AQ007, 38ARQ008,012, UNIT NOMINAL CAPACITY (kW) OPERATING WEIGHTS 38AQ007 38ARQ008 I 38ARQ012 I 38AOS016 21.1 26.4 I 35.1 I 52.7 15712101230 N/A 256 275 R-22 I 10 I 4.1 I 365 430 (kg) Aluminum-Fin Coils (standard) Copper-Fin Coils (optional) REFRIGERANT* Operating Charge, Typical (kg)l" Shipping Charge (kg) 9 .5 I I 9 4.1 17 1.3 Scroll COMPRESSOR Qty._Model Oil Charge (L) No. Cylinders Speed (r/s) OUTDOOR FANS Qty...
PAGE 8
Table lC -- Physical Data -- 38ARQ008,012 UNIT and 38AQS016 Units -- 50 Hz English 38ARQ008 OPERATING WEIGHTS (Ib) Aluminum-Fin Coils (tons) (standard) NOMINAL CAPACITY Copper-Fin Coils (optional) REFRIGERANT* Operating Charge, Typical (Ib)t Shipping Charge (Ib) 464 6.3 565 508 8.3 607 38AQS016 803 12.5 945 R-22 I I Scroll 22 9 1...ZR_94 | 1...ZR125 90 t NA I 2900 2900 37 3 Semi-hermetic reciprocating 1...06DF5371-t 110 128 6 1450 2...
PAGE 9
Table 1D -- Physical Data -- 38ARQ008,012 UNIT NOMINAL CAPACITY (kW) OPERATING WEIGHTS (kg) Aluminum-Fin Coils (standard) Copper-Fin Coils (optional) REFRIGERANT* Operating Charge, Typical (kg)t Shipping Charge (kg) and 38AQS016 Units -- 50 Hz Sl 38ARQ008 38ARQ012 38AOS016 22.1 29.2 43.9 210 256 230 275 365 430 R-22 9 4.1 I I Scroll 10 4.1 1...ZR 94 / 1...ZR125 2.7- t NA I 3.3 COMPRESSOR Qty._Model Oil Charge (L) No. Cylinders Speed (r/s) OUTDOOR FANS Qty...
PAGE 10
Step 3 -nections- Complete Refrigerant Piping Con- Select the filter drier for maximum unit capacity and minimum pressure drop. Complete the refrigerant piping fi'om indoor unit to outdoor unit before opening the liquid and vapor lines at the outdoor unit. Refer to Table 4 for specific filter driers. Refi'igerant lines nmst be cm'efully designed and constructed to ensure equipment reliability and efficiency.
PAGE 11
Table 4 -- Refrigerant Specialties UNIT LIQUID LINE SIZE 38AQ007 LIQUID LINE SOLENOID VALVE (LLSV) 200RB 200RB 1/2" 5/8" 38ARQ008 3/8" 1/2" 38AQS016 5/8...... 3/4......
PAGE 12
Perloc_fl codelequimments, provide anadequate fused disconnect switch withinsightofunitandoutofreach ofchildren. Provision forlocking switchopen(off)isadvisable toplevent powerfrombeingturned onwhileunitis beingserviced. Tile disconnect switch,luses, andfieldwiringmustcomplywith localrequilements. Refer toTable 7 forelectric_fl data. POWER WIRING- All powerwilingmustcomplywith applicable loc_drequirements.
PAGE 13
Table 7 -- Electrical Data UNIT 38 NOMINAL VOLTAGE (V-Ph-Hz) FACTORY-INSTALLED OPTION AQ007 OR DISCONNECT CONVENIENCE ARQ008 NONE OR DISCONNECT NONE OR DISCONNECT CONVENIENCE NONE ARQ012 18.9 146 5.1 28.7 45 506 9.5 73 2.6 14.5 20 575-3-60 517 633 7.6 58 1.2 10.7 15 39.0 60 43.8 60 19.8 30 21.9 30 19.8 30 45.0 60 50.0 70 23.0 30 25.0 30 18.0 25 20.0 25 187 NONE 190 1.5 418 506 15.0 95 0.7 400-3-50 360 440 15.0 95 0.7 187 254 34.0 225 1.
PAGE 14
460V _ I ! TRAN CONFIG I I ! , i ! ! _{_ TRf, N Fig. 9 -- Wiring Diagram -- 38ARQ008,012 CONNECTION BOARD (TB) THERMOSTAT (3(3(3C)- -q @ (3C)TO ELECTRIC HEATER ACCESSORY IF EQUIPPED -- Control Transformer C) .C) .C) Q G -© 4Z) Q r I I I I Fig. 10 -- Wiring Diagram -- 38ARQ008,012 14 LEGEND IFC -LLSV -TB -- Indoor Fan Contactor Liquid Line Solenoid Valve Terminal Block NOTES: 1. For thermostat and subbase part no. see price pages. 2, Use copper conductors only.
PAGE 15
]FM 40RMQ UNiT WIRING 4ORMQ ELECTRIC HEAT ACCESSORY .... -J THERMOSTAT 38AQS TERMINAl TB2 BLOCK REMOVE JUMPER L LEGEND EQUIP GND HC IFC IFM NEC TB -------- Equipment Ground Heater Contactor Indoor Fan Contactor Indoor Fan Motor National Electrical Code (U.S.A.) Terminal Block Fig.
PAGE 16
TB1 I_FLEL_D _ _ _ BISCONNECT__P_OW_E_R o_lHCl_ _ _]| _ - I __?_UP_PL_y _ _HCI_ EQUIP __-rr'_ 3-PhONLY GND c I j 4 I I Ir i i CIRCUlTBREAKER (5 HPAND LARGER) ' %" IFC I I- I- HTR1 ] , , ,- - -[---"_q@_BLK_------m I 40RMQ024 TERMINALBLOCKTB1 _- ] - 4 d_II_-BLK_ WIRINGEIELDPOWER E E E )IFM; -_@I_-BLK-_____j/ ! UNITWIRING J 40RMQ HEAT ACCESSORY HEATPUMP"A" E E -WHT_] F;- --WHT I J I I I I .
PAGE 17
TB1 _-I DISCONNECT l--a P_OW_ERp_pL_y_IIL21_ S-PhONLY .ORMOO28 HTR1 1---, CIRCUIT BREAKER 5HPANDLARGER I I I I 11 _ _ FIELD POWER WIRING Y'_ HCI_ I _____ _IFC _ -" ' _} - - PCfl_@-BLK-_€_ TERMINALTB1BLOCK -R-_ I _- _ _p__.
PAGE 18
PRE-START-UP c. IMPORTANT: Before beginning Pre-Start-Up or StartUp, review Start-Up Checklist at the back of this book. The checklist assures proper start-up of the system and provides a record of unit condition, application requirements, system information, and operation at initial start-up. Evacuate and dehydiate entire refrigerant system by use of methods described in GTAC II, Module 4, System Dehydiation. 38AQS016 only -- compressor oil level should be visible in sight glass.
PAGE 19
8. Backseat (open) compressor vapor and discharge valves. Now close valves one turn to _dlowrefiigerant pressure to reach test gages. Preliminary Charge 2. Turn off power to the unit, tag disconnect. 3. 4. Reverse any two of the unit power leads. Reapply power to the compressol: verily correct pressures. The vapor and dischtuge pressure to their norln¢fl start-up levels.
PAGE 20
O_DOOR Compressor Lockout (CLO) Device-Tile Compressor lockout (CLO) device prevents the compressor fiom stariing or running in a high pressure, loss-of-chmge or fieezestat open situation. Reset the CLO device by setting the thermostat to eliminate cooling demand and return it to the ong_ inal set point, ff the system shuts down again for the stone fault, determine the possible cause before attempting to _eset the CLO device.
PAGE 21
When the thermostat is satisfied, the circuits me opened, and the compressor, outdoor-fan motor, heatel_, and indoor-fan motor stop. Never charge liquid into the low-pressure side of system. Do not ovemharge. During charging or removed of refrigerant, be sum indoor-fan system is operating. DEFROST -- Defrost board (DB) is a time and temperature control, which includes a field-selectable time period between checks for frost (30, 50, and 90 minutes).
PAGE 22
Defrostis achieved by reversal fiom heating to cooling cycleanddeenergization of outdoor-fan motol.'s, allowing hot refrigerant gastodefrost outdoor coil.Defrost isachieved with a timersetto initiatedefrostevery30,50,or 90minutes (factory setat30minutes). Defrost isinitiated whenrefrigerant temperature leaving the outdoor coilismeasured below27F (2.8C),(typically when theoutdoor ambient temperature is below45F [7.2C] as sensed bythedefiost thermostat [DFTI).
PAGE 23
5. Remove screws fiom compressor mounting plate. 3. Excessive movement of copper cause higher levels of vibration service. Subcooled refrigerant liquid leaves the coil circuits through the side outlet on the liquid headers. The liquid refrigerant from each coil flows through check valves "B" which are open, enters the liquid line and goes to the indoor coil. 4.
PAGE 24
COMPRESSOR _ REVERSING VALVE TO ?M AT_'_O UL R _ VAPOR-_LINE INDOOR UNIT BALL VALVE ? d& CK VALVE B CK VALVE A CK VALVE C 1] f II FILTER DRIER LIQUID LINE FIXED ORIFICE METERING DEVICE [_ BALL VALVE FROM INDOOR UNIT Fig. 21 -- 38ARQ008, 012 Heating Mode (Size 008 Shown) 38AQS016 Cooling Mode Operation (See Fig. 22) 2.
PAGE 25
REVERSING VALVE REFRIGERANT MIXTURE f FROM INDOOR COiL TO INDOOR COIL ACCUMULATOR CN GAS AND OIL LIQUID LLSV _[J ./ ANGLE VALVE WITH SCHRADER PORT HOT GAS j CK VALVE C COIL RETURN BEND END Fig. 22 --38AQS016 Cooling Mode REVERSING VALVE REFRIGERANT MIXTURE DOlL TO INDOO_R FROM COIL _ GAS AND OIL _ CK VALVE B -- _ / LLSV _ J ANGLE VALVE WITH SCHRADER PORT CK VALVE A HOTGAS CK VALVE C COIL RETURN BEND END Fig.
PAGE 26
Coil Cleaning and Maintenance--This section discusses the cleaning and the maintenance of standard coils and E-Coated coils. Routine cleaning of coil surfaces is essential to minimize contamination build-up and remove harmful residue. Inspect coils monthly and clean as required. CLEANING STANDARD COILS -- Standard coils can be cleaned with a vacuum cleaner, washed out with low velocity water, blown out with compressed ail; or blushed (do not use wire brush). Fan motors _u'e dripproof but not waterproof.
PAGE 27
6. DO NOT USE water in excess of 130 F (54.4 C). Enzymes in coil cleaner will be destroyed and coil cleaner will not be effective. 4. 5. Thoroughly rinse all surfaces with low velocity clean water using downward rinsing motion of water spray nozzle. Protect fins from damage from the spray nozzle. Do not use bleach, harsh chemicals, or acid cleaneLs on outdoor or indoor coils of any kind.
PAGE 28
TROUBLESHOOTING CHART-- HEATING CYCLE INSUFFICIENT I t 1 I I I RUNSBUT COMPRESSOR CYCLESOFF I I I HEATING OR I 1 WILLNOTRUN COMPRESSOR NO I I COMPRESSOR RUNS, tNSUPFtCIENTttEATING I DISCHARGE CONTACTOR OPEN .
PAGE 29
TROUBLESHOOTING CHART I I I I I t +N+_c_o_ _t °NTA++o_ I OPEN CLOSED POWER CIRCUIT OPENING IN t 1 ,_ POWER SUPPLY COMPRESSOR 1 I SWITCH HIGH-PRESSURE I __[ -! VOLTAGE DEFECTIVELOWTRANSFOEMER BREAKER CIRCUIT OPEN AI J FAN MOTOR I COIL OR CONTACTS CONTROLRELAY DEFECTIVE t I __ l ""f OR COIL CONTACTOE DEFECTIVE I __[ REMOTECONTEOL DEFECTIVE CENTER [ CIRCUIT OFF 1 OPEN WINDINGS COMPR ESSQ R MOTOR I ++++1 SEIZED COMPRESSOR DEFECTIVE MOTOR I q RESTRICTED OR OUTDQOR AIR R
PAGE 30
Copyright 2004 Carrier Corporation Manufacturer reserves the right to discontinue, PC 111 or change at any time, specifications Catalog No. 533-80118 Printed in U.S.A. or designs without notice and without incurring obligations.
PAGE 31
START-UP I. PRELIMINARY OUTDOOR INDOOR INFORMATION UNIT: MODEL UNIT: MODEL ADDITIONAL CHECKLIST NO. NO. SERIAL NO.: SERIAL NO.: ACCESSORIES II. PRE-START-UP OUTDOOR IS THERE UNIT ANY SHIPPING DAMAGE'? (Y/N) IF SO, WHERE: WILL THIS DAMAGE CHECK POWER PREVENT SUPPLY.
PAGE 32
III. START-UP CHECK INDOOR FAN SPEED CHECK OUTDOOR AFTER AT LEAST AND RECORD. FAN SPEED AND RECORD.