Installation manual

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38AUQ

Heat Pu mp Condensing Units

60 Hz

With Puron

(R---410A) Refrigerant

S i z e s 1 6 --- 2 5

Installation, Start---Up and

Service Instructions

CONTENTS

SAFETY CONSIDERATIONS 2....................

INSTALLATION GUIDELINES 2..................

INSTALLATION 7 -- 16...........................

Step 1 -- Plan for Unit Location 7..................

Step 2 -- Complete Pre--Installation Checks 8.........

Step3–PrepareUnitMounting Support 8...........

Step 4 -- Rig and Mount the Unit 8.................

Step 5 -- Complete Refrigerant Piping Connections 8...

Step 6 -- Install Accessories 12....................

Step 7 -- Complete Electrical Connections 12.........

PRE-START-UP 17...............................

System Checks 17..............................

Turn On Crankcase Heaters 17....................

Preliminary Charge 17...........................

START--UP 17 -- 23..............................

38AUQ Units 17...............................

OPERATING SEQUENCE 24......................

Indoor (Supply) Fan 24..........................

Cooling Unit Without Economizer 24...............

Cooling Unit With Economizer 24.................

Heating 24....................................

Defrost Cycle 24...............................

Supplemental Heating/Emergency Heating 25........

Cooling and Heating Shutdown 25.................

ROUTINE SYSTEM MAINTENANCE 25............

Quarterly Inspection

(and 30 days after initial start) 25..................

SERVICE 25 - 36................................

Refrigeration System 25.........................

Compressor Oil 25..............................

Servicing Systems on Roofs

with Synthetic Materials 25.......................

Liquid Line Filter Driers 26.......................

Filed Refrigerant Access Ports 26..................

Outdoor Coil Metering Devices 26.................

Refrigerant System Pressure Access Ports 26.........

Compressor Protection 27........................

Crankcase Heater 27............................

Commercial Defrost Board 27.....................

Comfort Alert Diagnostic Module 32...............

Outdoor Fans 34................................

Lubrication 34.................................

Outdoor Coil Maintenance and

Cleaning Recommendations 34....................

Service Parts 36................................

Fastener Torque Values 36........................

TROUBLESHOOTING 37.........................

APPENDIX A

Air Conditioner and Heat Pump with Puron

–

Quick Reference Guide 38........................

APPENDIX B

Wiring Diagram List 38..........................

APPENDIX C

Low Ambient Option — Factory Installed 39.........

START--UP CHECKLIST 47 -- 48...................

Summary of content (48 pages)

PAGE 1
38AUQ Heat Pump Condensing Units 60 Hz With PuronR (R---410A) Refrigerant Sizes 16 --- 25 Installation, Start---Up and Service Instructions CONTENTS SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 2 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 36 INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . 2 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 25 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 2
SAFETY CONSIDERATIONS ! 38AUQ 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.
PAGE 3
! 7. Operate the system for 10 hr. Monitor the pressure drop across the suction line filter drier. If pressure drop exceeds 3 psig (21kPa), replace suction-line and liquid-line filter driers. Be sure to purge system with dry nitrogen and evacuate when replacing filter driers. Continue to monitor the pressure drop across suction-line filter drier. Repeat filter changes is necessary. Never leave suction-line filter drier in system longer than 72 hr (actual time).
PAGE 4
38AUQ Fig.
PAGE 5
Table 1A — Physical Data — 38AUQ*16-25 Units — 60 Hz English UNIT SIZE 38AUQ* 16 25 NOMINAL CAPACITY (tons) 15 20 REFRIGERANT SYSTEM‡ Refrigerant PuronR (R--- 410A) # Circuits / # Compressor / Type 2 / 2 / Scroll 2 / 2 / Scroll 9.0/9.0 9.0/9.
PAGE 6
Table 1B — Physical Data — 38AUQ*16-25 Units — 60 Hz SI UNIT SIZE 38AUQ* 16 25 NOMINAL CAPACITY (kW) 15 20 REFRIGERANT SYSTEM‡ Refrigerant PuronR (R--- 410A) # Circuits / # Compressor / Type 2 / 2 / Scroll 2 / 2 / Scroll 4.1/4.1 4.1/4.1 9.5/9.5 12.2/12.2 Acutrol Acutrol High---Pressure Trip / Reset (kPa) 4344 / 3482 4344 / 3482 Low---Pressure Trip / Reset (kPa) 372 / 807 372 / 807 ZP83 (2) ZP103 (2) Oil Charge A/B (L) 1.7 3.
PAGE 7
1 2 3 8 A U Q A 2 3 4 5 6 _____________ 7 8 9 10 11 12 13 14 15 16 17 18 5 A 0 C 6 – 0 A 0 A 0 ____ Model Type Packaging 38AU= Carrier Condensing Unit Puronr R--- 410A Refrigerant 1 = LTL 0 = Standard Type of Coil Q = Heat Pump Scroll Compressor Electrical Options A = None C = Non-Fused Disconnect Refrigerant Options A = None B = Low Ambient Service Options 0 = None 1 = Un-powered Convenience Outlet 2 = Powered Convenience Outlet Nominal Tonnage 16 = 15 Tons 25 = 20 Tons Not Used A
PAGE 8
Do not install the outdoor unit in an area where fresh air supply to the outdoor coil may be restricted or when recirculation from the condenser fan discharge is possible. Do not locate the unit in a well or next to high walls. Evaluate the path and required line length for interconnecting refrigeration piping, including suction riser requirements (outdoor unit above indoor unit), liquid line lift (outdoor unit below indoor unit) and hot gas bypass line.
PAGE 9
Table 2 – 38AUQ*16-- 25 Piping Recommendations (Two-Circuit Unit) R-410A Model Nominal Capacity 38AUQ*16 Equivalent Length Length Equiv 0-38 38-75 75-113 113-150 150-188 Length Lin 0-25 25-50 50-75 75-100 100-125 Liquid Line 1/ 1/ 1/ 1/ 1/ 2 2 2 2 2 Max Lift 38AUQ*25 Cool 25 50 75 100 125 Heat 25 50 60 60 60 Vapor Line 11/ 11/ 11/ 11/ Charge ea. (lbs) 20.9 22.8 Liquid Line 1/ 1/ 8 2 8 24.8 5/ 2 8 1/ 8 5/ 2 8 8 11/8 26.6 28.
PAGE 10
Table 3 – Puron-duty Filter Drier(s) Liquid Line OD Model-Size Qty 38AUQ*16 2 1/ 2 1/ 38AUQ*25 Desiccant Volume Part Number Ref 2-in 16 cu. in. KH43LG089 2-in 16 cu. in. KH43LG089 Table 4 – Refrigerant Specialties Part Numbers LIQUID LINE SIZE (in.
PAGE 11
Make Piping Connections — Evacuation/Dehydration — 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. Evacuate and dehydrate the connected refrigeration system(s) (excluding the 38AUQ unit) to 500 microns using a two-stage vacuum pump attached to the service ports outside the 38AUQ service valves, following description in GTAC II, Module 4, System Dehydration.
PAGE 12
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. NOTE: TEST LEADS - Unit may be equipped with short leads (pigtails) on the field line connection points on contactor C or optional disconnect switch.
PAGE 13
Units Without Disconnect Option C 11 Convenience Outlet GFCI TB1 13 Pwd-CO Fuse Switch Pwd-CO Transformer Disconnect per NEC L2 L3 208/230-3-60 460-3-60 575-3-60 Control Box Access Panel Units With Disconnect Option L1 2 L2 4 L3 6 1 Optional Disconnect Switch 3 Fig. 10 - Convenience Outlet Location Factory Wiring 5 Disconnect factory test leads; discard. Fig. 9 - Power Wiring Connections C10204 All field wiring must comply with the NEC and local requirements.
PAGE 14
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.
PAGE 15
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. (Note 1) (Note 3) 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.
PAGE 16
Table 7 – Electrical Data — 38AUQ*15-- 25 UNIT SIZE 38AUQ *16 38AUQ *25 UNIT SIZE 38AUQ *16 *25 NOMINAL POWER SUPPLY COMPRESSOR VOLTAGE RANGE No. 1 NO C.O. or UNPWRD C.O. No. 2 OFM POWER SUPPLY DISCONNECT SIZE V--- Ph--- Hz Min Max RLA LRA RLA LRA Qty FLA (ea) MCA FUSE or HACR BRKR 208/230---3---60 187 253 25.0 164 25.0 164 3 1.5 60.8/60.8 80/80 63/63 337/337 460 ---3 ---60 414 506 12.2 100 12.2 100 3 0.8 29.9 40 31 206 575 ---3 ---60 518 633 9.
PAGE 17
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. UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage. Prior to starting compressor, a preliminary charge of refrigerant must be added to avoid possible compressor damage.
PAGE 18
Compressor Overload — This overload interrupts power to the compressor when either the current or internal motor winding temperature becomes excessive, and automatically resets when the internal temperature drops to a safe level. This overload may require up to 60 minutes (or longer) to reset. If the internal overload is suspected of being open, disconnect the electrical power to the unit and check the circuit through the overload with an ohmmeter or continuity tester.
PAGE 19
38AUQ Fig.
PAGE 20
38AUQ Fig.
PAGE 21
38AUQ Fig.
PAGE 22
38AUQ Fig.
PAGE 23
38AUQ Fig.
PAGE 24
OPERATING SEQUENCE Base Unit Controls Indoor (Supply) Fan — The indoor fan contactor (IFC) is remotely located at the fan coil or fan section. If the thermostat fan operation is selected as Continuous, the IFC is energized and the indoor (supply) fan motor runs continuously. If the thermostat fan operation is selected as Automatic, the IFC will be energized on a call for Cooling or Heating; indoor (supply) fan motor runs.
PAGE 25
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. S Wire terminal tightness S Refrigerant charge level Economizer or Outside Air Damper S Inlet filters condition S Check damper travel (economizer) S Check gear and dampers for debris and dirt SERVICE Refrigeration System ! Supplemental Heat/Emergency Heat — EQUIPMENT DAMAGE HAZARD Failure to follow this caution may result in damage to equipment .
PAGE 26
2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run-offs, and protect drop cloth from tears caused by tools or components. 3. Place terry cloth shop towel inside unit immediately under component(s) to be serviced and prevent lubricant run-offs through the louvered openings in the base pan. 4. Perform required service. 5. Remove and dispose of any oil contaminated material per local codes.
PAGE 27
Compressor Protection Charge Switch trip setting is 27 psig ± 3 psig (186 ±21 kPa). Reset is automatic at 44 ±5 psig (303 ± 35 kPa). The compressor has internal limbered motor protection. Compressor Overtemperature Protection (IP) — The compressor has an internal protector to protect it against excessively high discharge gas temperatures. Crankcase Heater — The heater prevents refrigerant migration and compressor oil dilution during shutdown whenever compressor is not operating.
PAGE 28
Reversing Valve Control — The DFB has two outputs for unit reversing valve control. Operation of the reversing valves is based on internal logic; this application does not use an “O” or “B” signal to determine reversing valve position. Reversing valves are energized during the Cooling stages and de-energized during Heating cycles. Once energized at the start of a Cooling stage, the reversing valve will remain energized until the next Heating cycle demand is received.
PAGE 29
Defrost — If the space heating load is satisfied and compressor operation is terminated, the defrost control will remember where the run period was interrupted. On restart in Heating, the defrost control will resume unit operation at the point in the run period where it was last operating. The defrost control mode is a time/temperature sequence. There are two time components: The continuous run period and the test/defrost cycle period.
PAGE 30
38AUQ Fans Service Valves C10791 Fig. 26 - 38AUQ*16 Exterior Outdoor Coil Outdoor Coil Defrost Thermostat (DFT) High Flow Access Ports Defrost Thermostat (DFT) HPS LOC LOC HPS Fig.
PAGE 31
38AUQ Fans Service Valves C10793 Fig. 28 - 38AUQ*25 Exterior Outdoor Coil Outdoor Coil High Flow Access Port High Flow Access Port Defrost Thermostat (DFT) HPS Defrost Thermostat (DFT) LOC HPS LOC Fig.
PAGE 32
Comfort Alert Diagnostic Module POWER (GRN) The Comfort Alert Diagnostic Module (CADM) monitors and analyzes data from the Copeland Scroll® three-phase compressor and the thermostat demand. The CADM also provides a 3-minute anti-recycle time delay to compressor cycling. The CADM detects causes for electrical and system related failures. Flashing LEDs communicate the Alert codes to guide service technicians in accurately and quickly troubleshooting the system and determining root cause for the failure.
PAGE 33
Table 10 – 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” LED On Solid Thermostat demand signal Y is present, but the compressor is not running. 1. Compressor protector is open 2. Condensing unit power disconnect is open 3. Compressor circuit breaker or fuse(s) is open 4. Broken supply wires or connector is not making contact 5.
PAGE 34
38AUQ Table 11 – CADM Troubleshooting Miswired Module Indication Recommended Troubleshooting Action Green LED is not on, module does not power up Determine if both R and C module terminals are connected. Verify voltage in present at module’s R and C terminals. NOTE: The CADM requires a constant nominal 24VAC power supply. The wiring to the module’s R and C terminals must be directly from the control transformer.
PAGE 35
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. UNIT RELIABILTY HAZARD Failure to follow this caution may result in reduced unit performance . High velocity water from a pressure washer, garden hose, or compressed air should never be used to clean a coil. The force of the water or air jet will bend the fin edges and increase airside pressure drop.
PAGE 36
38AUQ 5. Mix Totaline environmentally sound coil cleaner in a 21/2 gallon garden sprayer according to the instructions included with the cleaner. The optimum solution temperature is 100°F (38°C). NOTE: Do NOT USE water in excess of 130°F (54°C), as the enzymatic activity will be destroyed. 6. Thoroughly apply Totaline® environmentally sound coil cleaner solution to all coil surfaces including the finned area, tube sheets and coil headers. 7.
PAGE 37
PROBLEM CAUSE REMEDY Compressor and Outdoor Fan Will Not Start. Power failure. Call power company. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Determine root cause. Defective thermostat, contactor, transformer, control relay, or capacitor. Replace component. Insufficient line voltage. Determine cause and correct. Incorrect or faulty wiring. Check wiring diagram and rewire correctly. Thermostat setting too high. Lower thermostat setting below room temperature.
PAGE 38
APPENDIX A S Do not install a suction-line filter drier in liquid-line. S POE oils absorb moisture rapidly. Do not expose oil to atmosphere. AIR CONDITIONER AND HEAT PUMP WITH PURON® — QUICK REFERENCE GUIDE S POE oils may cause damage to certain plastics and roofing materials. S 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®.
PAGE 39
APPENDIX C Units with the factory installed low ambient option are equipped with a MotormasterR solid-- state head pressure control which regulates fan speed. A temperature sensor, mounted on circuit 1 of the outdoor coil (see Figs. 32 and 33) controls the speed of approved outdoor fan motors in order to maintain a constant head pressure in the outdoor coil. The control maintains the appropriate head pressure at low ambient temperatures down to - 20_F (-- 28_C).
PAGE 40
Motormaster Sensor Must be positioned on Vapor Stub (Fourth from Top) 38AUQ Motormaster Sensor Must be positioned on Vapor Stub (Fourth from Top) C10795 Fig. 33 - Motormaster Sensor Location: 38AUQ*16 Fig.
PAGE 41
Fig.
PAGE 42
Fig.
PAGE 43
LEFT RIGHT Fig.
PAGE 44
LEFT RIGHT Fig.
PAGE 45
38AUQ
PAGE 46
38AUQ Copyright 2010 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 08/10 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
PAGE 47
START UP CHECKLIST I. PRELIMINARY INFORMATION OUTDOOR: MODEL NO. INDOOR: SERIAL NO. AIRHANDLER MANUFACTURER MODEL NO. SERIAL NO. ADDITIONAL ACCESSORIES II. PRE-START-UP OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE? (Y/N) WILL THIS DAMAGE PREVENT UNIT START-UP? (Y/N) CHECK POWER SUPPLY.
PAGE 48
CHECK VOLTAGE IMBALANCE LINE-TO-LINE VOLTS: AB V AC V (AB + AC + BC)/3 = AVERAGE VOLTAGE = BC V 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. CHECK INDOOR UNIT FAN SPEED AND RECORD. CHECK OUTDOOR UNIT FAN SPEED AND RECORD.