Carrier 38AU appendix Installation, Start---Up Service Instructions, Contents

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38AU

Air Cooled Condensing Units

60 Hz

With PuronR (R---410A) Refrigerant

Sizes 16---25

Installation, Start---Up and

Service Instructions

CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . 2 Replacement/Retrofit — R-22 to Puron . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 22 Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . . 11 Step 2 - Complete Pre-Installation Checks . . . . . . . . 11 Step 3 – Prepare Unit Mounting Support . . . . . . . . . . 12 Step 4 – Rig and Mount the Unit . . . . . . . . . . . . . . . . 12 Step 5 – Complete Refrigerant Piping Connections . . . 12 Step 6 – Install Accessories . . . . . . . . . . . . . . . . . . . . 17 Step 7 – Complete Electrical Connections . . . . . . . . . 18 PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Turn On Crankcase Heater . . . . . . . . . . . . . . . . . . . . . 23 Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 - 31 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 OPERATING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . 32 Indoor (Supply) Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cooling, Unit Without Economizer . . . . . . . . . . . . . . 32 Cooling, Unit With Economizer . . . . . . . . . . . . . . . . . 32 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 ROUTINE SYSTEM MAINTENANCE . . . . . . . . . . . . 33 Quarterly Inspection (and 30 days after initial start) . . . 33 Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 33 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 - 44 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 33

Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Servicing Systems on Roofs with

Synthetic Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Liquid Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . 34 Field Refrigerant Access Ports . . . . . . . . . . . . . . . . . . 34 Factory High-Flow Access Ports . . . . . . . . . . . . . . . . 34 Comfort Alert Diagnostic Module . . . . . . . . . . . . . . . 35 Compressor Protection . . . . . . . . . . . . . . . . . . . . . . . . 37 Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Low-Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . 37 High-Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . 37 Outdoor Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Coil Type Identification . . . . . . . . . . . . . . . . . . . . . . . 42 NOVATIONtCoil Cleaning and Maintenance . . . . . 42 Repairing NOVATION Condenser Tube Leaks . . . . . 42 Replacing NOVATION Condenser Coil . . . . . . . . . . . 43

Routine Cleaning of Round-Tube Plate Fin

(RTPF) Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . 44 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 44 - 45

APPENDIX A

Air Conditioner & Heat Pump with PuronR —

Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . 46

APPENDIX B

Wiring Diagram List . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

APPENDIX C

Low Ambient Option — Factory Installed . . . . . . . . . . 47 START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . 55 - 56

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Contents Contents Installation, Start---Up Service InstructionsInstallation Guideline Safety ConsiderationsReplacement/Retrofit R-22 to PuronR Unit Damage Hazard InstallationMchx UnitRtpf 38AUD*25 38AUZ*25Refrigerant TYPE‡ Unit Size 38AUCompressor Condenser FansNominal Capacity kW Pressurestat Settings kPa High CutoutRtpf Shipping Charge kg ScrollOil Charge A/B oz Rtpf Shipping Charge A/B lbFace Area sq ft total Rows/Fins per inch FPI Rtpf Shipping Charge A/B kg Operating Weight kg Novation Coil Al TubeOil Charge A/B L Qty...r/s Motor Hp Nema Diameter mmU Z a 2 5 a 0 G 6 a 0 a 0 a Matching 38AU Model To Evaporator Coil InstallationJobsite Survey Do not Bury Refrigeration LinesSlab Mount Provide Safety ReliefEquivalent Lengths for Common Fittings ft Check 38AU Model with Evaporator Coil ConnectionsSuction Riser Liquid Lift38AUZ 16-25 Piping Recommendations Single-Circuit Unit Vertical Separation outdoor unit above indoor unit 38AUD 16-25 Piping Recommendations Two-Circuit UnitInsulate Suction Lines Hot Gas BypassRefrigerant Specialties Part Numbers Install Filter Driers and Moisture IndicatorsCapacity Control Liquid Line Solenoid Valve Install Liquid Line Solenoid ValveSelecting an Accumulator Make Piping ConnectionsPreliminary Charge Evacuation/DehydrationUnits with Factory-Installed Disconnect Field Power SupplyFire Hazard All UnitsElectrical Operation Hazard Convenience OutletsConvenience Outlet Utilization Notice Label Field Control WiringThermostat Control Transformer WiringUnbalanced 3-Phase Supply Voltage Unit Wire/Fuse or Hacr Breaker Sizing DataSTART-UP PRE-START-UPSystem Check Preliminary ChecksAdjust Refrigerant Charge Advanced Scroll Temperature Protection AstpUsing plotted operating point Start UnitFinal Checks 38AUZ*25 Check Compressor Oil Level38AUD*16 Charging Chart Novation 38AUZ*16 Charging Chart Rtpf 38AUD*16 Charging Chart Rtpf 38AUD*25 Charging Chart Rtpf Typical 38AUZ Wiring Diagram 15 Ton 230V Tandem Unit Shown Typical 38AUD Wiring Diagram 15 Ton 230V Dual Unit Shown Base Unit Controls Operating SequenceService Routine System MaintenanceRefrigeration System Equipment Damage HazardFactory High-Flow Access Ports Field Refrigerant Access PortsLiquid Line Filter Drier Input Terminal Voltage Comfort Alert Diagnostic ModuleLockout LED Status CodesCompressor Protection 38AUD Size 16 Cabinet LPS 38AUZ,D Size 25 Cabinet 38AUZ*25 Compressor Assembly Rear View Repairing Novation Condenser Tube Leaks Novation Coil Cleaning and MaintenanceCoil Type Identification NOVATIONt TypeReplacing NOVATIONt Condenser Coil Routine Cleaning of Round-Tube Plate Fin Rtpf CoilsUnit Reliability Hazard Problem Solution Compressor does not RUN TroubleshootingCompressor Stops on HIGH-PRESSURE Switch Fastener Torque ValuesCompressor Running but Cooling Insufficient Problem Solution Compressor Cycles on LOW-PRESSURE SwitchUnit Operates TOO Long or Continuously System is NoisyAppendix a Wiring Diagram ListAppendix B Troubleshooting Low Ambient Option Factory InstalledAppendix C Operation38AUZ*16 & 38AUD*16 Novation 38AUZ*16/25 & 38AUD*16/25 Rtpf Motormaster Sensor LocationDimensions --- Inches Unit Baffle Wind Baffle DimensionDimensions --- MM Unit Baffle Wind Baffles Fabrication 15 Ton Wind Baffle Brackets Fabrication Front Front Back Left Right Catalog No 38AU---09SI II. PRE-START-UP Outdoor Unit START-UP ChecklistCheck Voltage Imbalance
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