Carrier 38AU Safety Considerations, Installation Guideline, Replacement/Retrofit R-22 to PuronR

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38AU

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 . 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, which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

!WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could cause in 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.

!WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause in personal injury,death and/or equipment damage.

PuronR (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.

!WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to follow this warning could cause in 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.

!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 38AU units.

INSTALLATION GUIDELINE

Replacement/Retrofit — R-22 to PuronR

Replacement/retrofit installations require change-out of outdoor unit, metering device, and filter driers. Change-out of indoor coil (evaporator) and interconnecting tubing is recommended.

Existing evaporator coil – If the existing evaporator coil may be re-used, check with the coil manufacturer to verify the coil construction is suitable for operation with the higher pressures of PuronR (R-410A). Also determine if the existing TXV valve is compatible with R-410A, replace if necessary. The minimum factory test pressure rating must be 250 psig (1725 kPa). Existing coil will need to be purged with Nitrogen to remove as much mineral oil as possible to eliminate cross contamination of oils.

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. 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.

Existing refrigeration piping – Reuse of existing refrigerant piping involves three issues: quality (strength) of existing tubing, cleanliness and tube size. Inspect all tube segments and joints for signs of damage, corrosion or poor brazing. Flush the interconnecting piping system with dry Nitrogen to eliminate as much trace of mineral oil as possible.

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Contents Installation, Start---Up Service Instructions ContentsReplacement/Retrofit R-22 to PuronR Safety ConsiderationsInstallation Guideline Installation Unit Damage HazardRtpf UnitMchx 38AUZ*25 38AUD*25Compressor Unit Size 38AURefrigerant TYPE‡ Condenser FansRtpf Shipping Charge kg Pressurestat Settings kPa High CutoutNominal Capacity kW ScrollFace Area sq ft total Rows/Fins per inch FPI Rtpf Shipping Charge A/B lbOil Charge A/B oz Oil Charge A/B L Operating Weight kg Novation Coil Al TubeRtpf Shipping Charge A/B kg Qty...r/s Motor Hp Nema Diameter mmU Z a 2 5 a 0 G 6 a 0 a 0 a Jobsite Survey InstallationMatching 38AU Model To Evaporator Coil Do not Bury Refrigeration LinesEquivalent Lengths for Common Fittings ft Provide Safety ReliefSlab Mount Check 38AU Model with Evaporator Coil Connections38AUZ 16-25 Piping Recommendations Single-Circuit Unit Liquid LiftSuction Riser Insulate Suction Lines 38AUD 16-25 Piping Recommendations Two-Circuit UnitVertical Separation outdoor unit above indoor unit Hot Gas BypassInstall Filter Driers and Moisture Indicators Refrigerant Specialties Part NumbersSelecting an Accumulator Install Liquid Line Solenoid ValveCapacity Control Liquid Line Solenoid Valve Make Piping ConnectionsEvacuation/Dehydration Preliminary ChargeFire Hazard Field Power SupplyUnits with Factory-Installed Disconnect All UnitsConvenience Outlets Electrical Operation HazardField Control Wiring Convenience Outlet Utilization Notice LabelControl Transformer Wiring ThermostatUnit Wire/Fuse or Hacr Breaker Sizing Data Unbalanced 3-Phase Supply VoltageSystem Check PRE-START-UPSTART-UP Preliminary ChecksUsing plotted operating point Advanced Scroll Temperature Protection AstpAdjust Refrigerant Charge Start Unit38AUZ*25 Check Compressor Oil Level Final Checks38AUD*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 Operating Sequence Base Unit ControlsRefrigeration System Routine System MaintenanceService Equipment Damage HazardLiquid Line Filter Drier Field Refrigerant Access PortsFactory High-Flow Access Ports Comfort Alert Diagnostic Module Input Terminal VoltageLED Status Codes LockoutCompressor Protection 38AUD Size 16 Cabinet LPS 38AUZ,D Size 25 Cabinet 38AUZ*25 Compressor Assembly Rear View Coil Type Identification Novation Coil Cleaning and MaintenanceRepairing Novation Condenser Tube Leaks NOVATIONt TypeUnit Reliability Hazard Routine Cleaning of Round-Tube Plate Fin Rtpf CoilsReplacing NOVATIONt Condenser Coil Compressor Stops on HIGH-PRESSURE Switch TroubleshootingProblem Solution Compressor does not RUN Fastener Torque ValuesUnit Operates TOO Long or Continuously Problem Solution Compressor Cycles on LOW-PRESSURE SwitchCompressor Running but Cooling Insufficient System is NoisyAppendix B Wiring Diagram ListAppendix a Appendix C Low Ambient Option Factory InstalledTroubleshooting OperationMotormaster Sensor Location 38AUZ*16 & 38AUD*16 Novation 38AUZ*16/25 & 38AUD*16/25 RtpfDimensions --- MM Unit Baffle Wind Baffle DimensionDimensions --- Inches Unit Baffle Wind Baffles Fabrication 15 Ton Wind Baffle Brackets Fabrication Front Front Back Left Right Catalog No 38AU---09SI START-UP Checklist II. PRE-START-UP Outdoor UnitCheck Voltage Imbalance
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