Carrier Gemini 38AU07 Series, Installation Instructions Manual

Page 1: ...his product Refer to the individual instructions packaged with the kits or accessories when installing 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 Con sult local building codes and appropriate national electri...

Page 2: ... 1 2 inch OD liquid line is rated at 33 higher tons with Puron than with R 22 at 5 F pressure drop A 1 1 8 inch OD suction line is rated at 53 higher tons with Puron than with R 22 at 2 F pressure drop Refrigeration lines selected for R 22 use are typically oversized for Puron applications Carefully check the existing suction line size against the table for maximum size replace ver tical riser seg...

Page 3: ...tion of suction tube size in vertical riser segments Check this unit s Model Number against the Model Number No menclature Fig 1 Determine the significance of this unit s val ues in Position 11 Coil type and Position 6 Hot Gas Bypass 38AUDC12 only Copy the unit s Model Number from the unit s dataplate into the open line in the header above Fig 1 to facilitate this step For date of unit manufacture...

Page 4: ...rd 1 LTL Electrical Options A None C Non Fused Disconnect Service Options 0 None 1 Un powered Convenience Outlet 2 Powered Convenience Outlet Not Used A Place Holder Design Rev B 38AUZ D E 08 only Voltage 1 575 3 60 5 208 230 3 6 6 460 3 60 Coil Options RTPF A Cu Al B Precoat Cu Al C E Coat Cu Al E Cu Cu M Cu Al with Louvered Hail Guard N Precoat Cu Al with Louvered Hail Guard P E Coat Cu Al with ...

Page 5: ...5 Fig 3 38AUD Z 07 14 Base Unit Dimensions ...

Page 6: ...TPF 490 222 177 80 120 54 78 35 114 52 18 457 2 24 609 6 24 609 6 50 3 8 1279 2 38AUZ 14 RTPF 598 271 195 88 142 64 110 50 151 68 20 508 0 25 635 0 24 609 6 50 3 8 1279 2 38AUD 12 RTPF 516 234 185 84 117 53 83 38 131 59 19 482 6 23 584 2 24 609 6 50 3 8 1279 2 38AUD 14 RTPF 654 297 214 97 155 70 120 54 165 75 20 508 0 25 635 0 24 609 6 50 3 8 1279 2 SINGLE CIRCUIT MODELS with RTPF ROUND TUBE PLATE...

Page 7: ...ees Raise and set the unit down carefully If it is necessary to roll the unit into position mount the unit on longitudinal rails using a minimum of 3 rollers Ap ply 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 Raise from above to lift the unit from the rails or pad when unit is in its fi...

Page 8: ... 5 3 1 0 8 4 6 1 2 1 6 2 1 0 7 2 5 0 8 2 9 1 0 3 3 1 1 Charge lb 15 6 19 0 19 7 20 8 24 1 23 1 26 9 25 1 30 7 26 0 32 8 27 0 34 8 27 9 37 1 TR 2 08 2 53 2 63 2 77 3 21 3 08 3 59 3 35 4 09 3 47 4 37 3 60 4 64 3 73 4 95 38AUZ 12 Liquid Line Size in 1 2 1 2 5 8 1 2 5 8 1 2 5 8 1 2 5 8 1 2 5 8 5 8 5 8 Liquid PD F 0 9 1 9 0 5 2 8 0 8 3 8 1 0 4 7 1 3 5 7 1 6 1 8 2 1 Max Lift ft 25 40 50 28 54 34 68 22 6...

Page 9: ...5 20 6 23 7 21 8 25 7 27 6 29 5 36 2 31 5 39 0 TR 1 36 1 44 1 52 1 56 1 65 1 90 1 74 2 05 2 21 2 36 2 89 2 52 3 12 TR Charge to unit capacity ratio lbs per ton at 45 F SST 95 F ODA Cap Red Capacity reduction caused by suction line pressure drop 2 F Liquid PD F Liquid line pressure drop saturated temperature degrees F Max Lift Maximum liquid lift Indoor unit ABOVE outdoor unit only at maximum permi...

Page 10: ...on Line Piping Speed Riser If the vertical elevation difference is greater than 20 ft 6 1 m linear feet or requires more than two short lift seg ments select the Circuit 1 suction line size from Double Suction Riser lines data under VAPOR RISER GREATER THAN 20 FT 6 1 M See Fig 6 Tube S is the horizontal line size Tube A is the reduced diameter riser size without bottom trap Tube B is the parallel ...

Page 11: ... should be connected to the 38AUD unit s Circuit 1 Note that refrigerant suction piping should be insulated Fig 8 Typical Evaporator Coil Connections 40RU INSTALL FILTER DRIER S AND MOISTURE INDICA TOR S Every unit MUST have a filter drier in the liquid line 38AUD models require two filter driers one in each liquid line Locate the filter drier s at the indoor unit close to the evaporator coil s th...

Page 12: ... the liquid solenoid valve loads Select TRAN3 transformer part number accord ing to unit power supply LEGEND Install as SVR 2 SVR 1 is factory installed INDOOR COIL CKT 2 AIRFLOW INDOOR COIL CKT 1 AIRFLOW 15 DIAMS MIN 10 DIAMS 8 DIAMS MIN TXV SENSING BULB EQUALIZER LINE SIGHT GLASS A LOCATION SIGHT GLASSES B LOCATION TXV CKT2 FILTER DRIER A LOCATION FILTER DRIERS B LOCATION FLOW TXV SENSING BULB T...

Page 13: ...ON Evacuate and dehydrate the connected refrigeration sys tem s excluding the 38AU unit to 500 microns using a two stage vacuum pump attached to the service ports outside the 38AU service valves following description in GTAC II Module 4 System Dehydration This unit is designed for use with Puron R 410A refrig erant Do not use any other refrigerant in this system Puron R 410A refrigerant is provide...

Page 14: ...gh an open ing in the access panel UNITS WITHOUT FACTORY INSTALLED NON FUSED DISCONNECT When installing units provide a disconnect switch per NEC National Electrical Code of adequate size Disconnect sizing data is provided on the unit informative plate Locate on unit cabinet or within sight of the unit per national or local codes Do not cover unit informative plate if mounting the disconnect on th...

Page 15: ... unit when the unit disconnect switch or HACR switch is open Other connection methods will result in the convenience outlet circuit being de energized when the unit disconnect or HACR switch is open See Fig 15 Fig 14 Convenience Outlet Location Fig 15 Powered Convenience Outlet Wiring The unit powered convenience outlet has a 1000 VA rated transformer Maximum continuous current must not exceed 8 A...

Page 16: ...al components Such operation would invalidate any applicable Carrier warranty Fig 16 Weatherproof Cover Installation FIELD CONTROL WIRING 38AU unit control voltage is 24 v See Fig 17 19 for typi cal field control connections and the unit s label diagram for field supplied wiring details Route control wires to the 38AU unit through the opening in unit s end panel to the con nections terminal board ...

Page 17: ...NO 208 230 3 60 187 253 48 1 245 2 1 5 64 64 80 80 59 59 251 251 NO 460 3 60 414 506 18 6 125 2 0 8 25 30 23 129 UNIT SIZE TWO STAGE COOLING NOMINAL POWER SUPPLY VOLTAGE RANGE COMPRESSOR OFM POWER SUPPLY DISCONNECT SIZE NO 1 Volts Min Max RLA LRA Qty FLA ea MCA Fuse or HACR Breaker FLA LRA 07 YES 575 3 60 518 633 6 3 55 2 0 7 11 15 11 61 YES 208 230 3 60 187 253 17 5 136 2 1 5 30 30 45 45 29 29 14...

Page 18: ...RESSOR No 2 OFM POWER SUPPLY DISCONNECT SIZE Volts Min Max RLA LRA RLA LRA Qty FLA ea MCA Fuse or HACR Brkr FLA LRA 12 575 518 633 5 7 39 5 7 39 2 0 7 15 20 15 82 208 230 3 60 187 253 15 9 110 15 9 110 2 1 5 39 39 50 50 40 40 226 226 460 3 60 414 506 7 7 52 7 7 52 2 0 8 19 25 20 108 14 575 3 60 518 633 7 7 54 7 7 54 2 0 7 19 25 19 112 208 230 3 60 187 253 22 4 149 22 4 149 2 1 5 54 54 60 60 55 55 ...

Page 19: ...19 Fig 17 Typical Single Circuit Single Stage 38AUZ Wiring Diagrams ...

Page 20: ...20 Fig 18 Typical Single Circuit Two Stage 38AUZ Wiring Diagram ...

Page 21: ...21 Fig 19 Typical Dual Circuit Two Stage 38AUD Wiring Diagram ...

Page 22: ...cting the PremierLink controller and its various sensors If the unit will be operating at 208 3 60 power remove the black wire BLK from the transformer primary connection labeled 230 and move it to the connection labeled 208 See Fig 22 Fig 22 Control Transformer Wiring EXTERNAL DEVICES The 38AU control transformers provide 24 v NEC Class 2 power sources to energize external control devices These d...

Page 23: ...ssary to wait the 24 hour period Preliminary Checks 1 Check that electric power supply agrees with unit name plate data 2 Verify that the compressor crankcase heater is securely in place 3 Check that the compressor crankcase heater has been on at least 24 hours 4 Recheck for leaks using the procedure outlined in the Pre Start Up section Leak Test and Dehydration If any leaks are detected repair as...

Page 24: ... charging charts are different from the type normally used The charts are based on charging the units to the correct subcooling for the various operating conditions Accurate pressure gage and temperature sensing device are required Con nect the pressure gage to the service port on the liquid line ser vice valve Mount the temperature sensing device on the liquid line close to the liquid line servic...

Page 25: ...3850 6 0 6 12 18 24 30 36 42 48 54 60 20 40 60 80 100 120 140 50 100 150 200 250 300 350 400 450 500 550 600 Temperature at Liquid Valve C F Pressure at Liquid Valve PSIG Kpa 6 Ton Charging Chart R 410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve C 38AU501045 ...

Page 26: ...54 60 20 40 60 80 100 120 140 50 100 150 200 250 300 350 400 450 500 550 600 Temperature at Liquid Valve C F Pressure at Liquid Valve PSIG Kpa 7 5 Ton Charging Chart R 410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve Add Charge if Above the Curve Remove Charge if Below the Curve 38AU501046 C ...

Page 27: ...3850 6 0 6 12 18 24 30 36 42 48 54 60 20 40 60 80 100 120 140 50 100 150 200 250 300 350 400 450 500 550 600 Temperature at Liquid Valve C F Pressure at Liquid Valve PSIG Kpa 10 Ton Charging Chart R 410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve 38AU501047 C ...

Page 28: ...850 6 0 6 12 18 24 30 36 42 48 54 60 20 40 60 80 100 120 140 50 100 150 200 250 300 350 400 450 500 550 600 Temperature at Liquid Valve C F Pressure at Liquid Valve PSIG Kpa 12 5 Ton Charging Chart R 410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve C 38AU501048 ...

Page 29: ...STAGE CHARGING CHART PURON COMPRESSOR FULL LOAD ALL CONDENSER FANS OPERATING 60 54 48 42 36 30 24 18 12 6 0 6 140 120 100 80 60 40 20 50 350 100 700 150 1050 200 1400 250 1750 300 2100 350 2450 400 2800 450 3150 500 3500 3850 550 600 Pressure at Liquid Valve PSIG Kpa Temperature at Liquid Valve C F PN 38AU000484 REV ...

Page 30: ...30 Fig 30 38AUZD E08 Charging Chart RTPF 7 5 Ton Dual Stage Charging Chart R 410A Refrigerant ...

Page 31: ...it B Charging Chart R 410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve 38AU501102 C C 38AU501102 350 700 1050 1400 1750 2100 2450 2800 3150 3500 3850 6 0 6 12 18 24 30 36 42 48 54 60 20 40 60 80 100 120 140 50 100 150 200 250 300 350 400 450 500 550 600 Temperature at Liquid Valve C F Pressure at Liquid Valve PSIG Kpa 12 5 Ton Circuit A Charging Chart R 410A Refriger...

Page 32: ... will be energized and indoor supply fan motor runs Thermostat output Y1 is energized terminal Y1 at 38AUD unit receives 24 v 24 v re ceived at CADM1 terminal Y If anti recycle time delay peri od has not expired CADM1 relay will remain open de ener gizing Solenoid Valve Relay 1 SVR1 and preventing com pressor start When safety pressure switches are closed and CADM1 time delay expires CADM1 relay c...

Page 33: ...is satisfied compressor contactor C2 Solenoid Valve Relay SVR2 and HGBP RE LAY are energized HGBP RELAY NC contacts open de en ergizing the HGBP SOLENOID solenoid valve closes blocking bypass vapor from the desuperheating tank and unit runs at full cooling capacity The model 38AUDC also includes the 32LT Motormaster low ambient control as a standard feature Refer to Appendix C for information on t...

Page 34: ...oofing materials Exposure even if immediately cleaned up may cause embrit tlement leading to cracking to occur in one year or more When performing any service which may risk exposure of compressor oil to the roof take appropriate precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing refriger ants leaks replacing refrigerant...

Page 35: ...D 14 shown FACTORY HIGH FLOW ACCESS PORTS There are two additional access ports in the system on the suction tube between the compressor and the suction ser vice valve and on the liquid tube near the liquid service valve see Fig 37 and 38 These are brass fittings with black plas tic caps The hose connection fittings are standard 1 4 in SAE Male Flare couplings Fig 37 Typical Interior Single Circui...

Page 36: ...s the presence of control power to the CADM The ALERT LED indicates an abnormal condition exists in the system through a flash code The ALERT LED will blink a number of times consecutively pause and the repeat the process The number of blinks defined in Table 13 cor relates to a particular abnormal condition troubleshooting tips are provided for each Alert code Reset of the ALERT may be automatic ...

Page 37: ...tact 6 Unusually long compressor protector reset time due to extreme ambient temperature 7 Compressor windings are damaged Yellow ALERT Flash Code 6 Missing Phase LOCKOUT 1 Compressor fuse is open on one phase 2 Broken wire or connector on one phase 3 Compressor motor winding is damaged 4 Utility supply has dropped one phase Yellow ALERT Flash Code 7 Reverse Phase LOCKOUT 1 Compressor running back...

Page 38: ...e environ mentally sound coil cleaner as described below Coil cleaning should be part of the unit s regularly sched uled maintenance procedures to ensure long life of the coil Failure to clean the coils may result in reduced durability in the environment Avoid the use of coil brighteners acid cleaning prior to painting high pressure washers poor quality water for cleaning Totaline environmentally ...

Page 39: ...on to all coil surfaces including the finned area tube sheets and coil headers 7 Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical up and down motion Avoid spraying in horizontal pattern to minimize poten tial for fin damage 8 Ensure cleaner thoroughly penetrates deep into finned areas 9 Interior and exterior finned areas must be thoroughly cleaned 10 Finned surfac...

Page 40: ...nning 1 Liquid line solenoid valve s fails to open 2 Filter drier plugged 3 Expansion valve power head defective 4 Low refrigerant charge 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 1 Check liquid line solenoid val...

Page 41: ... pumps will not remove moisture from oil Use only factory specified liquid line filter driers with rated working pressures greater than 600 psig Do not install a suction line filter drier in liquid line POE oils absorb moisture rapidly Do not expose oil to atmosphere POE oils may cause damage to certain plastics and roof ing materials Wrap all filter driers and service valves with wet cloth when b...

Page 42: ...8AUZ D E 08 208 230 3 60 38AU000759 460 3 60 38AU000760 575 3 60 38AU000758 38AUZ 07 208 230 3 60 38AU500320 460 3 60 38AU500432 575 3 60 38AU500337 38AUZ 12 208 230 3 60 38AU500320 460 3 60 38AU500432 575 3 60 38AU500337 38AUZ 14 208 230 3 60 38AU500320 460 3 60 38AU500432 575 3 60 38AU500337 38AUD 12 208 230 3 60 38AU50062 460 3 60 38AU50063 575 3 60 38AU50064 38AUD 14 208 230 3 60 38AU50062 460...

Page 43: ... close 57 F 5 F open 5 5 C 2 8 C close 13 9 C 2 8 C To override the speed control for full fan speed operation during service or maintenance either a remove sensor and place in hot water 120 F 49 C or b rewire to bypass control by connecting speed control input and output power wires Troubleshooting Speed Control Sensor Resistance OBSERVATION POSSIBLE REMEDY Fans won t start All fans Check power a...

Page 44: ...44 APPENDIX C LOW AMBIENT OPTION FACTORY INSTALLED CONT Fig A 38AUZ 07 14 Motormaster Sensor Locations RTPF 38AUZ 07 08 38AUZ 12 38AUZ 14 ...

Page 45: ...45 APPENDIX C LOW AMBIENT OPTION FACTORY INSTALLED CONT Fig B 38AUD 12 14 Motormaster Sensor Locations RTPF 38AUD 12 38AUD 14 ...

Page 46: ...46 APPENDIX C LOW AMBIENT OPTION FACTORY INSTALLED CONT Fig C Wind Baffles D K J H G F E C B A ...

Page 47: ...Z 14 38 AUD 14 RTPF LEFT SIDE 40 1 2 41 41 3 4 43 1 8 1 1 4 9 1 4 17 1 4 25 1 4 33 1 4 41 1 4 BACK 40 40 3 4 41 1 2 43 1 8 4 1 4 11 1 4 18 1 4 25 1 4 32 1 4 39 1 4 RIGHT SIDE 25 25 1 2 26 1 4 43 1 8 4 1 4 11 1 4 18 1 4 25 1 4 32 1 4 39 1 4 DIMENSIONS MM UNIT BAFFLE A B C D E F G H J K 38AUZ 07 RTPF LEFT SIDE 718 737 756 895 33 236 439 643 846 BACK 1016 1035 1054 895 107 284 462 640 818 38AUZ 08 RT...

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Page 50: ...to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53380020 01 Printed in U S A Form 38AU 7 14 03SI Pg 50 1 19 Replaces 38AU 7 14 02SI Carrier Corporation 2019 ...

Page 51: ...PROPERLY Y N __________ ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY Y N __________ CONTROLS ARE THERMOSTATAND INDOOR FAN CONTROL WIRING CONNECTIONS MADE AND CHECKED Y N __________ ARE ALL WIRING TERMINALS including main power supply TIGHT Y N __________ HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS Y N __________ INDOOR UNIT HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER ...

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