P01 - 38AU Carrier Air Cooled Condensing Units.pdf

38AU

Air Cooled Condensing Units 50 Hz With PuronR (R---410A) Refrigerant Sizes 07 --- 14

Installation, Start---Up and Service Instructions

CONTENTS

SAFETY CONSIDERATIONS 2

INSTALLATION GUIDELINES 2

Replacement/Retrofit — R--22 to Puron 2

INSTALLATION 10 - 21

Jobsite Survey 10

Step 1 -- Plan for Unit Location 10

Step 2 -- Complete Pre--Installation Checks 10

Step 3 -- Prepare Unit Mounting Support 10

Step 4 -- Rig and Mount the Unit 10

Step 5 -- Complete Refrigerant Piping Connections 11. . .

Step 6 -- Install Accessories 18

Step 7 -- Complete Electrical Connections 18

PRE-START-UP 22

System Check 22

Turn On Crankcase Heater 22

Preliminary Charge 22

START--UP 22 - 30

Preliminary Checks 22

Start Unit 23

OPERATING SEQUENCE 31

Indoor (Supply) Fan 31

Cooling, Unit Without Economizer 31

Cooling, Unit With Economizer 31

Heating 31

ROUTINE SYSTEM MAINTENANCE 32

Quarterly Inspection (and 30 days after initial start) 32. . .

Seasonal Maintenance 32

SERVICE 32 - 41

Refrigeration System 32

Compressor Oil 32

Servicing Systems on Roofs with Synthetic Materials 32

Liquid Line Filter Drier 33

Filed Refrigerant Access Ports 33

Factory High--Flow Access Ports 33

Comfort Alert Diagnostic Module 34

Compressor Protection 36

Crankcase Heater 36

Low--Pressure Switch 36

High--Pressure Switch 36

Outdoor Fans 36

Lubrication 36

Coil Type Identification 39

NOVATIONtCoil Cleaning and Maintenance 39

Repairing NOVATION Condenser Tube Leaks 39

Replacing NOVATION Condenser Coil 39

Routine Cleaning of Round-Tube Plate Fin (RTPF) Coils 40

Fastener Torque Values 41

TROUBLESHOOTING 41 -- 42

APPENDIX A

Air Conditioner & Heat Pump with PuronR — Quick Reference Guide 43

APPENDIX B

Wiring Diagram List 43

APPENDIX C

Low Ambient Option — Factory Installed 44

START--UP CHECKLIST 51 -- 52

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 for special requirements. In absence of local codes, it is recommended that the USA standard ANSI/NFPA 70, National Electrical Code (NEC), be followed.

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.

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.

! WARNING

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.

CAUTION!

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 1725 kPa (250 psig). 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.

A U

Same tube sizes are capable of handling higher flowrates (expressed as tons of cooling capacity) with Puron refrigerant compared to R--22 at constant pressure drops.

For example, a 1/2--inch OD liquid line is rated at 33% higher tons with PuronR 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 (see Table 7); replace vertical riser segments if necessary.

Check existing liquid line size against sizing data in Table 5 or 6; replace with smaller lines when feasible.

Installation –

1. Remove the existing evaporator coil or fan coil and install the replacement coil when appropriate.

2. Drain oil from low points and traps in suction line tubing (and hot gas bypass tubing if appropriate) and evaporator if they were not replaced. Removing oil from evaporator coil may require purging of the tubing with dry nitrogen.

3. Unless indoor unit is equipped with a Puron® approved metering device, change the metering device to a thermal expansion valve (TXV) designed for PuronR (R-410A).

4. Remove the existing outdoor unit. Install the new out-door unit according to these installation instructions.

5. Install a new field-supplied liquid-line filter drier at the indoor coil just upstream of the TXV or fix orifice metering device.

6. If a suction line filter drier is also to be installed, in-stall suction line drier downstream of suction line ser-vice valve at condensing unit.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Never install suction--line filter drier in the liquid--line of a PuronR system.

CAUTION!

7. If required, install a 100% activated alumina suction line filter drier at the outdoor unit.

8. Evacuate and charge the system according to the in-structions in this installation manual.

9. Operate the system for 10 hr. Monitor the pressure drop across the suction line filter drier. If pressure drop exceeds 21kPa (3 psig), 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 neces-sary. Never leave suction-line filter drier in system longer than 72 hr (actual time).

C101015

UNIT

STD. UNIT WT. CORNER A CORNER B CORNER C CORNER D CENTER OF GRAVITY UNIT HEIGHT

kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. X Y Z H

38AUZ*07

(MCHX) 149 328 58 128 31 68 28 62 32 70 533.2 mm

21 in

482.6 mm 19 in

330.2 mm 13 in

1076.0 mm 42 3/8 in

38AUZ*08

(MCHX) 160 353 63 138 33 72 29 65 35 78 482.6 mm

19 in

584.2 mm 23 in

330.2 mm 13 in

1076.0 mm 42 3/8 in

38AUD*12

(MCHX) 226 499 88 193 50 111 38 72 56 123 508.0 mm

20 in

584.2 mm 23 in

381.0 mm 15 in

1279.2 mm 50 3/8 in

38AUD*14

(MCHX) 229 505 86 190 40 88 34 76 68 151 508.0 mm

20 in

609.6 mm 24 in

381.0 mm 15 in

1279.2 mm 50 3/8 in

38AUZ*07

(RTPF) 176 389 64 141 44 96 28 62 41 91 457.2 mm

18 in

609.6 mm 24 in

533.4 mm 21 in

1076.0 mm 42 3/8 in

38AUZ*08

(RTPF) 177 391 64 142 44 96 28 62 41 91 457.2 mm

18 in

609.6 mm 24 in

533.4 mm 21 in

1076.0 mm 42 3/8 in

38AUD*12

(RTPF) 234 516 84 185 53 117 38 83 59 131 482.6 mm

19 in

584.2 mm 23 in

609.6 mm 24 in

1279.2 mm 50 3/8 in

LEGEND: MCXH = Novation™ coil RTPF = Round Tube/Plate Fin coil

Fig. 1 -- 38AU Unit Dimensions

Table 1A — Physical Data — 38AUZ*07-08 Units — 50 Hz SI

UNIT SIZE 38AU Z*07 Z*08

NOMINAL CAPACITY (kW) 18 22

OPERATING WEIGHTS (kg)

NOVATION™ Coil (Al Tube) 149 160

Round Tube/Plate Fin Coil (Cu/Al) 176 176

REFRIGERANT TYPE‡ R-410A

NOVATION Operating Charge, Typical (kg)† 3.8 4.6

NOVATION Shipping Charge (kg) 2.0 2.2

RTPF Operating Charge, Typical (kg)† 6.4 7.7

RTPF Shipping Charge (kg) 5.0 5.9

COMPRESSOR

Qty...Type 1...Scroll 1...Scroll

Oil Charge (L) 1.7 1.8

CONDENSER FANS

Qty...r/s 2...15.3

Motor kW 0.43 0.40

Diameter (mm) 560

Nominal Airflow (L/s) 1950 3000

RTPF CONDENSER COIL

Material (Tube/Fin) Cu / Al

Coil Type 3/8--- in RTPF

Rows/Fins per Meter (Fins/m) 2 / 670

Face Area (sq m total) 1.6 1.6

NOVATION CONDENSER COIL

Material (Tube/Fin) Al / Al

Coil Type Novation

Rows/Fins per Meter (Fins/m) 1 / 670

Face Area (sq m total) 1.6 1.9

CONTROLS

Pressurestat Settings (kPa)

High Cutout 4347 ± 70

Cut-in 3482 ± 138

Low Cutout 372 ± 21

Cut-in 807± 34

PIPING CONNECTIONS (in. ODS)

Qty...Suction 1...11/8 1...11/8

Qty...Liquid 1...3/8 1...1/2

LEGEND

RTPF — Round Tube/Plate Fin ODS — Outside Diameter Sweat (socket)

‡ Unit is factory-supplied with partial charge only.

† Typical operating charge with 7.6 m (25 ft) of interconnecting piping.

Table 1B — Physical Data — 38AUZ*07-08 Units — 50 Hz English

UNIT SIZE 38AU Z*07 Z*08

NOMINAL CAPACITY (tons) 6 7.5

OPERATING WEIGHTS (lb)

NOVATION™ Coil (Al Tube) 328 353

Round Tube/Plate Fin Coil (Cu/Al) 389 389

REFRIGERANT TYPE‡ R-410A

NOVATION Operating Charge, Typical (lb)† 8.4 10.2

NOVATION Shipping Charge (lb) 4.4 4.9

RTPF Operating Charge, Typical (lb)† 14.0 17.0

RTPF Shipping Charge (lb) 11.0 13.0

COMPRESSOR

Qty...Type 1...Scroll 1...Scroll

Oil Charge (oz) 56 60

CONDENSER FANS

Qty...Rpm 2...920

Motor Watts 430 400

Diameter 22

Nominal Airflow (Cfm Total) 4150 6300

RTPF CONDENSER COIL

Material (Tube/Fin) Cu / Al

Coil Type 3/8--- in RTPF

Rows/Fins per inch (FPI) 2/ 17

Face Area (sq ft total) 17.5 17.5

NOVATION CONDENSER COIL

Material (Tube/Fin) Al / Al

Coil Type Novation

Rows/Fins per inch (FPI) 1 / 17

Face Area (sq ft total) 17.5 20.5

CONTROLS

Pressurestat Settings (psig)

High Cutout 630 ± 10

Cut-in 505 ± 20

Low Cutout 54 ± 3

Cut-in 117 ± 5

PIPING CONNECTIONS (in. ODS)

Qty...Suction 1...11/8 1...11/8

Qty...Liquid 1...3/8 1...1/2

LEGEND

RTPF — Round Tube/Plate Fin ODS — Outside Diameter Sweat (socket)

‡ Unit is factory-supplied with partial charge only.

† Typical operating charge with 25 ft (7.6 m) of interconnecting piping.

Table 2A — Physical Data — 38AUD*12-14 Units — 50 Hz SI

UNIT SIZE 38AU D*12 D*14

NOMINAL CAPACITY (kW) 28 34

OPERATING WEIGHTS (kg)

NOVATION™ Coil (Al Tube) 226 229

Round Tube/Plate Fin Coil (Cu/Al) 234 ---

REFRIGERANT TYPE‡ R-410A

NOVATION Operating Charge A/B, Typical (kg)† 3.4 / 3.3 4.8 / 4.9

NOVATION Shipping Charge A/B (kg) 1.3 / 1.3 1.5 / 1.5

RTPF Operating Charge A/B, Typical (kg)† 5.0 / 5.0 ---

RTPF Shipping Charge A/B (kg) 3.6 / 3.6 ---

COMPRESSOR

Qty...Type 2...Scroll 2...Scroll

Oil Charge A/B (L) 1.2 1.7

CONDENSER FANS

Qty...r/s 2...15.3

Motor kW 0.40

Diameter (mm) 560

Nominal Airflow (l/s Total) 3000 2450

RTPF CONDENSER COIL

Material (Tube/Fin) Cu / Al ---

Coil Type 3/8--- in RTPF ---

Rows/Fins per Meter (Fins/m) 2 / 670 ---

Face Area (sq m total) 2.3 ---

NOVATION CONDENSER COIL

Material (Tube/Fin) Al / Al

Coil Type Novation

Rows/Fins per Meter (Fins/m) 1 / 670

Face Area (sq m total) 2.3 3.0

CONTROLS

Pressurestat Settings (kPa)

High Cutout 4347 ± 70

Cut-in 3482 ± 138

Low Cutout 372 ± 21

Cut-in 807 ± 34

PIPING CONNECTIONS (in. ODS)

Qty...Suction A/B 1...11/8 / 1...11/8 1...13/8 / 1...13/8

Qty...Liquid A/B 1...3/8 / 1...3/8 1...1/2 / 1...1/2

LEGEND

RTPF — Round Tube/Plate Fin ODS — Outside Diameter Sweat (socket)

‡ Unit is factory-supplied with partial charge only.

† Typical operating charge with 7.6 m (25 ft) of interconnecting piping.

Table 2B — Physical Data — 38AUD*12-14 Units — 50 Hz English

UNIT SIZE 38AU D*12 D*14

NOMINAL CAPACITY (tons) 10 12.5

OPERATING WEIGHTS (lb)

NOVATION™ Coil (Al Tube) 499 505

Round Tube/Plate Fin Coil (Cu/Al) 516 ---

REFRIGERANT TYPE‡ R-410A

NOVATION Operating Charge A/B, Typical (lb)† 7.4 / 7.3 10.8 / 10.9

NOVATION Shipping Charge A/B (lb) 3.0 / 3.0 3.5 / 3.5

RTPF Operating Charge A/B, Typical (lb)† 11.0 / 11.0 ---

RTPF Shipping Charge A/B (lb) 8.0 / 8.0 ---

COMPRESSOR

Qty...Type 2...Scroll 2...Scroll

Oil Charge A/B (oz) 42 60

CONDENSER FANS

Qty...Rpm 2...920

Motor Watts 400

Diameter 22

Nominal Airflow (Cfm Total) 6300 5200

RTPF CONDENSER COIL

Material (Tube/Fin) Cu / Al ---

Coil Type 3/8--- in RTPF ---

Rows/Fins per inch (FPI) 2 / 17 ---

Face Area (sq ft total) 25.1 ---

NOVATION CONDENSER COIL

Material (Tube/Fin) Al / Al

Coil Type Novation

Rows/Fins per inch (FPI) 1 / 17

Face Area (sq ft total) 25.0 31.8

CONTROLS

Pressurestat Settings (psig)

High Cutout 630 ± 10

Cut-in 505 ± 20

Low Cutout 54 ± 3

Cut-in 117 ± 5

PIPING CONNECTIONS (in. ODS)

Qty...Suction A/B 1...11/8 / 1...11/8 1...13/8 / 1...13/8

Qty...Liquid A/B 1...3/8 / 1...3/8 1...1/2 / ...11/2

LEGEND

RTPF — Round Tube/Plate Fin ODS — Outside Diameter Sweat (socket)

‡ Unit is factory-supplied with partial charge only.

† Typical operating charge with 25 ft (7.6 m) of interconnecting piping.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

3 8 A U D A 1 4 A 0 G 9 A 0 A 0 A 0

Model Type Packaging 38AU = Carrier Condensing Unit 0 = Standard

Type of Coil Electrical Options

D = Dual Circuit, A/C Scroll Compressor Z = Single Circuit, A/C Scroll Compressor A = None

C = Non-Fused Disconnect

1 = LTL

Service Options 0 = None

Nominal Capacity 07 = 18 kW (6 Tons) 08 = 22 kW (7.5 Tons)

Not Used

12 = 28 kW (10 Tons)

A = Place Holder

14 = 34 kW (12.5 Tons)

Base Unit Controls 0 = Electro-Mechanical Controls

Not Used A = Not Used

Design Revision

Voltage 9 = 400/3/60

Refrigerant Options A = None B = Low Ambient

Not Used 0 = Not Used

Coil Options

Puron® R–410A Refrigerant

A = Initial Rev (Discrete Model Number)

NOVATION™

G = Al/Al K = E-Coat Al/Al T = Al/Al with Hail Guard W = E-Coat Al/Al with Hail Guard

RTPF

A = Cu/Al B = Precoat (Cu/Al) C = E-Coat (Cu/Al)

N = Precoat (Cu/Al) with Hail Guard P = E-Coat (Cu/Al) with Hail Guard

M = Cu/Al with Hail Guard

C101016

Fig. 2 -- Model Number Nomenclature

SETANGISEDNOITISOP

)radnelac lacsif( erutcafunam fo keeW1−2

)ASU ,saxeT ,PTE = G( noitacol gnirutcafunaM5 rebmun laitneuqeS6−10

1 2 3 4 5 6 7 8 9 10 0 5 1 0 G 1 2 3 4 5

POSITION NUMBER

TYPICAL

Year of manufacture (”10” = 2010)3−4

C10068

Fig. 3 -- Serial Number Nomenclature

Matching 38AU Model To Evaporator Coil

The Model 38AUZ is a single-circuit unit design, requiring one set of refrigeration piping. This model can be connected to an evaporator coil with one circuit or with two circuits (by manifolding the evaporator connections into a single piping system).

The Model 38AUD is a dual-circuit unit design that requires two sets of refrigeration piping between the outdoor unit and the evaporator coil (or coils). This model can only be connected to an evaporator coil that has two refrigeration circuits (or to two separate evaporator coils).

The Model 38AUD CANNOT be connected to a single-circuit evaporator coil. The Model 38AUD CANNOT be field-converted to a single-circuit design.

Table 3 – Evaporator Coil Connections

Evaporator Coil has Connect to Model Notes

Single Circuit 38AUZ ONLY

Two Circuits

38AUZ

Manifold evaporator circuits into single piping system

Or

38AUD Use two separate piping systems

Before unpacking this new 38AU model, compare the evaporator coil design to the 38AU model.

.INSTALLATION

Jobsite Survey

Complete the following checks before installation.

1. Consult local building codes or the U.S.A. National Electrical Code (Ref: ANSI/NFPA 70, [American Na-tional Standards Institute/National Fire Protection As-sociation], latest revision) for special installation re-quirements

2. Determine unit location (from project plans) or select unit location.

3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.

Step 1 — Plan for Unit Location

Select a location for the unit and its support system (pad, rails or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings.

See Fig.4.

NOTE: Local codes may require different clearances than specified in Fig. 4. It is the responsibility of installers to be knowledgeable in local codes and to modify the recommended clearances to satisfy local codes.

NOTE: Consider also the effect of adjacent units on airflow performance and control box safety clearance.

REAR:

Min 18” (457 mm) requried for service

Note: Observe requirements for 39” (914 mm) operating clearance on either Left or Rear coil opening.

RIGHT:

Min 18” (457 mm) requried for service

LEFT:

Min 18” (457 mm) requried for service FRONT:

42” (1067 mm)

C110201

Fig. 4 -- Service Clearance Dimensional Drawing

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.

Relocate sections to minimize the length of interconnecting tubing.

DO NOT BURY REFRIGERATION LINES.

Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit.

Step 2 — Complete Pre-Installation Checks

Check Unit Electrical Characteristics: Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.

Un--crate 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 a claim with shipping company if the shipment is damaged or incomplete.

Consider System Requirements:

S Consult local building codes or the U.S.A. National

Electrical Code (Ref: ANSI/NFPA 70, [American National Standards Institute/National Fire Protection Association], latest revision) for special installation requirements.

S Allow sufficient space for airflow clearance, wiring, refrigerant piping, and servicing unit. See Fig. 1 for unit dimensions and weight distribution data.

S Locate the unit so that the outdoor coil (condenser) airflow is unrestricted on all sides and above.

S The unit may be mounted on a level pad directly on the base channels or mounted on raised pads at support points. See Tables 1A through 2B for unit operating weights. See Fig. 1 for weight distribution based on recommended support points.

NOTE: If vibration isolators are required for a particular installation, use the data in Fig. 1 to make the proper selection.

Step 3 — Prepare Unit Mounting Support

Slab Mount —

Provide a level concrete slab that extends a minimum of 150 mm (6 in.) beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow.

Step 4 — Rig and Mount the Unit

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage.

All panels must be in place when rigging. Unit is not designed for handling by fork truck.

CAUTION!

Rigging: These units are designed for overhead rigging.

Refer to the rigging label for preferred rigging method.

Spreader bars are not required if top crating is left on the unit. All panels must be in place when rigging. As further protection for coil faces, plywood sheets may be placed against the sides of the unit, behind cables. Run cables to a central suspension point so that the angle from the horizontal is not less than 45 degrees. 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.

Apply 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 final position.

After the unit is in position, remove all shipping materials and top crating.

Step 5 — Complete Refrigerant Piping Connections

IMPORTANT: Do not bury refrigerant piping underground.

IMPORTANT: A refrigerant receiver is not provided with the unit. Do not install a receiver.

Provide Safety Relief —

If local codes dictate an additional safety relief device, purchase locally and install locally. Installation will require the recovery of the factory shipping charge before the factory tubing can be cut and the supplemental relief device is installed.

Model 38AUD has two separate refrigeration systems. If required, each circuit will require a field-supplied/installed supplemental relief device.

Check 38AU Model with Evaporator Coil Connections —

Confirm before installation of unit that the evaporator coil connections are consistent with this 38AU model. See Table 3 on page 9.

Determine Refrigerant Line Sizes —

Select the recommended line sizes for 38AUZ and 38AUD unit from the appropriate tables.

Determine the linear length of interconnecting piping required between the outdoor unit and indoor unit (evaporator). Consider and identify also the arrangement of the tubing path (quantity and type of elbows in both lines), liquid line solenoid size, filter drier and any other refrigeration specialties located in the liquid line. Refer to the indoor unit installation instructions for additional details on refrigeration specialties devices.

Determine equivalent line length adjustments for path and components and add to linear line lengths. See Table 4, Equivalent Lengths for Common Fittings, for usual fitting types. Also identify adjustments for refrigeration specialties. Refer to Part 3 of the Carrier System Design Manual for additional data and information on equivalent lengths.

Table 4 – Equivalent Lengths for Common Fittings (EN units) mm Ref

Nominal Tube OD (in)

Elbows 90° Std

90° Lrad

90° Street

45° Std

45° Street

9.5 3/8 0.40 0.24 0.67 0.18 0.30

12.7 1/2 0.43 0.27 0.70 0.21 0.34

15.9 5/8 0.49 0.30 0.76 0.24 0.40

19.1 3/4 0.55 0.37 0.88 0.27 0.46

22.2 7/8 0.61 0.43 0.98 0.27 0.49

28.6 11/8 0.79 0.52 1.25 0.40 0.64

34.9 13/8 1.01 0.70 1.71 0.52 0.91

41.3 15/8 1.22 0.79 1.92 0.64 1.04

54.0 21/8 1.52 1.01 2.50 0.79 1.37 mm Ref

Nominal Tube OD (in)

Tees

Branch Flow

Straight-Thru

No Reduct

Reduce 25%

Reduce 50%

9.5 3/8 0.79 0.24 0.34 0.40

12.7 1/2 0.82 0.27 0.37 0.43

15.9 5/8 0.91 0.30 0.43 0.49

19.1 3/4 1.07 0.37 0.52 0.55

22.2 7/8 1.22 0.43 0.58 0.61

28.6 11/8 1.52 0.52 0.70 0.79

34.9 13/8 2.13 0.70 0.94 1.01

41.3 15/8 2.44 0.79 1.13 1.22

54.0 21/8 3.05 1.01 1.43 1.52

NOTE: Equivalent line lengths will vary based on tube diameter. Calculate equivalent line length for each pipe by adding equivalent length adjustments to linear lengths for each pipe.

Enter the appropriate table to select the recommended line sizes.

Model: Line Sizes Table Quantity of Line Sets

38AUZ 5 1

38AUD 6 2

Liquid Lift —

A liquid lift condition exists when the outdoor unit is located below the indoor (evaporator) unit and liquid flows vertically up in a portion of the liquid line. The vertical column of liquid reduces the available state point subcooling at the evaporator coil’s thermal expansion valve. This effect reduces the length of liquid lift (feet of elevation) that a liquid line size can accommodate. Longer linear tube lengths will also reduce the amount of liquid lift possible.

Check Tables 5 (38AUZ) and 6 (38AUD) for maximum liquid lift capabilities for line sizes. Reselect the liquid line tube size if necessary. If maximum available tube size cannot provide the required lift distance on this installation, relocate the outdoor unit to reduce the equivalent line length or the lift requirement.

Table 5 – 38AUZ 07-08 50Hz Piping Recommendations (Single-Circuit Unit)

R---410A Equivalent Length meter 0---12 12---23 23---34 34---46 46---57 feet 0---38 38---75 75---113 113---150 150---188

Model

Linear Length meter 0---7.5 7.5---15 15---23 23---30 30---38 feet 0---25 25---50 50---75 75---100 100---125

38AUZ*07 Liquid Line 3/8 3/8 1/2 3/8 1/2 3/8 1/2 3/8 1/2 Max Lift SI (m) Novation 7.5 15 16 23 9 29 10 34

RTPF 7.5 15 19 23 12 30 11 38

EN (ft) Novation 25 50 53 75 34 97 33 112

RTPF 25 50 63 75 42 100 38 125

Suction Line 7/8 7/8 7/8 7/8 7/8 1---1/8 Charge SI (kg) Novation 3.8 4.4 4.9 5.9 5.4 6.8 6.1 7.9

RTPF 6.4 7.0 7.4 8.5 7.9 9.3 8.7 10.4

EN (lbs) Novation 8.4 9.8 10.8 13.1 11.8 14.9 13.5 17.4

RTPF 14.0 15.4 16.4 18.7 17.4 20.5 19.1 23.0

38AUZ*08 Liquid Line 1/2 1/2 5/8 1/2 5/8 1/2 5/8 1/2 5/8 Max Lift SI (m) Novation 7.5 9 11 7 10 DNU 10 10 16

RTPF 7.5 15 NR 23 NR 27 30 18 38

EN (ft) Novation 25 30 38 24 36 DNU 35 33 53

RTPF 25 50 NR 75 NR 89 100 62 125

Suction Line 7/8 7/8 1---1/8 1---1/8 1---1/8 Charge SI (kg) Novation 5.5 6.3 7.2 7.4 8.6 DNU 9.9 9.1 11.2

RTPF 8.6 9.4 NR 10.4 NR 11.3 13.0 12.2 14.3

EN (lbs) Novation 12.2 13.9 15.8 16.2 19.0 DNU 21.9 20.0 24.8

RTPF 19.0 20.7 NR 23.0 NR 24.9 28.7 26.8 31.6

Legend:

Equivalent Length Equivalent tubing length, including effects of refrigeration specialties devices

Linear Length Linear tubing length, feet

Liquid Line Tubing size, inches OD.

Max Lift Maximum liquid lift (indoor unit ABOVE outdoor unit only), at maximum permitted liquid line pressure drop S Linear Length Less than 30 m (100 ft): Minimum 1.1° C (2.0° F) subcooling entering TXV S Linear Length Greater than 30 m (100 ft): Minimum 0.3° C (0.5° F) subcooling entering TXV

Suction Line Tube size, inches OD

Charge Charge Quantity, lbs. Calculated for both liquid line sizes (where applicable), but only with larger suction line size (where applicable)

DNU Do Not Use (pressure drop exceeds available subcooling in this model)

NR Not Recommended (use smaller liquid tube size)

SI Metric units of measure

EN English units of measure (I---P)

NOTE: For applications with equivalent length greater than 57 m (188 ft) and/or linear length greater than 38 m (125 ft), contact your local Carrier representative.

Table 6 – 38AUD 12-14 50Hz Piping Recommendations (Two-Circuit Unit)

NOTE: 38AUD requires TWO sets of refrigeration piping R---410A Equivalent Length meter 0---12 12---23 23---34 34---46 46---57 feet 0---38 38---75 75---113 113---150 150---188

Model

Linear Length meter 0---7.5 7.5---15 15---23 23---30 30---38 feet 0---25 25---50 50---75 75---100 100---125

38AUD*12 Liquid Line 3/8 3/8 3/8 1/2 3/8 1/2 3/8 1/2 Max Lift SI (m)

Novation 7.5 15 15 23 10 24 13 29

RTPF 7.5 15 15 23 10 27 11 32

EN (ft)

Novation 25 50 50 75 36 79 44 96

RTPF 25 50 50 75 36 89 39 106

Suction Line 7/8 7/8 7/8 7/8 1---1/8 Charge SI (kg)

Novation 3.3 3.8 4.2 5.3 4.7 6.1 5.1 6.9

RTPF 4.9 5.4 5.8 6.9 6.3 7.7 6.8 8.6

EN (lbs)

Novation 7.3 8.3 9.3 11.6 10.3 13.4 11.3 15.2

RTPF 10.9 11.9 12.9 15.2 13.9 17.0 14.9 18.8

38AUD*14 Liquid Line 3/8 1/2 5/8 1/2 5/8 1/2 5/8 1/2 5/8 Max Lift SI (m)

Novation 7.5 13 15 12 14 11 14 17 20 EN (ft)

Novation 25 45 50 42 49 39 48 56 68 Suction Line 7/8 7/8 7/8 1---1/8 1---1/8 Charge SI (kg)

Novation 4.6 5.8 6.6 6.6 7.8 7.6 10.7 9.4 12.0 EN (lbs)

Novation 10.1 12.7 14.6 14.5 17.3 16.8 23.5 20.7 26.4 Legend:

Equivalent Length Equivalent tubing length, including effects of refrigeration specialties devices

Linear Length Linear tubing length, feet

Liquid Line Tubing size, inches OD.

Max Lift Maximum liquid lift (indoor unit ABOVE outdoor unit only), at maximum permitted liquid line pressure drop S Linear Length Less than 30 m (100 ft): Minimum 1.1° C (2.0° F) subcooling entering TXV S Linear Length Greater than 30 m (100 ft): Minimum 0.3° C (0.5° F) subcooling entering TXV

Suction Line Tube size, inches OD

Charge Charge Quantity, lbs. Calculated for both liquid line sizes (where applicable), but only with larger suction line size (where applicable)

DNU Do Not Use (pressure drop exceeds available subcooling in this model)

NR Not Recommended (use smaller liquid tube size)

SI Metric units of measure

EN English units of measure (I---P)

NOTE: For applications with equivalent length greater than 57 m (188 ft) and/or linear length greater than 38 m (125 ft), contact your local Carrier representative.

Suction Riser —

A suction riser condition exists when the outdoor unit is located above the indoor (evaporator) unit and suction vapor must flow vertically up to return to the compressor.

Oil return is a concern when the suction tube size is too large to produce the minimum refrigerant velocity to ensure oil return at minimum load conditions.

Check Table 7 for maximum suction tube size for 38AU units at minimum load conditions. Consider suction speed riser (reduced tube size for vertical segment only) or double suction riser arrangement if the proposed suction tube size does not provide necessary minimum flowrates for this riser.

Table 7 – 38AU Maximum Suction Pipe Size

Model: Unit Size Maximum Tube Size

38AUZ 07 13/8

08 15/8

38AUD 12 13/8

14 13/8

Vertical Separation (outdoor unit above indoor unit) –

Vertical elevation difference of 60 m (200 ft) is permitted when the outdoor unit (38AUZ or 38AUD) is located above the indoor unit.

Insulate Suction Lines —

Apply closed-cell tubular insulation to all suction lines between evaporator coil connection and 38AU unit’s suction service valve.

Hot Gas Bypass —

Hot gas bypass, if used, should be introduced before the evaporator. (A bypass route that also bypasses the evaporator circuit may lead to oil trapping in the evaporator circuit during low load conditions and then to oil slugging as evaporator load increases.) Model 38AU units do not include a hot gas stub connection; a tee must be field-supplied and installed in the compressor discharge line. Run a 1/2-in OD line between outdoor unit and evaporator coil inlet. Install an Auxiliary Side Connector at the evaporator between TXV and distributor (follow instructions for the side connector part). Insulate the hot gas line.

38AUD: Generally only one hot gas bypass system will be applied on a two-circuit unit. Connect the hot gas bypass system to Circuit 1 (first-on/last-off, connected to the evaporator coil’s bottom circuit).

38AUD Piping Connections —

The 38AUD’s two circuits are designated Circuit 1 and Circuit 2. Circuit 1 is controlled by the thermostat’s Y1 (or TC1) contact and will be the first circuit on and last circuit off. Circuit 2 is controlled by the thermostat’s Y2

(or TC2) contact and this circuit is always the “lag” circuit.

See Fig. 5 for location of Circuit 1 and Circuit 2 service valves and field piping connections. Circuit 1 is on the right-hand side of the service valve compartment; Circuit 2 is on the left.

When a single piece evaporator coil with two separate circuits is connected to a 38AUD, the lower coil circuit should be connected to the 38AUD’s Circuit 1 so that the evaporator’s lower coil segment is first-on/last-off (to avoid re-evaporation of condensate on dry lower coil segments).

Circuit 1 Connections

Circuit 2 Connections

CKT

2 CKT

C10912

Fig. 5 -- 38AUD Service Valve Locations

Plan the Circuit 1 and Circuit 2 tubing segments carefully, mark each segment and check constantly as piping systems are assembled to avoid piping errors.

38AUD unit cannot be field-piped as a single-circuit/tandem system.

Connecting 40RU to 38AUD: The 40RU fan coil in sizes 12, 14 and 16 is a face-split coil design that also has its circuits designated as 1 and 2. See Fig. 6. Note that the lower coil segment changes as the arrangement of the 40RU changes. In a vertical arrangement, the 40RU’s lower coil segment is segment 2; this segment should be connected to the 38AUD’s Circuit 1. In a horizontal arrangement, the 40RU’s lower segment is now segment 1; this segment should be connected to the 38AUD’s Circuit 1.

Note that refrigerant suction piping should be insulated.

40RU

Arrangement

Cooling Stage

40RU Coil Segment

Connect to

38AUD

Vertical Y1 Y2

Circuit 1 Circuit 2

Horizontal Y1 Y2

Circuit 1 Circuit 2

FIRST ON/LAST OFF = 2

VERTICAL INSTALLATION

FIRST ON/LAST OFF = 1

HORIZONTAL INSTALLATION

C10071

Fig. 6 -- Typical Evaporator Coil Connections (40RU)

Install Filter Drier(s) and Moisture Indicator(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 thermal expansion valve (TXV) inlets.

38AU units include one (38AUZ) or two (38AUD) Puron-duty filter drier(s), shipped in cartons attached to the unit basepan. Remove the filter drier(s) and prepare to install in the liquid line(s) at the evaporator coil. Do not remove connection fitting plugs until ready to connect and braze the filter drier into the liquid line position.

Table 8 – Puron-duty Filter Drier(s)

Model-Size Qty Liquid Line OD

Desiccant Volume

Part Number Ref

38AUZ*07 1 3/8-in 8 cu. in. KH43LG091

38AUZ*08 1 1/2-in 16 cu. in. KH43LG085

38AUD*12 2 3/8-in 8 cu. in. KH43LG091

38AUD*14 2 1/2-in 16 cu. in. KH43LG085

Installation of liquid line moisture indicating sightglass in each circuit is recommended. Locate the sightglass(es) between the outlet of the filter drier and the TXV inlet.

Refer to Table 9 for recommendations on refrigeration specialties.

In some applications, depending on space and convenience requirements, it may be desirable to install 2 filter driers and sight glasses in a single circuit application. One filter drier and sight glass may be installed at A locations (see Fig. 7) or 2 filter driers and sight glasses may be installed at B locations (see Figs. 7 and 8).

Select the filter drier for maximum unit capacity and minimum pressure drop. Complete the refrigerant piping from the indoor unit to the outdoor unit before opening the liquid and suction lines at the outdoor unit.

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

CKT 2

FILTER DRIER

A LOCATION

FILTER

DRIERS

B LOCATION

FLOWTXV

SENSING

BULB

TXV

CKT 1

8 DIAMS

MIN

15 DIAMS

MIN 10

DIAMS

Single Circuit Coil Piping Configuration For single compressor condensing units

Dual Circuit Coil Piping Configuration For single compressor condensing units

15 DIAMS

MIN 10

DIAMS

8 DIAMS

MIN

INDOOR

COIL CKT

AIRFLOW

TXV

SENSING

BULB

EQUALIZER LINE

SIGHT GLASS

A LOCATION

TXV

FILTER DRIER

A LOCATION

LIQUID LINE

SOLENOID

VALVE

FLOW

LIQUID LINE

SOLENOID

VALVE

C10202

Fig. 7 -- Location of Sight Glass(es) and Filter Driers Typical 38AUZ Systems

Table 9 – Refrigerant Specialties Part Numbers

LIQUID LINE

SIZE (in.)

LIQUID LINE

SOLENOID VALVE (LLSV)

LLSV

COIL

SIGHT

GLASS

FILTER

DRIER

3/8 EF680033 EF680037 KM680008 provided with unit see Table 81/2 EF680035 EF680037 KM680004

38AUD units require TWO sets of parts.

AIRFLOW

SUCTION

CIRCUIT 2

SUCTION

CIRCUIT 1

AIRFLOW

15 DIAMS

MIN 10

DIAMS

8 DIAMS

MIN

TXV

SENSING

BULB

EQUALIZER LINE

SIGHT

GLASSES

TXV

CKT 2

FILTER

DRIERS

LIQUID LINE

SOLENOID VALVE

CIRCUIT 2

FLOW

LIQUID LINE

SOLENOID VALVE

CIRCUIT 1

FLOW

TXV

SENSING

BULB

TXV

CKT 1

8 DIAMS

MIN

15 DIAMS

MIN 10

DIAMS

Dual Circuit Coil Piping Configuration For two circuit condensing units

C10072

Fig. 8 -- Location of Sight Glasses and Filter Driers Typical 38AUD Systems

Install Liquid Line Solenoid Valve —

It is recommended that a solenoid valve be placed in the main liquid line (see Figs. 7 & 8) between the condensing unit and the evaporator coil. Locate the solenoid valve at the outlet end of the liquid line, near the evaporator coil connections, with flow direction arrow pointed at the evaporator coil. Refer to Table 9. (A liquid line solenoid valve is required when the liquid line length exceeds 23 m [75 ft].) This valve prevents refrigerant migration (which causes oil dilution) to the compressor during the off cycle, at low outdoor ambient temperatures.

Solenoid drop control wiring: control the power to the liquid line solenoid through a Solenoid Valve Relay (SVR) in all units. Use part number HN61PC005 (field--supplied, installed). 38AUZ unit requires one SVR; 38AUD unit requires two relays.

38AUD units also require a separate control power transformer for the liquid solenoid valve loads. Use transformer part number HT01BD602, according to unit power supply.

Mount the SVR (and transformer TRAN3 when used) in unit control box. Connect per wiring schematic label on unit or per Fig. 24 (38AUZ) or Fig. 25 (38AUD).

Capacity Control Liquid Line Solenoid Valve:

Evaporator capacity staging control via direct thermostat control of a liquid solenoid valve on the evaporator’s second stage circuit is not possible with 38AU models. If this installation is a retrofit for a unit that included automatic pressure--operated unloading, check the existing thermostat and liquid solenoid valve wiring for possible direct thermostat control of a solenoid valve; re--wire per Figs. 12 or 13 and 24 or 25.

Selecting an Accumulator –

Because all 38AU models use scroll compressors, an accumulator is not required. If an accumulator is to be added, check the accumulator manufacturer’s literature carefully for indication of its suitability for use with R--410A; look for minimum working pressure of 1380 kPa (200 psig). Select the accumulator first on the basis of its cataloged minimum capacity (tons) to ensure oil return from the accumulator, then on tube size or holding capacity.

Make Piping Connections —

Piping connections at the 38AU unit are ball valves with stub tube extensions. Do not open the unit service valves until all interconnecting tube brazing has been completed.

The stub tube connections include 1/4-in SAE service fittings with Schrader valve cores (see Fig. 9). Before making any brazed connections to the unit service valves, remove both Schrader valve caps and cores and save for re-installation. Connect a source for nitrogen to one of these service fittings during tube brazing to prevent the formation of copper oxides inside the tubes at brazed joints.

Factory High-Flow Access Port

Service Valve with Stem Cap

Field Service Access Port (Schrader core)

Sweat Connection

C10203

Fig. 9 -- Typical Piping Connection Assembly

When connecting the field tubing to the 38AU service valves, wrap the valves in wet rags to prevent overheating

Pressure-test all joints from outdoor unit connections over to the evaporator coil, using nitrogen as pressure and with soap-and-bubbles.

When pressure-testing is completed, remove the nitrogen source at the outdoor unit service valves and re-install the two Schrader valve cores. Torque the cores to 23-34 N-cm (2-3 in-lbs).

Evacuation/Dehydration —

Evacuate and dehydrate the connected refrigeration system(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.

UNIT OPERATION AND SAFETY HAZARD

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

PuronR (R--410A) refrigerant systems operate at higher pressure than standard R--22 systems. Do not use R--22 service equipment or components on Puron refrigerant equipment.

! WARNING

This unit is designed for use with Puron (R--410A) refrigerant. Do not use any other refrigerant in this system.

Puron (R--410A) refrigerant is provided in pink (rose) colored cylinders. These cylinders are available with and without dip tubes; cylinders with dip tubes will have a label indicating this feature. For a cylinder with a dip tube, place the cylinder in the upright position (access valve at the top) when removing liquid refrigerant for charging. For a cylinder without a dip tube, invert the cylinder (access valve on the bottom) when removing liquid refrigerant.

Because Puron (R--410A) refrigerant is a blend, it is strongly recommended that refrigerant always be removed from the cylinder as a liquid. Admit liquid refrigerant into the system in the discharge line. If adding refrigerant into the suction line, use a commercial metering/expansion device at the gauge manifold; remove liquid from the cylinder, pass it through the metering device at the gauge set and then pass it into the suction line as a vapor. Do not remove Puron (R--410A) refrigerant from the cylinder as a vapor.

Preliminary Charge —

Before starting the unit, charge R-410A liquid refrigerant into the high side of each 38AU circuit through the liquid service valve(s). The amount of refrigerant added must be at least 80% of the operating charge listed in Tables 5 or 6 for LINEAR line length LESS the factory charge quantity (if factory shipping charge has not been removed). See example below.

Allow high and low side pressures to equalize. If pressures do not equalize readily, charge R-410A vapor (using special service manifold with expansion device) into the suction line service port for the low side of system to assure charge in the evaporator. Refer to GTAC II, Module 5, Charging, Recover, Recycling, and Reclamation for liquid charging procedures.

Example (using Tables 5 and 6):

Unit 38AUZA08 with Novation coil Linear line length 25 m Estimated equivalent line length 37 m (add 50% to linear length) Liquid lift 8 m (indoor unit above outdoor unit)

See Table 5, 38AUZ models, for line sizes and system operating charge. Enter table in Equivalent Length column for 34-46 m.

Liquid line size: Note that a DNU code (Do Not Use) applies to 1/2-in. OD tube with Novation coil option for unit 38AUZ*08. Check liquid lift capability of 5/8-in OD tube against project requirements. Table 5 indicates 5/8-in tube allows 10 m lift which exceeds job requirements.

(Note: If maximum liquid lift value is not greater than project requirements, STOP. Select a new location for the outdoor unit that reduces lift and/or length requirements or select a unit model with RTPF coil option.)

Suction line size: Select 1-1/8-in. OD tube for this line length.

Note Operating Charge quantity: 9.9 kg.

Start-up Charge Calculation

Target start-up charge quantity is 80% of Operating Charge quantity:

Start-up Charge = 0.80 x 9.9 = 7.9 kg (use for recharge situation)

Deduct Shipping Charge if still available (new unit installation):

Shipping Charge (from Table 1A): 2.2 kg Field-Add for Start-up: 7.9 – 2.2 = 5.7 kg (use for new unit installation)

EN Units:

38AUZA08 with Novation coil Linear length 82 ft Equivalent length 123 ft Liquid lift 25 ft

Select liquid line as 5/8-in OD, suction line as 1-1/8-in OD.

Note Operating Charge quantity: 21.9 lbs

Start-up Charge Calculation

Target start-up charge quantity is 80% of Operating Charge quantity:

Start-up Charge = 0.80 x 21.9 = 17.5 lbs (use for recharge situation)

Deduct Shipping Charge if still available (new unit installation):

Shipping Charge (from Table 2A): 4.6 lbs Field-Add for Start-up: 17.5 – 4.6 = 12.9 lbs (use for new unit installation)

Step 6 — Install Accessories

Accessories requiring modifications to unit wiring should be completed now. These accessories may include Winter Start controls and Low Ambient controls. Refer to the instructions shipped with the accessory.

Step 7 — Complete Electrical Connections

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Do not use gas piping as an electrical ground. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with local electrical codes or in absence of local codes, it is recommended that the U.S.A. standard ANSI/NFPA 70, National Electrical Code (NEC), be followed.

! WARNING

NOTE: Check all factory and field electrical connections for tightness. Field-supplied wiring shall conform with the limitations of 33°C (63°F) rise.

Field Power Supply —

Field power wires are connected to the unit at line-side pressure lugs on compressor contactor C and TB1 (see wiring diagram label for control box component arrangement) or at factory-installed option non-fused disconnect switch. Max wire size is #4 AWG (copper only).

NOTE: TEST LEADS - Unit may be equipped with short leads (pigtails) on the field line connection points on contactor C or optional disconnect switch. These leads are for factory run-test purposes only; remove and discard before connecting field power wires to unit connection points. Make field power connections directly to line connection pressure lugs only.

FIRE HAZARD

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

Do not connect aluminum wire between disconnect switch and condensing unit. Use only copper wire.

(See Fig. 10.)

! WARNING

COPPER

WIRE ONLY

ELECTRIC

DISCONNECT

SWITCH

ALUMINUM

WIRE

A93033

Fig. 10 -- Disconnect Switch and Unit

Units Without Factory-Installed Disconnect —

When installing units, provide a disconnect switch of adequate size per local or national wiring code.

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 the unit cabinet.

Units with Factory-Installed Disconnect —

The factory-installed option disconnect switch is located in a weatherproof enclosure located under the main control box. The manual switch handle is accessible through an opening in the access panel.

All Units —

All field wiring must comply with all local codes. Size wire based on MCA (Minimum Circuit Amps) on the unit informative plate. See Fig. 11 for power wiring connections to the unit load terminals and equipment ground.

Provide a ground--fault and short--circuit over--current protection device (fuse or breaker) per local code (or in absence of local code, is is recommended that U.S.A.

standard, NEC Article 440, be followed). Refer to unit informative data plate for MOCP (Maximum Over--current Protection) device size.

All field wiring must comply with the appropriate national electrical codes and local requirements.

Affix the crankcase heater warning sticker to the unit disconnect switch.

Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate. See Tables 11 and 12. On 3-phase units, voltages between phases must be balanced within 2% and the current within 10%. Use the formula shown in the legend for Tables 11 and 12 Note 3 (see page 21) to determine the percent of voltage imbalance. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty.

Units Without Disconnect Option

Units With Disconnect Option

L1

L2

L3

Optional Disconnect

Switch

Disconnect factory test leads; discard.

Factory Wiring

11 13

L1 L2 L3

C1 TB1

Disconnect

C10074 Fig. 11 -- Power Wiring Connections

Table 10 – American/European Wire Conversions

AMERICAN EUROPEAN

Industry Standard Size

American Conversion Size (mm2)

Industry Standard Size (mm2)

20 AWG 0.52 0.5

18 AWG 0.82 1.0

16 AWG 1.30 1.5

14 AWG 2.08 2.5

12 AWG 3.30 4.0

10 AWG 5.25 6.0

8 AWG 6.36 10.0

6 AWG 13.29 16.0

4 AWG 21.14 25.0

3 AWG 26.65 —

2 AWG 33.61 35.0

1 AWG 42.39 50.0

1/0 AWG 53.49 —

2/0 AWG 67.42 70.0

3/0 AWG 85.00 95.0

4/0 AWG 107.9 120.0

Field Control Wiring —

38AU unit control voltage is 24 v. See Fig. 24 (38AUZ) and Fig. 25 (38AUD) for typical 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 connections terminal board in the unit’s control box.

Remainder of the system controls connection will vary according to the specific construction details of the indoor section (air handler or packaged fan coil). Fig. 12 (38AUZ) and Fig. 13 (38AUD) depict typical connections to a Carrier 40RU fan coil unit. Plan for field connections carefully and install control wiring correctly per the project plan.

Additional components and supplemental transformer accessory may be required.

The 38AU unit requires an external temperature control device. This device can be a thermostat (field-supplied) or a PremierLink controller (available as a field-installed accessory, for use on a Carrier Comfort Network or as a stand alone control).

Note 1: Connect only if thermostat requires 24-vac power source.

Note 2: Connect W1 and W2 if supplemental heaters are installed Field Wiring

(Note 1)

(Note 2)

(Note 2)

C10985

Fig. 12 -- Typical Remote Thermostat Connections

— 38AUZ

Note 1: Typical multi-function marking.