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38AE012,014,016
38AKS024
Air-Cooled Condensing Units
50/60 Hz
Installation, Start-Up and
Service Instructions
Only trained, qualified installers and service mechanics
CONTENTS
should install, start-up, and service this equipment (Fig. 1).
Page
Untrainedpersonnelcanperformbasicmaintenancefunc-
SAFETY CONSIDERATIONS...................1
tions such as cleaning coils.All other operations should be
INSTALLATION ..............................1-8
performed by trained service personnel.
Step 1 — Complete
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LEGEND NOTES: 1. SERVICEAREAS —Allow 3 ft (914) on both sides 1 5 A— 1⁄4-in. (32) diameter knockout for ⁄8-in. (16) ODM liquid line connection and 2 ft (610) on both ends of unit for servicing. 3 1 B— 1⁄4-in.(44.5)diameterknockoutforsuctionlineconnectionsof1 ⁄8in.(28.6) 2. Dimensions in ( ) are in millimeters. 3 5 (38AE012), 1 ⁄8 in. (35) (38AE014,016), 1 ⁄8 in. (41) (38AKS024) 7 C— ⁄8-in. (22.2) diameter knockout for control power D— 2-in. (50.8) diameter knockout for unit power Certified dimens
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2 3 45 6 7 1 12 11 10 9 8 LEGEND 1— Low-Voltage Fuse 5— No. 2 Fan 9— Compressor 2— No. 1 Fan 6— Terminal Block 1 (Unit Power) 10 — Low-Pressure Switch 3 3— High-Pressure Switch 7— Terminal Block 2 (Control Power) 11 — Hot Gas Bypass Piping Stub ( ⁄8-in. ODM) 4— Circuit Breakers 8— Wraparound Coil 12 — Muffler Fig. 2 — Component Locations (Typical — 38AE Shown) 3
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Table 1A — Physical Data (English, 60 Hz) UNIT 38AE012 38AE014 38AE016 38AKS024 OPERATING WEIGHT (lb) 732 779 789 900 REFRIGERANT* R-22 COMPRESSOR Reciprocating, Semi-Hermetic Speed (Rpm) 1750 No. Cylinders 666 4 Model No. 06DD824 06DD328 06DD537 06E4250 Oil (pt) 10 10 10 15.5 Crankcase Heater Watts 125 125 125 180 Unloader Setting (psig) Load 70±1 Unload 60±2 OUTDOOR-AIR FANS Axial Flow, Direct Drive No. ...Rpm 2...1075 Diameter (in.) 24 24 24 26 1 Motor Hp ⁄2 Nominal Total Airflow (Cfm) 8800 88
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Table 1C — Physical Data (English, 50 Hz) UNIT 38AE012 38AE014 38AE016 38AKS024 OPERATING WEIGHT (lb) 732 779 789 900 REFRIGERANT* R-22 COMPRESSOR Reciprocating, Semi-Hermetic Speed (Rpm) 1460 No. Cylinders 666 4 Model No. 06DD824 06DD328 06DD537 06E4250 Oil (pt) 10 10 10 15.5 Crankcase Heater Watts 125 125 125 180 Unloader Setting (psig) Load 70±1 Unload 60±2 OUTDOOR-AIR FANS Axial Flow, Direct Drive No. ...Rpm 2...900 Diameter (in.) 24 24 24 26 1 Motor Hp ⁄2 Nominal Total Airflow (Cfm) 7368 736
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Table2—Weight Distribution Step 3 — Complete Refrigerant Piping Connections WEIGHT — lb (kg) UNIT Support Point Total IMPORTANT: A refrigerant receiver is not provided Operating AB C D with the unit. Do not install a receiver. 38AE012 732 (333) 142 (65) 138 (63) 225 (102) 227(103) 38AE014 779 (354) 143 (65) 140 (64) 247 (112) 249 (113) SIZE REFRIGERANT LINES — Consider the length of 38AE016 789 (359) 143 (65) 143 (65) 250 (114) 253 (115) piping required between outdoor unit and indoor unit 38AKS
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INSTALLFILTERDRIER(S)ANDMOISTUREINDICA- TOR(S) — Every unit should have a filter drier and liquid- moistureindicator(sightglass).Insomeapplications,depending onspaceandconveniencerequirements,itmaybedesirable toinstall2filterdriersandsightglasses.Onefilterdrierand sight glass may be installed at A locations in Fig. 4. Or, 2 filterdriersandsightglassesmaybeinstalledatBlocations. Selectthefilterdrierformaximumunitcapacityandmini- mum pressure drop. Complete the refrigerant piping from indoorunittooutdo
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LEGEND C— Compressor Contactor R— Relay HD — Heating Device Factory Wiring IFC — Indoor-Fan Contactor Field Wiring LLSV — Liquid Line Solenoid Valve NOTES: 1. Combination LLSV plus IFC va should not exceed 30 va. 2. Do not exceed 5 va (24 vac) per coil. 3. If va values shown in Notes 1 and 2 must be exceeded, use accessory relay transformer package 38AE900001. Fig. 7 — Remote Thermostat Wiring Table 5A — Electrical Data (3 Ph/60 Hz) UNIT COMPR FAN MOTORS (Single Phase) Volts FLA (ea) UNIT MOCP T
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PRE-START-UP START-UP Evacuate and Dehydrate the entire refrigerant sys- ToStartUnit— Setthermostatsetpointbelowthespace tem by either of the methods described in Carrier Standard temperature.Afterstartingunit,thereisadelayofatleast3 Service Techniques Manual, Chapter 1. seconds before compressor starts. Leak Test the entire refrigerant system by the pres- Oil Charge (see Tables 1A-1D) —Allow unit to run for sure method described in Carrier Standard Service Tech- about 20 minutes. Stop unit and
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10 Fig. 9 — 38AE012 and 38AKS024 Charging Chart
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11 Fig. 10 — 38AE014 Charging Chart
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12 Fig. 11 — 38AE016 Charging Chart
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CheckOperation— Verifyoperationofallsafetycon- HeadPressureControl— Fancycling is a standard trols. Replace all service panels.Besurethatcontrolpanel feature.Theno.2fancyclesinresponsetochangesinliquid coverisclosedtightly. pressure.Theswitchcyclesthefanoffat126±4psig(869 ±28kPa)aspressuredecreases,andcyclesitbackonat257 (+5, −0) psig (1772 [+103, −0] kPa). OPERATING SEQUENCE Cooling— Whenthefirststage(TC1)ofthecoolingther- mostat closes, the timer starts. After approximately 3 sec- onds, the tim
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(38AE014,016,38AKS024)andrestrictoutdoorairflow.Use Outdoor Fans — Each fan is supported by a formed- a flashlight to determine if dirt or debris has collected be- wire mount bolted to the fan deck and covered with a wire tween coil sections. Clean coil as follows: guard. The exposed end of the motor shaft is covered with a rubber boot. In case a fan motor must be repaired or re- 1. Turn off unit power. placed, be sure the rubber boot is put back on when the fan 2. Remove screws holding rear corne
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TROUBLESHOOTING PROBLEM SOLUTION COMPRESSOR DOES NOT RUN Contactor Open 1. Power off. 1. Restore power. 2. Fuses blown in field power circuit. 2. After finding cause and correcting, replace with correct size fuse. 3. No control power. 3. Check secondary fuse(s); replace with correct type and size. Replace transformer if primary windings receiving power. 4. Thermostat circuit open. 4. Check thermostat setting. 5. Time GuardT II device not operating. 5. Check Time Guard II devices. 6. Compressor cir
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TROUBLESHOOTING (cont) PROBLEM SOLUTION COMPRESSOR CYCLES ON LOW-PRESSURE SWITCH (cont) Airflow Restricted 1. Coil iced up. 1. Check refrigerant charge. 2. Coil dirty. 2. Clean coil fins. 3. Air filters dirty. 3. Clean or replace filters. 4. Dampers closed. 4. Check damper operation and position. Indoor-Air Fan Stopped 1. Electrical connections loose. 1. Tighten all connections. 2. Fan relay defective. 2. Replace relay. 3. Motor overload open. 3. Power supply. 4. Motor defective. 4. Replace motor. 5
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PACKAGED SERVICE TRAINING Our packaged service training programs provide an excellent way to increase your knowledge of the equipment discussed in this manual. Product programs cover: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available. All programs include a video cassette and/or slides and a companion booklet. Use these for self teaching or to conduct full training sessions. For a free Service
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START-UP CHECKLIST A. Preliminary Information OUTDOOR: MODEL NO. SERIAL NO. INDOOR:AIR HANDLER MANUFACTURER MODELNO. SERIAL NO. ADDITIONALACCESSORIES B. Pre-Start-Up OUTDOOR UNIT IS THEREANY SHIPPING DAMAGE? (Y/N) IF SO, WHERE: WILLTHIS DAMAGE PREVENT UNIT START-UP? (Y/N) CHECK POWER SUPPLY. DOES ITAGREE WITH UNIT? (Y/N) HAS THE GROUND WIRE BEEN CONNECTED? (Y/N) HAS THE CIRCUIT PROTECTION BEEN SIZEDAND INSTALLED PROPERLY? (Y/N) ARE THE POWER WIRES TO THE UNIT SIZEDAND INSTALLED PROPERLY? (Y/N) H
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C. Start-Up CHECK EVAPORATOR FAN SPEEDAND RECORD. CHECK CONDENSER FAN SPEEDAND RECORD. AFTERAT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS: OIL PRESSURE SUCTION PRESSURE SUCTION LINE TEMP DISCHARGE PRESSURE DISCHARGE LINE TEMP ENTERING CONDENSERAIR TEMP LEAVING CONDENSERAIR TEMP EVAP ENTERING-AIR DB (dry bulb) TEMP EVAP ENTERINGAIR WB (wet bulb) TEMP EVAP LEAVINGAIR DB TEMP EVAP LEAVINGAIR WB TEMP COMPRESSORAMPS (L1/L2/L3) / / CHECK THE COMPRESSOR OIL LEVEL SIGHT GLASSES;ARE
