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GEMINI™ SELECT
38APS025-050,38APD025-100
Commercial Air-Cooled Condensing Units
with COMFORTLINK™ Controls
50/60 Hz
Controls, Start-Up, Operation,
Service, and Troubleshooting
CONTENTS Page
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Page
Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .1,2
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . .
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When working on this equipment, observe precautions in GENERAL the literature, and on tags, stickers, and labels attached to the This publication contains Controls Start-Up, Service, equipment, and any other safety precautions that apply. Follow Operation, and Troubleshooting information for the Gemini™ all safety codes. Wear safety glasses and work gloves. Use Select 38AP condensing units with ComfortLink controls. See care in handling, rigging, and setting this equipment, and in Table 1 for un
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LEGEND AUX — Auxiliary C— Contactor CB — Circuit Breaker CCHR — Crankcase Heater Relay CSB — Current Sensor Board EMM — Energy Management Module EQUIP GND — Equipment Ground FB — Fuse Block FC — Fan Contactor LON — Local Operating Network MBB — Main Base Board SW — Switch TB — Terminal Block TRAN — Transformer UPC — Unitary Protocol Converter Fig. 1 — Component Arrangement — Unit Sizes 025-030 3
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LEGEND AUX — Auxiliary C— Contactor CB — Circuit Breaker CCH — Crankcase Heater Relay CSB — Current Sensor Board EMM — Energy Management Module EQUIP GND — Equipment Ground FC — Fan Contactor FCB — Fan Circuit Breaker LON — Local Operating Network MBB — Main Base Board ® MM — Motormaster SW — Switch TB — Terminal Block TRAN — Transformer UPC — Unitary Protocol Converter Fig. 2 — Component Arrangement — Unit Sizes 040-060 4
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LEGEND AUX — Auxiliary C— Contactor CB — Circuit Breaker CCH — Crankcase Heater Relay CSB — Current Sensor Board CXB — Compressor Expansion Board EMM — Energy Management Module EQUIP GND — Equipment Ground FC — Fan Contactor FCB — Fan Circuit Breaker LON — Local Operating Network MBB — Main Base Board SW — Switch TB — Terminal Block TRAN — Transformer UPC — Unitary Protocol Converter Fig. 3 — Component Arrangement — Unit Sizes 070-100 5
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Fig. 4 — Power Wiring Schematic — 38APS,APD025-030 6
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Fig. 5 — Power Wiring Schematic — 38APS040,050 7
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Fig. 6 — Power Wiring Schematic — 38APD040-060 8
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Fig. 7 — Power Wiring Schematic — 38APD070-100 9
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Fig. 8 — Control Wiring Schematic — 38APS025-050 10
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Fig. 9 — Control Wiring Schematic — 38APD025-060 11
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Fig. 10 — Control Wiring Schematic — 38APD070-100 12
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Legend and Notes for Fig. 4-10 LEGEND NOTES: 1. Factory wiring is in accordance with UL (Underwriters Labora- ACCSY — Accessory tories) 1995 standards. Any field modifications or additions ALM — Alarm must be in compliance with all applicable codes. AMPS — Amperes 2. Use 75 C minimum wire for field power supply. AUX — Auxiliary 3. All field interlock contacts must have a minimum rating of C— Contactor 2 amps at 24-vac sealed. See field interlock wiring. CB — Circuit Breaker 4. Compressor and fan
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a38-7122 LEGEND b. Incoming wire size range for terminal block with MCA from 175.1 amps to 420 amps is 2 AWG to 600 kcmil. EQUIP GND — Equipment Ground c. Incoming wire size range for non-fused disconnect with MCA up to NEC — National Electrical Code 100 amps is 14 AWG to 1/0. d. Incoming wire size range for non-fused disconnect with MCA from NOTES: 100.1 amp to 200 amps is 6 AWG to 350 kcmil. 1. Factory wiring is in accordance with UL 1995 standards. Field modifications e. Incoming wire size ra
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LVT TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 STRIP REMOTE ON/OFF ALM R COOL 2 COOL 1 a38-7125 *Not required for single circuit units. Fig. 13 — Constant Volume Application Wiring Diagram 2-Stage Thermostat Control, Sizes 025-030 — without Digital Scroll Option LVT TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 STRIP REMOTE ON/OFF ALM R COOL2 COOL 1 a38-7126 *See Fig. 12 for MAT/RAT and SAT location. †Not required for single circuit u
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LVT TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 STRIP REMOTE ON/OFF ALM R SAT * a38-7128 *See Fig. 12 for MAT/RAT and SAT location. †Not required for single circuit units. Fig. 16 — Variable Air Volume Application Wiring Diagram, Sizes 025-100 LVT TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 STRIP a38-7129 Fig. 17 — Optional Energy Management Module Wiring Legend and Notes for Fig. 13-17 LEGEND a. Incoming wire size range for terminal
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ComfortLink Alarm Status MODE ESC ENTER Run Status Service Test Temperatures Pressures Setpoints Inputs Outputs Configuration Time Clock Operating Modes Alarms Display Module Usage SCROLLING MARQUEE DISPLAY — This device is the keypad interface used for accessing unit information, reading sensor values, and testing the unit. See Fig. 18. The scrolling marquee display is a 4-key, 4-character, 16-segment LED (light-emitting diode) display. Eleven mode LEDs are located on the display as well as an
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Adjusting the Contrast — The contrast of the display can be view screen. Pressing the up and down arrow keys simultane- adjusted to suit ambient conditions. To adjust the contrast of ously allows the user to adjust the display brightness. Use the the Navigator module, press the ESCAPE key until the dis- up or down arrow keys to adjust screen brightness. Press play reads, “Select a menu item.” Using the arrow keys move to accept the change. The Navigator module will ENTER to the Configuration mod
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RED LED - STATUS GREEN LED - YELLOW LED - LEN (LOCAL EQUIPMENT NETWORK) CCN (CARRIER COMFORT NETWORK) INSTANCE JUMPER CEPL130346-01 K11 K10 K9 K8 K6 K5 K7 J1 J2 STATUS J10 LEN J3 J4 K4 K3 K2 K1 CCN J5 J6 J7 J8 J9 Fig. 20 — Main Base Board Table 3 — Thermistor Designations positions, the unit is allowed to operate and respond to the THERMISTOR INPUT PIN CONNECTION POINT scheduling configuration, CCN configuration and set point Return Air (Accessory) MBB J8-11,12; LVT 19,20 data. See Fig. 21. Supp
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SCROLLING MARQUEE DISPLAY CB1 CB2 CB3 REMOTE OFF CONTROL SW1 OFF SW2 ENABLE ON LEGEND CB — Circuit Breaker ENABLE/OFF/REMOTE EMERGENCY SW — Switch CONTACT SWITCH ON-OFF SWITCH Fig. 21 — Scrolling Marquee, Enable/Off/Remote Contact Switch, and Emergency On/Off Switch Locations 4. The RJ14 CCN connector on LVT can also be used, but is ® Carrier Comfort Network (CCN) Interface — only intended for temporary connection (for example, a The 38AP units can be connected to the CCN if desired. The laptop
