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Carrier 38AU - page 1
1 38AU Air Cooled Con dens ing U nits 60 Hz W ith P uron R (R - - - 410A) Refrig erant S i z e s 1 6 --- 2 5 Installation, Start - - - Up and Service Instructions CONTENTS SAFET Y CONSIDE RA TIONS 2 .................... INST ALLA TION GUI DEL INE S 2 .................. Replacemen t/Retrofit — R- - 22 to Puro n 2 ........... INS T ALLA TION 1 1 - ...
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Carrier 38AU - page 2
2 SAF ETY CONSIDERA TIONS Impro per ins tallation, ad justment, alteration, s ervice, maintenance, o r us e can caus e explo sion , fire, electrical shock or other c onditions whic h may c ause personal injury or property dam age. Consult a qua lifi ed insta lle r , service agenc y , or your distributor or branch for infor mation or as sis tance. T ...
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Carrier 38AU - page 3
3 Same tub e sizes are capable o f handlin g higher flowrates (expressed as tons of cooli ng capa cit y) w it h Puron refrigera nt com pared t o R - - 22 at consta nt pressure drops. For examp le, a 1 / 2 - - inch O D liquid line is rated at 33% higher tons with Puron R than with R- - 22 (at 5 _ F pressure drop). A 1 1 / 8 - - inch OD s uction line ...
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Carrier 38AU - page 4
4 C10942 UNI T Standar d Wei g h t Corner A Corner B Corner C Corner D Cent er of Gravi ty Unit Heig ht lbs. kg . lbs. kg . lb s. kg. lb s. kg. lb s. kg. X Y Z H 38AUZ*16 (MC HX ) 633 288 220 100 134 61 135 61 144 65.5 38 [965.2] 19 [482.6] 15 [381] 50 3 / 8 [1279.2] 38AUD *16 (MC HX ) 633 288 220 100 134 61 135 61 144 65.5 38 [965.2] 19 [482.6] 15 ...
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Carrier 38AU - page 5
5 C10943 UNI T Standar d Wei g h t Corner A Corner B Corner C Corner D Cent er of Gravi ty Unit Heig ht lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. X Y Z H 38AUZ*25 (RT PF) 978 444 360 163 188 85 147 67 283 128 38 [965.2] 23 [584.2] 17 [431.8] 50 3 / 8 [1279.2] 38AUD *25 (RT PF) 978 444 360 163 188 85 147 67 283 128 38 [965.2] 23 [584.2] 17 [431.8 ...
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Carrier 38AU - page 6
6 Tab le 1A — Ph ysical Data — 38AUZ*16-25 Un i ts — 60 Hz En gl i sh UNI T SIZE 38A U Z*16 Z*25 NOM INA L C APAC IT Y ( ton s) 15 20 OPERA TING WEI GHTS (lb ) NOVAT IO N ™ Coil ( Al T ube) 633 --- Round T ube/P late Fin Coil ( Cu/Al ) 731 900 REFRIGERAN T TYPE ‡ R-410A NOVA TION Opera ting C har ge, T ypica l (lb) † 24.6 --- NOVATION S ...
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Carrier 38AU - page 7
7 Tab le 1B — Ph ysical Data — 38AUZ*16-25 Un i ts — 60 Hz SI UNI T SIZE 38A U Z*16 Z*25 NOM INA L C APACI T Y (k W) 52.7 70.3 OPERA TING W EIGHT (k g) NOVAT IO N ™ Coil ( Al T ube) 288 --- Round T ube/P late Fin Coil ( Cu/Al ) 332 409 REFRIGERAN T TYPE ‡ R-410A NOVA TION Opera ting C har ge, T ypica l (kg) † 11.1 --- NOVA TION Shippin ...
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Carrier 38AU - page 8
8 Tab le 2A — Ph ysical Data — 38AUD*16-25 Uni ts — 60 Hz En g li sh UNI T SIZE 38A U D*16 D* 25 NOM INA L C APAC IT Y ( ton s) 15 20 OPERA TING WEI GHTS (lb ) NOVAT IO N ™ Coil ( Al T ube) 633 --- Round T ube/P late Fin Coil ( Cu/Al ) 731 900 REFRIGERAN T TYPE ‡ R-410A NOVA TION Opera ting Cha rge A/B, T ypical (lb) † 12.0 / 12.0 --- N ...
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Carrier 38AU - page 9
9 Tab le 2B — Ph ysical Data — 38AUD*16-25 Uni ts — 60 Hz SI UNI T SIZE 38A U D*16 D* 25 NOM INA L C APACI T Y (k W) 52.7 70.3 OPERA TING W EIGHT (k g) NOVAT IO N ™ Coil ( Al T ube) 288 --- Round T ube/P late Fin Coil ( Cu/Al ) 332 409 REFRIGERAN T TYPE ‡ R-410A R-410A NOVA TION Opera ting Ch arge A /B, T y pical (kg) † 5.4 / 5.4 --- NO ...
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Carrier 38AU - page 10
10 Model T ype 3 8 A U = Ca rr i e r Condensing Unit Puron ® R - - - 410A Refrigerant Ty p e o f C o i l D = Dual Circuit, A/C Scroll Compressor Z = Single Circuit, A/C Scroll Compressor Refr igera nt Options A = None B = Low Ambient No minal T onnage 16 = 15 T ons 25 = 20 T ons Not U se d A = Not Used Not U se d 0 = Not Used 38 A U Z A 25A 0 G 6A ...
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Carrier 38AU - page 11
11 Matching 38AU Model T o Evaporator Coil The Model 38AUZ is a single-circ uit unit design, requiring one set of re frigera tion pi ping. T his mode l ca n be connected to an ev aporato r coil with one circuit or with two circ uits (by mani folding the eva porator connec tions into a sing le piping s ystem). The Model 38AUD is a dua l-ci rcuit uni ...
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Carrier 38AU - page 12
12 Ste p 3 — Pr epar e Unit M ount ing Support Sla b Mo unt — Pro vide a level co ncrete s lab that extend s a minimu m of 6 in. (150 m m) beyond uni t ca binet . Insta ll a grave l a pron in front of condenser c oil a ir inl et to prevent grass and foliage from obstruct ing ai rflow . Ste p 4 — Rig and Mo unt the U nit UNIT DAMAG E HAZ ARD F ...
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Carrier 38AU - page 13
13 Enter the appr opriate table to select the recommended line sizes . Model : Line Sizes T a ble Qu a nti ty of L in e Se ts 38AU Z 5 1 38AU D 6 2 Liqui d Li ft — A liquid lift condition exi sts when the outdoor unit is loca ted be low the indoor (evaporat or) unit a nd liquid flow s vertically u p in a portion of th e liquid line. The vertic al ...
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Carrier 38AU - page 14
14 T abl e 6 – 38 AUD 16- 25 P ipi ng Rec o mme ndat io ns (T wo-Ci rcui t Uni t) NOT E : 38AUD requires TWO set s of ref rigeration pip ing R - 410A Equival ent Length Ft 0-38 38-75 75-113 113-150 150-188 m 0-12 12-23 23-34 34-46 46-57 Model Linea r Length Ft 0-25 25-50 50-75 75-100 100-125 m 0-8 8-15 15-23 23-30 30-38 38AUD *16 Liquid Li ne 1 / ...
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Carrier 38AU - page 15
15 Circuit 1 Connections Circuit 2 Connections CKT 1 CKT 1 CKT 2 CKT 2 C10355 Fig. 6 - - 38AUD S ervi ce V alve Locati ons Plan the Ci rcuit 1 and Circ uit 2 t ubing segme nts care fully , mark each seg ment and check cons tantly as piping sys tems are assembled to av oid pipin g errors . 38AUD uni t cannot be fi eld-pi ped as a sing le-circuit/tan ...
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Carrier 38AU - page 16
16 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 LOCA TION TXV CKT 2 FIL TER DRIER A LOCATION FIL TER DRIERS B LOCA TION FLOW TXV SENSING BULB TXV CKT 1 8 DIAMS MIN 15 DIAMS MIN 10 DIAMS Single Circuit Coil Piping Configuration For single ...
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Carrier 38AU - page 17
17 The stub tube connec tions incl ude 1 / 4 -in SAE service fittings with S chrader valve cor es (see F ig. 10). Bef ore making any brazed connections to the unit service valves, remove bot h Schrader va lve c aps and core s and save for re-instal lat ion. Conne ct a source for ni trogen to one of these s ervice fittings during tube brazin g to pr ...
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Carrier 38AU - page 18
18 Step 7 — Co mpl ete El ectrica l Co nn ecti on s ELECTRIC AL SHOCK HAZARD Failure t o follow thi s warning could result in personal injury or dea th. Do not use ga s pi ping as an e lec tric al ground. Unit cabine t m ust have an unint errupte d, unbroke n ele ctri cal ground to minimize the poss ib ility of pers onal i njury if an ele ctri ca ...
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Carrier 38AU - page 19
19 11 1 3 L1 L2 L3 CT B 1 208/230-3-60 460-3-60 575-3-60 Units Without Disconnect Option Units With Disconnect Option 2 4 6 1 3 5 L1 L2 L3 Optional Disconnect Switch Disconnect factory test leads; discard. Factory Wiring Disconnect per NEC C10204 Fig. 12 - - Power W iring Con nectio ns Af fix the crankc ase hea ter warni ng sticke r to the unit dis ...
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Carrier 38AU - page 20
20 B 50HJ542739 Maximum Continuous use : 8 A mps 24/7 Conv enience Outlet Utilization NOTICE C10207 Fig. 15 - - Conv enien ce Outlet Utilizat ion N otice La bel T est the GFC I receptacle by press ing the TEST button on the face of the r eceptacle to trip and open the receptacle. Check for prope r grounding wires and power line phasing if the GFCI ...
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Carrier 38AU - page 21
21 Th ermost at — Ins tall a Carrier -approv ed access ory thermos tat according to installatio n instr uctions included w ith the accessor y . Locate the thermostat accesso ry on a solid wall in the conditi oned space to sense average te mpera ture in accordan ce with the thermo stat installatio n instr uctions . The 38A UZ is a s ingle-circu it ...
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Carrier 38AU - page 22
22 T ab le 10 – U nit W ire/Fus e or HAC R Brea ker S izing D ata UNIT SIZE 38AU NOMI NAL POWE R SUPPL Y VOL TAGE RANGE COMP RESSOR N O C.O . or UNPW RD C.O . No. 1 No. 2 OFM POWER SU PPL Y DISC ONNE CT SI ZE V --- P h --- H z Min Max RLA LRA RLA LRA Qty FLA (ea) MCA FUSE o r HACR BRKR FLA LRA D*16 Z*16 208/230 - - - 3 - - - 60 187 253 25.0 164 2 ...
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Carrier 38AU - page 23
23 PRE- ST AR T -UP IMP ORT ANT : Before be ginning Pre-Start-Up or Star t-Up, rev iew Start- Up Ch ecklist at the b ack of th is book. The Checkl ist assures proper start-up of a unit and provides a record of unit condi tion, appli cat ion requirem ents, system inform ati on, and operati on at initial star t-up. UNIT DAMAG E HAZ ARD Failur e to fo ...
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Carrier 38AU - page 24
24 Compr essor Ove rload — This overl oad i nterrupt s power to the compre ssor when either the curren t or internal moto r wind ing temperatu re becomes ex cess ive, and automatically res ets when the interna l tem perat ure drops to a safe level. T his ove rload may requi re up to 60 m inute s (or l onger) t o reset. If the interna l overl oad ...
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Carrier 38AU - page 25
25 38AUZ* 25 Chec k Compre ssor Oi l Le ve l — After adjusting the re frigera nt charge, al low the uni t t o run fully loaded for 20 minutes . Stop th e compres so rs and chec k the oil le vel. Oil l evel should be 1 / 3 to 1 / 2 up on the sight gla ss (see Fig. 22). 1 / 3 (MIN) 1 / 2 (MAX) C01377 Fig. 22 - - Recomme nded Oil Level — 38AUZ*25 ...
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Carrier 38AU - page 26
26 (CIRCUIT 1) (CIRCUIT 2) C10946 Fig. 24 - - 38AUD*16 Charging Ch art (Novation) 38AU ...
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Carrier 38AU - page 27
27 C10947 Fig. 25 - - 38AUZ*16 Charging Chart (R TP F) C10948 Fig. 26 - - 38AUZ*25 Charging Chart (R TP F) 38AU ...
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Carrier 38AU - page 28
28 C10949 Fig. 27 - - 38AUD*16 Charging Ch art (RTPF) 38AU ...
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Carrier 38AU - page 29
29 (CIRCUIT 1) (CIRCUIT 2) C10950 Fig. 28 - - 38AUD*25 Charging Ch art (RTPF) 38AU ...
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Carrier 38AU - page 30
30 C10212A Fig. 29 - - T ypical 38AUZ W i ring Diagram - (15 T on 230V T andem Unit Sh own) 38AU ...
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Carrier 38AU - page 31
31 C10213A Fig. 30 - - T ypical 38AUD Wiring Diagram - (15 T on 230V Dual Un it Shown) 38AU ...
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Carrier 38AU - page 32
32 OPERA T ING SEQUENCE Base Unit Controls Indoor (Suppl y) F an — The indoor fa n conta ctor (IFC) is rem otel y loca ted at the fan coil or fan s ection. If the thermo stat fan op eration is selected as Continuous, the IFC i s energized and the indoor (supply) fan motor runs continuously . If the the rmostat fan ope rati on is selected as Au to ...
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Carrier 38AU - page 33
33 ROUTINE SYSTEM MAINTENANCE These ite ms should be part of a routine mai ntena nce prog ram, to be checked ever y month or tw o, until a specific sched ule for each can be iden tified for this installation: Quarterl y Inspection (and 30 days after i nitial start) — Ind oor secti on S Condenser c oil clea nline ss checke d. S Return air f ilter ...
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Carrier 38AU - page 34
34 Liq uid L ine Filter D rier — The factory -pro vided filter dr ier is sp ecifically designed to operate w ith Puro n ® . Replace the filter drier with factory-authori zed components onl y with a filter drier with desiccant made from 100% molecular sieve grade XH -1 1. Filter dr ier must be replaced whenever th e refrigera nt system is opened. ...
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Carrier 38AU - page 35
35 Comfort Alert Diagnostic Module The Comfort Alert Diagnostic Module (CAD M) moni tors and anal yzes data from the Cope land Scroll ® three-ph ase compressor and t he t hermosta t de mand. The CADM also prov ides a 3 -minute anti- recycle time delay to comp ress or cycli ng. Ea ch c ompressor has a separat e CADM module . The CAD M detects caus ...
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Carrier 38AU - page 36
36 T abl e 11 – LED Status Code s Status LED Status LE D Descr iption S tat us LED T roub lesho oti ng Informat ion Green “PO WER” Mo du le h as p ow er Supp ly voltage is present a t module terminals Red “TRIP” LED On Sol id The rmostat d ema nd sign al Y is prese nt, but the com - pres sor is n ot running. 1. Compressor protect or is op ...
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Carrier 38AU - page 37
37 T abl e 12 – CADM T ro uble shoo ti ng Miswi red Module Indic ation Recommended T r oublesho oting Act ion Green L ED is not on, mo dule does no t power up Determi ne if b oth R and C module terminal s are connected. Veri fy v oltage in present at module’s R and C termi nals. NOT E : The CADM r equires a cons tant nom inal 2 4V AC power s up ...
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Carrier 38AU - page 38
38 Condenser Fans/Motors Service V alves Access Panel - Control Box & Compressors C10087 Fig. 34 - - 38AUD S iz e 16 Cabinet C10095 Fig. 35 - - 38AUD*16 Piping 38AU ...
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Carrier 38AU - page 39
39 Equalization LPS Oil Equalizer Line C10079 Fig. 36 - - 38AUZ*16 Compr essor Assembly (Rear V iew) C10214 Fig. 37 - - 38AUD*16 Compr essor Ass embly (Rear V iew) 38AU ...
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Carrier 38AU - page 40
40 Condenser Fans/Motors Service V alves Access Panel - Control Box & Compressors C10089 Fig. 38 - - 38AUZ,D Size 25 Cabinet CKT 2 CKT 2 CKT 1 CKT 1 HPS LPS HPS LPS C10090 Fig. 39 - - 38AUD*25 Piping 38AU ...
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Carrier 38AU - page 41
41 C10215 Fig. 40 - - 38AUZ*25 Compr essor Assembly (Rear V iew) C10091 Fig. 41 - - 38AUD*25 Compr essor Ass embly (Rear V iew) 38AU ...
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Carrier 38AU - page 42
42 Coil T ype Identifica tion 38AU units are ava ila ble with different coil types. Cl eani ng methods dif fer for each type so identifying the coil type is importa nt. Unit m odel number a nd appea rance ca n ident ify the coi l type. NOV A TIO N t Ty p e — The ne w NOV A TION Heat Exchange r T ec hnology is a n all - - a luminum construc tion w ...
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Carrier 38AU - page 43
43 oxyacety lene fuel an d torch . While the flame temperature for M AP P is low er than that of oxyacety lene (and thus prov ides mor e flexibility wh en work ing on aluminum), the flame temperatu re is s till higher than the melting temperatur e of aluminum, so u ser cautio n is required. Fo llow inst ructions carefully . Use the h eat shield . R ...
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Carrier 38AU - page 44
44 7. Hold garden spraye r nozzl e cl ose to finned are as and apply c lea ner with a verti cal , up-and-down motion. A void sp raying in h orizontal patter n to min imize po- tential for fin d amage. 8. Ensure cle aner thoroughly pene trat es deep i nto finne d areas . 9. Interior a nd exteri or finned area s must be thoroughly cleaned. 10. Finned ...
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Carrier 38AU - page 45
45 TROUBLESHOOTING (cont ) PROBLEM SOLUTION COMP RESSOR CYCLES ON L OW- PRESSURE SWITCH Indoor-Air Fan Running 1. Li q u i d l in e so le n o i d v a l v e ( s) f a i l s to op e n . 1. C heck li qu id line s olenoid valve(s) for proper operation. Replace if necessary . 2. Fil te r drie r plugged. 2 . Repl ace fi lter dr ier . 3. Expan sion valve p ...
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Carrier 38AU - page 46
46 APP ENDIX A Air Conditioner & Hea t P ump with PURON ® — Quick Reference Gui de S Puro n ® (R-410A) refrigera nt operat es at 50 percent t o 70 perce nt higher pre ssures than R-22. Be sure tha t servicing equipment and replacement c omponents are designed to ope rate with Puron ® . S Puro n ® refri gerant c ylinders are rose colore d. ...
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Carrier 38AU - page 47
47 APP ENDIX C Low Ambie nt Option — F actory I nstalled Units with th e factory ins talled low ambient option are equippe d with a Motorma ster R sol i d - - sta te h ea d pr essu re contr ol which reg ulates fan s peed. A temper ature sen sor , mounted on c ircui t 1 of the outdoor coi l (see Figs. 44 and 45) controls the speed of approved outd ...
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Carrier 38AU - page 48
48 Motormaster Sensor - Attach to Circuit 1 coil only . 508 mm (20 in) for Single Circuit 254 mm (10 in) for Dual Circuit C10093 Fig. 44 - - Motor master Sensor Location: 38AUZ*16 & 38AU D*16 (Novation) Motormaster Sensor - Must be positioned on V apor Stub of Circuit 1 coil only . C10094 Fig. 45 - - Motor master Sensor Location: 38AUZ*16/25 &a ...
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Carrier 38AU - page 49
49 T a b l e1 4–W i n dB a f f l eD i m e n s i o n DIM E NSI ONS - - - INC H E S UNI T BAFFLE A B C D E F G H J 38AU Z* 16 38AU D*16 (MCHX) LEFT SI DE 19 3 / 4 20 1 / 2 21 1 / 4 43 1 / 8 8 3 / 8 18 27 1 / 4 40 --- BACK 80 1 / 4 81 81 3 / 4 43 1 / 8 8 3 / 8 18 27 1 / 4 40 --- RIGHT S IDE 38 3 / 4 39 1 / 2 40 1 / 4 43 1 / 8 8 3 / 8 18 27 1 / 4 40 ...
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Carrier 38AU - page 50
50 C10363A Fig. 46 - - Wind Baffles - - Fabrication 38AU ...
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Carrier 38AU - page 51
51 C10366 Fig. 47 - - 15 T on Wind Baffle Brackets - - Fabrication 38AU ...
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Carrier 38AU - page 52
52 RIGHT BACK LEFT FRONT BOTTOM BRACKET TOP BRACKETS C10367 Fig. 48 - - Wind Baffle Installation — 15 T on Unit s 38AU ...
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Carrier 38AU - page 53
53 RIGHT BACK LEFT FRONT C10368 Fig. 49 - - Wind Baffle Installation — 20 T on Unit s 38AU ...
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Carrier 38AU - page 54
54 Copyright 2010 Carrier Corp. D 7310 W . Morris St. D I ndianapolis, I N 46231 Pr inted in U. S.A. Edition Date: 11/10 Manufacturer reser ves the right to change, at any time, specifications and d esigns without notice and without oblig ations. Catal og No : 38AU - - - 09SI Replaces : 38AU - - - 07SI 38AU ...
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Carrier 38AU - page 55
55 ST AR T -UP CHECKLIST I. P RELIMINAR Y INFORMA TION OUTDOOR: MODEL NO. SERI AL NO. INDOOR: AIRHANDLE R MANUF ACTUR ER MODEL NO. SERIAL NO. ADDITI ONAL ACCE SSORI ES II. PRE-ST AR T -UP OUTDOOR UNIT IS THE RE ANY SHIPPI NG DAMAGE? (Y/N) IF SO, WHERE: WI LL T HIS DAMAGE PREVE NT UNIT ST AR T - UP? (Y/N) CHEC K POWE R SUPPL Y . DOE S IT AGREE W IT ...
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Carrier 38AU - page 56
56 CHECK VOL T AGE IMBALANCE LINE -TO-L INE VOL T S: AB V AC V B C V (AB + AC + BC)/ 3 = A VE RAGE VOL T AGE = V MAXIMUM DEVI A T ION FR OM A VE RAGE VOL T AGE = V VOL T AGE IMBAL ANCE = 10 0 X (MAX DE VIA TION) /( A VE RAGE VOL T AGE ) = IF O VER 2% V OL T AGE IM BALAN CE, DO NO T A TTEMP T TO ST AR T SYS TEM! CALL L OCAL POW E R COMP ANY FOR ASSI ...
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