Carrier Heat Pump 38AUQ User Manual

38AUQ

Heat Pump Condensing Units

60 Hz

with Puron^®(R-410A) Refrigerant

Sizes 07, 08, and 12

Installation, Start-Up and

Service Instructions

Comfort Alert Diagnostic Module . . . . . . . . . . . . . . 28

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . 2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Step 1 – Plan for Unit Location . . . . . . . . . . . . . . . . . . . 7

Step 2 – Complete Pre-Installation Checks. . . . . . . . . . 7

Step 3 – Prepare Unit Mounting Support . . . . . . . . . . 7

Step 4 – Rig and Mount the Unit . . . . . . . . . . . . . . . . . . 7

Step 5 – Complete Refrigerant Piping Connections . . . 7

Step 6 – Install Accessories. . . . . . . . . . . . . . . . . . . . . . 10

Step 7 – Complete Electrical Connections . . . . . . . . . 10

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Turn On Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . 15

Preliminary Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 -18

38AUQ Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

OPERATING SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . 19

Indoor (Supply) Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cooling Unit Without Economizer. . . . . . . . . . . . . . . . . 19

Cooling, Unit With Economizer . . . . . . . . . . . . . . . . . . . 19

Heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Supplemental Heating/Emergency Heating . . . . . . . . 19

Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cooling and Heating Shutdown. . . . . . . . . . . . . . . . . 19

ROUTINE SYSTEM MAINTENANCE. . . . . . . . . . . . . . . 20

Quarterly Inspection (and 30 days after initial start). . 20

SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 31

Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 20

Compressor Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Outdoor Coil Maintenance and Cleaning

Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . 31

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

APPENDIX A

Air Conditioner and Heat Pump with Puron –

Quick Reference Guide. . . . . . . . . . . . . . . . . . . . . . . 33

APPENDIX B

Wiring Diagram List. . . . . . . . . . . . . . . . . . . . . . . . . 33

APPENDIX C

Motormaster Sensor Locations. . . . . . . . . . . . . . . . . 34

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . .CL-1, CL-2

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 and appropriate national electrical codes

(in USA, ANSI/NFPA70, National Electrical Code (NEC); in

Canada, CSA C22.1) for special requirements.

It is important to recognize safety information. This is the

Servicing Systems on Roofs with

safety-alert symbol

. When you see this symbol on the unit

Synthetic Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

and in instructions or manuals, be alert to the potential for

personal injury.

Liquid Line Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . 21

Filed Refrigerant Access Ports . . . . . . . . . . . . . . . . . 21

Outdoor Coil Metering Devices. . . . . . . . . . . . . . . . . 21

Refrigerant System Pressure Access Ports . . . . . . . . 21

Heat Pump Controls. . . . . . . . . . . . . . . . . . . . . . . . . . 22

Commercial Defrost Board . . . . . . . . . . . . . . . . . . . . . . 22

Crankcase Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Compressor Protection. . . . . . . . . . . . . . . . . . . . . . . . . . 22

Low-Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . 33

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.

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Standard

Weight

Corner

Center of Gravity

Unit Height

UNIT

lbs.

kg.

lbs.

kg.

lbs.

kg.

lbs.

kg.

lbs.

kg.

42-3/8

38AUQ*07

444 201 134

123

125

157

[584]

[660]

[330]

[1076]

42-3/8

[1076]

38AUQ*08 483 219 162

38AUQ*12

110

126

[508]

[610]

[330]

50-3/8

575 261 186

106

[533]

[610]

[584]

[1280]

Fig. 1 — 38AUQ*07-12 Unit Dimensions

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Table 1A — Physical Data — 38AUQ*07-12 Units — 60 Hz English

UNIT SIZE 38AUQ

*07

*08

*12

7.5

NOMINAL CAPACITY (tons)

OPERATING WEIGHTS (lb)

Aluminum-Fin Coils

444

483

R-410A

21.0

575

REFRIGERANT TYPE^‡

Operating Charge, Typical (lb)^†

18.0

10.0

27.0

15.0

Shipping Charge (lb)

12.0

COMPRESSOR

Qty...Type

1...Scroll

OUTDOOR FANS

Qty...Rpm

2...1100

Motor Hp

Diameter (in)

Nominal Airflow (Cfm Total)

Watts (Total)

6,000

610

6,000

610

6,000

610

1...Round Tube/Plate Fin (RTPF)

OUTDOOR COIL (Qty)

Face Area (sq ft total)

Rows/Fins per inch (FPI)

17.5

2/17

23.0

2/17

28.1

2/17

CONTROLS

Pressurestat Settings (psig)

High Cutout

Cut-in

630 ±10

505 ±20

27 ±3

630 ±10

505 ±20

27 ±3

630 ±10

505 ±20

27 ±3

Low Cutout

Cut-in

44 ±5

PIPING CONNECTIONS (in. ODS)

Qty...Vapor

1...1¹/₈

1...³/₈

1...1¹/₈

1...¹/₂

1...1³/₈

1...¹/₂

Qty...Liquid

LEGEND

ODS — Outside Diameter Sweat (socket)

‡ Unit is factory-supplied with partial charge only.

† Typical operating charge with 25 ft of interconnecting piping.

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Table 1B — Physical Data — 38AUQ*07-12 Units — 60 Hz SI

UNIT SIZE 38AUQ

*07

*08

*12

21.1

26.4

35.1

NOMINAL CAPACITY (kW)

OPERATING WEIGHT (kg)

Aluminum-Fin Coils

201

219

R-410A

9.5

261

REFRIGERANT TYPE^‡

Operating Charge, Typical (kg)^†

8.2

4.5

12.2

6.8

Shipping Charge (kg)

5.9

COMPRESSOR

Qty...Type

1...Scroll

CONDENSER FANS

Qty...r/s

2...18

Motor Hp NEMA

Diameter (mm)

Nominal Airflow (L/s)

Watts (Total)

560

2832

610

560

2832

610

560

2832

610

1...Round Tube/Plate Fin (RTPF)

CONDENSER COIL (Qty)

Face Area (sq m total)

1.6

2.1

2.6

Rows/Fins per Meter (Fins/m)

2/670

CONTROLS

Pressurestat Settings (kPa)

High Cutout

Cut-in

4344 ±70

3482 ±138 3482 ±138 3482 ±138

Low Cutout

Cut-in

186 ±21

303 ±35

186 ±21

303 ±35

186 ±21

303 ±35

PIPING CONNECTIONS (in. ODS)

Qty...Vapor

1...1¹/₈

1...³/₈

1...1¹/₈

1...¹/₂

1...1³/₈

1...¹/₂

Qty...Liquid

LEGEND

NEMA — National Electrical Manufacturers Association

ODS — Outside Diameter Sweat (socket)

‡ Unit is factory-supplied with partial charge only.

† Typical operating charge with 7.62 m of interconnecting piping.

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10 11 12 13 14 15 16 17 18

8 A U Q A 1 2 A 0

– 0 A 0 A 0

_____________

____

Model Type

Packaging

0 = Standard

1 = LTL

38AU= Carrier Condensing Unit

Puronr R---410A Refrigerant

Type of Coil

Q = Heat Pump Scroll Compressor

Electrical Options

A = None

C = Non-Fused Disconnect

Refrigerant Options

A = None

Service Options

B = Low Ambient

0 = None

1 = Un-powered Convenience Outlet

2 = Powered Convenience Outlet

Nominal Tonnage

07 = 6 Tons

08 = 7.5 Tons

12 = 10 Tons

Not Used

A = Place Holder

Not Used

Base Unit Controls

A = Not Used

0 = Electro-Mechanical Controls

Not Used

0 = Not Used

Design Revision

A = Initial Rev (Discrete Model Number)

Voltage

Coil Options

1 = 575/3/60

A= Al/Cu

B = Precoat Al/Cu

C = E-Coat Al/Cu

5 = 208/230/3/60

6 = 460/3/60

E= Cu/Cu

M= Al/Cu with Hail Guard

N = Precoat Al/Cu with Hail Guard

P = E-Coat Al/Cu with Hail Guard

R = Cu/Cu with Hail Guard

Fig. 2 — Model Number Nomenclature

POSITION NUMBER

TYPICAL

POSITION

1−2

DESIGNATES

Week of manufacture (fiscal calendar)

3−4

Year of manufacture (”09” = 2009)

Manufacturing location (G = ETP, Texas, USA)

Sequential number

6−10

Fig. 3 — Serial Number Nomenclature

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CONSIDER SYSTEM REQUIREMENTS

.INSTALLATION

• Consult local building codes and National Electrical

Code (NEC, U.S.A.) for special installation requirements.

• Allow sufficient space for airflow clearance, wiring,

refrigerant piping, and servicing unit. See Fig.1 for unit

dimensions and weight distribution data.

• Locate the unit so that the outdoor coil (condenser) air-

flow is unrestricted on all sides and above.

• 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 and 1B for unit operating weights.

See Fig. 1 for weight distribution based on recommended

support points.

Jobsite Survey

Complete the following checks before installation.

1. Consult local building codes and the NEC (National

Electrical Code) ANSI/NFPA 70 for special installation

requirements.

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

location.

3. Check for possible overhead obstructions which may in-

terfere with unit lifting or rigging.

Step 1 — Plan for Unit Location

NOTE: If vibration isolators are required for a particular

installation, use the data in Fig. 1 to make the proper

selection.

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.

Select a unit mounting system that provides adequate height to

allow for removal and disposal of frost and ice that will form

during the heating-defrost mode.

Step 3 — Prepare Unit Mounting Support

Slab Mount

Provide a level concrete slab that extends a minimum of 6 in.

(150 mm) beyond unit cabinet. Install a gravel apron in front of

condenser coil air inlet to prevent grass and foliage from

obstructing airflow.

NOTE: Consider also the effect of adjacent units on airflow

performance and control box safety clearance.

Step 4 — Rig and Mount the Unit

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 (out-

door unit above indoor unit), liquid line lift (outdoor unit below

indoor unit) and hot gas bypass line. Relocate sections to mini-

mize the length of interconnecting tubing.

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.

DO NOT BURY REFRIGERATION LINES.

RIGGING — These units are designed for overhead rigging.

Refer to the rigging label for preferred rigging method. Spread-

er bars are not required if top crating is left on the unit. All pan-

els 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.

Although unit is weatherproof, avoid locations that permit

water from higher level runoff and overhangs to fall onto the

unit.

RIGHT:

Min 18” (457 mm)

requried for service

REAR:

Min 18” (457 mm)

requried for service

LEFT:

Min 18” (457 mm)

FRONT:

requried for service

42” (1067 mm)

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.

Note: Observe requirements for 39” (914 mm) operating clearance

on either Left or Rear coil opening.

Step 5 — Complete Refrigerant Piping

Connections

Refrigerant lines must be carefully designed and constructed to

ensure equipment reliability and efficiency. Line length, pres-

sure drop, compressor oil return, and vertical separation are

several of the design criteria that must be evaluated. See

Table 2.

Fig. 4 — Service Clearance Dimensional Drawing

Step 2 — Complete Pre-Installation Checks

CHECK UNIT ELECTRICAL CHARACTERISTIC —

Confirm before installation of unit that voltage, amperage and

circuit protection requirements listed on unit data plate agree

with power supply provided.

UNCRATE 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.

IMPORTANT: Do not bury refrigerant piping underground.

INSPECT SHIPMENT — File a claim with shipping com-

pany if the shipment is damaged or incomplete.

IMPORTANT: A refrigerant receiver is not provided with

the unit. Do not install a receiver.

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Table 2 — 38AUQ*07-12 Piping Recommendations (Single-Circuit Unit)

Equivalent Length

R-410A

Model

0-38

38-75

75-113

113-150

Length Linear 0-25

Nominal Capacity Length Equiiv 0-38

25-50

38-75

50-75

75-113

75-100

113-115

38AUQ*07

38AUQ*08

38AUQ*12

Liquid Line

Max Lift

Cool

Heat

1-¹/₈

100

Suction Line

Charge (lbs)

Liquid Line

17.8

18.8

20.3

22.6

21.4

24.5

Max Lift

Cool

Heat

1-¹/₈

100

1-¹/₈

Suction Line

Charge (lbs)

Liquid Line

1-¹/₈

20.9

23.0

24.9

26.8

Max Lift

Cool

Heat

100

Suction Line

Charge (lbs)

1-¹/₈

1-³/₈

26.8

28.8

30.7

33.4

37.2

Legend:

Length Equiv

Liquid Line

Equivalent tubing length, including effects of refrigeration specialties devices

Tubing size, inches OD.

Max Lift

Cooling

Heating

Maximum liquid lift at maximum permitted liquid line pressure drop

• Indoor unit ABOVE outdoor unit

• Indoor unit BELOW outdoor unit

Suction Line

Charge

Tube size, inches OD

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

suction line size (where applicable)

NOTE:

For applications with linear length greater than 100 ft (30.5 m), contact your local Carrier representative.

CHECK VERTICAL SEPARATION — If there is any vertical

separation between the indoor and outdoor units, check to

ensure that the separation is within allowable limits. Relocate

equipment if necessary.

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.

REFRIGERANT LINE SIZING — Consider the length of

the piping required between the outdoor and indoor units. The

maximum allowable line length is 100 ft (30.5 m). See Table 2.

Refrigerant vapor piping should be insulated.

INSTALL FILTER

DRIER(S) AND

MOISTURE

INDICATOR(S) — Every unit MUST have a bi-directional

filter drier in the liquid line. Locate the filter drier at the indoor

unit, close to the evaporator coil’s thermal expansion valve

(TXV) inlets.

38AUQ units include one Puron-duty filter drier, shipped in

cartons attached to the unit basepan. Remove the filter drier

and prepare to install in the liquid line 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 4 — Puron-duty Filter Drier(s)

Liquid

Desiccant

Volume

Part

Number Ref

Model-Size

Qty

Line OD

38AUQ*07

38AUQ*08

38AUQ*12

³/₈-in

¹/₂-in

8 cu. in.

16 cu. in.

KH43LG091

KH43LG085

IMPORTANT: A refrigerant receiver is not provided

with the unit. Do not install a receiver.

Table 3 — Maximum Vertical Separation*

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 5 for recommendations on refrigeration

specialties.

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.

DISTANCE FT (M)

UNIT 38AUQ

UNIT 40RUQ

Unit 38AUQ

Above Unit 40RMQ

50 (15.2)

60 (18.3)

*Vertical distance between indoor and outdoor units.

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Table 5 — Refrigerant Specialties Part Numbers.

LIQUID LINE

SIZE (in.)

LIQUID LINE

SOLENOID VALVE (LLSV)

LLSV

COIL

SIGHT

GLASS

FILTER

DRIER

ALC-066208

ALC-066209^†

ALC-066212

AMG-24/50-60

HMI-1TT3

HMI-1TT4

HMI-1TT5

Provided with unit

See Table 4

†

38AUD units require TWO sets of parts.

INSTALL LIQUID LINE SOLENOID VALVE —

It is recommended that a bi-directional solenoid valve be

placed in the main liquid line (see Figs. 5 & 6) between the

outdoor unit and the indoor coil. Locate the solenoid valve at

the end of the liquid line, near the outdoor unit connections,

with flow direction arrow pointed at the outdoor unit. Refer to

Table 5. (A liquid line solenoid valve is required when the

liquid line length exceeds 75 ft [23 m].) This valve prevents

refrigerant migration (which causes oil dilution) to the

compressor during the off cycle, at low outdoor ambient

temperatures. Wire the solenoid according to the unit label

diagram.

EQUALIZER LINE

TXV

INDOOR

SENSING

BULB

COIL CKT 2

SIGHT GLASS

LOCATION

FILTER DRIER

LOCATION

TXV

AIRFLOW

15 DIAMS

CKT 2

MIN

DIAMS

8 DIAMS

MIN

TXV

SENSING

BULB

LIQUID

LINE

INDOOR

COIL CKT 1

SOLENOID

VALVE

TXV

AIRFLOW

15 DIAMS

MIN

CKT 1

DIAMS

8 DIAMS

MIN

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment

damage.

Failure to use a solenoid valve relay (SUR) accessory may

cause overload of Comfort Alert Diagnostic Module

(CADM) and compressor alarm lock out.

LEGEND

TXV — Thermostatic Expansion Valve

Fig.6 — Location of Sight Glass(es) and Filter Driers

(typical 38AUQ/40RUQ size 12 system)

CAPACITY CONTROL LIQUID LINE SOLENOID VALVE

Evaporator capacity control via liquid solenoid valve is not rec-

ommended for use with 38AUQ models.

Table 6 — Minimum Outdoor Air Operating Temperature

MINIMUM OUTDOOR

TEMP — F (C)*

EQUALIZER LINE

TXV

UNIT

COMPRESSOR

CAPACITY

Head Pressure

Control†

Standard Unit

INDOOR

SENSING

BULB

SIGHT GLASS

A LOCATION

COIL CKT

38AUQ07

38AUQ08

38AUQ12

35 (1.7)

–20 (–28.9)

FILTER DRIER

LOCATION

100

TXV

AIRFLOW

15 DIAMS

MIN

DIAMS

8 DIAMS

MIN

*Applies to Cooling mode of operation only.

LIQUID

LINE

†Wind baffles (field-supplied and field-installed) are recommended

for all units with low ambient head pressure control. Refer to Low

Ambient Control Installation Instructions (shipped with accessory)

for details.

SOLENOID

VALVE

LEGEND

TXV — Thermostatic Expansion Valve

Table 7 — Insulation for Vapor Line Exposed

to Outdoor Conditions

Fig.5 — Location of Sight Glass(es) and Filter Driers

(typical 38AUQ/40RUQ size 07 & 08 systems)

LENGTH OF EXPOSED

INSULATION THICKNESS†

VAPOR LINE*

in.

*Recommended vapor line insulation for piping exposed to outdoor

conditions to prevent loss of heating during heating cycle. When

vapor line goes through interior spaces, insulation should be

selected to prevent condensation on cooling cycle. Heating capac-

ity should be reduced 1000 Btuh (295 W) if over 35 ft (11 m) of

vapor line with ³/₄in. (19 mm) insulation is exposed to outdoor con-

ditions.

†Closed cell foam insulation with a thermal conductivity of: 0.28 Btu

• in./ft²• h • °F (0.04 W/m • °C).

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MAKE PIPING CONNECTIONS — Piping connections at

the 38AUQ unit are ball valves with stub tube extensions. Do

not open the unit service valves until all interconnecting tube

brazing as been completed.

The stub tube connections include ¼-in SAE service fittings

with Schrader valve cores (see Fig. 7). Before making any

brazed connections to the unit service valves, remove both

Schrader valve caps and cores and save for re-installation. Con-

nect 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.

Example:

38AUQ*08

60-ft (18.3 m) linear line length

Equivalent line length 90-ft (27.4 m)

Liquid Lift: 20-ft (6.1 m)

Select line sizes from Table 2 (38AUQ):

Liquid / in

Suction 1- / in.

Charge 23.0 lbs (at 75-ft linear length)

80% of Operating Charge:

0.80 x 23.0 = 17.6 lbs

Field Service

Factory Shipping Charge: 12 lbs

Access Port

Factory

High-Flow

(Schrader core)

Field-charge quantity: 17.6 lbs –12.0 lbs = 5.6 lbs

Access Port

For linear line lengths longer than 100 ft (30.5 m), contact your

local Carrier representative for system charge value.

Service Valve

with Stem Cap

Sweat

Connection

Step 6 — Install Accessories

Accessories requiring modifications to unit wiring should be

completed now. These accessories may include Winter Start

controls, Low Ambient controls, phase monitor, Compressor

LOCout. Refer to the instructions shipped with the accessory.

Fig. 7 — Typical Piping Connection Assembly

When connecting the field tubing to the 38AUQ service valves,

wrap the valves in wet rags to prevent overheating

Pressure-test all joints from outdoor unit connections over to

the indoor coil, using nitrogen as pressure and with soap-and-

bubbles.

Step 7 — Complete Electrical Connections

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 2-3 in-lbs (23-34

N-cm).

Where vapor line is exposed to outdoor air, line must be

insulated. See Table 7 for insulation requirements.

EVACUATION/DEHYDRATION — Evacuate and dehydrate

the connected refrigeration system(s) (excluding the 38AUQ

unit) to 500 microns using a two-stage vacuum pump attached

to the service ports outside the 38AUQ service valves, follow-

ing description in GTAC II, Module 4, System Dehydration.

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 NEC (National Electrical Code); ANSI/

NFPA 70, latest edition (in Canada, Canadian Electrical

Code CSA [Canadian Standards Association] C22.1), and

local electrical codes.

NOTE: Check all factory and field electrical connections

for tightness. Field-supplied wiring shall conform with the

limitations of 63°F (33°C) rise.

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal injury,

death and/or equipment damage.

Puron® (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.

Field Power Supply —

If equipped with optional Powered Convenience Outlet: The

power source leads to the convenience outlet's transformer pri-

mary are not factory connected. Installer must connect these

leads according to required operation of the convenience outlet.

If an always-energized convenience outlet operation is desired,

connect the source leads to the line side of the unit-mounted

disconnect. (Check with local codes to ensure this method is

acceptable in your area.) If a de-energize via unit disconnect

switch operation of the convenience outlet is desired, connect

the source leads to the load side of the unit disconnect. On a

unit without a unit-mounted disconnect, connect the source

leads to compressor contactor C and indoor fan contactor IFC

pressure lugs with unit field power leads.

All units except 208/230-v units are factory wired for the volt-

age shown on the nameplate. If the 208/230-v unit is to be con-

nected to a 208-v power supply, the control transformer must

be rewired by moving the black wire with the 1/4-in. female

spade connector from the 230-v connection and moving it to

the 208-v 1/4-in. male terminal on the primary side of the trans-

former. Refer to unit label diagram for additional information.

IMPORTANT: Charge in Cooling mode only!

PRELIMINARY CHARGE — Before starting the unit, charge

R-410A liquid refrigerant into the high side of each 38AUQ

circuit through the liquid service valve(s). The amount of

refrigerant added must be at least 80% of the operating charge

listed in Table 2 for LINEAR line length LESS the factory

charge quantity (if factory shipping charge has not been

removed). See the following example.

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.

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Field power wires are connected to the unit at line-side pres-

sure lugs on compressor contactor C and TB1 (see wiring dia-

gram label for control box component arrangement) or at facto-

ry-installed option non-fused disconnect switch. Max wire size

is #4 AWG (copper only).

Units Without Disconnect Option

TB1

NOTE: TEST LEADS - Unit may be equipped with short

leads (pigtails) on the field line connection points on con-

tactor 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.

Disconnect

per

NEC

208/230-3-60

460-3-60

575-3-60

Units With Disconnect Option

FIRE HAZARD

Failure to follow this warning could result in intermittent

operation or performance satisfaction.

Do not connect aluminum wire between disconnect switch

and condensing unit. Use only copper wire.

Optional

Disconnect

Switch

Factory

Wiring

(See Fig. 8.)

Disconnect factory test leads; discard.

Fig. 9 — Power Wiring Connections

ELECTRIC

DISCONNECT

SWITCH

All field wiring must comply with the NEC and local

requirements.

COPPER

WIRE ONLY

Voltage and Current Balance -

Voltage to compressor terminals during operation must be

within voltage range indicated on unit nameplate. See Table 10.

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 Table 8, Note 5 (see page 14) 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.

ALUMINUM

WIRE

Fig. 8 — Disconnect Switch and Unit

Units Without Factory-Installed 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 the unit cabinet.

Convenience Outlets

Units with Factory-Installed Disconnect —

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal

injury or death.

Units with convenience outlet circuits may use multiple

disconnects. Check convenience outlet for power status

before opening unit for service. Locate its disconnect

switch, if appropriate, and open it. Tag-out this switch, if

necessary.

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 NEC and all local codes.

Size wire based on MCA (Minimum Circuit Amps) on the unit

informative plate. See Fig. 9 for power wiring connections to

the unit power terminal block and equipment ground.

Maximum wire size is #4 ga AWG per pole.

Provide a ground-fault and short-circuit over-current protection

device (fuse or breaker) per NEC Article 440 (or local codes).

Refer to unit informative data plate for MOCP (Maximum

Over-current Protection) device size.

Two types of convenience outlets are offered on 38AUQ

models: Non-powered and unit-powered. Both types provide a

125-volt GFCI (ground-fault circuit-interrupter) duplex

receptacle rated at 15-A behind a hinged waterproof access

cover, located on the end panel of the unit. See Fig. 10.

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Convenience

Outlet

GFCI

Pwd-CO

Fuse

Switch

Pwd-CO

Transformer

UNIT

VOLTAGE

CONNECT

PRIMARY

CONNECTIONS

L1: RED + YEL

L2: BLU + GRA

TRANSFORMER

TERMINALS

H1 + H3

208,

230

240

H2 + H4

L1: RED

Splice BLU +

YEL

H2 + H3

460

575

480

Control Box

Access Panel

L2: GRA

L1: RED

L2: GRA

600

UNIT

VOLTAGE

CONNECT

PRIMARY

CONNECTIONS

TRANSFORMER

TERMINALS

Fig. 10 — Convenience Outlet Location

Non-powered type: This type requires the field installation of

a general-purpose 125-volt 15-A circuit powered from a source

elsewhere in the building. Observe national and local codes

when selecting wire size, fuse or breaker requirements and

disconnect switch size and location. Route 125-v power supply

conductors into the bottom of the utility box containing the

duplex receptacle.

208,

230

L1: RED + YEL

L2: BLU + GRA

H1 + H3

H2 + H4

240

L1: RED

Splice BLU +

YEL

H2 + H3

460

575

480

L2: GRA

L1: RED

L2: GRA

600

Unit-powered type: A unit-mounted transformer is factory-

installed to stepdown the main power supply voltage to the unit

to 115-v at the duplex receptacle. This option also includes a

manual switch with fuse, located in a utility box and mounted

on a bracket behind the convenience outlet; access is through

the unit's control box access panel. See Fig. 10.

The primary leads to the convenience outlet transformer are not

factory-connected. Selection of primary power source is a

customer-option. If local codes permit, the transformer primary

leads can be connected at the line-side terminals on the unit-

mounted non-fused disconnect or HACR breaker switch; this

will provide service power to the 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. 11.

Fig. 11 - Powered Convenience Outlet Wiring

Duty Cycle: the unit-powered convenience outlet has a duty

cycle limitation. The transformer is intended to provide power

on an intermittent basis for service tools, lamps, etc; it is not

intended to provide 15-amps loading for continuous duty loads

(such as electric heaters for overnight use). Observe a 50%

limit on circuit loading above 8-amps (i.e., limit loads

exceeding 8-amps to 30 minutes of operation every hour).

Test the GFCI receptacle by pressing the TEST button on the

face of the receptacle to trip and open the receptacle. Check for

proper grounding wires and power line phasing if the GFCI re-

ceptacle does not trip as required. Press the RESET button to

clear the tripped condition.

Fuse on power type: The factory fuse is a Bussman “Fusetron”

T-15, non-renewable screw-in (Edison base) type plug fuse.

Using unit-mounted convenience outlets: Units with unit-

mounded convenience outlet circuits will often require that two

disconnects be opened to de-energize all power to the unit.

Treat all units as electrically energized until the convenience

outlet power is also checked and de-energization is confirmed.

Observe National Electrical Code Article 210, Branch Circuits,

for use of convenience outlets.

Installing Weatherproof Cover

A weatherproof while-in-use cover for the factory-installed

convenience outlets is now required by UL standards. This

cover cannot be factory-mounted due its depth; it must be

installed at unit installation. For shipment, the convenience

outlet is covered with a blank cover plate.

The weatherproof cover kit is shipped in the unit's control box.

The kit includes the hinged cover, a backing plate and gasket.

DISCONNECT ALL POWER TO UNIT AND

CONVENIENCE OUTLET.

Remove the blank cover plate at the convenience outlet;

discard the blank cover.

Loosen the two screws at the GFCI duplex outlet, until

approximately / -in (13 mm) under screw heads are exposed.

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Press the gasket over the screw heads. Slip the backing plate

over the screw heads at the keyhole slots and align with the

gasket; tighten the two screws until snug (do not over-tighten).

Mount the weatherproof cover to the backing plate as shown in

Fig. 12. Remove two slot fillers in the bottom of the cover to

permit service tool cords to exit the cover. Check for full

closing and latching.

Thermostat —

Install a Carrier-approved accessory thermostat according to

installation instructions included with the accessory. For

complete economizer function, select a two—stage cooling

thermostat. Locate the thermostat accessory on a solid wall in

the conditioned space to sense average temperature in

accordance with the thermostat installation instructions.

If the thermostat contains a logic circuit requiring 24-v power,

use a thermostat cable or equivalent single leads of different

colors with minimum of five leads. If the thermostat does not

require a 24-v source (no “C” connection required), use a

thermostat cable or equivalent with minimum of four leads.

Check the thermostat installation instructions for additional

features which might require additional conductors in the

cable.

COVER – WHILE-IN-USE

RECEPTACLE

WEATHERPROOF

NOT INCLUDED

For wire runs up to 50 ft. (15 m), use no. 18 AWG (American

Wire Gage) insulated wire (35°C minimum). For 50 to 75 ft.

(15 to 23 m), use no. 16 AWG insulated wire (35°C minimum).

For over 75 ft. (23 m), use no. 14 AWG insulated wire (35°C

minimum). All wire sizes larger than no. 18 AWG cannot be

directly connected to the thermostat and will require a junction

box and splice at the thermostat.

PremierLink (accessory installation) – Refer to Form 33CS-

58SI for details on connecting the PremierLink controller and

its various sensors.

BASE PLATE FOR

GFCI RECEPTACLE

Fig. 12 — Weatherproof Cover Installation

All Units —

Voltage to compressor terminals during operation must be

within voltage range indicated on unit nameplate. See Table 8.

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 Table 8, Note 5 (see pages 14) 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.

O/B/Y2

(Notes 1, 2)

Field Control Wiring —

38AUQ unit control voltage is 24 v. See Fig. 19 for typical

field control connections and the unit’s label diagram for field-

supplied wiring details. Route control wires to the 38AUQ unit

through the opening in unit’s end panel to the connections

terminal board in the unit’s control box.

(Note 4)

(Note 3)

Remainder of the system controls connection will vary

according to the specific construction details of the indoor

section. Fig. 13 depicts typical connections to a Carrier 40RUQ

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 38AUQ 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: Typical multi-function marking. Follow manufacturer’s configuration

instructions to select Y2.

Note 2: Y2 to economizer required on single-stage cooling units when

integrated economizer function is desired

Note 3: Connect only if thermostat requires 24-vac power source.

Note 4: Connect W2 if supplemental heater installed

Field Wiring

Fig. 13 — Typical Remote Thermostat Connections

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Table 8 — Electrical Data — 38AUQ*07-12 60 Hz Units

NOMINAL

VOLTAGE

POWER

SUPPLY

UNIT

SIZE

38AUQ

FACTORY-

INSTALLED

OPTION

COMPRESSOR

FAN MOTORS

‡

RANGE

V-Ph-Hz

MIN

MAX

RLA

LRA

FLA (ea)

QTY

MCA

MOCP

NONE OR DISCONNECT

CONVENIENCE OUTLET

NONE OR DISCONNECT

CONVENIENCE OUTLET

NONE OR DISCONNECT

CONVENIENCE OUTLET

NONE OR DISCONNECT

CONVENIENCE OUTLET

NONE OR DISCONNECT

CONVENIENCE OUTLET

NONE OR DISCONNECT

CONVENIENCE OUTLET

NONE OR DISCONNECT

CONVENIENCE OUTLET

NONE OR DISCONNECT

CONVENIENCE OUTLET

NONE OR DISCONNECT

CONVENIENCE OUTLET

26.8

31.6

13.9

16.1

10.5

12.2

34.3

39.1

17.1

19.3

12.5

14.2

40.6

45.4

22.5

24.7

16.5

18.2

208/230-3-60

187

414

518

187

414

518

187

414

518

253

506

633

253

506

633

253

506

633

19.0

123

1.5

460-3-60

575-3-60

9.7

7.4

0.9

0.6

1.5

0.9

0.6

1.5

0.8

0.6

*07

208/230-3-60

460-3-60

25.0

12.2

9.0

164

100

*08

575-3-60

208/230-3-60

460-3-60

30.1

16.7

12.2

225

114

*12

575-3-60

LEGEND

5. Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is

greater than 2%. Use the following formula to determine the percentage

of voltage imbalance.

FLA

LRA

MCA

—

Full Load Amps

Locked Rotor Amps

Minimum Circuit Amps

max voltage deviation from average voltage

% Voltage Imbalance = 100 x

MOCP —

Maximum Overcurrent

Protection

average voltage

Example: Supply voltage is 208/230-3-60

NEC

RLA

—

National Electrical Code

Rated Load Amps

AB = 224 v

BC = 231 v

AC = 226 v

‡

Units are suitable for use on electrical systems where voltage supplied to

the unit terminals is not below or above the listed limits.

NOTES:

(224 + 231 + 226)

681

1. The MCA and MOCP values are calculated in accordance with the NEC,

Article 440.

Average Voltage =

2. Motor RLA and LRA values are established in accordance with Underwriters’

Laboratories (UL), Standard 1995.

227

3. The 575-v units are UL, Canada-listed only.

4. Convenience outlet is available as a factory-installed option and is 115-v,

1 ph, 60 Hz.

Determine maximum deviation from average voltage.

(AB) 227 – 224 = 3 v

(BC) 231 – 227 = 4 v

(AC) 227 – 226 = 1 v

Maximum deviation is 4 v.

Determine percent of voltage imbalance.

% Voltage Imbalance

= 100 x

= 1.76%

227

This amount of phase imbalance is satisfactory as it is below the

maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than

2%, contact your local electric utility company immediately.

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PRE-START-UP

START-UP

IMPORTANT: Before beginning Pre-Start-Up or Start-Up,

review Start-Up Checklist at the back of this book. The

Checklist assures proper start-up of a unit and provides a

record of unit condition, application requirements, system

information, and operation at initial start-up.

38AUQ Units

The compressor crankcase heater must be on for 24 hours

before start-up. After the heater has been on for 24 hours, the

unit can be started. If no time elapsed since the preliminary

charge step was completed, it is unnecessary to wait the 24-

hour period.

Preliminary Checks

1. Check that electric power supply agrees with unit

nameplate 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.

UNIT DAMAGE HAZARD

Do not attempt to start the heat pump system, even

momentarily, until the following steps have been

completed. Compressor damage may result.

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 required. Evacuate and

dehydrate as described in the Leak Test and Dehydration

section.

5. Ensure that the preliminary charge has been added as

described in the Pre-Start-Up section, Preliminary

Charge.

System Check

1. Check all indoor section and other equipment auxiliary

components. Consult the manufacturer’s instructions

regarding any other equipment connected to the con-

densing unit. If the unit has field-installed accessories,

be sure all are properly installed and correctly wired. If

used, the airflow switch must be properly installed.

2. Be sure the unit is properly leak checked and dehydrated.

3. Check tightness of all electrical connections.

4. Open the liquid line and suction line service valves.

5. Be sure the unit is properly charged. See “Preliminary

Charge”, below.

6. The electrical power source must agree with the unit’s

nameplate rating.

6. All internal wiring connections must be tight, and all

barriers and covers must be in place.

NOTE: The units are factory charged with the required

amount of oil. If recharging in required, use Emkarate

RL 32-3MAF.

Compressor Rotation

On 3-phase units with scroll compressors, it is important to be

certain that the compressor is rotating in the proper direction.

38AUQ units are equipped with a Comfort Alert Diagnostic

Module (CADM). Alert Code 7 indicates reverse power phas-

ing.

7. The crankcase heater must be firmly attached to the com-

pressor crankcase. Be sure the crankcase is warm (heater

must be on for 24 hours before starting compressor).

Turn On Crankcase Heater

To correct phase order:

1. Turn off power to the unit, tag disconnect.

2. Reverse any two of the unit power leads.

3. Reapply power to the compressor, verify correct pres-

sures.

Turn on the crankcase heater for 24 hours before starting the

unit to be sure all the refrigerant is out of the oil. To energize

the crankcase heater, proceed as follows:

1. Set the space thermostat set point above the space tem-

perature so there is no demand for cooling.

2. Close the field disconnect.

To verify the compressor is rotating in the proper direction:

1. Connect service gages to the suction and liquid pressure

fittings.

2. Energize the compressor.

3. The suction pressure should drop and the liquid pressure

should rise, as is normal on any start-up.

Preliminary Charge

Before starting the unit, charge liquid refrigerant into the high

side of the system through the liquid service valve. The amount

of refrigerant added must be at least 80% of the operating

charge listed in the Physical Data table (Tables 1A and 1B on

pages 4 and 5). Allow high and low side pressures to equalize

before starting compressor. If pressures do not equalize readily,

charge vapor on 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.

Compressor Overload

This overload interrupts power to the compressor when either

the current or internal motor winding temperature becomes ex-

cessive, and automatically resets when the internal temperature

drops to a safe level. This overload may require up to 60 min-

utes (or longer) to reset. If the internal overload is suspected of

being open, disconnect the electrical power to the unit and

check the circuit through the overload with an ohmmeter or

continuity tester.

UNIT DAMAGE HAZARD

Prior to starting compressor, a preliminary charge of

refrigerant must be added to avoid possible compressor

damage.

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Reset the space thermostat below ambient so that a call for

cooling is ensured.

Advanced Scroll Temperature Protection (ASTP)

A label located above the terminal box identifies Copeland

Scroll compressor models that contain this technology. See Fig.

14. Advanced Scroll Temperature Protection (ASTP) is a form

of internal discharge temperature protection, that unloads the

scroll compressor when the internal temperature reaches ap-

proximately 300°F. At this temperature, an internal bi-metal

disk valve opens and causes the scroll elements to separate,

which stops compression. Suction and discharge pressures bal-

ance while the motor continues to run. The longer the compres-

sor runs unloaded, the longer it must cool before the bi-metal

disk resets. See Fig. 15.

Never charge liquid into the low-pressure side of system.

Do not overcharge. During charging or removal of refriger-

ant, be sure indoor-fan system is operating. Ensure both

outdoor fan motors are running; bypass any Motormaster

function.

Adjust Refrigerant Charge

The unit must be charged in Cooling mode only. Refer to Cool-

ing Charging Charts, Fig. 16 through Fig. 18. For applications

with line lengths greater than 100 ft, contact Carrier representa-

tive. Vary refrigerant until the conditions of the chart are met.

The charts are based on charging the units to the correct sub-

cooling for the various operating conditions. Accurate pressure

gage and temperature sensing device are required. Connect the

pressure gage to the service port on the liquid line service

valve. Mount the temperature sensing device on the liquid line

close to the liquid line service valve, and insulate it so that out-

door ambient temperature does not affect the reading. Indoor

airflow must be within the unit’s normal operating range. Oper-

ate the unit for a minimum of 15 minutes. Ensure that pressure

and temperature readings have stabilized. Plot the liquid pres-

sure and temperature on chart and add or reduce the charge to

meet the curve. Adjust the charge to conform with the charging

chart, using the liquid pressure and temperature to read the

chart.

Fig. 14 — Advanced Scroll Temperature

Protection Label

Final Checks

Ensure that all safety controls are operating, control panel

covers are on, and the service panels are in place.

120

110

100

Compressor Unloaded Run Time (Minutes)

*Times are approximate.

NOTE: Various factors, including high humidity, high ambient

temperature, and the presence of a sound blanket will

increase cool-down times.

*Times are approximate.

NOTE: Various factors, including high humidity, high ambient

temperature, and the presence of a sound blanket will

increase cool-down times.

Fig. 15 — Recommended Minimum Cool-Down Time

After Compressor is Stopped

To manually reset ASTP, the compressor should be stopped

and allowed to cool. If the compressor is not stopped, the motor

will run until the motor protector trips, which occurs up to

90 minutes later. Advanced Scroll Temperature Protection will

reset automatically before the motor protector resets, which

may take up to 2 hours.

Start Unit

Set the space thermostat to a set point above space temperature

so that there is no demand for cooling. Close the 38 AUQ dis-

connect switch. Only the crankcase heater will be energized.

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Fig. 16 — 38AUQ*07 Charging Chart

Fig. 17 — 38AUQ*08 Charging Chart

Fig. 18 — 38AUQ*12 Charging Chart

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Fig. 19 — 38AUQ Wiring Diagram (208/230-3-60 shown)

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Solenoid Valve Relay SVR and compressor contactor C.SVR

contacts close, energizing the external liquid line solenoid

valve. Solenoid valve LLSV opens. Compressor contactor C

closes, energizing the compressor motor. Compressor starts

and system runs in Heating mode, providing Stage 1 Heat.

When the space heating load is satisfied terminal W1 is

de-energized. Compressor and outdoor fan operations stop.

Liquid line solenoid LLSV is de-energized and valve closes.

CADM begins its three-minute anti-recycle time delay.

If either the Loss of Charge (LOC) Switch or High Pressure

Switch (HPS) opens while, the compressor contactor C and re-

lay SVR are de-energized; compressor stops and liquid line so-

lenoid is de-energized (valve closes). CADM initiates a TRIP

event (compressor demand sensed at CADM terminal Y but no

current is measured at T1, T2, T3 motor sensors); CADM relay

opens and RED LED is illuminated. TRIP condition maintains

lockout of compressor operation until CADM is manually re-

set. Reset CADM by cycling unit main power.

OPERATING SEQUENCE

Base Unit Controls —

Indoor (Supply) Fan

The indoor fan contactor (IFC) is remotely located at the fan

coil or fan section. If the thermostat fan operation is selected as

Continuous, the IFC is energized and the indoor (supply) fan

motor runs continuously. If the thermostat fan operation is

selected as Automatic, the IFC will be energized on a call for

Cooling or Heating; indoor (supply) fan motor runs. When

thermostat is satisfied, the IFC is de-energized and indoor

(supply) fan motor stops.

Cooling, Unit Without Economizer

When thermostat calls for Cooling, terminal Y1 is energized.

The 38AUQ’s Defrost Board (DFB) receives this input at P2-5.

DFB issues 24-v outputs at OF, P3-7 (RVS1) and P3-10

(COMP1). The OF output energizes outdoor fan relay (OFR);

both outdoor fan motors start and run. The output RVS1 ener-

gizes the reversing valve solenoid (RVS); Reversing valve

switches to Cooling position.

Reversing valve solenoid remains de-energized until the next

Cooling cycle is initiated.

Defrost Cycle

Output PL3-10 (COMP1, 24-v) is received at CADM terminal

Y. If anti-recycle time delay period has not expired, safety pres-

sure switches are open, and/or lockout alarms are active,

CADM relay will remain open, preventing compressor start.

When safety pressure switches are closed and CADM time de-

lay expires, the CADM relay closes, energizing Solenoid Valve

Relay SVR and compressor contactor C. SVR contacts close,

energizing the external liquid line solenoid valve. Solenoid

valve LLSV opens. Compressor contactor C closes, energizing

the compressor motor. Compressor starts and system runs in

Cooling mode.

When space cooling load is satisfied, terminal Y1 is de-enger-

ized. Compressor and outdoor fan motors stop. Liquid line so-

lenoid valve LLSV is de-energized and valve closes. CADM

begins its three-minute anti-recycle time delay.

If either the Loss of Charge (LOC) Switch or High Pressure

Switch (HPS) opens while Y1 remains energized, the compres-

sor contactor C and relay SVR are de-energized; compressor

stops and liquid line solenoid is de-energized (valve closes).

CADM initiates a TRIP event (cooling demand sensed at

CADM terminal Y but no current is measured at T1, T2, T3

motor sensors); CADM relay opens and RED LED is illumi-

nated. TRIP condition maintains lockout of compressor opera-

tion until CADM is manually reset. Reset CADM by cycling

unit main power.

During the Heating Mode, frost and ice can develop on the out-

door coil. Defrost sequence will clear the frost and ice from the

coil by briefly reversing the Heating sequence periodically.

A window to test for a need to run the Defrost cycle opens at a

fixed period after the end of the last Defrost cycle or the previ-

ous test window closed. The window period is determined by

the configuration settings on the DFB’s DIP switches (see unit

wiring diagram).

If the outdoor coil’s Defrost Thermostat switch (DFT) is closed

(shorting DFB terminals DFT1 and DFT1), the Defrost cycle

will start. Output at OF is removed; outdoor fans stop during

the Defrost cycle. Output P3–7 (RVS1) is energized; reversing

valve solenoid RVS is energized and reversing valve changes

position, placing the circuit in a Cooling mode flow, directing

hot gas into the outdoor coil where its heat melts the frost and

loosens the ice on the coil face.

During the Defrost cycle, output EHEAT is also energized (if

not already energized by a thermostat W2 demand); supple-

mental heater will be energized. During the Defrost Cycle,

LED1 on the DFB will be illuminated. The Defrost cycle ends

when DFT opens (as liquid temperature exiting the coil rises

above DFT setpoint) or the defrost cycle runs for 10 minutes.

Output at EHEAT is removed; supplemental heater will be

de-energized (unless thermostat has a W2 demand). Output at

OF is restored; outdoor fans start again. Output P3–7 (RVS1) is

removed; reversing valve returns to Heating position.

Reversing valve solenoid (RVS) is energized in Cooling

modes. This solenoid will remain energized until the next Heat-

ing mode is initiated.

Defrost cycle is fixed at a maximum 10 minute duration limit.

The period to test and initiate a Defrost cycle can be configured

for 30, 60, 90 or 120 minutes.

Cooling, Unit With Economizer

Refer to fan coil unit installation instructions and economizer

accessory installation instructions for operating sequences

when system is equipped with accessory economizer.

Supplemental Heat/Emergency Heat

Supplemental heat type is determined by 40RUQ indoor unit

options and accessories. This heat is initiated when the indoor

unit W2 terminal is energized by the thermostat. (Or as detailed

in “Defrost Cycle” on page 19.) The thermostat may energizes

W2 as supplemental (2nd stage) heat at larger space heating de-

mand, or when selected as emergency heat mode. When the

space heating demand decreases below the 2nd stage limit, or

emergency heat is turned off, W2 is de-energized, and supple-

mental heat is turned off.

Heating

When the thermostat calls for first stage heating, terminal W1

is energized. The 38AUQ’s Defrost Board (DFB) receives this

input at P2-7. The DFB removes the output at P3-7 (RVS1); the

reversing valve solenoid is de-energized and the reversing

valve moves to Heating position.

DFB issues outputs at OF and P3-10 (COMP1). Outdoor fan

relay OFR is energized; both outdoor fan motors run.

Cooling and Heating Shutdown

Output PL3-10 (COMP1, 24-v) is received at CADM terminal

Y. If anti-recycle time delay period has not expired and/or

safety pressure switches are open, outdoor lockout alarms are

active, CADM relay will remain open, preventing compressor

start. When safety pressure switches are closed and CADM

time delay expires, the CADM relay closes, energizing

Partial or complete cooling or heating functions may shutdown

caused by loss of main power, open pressure switches, diag-

nostic alarms, or open internal compressor protections. See

Service section for further details.

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ROUTINE SYSTEM MAINTENANCE

SERVICE

These items should be part of a routine maintenance program,

to be checked every month or two, until a specific schedule for

each can be identified for this installation:

Refrigeration System

Quarterly Inspection

(and 30 days after initial start)

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in damage to

equipment.

This system uses Puron® refrigerant which has higher

pressures than R-22 and other refrigerants. No other refrig-

erant may be used in this system. Gage set, hoses, and re-

covery system must be designed to handle Puron®. If you

are unsure consult the equipment manufacturer.

Indoor section

• Coil cleanliness checked.

• Return air filter replacement

• Belt tension checked

• Belt condition checked

• Pulley alignment checked

• Fan shaft bearing locking collar tightness checked

• Condensate drain checked

• Blower motor amperage

Compressor Oil

Outdoor Section

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in damage to

equipment.

The compressor in a Puron system uses a polyolester

(POE) oil. This oil is extremely hygroscopic, meaning it

absorbs water readily. POE oils can absorb 15 times as

much water as other oils designed for HCFC and CFC re-

frigerants. Take all necessary precautions to avoid exposure

of the oil to the atmosphere.

• Fan motor mounting bolts tightness

• Compressor mounting bolts

• Fan blade positioning

• Control box cleanliness and wiring condition

• Wire terminal tightness

• Refrigerant charge level

Economizer or Outside Air Damper

• Inlet filters condition

Servicing Systems on Roofs With Synthetic

Materials — POE (polyolester) compressor lubricants are

known to cause long term damage to some synthetic roofing

materials. Exposure, even if immediately cleaned up, may

cause embrittlement (leading to cracking) to occur in one year

or more. When performing any service which may risk expo-

sure 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 refrig-

erants leaks, replacing refrigerant components such as filter

drier, pressure switch, metering device, coil, accumulator, or

reversing valve.

• Check damper travel (economizer)

• Check gear and dampers for debris and dirt

SYNTHETIC ROOF PRECAUTIONARY PROCEDURE

1. Cover extended roof working area with an impermeable

polyethylene (plastic) drop cloth or tarp. Cover an ap-

proximate 10 x 10 ft (3.3 x 3.3 m) area.

2. Cover area in front of the unit service panel with a terry

cloth shop towel to absorb lubricant spills and prevent

run-offs, and protect drop cloth from tears caused by tools

or components.

3. Place terry cloth shop towel inside unit immediately un-

der component(s) to be serviced and prevent lubricant

run-offs through the louvered openings in the base pan.

4. Perform required service.

5. Remove and dispose of any oil contaminated material per

local codes.

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To check the indoor coil, disconnect the supply fan signal

(A04-A06 direct-drive fans) or contactor (IFC) coil, then start

the circuit in a Cooling Mode (jumper R to Y1 or Y2) and ob-

serve the frosting pattern on the face of the indoor coil. A frost

pattern should develop uniformly across the face of the indoor

coil starting at each tube at the Acutrol nipple locations.

To check the outdoor coil, disconnect the outdoor fan motor.

Start the circuit in a Heating Mode (jumper R to W1 or W2)

and observe the frost pattern on the face of the outdoor coil.

Liquid Line Filter Drier

The factory-provided reversible filter drier is specifically de-

signed to operate with Puron®. Replace the filter drier with

factory-authorized components only with a filter drier with

desiccant made from 100% molecular sieve grade XH-11. Fil-

ter drier must be replaced whenever the refrigerant system is

opened.

When removing a filter drier, use a tubing cutter to cut the drier

from the system. Do not unsweat a filter drier from the sys-

tem. Heat from unsweating will release moisture and contami-

nants from drier into system.

Failure to develop frost at an outlet tube can indicate a plugged

or a missing orifice.

Refrigerant System Pressure Access Ports

Field Refrigerant Access Ports

There are two access ports in each circuit - on the suction tube

near the compressor and on the discharge tube near the com-

pressor. These are brass fittings with black plastic caps. The

hose connection fittings are standard 1/4 SAE Male Flare cou-

plings.

The brass fittings are two-piece High Flow valves, with a re-

ceptacle base brazed to the tubing and an integral spring-closed

check valve core screwed into the base. (See Fig. 20.) This

check valve is permanently assembled into this core body and

cannot be serviced separately; replace the entire core body if

necessary. Service tools are available from RCD that allow the

replacement of the check valve core without having to recover

the entire system refrigerant charge. Apply compressor refrig-

erant oil to the check valve core's bottom o-ring. Install the fit-

ting body with 96 +/-10 in-lbs of torque; do not overtighten.

Field service access to refrigerant pressures is through the

access ports located at the service valves (see Figs 24, 26 and

28). These ports are ¼-in SAE Flare couplings with Schrader

check valves and service caps. Use these ports to admit

nitrogen to the field tubing during brazing, to evacuate the

tubing and evaporator coil, to admit initial refrigerant charge

into the low-side of the system and when checking and

adjusting the system refrigerant charge. When service activities

are completed, ensure the service caps are in place and secure;

check for leaks. If the Schrader check valve must be removed

and re-installed, tighten to 2-3 in-lbs (23-34 N-cm).

Outdoor Coil Metering Devices

The metering devices are multiple fixed–bore devices (Acu-

trol™) swaged into the horizontal outlet tubes from the liquid

header, located at the entrance to each evaporator coil circuit

path. These are non–adjustable. Service requires replacing the

entire liquid header assembly.

SEAT

CORE

(Part No. EC39EZ067)

1/2-20 UNF RH

0.596

45°

30°

WASHER

O-RING

DEPRESSOR PERARI720

1/2" HEX

+.01/-.035

.47

5/8” HEX

FROM FACE OF BODY

This surface provides a metal to metal seal when

torqued into the seat. Appropriate handling is

required to not scratch or dent the surface.

7/16-20 UNF RH

Fig. 20 — CoreMax Access Port Assembly

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Control Circuit, 24-V

Heat Pump Controls

The control circuit is protected against overcurrent conditions

by a circuit breaker mounted on control transformer TRAN.

Reset is manual.

Compressor Protection

Compressor Overcurrent

The compressor has internal limbered motor protection.

Compressor Overtemperature

Crankcase Heater

The heater prevents refrigerant migration and compressor oil

dilution during shutdown whenever compressor is not operat-

ing. The heater is wired to cycle with the compressor; the heat-

er is off when compressor is running, and on when compressor

is off.

The crankcase heater will operate as long as the power circuit

is energized.

The compressor has an internal protector to protect it against

excessively high discharge gas temperatures.

High Pressure Switch

The system is provided with a high pressure switch mount-

ed on the discharge line. The switch is stem-mounted and

brazed into the discharge tube. Trip setting is 630 ± 10 psig

(4344 ± 69 kPa) when hot. Reset is automatic at 505 ± 20

psig (3482 ± 140 kPa).

IMPORTANT: Never open any switch or disconnect that

energizes the crankcase heater unless unit is being serviced

or is to be shut down for a prolonged period. After a pro-

longed shutdown on a service job, energize the crankcase

heater for 24 hours before starting the compressor.

Loss of Charge Switch

The system is protected against a loss of charge and low

evaporator coil loading condition by a loss of charge switch

located on the liquid line and a freeze protection thermostat on

the indoor coil. The switch is stem-mounted. Loss of Charge

Switch trip setting is 27 psig ± 3 psig (186 ±21 kPa). Reset is

automatic at 44 ±5 psig (303 ± 35 kPa).

Outdoor Fan Motor Protection

The outdoor fan motor is internally protected against overtem-

perature.

Commercial Defrost Control

The Commercial Defrost Control Board (DFB) coordinates

thermostat demands for supply fan control, 1 or 2 stage

cooling, 1 or 2 stage heating, emergency heating and defrost

control with unit operating sequences. See Fig. 22 for board

arrangement.

The DFB is located in the 38AUQ's main control box (see

Fig. 21). All connections are factory-wired. Refer to Table 12

for details of DFB Inputs and Outputs.

Table 12 —38AUQ Defrost Board I/O and Jumper Configurations

Inputs

Point Name

Type of I/O

DI, 24-vac

24-vac

Connection Pin Number

Unit Connection

Note

G Fan

P2-3

P2-5

Not used

Y1 Cool 1

TB-Y1

TB-W1

TRAN2

DFB

Wi Heat 1

P2-7

R Power

P3-1

C Common

DFT1 Defrost Switch

24-vac, ground

DI, 24-vac

P3-3

DFT-1 to DFT-1

Outputs

Point Name

OF OD Fan

RVS1

Type of I/O

DO, 24-vac

Connection Pin Number

Unit Connection

OFR

Note

P3-7 to P3-5

P3-6 to P3-4

P3-10

RVS1

Energize in COOL

RVS2

COMP 1

HEAT 2

CADM1-Y

HC-1 (TB4-1)

E-HEAT

Configuration

Point Name

Type of I/O

24-vac

Connection Pin Number

Unit Connection

Note

Select Jumper

1 Compressor

P1-1

P1-2

24-vac

Speed-Up Configuration

Point Name

Type of I/O

Connection Pin Number

Speed-Up Jumper

JMP17

JMP18

Jumper for 1-3 secs: Factory Test, defrost runs for 12 seconds or less

Jumper for 5-20 secs: Forced Defrost, defrost runs for 30 secs if DFT2 is open

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Fig. 21 — Defrost Control Board (DFB) Location

Defrost

The defrost control mode is a time/temperature sequence.

There are two time components: The continuous run period

and the test/defrost cycle period. The temperature component

is provided by the defrost thermostat (DFT1) mounted on the

outdoor coil.

The continuous run period is a fixed time period between the

end of the last defrost cycle (or start of the current Heating cy-

cle) during which no defrost will be permitted. This period can

be set at 30, 60, 90 or 120 minutes by changing the positions of

DIP switches SW1 and SW2 (see Fig. 23 and Table 13). The

default run period is 60 minutes.

DIP

Switches

Speed-Up

Jumpers

Fig. 22 — Defrost Control Board (DFB) Arrangement

Fig. 23 — DIP Switch Settings — Defrost Board

Reversing valve control

At the end of the continuous run period, the defrost control will

test for a need to defrost. On unit sizes 04-07 (single compres-

sor designs), DFT1 controls the start and termination of the de-

frost cycle. If DFT1 is still open, the defrost test/run window is

closed and the control repeats the continuous run period. If

DFT1 is closed, the defrost cycle is initiated. The defrost period

will end when DFT1 opens (indicating the outdoor coil has

been cleared of frost and ice) or a 10 minute elapsed period ex-

pires, whichever comes first.

The DFB has two outputs for unit reversing valve control. Op-

eration of the reversing valves is based on internal logic; this

application does not use an “O” or “B” signal to determine re-

versing valve position. Reversing valves are energized during

the Cooling stages and de-energized during Heating cycles.

Once energized at the start of a Cooling stage, the reversing

valve will remain energized until the next Heating cycle de-

mand is received. Once de-energized at the start of a Heating

cycle, the reversing valves will remain de-energized until the

next Cooling stage is initiated.

At the end of the unit defrost cycle, the unit will be returned to

Heating cycle for a full continuous run period.

If the space heating load is satisfied and compressor operation

is terminated, the defrost control will remember where the run

period was interrupted. On restart in Heating, the defrost con-

trol will resume unit operation at the point in the run period

where it was last operating.

Compressor control

The DFB receives inputs indicating Stage 1 Cooling and Stage

1 Heating from the space thermostat or unit control system

(PremierLink); it generates commands to start compressors

with or without reversing valve operation to produce Stage 1

Cooling (one compressor), or Stage 1 Heating (both compres-

sors run).

Table 13 —Dip Switch Position

Switch No.

■

Off

■

30 minutes

60 minutes

90 minutes

120 minutes

Fan Delay

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Defrost Thermostats

Defrost Speedup Functions

These are temperature switches that monitor the surface tem-

perature of the outdoor coil circuits. These switches are mount-

ed on the liquid tube exiting the outdoor coil heating circuits.

These switches close on temperature drop at 30°F (-1°C) and

reset open on temperature rise at 80°F (27°C).

The DFB permits the servicer to speed-up the defrost cycle.

There are two speed-up sequences: relative speed-up and an

immediate forced defrost. Speed-up sequences are initiated by

shorting jumper wires JMP17 and JMP18 together (see

Fig. 22); use a straight-edge screwdriver.

Shorting the jumpers for a period of 1 to 3 secs reduces the de-

frost timer periods by a factor of 0.1 sec/minute. (For example,

the 90 min run period is reduced to 9 secs.) The DFB will step

the unit through a Heating cycle and a Defrost cycle using

these reduced time periods. This mode ends after the Defrost

cycle.

Shorting the jumpers for a period of 5 to 20 secs bypasses the

remaining continuous run period and places the unit in a

Forced Defrost mode. If the controlling DFT is closed when

this mode is initiated, the unit will complete a normal defrost

period that will terminate when the controlling DFT opens or

the 10 minute defrost cycle limit is reached. If the controlling

DFT is open when this mode is initiated, the Defrost cycle will

run for 30 secs. Both modes end at the end of the Defrost cycle.

Indoor Fan Off Delay

The DFB can provide a 30 sec delay on Indoor Fan Off if the

thermostat's fan selector switch is set on AUTO control. DIP

Switch SW3 on the DFB selects use of the fan off time delay

feature. Setting SW3 in the OPEN position turns the Fan Off

Delay feature on; setting SW3 in the CLOSED position dis-

ables this feature. The delay period begins when Y1 demand or

W1 demand by the space thermostat is removed.

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Fans

Service

Valves

Fig. 24 — 38AUQ*07 Exterior

Outdoor Coil

Defrost

Thermostat

(DFT)

LOC

HPS

High Flow

Access Ports

Fig. 25 — 38AUQ*07 Interior

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Fans

Service

Valves

Fig. 26 — 38AUQ*08 Exterior

Outdoor Coil

Defrost

Thermostat

(DFT)

LOC

HPS

High Flow

Access Ports

Fig.27 — 38AUQ*08 Interior

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Fans

Service

Valves

Fig. 28 — 38AUQ*12 Exterior

Outdoor Coil

Defrost

Thermostat

(DFT)

LOC

HPS

High Flow

Access Ports

Fig. 29 — 38AUQ*12 Interior

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COMFORT ALERT DIAGNOSTIC

MODULE

POWER

(GRN)

The Comfort Alert Diagnostic Module (CADM) monitors and

analyzes data from the Copeland Scroll three-phase compres-

sor and the thermostat demand. The CADM also provides a

3-minute anti-recycle time delay to compressor cycling.

The CADM detects causes for electrical and system related

failures. Flashing LEDs communicate the Alert codes to guide

service technicians in accurately and quickly troubleshooting

the system and determining root cause for the failure.

Inputs to the CADM include 24-vac power, demand signal Y,

compressor contactor coil (common side) and compressor

power leads (from the compressor contactor).

ALERT

(YEL)

TRIP

Input

Control Power

Terminal Voltage

(RED)

24-V

Fig. 30 — CADM Housing/LED Locations

Control

Common

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 14, correlates

to a particular abnormal condition; troubleshooting tips are

provided for each Alert code. Reset of the ALERT may be

automatic or manual. If the fault condition causing the Alert is

self-corrected, the Alert code will be removed and the CADM

will automatically reset and allow the system to restart

normally. Manual reset for lockouts requires that main power

to the 38AUQ unit be recycled after the cause for the Alert

condition has been detected and corrected.

The TRIP LED indicates either a time-delay period is currently

active (RED LED is blinking) or the module has locked out the

compressor (RED LED is on steady). A lockout condition will

occur for some faults as identified in Table 14. Reset of the

TRIP LED requires that unit main power be recycled after the

loss of power to the compressor condition has been detected

and corrected.

Demand

24-V

Line

Contactor Coil

Compressor T1

Compressor T2

Compressor T3

Control of the compressor contactor coil is through a contact

between terminals P and C.

Communications of status and alert conditions is through three

LEDs located on the top edge of the module housing (see

Fig. 30): POWER (green), ALERT (yellow), and TRIP (red).

The POWER LED indicates the presence of control power to

the CADM.

Simultaneous Blinking of YELLOW and RED LEDs indicates

control power input to the CADM is low. Check control circuit

transformer and wiring.

Troubleshooting the CADM Wiring – Flashing LEDs also

indicate wiring problems to the CADM. See Table 15 for

discussion of additional LED flash codes and troubleshooting

instructions.

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Table 14 — LED Status Codes

Status LED

Status LED Description

Status LED Troubleshooting Information

Green “POWER” Module has power

Supply voltage is present at module terminals

Red “TRIP”

LED On Solid

Thermostat demand signal Y 1. Compressor protector is open

is present, but the

2. Condensing unit power disconnect is open

3. Compressor circuit breaker or fuse(s) is open

compressor is not running.

4. Broken supply wires or connector is not

making contact

5. Compressor power wires not routed through

Comfort Alert

6. Compressor contactor has failed open

Red “TRIP” LED The anti-short cycle timer (3 minutes), in module is preventing compressor

Flashing restart.

Module locks out compressor when compressor damaging ALERT code appears.

Lockout ALERT codes are noted in the Status LED Description.

During a compressor lock out, 24VAC power must be removed from module to manually reset.

Yellow “ALERT”

LED On Solid

A short circuit or over current 1. Compressor contactor coil shorted

condition exists on PROT

2. Electrical load too high for PROT circuit

terminal.

(maximum 1 Amp)

3. 24 V AC wired directly to PROT terminal

Yellow “ALERT”

Flash Code 2

System Pressure Trip

Discharge pressure out of

limits or compressor

overload (if no high pressure

switch in system)

1. High head pressure

2. Condenser coil poor air circulation (dirty,

blocked, damaged)

3. Condenser fan is not running

LOCKOUT

4. If low pressure switch is open:

Refer to Code 3 for troubleshooting

Yellow “ALERT”

Flash Code 3

Short Cycling

Compressor is running only

briefly LOCKOUT

1. If low pressure switch is open:

a. Low refrigerant charge

b. Evaporator blower is not running

c. Evaporator coil is frozen

d. Faulty metering device

e. Condenser coil is dirty

f. Liquid line restriction (filter drier blocked if

present)

2. If high pressure switch is open, go to Flash

Code 2 information

3. Intermittent thermostat demand signal

4. System or control board defective

Yellow “ALERT”

Flash Code 4

Locked Rotor

LOCKOUT

1. Low line voltage to compressor

2. Excessive liquid refrigerant in compressor

3. Compressor bearings are seized

Yellow “ALERT”

Flash Code 5

Open Circuit

1. Condensing unit power disconnect is open

2. Compressor circuit breaker or fuses are open

3. Compressor contactor has failed open

4. High pressure switch is open and requires

manual reset

5. Broken supply wires or connector is not

making contact

6. Unusually long compressor protector reset

time due to extreme ambient temperature

7. Compressor windings are damaged

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 6

Missing Phase

LOCKOUT

Yellow “ALERT”

Flash Code 7

Reverse Phase

LOCKOUT

1. Compressor running backward due to supply

phase reversal

Yellow “ALERT”

Flash Code 8

Welded Contactor

Compressor always runs

1. Compressor contactor has failed closed

2. Thermostat demand signal not connected to

module

Yellow “ALERT”

Flash Code 9

Low Voltage

Control circuit < 18VAC

1. Control circuit transformer is overloaded

2. Low line voltage to compressor

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Table 15 — CADM Troubleshooting

Miswired Module Indication

Recommended Troubleshooting Action

Green LED is not on,

module does not power up

Determine if both R and C module terminals are

connected. Verify voltage in present at module’s R and C

terminals.

NOTE: The CADM requires a constant nominal 24VAC

power supply. The wiring to the module’s R and C

terminals must be directly from the control transformer.

The module cannot receive its power from another device

that will interrupt the 24VAC power supply. See Fig. 19,

the 38AUQ Wiring Diagram.

Green LED Intermittent,

module powers up only

when compressor runs

Determine if R and Y terminals are wired in reverse. Verify

module’s R and C terminals have a constant source. See

“NOTE” above for details on R and C wiring.

TRIP LED is on but system

and compressor check OK

Verify Y terminal is wired properly per the 38AUQ wiring

diagram (see Fig. 19). Verify voltage at contactor coil falls

below 0.5VAC when off. Verify 24VAQC is present across

Y and C when thermostat demand signal is present. If not,

R and C are reverse wired.

TRIP LED and ALERT LED

flashing together

Verify R and C terminals are supplied with 19-28VAC.

ALERT Flash Code 3

(Compressor Short Cycling)

displayed incorrectly

Verify Y terminal is connected to 24VAC at contactor coil.

Verify voltage at contactor coil falls below 0.5VAC when

off.

ALERT Flash Code 5 or 6

(Open Circuit, Missing Phase)

displayed incorrectly

Check that compressor T1 and T3 wires are through

module’s current sensing holes. Verify Y terminal is

connected to 24VAC at contactor coil. Verify voltage at

contactor coil falls below 0.5VAC when off.

Alert Flash Code *

(Welded Contactor)

displayed incorrectly

Determine if module’s Y terminal is connected. Verify Y

terminal is connected to 24VAC at contactor coil. Verify

24VAC is present across Y and C when thermostat

demand signal is present. If not, R and C are reverse

wired. Verify voltage at contactor coil falls below 0.5VAC

when off.

Lubrication

FAN MOTORS have sealed bearings. No provisions are made

for lubrication.

COMPRESSOR has its own oil supply. Loss of oil due to a

leak in the system should be the only reason for adding oil after

the system has been in operation.

PERSONAL INJURY AND UNIT DAMAGE

HAZARD

Failure to follow this caution may result in personal injury

or equipment damage.

Only approved cleaning is recommended.

Outdoor Coil Maintenance and Cleaning

Recommendation

Routine Cleaning of Indoor Coil Surfaces

Periodic cleaning with Totaline environmentally sound coil

Routine cleaning of coil surfaces is essential to maintain proper

operation of the unit. Elimination of contamination and remov-

al of harmful residues will greatly increase the life of the coil

and extend the life of the unit. The following maintenance and

cleaning procedures are recommended as part of the routine

maintenance activities to extend the life of the coil.

cleaner is essential to extend the life of coils. This cleaner is

available from Carrier Replacement Components Division as

part number P902-0301 for one gallon container, and part num-

ber P902-0305 for a 5 gallon container. It is recommended that

all coils, including standard aluminum, pre-coated, copper/cop-

per or E-coated coils be cleaned with the Totaline environmen-

tally sound coil cleaner as described below. Coil cleaning

should be part of the unit's regularly scheduled maintenance

procedures to ensure long life of the coil. Failure to clean the

coils may result in reduced durability in the environment.

Remove Surface Loaded Fibers

Surface loaded fibers or dirt should be removed with a vacuum

cleaner. If a vacuum cleaner is not available, a soft non-metallic

bristle brush may be used. In either case, the tool should be

applied in the direction of the fins. Coil surfaces can be easily

damaged (fin edges can be easily bent over and damage the

coating of a protected coil) if the tool is applied across the fins.

Avoid the use of

• coil brighteners

NOTE: Use of a water stream, such as a garden hose,

against a surface loaded coil will drive the fibers and dirt

into the coil. This will make cleaning efforts more difficult.

Surface loaded fibers must be completely removed prior to

using low velocity clean water rinse.

• acid cleaning prior to painting

• high pressure washers

• poor quality water for cleaning

Totaline environmentally sound coil cleaner is nonflammable,

hypoallergenic, non bacterial, and a USDA accepted biode-

gradable agent that will not harm the coil or surrounding com-

ponents such as electrical wiring, painted metal surfaces, or in-

sulation. Use of non-recommended coil cleaners is strongly

discouraged since coil and unit durability could be affected.

Periodic Clean Water Rinse

A periodic clean water rinse is very beneficial for coils that are

applied in coastal or industrial environments. However, it is

very important that the water rinse is made with very low ve-

locity water stream to avoid damaging the fin edges. Monthly

cleaning as described below is recommended.

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Clean coil as follows:

1. Turn off unit power, tag disconnect.

2. Remove top panel screws on outdoor coil end of unit.

3. Remove coil corner post. To hold top panel open, place

coil corner post between top panel and center post.

4. Remove screws securing coil to compressor plate and

compressor access panel.

5. Use a water hose or other suitable equipment to flush

down the coil to remove dirt and debris. Clean the outer

surfaces with a stiff brush in the normal manner.

6. Remove the coil corner post from between the top panel

and center post. Reinstall the coil corner post and replace

all screws.

Totaline Environmentally Sound Coil Cleaner

Application Instructions

1. Proper eye protection such as safety glasses is recom-

mended during mixing and application.

2. Remove all surface loaded fibers and dirt with a vacuum

cleaner as described above.

3. Thoroughly wet finned surfaces with clean water and a

low velocity garden hose, being careful not to bend fins.

4. Mix Totaline environmentally sound coil cleaner in a 2 /

gallon garden spryer according to the instructions includ-

ed with the cleaner. The optimum solution temperature is

100°F (38°C).

NOTE: Do NOT USE water in excess of 130°F (54°C), as

the enzymatic activity will be destroyed.

Totaline Environmentally Sound Coil Cleaner

5. Thoroughly apply Totaline environmentally sound coil

cleaner solution to all coil surfaces including finned area,

tube sheets and coil headers.

6. Hold garden sprayer nozzle close to finned areas and ap-

ply cleaner with a vertical, up-and-down motion. Avoid

spraying in horizontal pattern to minimize potential for

fin damage.

7. Ensure cleaner thoroughly penetrates deep into finned ar-

eas.

8. Interior and exterior finned areas must be thoroughly

cleaned.

9. Finned surfaces should remain wet with cleaning solution

for 10 minutes.

10. Ensure surfaces are not allowed to dry before rinsing. Re-

apply cleaner as needed to ensure 10-minute saturation is

achieved.

Application Equipment

• 2- / gallon garden sprayer

• Water rinse with low velocity spray nozzle

UNIT DAMAGE HAZARD

Failure to follow this caution may result in corrosion and

damage to the unit.

Harsh chemicals, household bleach or acid or basic clean-

ers should not be used to clean outdoor or indoor coils of

any kind. These cleaners can be very difficult to rinse out of

the coil and can accelerate corrosion at the fin/tube inter-

face where dissimilar materials are in contact. If there is dirt

below the surface of the coil, use the Totaline environmen-

tally sound coil cleaner as described above.

11. Thoroughly rinse all surfaces with low velocity clean wa-

ter using downward rinsing motion of water spray nozzle.

Protect fins from damage from the spray nozzle.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in reduced unit

performance.

High velocity water from a pressure washer, garden hose,

or compressed air should never be used to clean a coil. The

force of the water or air jet will bend the fin edges and in-

crease airside pressure drop.

Service Parts

Listings of service parts for all units are available from the Re-

placement Components Division’s Electronic Parts Informa-

tion Catalog (EPIC). EPIC is available at Totaline stores, dis-

tributor and service office parts departments and on-line at

HVACPartners.com.

When entering EPIC, the full unit model number is required.

The model number includes the Design Revision reference val-

ue (see Fig. 2, Position 13). The unit model number is available

from the unit’s information data plate. (Do not use the “catalog

number” when using EPIC. The “catalog number” suppresses

the Design Revision value; failure to include Design Revision

value may cause an incorrect unit parts list to be displayed.)

When using EPIC, enter first four digits of the model number

only. Find appropriate model from sales packages listed. Be

sure to choose correct voltage and Design Revision.

EPIC is a product of RCD. To comment of the EPIC program,

use the “Comment” button inside the EPIC program.

FASTENER TORQUE VALUES

Table 16 — Torque Values

Compressor mounting bolts

65–75 in–lbs

20 ±2 in–lbs

84 ±2 in–lbs

96 ±10 in–lbs

2–3 in–lbs

(734–847 N–cm)

(226 ±23 N–cm)

(949 ±136 N–cm)

(1085 ±23 N–cm)

(23–34 N–cm)

Condenser fan motor mounting bolts

Condenser fan hub setscrew

High-flow service port

Schrader-type service check valve

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TROUBLESHOOTING

PROBLEM

CAUSE

REMEDY

Compressor and

Outdoor Fan

Will Not Start.

Power failure.

Call power company.

Fuse blown or circuit breaker tripped.

Replace fuse or reset circuit breaker. Determine root cause.

Replace component.

Defective thermostat, contactor, transformer,

control relay, or capacitor.

Insufficient line voltage.

Determine cause and correct.

Incorrect or faulty wiring.

Check wiring diagram and rewire correctly.

Lower thermostat setting below room temperature.

See problem ``Excessive head pressure.''

Check system for leaks. Repair as necessary.

See problem ``Suction pressure too low.''

Thermostat setting too high.

High pressure switch tripped.

Low pressure switch tripped.

Freeze-up protection thermostat tripped.

Compressor Will Not

Start But Outdoor

Fan Runs.

Faulty wiring or loose connections in compressor Check wiring and repair or replace.

circuit.

Compressor motor burned out, seized, or

internal overload open.

Determine cause. Replace compressor or allow enough time for

internal overload to cool and reset.

Defective run/start capacitor, overload, start

relay.

Determine cause and replace compressor.

One leg of 3-phase power dead.

Refrigerant overcharge or undercharge.

Defective compressor.

Replace fuse or reset circuit breaker. Determine cause.

Recover refrigerant, evacuate system, and recharge to nameplate.

Replace and determine cause.

Compressor Cycles

(Other Than

Normally Satisfying

Thermostat).

Insufficient line voltage.

Determine cause and correct.

Blocked outdoor coil or dirty air filter.

Determine cause and correct.

Defective run/start capacitor, overload, or start

relay.

Determine cause and replace.

Defective thermostat.

Replace thermostat.

Replace.

Faulty outdoor-fan (cooling) or indoor-fan

(heating) motor or capacitor.

Restriction in refrigerant system.

Locate restriction and remove.

Replace filter.

Compressor Operates Dirty air filter.

Continuously.

Unit undersized for load.

Decrease load or increase unit size.

Reset thermostat.

Thermostat set too low (cooling).

Low refrigerant charge.

Locate leak; repair and recharge.

Recover refrigerant, evacuate system, and recharge.

Clean coil or remove restriction.

Air in system.

Outdoor coil dirty or restricted.

Compressor rotating in the wrong direction.

Compressor Makes

Excessive Noise.

Reverse the 3-phase power leads as described in

Start-Up.

Excessive Head

Pressure.

Dirty outside air or return air filter (heating).

Dirty outdoor coil (cooling).

Replace filter.

Clean coil.

Refrigerant overcharged.

Recover excess refrigerant.

Recover refrigerant, evacuate system, and recharge.

Determine cause and correct.

Check for leaks; repair and recharge.

Replace compressor.

Air in system.

Condensing air restricted or air short-cycling.

Low refrigerant charge.

Head Pressure

Too Low.

Compressor scroll plates defective.

Restriction in liquid tube.

Remove restriction.

Excessive Suction

Pressure.

High heat load.

Check for source and eliminate.

Replace compressor.

Compressor scroll plates defective.

Refrigerant overcharged.

Recover excess refrigerant.

Replace filter.

Suction Pressure

Too Low.

Dirty air filter (cooling).

Dirty or heavily iced outdoor coil (heating).

Low refrigerant charge.

Clean outdoor coil. Check defrost cycle operation.

Check for leaks; repair and recharge.

Remove source of restriction.

Increase air quantity. Check filter and replace if necessary.

Reset thermostat.

Metering device or low side restricted.

Insufficient indoor airflow (cooling mode).

Temperature too low in conditioned area.

Field-installed filter drier restricted.

Outdoor ambient below 25°F (cooling).

Outdoor fan motor(s) not operating (heating).

Replace.

Install low?ambient kit.

Check fan motor operation.

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• 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

roofing materials.

APPENDIX A

AIR CONDITIONER AND HEAT PUMP WITH

PURON^®— QUICK REFERENCE GUIDE

• Puron (R-410A) refrigerant operates at 50 percent to

70 percent higher pressures than R-22. Be sure that

servicing equipment and replacement components are

• Wrap all filter driers and service valves with wet cloth

when brazing.

• A factory approved, liquid-line filter drier is required on

every unit.

designed to operate with Puron .

• Puron refrigerant cylinders are rose colored.

• Recovery cylinder service pressure rating must be 400

• Do not use an R-22 TXV.

psig, DOT 4BA400 or DOT BW400.

• If indoor unit is equipped with a TXV, it must be

• Puron

systems should be charged with liquid

changed to a Puron TXV.

refrigerant. Use a commercial type metering device in

the manifold hose when charging into suction line with

compressor operating.

• Never open system to atmosphere while it is under a

vacuum.

• When system must be opened for service, recover

refrigerant, break vacuum with dry nitrogen before

opening system.

• Manifold sets should be 700 psig high side and 180 psig

low side with 550 psig low-side retard.

• Use hoses with 700 psig service pressure rating.

• Always replace filter drier after opening system for

service.

• Leak detectors should be designed to detect HFC

refirgerant.

• Do not vent Puron into the atmosphere.

• Puron , as with other HFCs, is only compatible with

• Do not use capillary tube coils.

POE oils.

• Observe all warnings, cautions, and bold text.

• Vacuum pumps will not remove moisture from oil.

• Use only factory specified liquid-line filter driers with

rated working pressures greater than 600 psig.

• All Puron heat pumps must have indoor TXV.

• Do not leave Puron suction line driers in place for

more than 72 hours.

APPENDIX B

WIRING DIAGRAM LIST

38AUQ

Size

*07

Electrical Characteristics

208/230-3-60

460-3-60

Diagram Number

38AU500363

38AU500362

38AU500435

38AU500363

38AU500362

38AU500435

38AU500363

38AU500362

38AU500435

575-3-60

208/230-3-60

460-3-60

575-3-60

208/230-3-60

460-3-60

*08

*12

575-3-60

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APPENDIX C

MOTORMASTER SENSOR LOCATIONS

MOTOR MASTER SENSOR

MUST BE POSITIONED

ON VAPOR STUB

MOTOR MASTER SENSOR

MUST BE POSITIONED

ON VAPOR STUB

MOTOR MASTER SENSOR

MUST BE POSITIONED

BETWEEN METERING DEVICE

(SECOND FROM TOP)

(FOURTH FROM TOP)

AND TUBE SHEET

6T HEAT PUMP

7.5T HEAT PUMP

10T HEAT PUMP

Fig. 31 Motormaster Sensor Locations per Unit Size

Printed in U.S.A.

Edition Date: 09/09

Catalog No: 38AUQ-01SI

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Replaces: New

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III. START UP

START-UP CHECKLIST

I. PRELIMINARY INFORMATION

OUTDOOR: MODEL NO.

SERIAL NO.

INDOOR: AIR HANDLER MANUFACTURER

MODEL NO.

ADDITIONAL ACCESSORIES

II. PRE-START-UP

OUTDOOR UNIT

IS THERE ANY SHIPPING DAMAGE?

IF SO, WHERE:

(Y/N)

WILL THIS DAMAGE PREVENT UNIT START-UP?

(Y/N)

CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT?

(Y/N)

HAS THE GROUND WIRE BEEN CONNECTED?

(Y/N)

HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY?

ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY?

(Y/N)

CONTROLS

ARE THERMOSTAT AND INDOOR FAN CONTROL WIRING CONNECTIONS MADE AND CHECKED?

(Y/N)

ARE ALL WIRING TERMINALS (including main power supply) TIGHT?

HAS CRANKCASE HEATER BEEN ENERGIZED FOR 24 HOURS?

(Y/N)

INDOOR UNIT

HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE?

ARE PROPER AIR FILTERS IN PLACE? (Y/N)

HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT?

(Y/N)

DO THE FAN BELTS HAVE PROPER TENSION?

(Y/N)

HAS CORRECT FAN ROTATION BEEN CONFIRMED?

(Y/N)

PIPING

ARE LIQUID LINE SOLENOID VALVES LOCATED AT THE INDOOR COILS AS REQUIRED?

(Y/N)

HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR, OUTDOOR AND INDOOR COILS,

TXVs (Thermostatic Expansion Valves), SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE PLUGS

WITH A LEAK DETECTOR?

(Y/N)

LOCATE, REPAIR, AND REPORT ANY LEAKS.

HAVE LIQUID LINE SERVICE VALVES BEEN OPENED?

HAVE SUCTION SERVICE VALVES BEEN OPENED?

(Y/N)

CHECK VOLTAGE IMBALANCE

LINE-TO-LINE VOLTS:

(AB + AC + BC)/3 = AVERAGE VOLTAGE =

MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =

VOLTAGE IMBALANCE = 100 X (MAX DEVIATION)/(AVERAGE VOLTAGE) =

IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START SYSTEM!

CALL LOCAL POWER COMPANY FOR ASSISTANCE.

CL-1

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CHECK INDOOR UNIT FAN SPEED AND RECORD.

CHECK OUTDOOR UNIT FAN SPEED AND RECORD.

AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:

SUCTION PRESSURE

SUCTION LINE TEMP

LIQUID PRESSURE

LIQUID LINE TEMP

ENTERING OUTDOOR UNIT AIR TEMP

LEAVING OUTDOOR UNIT AIR TEMP

INDOOR UNIT ENTERING-AIR DB (dry bulb) TEMP

INDOOR UNIT ENTERING-AIR WB (wet bulb) TEMP

INDOOR UNIT LEAVING-AIR DB TEMP

INDOOR UNIT LEAVING-AIR WB TEMP

COMPRESSOR AMPS (L1/L2/L3)

NOTES:

Printed in U.S.A.

Edition Date: 11/09

Catalog No: 38AUQ-01SI

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Pg CL-2

Replaces: New

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