38AE012,014,016
38AKS024
Air-Cooled Condensing Units
50/60 Hz
Installation, Start-Up and
Service Instructions
Only trained, qualified installers and service mechanics
CONTENTS
should install, start-up, and service this equipment (Fig. 1).
Page
Untrained personnel can perform basic maintenance func-
tions such as cleaning coils. All other operations should be
performed by trained service personnel.
When working on the equipment, observe precautions in
the literature and on tags, stickers, and labels attached to the
equipment.
Follow all safety codes. Wear safety glasses and work gloves.
Keep quenching cloth and fire extinguisher nearby when
brazing. Use care in handling, rigging and setting bulky
equipment.
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Step 1 — Complete Pre-Installation Checks . . . . 1
Step 2 — Rig and Mount the Unit . . . . . . . . . . . . . 6
Step 3 — Complete Refrigerant Piping
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 4 — Install Accessories . . . . . . . . . . . . . . . . . 7
Step 5 — Complete Electrical Connections . . . . 7
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Evacuate and Dehydrate . . . . . . . . . . . . . . . . . . . . . . 9
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Turn On Crankcase Heaters . . . . . . . . . . . . . . . . . . 9
Add Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . 9
Before Starting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ELECTRIC SHOCK HAZARD
Separate power sources (main and control
power circuits) are used for these units. Be
sure both main and control power circuits are
disconnected before servicing.
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
To Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Check Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION
Step 1 — Complete Pre-Installation Checks
OPERATING SEQUENCE . . . . . . . . . . . . . . . . . . . . 13
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fan Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Winter Start Control . . . . . . . . . . . . . . . . . . . . . . . . . 13
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.
INSPECT SHIPMENT — File claim with shipping com-
pany if shipment is damaged or incomplete.
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,14
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . 13
Time Guardா II Circuit . . . . . . . . . . . . . . . . . . . . . . . 13
Winter Start Control . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Outdoor Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cleaning Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CONSIDER SYSTEM REQUIREMENTS
• Consult local building codes and National Electrical Code
(NEC, U.S.A.) for special installation requirements.
• Allow sufficient space for airflow clearance, wiring, re-
frigerant piping, and servicing unit. See Fig. 1. See
Fig. 2 for unit component locations.
• Locate unit so that outdoor coil (condenser) airflow is un-
restricted on all sides and above.
• Unit may be mounted on a level pad directly on the base
channels or mounted on raised pads at support points. See
Table 1A-1D for unit operating weights. See Table 2 for
weight distribution based on recommended support points.
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 15,16
START-UP CHECKLIST . . . . . . . . . . . . . . . . CL-1,CL-2
SAFETY CONSIDERATIONS
NOTE: If vibration isolators are required for a particular
installation, use the data in Table 2 to make the proper
selection.
Installing, starting up, and servicing air-conditioning equip-
ment can be hazardous due to system pressures, electrical
components, and equipment location (roofs, elevated struc-
tures, etc.).
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 PC 111 Catalog No. 563-746 Printed in U.S.A. Form 38A-4SI Pg 1 4-94 Replaces: 38AE-17SI
Tab 3a 2a
4
3
1
2
4
5
6
7
12
11
10
9
8
LEGEND
1
2
3
4
—
—
—
—
Low-Voltage Fuse
No. 1 Fan
High-Pressure Switch
Circuit Breakers
5
6
7
8
—
—
—
—
No. 2 Fan
9
—
—
—
—
Compressor
Terminal Block 1 (Unit Power)
10
Low-Pressure Switch
Terminal Block 2 (Control Power) 11
Wraparound Coil 12
Hot Gas Bypass Piping Stub (3⁄8-in. ODM)
Muffler
Fig. 2 — Component Locations (Typical — 38AE Shown)
3
Table 1A — Physical Data (English, 60 Hz)
UNIT
38AE012
38AE014
38AE016
38AKS024
OPERATING WEIGHT (lb)
REFRIGERANT*
732
779
789
900
R-22
COMPRESSOR
Speed (Rpm)
No. Cylinders
Model No.
Reciprocating, Semi-Hermetic
1750
6
06DD824
10
6
06DD328
10
6
06DD537
10
4
06E4250
15.5
Oil (pt)
Crankcase Heater Watts
Unloader Setting (psig)
Load
125
125
125
180
70 ± 1
60 ± 2
Unload
OUTDOOR-AIR FANS
No. ...Rpm
Axial Flow, Direct Drive
2...1075
Diameter (in.)
24
24
24
26
1
Motor Hp
Nominal Total Airflow (Cfm)
⁄
2
8800
8800
40.3
8800
11,000
OUTDOOR COIL
Face Area (sq ft)
29.2
Storage Capacity (lb)†
27.2
39.8
39.8
CONTROLS
Pressurestat Settings (psig)
High Cutout
Cut-in
395 ± 10
295 ± 10
29 ± 4
Low Cutout
Cut-in.
60 +15, –0
FUSIBLE PLUG (F)
200
PIPING CONNECTIONS (in. ODM)
Suction
Liquid
11⁄8
13⁄8
13⁄8
15⁄8
5
⁄
8
Unit is factory supplied with holding charge only.
†Storage capacity is measured at liquid saturated temperatures of 125 F for 38AE012,
123 F for 38AE014, and 130 F for 38AE016 and 38AKS024.
Table 1B — Physical Data (SI, 60 Hz)
UNIT
38AE012
38AE014
38AE016
38AKS024
OPERATING WEIGHT (kg)
REFRIGERANT*
333
354
359
408
R-22
COMPRESSOR
Speed (r/s)
Reciprocating, Semi-Hermetic
29.2
No. Cylinders
Model No.
6
06DD824
4.73
6
06DD328
4.73
6
06DD537
4.73
4
06E4250
7.33
Oil (L)
Crankcase Heater Watts
Unloader Setting (kPa)
Load
125
125
125
180
483 ± 6.9
414 + 103, –0
Unload
OUTDOOR-AIR FANS
No. ...r/s
Axial Flow, Direct Drive
2...17.9
Diameter (mm)
Motor Hp
610
610
610
661
1
⁄
2
Nominal Total Airflow (L/s)
4153
4153
18.3
4153
18.1
5566
OUTDOOR COIL
Face Area (sq m)
Storage Capacity (kg)†
2.71
12.4
18.1
CONTROLS
Pressurestat Settings (kPa)
High Cutout
Cut-in
2724 ± 68.9
2034 ± 68.9
200 ± 27.6
Low Cutout
Cut-in
414 + 103, –0
FUSIBLE PLUG (C)
93.3
PIPING CONNECTIONS (in. ODM)
Suction
Liquid
11⁄8
13⁄8
13⁄8
15⁄8
5
⁄
8
*Unit is factory supplied with holding charge only.
†Storage capacity is measured at liquid saturated temperatures of 51.7 C for 38AE012,
50.6 C for 38AE014, and 54.4 C for 38AE016 and 38AKS024.
4
Table 1C — Physical Data (English, 50 Hz)
UNIT
38AE012
38AE014
38AE016
38AKS024
OPERATING WEIGHT (lb)
REFRIGERANT*
732
779
789
900
R-22
COMPRESSOR
Speed (Rpm)
No. Cylinders
Model No.
Reciprocating, Semi-Hermetic
1460
6
06DD824
10
6
06DD328
10
6
06DD537
10
4
06E4250
15.5
Oil (pt)
Crankcase Heater Watts
Unloader Setting (psig)
Load
125
125
125
180
70 ± 1
60 ± 2
Unload
OUTDOOR-AIR FANS
No. ...Rpm
Axial Flow, Direct Drive
2...900
Diameter (in.)
24
24
24
26
1
Motor Hp
Nominal Total Airflow (Cfm)
⁄
2
7368
7368
40.3
7368
9210
OUTDOOR COIL
Face Area (sq ft)
29.2
Storage Capacity (lb)†
27.2
39.8
39.8
CONTROLS
Pressurestat Settings (psig)
High Cutout
Cut-in
Low Cutout
Cut-in
395 ± 10
295 ± 10
29 ± 4
60 + 15, –0
FUSIBLE PLUG (F)
200
PIPING CONNECTIONS (in. ODM)
Suction
Liquid
11⁄8
13⁄8
13⁄8
15⁄8
5
⁄
8
*Unit is factory supplied with holding charge only.
†Storage capacity is measured at liquid saturated temperatures of 125 F for 38AE012,
123 F for 38AE014, and 130 F for 38AE016 and 38AKS024.
Table 1D — Physical Data (SI, 50 Hz)
UNIT
38AE012
38AE014
38AE016
38AKS024
OPERATING WEIGHT (kg)
REFRIGERANT*
333
354
359
408
R-22
COMPRESSOR
Speed (r/s)
Reciprocating, Semi-Hermetic
24.3
No. Cylinders
Model No.
6
06DD824
4.73
6
06DD328
4.73
6
06DD537
4.73
4
06E4250
7.33
Oil (L)
Crankcase Heater Watts
Unloader Setting (kPa)
Load
125
125
125
180
483 ± 6.9
414 + 103, –0
Unload
OUTDOOR-AIR FANS
No. ...r/s
Axial Flow, Direct Drive
2...15.0
Diameter (mm)
Motor Hp
610
610
610
661
1
⁄
2
Nominal Total Airflow (L/s)
3728
3728
18.3
3728
18.1
4660
OUTDOOR COIL
Face Area (sq m)
Storage Capacity (kg)†
2.71
12.4
18.1
CONTROLS
Pressurestat Settings (kPa)
High Cutout
Cut-in
2724 ± 68.9
2034 ± 68.9
200 ± 27.6
Low Cutout
Cut-in
414 + 103, –0
FUSIBLE PLUG (C)
93.3
PIPING CONNECTIONS (in. ODM)
Suction
Liquid
11⁄8
13⁄8
13⁄8
15⁄8
5
⁄
8
*Unit is factory supplied with holding charge only.
†Storage capacity is measured at liquid saturated temperatures of 51.7 C for 38AE012,
50.6 C for 38AE014, and 54.4 C for 38AE016 and 38AKS024.
5
Table 2 — Weight Distribution
Step
3
—
Complete Refrigerant Piping
Connections
WEIGHT — lb (kg)
UNIT
Support Point
Total
IMPORTANT: A refrigerant receiver is not provided
with the unit. Do not install a receiver.
Operating
A
B
C
D
38AE012
38AE014
38AE016
38AKS024
732 (333)
779 (354)
789 (359)
900 (408)
142 (65) 138 (63) 225 (102)
227(103)
143 (65) 140 (64) 247 (112) 249 (113)
143 (65) 143 (65) 250 (114) 253 (115)
178 (81) 168 (76) 269 (122) 285 (129)
SIZE REFRIGERANT LINES — Consider the length of
piping required between outdoor unit and indoor unit
(evaporator), the amount of liquid lift, and compressor oil
return. See Tables 3, 4A, and 4B and also refer to Part 3 of
Carrier System Design Manual for design details and line
sizing. Refer to indoor installation instructions for addi-
tional information.
Table 3 — Liquid Line Data
MAXIMUM
ALLOWABLE
LIQUID LINE
LIQUID LIFT
ft (m)
UNIT
Maximum Filter Drier
Maximum
Allowable
Pressure Drop
psig (kPa)
Allowable
Temp.
Loss
and
60 Hz
50 Hz
Sight Glass
Flare Conn.*
in. (mm)
Step 2 — Rig and Mount the Unit
F (C)
38AE012
38AE014
38AE016
52 (15.8)
67 (20.4)
82 (25)
5
7 (48.3)
2 (1.1)
⁄8
Be sure unit panels are securely in place prior to
rigging.
38AKS024 87 (26.5) 86 (26)
*Inlet and outlet.
RIGGING — These units are designed for overhead rigging
only. For this purpose, the transverse base channels extend
beyond the sides of the unit, with holes provided in the end
plates to attach cables or hooks. Rig with top skid packaging
assembly in place to prevent unit damage by the rigging cable.
As further protection for the coil faces, plywood sheets can
be placed against the sides of the unit, behind the cables.
Run the 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.
NOTE: Data shown is for units operating at 45 F (7.2 C) saturated suction and
95 F (35 C) entering air.
Table 4A — Refrigerant Piping Sizes — 60 Hz
LENGTH OF INTERCONNECTING PIPING — FT (M)
0-15
15-25
25-50
50-75
75-100
(0-4.6)
(4.6-7.6) (7.6-15.2) (15.2-22.9) (22.9-30.5)
UNIT
Line Size — in. OD
L
S
L
S
L
S
L
S
L
S
If it is necessary to roll the unit into position, mount the
unit on longitudinal rails, using a minimum of 3 rollers. Ap-
ply force to the rails, not the unit. If the unit is to be skidded
into position, place it on a large pad and drag it by the pad.
Do not apply any force to the unit.
Raise from above to lift unit from the rails or pad when
unit is in final position.
1
1
5
5
5
38AE012
38AE014
38AE016
38AKS024
⁄2
⁄2
⁄2
⁄8
11⁄8
11⁄8
13⁄8
15⁄8
⁄
⁄
⁄
⁄
2
2
8
8
11⁄8
13⁄8
13⁄8
15⁄8
⁄
⁄
⁄
⁄
8
8
8
8
13⁄8
13⁄8
15⁄8
15⁄8
⁄
⁄
⁄
⁄
8
8
8
8
13⁄8
15⁄8
15⁄8
21⁄8
⁄8
⁄8
⁄8
⁄8
15⁄8
15⁄8
21⁄8
21⁄8
1
1
5
1
5
5
5
5
7
5
7
7
7
7
7
LEGEND
L
S
—
—
Liquid
Suction
Close coupled.
COMPRESSOR MOUNTING — As shipped, the compres-
sor is held tightly in place by self-locking bolts. Before start-
ing unit, loosen self-locking bolts until the snubber
washer can be moved sideways with finger pres-
sure. Do not remove shipping bolts. See Fig. 3.
NOTES:
1. Pipe sizes are based on a 2 F (1.1 C) loss for liquid lines and a 1.5 F
(0.8 C) loss for suction lines.
2. Pipe sizes are based on an equivalent length equal to the maximum length
of interconnecting piping plus 50% for fittings. A more accurate estimate may
result in smaller sizes.
Table 4B — Refrigerant Piping Sizes — 50 Hz
LENGTH OF INTERCONNECTING PIPING — FT (M)
0-15
(0-4.6)
15-25
25-50
50-75
75-100
(4.6-7.6) (7.6-15.2) (15.2-22.9) (22.9-30.5)
UNIT
Line Size — in. OD
L
S
L
S
L
S
L
S
L
S
1
1
5
5
5
38AE012
38AE014
38AE016
38AKS024
⁄2
⁄2
⁄2
⁄8
11⁄8
11⁄8
13⁄8
15⁄8
⁄
⁄
⁄
⁄
2
2
8
8
11⁄8
11⁄8
13⁄8
15⁄8
⁄
⁄
⁄
⁄
8
8
8
8
11⁄8
13⁄8
13⁄8
15⁄8
⁄
⁄
⁄
⁄
8
8
8
8
13⁄8
13⁄8
13⁄8
15⁄8
⁄8
⁄8
⁄8
⁄8
13⁄8
13⁄8
15⁄8
15⁄8
1
1
5
1
5
5
5
5
5
5
5
7
5
5
7
LEGEND
L
S
—
—
Liquid
Suction
Close coupled.
NOTES:
1. Pipe sizes are based on a 2 F (1.1 C) loss for liquid lines and a 1.5 F
(0.8 C) loss for suction lines.
2. Pipe sizes are based on an equivalent length equal to the maximum length
of interconnecting piping plus 50% for fittings. A more accurate estimate may
result in smaller sizes.
Fig. 3 — Compressor Mounting
6
INSTALL FILTER DRIER(S) AND MOISTURE INDICA-
TOR(S) — Every unit should have a filter drier and liquid-
moisture indicator (sight glass). In some applications, depending
on space and convenience requirements, it may be desirable
to install 2 filter driers and sight glasses. One filter drier and
sight glass may be installed at A locations in Fig. 4. Or, 2
filter driers and sight glasses may be installed at B locations.
Select the filter drier for maximum unit capacity and mini-
mum pressure drop. Complete the refrigerant piping from
indoor unit to outdoor unit before opening the liquid and suc-
tion lines at the outdoor unit.
NOTE: 38AKS024 has a fusible plug in the liquid line.
Fig. 5 — Location of Fusible Plug (38AE)
Step 4 — Install Accessories — Field install ac-
cessories such as winter start control or low-ambient control
before proceeding with wiring. Refer to the instructions shipped
with the accessory.
Step 5 — Complete Electrical Connections
POWER WIRING — Unit is factory wired for voltage shown
on nameplate. Provide adequate fused disconnect switch within
sight from unit and readily accessible from unit, but out of
the reach of children. Lock switch open (off) to prevent power
from being turned on while unit is being serviced. Discon-
nect switch, fuses, and field wiring must comply with na-
tional and local code requirements. See Tables 5A and 5B.
Route power wires through opening in unit end panel to
connection in unit control box as shown on unit label dia-
gram and in Fig. 6. Unit must be grounded.
TXV — Thermal Expansion Valve
Fig. 4 — Location of Sight Glass(es)
and Filter Drier(s)
Affix crankcase heater warning sticker to unit disconnect
switch.
CONTROL CIRCUIT WIRING — Control voltage is 24 v.
See Fig. 7 and unit label diagram for field-supplied wiring
details. Route control wires through opening in unit end panel
to connection in unit control box.
INSTALL LIQUID LINE SOLENOID VALVE — SOLE-
NOID DROP — It is recommended that a solenoid valve be
placed in the main liquid line (see Fig. 4) between condens-
ing unit (38AE/AKS) and fan coil (40RR, 40RE). (A liquid
line solenoid valve is required when the liquid line length
exceeds 100 ft [30.5 m] or when the condensing unit is con-
nected to the chiller barrel in a built-up chiller system.) This
valve prevents refrigerant migration (which causes oil dilu-
tion) to the compressor during the off cycle at low outdoor
ambient temperatures. The solenoid should be wired in par-
allel with the compressor contactor coil. This means of elec-
trical control is referred to as solenoid drop control.
INSTALL LIQUID LINE SOLENOID VALVE (OPTIONAL)
— CAPACITY CONTROL — If 2-step cooling is desired,
place a solenoid valve in the location shown in Fig. 4.
MAKE PIPING CONNECTIONS — Do not remove run-
around loop from suction and liquid line stubs in the com-
pressor compartment until piping connections are ready to
be made. Pass nitrogen or other inert gas through piping while
brazing to prevent formation of copper oxide.
Install field-supplied thermostatic expansion valve(s) in in-
door section. If 2 thermostatic expansion valves are installed
for 2-step cooling, install field-supplied liquid line solenoid
valve ahead of the second expansion valve.
PROVIDE SAFETY RELIEF — A fusible plug is located
on the compressor crankcase or in the liquid line (Fig. 5).
Do not cap this plug. If local code requires additional safety
devices, install them as directed.
LEGEND
EQUIP GND — Equipment Ground
NEC
— National Electrical Code
Factory Wiring
Field Wiring
Fig. 6 — Main Power Supply Wiring
7
LEGEND
C
—
—
—
—
Compressor Contactor
Heating Device
Indoor-Fan Contactor
Liquid Line Solenoid Valve
R
—
Relay
Factory Wiring
Field Wiring
HD
IFC
LLSV
NOTES:
1. Combination LLSV plus IFC va should not exceed 30 va.
2. Do not exceed 5 va (24 vac) per coil.
3. If va values shown in Notes 1 and 2 must be exceeded, use
accessory relay transformer package 38AE900001.
Fig. 7 — Remote Thermostat Wiring
Table 5A — Electrical Data (3 Ph/60 Hz)
UNIT
COMPR
FAN MOTORS (Single Phase)
FLA (ea)
Volts
UNIT
MOCP
(Fuse)
Total
Fan No.
Model
Supplied*
MCA
ICF
RLA
LRA
kW
Fans
Nameplate
Min
Max
1
2
501
201
601
101
208-230
380
187
342
414
518
253
418
528
660
62.5
35.0
29.1
22.8
178
101
81
100
50
43.6
24.0
20.0
15.7
170
93
4.3
4.3
2.3
1.8
3.7
3.7
1.9
1.8
38AE012
38AE014
38AE016
38AKS024
2
1.41
1.41
1.41
1.41
460
40
77
575
67
35
62
501
201
601
101
208-230
380
460
575
187
342
414
518
253
418
528
660
69.3
38.0
31.7
25.6
199
112
84
100
60
50
40
49.3
26.5
22.1
17.9
191
104
80
4.3
4.3
2.3
1.8
3.7
3.7
1.9
1.8
2
2
2
73
69
501
201
601
101
208-230
380
460
575
187
342
414
518
253
418
528
660
87.5
49.3
40.7
33.0
274
153
124
100
125
80
60
50
63.6
36.0
29.3
23.8
266
145
120
96
4.3
4.3
2.3
1.8
3.7
3.7
1.9
1.8
501
201
601
101
208-230
380
460
575
187
342
414
518
254
418
508
632
93.4
49.7
48.1
40.1
353
199
177
124
150
80
80
60
67.9
34.6
34.7
28.8
345
191
173
120
4.3
4.3
2.3
1.8
3.7
3.7
1.9
1.8
Table 5B — Electrical Data (3 Ph/50 Hz)
UNIT
COMPR
FAN MOTORS 230 v (Single Phase)
FLA (ea)
Volts
UNIT
MOCP
(Fuse)
Total
Fan No.
Model
Supplied*
MCA
ICF
RLA
LRA
kW
Fans
Nameplate
Min
Max
1
2
803
903
230
400
198
342
264
457
47.5
31.4
134
80
75
50
32.9
20.0
128
74
38AE012
38AE014
38AE016
2
2
2
2.9
3.5
1.20
1.20
1.20
803
903
230
400
198
342
264
457
51.0
34.0
149
89
75
50
35.7
22.1
143
83
2.9
2.9
3.5
3.5
803
903
230
400
198
342
264
457
66.9
43.0
206
121
100
60
47.9
29.3
200
115
803
303
903
230
346
400
198
311
342
254
380
440
91.8
51.5
50.2
213
121
179
150
80
80
67.9
33.3
34.6
207
115
173
38AKS024
2
2.9
3.5
1.20
LEGEND
FLA
ICF
—
—
—
—
—
Full Load Amps (Fan Motors)
Maximum Instantaneous Current Flow during start-up (LRA of compressor plus total FLA of fan motors)
Total Fan Motor Input (kilowatts)
kW
LRA
MCA
Locked Rotor Amps
Minimum Circuit Amps per NEC (U.S.A.), Section 430-24
MOCP — Maximum Overcurrent Protection (amps)
RLA
—
Rated Load Amps (Compressor)
*Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above
the listed limits.
NOTES:
1. The MCA and MOCP values are calculated in accordance with the National Electrical Code (NEC) article 440
(U.S.A. standard).
2. Motor RLA and LRA values are established in accordance with Underwriters’ Laboratories (UL) Standard 1995
(U.S.A. standard).
8
PRE-START-UP
START-UP
Evacuate and Dehydrate the entire refrigerant sys-
tem by either of the methods described in Carrier Standard
Service Techniques Manual, Chapter 1.
To Start Unit — Set thermostat set point below the space
temperature. After starting unit, there is a delay of at least 3
seconds before compressor starts.
Leak Test the entire refrigerant system by the pres-
sure method described in Carrier Standard Service Tech-
niques Manual, Chapter 1. Use R-22 at approximately
25 psig (172.4 kPa) backed up with an inert gas to a total
pressure not to exceed 245 psig (1689 kPa).
Oil Charge (see Tables 1A-1D) —Allow unit to run for
about 20 minutes. Stop unit and check compressor oil level
at sight glass. Add oil if necessary to bring oil to the correct
level shown in Fig. 8. Use only Carrier-approved compres-
sor oil. Approved oils are:
Witco Chemical Corp. . . . . . . . . . . . . . . . . Suniso 3GS
Texaco, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . WF32
Petroleum Specialties Co. . . . . . . . . . . . . . . . Cryol 150
Do not reuse drained oil or use any oil that has been ex-
posed to atmosphere. Procedures for adding or removing oil
are given in Carrier Standard Service Techniques Manual,
Chapter 1, Refrigerants.
Turn on Crankcase Heaters for 24 hours before start-
ing the unit to be sure all the refrigerant is out of the oil. To
energize the crankcase heaters, 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.
3. Turn the fan circuit breaker on. Leave the compressor cir-
cuit breakers off. The crankcase heaters are now
energized.
If oil is added, run unit for additional 10 minutes. Stop
unit and check oil level. If level is still low, add oil only after
determining that piping system is designed for proper oil re-
turn and that the system is not leaking oil.
Add Preliminary Charge to the refrigerant system ac-
cordingly to Carrier Standard Service Techniques Manual,
Chapter 1. By the liquid charging method and charging by
weight procedure, charge the units with approximately the
amounts of R-22 refrigerant shown in Table 6.
Table 6 — Charging Data (R-22)
REFRIGERANT CHARGE - lb (kg)
CONDENSING
TEMP
Required Charge
Above Clear
Outdoor Unit
Total Charge
(Approx)
UNIT
38AKS024
(06E COMPRESSOR)
38AE012,014,016
(06D COMPRESSOR)
DURING
CHARGING - F (C)
Sight Glass
38AE012
38AE014
38AE016
38AKS024
3.0 (1.4)
4.8 (2.2)
3.4 (1.5)
3.4 (1.5)
22 (10)
23 (10.5)
23 (10.5)
28 (12.7)
125 (51.7)
123 (50.6)
130 (54.4)
131 (54.8)
Fig. 8 — Operating Oil Levels
Refrigerant Charge — Actual start-up should be done
only under supervision of a qualified refrigeration me-
chanic. Refer to charging charts.
Before Starting Unit ensure the following:
See Fig. 9-11 for the particular unit being charged. Mea-
sure pressure at the liquid line service valve, being sure a
Schrader depressor is used if required. Also, measure liquid
line temperature as close to the liquid service valve as pos-
sible. Add or reduce charge until the pressure and tempera-
ture conditions of the charging charge curve are met. If liq-
uid pressure and temperature point falls above curve, add
charge. If liquid pressure and temperature point falls below
curve, reduce the charge until the conditions match the curve.
1. Compressor oil level must be at least within sight in
the compressor sight glass. Add oil if necessary (see
Tables 1A-1D and Oil Charge section).
2. Compressor holddown bolts must be snug, but not tight.
Refer to Compressor Mounting section and tag on com-
pressor foot.
3. All internal wiring connections must be tight; all barriers
and covers must be in place.
4. Electrical power source must agree with unit nameplate
rating.
5. All service valves must be open.
6. Crankcase heater must be firmly locked into the com-
pressor crankcase.
Never charge liquid into the low-pressure side of sys-
tem. Do not overcharge. During charging or removal of
refrigerant, be sure indoor fan system is operating.
9
10
11
12
Check Operation — Verify operation of all safety con-
trols. Replace all service panels. Be sure that control panel
cover is closed tightly.
Head Pressure Control — Fan cycling is a standard
feature. The no. 2 fan cycles in response to changes in liquid
pressure. The switch cycles the fan off at 126 ± 4 psig (869
± 28 kPa) as pressure decreases, and cycles it back on at 257
(+5, −0) psig (1772 [+103, −0] kPa).
OPERATING SEQUENCE
Cooling — When the first stage (TC1) of the cooling ther-
mostat closes, the timer starts. After approximately 3 sec-
onds, the timer activates the compressor and fan motor no.
1 contactor. When the liquid pressure builds to approxi-
mately 257 psig (1772 kPa), fan motor no. 2 is energized.
On demand for additional cooling capacity, the second stage
(TC2) of the cooling thermostat closes, energizing a field-
supplied liquid line solenoid (LLS) valve, which opens. This
increases the suction pressure, causing the compressor to op-
erate at higher capacity.
When fan switch is set at AUTO, the indoor-air fan cycles
with the compressor. When the switch is set at CONT, the
indoor-air fan runs continuously.
At shutdown, the Time Guard II timer prevents the com-
pressor from restarting for approximately 5 minutes.
When installed, a field-supplied solenoid valve (wired in
parallel with the compressor contactor coil), shuts off the liq-
uid line to prevent refrigerant migration back to the com-
pressor during the off cycle.
Heating — The heating thermostat (TH) energizes a field-
supplied relay which operates heating controls and ener-
gizes the indoor-fan relay. When the fan switch is set at AUTO,
the indoor-air fan cycles with the heating control. The indoor-
air fan runs continuously when the fan switch is set at CONT.
Fig. 12 — Compressor Capacity Control Unloader
Fan Cycling — Head pressure control is accomplished
by cycling the fans. The no. 2 fan responds to liquid line
pressure, cycling on at approximately 257 psig (1772 kPa)
and off at approximately 126 psig (869 kPa).
Time Guard II Circuit — Prevents short-cycling by pro-
viding a delay of approximately 5 minutes before restarting
compressor after shutdown from safety device action.
On start-up, the Time Guard II timer causes a delay of
approximately 3 seconds after thermostat closes.
On compressor shutdown, the timer recycles for approxi-
mately 5 minutes. During this time, the compressor cannot
restart.
Winter Start Control (If Installed) — When the com-
pressor starts, the control’s bypass timer contacts close for
150 seconds, thereby bypassing the low-pressure switch dur-
ing start-up. After 150 seconds, the bypass timer contacts
open and the low-pressure switch is restored to the safety
circuit.
Refer to Fig. 13 and to label diagram on unit.
SERVICE
Capacity Control — A suction pressure-actuated un-
loader controls 2 cylinders and provides capacity control. Un-
loaders are factory set (see Tables 1A-1D), but can be field
adjusted as described in the 2 following sections.
Fig. 13 — Timer Sequence Chart
CONTROL SET POINT (cylinder load point) is adjustable
from 0 to 85 psig (586 kPa). To adjust, turn control set point
adjustment nut (Fig. 12) clockwise to its bottom stop. In this
position, set point is 85 psig (586 kPa). Next, turn adjust-
ment counterclockwise to desired control set point. Every
full turn counterclockwise decreases set point by
7.5 psig (51.7 kPa).
Winter-Start Control (If Required) — Install Ac-
cessory Package 38AE900021.
Crankcase Heater — The heater prevents refrigerant
migration and compressor oil dilution during shutdown when-
ever compressor is not operating. It is wired into the control
circuit, and cycles with the compressor; the heater is off when
compressor is running, and on when compressor is off.
Both compressor service valves must be closed whenever
the crankcase heater is deenergized for more than 6 hours.
The crankcase heater is operable as long as the control cir-
cuit is energized.
PRESSURE DIFFERENTIAL (difference between cylinder
load and unload points) is adjustable from 6 to 22 psig (41.4
to 152 kPa). To adjust, turn pressure differential adjustment
screw (Fig. 12) counterclockwise to its back stop position.
In this position, differential is 6 psig (41.4 kPa). Next, turn
adjustment clockwise to desired pressure differential setting.
Every full turn clockwise increases differential by 1.5 psig
(10.3 kPa).
13
(38AE014,016, 38AKS024) and restrict outdoor airflow. Use
a flashlight to determine if dirt or debris has collected be-
tween coil sections. Clean coil as follows:
Outdoor Fans — Each fan is supported by a formed-
wire mount bolted to the fan deck and covered with a wire
guard. The exposed end of the motor shaft is covered with
a rubber boot. In case a fan motor must be repaired or re-
placed, be sure the rubber boot is put back on when the fan
is reinstalled and be sure the fan guard is in place before
starting the unit. Figure 14 shows the proper position of the
mounted fan. Fan motors have permanently lubricated
bearings.
1. Turn off unit power.
2. Remove screws holding rear corner posts and top
cover in place. Pivot top cover up 12 to 18 in. (305 to
457 mm) and support with a rigid support. See Fig. 15.
3. Remove clips securing tube sheets together at the return
bend end of the coil. Carefully spread the ends of the coil
rows apart by moving the outer sections. See Fig. 16.
4. Using a water hose, or other suitable equipment, flush down
between the sections of coil to remove dirt and debris.
5. Clean the remaining surfaces in the normal manner.
6. Reposition outer coil sections.
7. Reinstall clips which secure tube sheets.
8. Replace top cover and rear corner posts.
38AE012,014,016
38AKS024
Fig. 14 — Outdoor Fan
Lubrication
Fig. 15 — Pivot and Support Top Cover
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. See Oil Charge
section.
Cleaning Coils — The coils can be cleaned with a vacuum
cleaner, washed out with water, blown out with low-pressure
compressed air, or brushed (do not use wire brush). Fan mo-
tors are drip-proof but not waterproof.
Clean outdoor coil annually or as required by location or
outdoor air conditions. Inspect coil monthly, and clean as
required. Fins are not continuous through coil sections; dirt
and debris may pass through first section, become trapped
between the 2 rows of fins (38AE012) or 3 rows of fins
Fig. 16 — Coil Cleaning (Typical)
14
TROUBLESHOOTING
PROBLEM
COMPRESSOR DOES NOT RUN
Contactor Open
SOLUTION
1. Power off.
1. Restore power.
2. Fuses blown in field power circuit.
3. No control power.
2. After finding cause and correcting, replace with correct size fuse.
3. Check secondary fuse(s); replace with correct type and size.
Replace transformer if primary windings receiving power.
4. Thermostat circuit open.
4. Check thermostat setting.
5. Time Guardா II device not operating.
6. Compressor circuit breaker tripped.
5. Check Time Guard II devices.
6. Check for excessive compressor current draw. Reset breaker;
replace if defective.
7. Safety device lock-out circuit active.
8. Low-pressure switch open.
7. Reset lock-out circuit at thermostat or circuit breaker.
8. Check for refrigerant undercharge, obstruction of indoor airflow, or
whether compressor suction shutoff valve is fully open. Make sure liquid
line solenoid valve(s) is open.
9. High-pressure switch open.
9. Check for refrigerant overcharge, obstruction of outdoor airflow, air in
system, or whether compressor discharge valve is fully open. Be sure
outdoor fans are operating correctly.
10. Compressor overtemperature switch open.
11. Loose electrical connections.
12. Compressor stuck.
10. Check for open condition. Allow for reset. Replace if defective.
11. Tighten all connections.
12. See compressor service literature.
Contactor Closed
1. Compressor leads loose.
1. Check connections.
2. Motor windings open.
2. See compressor service literature.
3. Single phasing.
3. Check for blown fuse. Check for loose connection at compressor terminal.
COMPRESSOR STOPS ON HIGH-PRESSURE SWITCH
Outdoor Fan On
1. High-pressure switch faulty.
2. Reversed fan rotation.
3. Airflow restricted.
1. Replace switch.
2. Confirm rotation, correct if necessary.
3. Remove obstruction.
4. Air recirculating.
4. Clear airflow area.
5. Noncondensables in system.
6. Refrigerant overcharge.
7. Line voltage incorrect.
8. Refrigerant system restrictions.
5. Purge and recharge as required.
6. Purge as required.
7. Consult power company.
8. Check or replace filter drier, expansion valve, etc. Check that compressor
discharge service valve is fully open.
Outdoor Fan Off
1. Fan slips on shaft.
1. Tighten fan hub setscrews.
2. Check power and capacitor.
3. Replace bearings.
2. Motor not running.
3. Motor bearings stuck.
4. Motor overload open.
4. Check overload rating. Check for fan blade obstruction.
5. Replace motor.
5. Motor burned out.
COMPRESSOR CYCLES ON LOW-PRESSURE SWITCH
Indoor-Air Fan Running
1. Compressor suction service valve partially
closed.
1. Open valve fully.
2. Liquid line solenoid valve(s) fails to open.
2. Check liquid line solenoid valve(s) for proper operation. Replace if
necessary.
3. Filter drier plugged.
3. Replace filter drier.
4. Expansion valve power head defective.
5. Low refrigerant charge.
4. Replace power head.
5. Add charge. Check low-pressure switch setting.
15
TROUBLESHOOTING (cont)
PROBLEM
SOLUTION
COMPRESSOR CYCLES ON LOW-PRESSURE SWITCH (cont)
Airflow Restricted
1. Coil iced up.
2. Coil dirty.
1. Check refrigerant charge.
2. Clean coil fins.
3. Air filters dirty.
4. Dampers closed.
3. Clean or replace filters.
4. Check damper operation and position.
Indoor-Air Fan Stopped
1. Electrical connections loose.
2. Fan relay defective.
1. Tighten all connections.
2. Replace relay.
3. Motor overload open.
3. Power supply.
4. Motor defective.
4. Replace motor.
5. Fan belt broken or slipping.
COMPRESSOR RUNNING BUT COOLING INSUFFICIENT
5. Replace or tighten belt.
Suction Pressure Low
1. Refrigerant charge low.
2. Head pressure low.
1. Add refrigerant.
2. Check refrigerant charge.
Check outdoor-air fan thermostat settings.
3. Air filters dirty.
3. Clean or replace filters.
4. Replace power head.
5. Check low-pressure setting.
6. Remove obstruction.
4. Expansion valve power head defective.
5. Indoor coil partially iced.
6. Indoor airflow restricted.
Suction Pressure High
1. Unloaders not functioning.
1. Check unloader adjustments.
Check unloader setting.
2. Compressor valve defective.
3. Heat load excessive.
2. See compressor service literature.
3. Check for open doors or windows in vicinity of fan coil.
UNIT OPERATES TOO LONG OR CONTINUOUSLY
1. Low refrigerant charge.
2. Control contacts fused.
1. Add refrigerant.
2. Replace control.
3. Air in system.
3. Purge and evacuate system.
4. Clean or replace.
4. Partially plugged expansion valve or filter drier.
SYSTEM IS NOISY
1. Piping vibration.
1. Support piping as required.
2. Compressor noisy.
2. Check valve plates for valve noise. Replace compressor if
bearings are worn.
COMPRESSOR LOSES OIL
1. Leak in system.
1. Repair leak.
2. Crankcase heaters not energized during shutdown.
2. Check wiring and relays. Check heater and replace if
defective.
3. Improper interconnecting piping design.
FROSTED SUCTION LINE
3. Check piping for oil return. Replace if necessary.
Expansion valve admitting excess refrigerant.
HOT LIQUID LINE
Adjust expansion valve.
1. Shortage of refrigerant due to leak.
2. Expansion valve opens too wide.
FROSTED LIQUID LINE
1. Repair leak and recharge.
2. Adjust expansion valve.
1. Restricted filter drier.
1. Remove restriction or replace.
2. Replace valve.
2. Liquid line solenoid valve partially closed.
COMPRESSOR WILL NOT UNLOAD
1. Defective unloader.
1. Replace unloader.
2. Replace valve.
3. Rewire correctly.
4. Replace spring.
2. Defective capacity control solenoid valve (if used).
3. Miswired capacity control liquid line solenoid (if used).
4. Weak, broken, or wrong valve body spring.
COMPRESSOR WILL NOT LOAD
1. Miswired capacity control liquid line solenoid (if used).
2. Defective capacity control solenoid valve (if used).
3. Plugged strainer (high side).
1. Rewire correctly.
2. Replace valve.
3. Clean or replace strainer.
4. Clean or replace the necessary parts.
4. Stuck or damaged unloader piston or piston ring(s).
16
PACKAGED SERVICE TRAINING
Our packaged service training programs provide an excellent way to increase your knowledge of the
equipment discussed in this manual. Product programs cover:
• Unit Familiarization
• Installation Overview
• Maintenance
• Operating Sequence
A large selection of product, theory, and skills programs is available. All programs include a video
cassette and/or slides and a companion booklet. Use these for self teaching or to conduct full training
sessions.
For a free Service Training Material Catalog (STM), call 1-800-962-9212. Ordering instructions are
included.
Copyright 1994 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 PC 111 Catalog No. 563-746 Printed in U.S.A. Form 38A-4SI Pg 18 4-94 Replaces: 38AE-17SI
Tab 3a 2a
4
START-UP CHECKLIST
A. Preliminary Information
OUTDOOR: MODEL NO.
INDOOR: AIR HANDLER MANUFACTURER
MODEL NO.
SERIAL NO.
SERIAL NO.
ADDITIONAL ACCESSORIES
B. Pre-Start-Up
OUTDOOR UNIT
IS THERE ANY SHIPPING DAMAGE?
IF SO, WHERE:
(Y/N)
(Y/N)
WILL THIS DAMAGE PREVENT UNIT START-UP?
(Y/N)
CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT?
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)
(Y/N)
HAVE COMPRESSOR HOLDDOWN BOLTS BEEN LOOSENED (Snubber washers are snug, but not tight)?
(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)
(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)
(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 EVAPORATOR COILS AS REQUIRED?
(Y/N)
HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR, CONDENSER, EVAPORATOR(S),
TXVs (Thermostatic Expansion Valves), SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE PLUGS
WITH A LEAK DETECTOR?
(Y/N)
LOCATE, REPAIR, AND REPORT ANY LEAKS.
HAVE ALL COMPRESSOR SERVICE VALVES BEEN FULLY OPENED (BACKSEATED)?
(Y/N)
HAVE LIQUID LINE SERVICE VALVES BEEN OPENED?
(Y/N)
IS THE OIL LEVEL IN EACH COMPRESSOR CRANKCASE VISIBLE IN THE COMPRESSOR SIGHT GLASSES?
(Y/N)
CHECK VOLTAGE IMBALANCE
LINE-TO-LINE VOLTS:
(AB + AC + BC)/3 = AVERAGE VOLTAGE =
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =
AB
V
AC
V
BC
V
V
V
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
C. Start-Up
CHECK EVAPORATOR FAN SPEED AND RECORD.
CHECK CONDENSER FAN SPEED AND RECORD.
AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:
OIL PRESSURE
SUCTION PRESSURE
SUCTION LINE TEMP
DISCHARGE PRESSURE
DISCHARGE LINE TEMP
ENTERING CONDENSER AIR TEMP
LEAVING CONDENSER AIR TEMP
EVAP ENTERING-AIR DB (dry bulb) TEMP
EVAP ENTERING AIR WB (wet bulb) TEMP
EVAP LEAVING AIR DB TEMP
EVAP LEAVING AIR WB TEMP
COMPRESSOR AMPS (L1/L2/L3)
/
/
CHECK THE COMPRESSOR OIL LEVEL SIGHT GLASSES; ARE THE SIGHT GLASSES SHOWING
OIL LEVEL IN VIEW? (Y/N)
NOTES:
Copyright 1994 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 PC 111 Catalog No. 563-746 Printed in U.S.A. Form 38A-4SI Pg CL-2 4-94 Replaces: 38AE-17SI
Tab 3a 2a
4
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