Carrier 38AE016, 38AE012, 38AE014 User Manual

38AE012,014,016

38AKS024 Air-Cooled Condensing Units 50/60 Hz

Installation, Start-Up and

Service Instructions

CONTENTS

Page

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

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Step 1 Ð Complete Pre-Installation Checks . . . . 1

Step 2 Ð Rig and Mount the Unit . . . . . . . . . . . . . 6

Step 3 Ð Complete Refrigerant Piping

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 4 Ð Install Accessories . . . . . . . . . . . . . . . . . 7

Step 5 Ð 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

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

To Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Check Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

OPERATING SEQUENCE . . . . . . . . . . . . . . . . . . . . 13

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fan Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Winter Start Control . . . . . . . . . . . . . . . . . . . . . . . . . 13

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,14

Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . 13

Time GuardT II Circuit . . . . . . . . . . . . . . . . . . . . . . . 13

Winter Start Control . . . . . . . . . . . . . . . . . . . . . . . . . 13

Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Outdoor Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cleaning Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 15,16

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

SAFETY CONSIDERATIONS

Installing, starting up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.).

Only trained, quali®ed installers and service mechanics should install, start-up, and service this equipment (Fig. 1).

Untrained personnel can perform basic maintenance functions 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 ®re extinguisher nearby when brazing. Use care in handling, rigging and setting bulky equipment.

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.

INSTALLATION

Step 1 Ð Complete Pre-Installation Checks

UNCRATE UNIT Ð Remove unit packaging except for the top skid assembly, which should be left in place until after the unit is rigged into its ®nal location.

INSPECT SHIPMENT Ð File claim with shipping company if shipment is damaged or incomplete.

CONSIDER SYSTEM REQUIREMENTS

·Consult local building codes and National Electrical Code (NEC, U.S.A.) for special installation requirements.

·Allow sufficient space for air¯ow clearance, wiring, refrigerant piping, and servicing unit. See Fig. 1. See Fig. 2 for unit component locations.

·Locate unit so that outdoor coil (condenser) air¯ow is unrestricted 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.

NOTE: If vibration isolators are required for a particular installation, use the data in Table 2 to make the proper selection.

Manufacturer reserves the right to discontinue, or change at any time, speci®cations or designs without notice and without incurring obligations.

Book	1	4		PC 111	Catalog No. 563-746	Printed in U.S.A.	Form 38A-4SI	Pg 1	4-94	Replaces: 38AE-17SI
Tab	3a	2a

LEGEND

AÐ 11¤4-in. (32) diameter knockout for 5¤8-in. (16) ODM liquid line connection

BÐ 13¤4-in. (44.5) diameter knockout for suction line connections of 11¤8 in. (28.6) (38AE012), 13¤8 in. (35) (38AE014,016), 15¤8 in. (41) (38AKS024)

CÐ 7¤8-in. (22.2) diameter knockout for control power

DÐ 2-in. (50.8) diameter knockout for unit power

NOTES:

1.	SERVICE AREAS Ð Allow 3 ft (914) on both sides
	and 2 ft (610) on both ends of unit for servicing.
2.	Dimensions in ( ) are in millimeters.

Certi®ed dimension drawings are available on request.

Fig. 1 Ð Dimensions (ft-in.)

2

1																			2																									3											4																																							5																											6							7

	12		11		10	9	8
				LEGEND
1	Ð Low-Voltage Fuse	5	Ð No. 2 Fan		9	Ð Compressor
2	Ð No. 1 Fan	6	Ð Terminal Block 1	(Unit Power)	10	Ð Low-Pressure Switch
3	Ð High-Pressure Switch	7	Ð Terminal Block 2	(Control Power)	11 Ð Hot Gas Bypass Piping Stub (3¤8-in. ODM)
4	Ð Circuit Breakers	8	Ð Wraparound Coil		12	Ð Muffler

Fig. 2 Ð Component Locations (Typical Ð 38AE Shown)

3

Table 1A Ð Physical Data (English, 60 Hz)

UNIT	38AE012	38AE014		38AE016	38AKS024
OPERATING WEIGHT (lb)	732	779		789	900
REFRIGERANT*			R-22
COMPRESSOR		Reciprocating, Semi-Hermetic
Speed (Rpm)			1750
No. Cylinders	6	6		6	4
Model No.	06DD824	06DD328		06DD537	06E4250
Oil (pt)	10	10		10	15.5
Crankcase Heater Watts	125	125		125	180
Unloader Setting (psig)
Load			70 ± 1
Unload			60 ± 2
OUTDOOR-AIR FANS		Axial Flow, Direct Drive
No. ...Rpm			2...1075
Diameter (in.)	24	24		24	26
Motor Hp				1¤2
Nominal Total Air¯ow (Cfm)	8800	8800		8800	11,000
OUTDOOR COIL
Face Area (sq ft)			29.2
Storage Capacity (lb)²	27.2	40.3		39.8	39.8
CONTROLS
Pressurestat Settings (psig)
High Cutout			395 ± 10
Cut-in			295 ± 10
Low Cutout			29 ± 4
Cut-in.			60 +15, ±0
FUSIBLE PLUG (F)			200
PIPING CONNECTIONS (in. ODM)
Suction	11¤8	13¤8		13¤8	15¤8
Liquid				5¤8
Unit is factory supplied with holding charge only.

²Storage 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 Ð Physical Data (SI, 60 Hz)

UNIT	38AE012	38AE014		38AE016	38AKS024
OPERATING WEIGHT (kg)	333	354		359	408
REFRIGERANT*			R-22
COMPRESSOR		Reciprocating, Semi-Hermetic
Speed (r/s)			29.2
No. Cylinders	6	6		6	4
Model No.	06DD824	06DD328		06DD537	06E4250
Oil (L)	4.73	4.73		4.73	7.33
Crankcase Heater Watts	125	125		125	180
Unloader Setting (kPa)
Load			483 ± 6.9
Unload			414 + 103, ±0
OUTDOOR-AIR FANS		Axial Flow, Direct Drive
No. ...r/s			2...17.9
Diameter (mm)	610	610		610	661
Motor Hp				1¤2
Nominal Total Air¯ow (L/s)	4153	4153		4153	5566
OUTDOOR COIL
Face Area (sq m)			2.71
Storage Capacity (kg)²	12.4	18.3		18.1	18.1
CONTROLS
Pressurestat Settings (kPa)
High Cutout			2724 ± 68.9
Cut-in			2034 ± 68.9
Low Cutout			200 ± 27.6
Cut-in			414 + 103, ±0
FUSIBLE PLUG (C)			93.3
PIPING CONNECTIONS (in. ODM)
Suction	11¤8	13¤8		13¤8	15¤8
Liquid				5¤8

*Unit is factory supplied with holding charge only.

²Storage 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 Ð Physical Data (English, 50 Hz)

UNIT		38AE012	38AE014		38AE016	38AKS024
OPERATING WEIGHT (lb)		732	779		789	900
REFRIGERANT*				R-22
COMPRESSOR			Reciprocating, Semi-Hermetic
Speed (Rpm)				1460
No. Cylinders		6	6		6	4
Model No.		06DD824	06DD328		06DD537	06E4250
Oil (pt)		10	10		10	15.5
Crankcase Heater Watts		125	125		125	180
Unloader Setting (psig)
Load				70 ± 1
Unload				60 ± 2
OUTDOOR-AIR FANS			Axial Flow, Direct Drive
No. ...Rpm				2...900
Diameter (in.)		24	24		24	26
Motor Hp					1¤2
Nominal Total Air¯ow (Cfm)		7368	7368		7368	9210
OUTDOOR COIL
Face Area (sq ft)				29.2
Storage Capacity (lb)²		27.2	40.3		39.8	39.8
CONTROLS
Pressurestat Settings (psig)
High Cutout				395 ± 10
Cut-in				295 ± 10
Low Cutout				29 ± 4
Cut-in				60 + 15, ±0
FUSIBLE PLUG (F)				200
PIPING CONNECTIONS (in. ODM)
Suction		11¤8	13¤8		13¤8	15¤8
Liquid					5¤8
*Unit is factory supplied with holding charge only.
²Storage 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 Ð Physical Data (SI, 50 Hz)
UNIT		38AE012	38AE014		38AE016	38AKS024
OPERATING WEIGHT (kg)		333	354		359	408
REFRIGERANT*				R-22
COMPRESSOR			Reciprocating, Semi-Hermetic
Speed (r/s)				24.3
No. Cylinders		6	6		6	4
Model No.		06DD824	06DD328		06DD537	06E4250
Oil (L)		4.73	4.73		4.73	7.33
Crankcase Heater Watts		125	125		125	180
Unloader Setting (kPa)
Load				483 ± 6.9
Unload				414 + 103, ±0
OUTDOOR-AIR FANS			Axial Flow, Direct Drive
No. ...r/s				2...15.0
Diameter (mm)		610	610		610	661
Motor Hp					1¤2
Nominal Total Air¯ow (L/s)		3728	3728		3728	4660
OUTDOOR COIL
Face Area (sq m)				2.71
Storage Capacity (kg)²		12.4	18.3		18.1	18.1
CONTROLS
Pressurestat Settings (kPa)
High Cutout				2724 ± 68.9
Cut-in				2034 ± 68.9
Low Cutout				200 ± 27.6
Cut-in				414 + 103, ±0
FUSIBLE PLUG (C)				93.3
PIPING CONNECTIONS (in. ODM)
Suction		11¤8	13¤8		13¤8	15¤8
Liquid					5¤8

*Unit is factory supplied with holding charge only.

²Storage 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 Ð Weight Distribution

		WEIGHT Ð lb (kg)
UNIT	Total		Support Point
	Operating	A	B	C	D
38AE012	732 (333)	142 (65)	138 (63)	225 (102)	227(103)
38AE014	779 (354)	143 (65)	140 (64)	247 (112)	249 (113)
38AE016	789 (359)	143 (65)	143 (65)	250 (114)	253 (115)
38AKS024	900 (408)	178 (81)	168 (76)	269 (122)	285 (129)

Step 2 Ð Rig and Mount the Unit

Be sure unit panels are securely in place prior to rigging.

RIGGING Ð 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.

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.

Raise from above to lift unit from the rails or pad when unit is in ®nal position.

COMPRESSOR MOUNTING Ð As shipped, the compressor is held tightly in place by self-locking bolts. Before starting unit, loosen self-locking bolts until the snubber washer can be moved sideways with ®nger pressure. Do not remove shipping bolts. See Fig. 3.

Fig. 3 Ð Compressor Mounting

Step 3 Ð Complete Refrigerant Piping

Connections

IMPORTANT: A refrigerant receiver is not provided with the unit. Do not install a receiver.

SIZE REFRIGERANT LINES Ð 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 additional information.

	Table 3 Ð Liquid Line Data
	MAXIMUM
	ALLOWABLE			LIQUID LINE
	LIQUID LIFT
	ft (m)
UNIT			Maximum		Maximum	Filter Drier
					Allowable	and
			Allowable
	60 Hz	50 Hz			Temp.	Sight Glass
			Pressure Drop
					Loss	Flare Conn.*
			psig (kPa)
					F (C)	in. (mm)
38AE012	52 (15.8)
38AE014	67 (20.4)		7 (48.3)		2 (1.1)	5¤8
38AE016	82 (25)
38AKS024	87 (26.5)	86 (26)

*Inlet and outlet.

NOTE: Data shown is for units operating at 45 F (7.2 C) saturated suction and 95 F (35 C) entering air.

Table 4A Ð Refrigerant Piping Sizes Ð 60 Hz

LENGTH OF INTERCONNECTING PIPING Ð FT (M)

0-15

15-25

25-50

50-75

75-100

UNIT

(0-4.6)

(4.6-7.6)

(7.6-15.2)

(15.2-22.9)

(22.9-30.5)

Line Size Ð in. OD

L

S

L

S

L

S

L

S

L

S

38AE012

1¤2

11¤8

1¤2

11¤8

5¤8

13¤8

5¤8

13¤8

5¤8

15¤8

38AE014

1¤2

11¤8

1¤2

13¤8

5¤8

13¤8

5¤8

15¤8

7¤8

15¤8

38AE016

1¤2

13¤8

5¤8

13¤8

5¤8

15¤8

7¤8

15¤8

7¤8

21¤8

38AKS024

5¤8

15¤8

5¤8

15¤8

7¤8

15¤8

7¤8

21¤8

7¤8

21¤8

	LEGEND
L Ð	Liquid
S Ð	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 ®ttings. A more accurate estimate may result in smaller sizes.

Table 4B Ð Refrigerant Piping Sizes Ð 50 Hz

LENGTH OF INTERCONNECTING PIPING Ð FT (M)

0-15

15-25

25-50

50-75

75-100

UNIT

(0-4.6)

(4.6-7.6)

(7.6-15.2)

(15.2-22.9)

(22.9-30.5)

Line Size Ð in. OD

L

S

L

S

L

S

L

S

L

S

38AE012

1¤2

11¤8

1¤2

11¤8

5¤8

11¤8

5¤8

13¤8

5¤8

13¤8

38AE014

1¤2

11¤8

1¤2

11¤8

5¤8

13¤8

5¤8

13¤8

5¤8

13¤8

38AE016

1¤2

13¤8

5¤8

13¤8

5¤8

13¤8

5¤8

13¤8

5¤8

15¤8

38AKS024

5¤8

15¤8

5¤8

15¤8

5¤8

15¤8

7¤8

15¤8

7¤8

15¤8

	LEGEND
L Ð	Liquid
S Ð	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 ®ttings. A more accurate estimate may result in smaller sizes.

6