Carrier 38AK008, 38AKS009, 38AK012, 38AK007, 38AKS012 User Manual

38AK007,008,012

38AKS008,009,012 Air-Cooled Condensing Units

50/60 Hz

Installation, Start-Up and

Service Instructions

CONTENTS

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

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

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

•UNCRATE UNIT

•INSPECT SHIPMENT

•CONSIDER SYSTEM REQUIREMENTS

Step 2 — Rig and Mount the Unit . . . . . . . . . . . . . . . . . 4

•RIGGING

•COMPRESSOR MOUNTING

Step 3 — Complete Refrigerant Piping

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

•SIZE REFRIGERANT LINES

•FILTER DRIER AND MOISTURE INDICATOR

Step 4 — Make Electrical Connections . . . . . . . . . . . 6

•FIELD POWER SUPPLY

•FIELD CONTROL WIRING

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Compressor Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Evacuate and Dehydrate . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

Compressor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Cycle-LOC™ Device (CLO) . . . . . . . . . . . . . . . . . . . . . . 10

Low-Pressure/Loss-of-Charge Switch (LPS). . . . . 10

High-Pressure Switch (HPS). . . . . . . . . . . . . . . . . . . . . 10

High Flow Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Refrigerant Service Ports . . . . . . . . . . . . . . . . . . . . . . . 10

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 10

Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,12

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Condenser-Fan Adjustment . . . . . . . . . . . . . . . . . . . . . 11

Capacity Control — Unit 38AKS012 Only . . . . . . . . 12

Compressor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Crankcase Heater (Except 38AK007) . . . . . . . . . . . . 12

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . .13,14

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

SAFETY CONSIDERATIONS

Installing and servicing air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install or service air-conditioning equipment.

When working on air-conditioning equipment, observe precautions in literature and on tags and labels attached to unit.

NOTE: Ensure voltage listed on unit data plate agrees with electrical supply to unit.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly. Consult local building codes and National Electrical Code (NEC) (U.S.A. Standard) for special installation requirements.

Before installing or servicing system, always turn off main power to system and install lockout tag on disconnect. There may be more than one disconnect switch. Electrical shock can cause personal injury.

INSTALLATION

The 38AK007, 008, and 012 units use hermetic compressors. The 38AKS008, 009, and 012 units use semi-hermetic compressors. See Table 1A or 1B for physical data.

Step 1 — Complete Pre-Installation Checks

UNCRATE UNIT (See Fig. 1) — Remove unit packaging except for the top skid assembly and wood bumpers, which should be left in place until after unit is rigged into place.

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

Fig. 1 — Model 38AK (Size 007 Shown)

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

Book	1	4	PC 111	Catalog No. 533-80003	Printed in U.S.A.	Form 38A-9SI	Pg 1	5-01	Replaces: 38A-8SI
Tab	3a	2a

Table 1A — Physical Data — 50/60 Hz (English)

	UNIT 38	AK007		AK008		AK012				AKS008		AKS009				AKS012
OPERATING WEIGHT (lb)
Aluminum Coils (Standard)		340		392		426				510		564				564
Copper Coils (Optional)		386		460		503				578		632				632
RIGGING WEIGHT (lb)
Aluminum Coils (Standard)		390		442		476				560		614				614
Copper Coils (Optional)		436		510		553				628		682				682
REFRIGERANT*						R-22
COMPRESSOR		Bristol, Reciprocating		Copeland, Scroll		Copeland, Scroll				Reciprocating, Semi-Hermetic
Quantity...Type		1...H26A72Q		1...ZR94KC		1...ZR125KC				1...06DA818		1...06DA824				1...06DH824
																(See Note)
Quantity Cylinders		2		—		—				4				6
Speed (rpm) — 60 Hz		3500		3500		3500				1750			1750
	— 50 Hz									1460			1460
Oil Charge (oz)		65		85		110				88			128
CONDENSER FAN — 60 Hz					Propeller; Direct Drive
Quantity...Rpm		1...850						1...1100
Diameter (in.)		26						26
Motor Hp (NEMA)		1/						3/
Nominal Airflow (cfm)		3						4
		3800		6500		7000				6500		6500				6500
CONDENSER FAN — 50 Hz					Propeller; Direct Drive
Quantity...Rpm					1...960
Diameter (in.)					26
Motor Hp (NEMA)					1/
Nominal Airflow (cfm)					3
		3150		5400		5800				5400		5400				5400
CONDENSER COIL				Enhanced Copper Tubes, Aluminum Lanced Fins
Face Area (sq ft)		12.24		15.75		20.5				18.0		18.0				18.0
Storage Capacity (lb)†		11.26		14.88		18.87				16.56		16.56				16.56
CONNECTIONS (sweat)		11/8		11/8		11/8				11/8		11/8				11/8
Suction (in.)
Liquid (in.)		1/		1/		5/				1/		5/				5/
		2		2		8				2		8				8
CONTROLS
Pressurestat Settings (psig)
High	Cutout				426 ±		7
	Cut-in				320 ± 20
Low	Cutout				7 ±		3
	Cut-in				22 ±		5

LEGEND

NEMA — National Electrical Manufacturing Association

*Unit is factory supplied with holding charge only.

†Storage capacity of condenser coil with coil 80% full of liquid R-22 at 124 F.

NOTE: Unit 38AKS012 has one step of unloading. Full load is 100% capacity, and one step of unloading is 67% capacity. Unit 38AKS012 has the following unloader settings: load is 70 ± 1 psig and unload is 60 ± 2 psig.

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Table 1B — Physical Data — 50/60 Hz (SI)

	UNIT 38	AK007		AK008		AK012		AKS008		AKS009			AKS012
OPERATING WEIGHT (kg)
Aluminum Coils (Standard)		154		177		192		231		256			256
Copper Coils (Optional)		175		208		215		262		287			287
RIGGING WEIGHT (kg)
Aluminum Coils (Standard)		176		200		215		254		279			279
Copper Coils (Optional)		198		231		250		285		309			309
REFRIGERANT*						R-22
COMPRESSOR		Bristol, Reciprocating		Copeland, Scroll		Copeland, Scroll		Reciprocating, Semi-Hermetic
Quantity...Type		1...H26A72Q		1...ZR94KC		1...ZR125KC		1...06DA818		1...06DA824			1...06DH824
													(See Note 1)
Quantity Cylinders		2		—		—		4			6
Speed (r/s) — 60 Hz		58.4		58.4		58.4		29.2			29.2
	— 50 Hz	48.4		48.4		48.4		24.2			24.2
Oil Charge (L)		1.92		2.51		3.25		2.60			3.78
CONDENSER FAN — 60 Hz						Propeller; Direct Drive
Quantity...R/s		1...14.2						1...18.3
Diameter (mm)		660						660
Motor Hp (NEMA)		1/						3/
Nominal Airflow (L/s)		3						4
		1800		3050		3300		3050		3050			3050
CONDENSER FAN — 50 Hz						Propeller; Direct Drive
Quantity...R/s					1...16.0
Diameter (mm)					660
Motor Hp (NEMA)					1/
Nominal Airflow (L/s)					3
		1490		2550		2750		2550		2550			2550
CONDENSER COIL				Enhanced Copper Tubes, Aluminum Lanced Fins
Face Area (sq m)		1.14		1.46		1.90		1.67		1.67			1.67
Storage Capacity (kg)†		5.1		6.75		8.6		7.5		7.5			7.5
CONNECTIONS (sweat)		11/8		11/8		11/8		11/8		11/8			11/8
Suction (in.)
Liquid (in.)		1/		1/		5/		1/		5/			5/
		2		2		8		2		8			8
CONTROLS
Pressurestat Settings (kPa)
High	Cutout				2937 ±		48
	Cut-in				2206 ± 138
Low	Cutout				48 ±		20
	Cut-in				151 ±		34

LEGEND

NEMA — National Electrical Manufacturing Association

*Unit is factory supplied with holding charge only.

†Storage capacity of condenser coil with coil 80% full of liquid R-22 at 51 C. NOTES:

1.Unit 38AKS012 has one step of unloading. Full load is 100% capacity, and one step of unloading is 67% capacity. Unit 38AKS012 has the following unloader settings: load is 483 ± 6.9 kPa and unload is 414 ± 13.8 kPa.

2.Equivalent mm values for connectors are as follows:

in. mm

1/		12.7
2		15.9
5/
8		28.6
11/	8

3

CONSIDER SYSTEM REQUIREMENTS

•Consult local building codes and NEC for special installation requirements.

•Allow sufficient space for airflow clearance, wiring, refrigerant piping, and unit servicing. See Fig. 2.

•Locate unit so that condenser airflow is unrestricted on all sides and above. Refer to Fig. 2.

•Unit may be mounted on a level pad directly on base rails or mounted on raised pads at support points. See Table 2 for weight distribution based on recommended support points.

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

Table 2 — Weight Distribution

UNIT	STD UNIT		CORNER			CORNER			CORNER			CORNER
			W				X			Y			Z
38AK
	Lb	Kg	Lb		Kg	Lb		Kg	Lb		Kg	Lb		Kg
			With Aluminum Coil
007	340	154	86		39	53		24	77		35	124		56
008	392	177	86		39	78		35	99		45	107		49
012	426	192	89		40	92		42	109		49	105		48
S008	510	231	115		52	89		40	133		60	173		87
S009,S012	564	256	133		60	97		44	141		64	193		88
			With Copper Coil
007	386	175	106		48	65		30	82		37	133		60
008	460	208	114		52	95		43	108		49	121		55
012	503	215	118		53	116		53	119		54	119		54
S008	578	262	143		65	106		48	142		64	187		85
S009,S012	632	287	161		73	114		52	150		68	207		94

NOTES:

1. Dimensions in [ ] are in millimeters.

2. See Fig. 3 for additional information.

Step 2 — Rig and Mount the Unit

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

RIGGING — These units are designed for overhead rigging. Refer to rigging label for preferred rigging method. Spreader bars are not required if top crating is left on unit. All panels must be in place when rigging. (See Fig. 3.) As further protection for coil faces, plywood sheets may be placed against sides of unit, behind cables. Run cables to a central suspension point so that angle from the horizontal is not less than 45 degrees. Raise and set unit down carefully.

If it is necessary to roll unit into position, mount unit on rails, using a minimum of 3 rollers. Apply force to rails, not unit. If 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 unit.

Raise from above to lift unit from rails or pad when unit is in final position.

After unit is in position, remove all shipping materials and top crating.

COMPRESSOR MOUNTING — Compressors are shipped from the factory held down by 4 bolts. After unit is installed, loosen each bolt until the snubber washer can be moved with finger pressure. See Fig. 4.

Step 3 — Complete Refrigerant Piping Connections — Suction connection is sweat with plastic cap; liquid connection is sweat with plastic cap. Refer to Table 3A or 3B for the proper line sizes. Follow standard piping practices.

SIZE REFRIGERANT LINES — Consider length of piping required between condensing unit and air handler, amount of liquid lift, and compressor oil return. See Table 4A and 4B and also refer to Part 3 of Carrier System Design Manual for design details and line sizing. Refer to air handler installation instructions for additional information.

Table 3A — Refrigerant Piping Sizes — 60 Hz

LINEAR LENGTH OF PIPING — FT (M)

		0-25			25-50		50-75			75-100
UNIT	(0-7.6)				(7.6-15.2)		(15.2-22.9)			(22.9-30.5)
38					Line Size (in. OD)
	L		S		L	S	L	S		L	S
AK007	1/		11/	8	1/	11/	1/	11/	8	1/	11/	8
		2			2	8	2			2
AK008	1/	2	11/	8	1/	11/	5/	11/	8	5/	13/	8
					2	8	8			8
AK012	5/		11/	8	5/	13/	5/	13/	8	5/	13/	8
		8			8	8	8			8
AKS008	1/		11/	8	1/	11/	5/	11/	8	5/	13/	8
		2			2	8	8			8
AKS009	5/		11/	8	5/	11/	5/	13/	8	5/	13/	8
		8			8	8	8			8
AKS012	5/		11/	8	5/	11/	5/	13/	8	5/	13/	8
		8			8	8	8			8

LEGEND

L — Liquid LIne

S — Suction Line

Table 3B — Refrigerant Piping Sizes — 50 Hz

LINEAR LENGTH OF PIPING — FT (M)

	0-25		25-50		50-75		75-100
UNIT	(0-7.6)		(7.6-15.2)		(15.2-22.9)		(22.9-30.5)
38			Line Size (in. OD)
	L	S	L	S	L	S	L	S
AK007	1/2	11/8	1/2	11/8	1/2	11/8	1/2	11/8
AK008	1/2	11/8	1/2	11/8	5/8	13/8	5/8	13/8
AK012	5/8	11/8	5/8	13/8	5/8	13/8	5/8	13/8
AKS008	1/2	11/8	1/2	11/8	5/8	13/8	5/8	13/8
AKS009	5/8	11/8	5/8	11/8	5/8	13/8	5/8	13/8
AKS012	5/8	11/8	5/8	11/8	5/8	13/8	5/8	13/8

LEGEND

L — Liquid LIne

S — Suction Line

NOTES FOR TABLES 3A AND 3B:

1.Pipe sizes are based on a 2 F (1 C) loss for liquid and suction lines.

2.Pipe sizes are based on the maximum linear length shown for each column, plus a 50% allowance for fittings.

3.Charge units with R-22 in accordance with unit installation instructions.

4.Line size conversion to mm is:

in.	mm
1/2	12.7
5/8	15.9
11/8	28.6
13/8	34.9

4

	UNIT 38	DIM. A	DIM. B	DIM. C	DIM. D	DIM. E	DIM. F
	AK007	1′-61/2″	1′-23/4″	—	1′-21/4″	1′-45/16″	2′-95/16″
		[470.0]	[375.0]	—	[362]	[415]	[846.5]
	AK008	1′-8″	1′-61/2″	—	1′-3″	2′-5/16″	3′-57/16″
		[508.0]	[470.0]	—	[381]	[613]	[1052.5]
	AK012	1′-9″	1′-8″	2′-0″	1′-3″	2′-5/16″	3′-57/16″
		[533.4]	[508.0]	[609.6]	[381]	[613]	[1052.5]
	AKS008	1′-6″	1′-43/4″	2′-913/16″	1′-3″	2′-5/16″	3′-57/16″
		[457.2]	[425.5]	[858.8]	[381]	[613]	[1052.5]
	AKS009	1′-7″	1′-5″	2′-913/16″	1′-3″	2′-5/16″	3′-57/16″
		[482.6]	[431.8]	[858.8]	[381]	[613]	[1052.5]
	AKS012	1′-7″	1′-5″	2′-913/16″	1′-3″	2′-5/16″	3′-57/16″
		[482.6]	[431.8]	[858.8]	[381]	[613]	[1052.5]
	NOTES:
	1. Dimensions in [	] are in millimeters.

2. Center of Gravity. See chart for dimensions.

3.Direction of Airflow.

4.Minimum clearance (local codes or jurisdiction may prevail):

a.Condenser coil, for proper airflow, 36 in. [914] one side, 12 in. [305] the other. The left or rear side getting the greater clearance is optional.

b.Overhead, 60 in. [1524] to assure proper condenser fan operation.

c.Between units, control box side, 42 in. [1067] per NEC (National Electrical Code) (U.S.A. Standard).

d.Between unit and ungrounded surfaces, control box side, 36 in. [914] per NEC.

e.Between unit and block or concrete walls and

other grounded surfaces, control box side, 42 in. [1067] per NEC.

5.With the exception of the clearance for the condenser coil as stated in Note 4b, a removable fence or barricade requires no clearance.

6.Units may be installed on combustible floors made from wood or Class A, B, or C roof covering material.

ELECTRICAL CONNECTIONS

CONNECTION SIZES

AA13/8″ Dia [35] Field Power Supply Hole

BB2″ Dia [51] Power Supply Knockout

CC21/2″ Dia [64] Power Supply Knockout

DD7/8″ Dia [22] Field Control Wiring Hole

SERVICE VALVE CONNECTIONS — 50/60 Hz

UNIT 38	SUCTION	LIQUID
AK007	11/8″ [28.6]	11/2″ [12.7]
AK008	11/8″ [28.6]	11/2″ [12.7]
AK012	11/8″ [28.6]	15/8″ [15.9]
AKS008	11/8″ [28.6]	11/2″ [12.7]
AKS009	11/8″ [28.6]	15/8″ [15.9]
AKS012	11/8″ [28.6]	15/8″ [15.9]

Fig. 2 — Dimensions (ft-in.)

UNIT	RIGGING			A			B			C
	WEIGHT*
38
	lb	kg	in.		mm	in.		mm	in.		mm
AK007	390	176	45.0		1143	38.5		978	35.5		904
AK008	442	200	45.0		1143	38.5		978	43.5		1105
AK012	476	215	45.0		1143	38.5		978	43.5		1105
AKS008	560	254	45.0		1143	38.5		978	43.5		1105
AKS009	614	279	45.0		1143	38.5		978	43.5		1105
AKS012	614	279	45.0		1143	38.5		978	43.5		1105

*Weights are for aluminum coils.

Fig. 3 — Rigging Label

5