Carrier 38AE016, 38AE012, 38AE014 User Manual

38AE012,014,016

Air-Cooled Condensing Units

Installation, Start-Up and

Service Instructions

38AKS024

50/60 Hz

CONTENTS

Page

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

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, qualified 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 allsafetycodes.Wear safetyglassesandworkgloves.
Keep quenching cloth and fire 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 — Complete Pre-Installation Checks

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 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 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.

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, specifications or designs without notice and without incurring obligations.

Book 1 4
Tab 3a 2a

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

A—1
B—13⁄4-in. (44.5)diameterknockout for suctionlineconnections of 11⁄8in. (28.6)

C—
D—2-in. (50.8) diameter knockout for unit power

1

⁄4-in. (32) diameter knockout for5⁄8-in. (16) ODM liquid line connection

(38AE012), 13⁄8in. (35) (38AE014,016), 15⁄8in. (41) (38AKS024)

7

⁄8-in. (22.2) diameter knockout for control power

Certified dimension drawings are available on request.

Fig. 1 — Dimensions (ft-in.)

LEGEND

NOTES:

1. SERVICE AREAS —Allow 3 ft (914) on both sides
and 2 ft (610) on both ends of unit for servicing.

2. Dimensions in ( ) are in millimeters.

2

1

2 4567

3

LEGEND

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

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

3

⁄8-in. ODM)

812 91011

3

Table 1A — 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 666 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
Nominal Total Airflow (Cfm) 8800 8800 8800 11,000

OUTDOOR COIL

Face Area (sq ft) 29.2
Storage Capacity (lb)† 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 1
Liquid

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.

1

⁄

8

13⁄

8

1

⁄

2

13⁄

5

⁄

8

8

15⁄

8

Table 1B — 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 666 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
Nominal Total Airflow (L/s) 4153 4153 4153 5566

OUTDOOR COIL

Face Area (sq m) 2.71
Storage Capacity (kg)† 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 1
Liquid

*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.

1

⁄

8

13⁄

8

1

⁄

2

13⁄

5

⁄

8

8

15⁄

8

4

Table 1C — 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 666 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
Nominal Total Airflow (Cfm) 7368 7368 7368 9210

OUTDOOR COIL

Face Area (sq ft) 29.2
Storage Capacity (lb)† 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 1
Liquid

*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.

1

⁄

8

13⁄

8

1

⁄

2

13⁄

5

⁄

8

8

15⁄

8

Table 1D — 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 666 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
Nominal Total Airflow (L/s) 3728 3728 3728 4660

OUTDOOR COIL

Face Area (sq m) 2.71
Storage Capacity (kg)† 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 1
Liquid

*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.

1

⁄

8

13⁄

8

1

⁄

2

13⁄

5

⁄

8

8

15⁄

8

5

Table2—Weight Distribution

UNIT

Total

Operating

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)

WEIGHT — lb (kg)

Support Point

AB C D

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
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 final position.

COMPRESSOR MOUNTING — As shipped, the compres­sor is held tightly in placebyself-lockingbolts.Before start-

ing unit, loosenself-locking bolts until the snubber
washer can be moved sideways with finger pres­sure. Do not remove shipping bolts. See Fig. 3.

Step 3 — Complete Refrigerant Piping
Connections

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

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 addi­tional information.

Table 3 — Liquid Line Data

MAXIMUM

ALLOWABLE

LIQUID LIFT

UNIT

ft (m)

60 Hz 50 Hz

Maximum
Allowable

Pressure Drop

psig (kPa)

38AE012 52 (15.8)
38AE014 67 (20.4)
38AE016 82 (25)

7 (48.3) 2 (1.1)

38AKS024 87 (26.5) 86 (26)

*Inlet and outlet.
NOTE: Data shown isfor units operating at 45 F (7.2C)saturated suction and

95 F (35 C) entering air.

Table 4A — Refrigerant Piping Sizes — 60 Hz

LENGTH OF INTERCONNECTING PIPING — FT (M)

0-15

UNIT

(0-4.6)

LSLSLSLSLS

1

38AE012

⁄211⁄

38AE0141⁄211⁄
38AE0161⁄213⁄

38AKS0245⁄815⁄

LEGEND

L—Liquid
S—Suction

Close coupled.

NOTES:

1. Pipe sizes are based ona2F(1.1 C) loss for liquid lines and a 1.5 F
(0.8 C) loss for suction lines.

2. Pipe sizes are basedonan equivalent length equal to the maximumlength
ofinterconnectingpiping plus50% forfittings. Amore accurate estimatemay
result in smaller sizes.

8
8
8
8

15-25

(4.6-7.6)

1

⁄211⁄

1

⁄213⁄

5

⁄813⁄

5

⁄815⁄

8
8
8
8

(7.6-15.2)

Line Size — in. OD

5

⁄813⁄

5

⁄813⁄

5

⁄815⁄

7

⁄815⁄

25-50

LIQUID LINE

Maximum
Allowable

Temp.

50-75

(15.2-22.9)

5

8

⁄813⁄

5

8

⁄815⁄

7

8

⁄815⁄

7

8

⁄821⁄

Loss
F (C)

Filter Drier

Sight Glass

Flare Conn.*

(22.9-30.5)

5

8

⁄815⁄

7

8

⁄815⁄

7

8

⁄821⁄

7

8

⁄821⁄

and

in. (mm)

5

⁄

8

75-100

8
8
8
8

Fig. 3 — Compressor Mounting

Table 4B — Refrigerant Piping Sizes — 50 Hz

LENGTH OF INTERCONNECTING PIPING — FT (M)

UNIT

0-15

(0-4.6)

15-25

(4.6-7.6)

25-50

(7.6-15.2)

50-75

(15.2-22.9)

Line Size — in. OD

LSLSLSLSLS

1

38AE012

⁄211⁄

38AE0141⁄211⁄
38AE0161⁄213⁄

38AKS0245⁄815⁄

1

8

⁄211⁄

1

8

⁄211⁄

5

8

⁄813⁄

5

8

⁄815⁄

5

8

⁄811⁄

5

8

⁄813⁄

5

8

⁄813⁄

5

8

⁄815⁄

8
8
8
8

5

⁄813⁄

5

⁄813⁄

5

⁄813⁄

7

⁄815⁄

8
8
8
8

LEGEND

L—Liquid
S—Suction

Close coupled.

NOTES:

1. Pipe sizes are based ona2F(1.1 C) loss for liquid lines and a 1.5 F
(0.8 C) loss for suction lines.

2. Pipe sizes are basedonan equivalent length equal to the maximumlength
ofinterconnectingpiping plus50% forfittings. Amore accurate estimatemay
result in smaller sizes.

6

75-100

(22.9-30.5)

5

⁄813⁄

5

⁄813⁄

5

⁄815⁄

7

⁄815⁄

8
8
8
8