Carrier 38EB User Manual

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Page 1

Number One AirCoxIitbning l\Mer

Installation, Start-Up '

Division of Carrier Corporatio

Carrier Parkway • Syracuse NY 13221

and Service Instructions

Air-Cooled Condensing Units

INDEX

SAFETY CONSIDERATIONS......................

INSTALLATION

Step 1 — Check Equipment and

Jobsite..............................................................I

• UNPACK UNIT

• INSPECT EQUIPMENT

• COMPLETE OR CONSIDER SYSTEM REQUIREMENTS

Step 2 — Make Piping Connections

• REPLACE THE ACCURATER™ REFRIGERANT CONTROL PISTON IN THE INDOOR COIL IF REQUIRED

• CONNECT REFRIGERANT LINES

Step 3 — Make Electrical

Connections....................................................5

• INSTALL A BRANCH CIRCUIT DISCONNECT PER NEC

• ROUTE LINE POWER LEADS INTO UNIT

• CONNECT GROUND LEAD AND POWER WIRING

• CONNECT CONTROL POWER WIRING

START-UP

SERVICE............................................................. 8-10

MAINTENANCE..................................................11,12

Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and quali fied service personnel should install, repair or

service air conditioning equipment.

Untrained personnel can perform basic mainten ance functions of cleaning coils and filters and re placing filters. All other operations should be performed by trained service personnel. When working on air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may

apply.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing opera tions. Have fire extinguisher available for all brazing operations.

...........................................

_______

...........................................................

SAFETY CONSIDERATIONS

Page

.. 1

. 1-6

6-8

WAR-NiNG: Before perfosrmisg service or majnteiiatice орегайоиз or system, tarn off

vaaia power to isdoor tmit tsml outdoor

■ask. Тош off accessory beater power switch is

appiicaMe, E^ecfircal sihock, could cause pers<mal injury.

Table 1 — Physical Data (Refer to Fig. 1)

MODEL38EB OPER WT(lb) DIMENSIONS (ft-in.)

Diameter A Height B

CONNECTIONS (in.)

Suction (ODF) Liquid (ODF)

REFRIG LINES

Suction (in. ODF) Liquid (in ODF)

*Fora1-1/8in suction line on 38EB048,060, a 3/4-in x 1-1/8 in suction

valve connection adapter is available as an accessory See Table 3

015 018

024

030

116

1-9-3/4

Recommended Field-Supplied Sizes

5/8 i 3/4 i 7/8 1 1-1/8

130

2-2-3/8 ) 2-8

5/8

137 165 181

INSTALLATION

Step 1 — Check Equipment and Jobsite

UNPACK UNIT — Move to final location. Slide from carton taking special care not to damage serv ice valves or grilles.

INSPECT EQUIPMENT — File claim with ship ping company if damaged or incomplete.

COMPLETE OR CONSIDER SYSTEM RE

QUIREMENTS before installation:

Consult local building codes and National Elec

trical Code (NEC) for special installation

requirements.

When installing, allow sufficient space for airflow

clearance, wiring, refrigerant piping and service.

Maintain a minimum of 4 ft clearance from obstruc tions above and 18 in. on sides of unit. Maintain a distance of 24 in. between condensing units. Posi tion so water from roof or eaves does not flow directly on unit.

Install on a solid, level mounting pad. It is not necessary to attach unit to pad but if desired or required by local code, position tiedown bolts in pad. Fasten unit to pad using 2 holes provided in unit base. See Fig. 1.

036

2-2-3/8 1 2-8 1 3-2

3/8

042

048 060 212 230.

2-5-1/4

3/4*

Form 38EB-3SI

Page 2

4'-0" OVERHEAD SPACE REQUIRED FOR SERVICE AND AIRFLOW

LIQUID VALVE SERVICE PORT

CONDENSER AIRFLOW

KW r-6''AIRFL0W

■•••••■ AND SERVICE CLEARANCE

SUCTION VALVE SERVICE PORT

rectly sized for an evaporator of the same capacity as the condensing unit, so piston change is not neces sary. Mix-matching of condensing unit with evap orator requires field replacement of piston. Refer to Table 2. Replace piston, if required, before connec ting refrigerant lines. Piston replacement instruc tions are included in evaporator installation book.

After system installation is complete, use Charging Chart to check and/or adjust refrigerant charge.

Condensing Units Connected to Carrier-Approved Evaporators — Condensing units contain correct system refrigerant charge for operation with evap orator of the same size when connected by 25 ft or less of field-supplied or Carrier accessory tubing. Check refrigerant charge for maximum efficiency (see Refrigerant Charging, page 6).

Table 2 — Optimization Chart

(Outdoor air design temperature, db-F,

100 F and below)

COND

UNIT

38EB

015 TWl 46 i 018 ’ . 4

024 030 036 042 048 060

Factory-installed piston. Obtain replacement pistons thru

local Carrier distributor.

ACCURATER™ PISTON NO.

Evap Size (Coil or Fan Coil)

ÒTFI”M4TCÌ301

> I j_V'

036

TXV

65 6? 70

048 060

042

— — —

— —

TXV

,...78...

—

p»

TXV

i 82

^CONCRETE PAD SHOULD WEIGH 1^ TO 2 TIMES WEIGHT OF UNIT

Certified dimension drawings available upon request

Fig. 1 — Dimensions, Connections and

Mounting Pad (Refer to Table 1)

Carrier Cooling System Capacity Optimization —

AccuRater™ (bypass type) refrigerant control, with field-replaceable piston (see Fig. 2), is supplied on evaporator. Use Optimization Chart, Table 2 to find AccuRater piston size required for condenser/ evaporator system being installed. Pistons are cor-

njmm

Fig. 2 — AccuRater (Bypass Type)

Components

Step 2 — Make Piping Connections — Con

densing units may be connected to evaporator sec tions using Carrier accessory tubing package (Table

3) or field-supplied tubing of refrigerant grade, correct size and condition (Table 1). For tubing requirements beyond 50 ft, obtain information from local Carrier distributor.

If or

1$ osigd wism saaldog

If 1-1/8 in. tubing is used (38EB048,060), braze

it to the accessory 1 -1 / 8 x 3/4-in. suction connection

Page 3

adapter (Carrier Part No. 28VQ900011) or to cor rectly sized field-supplied adapter, then make Com patible Fitting connections.

WARNING: iX> NOT BURY UNESETS- If

fdfigerans

E b. veitkaS Ui« to the vah;« irastxsciioiis m

Isolate interconnecting tubing from framing and ductwork or where tubing runs thru stud spaces, en closed ceilings or pipe chases. Use isolation type hanger (Fig. 3) since rigid fastening transmits pulsa tions to structure creating objectionable sound.

For maximum capacity on 38EB048 and 060 sys^ terns use 1 -1 / 8 in. suction line. A capacity reduction results if Carrier accessory tubing is used on these systems. (Example; When a 25-ft accessory tubing package is used on a 38EB048 system, the smaller suction line results in a 3% capacity reduction.)

Length of interconnecting tubing may necessitate refrigerant charge adjustment. Follow special re quirements described in Start-Up, Refrigerant Charging, page 6. Do not use less than 10 ft of inter connecting tubing. On Carrier accessory tubing packages, do not cut 5/ 16-in. or 1/4-in. liquid line or 7/8-in. suction line. These tubing packages have swaged ends that, if cut, will not fit into refrigerant line fittings. Bend or coil excess tubing to fit.

Do not use damaged, undersized or contaminated tubing. Always evacuate or purge evaporator coil

and tubing system. When purging, use field-supplied refrigerant, not unit holding charge refrigerant.

When making tubing connections, be sure to pro

vide clearance at unit for electrical connections.

REPLACE THE ACCURATER™ REFRIG ERANT CONTROL PISTON IN THE INDOOR COIL, if required, before connecting refrigerant lines. See Carrier Cooling System Capacity Optimi zation, page 2.

CONNECT REFRIGERANT LINES to fittings on condensing unit suction and liquid service valves (Fig. 1). Unit Compatible Fittings permit mechanical

(quick connect) or sweat connections. Models 38EB048,060 — When using 1 -1 / 8 in. field-

supplied suction line, use field-supplied 3/4-in. by

1-1/8 in. suction valve connection adapter (28VQ900011). Sweat connect refrigerant suction line to 1-1/8 in. end of adapter. Be sure to provide a heat sink at the service valve to prevent damage during sweating operation. Connect 3/4-in. end of

adapter to unit suction line Compatible Fitting. Connect liquid refrigerant line to unit. When a 7/8-in. field-supplied suction line is used, provide a field-supplied 3/ 4-in. to 7/ 8-in. suction line adapter. (Not necessary if 38LS accessory tubing is used.)

Mechanical Connection — (Mate one set of connec

tions at a time.)

1. Loosen nut on Compatible Fitting one turn. Do not remove.

2. Remove plug and be sure O-ring is in the groove inside the Compatible Fitting.

3. Cut tubing to correct length, deburr and size as necessary.

4. Insert tube into Compatible Fitting until it bottoms. Tighten nut until it bottoms on back coupling flange. Keep tube bottomed in Compat ible Fitting while tightening nut.

SweatT/onnection — (Use refrigerant grade tubing.-)

1. Remove locking nut, rubber O-ring and Schrader core and cap from valve service port.

2. Cut tubing to correct length, deburr and size as necessary.

3. Insert tube in Compatible Fitting until it bottoms. Wrap top and bottom of service valves in wet cloth to prevent damage by heat. Solder with lowtemperature (430 F) silver alloy solder.

4. Replace Schrader core and cap.

5. Evacuate or purge system using field-supplied refrigerant.

Page 4

Table 3 — Accessories

PART NO.

38CQ900141 HH01AD040

HH93AZ040 HH07AT170

HH07AT174 HH93AZ176

HH01AD042 HH93AZ042

HH01YA192 HH93YZ194

38GS900102 38GS900212 HT32BH246 38UE900201 HC95DE088

HN61HB513

HC95DD121 HN61HB515

HC95DE066 HN61HB513

HC95DE088 HN61HB515

HC95DE088 HN61HB506

38EB660002 09WQ036,060 38GS900321

28VQ900011 Twelve 3/4- x 1-1/8 in Connection Adapters

PACKAGES

38LS958151 15 38LS958201 20

. 38LS958251 25 3/8

38LS958301 38LS958351 38LS958401 38LS958501

38LS934151 15 38LS934201 38LS934251 38LS934301 38LS934351 38LS934401 38LS934501

38LS978151 38LS978201 38LS978251 25 38LS978301 30 38LS978351 38LS978401 40

38LS978501

Solid-State Time Guard (Six 38CQ900152)

Low-Voltage Control Honeywell Deluxe Thermostat Thermostat Subbase

Low-Voltage Control

Honeywell Thermostat Thermostat Subbase

Low-Voltage Control Honeywell Thermostat

Thermostat Subbase

Low-Voltage Control Grayson Thermostat

Thermostat Subbase

Indoor Fan Relay (Six HN61KJ210) Low-Voltage Transformer (Six 38GS900091) Crankcase Heater* Crankcase Heater Relay (Six 38UE900212)* Start Capacitor*

Relay* Start Capacitor*

Relay*

Wire Bundle for Start Capacitors and Relays*

Refrigerant-to-Water Heat Exchanger for Chilled Water Systems Liquid Line Filter Drier

Length

(ft)

30 35 40 50

20 25 30 35 40

50 15

(in.)

3/8 3/8 3/8 3/8

5/16 5/16 5/16 1/4

3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8

3/8 3/8 3/8 3/8

3/8 3/8 3/8 3/8 3/8 3/8

3/8 3/8

DESCRIPTION

Liquid

Tube End

OD (in.)

3/8 3/8 3/8 3/8 3/8

3/8 3/8

3/8

TUBlNGt

Suctionj;

(in.)

5/8 5/8 5/8 5/8 5/8 5/8 5/8

3/4 3/4 3/4 3/4

3/4 3/4 3/4 3/4 3/4

3/4 3/4

3/4

7/8

Tube End

OD (in.)

Evap

3/4** 3/4**

3/4**

3/4** 3/4** 3/4** 3/4**

3/4 3/4

3/4 3/4 3/4

3/4

3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4

Cond

MODEL

38EB

All

015300, 018300

024300, 030300

036310

042360

048310

All

048, 060

38EB

5/8

5/8 5/8 5/8 5/8

3/4 030, 036

3/4

3/4 3/4

015, 018, 024

r:'

*Available thru Carrier Service Parts tFor maximum capacities, use suction line sizes recommended in

Table 1 Use of accessory tubing packages smaller than recom

mended may result in slight capacity loss (see Note 2)

tSuction line is insulated and has a 90 degree bend at one end

**For 5/8-in evaporator connection, cut off 3/4-in end

NOTES

1 Do not cut 3/8-in OD liquid line toa length shorterthan 10feet

Do not cut 5/16-or 1/4-in liquid line Do not cut 7/8-in OD suction lines

2 Field-supplied 1-1/8 in suction line is recommended on

38EB048 and 060 If accessory tubing package is used, a capacity reduction can result

Page 5

Table 4 — Electrical Data

COND UNIT 38EB

015300 35 0 1 018300 41 0 9 1 024300 030310 036310 254 042360 108 0 21 7 048310 145 0 25 7 048350 060350

V/PH

208-230/1

230/1

VOLTS*

Max

OPER

Min

197

207

COMPR

LRA RLA

59 0 69 0 ; 93 0: 20 2

105.57^ 150 0 i

133;

16 2

22.9 35 3

7.4

FAN

FLA

1 25

Min Wire

Sizet

(AWG)

12 33

BRANCH CIRCUIT

Max

Wiret

Min Ground

34 28 12

42 34 45 41

50 30

Wire

Sizet

Max Fuse or

HACR Type

Ckt Bkr Amps**

15 10 5 20 30 35 45 50 29 5

60 34 5 50 60

MCA

12 7 17 9 21 5 27 7

31 0 46 5

AWG — American Wire Gage FLA — Full Load Amps HACR — Heating, Air Conditioning and Refrigeration LRA — Locked Rotor Amps

MCA — Minimum Circuit Amps

RLA — Rated Load Amps

^Permissible limits of the voltage range at which the unit will

operate satisfactorily

Step 3 — Make Electrical Connections — Be

sure field wiring complies with local and national fire, safety and electrical codes, and that voltage to unit is within limits shown in Table 4. Contact local power company for correction of improper line voltage.

cöüiti afleci Csmer

Do »ot ana ia

mäy niíOaaio above m

See Table 4 for recommended wire and fuse sizes.

When making electric connections, provide clear

ance at unit for refrigerant piping connections.

INSTALL A BRANCH CIRCUIT DISCONNECT PER NEC of adequate size to handle unit starting current. Locate disconnect within sight from and readily accessible from the unit, per section 440-14 of National Electrical Code (NEC).

ROUTE LINE POWER LEADS INTO UNIT — Extend leads from disconnect thru power wiring

hole provided (see Fig. 1) and into unit splice area.

Remove top cover to gain access to unit wiring. CONNECT GROUND LEAD AND POWER

WIRING — Connect ground lead to a ground lug

in control box for safety. Then connect power wiring.

fCopper wire sizes based on 60 C Use copper or copper-clad

aluminum wire only Use latest NEC requirements for copperclad aluminum conductor sizing

^Required when using nonmetallic conduit “Maximum dual element size NOTE Control circuit is 24v on all units and requires external power source

— GROUND LEAD-|-[1]GR0UNDING LUG

I-PHASE

CONN. TO DISCONNECT PER NEC

Splice Connections

-------------

------------- Factory Wiring

Field Wiring

------

BLK

-YEL-

1-PHASE COND UNIT

-----------

Fig. 4 — Line Power Connections

See Fig. 4. Splice line power leads to yellow and black pigtails. Use wire nuts and tape at each con nection. Connect unit wiring to copper or copperclad aluminum power wiring. Do not connect to aluminum wiring.

CONNECT CONTROL POWER WIRING —

Route 24-v control wires thru control wiring hole

and connect to pigtails supplied with unit (Fig. 1).

Splice control leads to black and blue pigtails on all units. See Fig. 5.

Use furnace or fan coil transformer as 24-v (40-va minimum) supply for system as shown in Fig. 5, or use accessory transformer shown in Table J.

Page 6

THERMOSTAT SUBBASE HH93AZ042 OR HH93AZ040

THERMOSTAT SUBBASE

38EB

-j

TO IFM LINE VOLTAGE

:}“\POWER

SUPPLY

TRANS

ARRANGEMENT A-(COOLING ONLY)

“©n

START-UP

1. Backseat (open) liquid and suction line service valves.

2. Set thermostat selector switch at OFF.

3. Set room thermostat at desired temperature. Be sure this temperature is below indoor ambient.

4. Close electrical disconnects energizing entire system.

5. Set room thermostat at COOL and fan switch at FAN or AUTO, as desired. Operate unit for 15 minutes; then check system refrigerant charge. See Refrigerant Charging, below.

Motors and controls are designed to operate satis

factorily in the voltage range shown in Table 4. If

necessary to use manifold gages for servicing, refer to Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants, page 1-5, Fig. 8 for bypass

method of returning charge to system. Removal of liquid line charging hose without following these precautions could result in some loss of charge.

Refrigerant Charging

ARRANGEMENT B-ONE TRANSFORMER (COOLING AND ONE-STAGE HEATING)

THERMOSTAT SUBBASE HH93AZI76

ARRANGEMENT C-ONE TRANSFORMER

(COOLING AND TWO-STAGE HEATING)

IFR, FS and IFM are located in furnace on heating-cooling

applications If accessory IFR is required for cooling-only

‘Connect FS to low-speed indoor fan terminal when 2-speed fan

C — Contactor (12-va) Trans — Transformer FS — Fan Switch HC — Heating Control Field Splice IFM — Indoor Fan Motor

IFR — Indoor Fan Relay

NOTE Refer to unit wiring label for wire colors: C to G and C to Y connections

applications, locate (IFR) in fan coil

is used

________ ________

Field Wiring Factory Wiring

>• Fig. 5 — Control Circuit Connections

CAUTION: To

Do sot morchsrge sysiiem. As ovorcbsf®e

cas

Condensing units contain correct operating

charge for complete system when connected to

Carrier-approved evaporators of same capacity as condensing unit with 25 ft or less of Carrier accessory tubing or field-supplied tubing of recommended size. For every 10 ft of liquid line of recommended size over 25 ft, add refrigerant charge as follows: .41b for 3/8-in. line; .28 lb for 5/ 16-in. line. On all other systems, adjust charge for correct operation as applicable.

Service port connections are provided on liquid and suction line service valves for evacuation and charging. See Fig. 1.

TO CHECK, ADJUST OR REPLACE REFRIG ERANT CHARGE use method recommended in Table 6. Details of charging methods are listed below.

Before recharging system, thoroughly evacuate

system and then weigh in refrigerant charge speci fied in Table 5. Check or adjust charge as required.

Refer to Carrier Standard Service Techniques

Manual, Chapter 1, Refrigerants, for additional sys

tem evacuation and dehydration instructions.

WEIGHT METHOD — Refer to Table 5 or unit

nameplate for correct system refrigerant charge.

Remove any refrigerant remaining in system before

recharging.

Page 7

Table 5 — Service Data

UNIT 38EB

015300 018300

024300 030310 036310 7 5 042360 6 3 048310 048350 060350

‘Factory refrigerant charge is adequate when evaporator and

condensing unit are the same size and are connected with 25ft or less of field-supplied tubing of recommended size or Carrier accessory tubing

R-22 CHG‘

(lb)

3 3

5 3

6 1 7 2

9 6

CONDENSER

FAN RPM

1110

1075

When system is not evacuated, subtract the

following amount from total charge.

38EB015 thru 030 — .10 lb (1.6 oz) 38EB036 thru 060 — .20 lb (3.2 oz)

The Dial-a-charge charging cylinder is an accu rate device used to recharge system by weight. These cylinders are available at refrigeration supply firms.

CHARGING CHART METHOD — Use Charging

Chart, Fig. 6, and the following procedure.

1. Operate unit a minimum of 10 minutes before checking charge.

2. Measure suction pressure by attaching a gage to suction valve service port.

3. Measure suction line temperature by attaching a service thermometer to unit suction line near suc

tion valve. (Insulate thermometer for accurate

readings.)

4. Measure outdoor (condenser inlet) air dry-bulb temperature with a second thermometer.

5. Refer to Charging Chart (Fig. 6). Find air tem perature entering condenser and project hori zontally to curve showing suction pressures (psig at suction valve).

6. From this interseetion, project vertically down ward to suction line temperature.

Fig. 6 — 38EB Charging Chart

(AccuRaterT"'' System)

7. If unit has a higher suetion line temperature than charted temperature, add refrigerant until charted temperature is reached.

8. If unit has a lower suction line temperature than charted temperature, bleed refrigerant until charted temperature is reached.

9. If air temperature entering condenser or pressure at suction valve changes, charge to new suction

line temperature indicated on chart.

CHARGEMASTER® METHOD — Operate unit for 10 minutes before using Chargemaster (Carrier

Part No. 38GC680004).

1. Tape Chargemaster feeler bulb to suction line close to condensing unit. Insulate bulb. Ensure suction line is clean for good contact with bulb. (Uninsulated bulb or dirty suction line will seri

ously affect accuracy of temperature readings.)

2. Connect refrigerant drum to Chargemaster inlet

port keeping drum in position for vapor charging.

Table 6 — Refrigerant Charging Methods

METHODS OF CHECKING OR

COND UNIT

38EB System Refrigerant Control

ALL

‘Sight glass field supplied and installed In liquid refrigerant line.

ADJUSTING CHARGE

Non TXV j

Chargemaster® |

or 1

Charging Chart 1

TXV

Sight

Glass‘

METHODS FOR COMPLETE

System Refrigerant Control

Non TXV

Weight Method

plus

Chargemaster or

Charging Chart

RECHARGING

1 TXV

Weight Method

1 plus 1 Sight Glass*

Page 8

3. Connect Chargemaster outlet port to unit suction valve service port.

4. Crack valves on refrigerant drum and Chargemaster to purge lines from drum to suction valve. After purging lines, close valve on Chargemaster

only.

5. Measure outdoor air dry-bulb temperature.

6. Crack unit suction valve and read evaporator

temperature at red needle position on Chargemaster temperature gage and suction line tem

perature at black needle position.

1. Énter Chargemaster Charging Chart, Table 7, at

outdoor air temperature (step 5) and evaporator temperature (step 6). Find the suction line tem perature required for correct system charge. If actual suction line temperature (step 6) is higher than table value, the system is undercharged. If

suction line temperature is lower than table

value, system is overcharged.

EXAMPLE: At outdoor air temperature of 84 F

and evaporator temperature of 43 F, the system

will be correctly charged at 76 F ± 2 F suction line temperature. See Table 7.

8. Add charge by slowly opening Chargemaster valve. If necessary, reduce charge by bleeding at

liquid line service valve. Check outdoor air and

evaporator temperature during procedure. If they

change, refer back to Chargemaster Charging Chart.

Correct use of Chargemaster ensures that an opti

mum refrigerant charge will be in system when con

ditions and system components are normal.

However, the Chargemaster does not solve or fix system abnormalities. It indicates correct charge for condition of the system. It will not make corrections for dirty filters, slow fans, excessively long or short suction lines or other abnormal conditions. This charging device ensures that a correct relationship exists between outdoor temperature, evaporator temperature, and suction line temperature on a spe cific system.

SIGHT GLASS METHOD — (Field-supplied sight glass installed in liquid line.) A satisfactory oper ating charge can be obtained on thermal expansion valve systems only by charging to a clear sight glass. For optimum charge, increase high-side pressure to 380 ± 10 psig by blocking condenser fan discharge or air entering condenser. Charge to a clear sight glass while holding constant high-side pressure. For peak efficiency, adjust charge to yield a liquid refrig erant temperature at the evaporator that is approxi mately the same as outdoor dry-bulb temperature.

Table 7 — 38EB Chargemaster® Charging

Chart (AccuRater™ System)

OUTDOOR

TEMP

(F)

60 62 30 38 64 66 68 70 32 41 52 64 72 31 74 30 76 78 80 82

86 88 90 34 42 92 94 39 47 96 38 45 98 36

100 102 41 104 39 46 106 45 108 43 110 112

114

Example

EVAPORATOR TEMPERATURE (F)

2TT25l^l3TT34T37^

SucüônUnëT^^ (f )

28 27

37 35 34

29 27 26

51 3ê 47 60

54 67

39 50 61 37

48 46 56 66

44 54

35 33 42 32

375046

58 69

72 1

63 61 72 596568

53 51 49

44 42 49

ta ta

63 61 59 57

55 53 51

48 55

73 85 70

81 68 78 90 65 75 86

72 83

63 61

70 80 59 67 77 57 65 75

53 61 70

51 59 68 49 57 65 47

55 63

46 53

50 59

SERVICE

Compressor Removal — See Table 8 for com

pressor information and Fig. 7 for component loca tion. Shut off power to unit. Remove refrigerant

from unit using refrigerant removal methods de scribed in Carrier Standard Service Techniques

Manual, Chapter 1, Refrigerants. Be sure system pressure is 0 psig before attempting compressor removal.

■ Table 8 — Compressor Data

UNIT

38EB

015301 AJ8516G 018301 AJ8520G 024301

030301 036301 042361 AV5542E 048311 048351 PC5016BD 060351 PC6416AG

‘Refer to Carrier Service Parts Catalog for replacement model

numbers

fWhere piping exceeds 50ft, contact your local Carrier distributor

PRODUCTION

COMPR*

CRD1-0200PFV CRF1-0250PFV 55 CRJ1-0300PFV 55

YRD-0400-PFV 72

OIL CHARGE (oz)t

Initial Recharge

26 24 26 24 55 51

66 62 66 62

51 51

50 68

Page 9

SUCTION LINE HOT GAS DISCHARGE LINE

.CONDENSER COIL

\ \ £8í№mw Í

Fig. 7 — Condensing Unit 38EB Component Locations

Follow safety codes. Wear safety glasses and

work gloves. Have quenching cloth available.

COMPRESSOR

DISCHARGE GRILLE (FAN MOTOR UNDERNEATH)"

WIRE ACCESS OPENING

TOP COVER

FAN MOTOR AND COMPRESSOR

LEADS

1. Remove top cover by loosening 6 screws around unit and 2 screws in connector plate. Lift cover straight up.

2. Disconnect high- and low-voltage field wiring and fan motor leads from capacitor and contactor.

3. Remove 4 screws holding discharge grille in

place. Lift grille from unit.

4. Disconnect compressor leads (crankcase heater,

low-pressure switch, if so equipped) from elec trical components and pull them thru the wire access opening into the coil section. Lift fan orifice/control ring after pinching and pressing down on 3 plastic pins of tube supports.

5. Remove louvered casing by taking out 16 screws securing it to the cabinet and sliding it away from the coil.

6. Using a midget tubing cutter, cut liquid and

discharge lines on the coil and suction line at a convenient place for easy reassembly with copper slip couplings.

7. After plugging connections, remove condenser coil by pinching plastic pins of tube supports that extend into basepan and lift vertically. Set coil on a clean, flat surface.

8. Remove compressor holddown bolts and slide out compressor. Remove crankcase heater, if so equipped.

9. Carefully unbraze suetion and discharge line piping stubs from compressor after noting posi

tion of stubs to assist when reinstalling.

10. Install new compressor, placing crankcase heater around compressor, if so equipped. Be sure compressor holddown bolts are in place.

11. Replace coil; braze suction and discharge lines to compressor piping stubs (at points where cut. Step 6); rewire compressor and leak test.

12. Replace fan orifice/control ring; connect com pressor wires after feeding them thru control ring; replace fan/grille assembly and rewire; connect high- and low-voltage power wiring; and replace louvered casing.

13. Replace top cover by running screws into orifice

loosely and tighten when cover is in place.

14. Evacuate and recharge system.

Filter Drier — Install field-supplied filter drier

(Table 3) in system liquid line when refrigerant system is opened for serviee as described under Compressor Removal. Position drier in liquid line at convenient location.

Pumpdown Procedure — The system may be

pumped down in order to make repairs on low side without losing complete refrigerant charge.

1. Attach pressure gage to suction service valve gage port.

2. Frontseat the liquid line valve.

3. Start unit and run until suction pressure reaches 5 psig (see Caution).

4. Shut unit off and frontseat suction valve.

5. Vent remaining pressure to atmosphere.

Page 10

Unit Controls and Safety Devices

HIGH-PRESSURE RELIEF VALVE is located in compressor. Relief valve opens if system operating pressure differential between suction and discharge pressure reaches 400 to 500 psi on all models.

LOW-PRESSURE SWITCH (015 and 018 models only) is located on unit suction line. Low-pressure

switch settings are: cutout, 31 ±4psig; cut-in. 60

(+15, -0) psig. INTERNAL TEMPERATURE AND/OR CUR

RENT SENSITIVE OVERLOADS reset automati cally when motor internal temperatures drop to a safe level (overload may require up to 30 minutes to reset). When internal overload is suspected of being

open, check by using an ohmmeter or continuity tester. If necessary, refer to Carrier Standard Serv

ice Techniques Manual, Chapter 2, Electrical, for

complete instructions.

INHERENT FAN MOTOR PROTECTION pro

tects motor from abnormal current and temperature.

SOLID-STATE TIME GUARD II CIRCUIT, if so equipped, protects unit compressor by prevent ing short cycling. Time Guard II circuit provides a

5 ± 2-minute delay before restarting compressor after shutdown for any reason. On normal start-up, the 5-minute delay occurs before thermostat closes.

After thermostat closes, the Time Guard II circuit

then provides a 3-second delay to prevent contactor

chattering.

CRANKCASE HEATER (when equipped) — The

purpose of the heater is to keep the crankcase warm

during the off cycle and thus prevent dilution of

the oil with refrigerant. This assures good lubrica

tion and prevents loss of oil from crankcase during

start-up.

CRANKCASE HEATER RELAY deactivates heater when compressor is operating for maximum energy efficiency.

Compatible Fitting Repair

MECHANICAL CONNECTION — Frontseat unit service valves. Relieve refrigerant pressure from tubing. Back off locknut from Compatible Fitting onto tube. Cut fitting between threads and O-ring

as shown in Fig. 8. Remove tubing section remain ing in threaded portion of fitting. Discard locknut.

Clean, flux, and insert new tube end into remain ing portion of Compatible Fitting. Wrap valve base in wet rag. Heat and apply low-temperature (430 F) solder.

SWEAT CONNECTION — Frontseat unit service

valves. Relieve refrigerant pressure from tubing.

Clean and flux area around leak. Repair using low-

temperature (430 F) solder.

Evacuate or purge evaporator coil and tubing system. Add refrigerant charge. See Refrigerant Charging instructions described previously.

Condenser Fan Adjustment — Required fan

position is shown in Fig. 9. Adjust fan by loosening

setscrew(s) and moving fan blade up or down.

ÎtAAAAfAfVAWA'.

Fig. 9 — Condenser Fan Position

Condenser Fan Motor Removal

1. Shut off power to unit. Failure to do so may result in electric shock or injury from rotating fan blade.

2. Remove top cover by loosening 8 screws and lifting straight up.

3. Disconnect fan motor leads from control leads. See Fig. 7.

4. Remove 4 screws holding fan motor/discharge grille in place and lift assembly from unit.

5. Remove Carrier nameplate by straightening tabs.

6. Remove 4 nuts holding fan motor to discharge grille. Remove motor and leads.

7. Reassembly is reverse of above procedure. Make sure fan is positioned correctly as in Fig. 9.

Page 11

MAINTENANCE

-^Lubrication

COMPRESSOR contains factory oil charge. Re

place oil when lost. See Table 8 for oil recharge and

refer to Carrier Standard Service Techniques Manual, Chapter 1, page 1-21, for oil recharging procedure. Use Carrier PP33-1, Texaco WFI-32 or Suniso 3GS oil.

FAN MOTOR BEARINGS are prelubricated for 3 years heavy duty or 5 years normal duty. When lubrication is necessary, send motor to authorized motor repair shop.

^ Coil Repair — A flare-union coupling repair kit

is available, with instructions, thru Carrier Service

Parts.

Coil Cleaning to be done at the beginning of

each cooling season or more often if required.

5. Using garden hose, spray coil vertically down ward with a constant stream of water at moderate pressure (see Fig. 11). Keep nozzle at a 15 to 20 degree angle, about 3 in. from coil face and 18 in.

from tube. Spray so debris is washed out and

away from coil.

6. Reinstall louvered casing being careful not to damage coil.

7. Restore power to unit.

Follow iliese stì«€niciìom corttfoHy, Coniaci

1. Shut off power to unit.

2. Remove louvered casing by taking out 16 screws securing it to the cabinet and sliding it away from the coil.

3. Clean coil using vacuum cleaner and its crevice tool (see Fig. 10). Work crevice tool vertically making sure tool only touches dirt on fins. To prevent fin removal, do not “scrub” fins with tool

or move tool horizontally.

4. If oil deposits are present, spray coil with house

hold detergent (Fantastic, Lestoil, 409, or any similar type). Wait 10 minutes then proceed to step 5.

Fig. 10 — Crevice Cleaning Tool

Fig. 11

f n

Positioning Hose to Spray Coil

Page 12

TROUBLESHOOTING GUIDE

SYMPTOM AND

PROBABLE CAUSE

COMPRESSOR SHUTS OFF. FAN OVERLOAD

OR HIGH-PRESSURE SWITCH CUT OUT, OR

INTERNAL PRESSURE RELIEF OPENS

Condenser Fan On

1. Condenser air restricted or recirculating.

2. Refrigerant overcharge; noncondensables in

system; system restricted.

3. Improper line voltage, loose electrical connec tions, faulty run capacitor.

Condenser Fan Off

1. Fan slipping on shaft, fan motor bearing stuck, fan motor defective.

2. Loose electrical connections. Fan motor over

load open.

COMPRESSOR RUNS BUT COOLING IS INSUFFICIENT

1. Low refrigerant charge.

2. Dirty filters, partially restrict airflow (evaporator

coil may be partially iced).

High Suction Pressure

1. Defective compressor valves (accompanied by

low head pressure).

COMPRESSOR SHUTS OFF FROM LOW-PRESSURE SWITCH CUTOUT

Evaporator Fan Runs

1. Low refrigerant charge or restricted evaporator

air.

2. Restricted refrigerant flow.

' Evaporator Fan Stopped

1. Evaporator fan-motor defective or inoperative.

PROBABLE REMEDY

1. Condenser coil blocked. See Maintenance, Coil

Cleaning. Check airflow clearance (Fig. 1).

2. Review Refrigerant Charging procedures; purge system, replace filter drier, check refrigerant control.

3. Review Installation, Step 3; replace capacitor.

1. Tighten fan hub setscrews, see Condenser Fan

Motor Removal.

2. Check unit wiring. Check motor bearings. Re place motor.

1. Check Refrigerant Charging procedures.

2. Check evaporator air system for dirty filters, obstruction in ductwork, improper damper settings. Refer to coil, fan coil or furnace

instructions as applicable.

1. Perform Compressor Replacement procedure.

Recheck system charge.

1. See Compressor Runs But Cooling Is Insufficient

above regarding filters, ductwork, etc.

2. Check refrigerant flow device, be sure correct

AccuRater^^'^ or TXV is used.

1. Check furnace or fan instructions regarding de

fective fan relay, belt adjustment, condition of

motor bearings and overloads, check and tighten electrical connections, check power supply.

COMPRESSOR SHUTS OFF,

WILL NOT RESTART

Contactor Open

1. Burned out transformer, open thermostat circuit,

faulty control relay, open overload.

Contactor Closed or Closes Then Opens

1. Compressor power is out, compressor motor is burned out or internal overloads are open. Time Guard II circuit faulty.

For replacement items use Carrier Specified Parts

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

1 4

Book

Tab 3a 2a

Form38EB-3SI Supersedes 38EB-2S1,

38EB001and38EB002

1. Check control circuit components and wiring. Refer to unit label diagram, check all conditions. Refer to Standard System Techniques Manual, Chapter 2, Electrical.

1. Check main power supply wiring. Refer to Elec

trical Data table and label diagram. Substitute Time Guard II with a replacement to verify its

operation. Refer to Standard Service Techniques Manual, Chapter 2, Electrical.

Printed in U S A.

6-82

PC 101

Catalog No 533-879