Number One Ar Conditioning Maker
Installation, Start-Up "
c
c
O
Carrier Parkway • Syracuse, N Y 13221
Air-Cooled Condensing Units
INDEX
and Service Instructions
SAFETY CONSIDERATIONS
INSTALLATION........................................................1-6
Step 1 — Check Equipment and
Jobsite
................................................................
• 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 — Install Solenoid on Indoor
Coil Liquid Line Fitting......................................3
Step 4 — Make Electrical
Connections
.......................................................
• 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............................................................... 6-8
SERVICE.................................................................. 8-10 '
MAINTENANCE......................................................10-12
SAFETY CONSIDERATIONS
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 mainte
nance functions of cleaning coils and filters and re
placing filters. All other operations should be per
formed 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.
..................................
_________
Page
1
1
2
4
Follow all safety codes. Wear safety glasses and
work gloves. U se quenching cloth for brazing opera
tions. Have fire extinguisher available for all brazing
operations.
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. Check
factory supplied (field installed) liquid line solenoid
valve for shipping damage.
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.
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.
© Carrier Corporation 1983
Form 38ED-1SI
4'-0" OVERHEAD SPACE REQUIRED
FOR SERVICE AND AIRFLOW
l-t DIAM HOLE
FOR POWER
WIRING
Table 1 — Physical Data (Refer to Fig. 1)
036
MODEL 38ED
OPER WT (lb)
DIMENSIONS
Diameter A
Unit Height B
CONNECTIONS {in )
Suction (ODF)*
Liquid (ODF)*
REFRIG LINES (in )
Suction (ODF)
Liquid (ODF)
*For a IVs-in suction line on 38ED036,042,048,060, a %-in x IVs-in
suction valve connection adapter is available as an accessory See Table 3
024 030
018
167 190
2-2'%( 2-8% ¡3-1%
190
2-5%
3/4 1'/e*
042 048 060
246
223*
3/4
3/8
3/s
278
248
3-2«/„
2-8% ( 3-2Vb4
LIQUID VALVE SERVICE PORT
CONDENSER AIRFLOW
1-6 AIRFLOW
AND SERVICE
.CLEARANCE
SUCTION VALVE SERVICE PORT
Table 2 — Optimization Chart
(Outdoor air design temperature, db-F.
100 F and beiow)
MODEL
018
50
018
024
030
036
042
048
060
—
^63
-- —
—
___
- -
Factory-supplied piston Obtain replacement pistons thru local
Carrier distributor
ACCURATER™ PISTON NO
Evap Size (Coil or Fan Coil)
024 030
—
— —
— —
036
TXV
52
65
67
-
70
—
042-
__
TXV
78
-
-
048
TXV
W№
■ 84 S
— — —
— — —
060
TXV
80
m
28AR062
—
—
TXV
■i:-:-v86
♦CONCRETE PAD SHOULD WEIGH TO 2 TIMES WEIGHT OF UNIT
Certified dimension drawings are available upon request
Fig. 1 — Dimensions. Connections and
Mounting Pad (Refer to Table 1)
When evaporator is more than 2 sizes larger than
condensing unit (i.e. 38ED018I28HQ036), remove
AccuRater and use a bleed-type thermal expansion
valve (TXV) for refrigerant control. Size TXV to
nominal capacity of condensing unit.
Replace piston, only if required (Table 2), before
connecting refrigerant lines. Piston replacement in
structions are included in evaporator installation
book. After system installation is complete, use
Charging Chart to check and/or adjust refrigerant
charge.
Fig. 2 — AccuRater (Bypass Type)
Components
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).
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.
When 1-1/8 in. tubing is used (38ED036,042,
048,060) braze it to the accessory 1-1/8 x 3/4-in.
suction connection adapter (Carrier Part No.
28VQ900011) or to correctly sized field-supplied
adapter, then make Compatible Fittingconnections.
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.
PIPE
HANGER
LIQUID LINE
Fig. 3 — Refrigerant Line Hangers
INSULATION
0" THICK)
Use 1-1/8 in. suction line on 38ED036,042,048
and 060 systems. 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 38ED048 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 1.
CONNECT REFRIGERANT LINES to fittings on
condensing unit suction and liquid service valves
(Fig. 1). Unit Compatible Fittings permit mechan
ical (quick connect) or sweat connections.
Models 38ED036,042,048,060 — 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 eonnec-
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 Com
patible Fitting while tightening nut.
Sweat Connection — (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.
Step 3 — Install Solenoid on Indoor Coil Liquid
Line Fitting — Before making liquid line connec
tions, install factory-supplied solenoid on indoor
coil liquid line fitting. It is not necessary to flare the
system liquid line if an accessory flare-to-Compatible
Fitting coupler is used (refer to indoor coil installa
tion instructions. Accessory Flare to Compatible
Coupler).
See Fig. 4 and install as follows:
1. Remove coil liquid line cap and discard.
2. Attach field-supplied flare fittings to solenoid
valve straight 3/8-in. stubs.
Fig. 4 — Solenoid Installation
Connect solenoid to tube assembly, making sure
3.
solenoid flow arrows point towards indoor coil.
Mount solenoid in any position except valve
body at top and electric coil at bottom (see Fig. 4).
Tighten flare nuts.
4.
Wire coil into system control circuit as shown in
5.
Fig. 5.
Step 4 — 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.
Table 3 — Accessories
PART NO.
HH01AD040
HH93AZ040
HH51AR001
HH07AT170
HH07AT174
HH93AZ176
HH01AD042
HH93AZ042
38VH90000106
38GS900102
HT01AW230
09WQ036.060
38GS900321
28VQ9000112
TUBING
PACKAGES
38LS934151
38LS934201
38LS934251
38LS934301
38LS934351
38LS934401
38LS934501
38LS978151
38LS978201
38LS978251
38LS978301
38LS978351
38LS978401
38LS978501
*For 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)
fSuction line is insulated and has a 90 degree bend at one end
Low-Voltage Control — Honeywell Deluxe Thermostat
Thermostat Subbase
Comfort Control Center (Use with HH01AD040)
Low-Voltage Control — Honeywell Thermostat
Thermostat Subbase (with Automatic Changeover)
Low-Voltage Control — Honeywell Thermostat
Thermostat Subbase
Thermocharger™ Replacement Unit Module (Six 38VH900001)
Indoor Fan Relay (Six HN61KJ210)
Low-Voltage Transformer (60va) — Available thru Carrier Service Parts
Refrigerant-to-water heat exchanger for chilled water systems
Liquid Line Filter Drier (Six 38GS900332)
Twelve % X IVs-in suction connection adapters
Liquid
Length
(ft)
15
20 3/8
25
30 3/s
35 3/8
40
50 3/s
15 3/8
20 3/8
25
30
35 3/8
40 3/8
50 3/8
OD
(in.)
ys 3/8 3/4 3/4 3/4
3/s
3/8
3/s
3/s
DESCRIPTION
TUBING*
Suctiont
Tube End
OD (in.)
3/8
3/8
3/8
3/8
ya
ya
3/8 3/8
ya
3/8
3/8
3/8 3/8 3/4 3/4
3/8
3/s
OD
(in.)
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
3/8 3/4 3/4
3/8
3/8 3/4 3/4
3/8
3/8
NOTES;
Do not cut ys-in OD liquid line to a length shorter than 10 feet
1
Do not cut ya-in OD suction lines
Field-supplied IVs-in suction line is recommended on 38ED
036,042,048 and 060 If accessory tubing package is used, a
capacity reduction can result
Tube End
OD (in.)
Evap Cond
3/4
3/4 3/4
3/4 3^
3/4 3/4
MODEL 38ED
All
042,048,060
MODEL
38ED
3/4
3/4
3/4
3/4
3/4
036,042,
048,060
(See Note 2)
1.,
THERMOSTAT SUBBASE
HH93AZ042 OR
HH93AZ040
TRANS
MIN 60VA
THERMOSTAT
SUBBASE
HHAZ93I76
RH
TRANS
___
ARRANGEMENT A — COOLING ONLY
THERMOSTAT SUBBASE
HH93AZ042 OR
HH93AZ040
TRANS
—
RC
ARRANGEMENT C — ONE TRANSFORMER,
COOLING AND TWO-STAGE HEATING
-------
1
ARRANGEMENT B — ONE TRANSFORMER,
COOLING AND ONE-STAGE HEATING
Fig. 5 — 24-Volt Control Circuit Connections
Table 4 — Electrical Data (60 Hz)
MODEL
38ED
V/PH
OPER
VOLTS*
Max
Min
018
024
030
036
208-230/1
254 197
042
048
207 130 0 27 8
060
230/1
254
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
COMPR
LRA
43 0
54 0
65.0
78 8 13 5
95 0 19 7
116 0
RLA
7 8
11 5
13 7
23 7
-A J
FAN
FLA
1 1
1 7
NOTE Refer to unit label wiring diagram for wire colors
IFR, IFM and LLS are located indoors on heating-cooling
applications If accessory IFR is required for cooling-only
applications, locate IFR in fan coil
C — Contactor
HC — Heating Control
IFM — Indoor Fan Motor
IFR — Indoor Fan Relay
LLS — Liquid Line Solenoid Valve
NC — Normally Closed
Trans — Transformer
BRANCH CIRCUIT
Min Wire
Sizef
(AWG)
14 32
12
12 31
12 31
10
8 44
8 38
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 24 v on all units and requires external
power source
Max
Ft
Wiref
37
34
Min Ground
Wire
Size}
14
12 25
12
12
10 45
10 50
10 60
Max Fuse or
HACR Type
Ckt Bkr Amps**
15
30 18,2
30
MCA
10 9
15 5
18.0
26 3
31 3
36.5
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.
See Fig. 6. Splice line power leads to yellow and
black pigtails. Use wire nuts and tape at each con
nection. Connect unit wiring to copper or copper-
clad aluminum power wiring. Do not connect to
aluminum wiring.
■
-------
GROUND LEAD-KDGROUNDING LUG
I-PHASE
CONN. TO
DISCONNECT
PER NEC
Splice Connections
Field Wiring
Factory Wiring
Fig. 6 — Line Power Connections
BLK
-----------
-YEL-
I-PHASE
CONO UNIT
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 a furnace or fan coil transformer as 24-v
(60-va minimum) supply for system as shown in Fig. 5
or use accessory transformer shown in Table 3).
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
temperature.
4. Energize electrical disconnects for entire system.
5. Set room thermostat at COOL and fan switch at
FAN or AUTO, as desired. Operate unit for 15
minutes; then cheek system refrigerant charge.
See Refrigerant Charging, this page.
Motors and controls are designed to operate satisfaetorily 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 eharge.
Refrigerant Charging
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 acces
sory 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:
.4 lb 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 5. Details of charging methods are listed
below.
Before recharging system, thoroughly evacuate
system and then weigh in refrigerant charge speci
fied in Table 6. Check or adjust charge as required.
Refer to Carrier Standard Service Techniques
Manual, Chapter 1, Refrigerants, for additional
system evacuation and dehydration instructions.
WEIGHT METHOD — Refer to Table 6 or unit
nameplate for correct system refrigerant charge.
Remove any refrigerant remaining in system before
recharging.
When system is not evaeuated, subtract the
following amount from total charge.
38ED018 thru 036 — .10 lb (1.6 oz)
38ED042 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. 7, and the following procedure.
1. Operate unit a minimum of 10 minutes before
checking charge.
Table 5 — Refrigerant Charging Methods
METHODS OF CHECKING OR
MODEL
38ED
ALL
'Sight glass field supplied and installed in liquid refrigerant line
ADJUSTING CHARGE
System Refrigerant Control
Non TXV
Chargemaster®
or
Charging Chart
Table 6 — Service Data
MODEL
38ED
018
024
030
036
042
048
060
'Factory refrigerant charge is adequate when evaporator and con
densing unit are the same size and are connected with 25 ft or
less of field-supplied tubing of recommended size or Carrier
accessory tubing
R-22 CHARGE*
(lb)
6 5
74
7 6
8 5
90
8.0
10 2
CONDENSER
FAN RPM
830
840
(AccuRater™ System)
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.
TXV Non TXV
Weight Method
Sight
Glass*
plus
Chargemaster or
Charging Chart
5. Refer to Charging Chart (Fig. 7). Find air tem
perature entering condenser and project hori
zontally to curve showing suction pressures
(psig at suction valve).
6. From this intersection, project vertically down
ward to suction line temperature.
7. If unit has a higher suction 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.
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.
7. Enter 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
METHODS FOR COMPLETE
RECHARGING
System Refrigerant Control
TXV
Weight Method
plus
Sight Glass*
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 85 F
and evaporator temperature of 44 F, the system
will be correctly charged at 60 F ± 2 F suction
line temperature. See Table 7.
Table 7 — 38ED Chargemaster Charging Chart
(AccuRater™ System)
SATURATED EVAPORATOR TEMPERATURE (F)
60 60
65
70
75
80
90
95
I Example
34 36
49 58 65
41
35 41 48
32
38 40
48 58 68
36; 42 50 59; 80
42
Suction Line Temperature (F)
58
■
7é;:
6g;
42
48 53 59 67
46 48 50 52 54
82
71
61 69 78
52
44 53
79
58
68 88
60 75 104
49 54
56
65
80
69
TEMP
(F)
100 43 47
105
110
115 50 62
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 Charg
ing Chart.
Correct use of Chargemaster ensures that an opti
mum refrigerant charge will be in system when con
ditions and system components are normal. How
ever, the Chargemaster does not solve or fix system
abnormalities. It indicates correct charge for condi
tion of the system. It will not make corrections for
dirty filters, slow fans, excessively long or short suc
tion lines or other abnormal conditions. This charg
ing device ensures that a correct relationship exists
between outdoor temperature, evaporator tempera
ture, and suction line temperature on a specific
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.
SERVICE
Compressor Removal — See Table 8 for com
pressor information and Fig. 8 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.
ACCUMULATOR CONDENSER COIL
COMPRESSOR
(SOUND SHIELD
REMOVED)
Fig. 8 — Component Locations
8
DISCHARGE GRILLE
(FAN MOTOR UNDERNEATH)
(TOP COVER AND LOUVERED CASING REMOVED)
Table 8 — Compressor Data
MODEL
38ED
018
024
030
036 AV5532H 54 50
042
048
060 PC60
numbers
fWhere piping exceeds 50 ft, contact your local Carrier distributor
PRODUCTION
COMPRESSOR*
AB5515H
CRC-1
CRE-1
AV5538E
AV5546E
OIL CHARGE (oz)t
Initial Recharge
32
55 51
55
54 50
54 50
66 64
30
51
Follow safety codes. Wear safety glasses and
work gloves. Have quenching cloth available.
1. Remove top cover by loosening screws around
unit and 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 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 eoil.
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.
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 easing.
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 service 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.
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.
Remove compressor holddown bolts and slide
8.
out compressor. Remove crankcase heater, if so
equipped.
9. Carefully unbraze suction and discharge line
piping stubs from compressor after noting posi
tion of stubs to assist when reinstalling.
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 ± 4 psig; cut-in, 60
(+15, -0) psig.
COMPRESSOR INTERNAL TEMPERATURE
AND/OR CURRENT SENSITIVE OVER
LOADS reset automatically 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 Service 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,
protects unit compressor by preventing 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 — 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 lubrication and pre
vents 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. 9. Remove tubing section remain
ing in threaded portion of fitting. Discard locknut.
Clean, flux and insert new tube end into remaining
portion of Compatible Fitting. Wrap valve base in
wet rag. Heat and apply low-temperature (430 F)
solder.
Condenser Fan Adjustment — Required fan
position is shown in Fig. 10. Adjust fan by loosening
setscrew(s) and moving fan blade up or down.
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 screws and lift
ing straight up.
3. Disconnect fan motor leads from control leads.
See Fig. 8.
4. Remove Carrier medallion by turning 4 Tinnerman fasteners 1/4 turn each.
5. Remove screws holding fan motor/discharge
grille in place and lift assembly from unit.
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. 10.
Fig. 10 — Condenser Fan Position
MAINTENANCE
Fig. 9 — Repair of Mechanical Connection
SWEAT CONNECTION — Frontseat unit service
valve. 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.
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, from Carrier Service
parts.
Coil Cleaning to be done at the beginning of
each cooling season or more often if required.
10
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. 11). 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.
5. Using garden hose, spray coil vertically down
ward with a constant stream of water at moderate
pressure (see Fig. 12). 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.
Fig. 11 — Crevice Cleaning Tool
Fig. 12 — Positioning Hose to Spray Coil
11
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
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
Condenser coil blocked See Maintenance, Coil
Cleaning Check airflow clearance (Fig 1)
n
Review Refrigerant Charging procedures, purge
system, replace filter drier, check refrigerant
control.
Review Installation, Step 4; replace capacitor.
3.
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
Check control circuit components and wiring.
Refer to unit label diagram, check all conditions.
Refer to Standard Service Techniques Manual,
Chapter 2, Electrical.
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
Book 1 4
Tab 3a 2a
Form38ED-1SI New Printed in U.S.A
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
1-83 PC 101
Catalog No. 563-822
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