Carrier 38GS User Manual

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Page 1

Number One Airconditioning Mater

Syracuse New York

Air-Cooled Condensing Units

g DIAM KOS FOR CONTROL WIRING

SUCTION LINE CONN

SUCTION LINE VALVE

4'-0" OVERHEAD SPACE REQ'D FOR SERVICE AND AIR FLOW

3 -0 (BOTH SIDES)

LIQUID LINE VALVE

LIQUID LINE CONN

CONCRETE

MOUNTING

TRANSPORTATION DAMAGE

File claim with shipping company if shipment is

damaged or incomplete.

Unpackaging Unit — Move condensing unit to final

location. Open carton at end marked “compressor end.” Slide unit from carton taking special care to not damage service valves or grilles.

PRELIMINARY SURVEY

Consult local building codes and National Electrical Code (NEC) for special installation requirements.

When installing unit, allow sufficient space for air flow clearance, wiring, refrigerant piping and servicing unit. Position unit so water from roof or eaves does not flow directly on top of unit.

Install unit on a solid, level mounting pad. Unit can be attached to pad with a mastic adhesive or

by drilling holes in base pan for 1/4-in. mounting bolts. Do not block base pan water drainage holes.

38GS,CC,CE Condensing Units Connected to Carrier Matched Evaporators with Carrier Acces

sory Tubing — Check system refrigerant charge

when tubing lengths are above or below 25 feet. See Refrigerant Charging (page 10) for details.

Fig. 1 — Dimensions, Connections and Mounting Pad

38GS,CC,CE Unit

Table 1 — Installation Data

38GS

014

COND UNIT 38CC

OPER WT (lb) 130 135 UNIT DIM. (ft-in.)

Length A

Width B

Height G

REFRIG CONN.(in.)

Suction (ODF)

Liquid (ODF)

*5/8-in suction connection on 38CE002

t38CE045,005 and 38GS.CC060 are factory supplied with 3/4- to

1 1/8-in suction valve adapter (field installed) for 1 1/8-in

suction line

38CB

- - -

'l-4

% lYsT '/b I

018

1-4

024

142|149

Com

036 042

030 030 036 002* 003 004 045 005

158 191

2-10V4

1-10

1-4 1 1-4 (2-0

DOtible Fittings

048 060t

042 048 060t

193 200

----

2-0 2-0

-----

'/4t

38GS,CC,CE Condensing Units Connected to NonCarrier Evaporators — Check refrigerant charge

when condensing unit is added to a system in which other than a Carrier approved evaporator is being used or where the evaporator has been previously installed. Field-supplied refrigerant pip ing must be in accordance with Field-Supplied Piping Data, Table 3.

Where indicated on Table 3 for 38GS,CE units,

install a liquid line filter-drier and accessory crank case heater on condensing unit. (Filter-drier is factory supplied on CE045,005 units.) Accessory start capacitor and relay also required on 38GS

units, but not normally required on 38CE units.

See Compressor Service (page 7). All above items are standard or not required for 38CC units.

Use an evaporator coil with a bleed-type ex pansion device. If coil does not have a bleed-type expansion device it may be necessary to add an accessory start capacitor and relay to condensing unit. This would require removing compressor start

thermistor (PTC device) on units so equipped.

Form 38GS-13SI

Page 2

Table 2 — Accessories

PART

NUMBER

HH01AD040 HH93AZ040

JHH51AR00J[^

HH07AT070, HH07AT074 H N93^076

HH0iAD042”

HH93AZ042 HH01YA092

HH_93_YZ094 32LT900301

(200-3 Ph) 32LT900601 (460-3 Ph)

38GS900102 38GS900212

38GS900112 38GS900292

38GS900172 38GS900182

38GC900031 10 38GC900071 10 38GC900041 38GC900081 38GS900221 38GC900091 38GC900061 35

38GC900101 38GC900191 50 % 38GC900ni

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

Low-Voltage Control — Grayson Thermostat Thermostat Subbase

Solid State Head Pressure Control

Indoor Fan Relays (^¡x HN61KJ210)

40VA Low-Voltage Control Transformers (24 V - Six 38GS900Q9])

Crankcase Heaters (Six 38GS900131)

Crankcase Heaters (Six 38GS900281) Start Capacitor and Relay Package (Six 38GS900041) Start Capacitor

Tubing Pa

Liqui d

Lgth

(ft)

18 18 25 25

(in.)

r 5/^

% % % : %

Tube End

OD (in.)

DESCRIPTION

and Relay F^ackage (Six 38GS900051

ckages

Suction*

(in.)

^8 ^8

y« , % %

T ubeODFnd

in.)

Evap

^8 % 1 % % ^8 %

I V4t

Cond

^41 I

%t % % ^/4 %t

y —

/4 k4

38CC — (Fan motor suitable for 32LT)

38GS

014,018,024

3/ H

030,036,042,048

014,018,024

030,036,042,048 014,018,024 030,036,042,048 014,018,024

=/8

030,036,042,048

014,018,024 -

030,036,042,048

USAGE

38GS,CC,CE

38GS,CC,CE 38GS,CC,CE

38GS (except 38G5014), 38CE

38GS0Ì4

38GS (except 38GSÒ42), 38CE

38GS042

UNIT

38CC

030,036,042,048

38CE

002

003,004,045,005

002

003,004,045,005

002

“0Ü3%O470457O0r^

002 003,004,045,005 002 003,004,045,005

*AII suction lines have a 90° bend at one end

tForb/8-in evaporator connection, cut off 3/4-in end

PIPING CONNECTIONS

Condensing units can be connected to evap orator sections using Carrier accessory tubing package or field-supplied tubing of refrigerant grade. (Accessory tubing not available for 38GS060, 38CC060.) See Table 2 for accessory tubing sizes and Table 3 for recommended fieldsupplied tubing sizes. Where evaporator is 20 ft or more below condensing unit, reduce liquid line size one diameter (min 1/4-in. OD).

A capacity reduction will result if accessory tubing is used in 38CE045,005 systems. For example, when a 25 ft accessory tubing package is used, there will be a capacity reduction of 3 3/4% on 38CE045 and 5% on 38CE005 systems. For maximum capacity from these systems, use tubing sizes shown in Table 3.

When other than 25 ft of interconnecting tubing is used, follow special requirements de scribed in Refrigerant Charging. Do not use less

than 10 ft of liquid line. Do not cut 5/16-in. or

1/4-in. liquid line. Bend or coil to fit.

Do not use damaged or contaminated tubing. If accessory tubing package or evaporator section has been open for more than 15 seconds per connec tion, evacuate or purge evaporator coil and tubing system (use field-supplied refrigerant, not unit refrigerant). Always evacuate or purge if fieldsupplied tubing is used.

Before Connecting Unit Piping, consider the

following: 38CE045,005 AND 38CC UNITS - A filter-drier package is shipped with these units. Included with

filter-drier are 2 short length tubing assemblies that are equipped with flare and/or Compatible Fit

tings. Use tubing assemblies to install filter-drier into system liquid line at evaporator or condensing unit. See Fig. 2. Connect tubing assembly A (90°

assembly) to evaporator or condensing unit liquid line Compatible Fitting. Complete the filter-drier installation as shown.

Page 3

Table 3 — Field-Supplied Piping Data

MAX COND

COND

X-

f 3 UNIT

38GS014, 38GS018

38GS024

38GS030, 38CC030, 38CE002

38GS036, 38CC036, 38CE003

38GS042, 38CC042, 38CE004

38GS048,

38CC048

38CE045

38GS06 0, 38CC060, 38CE005

Cap. Tube TXV

NOTES

REFRIG

CONTROL

TXV

Cap. Tube

AccuRater'*'^

TXV

Cap. Tube

AccuRater

Cap. Tube

AccuRater

TXV

Cap. Tube

AccuRater

TXV

Cap Tube

AccuRater

TXV

Cap Tube

AccuRater

TXV

Cap. Tube

AccuRater

L^y

Cap. Tube

AccuRater

Crankcase heater and liquid line filter-drier required on 38GS and 38CE units Accessory start capacitor

with relay also required on 38GS unit, but not

normally required on 38CE units See Compressor Service Reduce liquid line diameter by 1/8-in OD

(min 1/4-in OD) when evaporator is 20 ft or more

below condensing unit

■ Capillary Tube

- Thermal Expansion Valve

1 The following system modifications are required adjust

refrigerant charge on systems with over 25 ft separation

UNIT HT (ft)

Above

Evap

150

90 ■

150

Be low

Evap

90 50 %

25- 50 51» 7S 7&~ 1

Suet Liq

'8 V» 'x iiiiii lili

IV»

V» T

V»

% liM

% Iliiii

V»

REFRIGERANT LINE LENGTH (ft)

Line Diameter (in* OD)

IIBI

ilM

iiiiiiiiiii

wmmmmmmm

N s

T %

between condensing unit and evaporator (See Refrigerant Charging ) Adjust system oil charge as described in Note 2 Oil charge adjustment add 1% of nominal oil charge in system (Table 7) for each 10 ft of refrigerant line length above 50 feet Eor example, a system that has a 50-oz oil charge with 1 50 ft of interconnecting piping requires 5 oz of additional oil as shown below:

iÄiii

ISl

150 ft - 50 ft = 100 ft 100 ft -E 10 ft = 10 ft

Litj 1 LEíj

iiiiii

■

ilBi %

■

11»

Äiii

10x1% = 10% ( 10)

10 X 50 oz = 5 oz

Do not permit condensing unit to short cycle, particularly on applications with long vertical line lengths Correct short cycling condition immediately

¡Mil

Í.

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

Connection Procedure — When making tubing

connections, be sure to provide clearance at unit for electrical connections.

Connect refrigerant liquid and suction lines to condensing unit, Fig. 1. Unit Compatible Fittings permit 2 methods of refrigerant line connection; mechanical (quick connect) or sweat connection. Make suction line connection first.

38CE045,005, 38GS060 AND 38CC060 UNITS Remove suction line adapter taped to compressor suction line. Connect 3/4-in. end of adapter to unit suction line Compatible Fitting. Sweat connect refrigerant suction line to 1 1/8-in. end of adapter. Connect liquid refrigerant line to unit.

MECHANICAL CONNECTION (Mate one set of connections at a time.)

1. Loosen nut on Compatible Fitting one turn. Do not remove. Remove plug and be sure 0-ring is in the groove

inside the Compatible Fitting. Cut tubing to correct length.

3. Use gage on tag attached to service valve to

4. mark tube end for correct insertion depth. Insert tube into Compatible Fitting until it

bottoms. (Tube should be inserted at least as far as mark on tubing.)

Tighten nut until it bottoms on back coupling

5. flange.

Page 4

Fig. 2 — Filter-Drier Assembly Installation (38CC, 38CE045 and 005)

SWEAT CONNECTION (Use refrigerant grade

tubing.)

1. Remove locking nut, rubber 0-ring and Schrader core from valve.

2. Cut tubing to correct length.

3. Insert tube into Compatible Fitting. Wrap top and bottom of service valves in wet cloth to prevent damage by heat. Solder with low temperature (450 F) silver alloy solder.

4. Replace Schrader core.

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

ELECTRICAL DATA AND WIRING

Field wiring must comply with local and

national fire, safety and electrical codes. Voltage to unit must be within ± 10% of voltage indicated on

nameplate. Contact local power company for correction of improper line voltage.

of ifolt ois tmpro|>er Ime

When making electrical connections, provide clearance at unit for refrigerant piping connections. See Table 4 for recommended wire and fuse sizes.

Install a Branch Circuit Fused Disconnect of

adequate size to handle unit starting current. Locate disconnect within sight of and readily accessible from the unit, per section 440-14 of

National Electrical Code (NEC).

Bring Line Power Leads Into Unit — Extend leads

from fused disconnect thru hole provided in service embossment (Fig. 1) and thru 7/8-in. hole into control box.

Connect Ground Lead to a Ground Lug in Control

Box for safety. Connect power wiring. See Fig. 3.

Splice line power leads to red and violet pigtails on 38GS,CE units or to yellow pigtails (3) on 38CC

units. Use wire nuts supplied with unit. Tape each

connection. Wire nuts are suitable for copper or aluminum wire since they contain joint compound.

Control Power (24 v) wiring is brought thru hole in

service embossment and spliced to yellow pigtails on all units. See Fig. 4.

Furnace or fan-coil transformer must be used as

24-v supply for system as shown in Fig. 4 (At least

a 40-va transformer is recommended.) Current 38GS048,060 and 38CC048,060 units are equip ped with a low-voltage transformer used to power contactor thru unit control circuit. This trans former must not be used for powering the indoor thermostat control circuit.

Page 5

I-PHASE CONN. TO FUSED DISCONNECT

3-PHASE

CONN. TO

FUSED

DISCONNECT

SPLICE

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

FACTORY WIRING

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

FIELD WIRING

—

--I3D GROUND LUG 386S,CEC0NDUNIT

-YEL-

-------I3D GROUND LUG

38CC CONO UNIT

Fig. 3 — Line Power Connections

THERMOSTAT SUBBASE

THERMOSTAT SUBBASE HH93AZ076

(COOLING ONLY)

THERMOSTAT SUBBASE HH93AZ042 OR

ONE TRANSFORMER

(COOLING AND ONE-STAGE HEATING)

^CONNECT FS TO LOW-SPEED INDOOR FAN TERMINAL

WHEN 2-SPEED FAN IS USED

IFR, FS and IFM are located in furnace on heating-cooling applications If accessory IFR is required for cooling only applications, locate (IFR) in fan coiI

ARRANGEMENT C-

ONE TRANSFORMER

(COOLING AND 2-STAGE HEATING)

^CONNECT FS TO LOW-SPEED INDOOR FAN TERMINAL

WHEN 2-SPEED FAN IS USED

Fig. 4 -- Control Circuit Connections

Control Relay (10 va) or Contactor Fan Switch Heating Control I ndoor Fan Motor I ndoor Fan Relay Transformer

Field Splice

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

Field Wiring

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

Page 6

Table 4 — Electrical Data

030 036 036 042 042 042 048 048 048 060 060 060

___ ___ ___ ___ ___

___ ___ ___ ___ ___ ___ ___

200/230/3 253

460/3 506 200/3

230/3 253 460/3 506 200/3 230/3 253 460/3 200/3

230/3

460/3 506

220 180 92

220

506 220 253 207

38CE 002 003

___ ___

230/1 253 230/1

253

004___ 230/1 253 045 005

___ ___

230/1 253 230/1 253

180 180 80/70 414

207 414 46

180 90 207 78.5 414 39 3

180

414

207 65 207 82 207 207 88 23.9 207 100 27.9

70/60

13 0/11 5 14 0/12 6

100

~88 19.8

6 5 17 0 15 8

7 8 18 6

16.1

8 3 23 0 20 5 10 3

10.3 16 8

FAN

FLA

2.4 14

2.1 2 4

2,4

.........

2 1

2.1 14 2 4

2.4 10 2 1

2.1 2 4 8

2.4 2 1 10

2.1 10 36 2 4 8

2.4 2 1

2.1

2.1 8

2.1 2 1

2 0/2 .0

2 0/2 0

1.0 2 0 2 0

1 0 14

2 0

2.0

1 0 14

2.0 8

2 0 10 1 0 14

2-.1

2 1

2.1

2.1 10 31 55 2 1

___12______

BRANCH CIRCUIT

Wire Sizef

(AWG)

14 12

12 36 25

12 31 30 12 31 30

10 10 33 50

8 6

12 14 91 10 49 10 58

10 10

12 10 10 36

Max

Wiref

40 33

..37

..........

40 35

45 50 45

44 36

41 42

49 45 30/30

100

46 60

100 20

'■ 67 50

1 74

42 42

42 60

Fusei Amps

20 20 30

25 35

30 45

55 65

65 55 75

30/25

15 35 35

15 40 35

25 35 45

FLA — Full Load Amps LRA — Locked Rotor Amps

______Electrical data shown applicable to all units for

which complete model number is not shown

•Permissible limits of the voltage range at which the units will operate satisfactorily

START-UP INSTRUCTIONS

If unit is equipped with crankcase heater, energize heater a minimum of 24 hours before starting unit To energize heater only, set thermo

stat at “Off” position and close electrical dis

connect to condensing unit.

Units with Time Guard® circuit or solid state time-delay may not start for approximately 4 to 5 minutes after thermostat closes. See compressor controls, pages 7 and 8.

Start Procedure

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

(■Copper wire sizes Aluminum field wiring may be used when splice-

connected to copper pigtails from unit with factory-supplied wire nuts

Use latest National Electrical Code for aluminum wire sizing

^Maximum dual element fuse size

NOTE Control circuit voltage is 24 volts on all units

ov«rtii^i<?n servkc

4 Do exscod

6 fi-lb lorquc »hen

iighiiiiing.

2. Set thermostat selector switch at "Off.”

3. Set room thermostat at desired temperature.

4. Close electrical disconnects energizing entire system.

5. Set room thermostat at “Cool” and fan switch

as desired (“Fan”) (“Auto.”).

Check system refrigerant charge. See Refrig

erant Charging.

Motors and controls will operate satisfactorily

in a range from 10% above to 10% below nominal unit voltage (Table 4).

Page 7

Do not connect charging hoses to capillarycontrolled system during initial start procedure. (Loss of charge from this procedure may result in capacity reduction.) If necessary to add manifold

f • gages for servicing, refer to Carrier Standard

Service Techniques Manual, Chapter 1, pages 1—5, Fig. 8, for bypass method of returning charge to

system. (A charging hose valve must be used to accomplish bypass of refrigerant on all units.)

Table 5 — Service Data

CONO

UNIT

38GS014 38GS018 38GS024 38GS030 38GS036 38GS042 4-12 38GS048 5- 3 38GS060

38CC030 3- 2 38CC036 38CC042 3-12 38CC048

38CC060 5- 3

38CE002

38CE003 38CE004 5- 2

38CE045 38CE005

"■Factory refrigerant charge adequate for complete system when

connected to Carrier approved evaporators mat are the same size as condensing unit, with 25 ft of tubing

R-22

CHG*

(lb—oz)

3- 0 2600 3- 0 3- 0 3- 2 3-M

5- 3

3-14

5- 3

4- 7

4-11

5- 6

5-11

CONDENSER

Rpm

1060 17/2

1070/870

975/800

Diam

COMPRESSOR SERVICE

Unit Single-Phase Compressors of the Split Capaci

tor (PSC) Type require an equalized system pres

sure to start. When supply voltage is within 10% limit and compressor does not start, give com pressor a temporary capacitance boost. See Carrier Standard Service Techniques Manual, Chapter 2, for details. Use a 130-mfd start capacitor. Connect wires with insulated probes to each capacitor terminal. Touch probes to each side of run capacitor or to compressor motor terminals R and S. Start compressor; pull probes away after 3

seconds. Discharge start capacitor. Run compressor

for 10 minutes, then shut off and allow system pressure to equalize. Try restarting without boost capacitor. If after 2 attempts (without boost capacitor) the compressor does not start, add an accessory start capacitor relay package.

Unit Single-Phase Compressors That are Equipped

With a Compressor Start Thermistor (PTC device);

if compressor will not start, check the thermistor

with an ohmmeter as described below. (If evap orator coil does not have a bleed-type expansion device, it may be necessary to remove PTC device and replace with accessory start capacitor and relay.)

(in.)

17/2

FAN

2600/2100

2600/2100 2800/2300

2700/2200 2700/2200

Cfm

2600 2600 2600 2600

2800 2800

2800

2600 2600 2800 2800 2800

CHECKING START THERMISTOR

1. Shut off all power to unit and wait 5 minutes for thermistor to cool to outdoor temperature.

2. Measure resistance of thermistor with ohmmeter. Normal resistance readings are 50 to 90 ohms at 75 F outdoor temperature.

3. If ohmmeter resistance reading is 0 or much higher than 90 ohms the thermistor is defective

and must be replaced.

If start thermistor is good and compressor will

not start, disconnect the thermistor from starting circuit and give compressor a temporary capaci tance boost as described above. Run compressor for 10 minutes, then shut off and allow system pressure to equalize. Reconnect start thermistor and try restarting compressor without boost capac itor. If after 2 attempts the compressor does not start, remove thermistor and add an accessory start

capacitor relay package.

38CC Units — Compressor start capacitor and relay

or thermistor (PTC) are not required on 3-phase 38CC units.

Safety Devices — Refer to Table 6 for particular

safety controls that each unit is equipped with.

Table 6 — Compressor Safety Controls

SAFETY CONTROLS

INTERNAL CURRENT-

TEMP SENSITIVE OVERLOAD

INTERNAL THERMO

(Pilot Duty)

LOW-PRESS. SWITCH

HIGH-PRESS. SWITCH

CRANKCASE HEATER Accessory

OUTDOOR FAN

THERMOSTAT TIME GUARD® CPCS

SOLID STATE TIMER

CPCS

Compressor Protection Control System

38GS

014,018 024,030

036,042,048

060

ENSING 1

030,036, 042,048

030, Ò3C

042,048,

030,036, 042,048.

030,036,

048,060 -

38CC ^

060

042

NITS

38CE

002,003, 004,045,

005

Accessory

002,003, 004,045,005

045,005

COND

UNIT PROTECTION

Internal Current And Temperature Sensitive Over

loads reset automatically when internal motor

temperature drops to a safe level (overloads may require up to 30 minutes to reset). When an 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, for complete instructions.

Page 8

Low-Pressure Switch is located on unit suction line

and resets automatically. Low-pressure switch set tings are: cutout, 31+4 psig; cut-in, 60 (+ 15, - 0)

psig.

High-Pressure Switch is located on unit liquid line

and resets automatically. High pressurestat settings are; cutout, 425 ± 5 psig; cut-in, 320 ± 20 psig.

Crankcase Heater warms compressor crankcase.

Prevents refrigerant dilution of oil in crankcase.

Outdoor Fan Thermostat maintains proper con

densing temperature at high outdoor temperatures by switching fan to high speed. Located in control box (on 38CE).

Filter-Drier is installed in liquid line.

Time Guard® Circuit provides for a 5-minute delay

before restarting compressor after shutdown for

any reason. On normal start-up the Time Guard timer causes a delay of 15 seconds after thermostat closes before compressor will start. On compressor shutdown, the timer recycles for 4 minutes, 45 seconds. During this time the compressor cannot start.

Solid State Time Delay provides for a 4-minute

delay before restarting compressor after shutdown for any reason. On normal start-up, timer is energized after thermostat closes and causes a 4-minute delay before compressor will start.

Compressor Protectibn Control System (CPCS —

Solid State) provides; compressor motor locked rotor protection; compressor start winding pro

tection; compressor motor running overload pro tection; compressor overtemperature protection;

contactor antichatter protection.

The CPCS also provides for a 4- to 6-minute delay before restarting compressor after shutdown for any reason. I f compressor loading was light at the moment compressor was shut off, the delay will be approximately 4 minutes. If loading was

heavy, the delay will be approximately 6 minutes. To troubleshoot the CPCS, use unit label diagram

or wiring booklet and the following Control Circuit Troubleshooting Chart.

CONTROL CIRCUIT TROUBLESHOOTING CHART NOTES:

2. To disconnect plug from receptacle on CPCS board — press in tabs located on the receptacle and pull plug gently while holding tabs. Do not pull on wiring.

When performing troubleshooting checks, CPCS

3. receptacle must be plugged into CPCS board.

Receptacle female connections, which do not

4. grip the male pin tightly, may be repaired with a small pen knife.

When taking meter readings at CPCS receptacle,

5. bottom meter probe into terminal hole to

ensure good electrical contact. Replace CPCS board if electrical short circuit

causes compressor failure. An electrical short in compressor can short the triac (electronic switch located on CPCS board). Triac may fail in a closed (conducting) position and will not open the control circuit.

Compressor Removal (See Table 7 for compressor

information and Fig. 5 for component location.)

1. Shut off power to unit. Vent refrigerant to atmosphere or use refrigerant removal methods shown in Carrier Standard Service Techniques Manual, Chapter 1.

Remove top access cover and rear access wrap

per (Fig. 5).

Remove power leads from compressor terminal

3. box. Unsweat suction and hot gas lines.

Remove compressor hold-down bolts. Lift

compressor out thru top or back of unit.

CONTROL

COMPRESSOR TERMINAL BOX

CAUTiON: Iks nmt

i>ece|siacle fiHscomsctsd fr«i ebm* will up CICS

1. Ensure thermostat calls for cooling before troubleshooting unit.

LIQUID LINE

Fig. 5 — Condensing Unit with Access

Panels Removed

(38CE Unit Shown)

Page 9

■ .

CONTROL CIRCUIT TROUBLESHOOTING CHART (GS,CC048 and 060)

Before attempting any corrective action, wait 8 minutes after power is supplied to permit CPCS time delay period to end. If control circuit

broken and unit has no time delay (or if time delay is over 8 minutes), replace CPCS board

tVoltage reading less than 20 volts may result from feedback circuit

I—mnrnnrtWfsrr—I r* Olif *—

26VA

O CPCS Receptacle ^Component Connections

TYPICAL CONTROL CIRCUIT

INDOOR UNIT TRANSFORMER

THERMOSTAT " ^Q—-—(CR

--0-^-0-

TRIAC

(COOLING), ,

Page 10

Table 7 — Compressor Data

COND

UNIT

38GS014__. 38GS014-.. 38GS018200

38GS0182iO

38GS018300 38GS0183IO 38GS024200

38GS0242i0 38GS024300 38GS024370 38GS030200

38GS0302I0 38GS030300 230/1 38GS0303i0

38GS036200

38GS0362fO

38GS036300

38GS0363i0

38GS042___

38GS048___

38GS060

38CC030.__ 200/230/3

38CC036___ 38CC036___ 38CC042___ 38CC042 38CC042__. 38CC048___

38CC048

38CC048-__ 460/3

38CC060

38CC060___ 230/3

38CC060

38CE002

38CE003

38CE004 38CE045

38CE005

---------

* Refer to Service Parts Catalog for replacement compressor

model numbers Single-phase units may include compressor start assist device

___

___ ___ ___

___

Tabular data shown applicable to all models except

those shown italicized 000

V/PH

208/1 230/1 208/1 208/1 230/1 230/1 208/1 208/1 230/1 230/1 208/1 208/1

230/1 208/1 208/1 230/1 230/1 230/1 230/1 230/1

200/230/3

460/3 200/3 230/3 460/3 200/3 230/3

200/3

400/3

230/1 230/1

230/1

PRODUCTION

COMPR*

38GS400804 38GS400804

38GC401994

MD2023CB

38GC400224 21

MD2023CB 44

38GL400314

MB2723CB 44

38GL400324

MD2723CB

38GC401984 42

MB3423CB

38GC401404

MC3423CB 44

38GC402004

MB4023CB

38GC401564

MC4023CB 44

38GS400424

PC5329AD PC6728AB

MF3423BC MF4023CB

MH4023CB 44

38GR403364 46

38GR403364 46 38GR403374 46 PF5326AD 76 PG5326AD 76 PH5326AD 76

PF6725AA PG6725AA 76 PH6725AA

MD2023CB 44 MD3023CB 44 MC3423CB

PC4629AD 76 PC5329AD 76

OIL

RECHG

(Oz)

21 21 21

42 44

44 42

46 44 46

46 76 76

44 44

• 76

PUMPDOWN PROCEDURE

The 38GS,CC,CE units may be pumped down in

order to make repairs on low side of system without losing complete refrigerant charge.

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

2. Frontseat the liquid line valve.

3. Jumper low-pressure switch (if unit is so equipped).

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

5. Shut unit off and frontseat suction valve.

6. Vent remaining pressure to atmosphere.

REFRIGERANT CHARGING

The 38GS,CC,CE condensing units contain

correct operating charge for complete system when connected to Carrier approved evaporators that are the same size as condensing unit, with 25 ft or less of tubing of recommended size. Charge adjustment may be required on other systems.

Listed (Table 8) and described below are

recommended methods of checking, adjusting or recharging Carrier approved systems. When recharg ing these systems, evacuate system to 5000 mi crons (29.7-in. vacuum), and weigh in charge shown in Table 5. When system is not evacuated, subtract the following amount from total charge.

38GS014,018,024; 38CE002 - .11 lb (1.6 oz) 38GS030,036; 38CE003,004; 38CC030,036 - .21

lb (3.2 oz) 38GS042,048,060; 3 8CC042,048,060;

38CE045,005 - .31 lb (4.8 oz) (Dial-a-charge charging cylinder is an accurate

device used to recharge systems by weight. These cylinders are available at refrigeration supply firms.) After weighing in charge, check or adjust charge using the Chargemaster® charging device, charging chart or sight glass method as recom mended in Table 8. Refer to Carrier Standard Service Techniques Manual, Chapter 1, for system evacuation — dehydration instructions.

When 38GS,CC,CE condensing units are con nected to other than a Carrier evaporator, evacuate system and weigh in charge shown in Table 5 or use sight glass method of recharging (38CC thermal expansion valve systems only).

Page 11

Table 8 — Refrigerant Charging Methods

(Carrier Approved Systems)

METHODS OF CHECKING

CONO

UNIT

AccuRater^ ^

38GS

38CC

38CE

TXV — Thermal Expansion Valve

0^ ADJUSTING CHARGE

System Refrigerant Control

Capillary

Tube

Chargemaster ®

Charging Chart

Chargemaster

Charging Chart

Chargemaster

Charging Chart

TXV

Charging Chart

Sight Glass

Charging Chart

Charging Chart Method — For thermal expansion

valve systems, use Charging Chart, Fig. 6 or 7. See Carrier Standard Service Techniques Manual, Chapter 1, for procedure. For capillary tube or

AccuRater"''i'^ systems, use Charging Chart, Fig. 8 or 9 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

compressor. (Insulate thermometer for accurate

readings.)

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

5. Refer to Charging Chart (Fig. 8 or 9). Find condenser air temperature and project hori zontally to curve showing suction pressure.

6. From intersect point, project vertically down ward to chart suction hne temperature.

7. If unit has a higher suction line temperature than chart, add refrigerant until chart tempera

ture is reached.

8. If unit has a lower suction line temperature than chart, bleed refrigerant until chart tem perature is reached.

9. If condenser inlet air temperature or unit suction pressure changes, change to new suction line temperature on chart.

Chargemaster® Operation — Operate unit 10 min

utes before using Chargemaster (Carrier Part No. 38GC680004).

RECHARGING METHODS

System Refrigerant Control

AccuRater

Weight Method

Chargemaster or

Charging Chart Wei ght Method

Chargemaster or

Charging Chart

Weight Method

Chargemaster or

Charging Chart

Capillary

Tube

plus

TXV

Wei ght Method

plus

Charging Chart

Weight Method

plus

Charging Chart or

Sight Glass

Wei ght Method

plus

Charging Chart

1. Tape Chargemaster feeler bulb to suction line close to condensing unit. Insulate bulb. Ensure

suction line is clean for good contact with bulb.

2. Connect refrigerant drum to Chargemaster inlet port with drum in position for vapor charging.

3. Connect Chargemaster outlet port to unit suc tion 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 Charge-

master 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.

CAIHIOI^; Do myi tmé

7. Enter Chargemaster Charging Chart, Table 9 or

10, at outdoor air temperature (step 5) and evaporator temperature (step 6). Find the suction line temperature required for correct system charge. If actual suction line tempera ture (step 6) is higher than table value, the

system is undercharged. If suction line tempera ture is lower than table value, the system is overcharged.

Example (Table 10): At outdoor air tempera ture of 85 F and evaporator temperature of 44 F, the system will be correctly charged at 71 F ± 2 F suction line temperature.

Page 12

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 for new value.

Correct use of Chargemaster ensures an opti mum refrigerant charge will be in system when conditions and system components are normal. However, the Chargemaster does not solve or fix system abnormalities. It indicates correct charge for condition of system. It will not make correc tions for dirty filters, slow fans, excessively long or short suction lines or other abnormal conditions.

This charging device ensures that a correct relation ship exists between outdoor temperature, evap

orator temperature, and suction line temperature

on a specific system.

Sight Glass Method — A satisfactory operating

charge can be obtained on thermal expansion valve

systems by charging to a clear sight glass. For optimum charge, elevate high-side pressure to 380 ± 10 psig by blocking condenser fan discharge or condenser entering air. Charge to a clear sight glass while holding high-side pressure constant. For peak efficiency, adjust charge to yield a liquid refrigerant temperature at the evaporator that is approximately the same as outdoor dry-bulb

temperature.

Page 13

Table 9 — 38GS,CC Chargemaster® Charging Chart

(Capillary Tube or AccuRaterTM Systems)

30 40 50 60 70

SUCTION LINE TEMPERATURE (»F)

Fig. 8 — 38GS,CC Charging Chart

(Capillary Tube or AccuRaterTM Systems)

UU1UUUK

TEMP (F)

60 62 64 66

32 40 30- 38 28 27

68 70 72 74 76 78 80 82

84 86 88 90 92 94 96

98 36 100 102

104 106 108

112 114

*Saturated evaporator temperature which is the equivalent tem

perature of pressure taken at the condensing unit suction service valve

EVAPORATOR TEMP (F)*

25 _

“1"

34 37

3ii

Suction L.ine Temperatures

51 ^

49 37 47 35 45 57 34 32 31 30 29 36 46 27 35 44 26

39 50

32 40

29 37

61 72 58

56 54 63 75 52 61

50 59 48

46 55 44 53 61 70

42 51

41 49 57

57 66

47 55 45 53 44 51 42 41 48 55

39 46

43 45 48

80 76

73 85

68 78 90

65 75 86

63 72 83

70 80

67 77

49 57

53 61

45 51 59 68

43 49 57 65 41

47 55 63 46 53

61 59

Fig. 9 — 38CE Charging Chart

(Capillary Tube or AccuRaterTM Systems)

Table 10 — 38CE Chargemaster® Charging Chart

(Capillary Tube or AccuRaterTM Systems)

EVAPORATOR TEMP (F)

TEMP (F)

60 65 70 75 80

60 49 41 48 58 35 31

iii

90 40

95 100 105 44

115

Example

36j3Sj40|42

Suction Line

58 65

41 48 58

36 42

......

.1.

— •1

>, V'

47 53 42

'em

75 69

48 53 43

4^48|50

peratore (F]

6; 69

4/ 52

48 53

78 67 79

68 88

49 54 65

104

80 69

Page 14

COMPATIBLE FITTING REPAIR

Leaking Mechanical Connection — Frontseat con

densing unit service valves and relieve refrigerant pressure in tubing. Back locknut off Compatible Fitting onto tube. Cut fitting between threads and seal ring head as shown in Fig. 10. Remove tubing section remaining 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 tempera ture (450 F) solder.

Leaking Sweat Connection — Frontseat service

valves and relieve refrigerant pressure in tubing. Clean and flux area around leak and apply low temperature (450 F) solder.

Evacuate or purge evaporator coil and tubing system. Add refrigerant charge (see charging instructions).

Off íA&m

Fan Motor Removal

1. Shut off power to unit.

2. Remove unit top access cover and fan grille.

3. Disconnect fan motor wires from fan capacitor and control relay or contactor. Pull wires out of control box.

4. Remove fan from motor shaft by pulling upward on fan hub.

5. Loosen bolt holding fan motor to motor mounting bracket. Remove motor thru top of unit. To replace motor, place motor on self positioning motor mounting flanges and re tighten bolt.

Fig. 11 — Condenser Fan Position

Fig. 10 — Repair of Mechanical Connection

CONDENSER

Coil Cleaning — Ensure power to unit is shut off

Clean the condensing unit coil at the beginning of every cooling season or more often if required. Use ordinary garden hose at a pressure high enough to clean efficiently. For best results, unscrew and remove unit top cover (grille). Insert hose nozzle between fan blades and spray coil fins from inside-to-outside the unit. If unit has a double-row coil, loosen screws to separate coils, and flush dirt

toward outside of both coils. Flush dirt from base

pan by spraying water thru top of unit. Avoid

splashing mud on coil or water on the fan motor.

Metal Fan — Required fan position is shown in Fig.

11. Adjust fan by loosening setscrew and moving

fan blades up or down.

Plastic Fan is correctly positioned in unit by

placing fan on motor shaft — align flat mark on top of fan hub with flat on shaft. Press down evenly on top of fan hub until shaft bottoms in fan hub.

LUBRICATION

Fan Motor Bearings — Oiling holes are provided at

each end of current condenser fan motor. Remove fan motor and lubricate motor with 32 drops (16 drops per hole) of SAE-10 nondetergent oil at intervals described below:

a. Annually, when environment is very dirty,

ambient temperature is higher than 105 F and average unit operating time exceeds 15 hours a day.

b. Every 3 years when environment is reasonably

clean, ambient temperature is less than 105 F and unit operating time averages 8 to 15 hours a day.

c. Every 5 years when environment is clean,

ambient temperature is less than 105 F and unit operating time averages less than 8 hours a day.

Compressor contains factory oil charge. When oil is

lost, see Table 7 for oil charge and Carrier Standard Service Techniques Manual, Chapter 1, page 1—21, for instructions. Use Carrier PP33-1, Texaco Capella B or Suniso 3G oil.

Page 15

TROUBLESHOOTING CHART*

*To troubleshoot control circuit on 38GS048,060 and 38CC048.060 units, see Control Circuit Troubleshooting Chart, page 9.

Page 16

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.

Tab 4

Form 38GS-13SI Supersedes 38GS-10SI

Printed in U.S.A. 2-75 Codes D and MS Catalog No. 533-810

Carrier 38GS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Air-Cooled Condensing Units

TRANSPORTATION DAMAGE

PRELIMINARY SURVEY

PIPING CONNECTIONS

ELECTRICAL DATA AND WIRING

of ifolt ois tmpro|>er Ime

Install a Branch Circuit Fused Disconnect of

Fig. 4 -- Control Circuit Connections

START-UP INSTRUCTIONS

Start Procedure

COMPRESSOR SERVICE

UNIT PROTECTION

CONTROL CIRCUIT TROUBLESHOOTING CHART (GS,CC048 and 060)

PUMPDOWN PROCEDURE

REFRIGERANT CHARGING

CAIHIOI^; Do myi tmé

Fan Motor Removal

CONDENSER

LUBRICATION