Carrier 38SE User Manual

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Page 1

Number One Air Conditioning Mater

Division of Carrier Corporation

Carrier Parkway ♦ Syracuse NY 13201

Air-Cooled Condensing Units

TRANSPORTATION DAMAGE

File claim with shipping company if shipment is

damaged or incomplete.

PRELIMINARY SURVEY

Consult local building codes and National Electrical

Code (NEC) for special installation requirements.

When installing unit, allow sufficient space for airflow clearance, wiring, refrigerant piping and servicing unit. Recommended minimum requirement is 3 ft (Fig. 1).

Position unit so water from roof or eaves will not pour directly on top of unit.

Install unit on a solid, level mounting pad. Position

tie-down bolts in pad. Any 2 holes in unit base may be used to fasten unit to pad.

38GR Condensing Units Connected to Carrier-Approved

Evaporators with Carrier Accessory Tubing — 38GR units

contain correct refrigerant charge when evaporator is same size, or one size larger than condensing unit and are connected with Carrier accessory tubing. Check refrigerant

38SE,GR

SUCTION LINE CONN (ON SERVICE VALVE) LIQUID LINE

CONN.(ON SERVICE,!

VALVE)

5." |3'*

16 “ ' 8

MTG SLOTS (USE ANY 2)

uSl SPACE REQUIRED FOR SERVICE

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

10^

CONCRETE MOUNTING PAD^(SQUARE OR CIRCULAR)

^CONCRETE PAD SHOULD WEIGH |-| TO 2 TIMES WEIGHT OF UNIT

DIAM HOLE

FOR CONTROL WIRIN(3

Fig. 1 — Dimensions, Connections and Mounting Pad

Table 1 — Installation Data

CONDENSING UNIT

OPERATING WT (lb) DIMENSIONS

(ft-in.)

REFRIG CONN.

*38GR005,006 and 38SE004,045,055 supplied with 3/4-in to 1 1 /8-in suction valve connection adapter (field installed) for 1 1 /8-in suction

line (field supplied)

Diam A Height В Suet ODF Liq ODF

002

151 170 182 194 1 234

2-4

003

2-4 2-4 2-4

38GR

004

2-5У4

charge when tubing lengths are above 50 feet. See Refrig erant Charging for details.

38SE Condensing Units Connected to Carrier-Approved

Evaporators — 38SE units contain correct system refrig

erant charge when evaporator is same size as condensing unit, and they are connected with 25 ft or less of field-supplied tubing of recommended size (see Piping Connections) or 50 ft or less of Carrier accessory tubing. Check refrigerant charge for maximum system efficiency. See Refrigerant Charging for details.

38GR,SE Condensing Units Connected to Non-Carrier

Evaporators — Check refrigerant charge when the 38GR,SE

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 piping must be in accordance with Refrigerant Piping Data table.

Use an evaporator coil with a bleed-type expansion

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.

PIPING CONNECTIONS

The 38GR,SE condensing units can be connected to

evaporator sections using Carrier accessory tubing package or field-supplied tubing of refrigerant grade (Accessory

045

'A ’/4*

005

2-8 2-8

006

260

3/*

002

176 180

2-4

003 004

2-4 2-8 3-8 3-8

У4 У4 *

38SE

192

2-5У4

045 055

248

255

3/*-

Fornn 38SE-3SI

Page 2

tubing not available for 38GR006.) See Table 2 for accessory tubing sizes and Table 3 for recommended field-supplied 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 results if accessory tubing is used in 38SE004,045,055 systems. For example, when a 25 ft accessory tubing package is used, there is a capacity reduction of 2 1/2% on 38SE004, 3 3/4% on 38SE045 and 5% on 38SE055 systems. For maximum capacity from these systems, use tubing sizes shown in Table 3.

Connection Recommendations — Do not use damaged or

contaminated tubing. 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.

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

When making piping 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 mechanical (quick-connect) or sweat connections.

Table 2 — Accessories

PART NO.

HH01AD040 HH93AZ040

HH51AR001

HH07AT070, HH07AT074 HH93AZ076

HH01AD042 HH93AZ042

HH01YA092 HH93YZ094

32LT900301

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, and/or motor required.

38GR005,006; 38SE004.045.055 Units - When using

1 1/8-in. field-supplied siictlSff'line, 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. When a 7/8-in. field-supplied suction line is used on 38SE003 or 38GR045, a field-supplied 3/4-in. to 7/8-in. suction line adapter must be provided.

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 0-ring is in the groove inside the compatible fitting.

3. Cut tubing to correct length.

4. Use gage on tag attached to service valve to mark tube end for correct insertion depth. Insert tube into com patible fitting until it bottoms. (Tube should be inserted at least as far as mark on tubing.)

5. Tighten nut until it bottoms on back coupling flange

SWEAT CONNECTION (Use refrigerant grade tubing.)

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

2. Cut tubing to correct length.

DESCRIPTION

Special field-installed fan

38GC900-152 38GB900021

38GC900031 38GC900041 18 38GS900221 25 38GC900061 35 38GC900191

38GC900071 10

38GC900081 38GC900091 38GC900101

38GC900in

Indoor Fan Relay (Six — 38BA400693) Thermal Expansion Valve (Six — EA61DC100)

Len gth

(ft)

UNIT

Motor No.

Fan No.

UNIT

Motor No.

(in.)

18 25 35 50 Ve

TUBING PACKAGES

L iquid Suction*

Tube End

(in.)

Ve Ve

Vie

Ve Ve

Ve Ve Vet Ve Ve Ve Ve Ve

Ve Ve

38SE002,003

HC38VE851 LA01AA020

38GR002,003,004,045

HC38VE851

(in.)

Ve Ve

Ve Ve Ve

Evap

Vet Vet Ve Vet Vet

Ve Ve Ve

Ve Ve

Tube End

OD (in.)

Cond

Ve Ve

HC40VL701 LA01AA023

38GR005,006

HC40VL701

38SE002, 38GR002

38SE003,004,045,055 38GR003,004,045,005

Ve :

*Suction line is insulated and has a 90 bend at one end fFor 5/8-in evaporator connection, cut off 3/4-in. end.

NOTE: Do not cut 3/8-in OD liquid line to a length shorter than 10 feet Do not cut 5/1 6-or 1/4-in liquid line.

38SE004

UNIT

Page 3

Table 3 — Field-Supplied Piping Data

COND

UNIT

38GR002

38GR003

38GR004

38GR045

38GR005

38GR006

38SE002

38SE003

38SE004

38SE045

38SE055

REFRIG

CONTROL

TXV 90 90

Cap. Tube or AccuRater'*'^

TXV

Cap. Tube or

AccuRater

TXV

Cap. Tube or

AccuRater

TXV

Cap. Tube or

AccuRater

TXV 90

Cap. Tube or

AccuRater

TXV 90 90

Cap. Tube or

AccuRater

TXV

Cap. Tube or

AccuRater

TXV

Cap. Tube or

AccuRater

TXV

Cap. Tube or

AccuRater

TXV 90

Cap. Tube or

AccuRater

TXV

Cap. Tube or

AccuRater

Cap. Tube — Capillary Tube TXV — Thermal Expansion Valve

MAX COND

UNIT HT (ft)

Above

Evap

150

150 50

90 90

150

ISO 50

150 50

90 90

150

150 50

90 90

150 50

150

90 90

150 50

NOTES: 1 Systems with over 50 ft separation between condensing unit and evaporator require refrigerant

2 Reduce liquid line diameter by 1/8-in OD (minimum 1/4-in OD) when evaporator is 20 ft or

REFRIGERANT LINE LENGTH (ft)

25-50

Below

Evap

charge adjustment to ensure the proper superheat at compressor See Refrigerant Charging, page

5 Oil charge adjustment may also be required

Suet

^4 %

IVs

iVs

IVa

IVs

iVa

Liq

% V4

Suet

51-75 76-100

Line Diameter (in. OD)

Suet Liq

Liq

Vs V4

V4 Vs V4

V4 Vs Vs

IVs

Vs Vs

IVs

Vs V.

IVs

IVs Vs

IVs

Vs V4

Vs Vs V2

101-125

Suet Liq

IVs

/8 Vs

IVs

126-150

Suet

V4 Vs

V, Vs

IVs

Vs Vs

IVs

Liq

more below condensing unit

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.

SERVICE DOOR

Service door can be opened or removed for wiring or

servicing unit

Remove 3 screws from left side of service door (Fig. 1)

to swing door open.

Door Removal — Turn power off. Disconnect wiring from

control panel mounted on door. Refer to Fig. 7 and 8. After wiring is disconnected, lift door from roll pin hinges.

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. On 3-phase units, phases must be balanced within 2%. Contact local power company for correction of improper line voltage.

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

Page 4

Table 4 — Electrical Data

COND

UNIT

V/PH

OPER VOLTS*

COMPR

LRA FLA

Max Min

38GR002---

38GR0023I0

38GR003---

38GR003310

38GR004---

230/1 253 207

38GR0043J0

38GR045---

38GR005---

38GR006---

38GR003---

38GR0034Í0

38GR004---

38GR0044J0 200/3

38GR045---

220 180

72.0

90.0

100.0 100 0

94.0

106.0

135.0

60.0

70.0

69.0 80 0

79.0

38GR005--- 87.0 38GR006---

38GR003---

38GR0035Í0

113.0 24.0

50.0

60.0

38GR004--- 60.0

38GR0045J0 230/3

38GR045--38GR005---

38GR006--38GR004---

38GR004610

38GR045---

460/3

38GR005--38GR006---

38SE002--. 38SE003--38SE004---

230/1

38SE045---

38SE055---

253

506

253

207 70.0

414

207

67.0

70.0

98.0

30.0

35.0

35 0

35.0

49.0

65.0

72.0

90.0

94.0

106.0

Corresponding wire sizes and wire lengths

FLA — Full Load Amps

LRA — Locked Rotor Amps

--------Electrical data shown applicable to all units for which com plete model numbers are not shown Example: 38GR003--applies to all 003 models except 38GR003Ji0.

FAN BRANCH CIRCUIT

Wire

FLA

Sizet

(AWG)

14.8

14.8 1 0 12

19.2

22.9 1 3 22 9

23.9 1.3

27.9 2.0 8 42 0 Í

39.0 2.0 6

13.0

13.0 14 0 14 0

16.7 1.3 12

18.3 2.0

11.5

12.6

12.6 14 3

16.4

19.9

6.5

7.2 8 8

10 4

10.3

14.8 19 2 23 9

28.0

1.0 12 32.0 30

1.1 10 39 0 40

1.1

1 3

1.1 1 1 12

1.3 12

1.3

2 0

1 1 1 1 12

1.3 1 3 12

1 3 2 0 10 2 0 10 47 0

5 5

1.3

1.3 .8

.8 .8

1 3

2.2

1. ' 32 0 30

10 10 10

8 49.0

12 42.0

12 1.'^ zL.

12 25

mf.

12 42 0

\-xi:

14 14

i n ;

1 n

14 14

12 10 10

10 »

39.0 L 40

33.0 33-0

47.0

42.0

39.0

39.0 i: ' 30 33 0 i

46.0 40

64.0 / 50

52.0 1

47.0

56.0 35

110.0

100.0 1

81.0 Í

70.{'

29 1 '■

40.0

*Permissible limits of the voltage range at which the unit will oper

ate satisfactorily

tCopper wire sizes and lengths Use latest National Electrical Code

(NEC) for aluminum wire sizing

-> Maximum dual element fuse size NOTE Control circuit voltage is 24 volts on all units On 3-phase units, phases must be balanced within 2%

Max Ftt Wire

32 0 $XÙ

32 0 SBJB

430

Fuse Ampst

50 50 50 60 80

30 30 30

15 15 15 20 20

20 30 40

50 60

3-PHASE CONN.TO FUSED DISCONNECT

I-PHASE CONN TO FUSED DISCONNECT

— GROUND LEAD-

—

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

■

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

--------

COND UNIT

GROUNDING LUG

BRN _

ORN

-----------

BLK

-----------

(38GR ONLY)

A—A Splice Connections

---------

Field Wiring

---------

Factory Wiring

Fig. 2 — Line Power Connections

Install a Branch Circuit Fused Disconnect of adequate size

to handle unit starting current Locate disconnect within sight of and readily accessible to the unit, per section

440-14 of National Electrical Code (NEC).

1076

Bring Line Power Leads Into Unit — Extend leads from

fused disconnect thru hole provided in base pan (Fig. 1) and into unit junction box.

CONNECT GROUND LEAD TO GROUND LUG OR SCREW IN JUNCTION BOX for safety. Connect power wiring. See Fig. 2. Splice line power leads to brown and orange pigtails on 1-phase units or brown, orange and black pigtails on 3-phase units. Use wire nuts supplied with unit. Tape each connection. When aluminum field wire is used, lubricate splices with splice compound (also supplied) before using wire nuts.

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

in unit base pan (Fig. 1) and into low-voltage section of unit junction box. Splice control leads to yellow pigtails on control relay. See Fig. 3. For aluminum wire splices use

factory supplied and lubricated wire nuts. Furnace or fan

coil transformer must be used as 24-v supply for system as shown in Fig. 3. All 38SE units are equipped with transformer used to power contactor thru unit control circuit only, and must not be used to power thermostat circuit.

Page 5

THERMOSTAT SUBBASE HH93AZ042 OR HH93AZ040

THERMOSTAT SUBBASE

* CONNECT FS TO LOW-SPEED INDOOR FAN TERMINAL

WHEN TWO-SPEED FAN IS USED

THERMOSTAT SUBBASE HH93AZ076

ARRANGEMENT A-(COOLING ONLY)

(COOLING AND ONE-STAGE HEATING)

-LEAVE JUMPER ON

SUBBASE (RH TORO)

38SE.gr

0 &■

TOIFM LINE

..0^ VOLTAGE

POWER

m SUPPLY

@--

1TRANS

HCl

[vië

ARRANGEMENT C-ONE TRANSFORMER (COOLING AND TWO-STAGE HEATING)

* CONNECT FS TO LOW-SPEED INDOOR FAN TERMINAL

WHEN TWO-SPEED FAN IS USED

I IFR.FSand IFM are located in furnace on heating-cooling

applications If accessory IFR is required for cooling only applications, locate (IFR) in fan coil

— Control Relay (10 va)

— Fan Switch

— Heating Control

HC IFM — Indoor Fan Motor

IFR — Indoor Fan Relay

LEGEND

Trans

Fig. 3 — Control Circuit Connections

START-UP INSTRUCTIONS

Energize cranlscase heater a minimum of 24 hours before starting unit. To energize heater only, turn the thermostat to “Off’ position and close electrical disconnect to condensing unit.

FURNACE

— Transformer

Field Splice

—

Field Wiring

Factory Wiring

Start Procedure

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

2. Set thermostat selector switch at “Off.”

3. Set room thermostat to desired temperature.

4. Close electrical disconnects energizing entire system.

5. Set room thermostat at “Cool” and fan switch as desired (“Fan”) (“Auto.”). Unit will start in 4 to 6 minutes. Operate unit for 15 minutes, then check system refrig erant charge. See Refrigerant Charging.

Motors and controls operate satisfactorily in a range

from 10% above to 10% below nominal unit voltage (Table

4)Do not connect charging hoses during initial start

procedure. (Loss of charge from this procedure may result in capacity reduction.) If necessary to add manifold gages for servicing, refer to Carrier Standard Service Techniques Manual, Chapter 1, page 1-5, Fig. 8, for bypass method of returning charge to system.

SERVICE

Table 5 — Service Data

COND

UNIT

38GR002 38GR003 5- 6 1050 38GR004

38GR045 38GR005 6-10 1070 38GR006 6-10 1070 38SE002 38SE003 38SE004 7-14

38SE045

38SE055

*38GR: Factory refrigerant charge adequate when condensing

38SE Factory refrigerant charge adequate when condensing

R-22

CHG*

(Ib-oz)

5-10

6- 5 1050 6- 5 1050 850

5- 8 5-13 850

9- 8

units are connected to Carrier approved evaporators that are the same size as (or one size larger than) con densing unit with Carrier accessory tubing

units are connected to Carrier approved evaporators

that are the same size as condensing unit See Refrigerant Charging for details

CONDENSER FAN

Lo Hi Lo

1050 850

850 20 850

870 870

850

850 925

825

1025

Dì am

(in.)

20 2800 2300

20 3100 2600 20 3100 20 3700 3200 20 3700 3200 20 2400

20 2400

20 2700

20 20 3900 3400

Cfm

2800 2300

3200

2600

REFRIGERANT CHARGING

38GR,SE condensing units contain correct operating

charge for complete system when connected to Carrier

approved evaporators. Evaporators must be same size (or one size larger than 38GR) as condensing unit with 50 ft or

less of Carrier accessory tubing or 25 ft or less of

field-supplied tubing of recommended size. For every 10 ft of liquid line of recommended size over 50 ft, add

refrigerant charge as follows' .7 lb for 1/2-in. line, .4 lb for 3/8-in. line, 1.1 lb for 5/8-in. line. Charge adjustment may be required on other systems.

To Check, Adjust or Replace Refrigerant Charge on all

Carrier approved systems, use method recommended in

Table 5. Details of charging methods are listed below.

Before recharging Carrier approved systems, evacuate system to 500 microns and then weigh in refrigerant charge specified in Table 5. Check or adjust charge as required. If

Page 6

necessaiy, refer to Carrier Standard Service Techniques Manual, Chapter 1, for system evacuation-dehydration instructions.

When 38GR,SE condensing units are connected to other than a Carrier evaporator, evacuate system and weigh in charge shown in Table 5 or use sight glass method of recharging.

D» iiot toe sysieiss. A» om-

Weight Method — Refer to Table 5 or unit nameplate for

correct system refrigerant charge. Blow any refrigerant remaining in system before recharging.

When system is not evacuated, subtract the following

amount from total charge; 38GR,SE002 - .10 lb (1.6 oz)

38GR,SE003,004,045,005,055,006 - .20 lb (3.2 oz)

Keep refrigerant recharge within one oz of specified charge on 002 systems and within 2 oz on 003,004,045, 005,055,006 systems.

Dial-a-charge charging cylinder is an accurate device used

to recharge systems by weight. These cylinders are available

at refrigeration supply firms.

Charging Chart Method

38GR THERMAL EXPANSION VALVE SYSTEMS - Use Charging Chart, Fig 4 or Fig. 5. See Carrier Standard Service Techniques Manual, Chapter 1, for procedure.

38SE CAPILLARY TUBE OR ACCURATERTm SYSTEMS — 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 compressor. (Insulate thermometer for accurate readings.)

4. Measure outdoor (condenser inlet) air dry-bulb temper ature with second thermometer.

5. Refer to Charging Chart (Fig. 6). Find condenser air temperature and project horizontally to curve showing

suction pressure.

6. From intersect point, project vertically downward to chart suction line temperature.

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

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

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

Chargemaster® Operation — Operate unit 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.

2. Connect refrigerant drum to Chargemaster inlet port

with 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.

50 60 70 80 90

PRESSURE AT SUCTION SERVICE VALVE (PSIG)

Fig. 4 - 38GR002,003,004,045,005 Charging Chart -

TXV Systems

50 60 70 80

PRESSURE AT SUCTION SERVICE VALVE (PSIG)

Fig. 5 — 38GR006 Charging Chart — TXV Systems

6. Crack unit suction valve and read evaporator temper ature at red needle position on Chargemaster temper

ature gage and suction line temperature at black needle

position.

CAOTICA; '

Page 7

Table 6 — Refrigerant Charging Methods (Carrier Approved Systems)

METHODS OF CHECKING

OR ADJUSTING CHARGE

COND UNIT ;

AccuRater^M Capillary Tube

38GR

38SE

NOTE; 38SE operates at lower head pressure than comparable units Do not expect as high pressure when charging or adding charge

System Refriqerant Control

Chargemaster®

Chargemaster

Charging Chart

TXV

Charging Chart

Sight Glass

AccuRater Capíllary Tube

COMPLETE RECHARGING

System Refrigerant Control

Weight Method

Plus

Chargemaster

Weight Method

Plus

Chargemaster or

Charging Chart

Table 7 — Chargemaster Charging Chart

(38GR Capillary Tube or AccuRater Systems)

Fig. 6 — 38SE Charging Chart

(Capillary Tube or AccuRater Systems with or

without Suction-Liquid Line Heat Interchange)

7. Enter Chargemaster Charging Chart, Table 7 or 8, at outdoor air temperature (step 5) and evaporator temper ature (step 6). Find the suction line temperature

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, the system is overcharged.

Example: At outdoor air temperature of 85 F and evaporator temperature of 44 F, the system will be correctly charged at 71 F ±2 F suction line temperature. See Table 8.

8. Add charge by slowly opening Chargemaster valve. If necessary, reduce charge by bleeding at liquid line service valve. Check outdoor air and evaporator temper ature during procedure. If they change, refer back to

OUTDOOR

TEMP (F)

60 62 64 66 27 35 45 57 68 70 32 72 31 74 76 78 80 82

86 88 35 90 92 94 39 96 38 45

98 100 102 104 106 45 51 108 110 112 114

*Saturated evaporator temperature which is the equivalent tem

perature of pressure taken at the condensing unitsuction service valve

21 I 25 I 28 I 31 I 34 I 37

32 40 30

38 37 47 60

34 43 54 67

30^ 29 36 46

Example

Suction Line Temperature table for new value. Correct use of Chargemaster ensures an optimum refrig

erant 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 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 specific system.

Sight Glass Method — A satisfactory operating charge can

he 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.

METHODS FOR

Weight Method

Charging Chart

Sight Glass

Weight Method

Sight Glass

EVAPORATOR TEMP (F)

43 I 45 48

Suction Line Temperotures

51 49

52 64

50 61 72"

39 37 48

35 44 54 63.. 33 42

58 69" 56

.50

46 55" "63 73 85

44 53 61 42

41 49 57 65 75 86

61 "

51 59 68 78

55 63 72 83

49 57 65

48 55

39 46 53 61

43 49 57 65 41

TXV

Plus

80 76

70 80

61 59 67 77

59 68

53 61

50 59

—

75 73

Page 8

Table 8 — Chargemaster® Charging Chart

(38SE Capillary Tube or AccuRater^'^ Systems)

OUTDOOR

TEMP (F)

60 65 70 75 35

"To” '

95 100 105

32| 34136

60 4% 58 65 41 48 58

41 48 58 68

31 36 .42

-------

115

Example

High-Pressure Relief Valve is located in compressor when so

EVAPORATOR TEMP (F)

38 40 42 im 46 |48 50 52

Suction Line Temperature (F)

— -

68 70

50 44

40w47

59.

69^

53 j 61 48 53 43 I 47

I 44

UNIT PROTECTION

—

■■¿9'

78“

48 53 60

—

54 50 62

75 65

104

equipped. Relief valve opens at a pressure differential of approximately 450 — 550 psi between suction and discharge. Valve permits pressure equalization at running condition described above and during unit shutdown. A hissing sound during pressure equalization does not indicate bad valves.

High Pressurestat is located on unit liquid line. High

pressurestat settings are; cutout, 425 ± 5 psig; cut-in, 320 ±

20 psig.

Low Pressurestat is located on unit suction line. Low

pressurestat settings are; cutout, 31 ± 4 psig, cut-in, 60

(+15,-0) psig.

Internal Temperature And/Or Current Sensitive Overloads

reset automatically when internal motor 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, for complete instructions.

Outdoor Fan Thermostat (38SE055 and 38GR units)

switches fan to high speed (Table 5) when outdoor

temperature reaches 90 F — maintains proper condensing temperature at high outdoor air temperatures. Thermostat is located on Control Panel, Fig. 7.

Filter-Drier is installed in liquid line.

FAN THERMOSTAT «F SO EQUIPPED)

CONTROL TRANSFORMER

(DUAL SECONDARY)

'CS CEPTACLE

ITROL RELAY

CONTACTOR

Fig. 7 — Control Panel (Cover Removed)

Compressor Protection Control System (CPCS — Solid

State, Fig. 7) provides; compressor motor locked rotor protection; compressor start winding protection; compres sor motor running overload protection; compressor over temperature protection; contactor anti-chatter protection.

The CPCS also provides for a 4- to 6-minute delay before restarting compressor after shutdown for any reason. If 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. The CPCS board is located on control panel beneath a sheet metal protective cover. To troubleshoot the CPCS, remove protective sheet metal cover, and use unit

label diagram or wiring booklet with Control Circuit Troubleshooting Chart, page 9.

TROUBLESHOOTING CHART NOTES (Page 9);

1. Ensure thermostat calls for cooling before troubleshooring unit.

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.

3. When performing troubleshooting checks, CPCS recep tacle must be plugged into CPCS board,

4. Receptacle female connections, which do not grip the male pin tightly, may be repaired with a small pen knife.

5. When taking meter readings at CPCS receptacle, bottom meter probe into terminal hole to ensure good electrical contact.

6. 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 not open the control circuit.

PUMPDOWN PROCEDURE

The 38GR,SE 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.

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.

CACTfC^' Thtf 58GR «fill -idd c»nly

suppii&l af

msv icaus« tiKtts 1« syde op pre^pf-

stsi by & djsdtejfgi pfissiiro a

sudifpti rtp? i>i AtOicin" fessfore stis.'ifoi!

reiscte ? ppit, ff sha «¿rctifa, abKi urti! >4i

fipataeat awtsstsi 'tslve vpiit fc-

COMPRESSOR SERVICE

Unit Single-Phase Compressors of the split capacitor (PSC)

type require an equalized system pressure to start. When supply voltage is within 10% limit and compressor does not start, give compressor a temporary capacitance boost. See

V-

Page 9

CONTROL CIRCUIT TROUBLESHOOTING CHART

fofs wvi<sa ommxiix^ |b«sC8!^ of isssancaof higff volisga).

sm^ag tssAs^ssrim- & ^ priJiesisiya «¡«tmi sys^era biw<S, Sb«'! ad fea-

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

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

CONTACTS CLOSE

iMMEDiATELY, UNiT DOES NOT RUN

CONTACTS WON'T STAY CLOSED. OR, CONTACTS

OPEN BEFORE ROOM ’ THERMOSTAT iS SATiSFiED

VOLTAGE LOW OR_

NO VOLTAGE

LOOSE CONNECTIONS-

OR IMPROPER WIRING

VOLTAGE LOW OR.

NO VOLTAGE

----------

CPCS Board and control circuit func

►

tion Check compressor, run capacitor, start gear and internal compressor protection

Check system pressures and current

draw

Obtain correct voltage

Repair connection or correct wiring

Replace transformer

____ __________

VOLTAGE LOW OR NO VOLTAGE

VOLTAGE CORRECT-

VOLTAGE IS LOWER. THAN 20 VOLTSt

VOLTAGE IS LOWER.

THAN 20 VOLTSt

VOLTAGE IS LOWER

THAN 20 VOLTSt

Replace transformer

Replace contactor

Check indoor unit power. indoor transformer, thermostat or relay

System pressure too high or bad high-

pressure switch

System pressure too low, bad lowpressure switch or open internal pro

tector (IP)

control

L| L2

I—nfTWWOlWi

2SVA

----

TYPICAL CONTROL CIRCUIT

O CPCS Receptacle

o Component Connections

tVoltage reading less than 20 volts may result from feedback circuit.

INDOOR UNIT TRANSFORMER

0—^—0—

TRIAC

Page 10

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

follows;

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 (PTC device) is good and compressor will not start, disconnect the thermistor from starting circuit and give compressor a temporary capacitance 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 ca pacitor. If after 2 attempts the compressor does not start,

remove thermistor and add an accessory start capacitor re

lay package.

Compressor Removal

38GR; 38SE002,003,004 UNITS - See Table 9 for compressor information and Fig. 8 for component location. Shut off power to unit. Vent refrigerant to atmosphere or use refrigerant removal methods shown in Carrier Standard Service Techniques Manual, Chapter 1.

1. Remove unit top cover (grille). Open or remove service door.

2. Disconnect fan motor leads from control panel located on service door. See Fig. 7 and refer to Service Door on page 3. Remove 6 screws holding fan motor orifice

assembly in place and lift assembly from unit.

3. Compressor outer sound shield is fastened to tube sheets

and to base pan. Loosen screws and remove sound shield by sliding it straight up using tube sheets as guides.

4. (38SE only) — Warp top cover of inner compressor

sound shield upward to clear compressor process tube. Carefully slide cover over the tubing.

.TOP GRILLE COVER

FAN MOTOR-ORIFICE ASSEMBLY

SERVICE DOOR

SUCTION LINE

COMPRESSOR

JCONTROL

LIQUID VALVE SERVICE PORT

SUCTION VALVE SERVICE PORT

Fig. 8 — 38GR Condensing Unit with Service Door Open

»PANEL

COVER

5. (38SE only) — Slide inner compressor sound shield terminal box cover upward and out.

6. Remove compressor terminal box cover, disconnect and remove compressor power leads.

7. (38SE only) — Lift off inner compressor sound shield.

8. Unsweat suction and hot-gas lines.

9. Remove compressor hold-down bolts. Lift compressor out thru top of unit.

Table 9 — Compressor Data

COND

UNIT

38GR002--38GR002320 38GR003--38GR0033I0 38GR004--38GR0043IO 38GR045--- PC4Ó26AD 76 0 38GR005--- PC5326AD 76.0 38GR006--- PC6725AB 76 0

38GR003--38GR0034Í0

38GR004--- RF3922CJ 38GR0044Í0 38GR045--38GR0£)5--38GR006--- PF6725AA 76 0

38GR003--- RG3522CJ

38GR0035I0 38GR004---

38GR0045Í0

38GR045---

38GR005---

38GR006---

38GR004---

38GR0046Í0

38GR045--- 460/3

38GR005---

38GR006---

38SE002---

38SE003--- MD2723CB

38SE004---

38SE045---

38SE055--- PC5326AD

shown italicized 000.

* Refer to Service Parts catalog for replacement compressor model

numbers. The 38GR.SE single-phase compressors include start

assist.

V/PH

230/1*

200/3

230/3

230/1 MC3423CB

PRODUCTION COMPRESSOR*

38GL400324

MD2723CB 38GR400234 31.5 MC3423CB 43.2 38GC401564 MC4023CB 43.2

RF3522CJ

MF3423CB

MF4023CB

PF4626AD PF5326AD

MG3423CB

RG3922CJ

MG4023CB

PG4626AD PG5326AD 76 0 PG6725AA 76 0

RH3922CJ

MH4023CB

PH4626AD PH5326AD PH6725AA

MD2023CB

PC4Ó26AD 76 0

OIL RECHARGE

(oz)

40.5

43.2

45.0

50.4 43 2 50 4

43.2

76.0

50.4 43 2

50.4

43.2

76.0

50 4

43 2

76.0

76.0 43 2

43.2

76.0

38SE045,055 UNITS

1. Open and remove service door. See Fig. 7 and refer to Service Door on page 3.

2. Disconnect fan motor leads and crankcase heater leads from control panel located on service door.

3. Remove cover plate on compressor terminal box and disconnect all leads.

4. Remove 4 screws holding compressor plastic sound shield in place. Slide shield upward 6 to 10 inches.

5. Unsweat suction and hot-gas lines at compressor (dis connect convenient connection at sight glass or filterdrier).

6. Remove 3 screws holding coil to base pan.

7. From front of unit (coil-emblem side) hft complete

disconnected coil-fan-top cover assembly off from

compressor-base pan assembly.

Page 11

8. Remove compressor from base pan and replace with new compressor. Install crankcase heater (step 2) on new compressor.

9. Replace coil-fan-top cover assembly on compressor-base pan assembly; reconnect all joints and wiring; recharge unit.

COMPATIBLE FITTING REPAIR

Leaking Mechanical Connection — Frontseat condensing

unit service valves and reheve refrigerant pressure in tubing. Back locknut off compatible fitting onto tube. Cut fitting between threads and seal ring head as shown in Fig. 9. Remove tubing section remaining in threaded portion of fitting. Discard locknut.

Clean, flux, and insert new tube end into remaining por

tion of compatible fitting. Wrap valve base in wet rag. Heat and apply low-temperature (450 F) solder.

Fig. 9 — Repair of Mechanical Connection

Metal Fan — Required fan position is shown in Fig. 10.

Adjust fan by loosening setscrew and moving fan blades up or down.

Fan Motor Removal

1. Shut off power to unit.

2 Remove unit top cover (grille). Open or remove service

door. With door open, remove control panel cover.

3. Disconnect fan motor leads (3) from control panel located on service door. See Fig. 7.

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

5. Remove bolt holding fan motor to motor mounting bracket. Remove motor with wiring thru top of unit. To replace motor, place motor on self-positioning motor mounting bracket and retighten bolt.

Before replacing metal fan, be sure moisture protectors

are in place on motor shaft.

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 instmctions).

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.

LUBRICATION

Fan Motor Bearings — OiUng holes are provided at each end

of 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 9 for oil recharge 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 12

Condenser Fan On

Condenser Air Restricted Condenser Air Recirculating

Noncondensables in System Refrigerant Overcharge Improper Line Voltage Refrigerant System Restriction Loose Electric Connections Faulty Run Capacitor

Condenser Fan Off

Fan Slipping on Shaft Loose Electric Connections Fan Motor Overload Open Fan Motor Bearings Stuck Fan Motor Defective

Low Suction Pressure

Low Refrig Charge

High Suction Pressure

Low Head Pressure Defective Compressor Valves

Slightly Low Suction Pressure

Dirty Filters Partially Restricted Airflow Coil Partially Iced Slightly Low on Refrigerant Duct Restricted

Dampers Partially Closed

TROUBLESHOOTING CHART*

Evaporative Fan Running

Low Refrig Charge Restricted Refrig Flow

Restricted Capillary Defective TXV

Restricted Evaporator Air

Dirty or Iced Coil Plugged Filter Dampers Closed Restricted Ductwork

Evaporator Fan Stopped

Defective Fan Relay Loose Leads Overload Open Burned Out Motor Broken Belt

Contactor Open

Dead Transformer Thermostat Circuit Open Faulty Control Relay Overload Open Contactor Coil Open Loose Connection

Contactor Closed

Loose Leads at Compressor Loose Leads at Contactor Motor Windings Open Internal Compr Overload Open

Contactor Closed, Then Opens

Overload Opens

Faulty CPCS Boord

_____________

Compressor Stuck

______________

*To troubleshoot control circuit, see Control Circuit Troubleshooting Chart, page 9.

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 38SE-3S1 Supersedes 38GR-3SI, 38SE-2SI Printed in U S.A 1076

3-75 PC 101 Catalog No. 533-827

1 Book 1

1 Tab