Carrier Gemini 38AU 07 Series Installation, Start-up And Service Instructions Manual

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Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.Catalog No. 04-53380041-01 Printed in U.S.A. Form 38AU-7-14-05SI Pg 1 2-2020 Replaces: 38AU-7-14-04SIInstallation, Start-Up and Service InstructionsCONTENTSPageSAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . 2Replacement/Retrofit —R-22 to Puron Refrigerant . . . . . . . . . . . . . . . . . . . 2Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . 2Identify Factory Options . . . . . . . . . . . . . . . . . . . . . . . 3Matching 38AU Model to Evaporator Coil . . . . . . . . . 3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Step 1 — Plan for Unit Location . . . . . . . . . . . . . . . . 6Step 2 — Complete Pre-Installation Checks . . . . . . . 7Step 3 — Prepare Unit Mounting Support . . . . . . . . 7Step 4 — Rig and Mount the Unit . . . . . . . . . . . . . . . 7Step 5 — Determine Refrigerant Line Sizes . . . . . . . 7Suction Riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Step 6 — Complete Refrigerant PipingConnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Step 7 — Install Accessories . . . . . . . . . . . . . . . . . . 14Step 8 — Complete Electrical Connections . . . . . . 14Step 9 — Wind Baffles for Low Ambient Control . . 20PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Turn On Crankcase Heater . . . . . . . . . . . . . . . . . . . . 20Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . . . . . 20START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 20Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21OPERATING SEQUENCE . . . . . . . . . . . . . . . . . . . . . 29Base Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 2938AUDC with SVR Relays . . . . . . . . . . . . . . . . . . . . . 30All Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Quarterly Inspection(and 30 days after initial start) . . . . . . . . . . . . . . . 31Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . . 31SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . 31Comfort Alert Diagnostic Module . . . . . . . . . . . . . . 33Compressor Protection . . . . . . . . . . . . . . . . . . . . . . 35Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . 36TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 36APPENDIX A — AIR CONDITIONER AND HEAT PUMPWITH PURON – QUICK REFERENCE GUIDE . . . 38APPENDIX B — WIRING DIAGRAMS . . . . . . . . . . . . 38APPENDIX C — LOW AMBIENT OPTION . . . . . . . . 50START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1SAFETY CONSIDERATIONSImproper installation, adjustment, alteration, service,maintenance, or use can cause explosion, fire, electrical shock orother conditions which may cause personal injury or propertydamage. Consult a qualified installer, service agency, or yourdistributor or branch for information or assistance. The qualifiedinstaller or agency must use factory-authorized kits or accessorieswhen modifying this product. Refer to the individual instructionspackaged with the kits or accessories when installing.Follow all safety codes. Wear safety glasses and work gloves. Usequenching cloths for brazing operations and have a fireextinguisher available. Read these instructions thoroughly andfollow all warnings or cautions attached to the unit. Consult localbuilding codes and appropriate national electrical codes (in USA,ANSI/NFPA70, National Electrical Code (NEC); in Canada, CSAC22.1) for special requirements.It is important to recognize safety information. This is the safety-alert symbol . When you see this symbol on the unit and ininstructions or manuals, be alert to the potential for personalinjury.Understand the signal words DANGER, WARNING, CAUTION,and NOTE. These words are used with the safety-alert symbol.DANGER identifies the most serious hazards which will result insevere personal injury or death. WARNING signifies hazardswhich could result in personal injury or death. CAUTION is usedto identify unsafe practices, which may result in minor personalinjury or product and property damage. NOTE is used to highlightsuggestions which will result in enhanced installation, reliability,or operation.DANGERELECTRICAL SHOCK HAZARDFailure to follow this warning will result in personal injury ordeath.Before performing service or maintenance operations on unit,turn off main power switch to unit and install lock(s) and lock-out tag(s). Ensure electrical service to rooftop unit agrees withvoltage and amperage listed on the unit rating plate. Unit mayhave more than one power switch.WARNINGUNIT OPERATION AND SAFETY HAZARDFailure to follow this warning could cause personal injury,death and/or equipment damage.R-410A refrigerant systems operate at higher pressures thanstandard R-22 systems. Do not use R-22 service equipment orcomponents on R-410A refrigerant equipment.Gemini™38AU**07-14Air-Cooled Condensing Unitswith Puron® (R-410A) Refrigerant