Carrier Gemini 38AU07 Series Installation Instructions Manual

Contents

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.Catalog No. 04-53380020-01 Printed in U.S.A. Form 38AU-7-14-03SI Pg 1 1-19 Replaces: 38AU-7-14-02SIInstallation InstructionsCONTENTSPageSAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1INSTALLATION GUIDELINES. . . . . . . . . . . . . . . . . . . . . 2Replacement/Retrofit — R-22 to Puron . . . . . . . . . . . 2Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . . . 3Identify 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Step 7 — Install Accessories . . . . . . . . . . . . . . . . . . . . 14Step 8 — Complete Electrical Connections. . . . . . 14Step 9 — Wind Baffles for Low AmbientControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Turn on Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . 23Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Start Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24OPERATING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . 32Base Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3238AUDC with SVR Relays . . . . . . . . . . . . . . . . . . . . . . . 33All Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Quarterly Inspection (and 30 Days AfterInitial Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 34SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Comfort Alert Diagnostic Module . . . . . . . . . . . . . . . 36Compressor Protection . . . . . . . . . . . . . . . . . . . . . . . . . 38Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . 39TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Appendix A — Air Conditioner and Heat Pumpwith Puron® Quick Reference Guide . . . . . . . . . 41Appendix B — Wiring Diagram List . . . . . . . . . . . . . 42Appendix B — Low Ambient-Option,Factory Installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . CL-1SAFETY CONSIDERATIONSImproper installation, adjustment, alteration, service, main-tenance, 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 quali-fied installer or agency must use factory-authorized kits or ac-cessories when modifying this product. Refer to the individualinstructions packaged with the kits or accessories wheninstalling.Follow all safety codes. Wear safety glasses and workgloves. Use quenching cloths for brazing operations and have afire extinguisher available. Read these instructions thoroughlyand follow all warnings or cautions attached to the unit. Con-sult local building codes and appropriate national electricalcodes (in USA, ANSI/NFPA 70, National Electrical Code(NEC); in Canada, CSA C22.1) for special requirements.It is important to recognize safety information. This is thesafety-alert symbol . When you see this symbol on the unitand in instructions or manuals, be alert to the potential for per-sonal injury.Understand the signal words DANGER, WARNING, CAU-TION, and NOTE. These words are used with the safety-alertsymbol. DANGER identifies the most serious hazards whichwill result in severe personal injury or death. WARNING signi-fies hazards which could result in personal injury or death.CAUTION is used to identify unsafe practices, which may re-sult in minor personal injury or product and property damage.NOTE is used to highlight suggestions which will result in en-hanced installation, reliability, or operation.WARNINGFIRE, EXPLOSION HAZARDFailure to follow this warning could result in personalinjury or death.Disconnect gas piping from unit when leak testing at pres-sure greater than 0.5 psig (3450 Pa). Pressures greater than0.5 psig (3450 Pa) will cause gas valve damage resulting inhazardous condition. If gas valve is subjected to pressuregreater than 0.5 psig (3450 Pa), it must be replaced beforeuse. When pressure testing field-supplied gas piping atpressures of 0.5 psig (3450 Pa) or less, a unit connected tosuch piping must be isolated by closing the manual gasvalve.WARNINGELECTRICAL SHOCK HAZARDFailure to follow this warning could cause personal injuryor death.Before performing service or maintenance operations onunit, always turn off main power switch to unit and installlock(s) and lockout tag(s). Unit may have more than onepower switch.Gemini™38AU07-14Air-Cooled Condensing Unitswith Puron ® (R-410A) Refrigerant