Carrier 38AUD 16 Series Manuals

1 38AUD Air Cooled Condensing Units 50 Hz With PuronR (R---410A) Refrigerant Sizes 16---25 Installation, Start---Up and Service Instructions CONTENTS SAFETY CONSIDERATIONS 2 . . . . . . . . . . . . . . . . . . . . INSTALLATION GUIDELINES 2 . . . . . . . . . . . . . . . . . . Replacement/Retrofit — R--22 to Puron 2 . . . . . . . . . . . INSTALLATION 8--18 . . . . . . . . . . . . . . . . . . . . . . . . . . . Jobsite Survey 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1 -- Plan for Unit Location 9 . . . . . . . . . . . . . . . . . . Step 2 -- Complete Pre--Installation Checks 9 . . . . . . . . . Step 3 – Prepare Unit Mounting Support 9 . . . . . . . . . . . Step 4 – Rig and Mount the Unit 9 . . . . . . . . . . . . . . . . . Step 5 – Complete Refrigerant Piping Connections 10 . . Step 6 – Install Accessories 15 . . . . . . . . . . . . . . . . . . . . Step 7 – Complete Electrical Connections 15 . . . . . . . . . PRE-START-UP 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Check 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn On Crankcase Heater 19 . . . . . . . . . . . . . . . . . . . . . Preliminary Charge 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . START--UP 19--25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary Checks 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Unit 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING SEQUENCE 26 . . . . . . . . . . . . . . . . . . . . . . Indoor (Supply) Fan 26 . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling, Unit Without Economizer 26 . . . . . . . . . . . . . . Cooling, Unit With Economizer 26 . . . . . . . . . . . . . . . . . Heating 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROUTINE SYSTEM MAINTENANCE 27 . . . . . . . . . . . . Quarterly Inspection (and 30 days after initial start) 27 . . . . . . . . . . . . . . . . . . Seasonal Maintenance 27 . . . . . . . . . . . . . . . . . . . . . . . . SERVICE 27--37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigeration System 27 . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing Systems on Roofs with Synthetic Materials 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Line Filter Drier 28 . . . . . . . . . . . . . . . . . . . . . . . Field Refrigerant Access Ports 28 . . . . . . . . . . . . . . . . . . Factory High--Flow Access Ports 28 . . . . . . . . . . . . . . . . Comfort Alert Diagnostic Module 29 . . . . . . . . . . . . . . . Compressor Protection 31 . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Heater 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low--Pressure Switch 31 . . . . . . . . . . . . . . . . . . . . . . . . . High--Pressure Switch 31 . . . . . . . . . . . . . . . . . . . . . . . . . Outdoor Fans 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Type Identification 35 . . . . . . . . . . . . . . . . . . . . . . . NOVATIONtCoil Cleaning and Maintenance 35 . . . . . Repairing NOVATION Condenser Tube Leaks 35 . . . . . Replacing NOVATION Condenser Coil 36 . . . . . . . . . . . Routine Cleaning of Round-Tube Plate Fin (RTPF) Coils 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Torque Values 37 . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 37--38 . . . . . . . . . . . . . . . . . . . . . . APPENDIX A Air Conditioner & Heat Pump with PuronR — Quick Reference Guide 39 . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX B Wiring Diagram List 39 . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX C Low Ambient Option — Factory Installed 40 . . . . . . . . . START--UP CHECKLIST . . . . . . . . . . . . . . . . . . . . 47--48 2 SAFETY CONSIDERATIONS Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions package Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloths for brazing operations and have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes for special requirements. In absence of local codes, it is recommended that the USA standard ANSI/NFPA 70, National Electrical Code (NEC), be followed. It is important to recognize safety information. This is the safety--alert symbol . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. 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 in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices, which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation. ELECTRICAL SHOCK HAZARD Failure to follow this warning could cause in personal injury or death. Before performing service or maintenance operations on unit, always turn off main power switch to unit and install lockout tag. Unit may have more than one power switch. ! WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could cause in personal injury,death and/or equipment damage. PuronR (R--410A) refrigerant systems operate at higher pressures than standard R--22 systems. Do not use R--22 service equipment or components on Puron refrigerant equipment. ! WARNING PERSONAL INJURY AND ENVIRONMENTAL HAZARD Failure to follow this warning could cause in personal injury or death. Relieve pressure and recover all refrigerant before system repair or final unit disposal. Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils. ! WARNING CUT HAZARD Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing 38AUD units. CAUTION ! INSTALLATION GUIDELINE Replacement /Retrofit — R--22 to PuronR Replacement/retrofit installations require change-out of outdoor unit, metering device, and filter driers. Change-out of indoor coil (evaporator) and interconnecting tubing is recommended. Existing evaporator coil – If the existing evaporator coil may be re-used, check with the coil manufacturer to verify the coil construction is suitable for operation with the higher pressures of PuronR (R-410A). Also determine if the existing TXV valve is compatible with R-410A, replace if necessary. The minimum factory test pressure rating must be 1725 kPa (250 psig). Existing coil will need to be purged with Nitrogen to remove as much mineral oil as possible to eliminate cross contamination of oils. Acid test – If the existing system is being replaced because of a compressor electrical failure, assume acid is in system. If system is being replaced for any other reason, use an approved acid test kit to determine acid level. If even low levels of acid are detected, install a 100 percent activated alumina suction-line filter drier in addition to the replacement liquid-line filter drier. Remove the suction line filter drier as soon as possible, with a maximum of 72 hr of operation. Recommendation: Install a ball valve in the liquid line at the filter drier location when installing a suction filter in the suction line. Existing refrigeration piping – Reuse of existing refrigerant piping involves three issues: quality (strength) of existing tubing, cleanliness and tube size. Inspect all tube segments and joints for signs of damage, corrosion or poor brazing. Flush the interconnecting piping system with dry Nitrogen to eliminate as much trace of mineral oil as possible. 38AUD 3 Same tube sizes are capable of handling higher flowrates (expressed as tons of cooling capacity) with Puron refrigerant compared to R--22 at constant pressure drops. For example, a 1/2--inch OD liquid line is rated at 33% higher tons with PuronR than with R--22 (at 5_F pressure drop). A 1 1/8--inch OD suction line is rated at 53% higher tons with Puron than with R--22 (at 2_F pressure drop). Refrigeration lines selected for R--22 use are typically oversized for Puron applications. Carefully check the existing suction line size against the table for maximum size (see Table 5); replace vertical riser segments if necessary. Check existing liquid line size against sizing data in Table 4; replace with smaller lines when feasible. Installation – 1. Remove the existing evaporator coil or fan coil and install the replacement coil when appropriate. 2. Drain oil from low points and traps in suction line tubing (and hot gas bypass tubing if appropriate) and evaporator if they were not replaced. Removing oil from evaporator coil may require purging of the tubing with dry nitrogen. 3. Unless indoor unit is equipped with a Puron ap- proved metering device, change the metering device to a thermal expansion valve (TXV) designed for PuronR (R-410A). 4. Remove the existing outdoor unit. Install the new out- door unit according to these installation instructions. 5. Install a new field-supplied liquid-line filter drier at the indoor coil just upstream of the TXV or fix orifice metering device. 6. If a suction line filter drier is also to be installed, in- stall suction line drier downstream of suction line ser- vice valve at condensing unit. UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation. Never install suction--line filter drier in the liquid--line of a PuronR system. CAUTION ! 7. If required, install a 100% activated alumina suction line filter drier at the outdoor unit. 8. Evacuate and charge the system according to the in- structions in this installation manual. 9. Operate the system for 10 hr. Monitor the pressure drop across the suction line filter drier. If pressure drop exceeds 21kPa (3 psig), replace suction-line and liquid-line filter driers. Be sure to purge system with dry nitrogen and evacuate when replacing filter driers. Continue to monitor the pressure drop across suction-line filter drier. Repeat filter changes is neces- sary. Never leave suction-line filter drier in system longer than 72 hr (actual time). 38AUD