Carrier GEMINI 38APD025-100 User Manual

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53380003-01 Printed in U.S.A. Form 38AP-1T Pg 1 210 11-09 Replaces: New
Controls, Start-Up, Operation,
Service, and Troubleshooting
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . .1,2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conventions Used in This Manual. . . . . . . . . . . . . . . . 2
Display Module Usage . . . . . . . . . . . . . . . . . . . . . . . . . . 17
• SCROLLING MARQUEE DISPLAY
• ACCESSORY NAVIGATOR™ DISPLAY MODULE
Main Base Board (MBB) . . . . . . . . . . . . . . . . . . . . . . . . . 18
Current Sensor Board (CSB) . . . . . . . . . . . . . . . . . . . . 18
Energy Management Module (EMM) . . . . . . . . . . . . . 18
Compressor Expansion Module (CXB) . . . . . . . . . . 19
AUX Board (AUX). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Enable/Off/Remote Contact Switch. . . . . . . . . . . . . . 19
Emergency On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . 19
Board Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Module Communication. . . . . . . . . . . . . . . . . 19
Carrier Comfort Network
®
(CCN) Interface. . . . . . . 20
OPERATING DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
• RETURN AIR TEMPERATURE (RAT) ACCESSORY
• SUPPLY AIR TEMPERATURE (SAT) ACCESSORY
• COMPRESSOR RETURN GAS TEMPERATURE
SENSOR (RGT)
• OUTDOOR-AIR TEMPERATURE SENSOR (OAT)
• DISCHARGE TEMPERATURE THERMISTOR (DTT)
• SPACE TEMPERATURE SENSOR (SPT)
Fan Status Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Thermostat Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure Transducer Inputs. . . . . . . . . . . . . . . . . . . . . 23
Energy Management Module . . . . . . . . . . . . . . . . . . . . 23
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operation of Machine Based on Control
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Set Point Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
• DEMAND LIMIT (2-Stage Switch Controlled)
• EXTERNALLY POWERED DEMAND LIMIT
(4 to 20 mA Controlled)
• DEMAND LIMIT (CCN Loadshed Controlled)
Cooling Set Point (4 to 20 mA) . . . . . . . . . . . . . . . . . . 32
Digital Scroll Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-49
Preliminary Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjust Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 34
Check Compressor Oil Level . . . . . . . . . . . . . . . . . . . . 47
Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Page
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Actual Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Operating Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
• AMBIENT LIMITATIONS
• VOLTAGE (ALL UNITS)
Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-59
Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . 49
• CONTROL COMPONENTS
Thermistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pressure Transducers. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Condenser Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Motormaster
®
V Controller . . . . . . . . . . . . . . . . . . . . . . 54
• GENERAL OPERATION
• CONFIGURATION
• DRIVE PROGRAMMING
•EPM CHIP
• LOSS OF CCN COMMUNICATIONS
• TROUBLESHOOTING
• REPLACING DEFECTIVE MODULES
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59,60
Recommended Maintenance Schedule . . . . . . . . . . 59
Microchannel Heat Exchanger (MCHX) Condenser
Coil Maintenance and Cleaning
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 60-66
Complete Unit Stoppage and Restart. . . . . . . . . . . . 60
• GENERAL POWER FAILURE
• UNIT ENABLE-OFF-REMOTE CONTACT SWITCH
IS OFF
• FAN STATUS INPUT OPEN
• OPEN 24-V CONTROL CIRCUIT BREAKER(S)
• COOLING LOAD SATISFIED
• THERMISTOR FAILURE
• COMPRESSOR SAFETIES
Alarms and Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
APPENDIX A — DISPLAY TABLES . . . . . . . . . . . 67-78
APPENDIX B — CCN TABLES . . . . . . . . . . . . . . . . 79-84
START-UP CHECKLIST FOR 38AP SPLIT SYSTEM
CONDENSING UNIT . . . . . . . . . . . . . . . . . . . . CL-1-CL-5
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can be
hazardous due to system pressures, electrical components, and
equipment location (roof, elevated structures, mechanical
rooms, etc.). Only trained, qualified installers and service
mechanics should install, start up, and service this equipment.
GEMINI™ SELECT
38APS025-050,38APD025-100
Commercial Air-Cooled Condensing Units
with COMFORTLINK™ Controls
50/60 Hz

Carrier GEMINI 38APD025-100 Specifications

General

Brand	Carrier
Model	GEMINI 38APD025-100
Category	Air Conditioner
Language	English

Summary

SAFETY CONSIDERATIONS

CONTROLS

General

Overview of the 38AP condensing unit's ComfortLink control system.

Conventions Used in This Manual

Explains text conventions for navigating the control system display menus.

Display Module Usage

Details the 4-key interface for accessing unit information and testing.

CONTROL COMPONENTS

Overview of the main control components like MBB, CSB, EMM.

Sensors

Details various sensors used for monitoring unit conditions.

Operating Modes

Describes various operating modes like Ramp Load and Demand Limit.

Set Point Adjustment

Covers adjusting set points for cooling and temperature reset.

Demand Limit

Explains different types of demand limiting configurations.

PRE-START-UP

System Check

Verifies proper installation and condition of unit components before start-up.

Adjust Refrigerant Charge

Check Compressor Oil Level

Actual Start-Up

Steps for starting the unit, including fan and control checks.

OPERATION

Ambient Limitations

Lists minimum and maximum ambient operating temperatures for the unit.

Voltage (All Units)

Explains acceptable supply voltage ranges and imbalance limits.

Operation Sequence

Describes the unit's start-up and running sequence.

SERVICE

Electronic Components

Overview of the control system and component access.

Thermistors

Details thermistor functions and types used for unit control.

Pressure Transducers

Motormaster® V Controller

Low-ambient operation accessory and troubleshooting.

DRIVE PROGRAMMING

Fault Codes

REPLACING DEFECTIVE MODULES

COMPRESSOR REPLACEMENT

Refers to procedures included with new compressors for replacement.

TROUBLESHOOTING

Complete Unit Stoppage and Restart

Discusses unit stoppage causes and restart methods.

Compressor Safeties

Explains compressor protection mechanisms and triggers.

Advanced Scroll Temperature Protection

Alarms and Alerts

Warnings of abnormal conditions causing shutdown, with code numbers.

Wiring Error

COMPRESSOR STUCK ON FAILURE ALARMS

Alarms when current sensor detects current when compressor is off.

T114 (Circuit A Low Superheat)

A151 (Illegal Configuration)

Indicates an invalid configuration has been entered into the system.

Table 26 Alarm and Alert Codes

Compressor Availability Alerts

Alerts for circuit compressor availability issues.

Compressor Failure Alerts

Alerts for compressor failure due to current sensor issues.

Thermistor Failure Alerts

Alerts for thermistor failures in various sensors.

Pressure Transducer Failure Alerts

Alerts for discharge and suction pressure transducer failures.

Loss of Charge Alerts

Alerts for low refrigerant charge conditions.

APPENDIX A — DISPLAY TABLES (cont)

Run Status Mode and Sub-Mode Directory

Lists items and displays for Run Status mode.

APPENDIX A — DISPLAY TABLES (cont)

Service Test Mode and Sub-Mode Directory

Lists items and displays for Service Test mode.

APPENDIX A — DISPLAY TABLES (cont)

Temperature Mode and Sub-Mode Directory

Lists items and displays for Temperature mode.

APPENDIX A — DISPLAY TABLES (cont)

Inputs Mode and Sub-Mode Directory

Lists items and displays for Inputs mode.

Outputs Mode and Sub-Mode Directory

Lists items and displays for Outputs mode.

APPENDIX A — DISPLAY TABLES (cont)

Configuration Mode and Sub-Mode Directory

Lists items and displays for Configuration mode.

APPENDIX A — DISPLAY TABLES (cont)

Time Clock Mode and Sub-Mode Directory

Lists items and displays for Time Clock mode.

APPENDIX A — DISPLAY TABLES (cont)

Operating Mode and Sub-Mode Directory

Lists modes controlling the unit.

Alarms Mode and Sub-Mode Directory

Lists active alarms and alert history.

APPENDIX B — CCN TABLES (cont)

Status Tables

Displays unit parameters and their point names.

APPENDIX B — CCN TABLES (cont)

CCN Configuration Tables

Lists CCN configuration parameters and their point names.

APPENDIX B — CCN TABLES (cont)

CCN Maintenance Tables

Lists CCN maintenance parameters.

Start-Up Checklist for 38AP Split System Condensing Unit

I. Project Information

Section for recording project details like job name and address.

II. Preliminary Equipment Check

Checks for physical damage and proper installation of unit components.

Refrigeration System Check

III. Unit Start-Up

Steps for verifying unit start-up conditions and parameters.

Start and Operate Machine. Complete the Following:

OPERATING DATA:

Section to record operating temperatures and pressures in stable condition.