Installation, Start-Up and Service Instructions

Transcription

1 09AW,AZ Remote Air-Cooled Condenser 1 to 20 Tons Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS GENERAL ,2 INSTALLATION Step 1 Complete Pre-Installation Checks Step 2 Rig and Place Unit LOCATION RIGGING PLACING UNIT MOUNTING UNIT Step 3 Complete Refrigerant Piping GENERAL COIL CIRCUITING LIQUID LIFT REFRIGERANT LINE SIZING LIQUID SHUTOFF VALVE AND SIGHT GLASS PRESSURE RELIEF CHECK VALVE REFRIGERANT RECEIVER COIL CONNECTIONS Step 4 Complete Electrical Connections GENERAL CONNECTIONS MAIN POWER WIRING CONTROL CIRCUIT POWER WIRING GENERAL WIRING NOTES FAN CYCLING HEAD PRESSURE CONTROL HEAD PRESSURE CONTROL MOTOR HEAD PRESSURE CONTROL START-UP System Evacuation and Dehydration Charging Procedure Check Operation of Condenser Fan Motor Controls and Rotation of Fans Clockwise (CW) SERVICE ,24 Fan Guard Removal Condenser Fan Adjustment Fan Motor Removal MAINTENANCE ,25 Condenser Coil Maintenance and Cleaning Lubrication TROUBLESHOOTING START-UP CHECKLIST CL-1, CL-2 SAFETY CONSIDERATIONS Installing, starting up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical components, and equipment location. Only trained, qualified installers and service mechanics should install, start-up, and service the 09AW,AZ equipment (Fig. 1A and 1B). When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment. Follow all safety codes. Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher nearby when brazing. Use care in handling, rigging, and setting bulky equipment. Separate power sources (main and control power circuits) are used for these units. Be sure both main and control power circuits are disconnected before servicing. Electrical shock could cause personal injury. Fig. 1A Typical 09AWH012 Unit Fig. 1B Typical 09AWV012 Unit GENERAL These units are remote air-cooled condensers for use as part of an Ecozone indoor package system or with liquid chilling packages, or other air-cooled compressor and remote condenser units. Models are available for either vertical or horizontal airflow. Two types are available: 09AW units for general applications, and 09AZ units that have been optimized for use with the 50BZ remote air-cooled vertical package units. Refer to Fig. 2 and 3 for model number nomenclature. Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 2 4 PC 111 Catalog No Printed in U.S.A. Form 09AW,AZ-2SI Pg Replaces: 09AW,AZ-1SI Tab 4a 4a

2 Units are remote air-cooled condensers with direct drive axial flow condenser fan. These units are available in nominal heat rejection capacity in 11 sizes from 1 to 20 tons. Inlet and discharge are on opposite sides of the unit. Units may be mounted in any area having unobstructed air circulation. Low silhouette permits installation on varied ground, roof, or suspended applications. Each unit consists of direct-drive motor(s), propeller fan(s), fan guards, motor mounts, condenser coil with optional integral subcooling circuit (standard on 09AZ), and electrical junction box. Factory options that extend the capability and features of the unit are available. Check space requirements, service clearances, floor strength, location of piping, size of power supply, and airflow clearances before installing. See Fig for unit dimensions and Table 1 for unit operating weights. INSTALLATION Step 1 Complete Pre-Installation Checks Examine unit for damage incurred during shipment. File claim immediately with transit company if damage is found. Check the shipment for completeness. Verify that the nameplate electrical requirements match the available power supply. Step 2 Rig and Place Unit LOCATION If roof installation is specified, make certain that roof structure can support condenser weight. Refer to Table 1. Locate condenser where an adequate supply of inlet outdoor air is available. Do not locate where the possibility of air recirculation exists, such as under a roof overhang. Locate in an area free from airborne dirt or other foreign material that could clog condenser units. Units 09AW and 09AZ006,008 can be assembled for either horizontal or vertical airflow. The mounting stand is shipped unassembled with each unit. Fasteners are included. Assembly instructions are on page 16. It is a simple procedure to assemble the stand to the unit for either vertical or horizontal airflow. Vertical airflow units 09AWV,AWW and 09AZV,AZW are shipped with the legs installed and are shipped with legs retracted, they must be adjusted to operating position for unit installation. No assembly is required. Horizontal models 09AWH,AWL and 09AZH, AZL must have the legs field installed. RIGGING Leave the units in the carton or on the skid until they are as close to the installation location as possible. The method of rigging depends on the unit size. Models 09AWH,AWL and 09AZH,AZL006,008 may be lifted into position by grasping underneath the cabinet or by using the lifting holes. Never lift the unit by the header or the return bends. The preferred method for all other units is with spreader bars from above the unit. Lifting lugs are provided to aid in lifting the unit. Use 2-in. OD pipe and hooks in lifting eyes. Rig with 4 cables and spreader bars. All panels must be in place when rigging. See Table 1 and Fig. 12 for details concerning shipping weights, distance between lifting holes, center of gravity, and spreader bar dimensions. If overhead rigging is not possible, place unit on skid or pad for rolling or dragging. When dragging, pull the pad. Do not apply force to the unit. When in final position, raise from above to lift unit off skid. PLACING UNIT The 09AW,AZ units are designed for outdoor applications. If the unit is mounted indoors, provisions must be made to ensure that discharge air is not recirculated into the unit. If the unit is ducted, the duct must not add more than 0.1 in. wg to the static pressure imposed on the fans. Horizontal units 09AWH,AWL and 09AZH,AZL should be installed with coil side facing the prevailing winds. If strong variable winds are common, it is recommended that a fieldfabricated wind baffle be used on the inlet side of the unit. See Fig. 13. Maintain at least 24 in. between the face of the coil and any obstruction such as another unit or a wall. If the unit discharges toward a wall, space the unit at least 48 in. from the wall. If several units are installed in the same area, make sure that discharge air from one unit does not become intake air for another. Vertical units 09AWV,AWW,AZV,AZW and smaller horizontal units, when installed as vertical discharge units, should be located no closer than the width of the unit to an obstruction such as a wall or another unit. Keep the area around each unit clear to avoid restricting the airflow to the unit. There must be 4 ft for service and for unrestricted airflow on all sides of the unit and a minimum of 8 ft clear air space above units. See Fig For multiple units, allow 8 ft separation between units for airflow and service. MOUNTING UNIT Units must be level to ensure proper drainage of liquid refrigerant and oil. When units are installed on a roof, they must be mounted on support beams that span load walls. Ground mounted units should be installed on concrete pads of sufficient size to prevent grass and brush from blocking the unit inlet. When unit is level and in proper location, use mounting holes in legs for securing unit to supporting structure. Fasteners for mounting unit must be field supplied. If unit is to be mounted on vibration isolators, use mounting holes in bottom of support legs as support points, and locate isolators at those points. Step 3 Complete Refrigerant Piping Refer to Tables 1 and 2 for standard unit circuiting and operating charge. GENERAL All field leak and pressure testing should be in accordance with local code requirements. If no local code exists, follow American National Standards Institute (ANSI), American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) Safety Standard 15, latest revision. For leak testing procedures, refer to the Carrier Refrigerant Service Techniques manual. Perform Phos-copper brazing on all field-made connections while protecting adjacent points from heat. COIL CIRCUITING Units must be ordered from the factory with the required number of circuits and with optional final pass subcooling circuit if required by the application. The 09AZ units do not have circuiting options but are circuited to match with the Ecozone 50BZ units of the same tonnage size. Two-circuit condensers may be manifolded together if required by the application. To prevent unit damage, never connect two separate compressor-evaporator circuits together on the same condenser circuit. To avoid damage to units, do not forklift them unless they are attached to skids designed for forklifting. Forklift trucks used to lift units on skids must have forks a minimum of 48 in. long. 2

3 09 AW H 012 V E A Ecozone 09 Remote Air-Cooled Condenser AW Direct-Drive General Purpose Configuration H Horizontal, Standard Motor V Vertical, Standard Motor* L Horizontal, Low Sound Motor W Vertical, Low Sound Motor* Nominal Heat Rejection Size Tons Size Tons / Motor Control Option - Open Drip Proof (ODP) C Contactors, ODP F Fan Cycling, ODP V Speed Control, ODP** T Totally Enclosed, Air Over Motor (TEAO) E Contactors, TEAO D Fan Cycling, TEAO W Speed Control, TEAO** Circuiting Option - Single Circuit, No Subcooling A Single Circuit with Subcooling D Two Circuit, No Subcooling E Two Circuit with Subcooling Factory Options A Aluminum Cabinet B Fused Disconnect C 24 Volt Transformer D Aluminum Cabinet, Fused Disconnect E Aluminum Cabinet, 24 Volt Transformer F Fused Disconnect, 24 Volt Transformer G Aluminum Cabinet, Fused Disconnect, 24 Volt Transformer Packaging 1 Standard Design Series V-Ph-Hz (sizes ) or (sizes ) 3 208/ / Coil Construction Option - Aluminum Fin/Copper Tube C Copper Fin/Copper Tube E Polyester Coated Aluminum Fin/Copper Tube X E-Coated Aluminum Fin/Copper Tube Z E-Coated Copper Fin/Copper Tube *Units only. Sizes 001 to 012 may be field mounted for vertical or horizontal airflow. Fan cycling includes contactors. **Speed control includes contactors on all units and fan cycling on 006 to 020 unit sizes. Fused disconnect available on 3-phase units only. Fig. 2 09AW Model Number Nomenclature 09 AZ H 012 V A Ecozone 09 Remote Air-Cooled Condenser Factory Options A Aluminum Cabinet B Fused Disconnect D Aluminum Cabinet, Fused Disconnect F Fused Disconnect, 24 Volt Transformer AZ Direct-Drive (Sized to Work Best with 50BZ) Configuration H Horizontal, Standard Motor V Vertical, Standard Motor* L Horizontal, Low Sound Motor W Vertical, Low Sound Motor* Nominal Heat Rejection Size Tons Size Tons / Motor Control Option - Open Drip Proof (ODP) with Contactors F Fan Cycling, ODP V Speed Control, ODP T Totally Enclosed, Air Over Motor (TEAO) with Contactor D Fan Cycling, TEAO W Speed Control, TEAO Circuiting Option - Single Circuit or Two Circuit with Subcooling** 3 Packaging 1 Standard Design Series V-Ph-Hz (sizes ) or (sizes ) 3 208/ / Fig. 3 09AZ Model Number Nomenclature Coil Construction Option - Aluminum Fin/Copper Tube C Copper Fin/Copper Tube E Polyester Coated Aluminum Fin/Copper Tube X E-Coated Aluminum Fin/Copper Tube Z E-Coated Copper Fin/Copper Tube *Units only. Sizes 006 to 008 may be field mounted for vertical or horizontal airflow. Fan cycling included with speed control on 008 to 016 size units. **As required with 50BZ of the same tonnage size. Fused disconnect available on 3-phase units only.

4 HORIZONTAL DISCHARGE VERTICAL DISCHARGE *Coil connection dimensions reflect single circuit units. Control box size varies depending on control options. UNIT 09AWH, 09AWL FAN QUANTITY TOTAL WEIGHT (lbs) DIMENSIONS (in.) A B C D E** F** G** H** 1 Ckt 2 Ckt X Y X Y / / / / / 4 5/ 8 5/ / / / / / 4 7/ 8 5/ 8 5/ 8 5/ / / / / / 4 7/ 8 5/ 8 7/ 8 5/ / / / / / / 8 7/ 8 7/ 8 5/ 8 **Approximate dimensions. Fig. 4 Base Unit Dimensions; 09AWH,AWL

5 HORIZONTAL DISCHARGE VERTICAL DISCHARGE *Coil connection dimensions reflect single circuit units. Control box size varies depending on control options. UNIT 09AWH,09AWL FAN QUANTITY TOTAL WEIGHT (lbs) DIMENSIONS (in.) Ckt 1 Ckt 2 A** B** C** D E D E / / / / 8 7 / 8 7 / 8 5 / / / / / / 8 7 / 8 5 / / / / / / 8 7/ 8 **Approximate dimensions. Fig. 5 Base Unit Dimensions; 09AWH,AWL

6 HORIZONTAL DISCHARGE 24 1/2 7 1/4 2 3/4 4 1/2 23 1/2 24 CLEARANCE AIRFLOW CLEARANCE 3 19 (APPROX) 46 1/ MAX. 98 1/ /2 DIA. (4) LIFTING HOLES ELECTRICAL* CONTROL BOX INLET GAS CONNECTION* B 48 LIQUID OUTLET CONNECTION* A 48 CLEARANCE 19 (APPROX) 3/4 ELECTRICAL POWER CONNECTION 48 CLEARANCE *Coil connection dimensions reflect single circuit units. Control box size varies depending on control options. 46 1/4 MTG. CTR S 1/2 99 1/4 UNIT 100 1/4 FAN QUANTITY 47 3/4 TOTAL WEIGHT (lbs) 1/2 DIMENSIONS (in.) Ckt 1 Ckt 2 A B A B / / / 8 7/ 8 09AWH,09AWL / / / 8 7 / / / / 8 7 / / / / 8 7/ 8 Fig. 6 Base Unit Dimensions 09AWH,AWL

7 VERTICAL AIRFLOW *Control box size varies depending on control options. UNIT FAN QUANTITY TOTAL WEIGHT (lbs) DIMENSIONS (in.) Ckt 1 Ckt 2 A B A B / / / 8 7 / 8 09AWV,AWW / / / 8 7 / / / / 8 7/ / / / 8 7 / 8 Fig. 7 Base Unit Dimensions; 09AWV,AWW

8 HORIZONTAL DISCHARGE VERTICAL DISCHARGE *Control box size varies depending on control options. NOTES: 1. Service clearance must be at least 48 in. on all sides. 2. Field assembly of discharge liquid headers is required. UNIT FAN QUANTITY TOTAL WEIGHT (lbs) DIMENSIONS (in.) A B C D E F G H X Y 09AZH / / / / / 4 7/ 8 5/ 8 Fig. 8 Base Unit Dimensions; 09AZH006 8

9 HORIZONTAL DISCHARGE 8 MAX. 98 1/ /2 2 3/4 7 1/2 1 1/2 DIA. (4) LIFTING HOLES ELECTRICAL CONTROL BOX 4 1/2 23 1/2 INLET GAS* CONNECTION B 24 CLEARANCE AIRFLOW 48 CLEARANCE (APPROX) LIQUID OUTLET CONNECTION* A (APPROX) 48 CLEARANCE 3/4 ELECTRICAL POWER CONNECTION 46 1/4 48 1/2 46 1/4 MTG. CTR S /4 47 3/4 1/2 VERTICAL AIRFLOW *Coil connection dimensions reflect single circuit units. Control box size varies depending on control options. UNIT FAN QUANTITY TOTAL WEIGHT (lbs) DIMENSIONS (in.) A B 09AZH / / 8 09AZL / / / / 8 Fig. 9 Base Unit Dimensions; 09AZH008, 09AZL006,008 9

10 HORIZONTAL DISCHARGE 24 1/2 7 1/4 2 3/4 61 3/4 42 3/4 38 1/4 AIRFLOW / (APPROX) 46 1/ MAX. 98 1/ /2 DIA. (4) LIFTING HOLES ELECTRICAL* CONTROL BOX INLET GAS CONNECTION CIRCUIT 1 HEAD PRESSURE CONNECTION PORT SUBCOOLER OUTLET CONNECTION INLET GAS 1 1/8 CONNECTION 48 CIRCUIT 2 SUBCOOLER OUTLET 7/8 CONNECTION 19 (APPROX) 3/4 ELECTRICAL POWER CONNECTION 1/2 46 1/4 MTG. CTR S 99 1/ /4 47 3/4 1/2 *Control box size varies depending on control options. UNIT FAN QUANTITY TOTAL WEIGHT (lbs) AZH AZL Fig. 10 Base Unit Dimensions; 09AZH,AZL

11 VERTICAL AIRFLOW *Control box size varies depending on control options. UNIT FAN QUANTITY TOTAL WEIGHT (lbs) AZV AZW Fig. 11 Base Unit Dimensions; 09AZV,AZW

12 Table 1 Physical Data UNIT 09AWH,AWV RATING (Tons) / OPERATING WEIGHT (lb) SHIPPING WEIGHT (lb) REFRIGERANT R-22/R-134a (See Table 2 for Operating Charge) NOM HEAT REJECTION* FAN Direct Drive Quantity Prop. Diameter (in.) Blade Quantity Rpm Total Airflow (cfm) ,700 15,600 15,400 15,300 Motor Hp (per fan) 1/ 2 1/ 2 1/ 2 1/ 2 1/ 2 1/ 2 1/ / / / / 2 COIL Cu Tube/Al Fin or Cu Tube/Cu Fin or Cu Tube with Coated Fin Arrangement May be mounted Vertical/Horizontal** Factory ordered Vertical or Horizontal Rows Fins/in Total Face Area (sq ft) Number of Circuits 1 1 or 2 Subcooler Optional CONNECTIONS (in.)*** In, 1 Circuit 5 / 8 7 / 8 7 / / 8 7 / / / / / / / 8 Out, 1 Circuit 5 / 8 5 / 8 5 / 8 7 / 8 5 / 8 7 / / / / / / 8 In, 2 Circuit N/A 5 / 8 7 / 8 5 / 8 7 / 8 7 / / / / / / 8 Out, 2 Circuit 5 / 8 5 / 8 5 / 8 5/ 8 5 / 8 7 / 8 7 / 8 7 / 8 7 / / 8 UNIT 09AWL,AWW RATING (Tons) / OPERATING WEIGHT (lb) SHIPPING WEIGHT (lb) REFRIGERANT R-22/R-134a (See Table 2 for Operating Charge) NOM HEAT REJECTION* FAN Direct Drive Quantity Prop. Diameter (in.) Blade Quantity Rpm Total Airflow (cfm) ,600 11,400 11,500 11,300 Motor Hp (per fan) 1 / 1 4 / 1 4 / 1 4 / 1 4 / 1 4 / 1 4 / 1 4 / 1 2 / 1 2 / 1 2 / 2 COIL Cu Tube/Al Fin or Cu Tube/Cu Fin or Cu Tube with Coated Fin Arrangement May be mounted Vertical/Horizontal** Factory ordered Vertical or Horizontal Rows Fins/in Total Face Area (sq ft) Number of Circuits 1 1 or 2 Subcooler Optional CONNECTIONS (in.)*** In, 1 Circuit 5 / 8 7 / 8 7 / / 8 7 / / / / / / / 8 Out, 1 Circuit 5 / 8 5 / 8 5 / 8 7 / 8 5 / 8 7 / / / / / / 8 In, 2 Circuit N/A 5 / 8 7 / 8 5 / 8 7 / 8 7 / / / / / / 8 Out, 2 Circuit 5 / 8 5 / 8 5 / 8 5/ 8 5 / 8 7 / 8 7 / 8 7 / 8 7 / / 8 *Heat rejection is based on 25 F temperature difference from saturated discharge temperature to entering-air temperature. Motors on single phase units sized are 1 hp. **Units may be mounted vertically or horizontally. Unit is factory ordered for vertical or horizontal discharge. ***Connection sizes depend on number of circuits used. 12

13 Table 1 Physical Data (cont) UNIT 09AZH,AZV 09AZL,AZW RATING (Tons) / / OPERATING WEIGHT (lb) SHIPPING WEIGHT (lb) REFRIGERANT R-22/R-134a (See Table 2 for Operating Charge) NOM HEAT REJECTION* FAN Direct Drive Quantity Prop. Diameter (in.) Blade Quantity Rpm Total Airflow (cfm) ,260 15,132 14, ,070 10,872 10,566 Motor Hp (per fan) 1/ 2 1/ / / / 2 1/ 4 1/ 4 1/ 2 1/ 2 1/ 2 COIL Cu Tube/Al Fin or Cu Tube/Cu Fin or Cu Tube with Coated Fin Arrangement ** ** Rows Fins/in Total Face Area (sq ft) Number of Circuits Subcooler Standard CONNECTIONS (in.) In, 1 Circuit 7 / / 8 N/A N/A N/A 1 1 / / 8 N/A N/A N/A Out, 1 Circuit 5 / / 8 7 / 8 7 / 8 In, 2 Circuit N/A N/A 7 / / / 8 N/A N/A 1 1 / / / 8 Out, 2 Circuit 7 / 8 7 / 8 7 / 8 7 / 8 7 / / 8 *Heat rejection is based on 25 F temperature difference from saturated discharge temperature to entering-air temperature. Unit may be mounted vertically or horizontally. **Unit is factory ordered for vertical or horizontal discharge. 13

14 L* 8 FT. MIN. GRAVITY CL C B GRAVITY CL A *Length of spreader bar (L) should be approximately equal to the distance between hoisting points. NOTE: Unit weight is nearly equally distributed on each leg within 10%. RIGGING INFORMATION 09AWH, 09AWL 09AWV, 09AWW 09AZH 09AZL 09AZV 09AZW UNIT TOTAL WT (lb) DIMENSIONS (in.) CENTER OF GRAVITY (in.) Operating Shipping A L B C / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / 8 Fig. 12 Rigging with Spreader Bars (Field Supplied) 14

15 Table 2 Condenser Refrigerant Charge per Circuit WITHOUT SUBCOOLER CIRCUIT WITH OPTIONAL SUBCOOLER CIRCUIT UNIT CIRCUITS Tubes Min. Charge (lbs) Max Charge (lbs) Tubes Total Charge (Note 1) (Note 2) (Note 3) 09AW AW AW AW AW AW AW AW AW AW AW NOTES: 1. Tubes are number of condensing tubes (less the subcooler circuit). 2. Minimum charge is based on 5 F subcooling when optional subcooler circuit is used. 3. Maximum charge is based on 15 F subcooling when optional subcooler circuit is used. 4. Storage volume is based on 80% liquid and 20% vapor at 100 F, R-22 refrigerant. For charge with R-134a, multiply ratings by STORAGE VOLUME (lbs) (Note 4) 09AZH006 1 N/A N/A AZL006 1 N/A N/A AZH008 1 N/A N/A AZL008 1 N/A N/A AZH,AZV012 2 N/A N/A AZL,AZW012 2 N/A N/A AZH,AZV014 2 N/A N/A AZL,AZW014 2 N/A N/A AZH,AZV016 2 N/A N/A AZL,AZW016 2 N/A N/A

16 FIELD FABRICATED WIND BAFFLE ITEM 3 FIELD FABRICATED SUPPORT ANGLES AS REQUIRED 24" MIN. VERTICAL LEG* VERTICAL LEG* ITEM 1 NUT* ITEM 2 (HIDDEN) BASE/FOOT* BOLT* BOLT* BASE/FOOT* VERTICAL LEG* *Provided standard on horizontal units, invert stand for suspended mounting. 12 3/4" 1/4" DIAM HOLES 7/32" DIAM 5 HOLES 7/32" DIAM "F" HOLES 1" 1/4" 24 9/16" 7 1/2" 23/32" 17 5/32" 1/4" 1/2" 3/4" 30 1/4" 6" 1/4" 1/4" 7 1/2" 7 1/2" 30 B 1 3/16" 7 1/2" 1/4" MAKE ONE AS SHOWN AND ONE OPPOSITE HAND 3/4" 9/32" DIAM 2 HOLES 9/32" DIAM 5 HOLES 6" 6" 6" 1 1/2" C 1 1/2" 1 3/16" A 10 5/8" 10 1/8" 6" TYPICAL 1/2" ITEM 1 (16 GA) ITEM 2 (16 GA) ITEM 3 (18 GA) NOTE: Wind baffle installation does not apply on vertical airflow units. UNIT SIZE DIMENSIONS (in.) 09AWH,AWL A B C 001, / / / 2 003, / / / 2 006,008, / / / 2 014,016,018, AZH,AZL 006 (AZH) 31 1 / / / (AZL) 61 1 / / / 2 008,012,014, Fig. 13 Horizontal Field Fabricated Wind Baffle Dimensions and Leg Installation Instructions 16

17 NOTE: All coils are purged with dry nitrogen and then capped prior to shipment. The coils DO NOT contain a refrigerant holding charge. LIQUID LIFT Amount of liquid lift available before refrigerant flashing occurs depends on amount of liquid sub-cooling in the system. All 09AW,AZ condensers have positive subcooling when applied with 15 F subcooling and subcooling circuit. With subcooling, it is possible to overcome an appreciable pressure drop and/or static head pressure (due to elevation of the liquid metering device above the condenser when condenser is below evaporator coil). When 09AW,AZ condensers are applied with 5 F subcooling, they may not provide positive subcooling at expansion device (TXV). If subcooling is required, it must be obtained by external means such as a liquid suction interchanger. It is recommended that the evaporator be either at the same level as the condenser or lower than the condenser when 5 F subcooling is used. REFRIGERANT LINE SIZING Sizing depends on the length of lines between various sections of the refrigerant system. Consider the amount of liquid lift and pressure drop in the system as well as proper compressor oil return. Consult Carrier System Design Manual, Part 3, or ASHRAE section for proper piping sizes and design. Use the following guideline for refrigerant piping: Discharge Lines Base line size on a 2 F change in saturated condensing temperature. Lines must be sized and routed so that oil is carried through the system. When the condenser is located at a higher level than the compressor, take special precautions that oil will return at reduced capacity. A double hot gas riser may be required with high lift and a large degree of unloading. Be sure to trap the connections between both risers. See Fig. 14. RISER NO. 1 FROM COMPRESSOR RISER NO. 2 Fig. 14 Double Hot Gas Riser TO CONDENSER Protect the compressor from liquid refrigerant or oil draining back during compressor off cycles. The highest point in the discharge line should be above the highest point in the condenser coil. A purge valve should be applied at this point. The hot gas line should loop to the floor if the condenser is located above the compressor, especially if the hot gas riser is long. If the condenser is located where the entering-air temperature could be higher than the ambient at the compressor location, a check valve should be installed in the hot gas line. Liquid Lines Liquid lines can generally be sized for a 1 to 2 F change in saturation temperature. Liquid lines should be as small as possible to minimize system change. Liquid lines should be free of traps and loops. Piping should be routed to avoid excessive strain on system components or piping. Discharge lines must be supported with rigid pipe supports to prevent transmission of vibration and movement of the line. The discharge line should be well supported near the condenser hot gas connection. Use offsets in interconnecting lines between 2 condensers and provide isolation where pipes pass through building walls or floors. LIQUID SHUTOFF VALVE AND SIGHT GLASS A shutoff valve is not supplied with 09AW,AZ condensers. It is strongly recommended that a full line size liquid shutoff valve (see Fig. 15 and 16) be field supplied near condenser to allow for servicing parts of the refrigerant circuit. A field-supplied moisture-indicating sight glass is recommended for use in charging and servicing the system. A Schrader port connection is also recommended on the liquid and discharge line at the condenser for ease in troubleshooting when the condenser is located out of sight from the compressor evaporator unit. PRESSURE RELIEF The American National Standards Institute and American Society of Heating, Refrigeration, and Air Conditioning Engineers (ANSI/ASHRAE) 15 Safety Code for Mechanical Refrigeration states the following: Every refrigerant system shall be protected by a pressure relief device unless so constructed that the pressure due to fire conditions will be safely relieved by some part of the system. Since 09AW,AZ condensers have no pressure relief device, one should be field supplied and installed just before the liquid line service valve. See Fig. 15 and 16. When the split coil is used with multiple systems, each system must have its own pressure relief. If desired, the pressure relief requirement can also be satisfied by installing a fusible plug in the liquid line. To do so, install a tee in the liquid line with a 1 / 4 -in. NPT fitting on the tee side, and install a fusible plug (part no. EK02KK105 or similar). The temperature rating of the fusible plug should be between 205 F and 220 F. If a service valve is used on the liquid line, be sure that both the piping system and the condenser are protected for relief if all service valves are closed. NOTE: If the condenser is located indoors, requirements for venting the fusible plug to the outdoors may apply. Consult local code requirements. CHECK VALVE When the 09AW,AZ condenser is installed with the condenser located above the compressor evaporator, it is recommended that a field-supplied check valve be installed on the hot gas discharge line. This prevents refrigerant which condenses in the discharge line during the off cycle from draining back into the compressor. Install the check valve at the compressor line before the line goes up to the condenser. Check valve part number EC37BP183 or similar may be used. REFRIGERANT RECEIVER A refrigerant receiver is NOT furnished with 09AW,AZ condensers and is not recommended for normal applications as its use is detrimental to adequate refrigerant storage volume and the desired effects of subcooling. However, if a particular application requires a receiver to increase refrigerant holding capacity of the condenser, a receiver can be used. Carrier recommends the following installation in such a case. See Fig. 17. NOTE: When a receiver is to be used all year it should be installed indoors. 17

18 SEE NOTE 4 CONTROL BOX HOT GAS LINE COMPRESSOR ELECTRICAL POWER CONNECTION TO NEC DISCONNECT LOW VOLTAGE TO COMPRESSOR CONTROL UNIT MUFFLER CHECK VALVE* PRESSURE RELIEF DEVICE* SHUTOFF VALVE* SEE NOTE 5 LIQUID LINE FILTER-DRIER* MOISTURE INDICATOR* SEE NOTE 3 *Field supplied. NOTES: 1. Wiring and piping shown are general points of connection guides only and are not intended for or to include all details for a specific installation. 2. All wiring must comply with applicable local and national codes. 3. All piping must follow standard piping techniques. Refer to Carrier System Design Manual, Part 3, ASHRAE section on refrigerant piping, or the Carrier E20-II Software Refrigerant Piping program, for proper piping sizes and design. 4. Hot gas lines should rise above refrigerant level in condenser circuit. 5. Trap should be installed on hot gas lines to prevent condenser oil and refrigerant vapor migration from accumulating on compressor heads during off cycle. 6. For piping lengths greater than 50 ft (15.2 m), provide support to liquid and gas lines near the connections to the coil. 7. Pitch all horizontal lines downward in the direction of refrigerant flow. 8. For pressure relief requirements, see latest revision of ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) Standard 15, Safety Code for Mechanical Refrigeration. Fig. 15 Typical Piping for 09AW,AZ Condenser with a Single Compressor 18

19 AIRFLOW SEE NOTE 4 HOT GAS LINES CONTROL BOX ELECTRICAL POWER CONNECTION TO NEC DISCONNECT CHECK VALVE* SEE NOTE 3 COMPRESSORS LOW VOLTAGE FROM INDOOR COMPRESSOR CONTROL CIRCUIT PRESSURE RELIEF DEVICES* SHUTOFF VALVES* FILTER-DRIERS* MUFFLER SEE NOTE 7 MUFFLER MOISTURE INDICATORS* (SIGHT GLASS) SEE NOTE 5 CHECK VALVE* SEE NOTE 7 SEE NOTE 7 *Field supplied. NOTES: 1. Wiring and piping shown are general points of connection guides only and are not intended for or to include all details for a specific installation. 2. All wiring must comply with applicable local and national codes. 3. All piping must follow standard piping techniques. Refer to Carrier System Design Manual, Part 3, ASHRAE section on refrigerant piping, or the Carrier E20-II Software Refrigerant Piping program, for proper piping sizes and design. 4. Hot gas lines should rise above refrigerant level in condenser circuit. 5. Trap should be installed on hot gas lines to prevent condenser oil and refrigerant vapor migration from accumulating on compressor heads during off cycle. 6. For piping lengths greater than 50 ft (15.2 m), provide support to liquid and gas lines near the connections to the coil. 7. Pitch all horizontal lines downward in the direction of refrigerant flow. 8. For pressure relief requirements, see latest revision of ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) Standard 15, Safety Code for Mechanical Refrigeration. Fig. 16 Typical Piping for 09AW,AZ Condenser with a Dual Split System 19

20 Locate the receiver below the condenser. The condenser to receiver liquid line must be sized to allow free drainage. This line should be sized so the velocity does not exceed 100 fpm. Generous sizing of the liquid (condensate) line is especially important if the receiver is exposed at any time to a warmer entering-air temperature than the condenser. It must be large enough for the liquid to flow to the receiver and at the same time allow flow of refrigerant vapor in the opposite direction back to the condenser. The receiver will become vapor locked under these conditions if re-evaporated gas is not allowed to flow back to the condenser for recondensation. Locate valves on each side of the receiver so receiver will be isolated from system for normal operation. Procedure for Using the Refrigerant Receiver (Fig. 17) During Normal Operation Valve A is open and valves B and C are closed. Receiver is isolated from the system. For Servicing Valves A and C are closed and valve B is open. Run unit until all the refrigerant is in the receiver and then close valve B. Unit is now ready for servicing. To Resume Operation Leave valve A closed and open valves B and C. Run unit until the stored refrigerant is drawn into the system. To completely remove the refrigerant from the receiver, throttle valve B while noting condition of refrigerant in the liquid line sight glass; also monitor suction pressures. A sudden surge of bubbles in the sight glass and a rapid decrease in suction pressure indicates that all the refrigerant has been withdrawn from the receiver. Immediately close valves B and C, and then open valve A. The unit should now be ready for normal operation, with the receiver isolated from the system. The system should be charged to a clear sight glass when under normal operation. COIL CONNECTIONS See Table 1 for the necessary connections. Step 4 Complete Electrical Connections GENERAL Verify that nameplate electrical requirements match available power supply. Voltage at condenser must be within the minimum and maximum shown in Table 3, and phases must be balanced within 2%. Contact local power company for line voltage corrections. Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine the percentage of voltage imbalance: max voltage deviation % Voltage Imbalance = 100 x from average voltage Average voltage Example: Supply voltage is AB = 243 volts BC = 236 volts AC = 238 volts Average Voltage = = 3 = 239 volts Determine maximum deviation from average voltage: (AB) = 4 volts (BC) = 3 volts (AC) = 1 volt Maximum deviation is then 4 volts. To determine the percentage of voltage imbalance: % Voltage Imbalance = 100 x = 1.7% This amount of phase imbalance is satisfactory since it is below the maximum allowable of 2%. IMPORTANT: If supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately. *Field-supplied. A Bypass valve B Receiver inlet valve C Receiver outlet valve Fig. 17 Piping for Optional Receiver Condenser operation on improper line voltage or excessive phase imbalance may be considered abuse and any resulting damage may not be covered by Carrier warranty. All wiring must be in accordance with NEC (National Electrical Code, U.S.A.) regulations or local codes. CONNECTIONS Refer to Table 3 and Fig. 18 for field wiring details. MAIN POWER WIRING Install field-supplied branch circuit fused disconnect(s) of a type that can be locked OFF or OPEN. Disconnect(s) must be within sight from and readily accessible from unit in compliance with NEC Article or local code. The units must have adequate overcurrent protection, fuses, or HACR (Heating, Air Conditioning, and Refrigeration) breakers according to the national and applicable local codes. For field power connections, all main power wiring enters the unit through a factory-punched access hole under the control box. Attach power wires to power terminal block (or the fan relay if not equipped with a power terminal block), to the 3 power connections in the unit control box. Be sure to install a ground wire. See Fig

21 AWH, AWV UNIT 09 UNIT 09 AWL, AWW AZH, AZV AZL, AZW UNIT 09 UNIT , 002, 003, , 008, , 016, 018, , 002, 003, , 008, , 016, 018, , , 014, 016 Table 3 Electrical Data V-PH-Hz VOLTAGE RANGE CONDENSER FAN POWER SUPPLY* Min Max Hp/Fan FLA MCA MOCP 208/ / / / / / / / / / / / / / / / / V-PH-Hz VOLTAGE RANGE CONDENSER FAN POWER SUPPLY* Min Max Hp/Fan FLA MCA MOCP 208/ / / / / / / / / / / / / / / V-PH-Hz VOLTAGE RANGE CONDENSER FAN POWER SUPPLY* Min Max Hp/Fan FLA MCA MOCP 208/ / / / / / / / / / / / / / / / / / V-PH-Hz VOLTAGE RANGE CONDENSER FAN POWER SUPPLY* Min Max Hp/Fan FLA MCA MOCP 208/ / / / / / / / / / CONTROL CIRCUIT POWER WIRING Connect 24-v control wires to the 2 low-voltage connections at the control terminal block. GENERAL WIRING NOTES Factory options including speed control, head pressure control, winter start control, fan cycling, and electrical interlock, may affect wiring connections. 1. Power entry is at one end only. 2. Fan motors are thermally protected. All 3-phase motors are protected against primary single-phasing conditions. 3. Replacement of factory wires must be with appliance wiring material rated 105 C or its equivalent. 4. Factory wiring is in accordance with National Electrical Code. Field modifications or additions must be in compliance with all applicable codes. FAN CYCLING HEAD PRESSURE CONTROL This factory mounted thermostat control option may be used with all 2 condenser-fan models. The control allows head pressure control by stopping the second condenser fan when the ambient temperature is below 60 F. On 2 condenser-fan units, fan cycling head pressure control is installed as part of the head pressure control option. Fan control switch is adjustable from 20 F to 70 F and factory set at 60 F. The fan nearest the header end of the unit is not cycled. The optional factory-installed fan cycling package consists of fan contactors and an entering-air thermostat installed in the condenser control box. Set the thermostat per the setting in Table 4. If design temperature difference (TD) is unknown use 25 F TD. NOTE: Table 4 is for 2-fan units. Table 4 Fan Cycling Thermostat Setting FAN QUANTITY 2 LEGEND TD Temperature Difference DESIGN TD (F) THERMOSTAT SET POINT (F) LEGEND FLA Full Load Amps MCA Minimum Circuit Amps MOCP Maximum Overcurrent Protective Device (see Note 1) NEC National Electrical Code *Min Ckt Amps and MOCP Amps values per NEC rounded to full wire size (see Note 1). Fan quantity. NOTES: 1. In compliance with NEC requirements for multimotor and combination load equipment (NEC Articles 430 and 440), the overcurrent protective device for the unit shall be either circuit breaker (where available) or fuse. Canadian units may be fuse or HACR circuit breaker. 2. Wire sizing amps (MCA) are a sum of 125% of the condenser-fan motor FLA. 3. Motors are protected against primary single phasing condition. 4. Three-phase voltage imbalance must not exceed 2%. 5. The 575-v units not available with low sound motors. 21

22 SINGLE PHASE POWER SCHEMATIC PB1 CONTACTOR OPTION M1 NEC DISCONNECT CAP MTR 1 EQUIP GND M2 MTR 2 CAP TRAN 24 VAC TRANSFORMER OPTION FROM INDOOR UNIT (24v) CONTROL SCHEMATIC TB1 OPTIONAL FAN CYCLING FC2 M1 M2 THREE PHASE POWER SCHEMATIC OPTIONAL FUSED DISCONNECT POWER TERMINAL BLOCK PB1 CONTACTOR OPTION M1 MTR 1 EQUIP GND M2 MTR 2 24 VAC FROM INDOOR UNIT (24v) CONTROL SCHEMATIC TB1 OPTIONAL FAN CYCLING FC2 TRAN TRANSFORMER OPTION M1 M2 LEGEND EQUIP Equipment FC2 Fan Cycling Control GND Ground M1, M2 Fan Motor Contactor MTR1, MTR2 Fan Motor NEC National Electrical Code PB1 Power Terminal Block TB1 Control Terminal Block TRAN Transformer NOTES: 1. Motor 1 is located on header end of the unit. 2. Field control connections are made to terminal block TB1. Contactor (when supplied) holding voltage is 24 volts. 3. See unit wiring book for wiring with factory-installed head pressure control. Fig. 18 Typical Wiring Schematic (09AZH012 Shown) 22

23 HEAD PRESSURE CONTROL this factory-installed option reduces the condensing capacity under low outdoor temperature conditions. See Table 5 for minimum operation with each step of head pressure control. Depending on the indoor compressor and evaporator unit the 09AW,AZ unit is matched with, certain other system modifications may be required. Also, the load on the condenser will affect the need for head pressure control. If the condenser is used on a system for comfort cooling application, assume the minimum capacity step must be met. Table 5 Minimum Outdoor-Air Operating Temperature FAN 1 2 HEAD PRESSURE CONTROL None Head Pressure Control None Fan Cycle Switch Head Pressure Control TD (F) LEGEND TD Temperature Difference COMPRESSOR CAPACITY (%) Minimum Outdoor Air Temperature (F) MOTOR HEAD PRESSURE CONTROL All units, when ordered with fan head pressure control are furnished with the number 1 condenser motor as a single-phase motor for use with head pressure control. The optional factory-mounted motor head pressure control contains a fan head pressure control device activated by a pressure sensor. The kit controls condenser-fan motor speed in response to the saturated condensing pressure. For outdoor temperatures down to 20 F ( 29 C), it maintains the condensing temperature at 100 F ± 10 F (38 C ± 6 C). If indoor unit has a low-pressure switch, the use of the winterstart kit (part no. CRWINSTR01A00) is recommended. This kit bypasses the low-pressure switch on start-up. The use of the defrost thermostat kit (part no. 50BB ) is also recommended for sensing frost on the evaporator coil if suction temperature drops too low. In addition, the 09AW,AZ units may require a field fabricated wind baffle for condenser inlet to reduce wind circulation, which will affect the stable operation of the motor head pressure control. START-UP To prevent personal injury, be sure wire fan guards are secured in place over each fan discharge (or that fans are ducted), before starting the unit. Complete Unit Start-Up Checklist on page CL-1 during initial start-up of this system. System Evacuation and Dehydration Refer to GTAC II, Module 4, Dehydration for Proper Evacuation and Dehydration Techniques. Charging Procedure BEFORE CHARGING THE SYSTEM, INSTALL OR REPLACE THE FILTER- DRIER(S) CONNECTED TO THE LIQUID LINE IN THE INDOOR UNIT TO PREVENT CONTAMINATION WITH- IN THE SYSTEM. Refer to GTAC II, Module 5 Charging, Recovery, Recycling, and Reclamation and Carrier Refrigerant Service Techniques manual for proper charging techniques. Charge by weight or to subcooling. When this is not possible, charge to a clear sight glass. The required weight of refrigerant is the sum of the operating charges of the condenser, evaporator, refrigerant specialties, and the refrigerant lines. See Table 6 for weight of refrigerant in lines and Table 2 for standard weight of charge in condenser. When charging to clear sight glass add a maximum of 1 / 2 lb of R-22 per ton over clear sight glass to flood sub-cooler sections of the condenser coils. See Table 2 for charging data. Table 6 Weight of Refrigerant in Lines (lbs per 100 ft) LINE SIZE LIQUID LINE 110 F SUCTION LINE 40 F DISCHARGE LINE 115 F OD R-22 R-134a R-22 R-134a R-22 R-134a 5 / / / / / / / / / Check Operation of Condenser Fan Motor Controls and Rotation of Fans Clockwise (CW) Rotation should be clockwise as viewed looking into fan discharge. IMPORTANT: Check for proper fan rotation. If rotation needs to be reversed on three-phase motors, disconnect main power supply and switch any 2 leads at the load side of the disconnect switch. SERVICE Fan Guard Removal Remove the eight 1 / 4 - x 5 / 8 -in. self-tapping hex-head screws that hold the fan grille to the condenser-fan panel, and remove the grille. Condenser Fan Adjustment To prevent personal injury, be sure wire fan guards are secured in place over each fan discharge before starting the unit. 1. Be sure power is off to the condenser-fan motor. 2. Remove the fan guard. 3. Remove the cap, and set screws on the fan hub. 4. Adjust fan. See Fig Tighten fan hub securely on the motor shaft with set screw that bears against the key. 6. Replace the permagum sealing material and the rubber cap over the end of the motor shaft to prevent moisture from causing fan to rust on the shaft. 7. Replace the fan guard. 23

24 HUB TOP COVER FAN SHAFT 1/3 HEIGHT OF FAN BLADE ABOVE VENTURI LIP FILL HOLE IN FAN HUB WITH PERMAGUM FAN BLADE HUB PLATE Fig. 19 Location of Propeller on Motor Shaft from Outside of Orifice Ring Fan Motor Removal 1. Make certain condenser power is off. 2. Remove fan guard and fan. 3. Loosen nut on the motor holding clamp that secures motor to motor support. 4. Lift motor upward. Remove the fan wheel through the fan discharge opening. Remove wire connectors. 5. Replace in opposite order. Be sure to check location of fan in orifice when replacing fan. MAINTENANCE The 09AW,AZ units require very little maintenance. Regular maintenance should include cleaning the surface of the coil and checking to make sure that all electrical connections are tight. All motors have permanently sealed ball bearings that do not require lubrication. Check for loose electrical connections, oil level, proper refrigerant charge, and refrigerant piping leaks. Do not use high-pressure water or air to clean condenser coils. Damage to fins may result. Units installed in corrosive environments should be cleaned as part of a planned maintenance schedule. In this type of application, all accumulations of dirt should be cleaned off the coil. Condenser-fan motors are drip-proof but not watertight. Condenser Coil Maintenance and Cleaning Routine cleaning of condenser coil surfaces is essential to maintain proper operation of the unit. Elimination of contamination and removal of harmful residue will greatly increase the life of the coil and extend the life of the unit. The following maintenance and cleaning procedures are recommended as part of the routine maintenance activities to extend the life of the coil. REMOVE SURFACE LOADED FIBERS Surface loaded fibers or dirt should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft brush may be used. The cleaning tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins. NOTE: Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse. PERIODIC CLEAN WATER RINSE A periodic clean water rinse is beneficial for coils that are applied in coastal or industrial environments. However, it is important that the water rinse is made with very low velocity water stream to avoid damaging the fin edges. Monthly cleaning is recommended. ROUTINE COIL SURFACE CLEANING Monthly cleaning with Enviro-Shield Coil Cleaner is essential to extend the life of coils. It is recommended that all coils, including standard aluminum, precoated, copper/copper, or E-coated coils are cleaned with Enviro-Shield Coil Cleaner. Coil cleaning should be part of the regularly scheduled maintenance procedures of the unit to ensure long life of the coil. Failure to clean the coils may result in reduced durability of the coil in the environment. Enviro-Shield Coil Cleaner is non-flammable, hypoallergenic, non-bacterial, USDA accepted biodegradable and 100% ecologically safe agent that will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces or insulation. Use of non-recommended coil cleaners is strongly discouraged since coil and unit durability could be affected. The following field-supplied equipment is required for coil cleaning: 2 1 / 2 Gallon Garden Sprayer Water Rinse with Low Velocity Spray Nozzle Enviro-Shield Coil Cleaner TO CLEAN THE COIL Wear proper eye protection such as safety glasses during mixing and application. 1. Remove all surface loaded fibers and dirt with a vacuum cleaner. 2. Thoroughly immerse finned surfaces with clean water using a low velocity water stream from a garden hose being careful not to bend fins. 3. Mix Enviro-Shield Coil Cleaner in a 2 1 / 2 gallon garden sprayer according to the instructions included with the Enviro-Shield Coil Cleaner. The optimum solution temperature is 100 F. IMPORTANT: DO NOT USE water with temperature in excess of 130 F. Enzymes in coil cleaner will be destroyed and coil cleaner will not be effective. 4. Thoroughly apply Enviro-Shield Coil Cleaner solution to all coil surfaces including finned area, tube sheets, and coil headers. Hold garden sprayer nozzle close to finned areas and apply cleaner with a vertical, up-and-down motion. Avoid spraying in horizontal pattern to minimize potential for fin damage. Ensure cleaner thoroughly penetrates deep into finned areas. Interior and exterior finned areas must be thoroughly cleaned. 5. Allow finned surfaces to remain wet with cleaning solution for 10 minutes. Ensure surfaces are not allowed to dry before rinsing. Reapply cleaner as needed to ensure 10-minute saturation is achieved. 6. Thoroughly rinse all surfaces with low velocity clean water using downward rinsing motion of water spray nozzle. Protect fins from damage from the spray nozzle. Harsh chemical, household bleach, or acid cleaners should not be used to clean condenser or evaporator coils. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin/tube interface where dissimilar materials are in contact. If there is dirt below the surface of the coil, use the E-coat Enviro-Shield Coil Cleaner to clean the coil. High velocity water from a pressure washer or garden hose, or compressed air should never be used to clean a coil. The force of the water or air jet will bend the fin edges and increase airside pressure drop. Reduced unit performance or nuisance unit shutdown may occur. 24