Carrier 09BY006-024 User's Manual
Contents
1. HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT Y N DO THE FAN BELTS HAVE PROPER TENSION Y N __ HAS CORRECT FAN ROTATION BEEN CONFIRMED Y N __ PIPING HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR CONDENSER EVAPORATOR TXVs Thermostatic Expansion Valves SOLENOID VALVES FILTER DRIERS AND FUSIBLE PLUGS WITH A LEAK DETECTOR Y N LOCATE REPAIR AND REPORT ANY LEAKS HAVE ALL COMPRESSOR SERVICE VALVES BEEN FULLY OPENED BACKSEATED Y N HAVE LIQUID LINE SERVICE VALVES BEEN OPENED Y N IS THE OIL LEVEL IN THE COMPRESSOR CRANKCASE ON THE UNIT IN VIEW IN THE COMPRESSOR SIGHT GLASS IF APPROPRIATE Y N HAS CONDENSER PRESSURE RELIEF BEEN PROVIDED Y N CL 1 CHECK VOLTAGE IMBALANCE IS CONDENSER MOTOR WIRED FOR CORRECT VOLTAGE Y N LINE TO LINE VOLTS AB V V BC V AC BC 3 AVERAGE VOLTAGE V MAXIMUM DEVIATION FROM AVERAGE VOLTAGE V VOLTAGE IMBALANCE 100 X MAX DEVIATION AVERAGE VOLTAGE 96 IF OVER 296 VOLTAGE IMBALANCE DO NOT ATTEMPT TO START SYSTEM CALL LOCAL POWER COMPANY FOR ASSISTANCE C Start Up CHECK INDOOR EVAPORATOR FAN SPEED AND RECORD CHECK OUTDOOR CONDENSER FAN SPEED AND RECORD AFTER AT LEAST 15 MINUTES RUNNING TIME RECORD THE FOLLOWING MEASUREMENTS OIL PRESSURE Where Appropriate SUCTION PRESSURE SUCTION LINE TEMP DISCHARGE PRESSURE DISCHARGE LINE TEMP ENTERING CONDENSER AIR TEMP LEAVING CONDENSER AIR TEMP EVAP ENTERING AIR2. 09BY006 024 Air Cooled Condenser Units 5 to 20 Tons Installation Start Up and CONTENTS Page SAFETY CONSIDERATIONS 1 GENERAL pA eae 1 INSTALLATION 1 12 Step 1 Complete Pre Installation Checks 1 Step 2 Rig and Place Unit 7 RIGGING PLACING THE UNIT VIBRATION ISOLATION POSITIONING THE 09BY UNIT VERTICAL DISCHARGE Step 3 Install Accessory Low Ambient Kit or Inlet Filter Kit If Required 8 Step 4 Install Rain Drain 8 Step 5 Complete Refrigerant Piping 8 GENERAL REFRIGERANT LINE SIZING PRESSURE RELIEF REFRIGERANT RECEIVER LIQUID LIFT SWEAT CONNECTIONS FIELD PIPING MANIFOLDING CIRCUITS CHECK VALVE SERVICE VALVES Step 6 Ductwork 10 CONDENSER AIR DUCT INSULATION Step 7 Insulate the Unit 11 Step 8 Complete Electrical Connections 11 GENERAL MAIN POWER WIRING CONTROL CIRCUIT POWER WIRING GENERAL WIRING NOTES START UP e Aw E au 13 System Evacuation and Dehydration 13 Charging Procedure 13 Check Operation of Condenser Fan Motor Controls and Rotation of Fans 13 Adjust Fan Speed 13 SERVICE crt bete s 13 15 Cleaning Condenser Coils 13 Lubrication 13 Condenser Fan
3. Inspection Check coil baffles for tight fit to prevent air from bypassing the coil Check panels for air leakage particularly those sealing the fan and coil compartments Check for loose electrical connections oil level proper refrigerant charge and refrigerant piping leaks The 09 fan motor and fan shaft bearings are permanently lubricated Further lubrication is not required Before start up be sure all service valves are open backseated Air Filters Air filters may be installed on the con denser air inlet Air filters should be replaced or cleaned on a regular basis depending on how dirty the operating envi ronment is Failure to clean air filters regularly will result in loss of unit performance and possible nuisance tripping of the high pressure switch Condensate Drain If the 09BY unit is used with a condensate drain to remove rain water the drain pan and trap should be cleaned at least twice per year After cleaning test the condensate drain for proper operation by pouring a bucket of water into the condensate drain pan The water should flow out immediately and evenly TROUBLESHOOTING See Table 6 for problems and possible solutions Table 6 Troubleshooting PROBLEM POTENTIAL CAUSE SOLUTION 1 Fan belts are slipping or broken 1 Check and replace belts as necessary 2 Fan is not delivering adequate air for condenser 2 Check airflow see Table 2 Unit is tripping on 3 Low ambient damper
4. DB dry bulb TEMP EVAP ENTERING AIR WB wet bulb TEMP EVAP LEAVING AIR DB TEMP EVAP LEAVING AIR WB TEMP COMPRESSOR AMPS CIRCUITA LIL2 CIRCUIT L1 L2 __ __ CIRCUIT L1 L2 NOTES Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 2 4 PC 111 Catalog No 530 969 Printed in U S A Form 09BY 2S1 CL 2 9 96 Replaces 09 15 Tab 4 4 CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE
5. Yeu E 502 F 0 174 1 118 F 347 G 1 4 1 4 2 0 G 610 H 01 1 3 H 394 J 0 3 0 27 63 K 5 3 7 0 K 2140 L 2 3 29 L 838 M 0 0 19 0 194e 0 194 0 3 M 40 40 40 40 80 L7 6n 2 P 37 46 P 1372 R 15 115 20 R 610 MOTOR ACCESS TYPICAL ALL UNITS PANEL CONTROL AND POWER CONNECTION 7 8 DIA 22 0 2 15 16 76MM 0 3 9 15 91MM 0 3 9 16 91MM 0 4 13 16 120MM RAIN DRAIN 1 06 DIA 27MM 0 1 25MM 0 3 1 8 80MM 0 3 15 16 100MM 0 4 3 4 121MM 0 2 3 8 0 6 1 16 1154 1 RAIN DRAIN 1 06 DIA 27MM 0 3 15 16 100MM LEFT SIDE 012 014 ONLY Fig 3 Base Unit Dimensions CORNER WEIGHTS Lb SIZE D 006 42 008 44 012 64 014 78 016 91 024 95 REFRIGERANT CONNECTION ACCESS HOLES 1 1 2 DIA 38MM ACCESS PANEL CONTROL AND POWER CONNECTION 7 8 DIA 22 MM 0 1 3 8 35MM 0 4 5 16 110MM 0 1 13 16 47MM 0 5 1 8 130MM 0 2 3 8 60MM RAIN DRAIN 0 3 1 8 80MM D 1 067 L27MM 0 8 3 4 223MM 0 2 3 8 60MM 0 2 3 8 60MM 1 6 1 4 463MM 0 2 3 8 60 1 0 2 3 8 60MM CORNER FRONT CORNER RIGHT SIDE 016 024 ONLY A B REFRIGERANT COIL CONNECTIONS AT THE CONTROL BOX END 1 2 13 MM LIQUID 5 8 16 MM SUCTION 005 C TYP G F H CONTROL POWER CONNECTION 7 8 DIA 22 MM NOTE ALL CABINET
6. care not to puncture the coil when removing and installing screws CONDENSER AIR DUCT INSULATION The con denser air duct must be insulated on indoor installations to prevent moisture condensation on the unit panels during cold weather Insulate as follows 1 If metal ductwork is used insulation may be applied on the inside of the duct This installation should be ex tended to cover the inside of the 09BY duct flanges It is necessary to insulate the inside of the ducts at the duct flanges to reduce heat loss from the metal cabinet by conduction through the duct flanges and into the cold duct Interior insulation allows the metal duct to approach room temperature It also prevents condensation from forming and collecting under the insulation which will occur with exterior duct insulation NOTE Fiberglass duct board may also be used if per mitted by local codes 2 If insulation is applied to the outside of the metal duct the inside must be insulated for a length of 10 in from the unit including the duct flanges or up to the flexible duct vapor barrier on the outside which must be tightly sealed to prevent condensation under the insulation DIMENSIONS in Pea ite 6 37 16 25 e 20 16 26 457 24 14 6 20 16 26 so 14 6 20 30 26 63 so 20 2s 36 so 20 e 25 30 36 8575 INLET LOUVER DETAIL 14 GAGE ALUMINUM OR 18 GAGE GALVANIZ
7. from average voltage 100 x rigid foamed insulation such as Styrofoam will be re quired inside the ducts to prevent air erosion The insu lation must be firmly secured in the discharge duct near the blower discharge to withstand the high air velocity Step 7 Insulate the Unit The 09BY units are not insulated If the unit will be operated during cold weather and the equipment room is not at outdoor temperatures the unit cabinet should be insulated to prevent condensation In sulate the unit in the same manner as the ductwork insula tion described in Condenser Air Duct Insulation section on page 10 A B C Table 4 Electrical Data average voltage Example Supply voltage is 240 3 60 AB 243 v BC 236 v AC 238 v 243 236 238 Average Voltage 3 717 3 239 v UNIT VOLTAGE SUPPLYVOLTAGE POWER SUPPLY D9BY 3 Ph 60 Hz FLA Hp MCA MOCP 15 006 15 15 20 008 60 15 15 20 012 60 15 15 208 230 187 254 20 9 35 15 35 016 15 15 30 8 60 024 14 0 10 30 ES 20 LEGEND EMi allowable phase imbalance Voltage 2 Amps 10 FLA Full Load Amps 2 Maximum incoming wire size for power circuit is 2 0 max MCA Minimum Circuit Amps Used for wire sizing Complies with NEC Section 430 24 MOCP Maximum Overcurrent Protection NEC National Electrical Code Units are suitable for use on electrical systems where voltage sup p
8. indoors requirements for venting the fusible plug to the out doors may apply Consult local code requirements REFRIGERANT RECEIVER A refrigerant receiver is not furnished with O9BY condensers and is not recommended for normal applications LIQUID LIFT Amount of liquid lift available before frigerant flashing occurs depends on amount of liquid sub cooling in the system All 09BY condensers have positive subcooling when ap plied with optimum charge 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 O9BY condensers are applied with minimum charge they do not provide positive subcooling If subcooling is re quired it must be obtained by external means such as a liq uid suction interchanger It is recommended that the evaporator be either at the same level as the condenser or lower than the condenser when mini mum is used SWEAT CONNECTIONS Connections are made inside the unit and piping may enter from either side For ease in brazing it is recommended that all internal solder joints be made before unit is placed in its final position See 50BZ or other compressor bearing unit base unit installation instruc tions for proper line sizing and piping procedures FIELD PIPING For 09BY remote installation select pipe sizes according to length fr
9. is provided shipped in the fan section This kit consists of PVC drain fittings to adapt to field supplied threaded pipe Make connections through the unit side panel Some applications may require connection to either galva nized steel or copper drain pipe consult local code require ments for details If unit is located inside the building the drain connection near the refrigerant piping can be used for external drainage Run drain connection to a trapped drain and plug unused connection IMPORTANT NEVER use pipe smaller than 34 in in the drain run For vertical discharge units provide a rain drain on the back of the unit Pitch drain pipe downward at a slope of at least Va in per ft for proper drainage Provide tees plugged on one side for cleanouts Leave clearance for servicing and observe all lo cal sanitary codes Refer to Carrier System Design Manual for additional pip ing details Step 5 Complete Refrigerant Piping GENERAL field leak and pressure testing should be done in accordance with local code requirements If a local code does not exist use ASHRAE American Society of Heat ing Refrigeration and Air Conditioning Engineers Stand ard 15 Safety Code for Mechanical Refrigeration For leak testing procedures refer to the Carrier Refrig erant Service Techniques book Form SFT 01 For any parts that need to be removed use a mini tubing cutter Perform phos copper brazing on all field m
10. 0000 586 163 598 209 668 235 743 283 799 325 2 14000 821 612 872 702 770 955 8s 16000 Seal LEGEND BHP Brake Horsepower NOTES 1 Shaded areas indicate field supplied drive and or motor are required 2 Nominal cfm is 600 cfm ton 14 TO CHANGE FAN WHEEL If a fan wheel should fail it may be replaced as follows 1 Remove belts from fan pulley 2 Loosen locking collars on the fan bearings and set screws on the fan wheels 3 Remove the shaft through the access panel on either side of the unit 4 Remove the fan cut off plate in the fan discharge 5 Remove the fan wheel through the fan discharge opening 6 Replace the wheel and reverse Steps 1 4 above TO REPLACE FAN BEARING If a fan bearing fails replace it as follows Remove belts from the fan pulley Support fan shaft Loosen locking collar on fan bearing Remove bearing from the shaft Install new bearing onto the shaft and reverse Steps 1 3 above NOTE Fan bearing and shaft are metric sizes MAINTENANCE Cleaning The 09BY unit should be thoroughly cleaned inside and out Frequency of cleaning will depend on unit location and area conditions 15 Drains must be kept free of dirt and trash Coils can be cleaned with a stiff brush vacuum cleaner or compressed air Coil can be reached through access panels
11. 12 5 014 p __ 2 5 a 016 p ak es c a 024 See eee ee eS ee 5 LEGEND 5 Standard O Optional NOTE Contact your local representative for use with reciprocating air cooled chillers and other compressor bearing unit combinations Table 2 Physical Data UNIT 09 oos o2 o4 NOMINAL TONS 20 OPERATING WEIGHT Lb 970 REFRIGERANT R 22 Number of Circuits 1 1 2 2 2 3 Minimum Charge Lb Ckt 6 11 6 6 11 11 11 Optimum Charge Lb Ckt 8 38 14 5 8 38 8 38 14 5 14 5 14 5 Storage Volume Ft Ckt 0 31 0 47 0 31 0 31 0 47 0 47 0 47 Holding Charge Nitrogen Charge CONDENSER FAN Belt Drive Centrifutal Nominal Airflow Cfm 3000 4500 6000 7200 9000 12 000 Cfm Range 2000 4500 3400 6400 4500 7000 6000 7600 6700 9750 7500 11 000 Quantity 2 2 2 2 2 2 Size in 8 8 x 8 8 11 0 x 11 0 11 0 x 11 0 11 0 x 11 0 12 4 x 12 4 14 0 x 14 0 Pulley Size in 516 798 658 616 10 1316 Motor Pulley Range in 4316 52 4316 512 4 5 4 5 434 6 598 658 1365 1566 960 1260 1106 1455 1045 1306 840 1050 686 847 Maximum Fan Rpm 1705 1365 1365 1365 1210 955 Belt Quantity Size 1 41 1 46 1 45 2 45 2 88 3 90 Pulley Center Line Distance in 11 2 12 6 13 6 15 0 13 6 15 0 13 6 15 0 32 6 33 8 30 0 30 7 Fan Shaft mm 20 25 25 25 25 30 Motor Shaft in 78 1 1 1 1 1 Motor Hp Type 2 TEFCt 3 TEFC 3 TEFC 5 TEFC 5 TEFC 10 TEFC Motor Frame Size 145T 182T 182T 184T
12. 184T 215T Maximum Motor Hp 3 5 5 5 5 10 CONDENSER COIL in OD Enhanced Copper Tube Aluminum Fin Rows Fins per in 4 14 5 14 5 14 5 14 15 5 15 Face Area sq ft 6 33 8 75 10 12 11 45 19 38 19 38 CONNECTIONS Hot Gas Quantity 1 1 2 2 2 3 Size in Ve Ve Ve Ve Ve Ve Liquid Line Quantity 1 1 2 2 2 3 Size in 1 Ve Ve Ve Ve Ve Condensate Drain in 34 FPT CONTROLS 24 V Control Fan Contactor Provided in Unit Metric size TTEFC Totally Enclosed Fan Cooled NOTE Optimum charge is based on 15 F subcooling Minimum charge is based on 5 F subcooling Step 2 Rig and Place Unit RIGGING The O9BY units are mounted on skids Leave the unit on the skid until it is in the final position While on the skid the unit can be rolled dragged or forklifted do not apply force to the unit Use a minimum of 3 rollers when rolling and raise from above to remove the skid when unit is in the final position See Fig 4 for rigging details PLACING THE UNIT Locate the condenser where an adequate supply of outdoor air is available for the unit inlet NOTE Unit inlet and discharge may both be ducted to the outside Either provide inlet filters to protect the condenser coils or locate the condenser in an area free from airborne dirt or other foreign material which could clog the coils For mul tiple units allow service clearance Fig 3 between units and locate unit discharges and inlets so that recirculation of conden
13. Adjustment 13 TO CHANGE FAN SPEED PULLEY ALIGNMENT BELT TENSION ADJUSTMENT TO CHANGE FAN WHEEL TO REPLACE FAN BEARING MAINTENANCE 15 Cleaning eoe eere 15 15 Air Filtets omen ues 15 Condensate Drain 15 TROUBLESHOOTING 16 START UP CHECKLIST CL 1 CL 2 Service Instructions SAFETY CONSIDERATIONS Installing starting up and servicing air conditioning equip ment 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 this 09 equipment Fig 1 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 braz ing Use care in handling rigging and setting bulky equipment ELECTRIC SHOCK HAZARD 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 GENERAL The 09BY air cooled condenser is a remote air cooled con denser designed to be used with the 50BZ vertical packaged units See Table 1 Airflow is horizontal both into an
14. DE VIEW REAR VIEW HORIZONTAL DISCHARGE LEFT SIDE VIEW DISCHARGE PROTECTION SCREEN CONDENSER COIL MOTOR ADJUSTING PLATE MOTOR VIEW A A Fig 1 O9BY Unit 008 014 Shown TUBING FIELD SUPPLIED SUPPORTS 09BY MOUNTED REMOTELY ABOVE 50BZ 09 TUBING 09BY MOUNTED REMOTELY INSIDE OF WINDOW O9BY MOUNTED REMOTELY ON OUTSIDE WALL FIELD SUPPLIED SUPPORTS LEGEND O Refrigerant Connection Field Supplied Refrigerant Piping Field Supplied Floor Stand Height to Match Wall Opening HANGER RODS TO OUTSIDE E INSULATE IF THROUGH TO RAIN DRAIN CONDITIONED SPACE v REQUIRED IF RAIN WILL ENTER UNIT TO REFRIGERANT PIPING COMPRESSOR EVAPORATOR UNIT 09BY IN REMOTE APPLICATION WITH DUCTWORK Shown Suspended from Ceiling OUTSIDE WALL WALL LOUVERS FIELD SUPPLIED HEIGHT AS REQUIRED TO RAIN FOR WINDOW DRAIN OR WALL REQUIRED OPENING FLOOR RAIN WILL STAND ENTER UNIT 09BY DIRECT CONNECTION TO 50BZ UNIT Fig 2 Mounting Applications 09 DIMENSIONS English O9BY DIMENSIONS 51 8 012 016 024 006 012 014 016 024 DIMENSION Ftin Ft in Ft in Ft in DIMENSION mm A 3 6 9 5 0 A 1526 B 1 196 2 974 500 600 600 600 850 C 5 11 7 C 2300 D 2 34s 2 1 D 911 deg
15. ED STEEL FLANGE NOT PERMISSIBLE BLADE STIFFENER FOR LOUVER WIDTHS OVER 30 DEFLECTOR DETAIL TO HELP PREVENT RECIRCULATION DISCHARGE VANE DEFLECTOR CONDENSER INTAKE Fig 9 Condenser Ductwork Details Fig 10 Placement of Duct Flanges Units O9BY016 and 09BY024 3 Ahigh density fiberglass 2 Ib minimum density or semi Step 8 Complete Electrical Connections IMPORTANT Units may be used on 208 230 460 or 575 v 3 phase systems As shipped from the fac tory units are wired for 460 v or 575 v operation If the unit will be used on a 208 or 230 v system rewire the condenser fan motor prior to unit start up The 575 v motor is connected to the proper voltage as shipped and all connections are internal to the motor To rewire the unit disconnect and reconnect the wires at the motor junction box as shown on the connection diagram on the unit motor cover or in the unit wiring book GENERAL Verify that nameplate electrical requirements match available power supply Voltage at condenser must be within the minimum and maximum shown in Table 4 and phases must be balanced within 296 Contact local power com pany 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 volt age imbalance Voltage Imbalance max voltage deviation
16. HOLES ARE THE SAME NEAR AND FAR SIDE ACCESS PANEL TO REFRIGERANT CONNECTION CONTROL ACCESS HOLES 1 1 2 DIA 38MM BOX 0 2 9 16 65MM 07 4 9 16 116MM 0 2 5 8 66 MM 0 2 51MM 0 5 1 8 130MM 0 3 15 16 100MM AIR FLOW REFRIGERANT CONNECTION ACCESS HOLES 1 1 2701 38MM 55 0 2 3 8 60MM ACCESS 0 2 3 8 60MM PANEL S 0 2 3 8 AIR FLOW 012 014 ONLY 60MM FRONT HORIZONTAL DISCHARGE OR TOP VERTICAL DISCHARGE NOTES 1 Operational clearances are 0 in on all sides of the unit 2 Service clearances are 0 in minimum on the top rear and front of the unit A minimum of 3 ft service clearance is required on the unit right side and a 3 ft clearance is recommended on the left side 2 ft is the minimum One side of the unit either right left or rear should have the following minimum clearance for removal of the blower shaft CONTROL BOX FD 07 2 11 16 69MM P 0 13 16 21MM 0 4 3 4 121MM 0 3 15 16 100MM 0 2 3 8 D A 27M1 0 3 1 8 BOMM RIGHT SIDE 008 012 014 ONLY UNIT APPROX SHAFT LENGTH SIZE in 006 41 0 008 47 0 012 51 0 014 51 0 016 55 5 024 73 0 Fig 3 Base Unit Dimensions cont 5 Table 1 Condenser Unit Application UNIT 09BY 5087 000 oz os ose 024 006 S oos NN 008 5 0
17. ade con nections while protecting adjacent joints from heat REFRIGERANT LINE SIZING Sizing depends on length of lines between various sections of the refrigerant system Consider the amount of liquid lift and drop in the system as well as proper compressor oil return Consult Carrier System Design Manual Part 3 or Carrier 20 Refrig erant Piping Computer Program for proper piping sizes and design PRESSURE RELIEF The ASHRAE Standard 15 Safety Code for Mechanical Refrigeration states Every refriger ating system shall be protected by a pressure relief device or some other means designed to safely relieve pressure due to fire or other abnormal conditions Since OOBY condensers do not have pressure relief devices one must be field sup plied and installed either before the liquid line service valve or inside the 09 unit Each circuit must have its own pres sure relief If desired the pressure relief requirement can also be sat isfied by installing a fusible plug in the liquid line To do so install a tee in the liquid line with a 4 in NPT fitting on the tee side and install a fusible plug part no EKO2KK105 or similar The temperature rating of the fusible plug should be between 205 F and 220 F 96 C and 104 C 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 serv ice valves are closed Note that if the condenser is located
18. ame evaporator See Manifolding Circuits section on this page for details NOTES 1 A standard number of elbows and fittings have been considered in sizing piping approximately 20 loss Special applications may require different minimum refrigerant line sizes Contact your local representative for assistance as required 26 TO 50 EL 18 75 76 100 el 78 2 Line sizes in inches 3 A hot gas line check valve is recommended when the 09BY con denser is installed above the compressor Pressure loss through recommended hot gas line check valve has been included in 16 to 100 ft length applications CHECK VALVE When 09 condenser is installed with the condenser located above the compressor evapora tor it is recommended that a field supplied check valve be installed on the hot gas discharge line This prevents refrig erant 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 no EC37BP183 or similar may be used SERVICE VALVES Service valves are not factory in stalled on the 09 units If isolation of the refrigerant charge in the condenser from the unit or the piping system is de sired it is recommended that field supplied service valves be installed in the discharge and liquid line inside the O9BY condenser A Schrader port connect
19. con trol box Attach power wires to the 3 power connections in the unit control box using field supplied wirenuts Be sure to install a ground wire See Fig 11 CONTROL CIRCUIT POWER WIRING Connect 24 v control wires to the 2 low voltage connections at the com pressor contactor Use field supplied wirenuts to make the connections in the control box low voltage section GENERAL WIRING NOTES 1 Power entry is at one end only 2 Fan motors are thermally protected All motors are pro tected against primary single phasing conditions 3 Replacement of factory wires must be with appliance wir ing material rated 105 C or its equivalent 4 Factory wiring is in accordance with NEC Field modi fications or additions must be in compliance with all ap plicable codes TO POWER Fig 11 Combination Field Wiring START UP A CAUTION 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 prior to 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 DRI ER S CONNECTED TO THE LIQUID LINE IN THE INDOOR UNIT TO PREVENT CONTAMINATION WITHIN THE SYSTEM Refer to II Module 5 Charging Recov
20. d out from the same face of the unit The unit is designed to be mounted indoors in a window through the wall in high rise buildings or on the wall on the building exterior See Fig 2 for typical applications Ductwork is not needed but may be added easily if required by the application Airflow is pro vided by centrifugal fans with an adjustable belt drive to meet varying static requirements Units may also be matched with other compressor and evaporator combinations Contact your local representative for more details Check space requirements service clearances floor strength location of piping size of power supply and location of duct work if used before installing See Fig 3 for unit dimen sions and Table 2 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 elec trical requirements match the available power supply Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 530 969 Book 2 4 PC 111 Tab 4a 4a Printed in U S A Form 09BY 2SI Pg 1 9 96 Replaces 09BY 1SI CONDENSER FANS DISCHARGE n l 4 Eco D ji INLET TIT Li CONTROL BOX RIGHT SI
21. en fan motor mounting plate bolts Do not loosen motor mounting bracket from unit Move fan motor mount ing plate until proper belt tension is achieved approxi mately 2 in deflection with 8 Ib tension at midpoint of belt span Dp MOVABLE FLANGE STRAIGHTEDGE MUST BE PARALLEL WITH BELT MOTOR AND FAN SHAFTS MUST BE PARALLEL SETSCREWS FIXED FLANGE SINGLE GROOVE Fig 12 Condenser Fan Pulley Adjustment UNIT AIRFLOW 09BY Cfm Table 5 Condenser Fan Performance EXTERNAL STATIC PRESSURE in wg ERE 1 0 Bhp 2000 26 51 Eem Enp 80 08 1 34 1449 1 60 293 40 1952 208 1487 261 1608 18 1704 358 5000 589 043 121 1000 1 61 200 1201 244 3 63 5000 2 00 i098 254 1194 309 eooo 1175 5 01 5000 743 1 44 846 1 87 957 2 41 1089 3 38 1154 3 79 1214 4 40 aad 5000 15 ils 62 1 98 34 1166 2 73 1258 3 21 oa 7000 toss s27 n7 388 3s ids P 1243 459 ims 58 ERN EN 309 3 75 4 75 5 79 2000 TE E eoo a ma 57 15 nea 701 221 763 268 313 854 3 76 7
22. ery Recycling and Reclamation for proper charging techniques Check Operation of Condenser Fan Motor Con trols and Rotation of Fans Rotation should be clockwise as viewed from belt access panel IMPORTANT Check for proper fan rotation If rota tion needs to be reversed disconnect main power sup ply and switch any 2 leads at the load side of the dis connect switch Adjust Fan Speed The 09BY units are belt driven condenser units and allow for a wide range of inlet static and condenser airflow requirements It may be necessary to ad just the condenser airflow to account for these inlet condi tions Inadequate airflow will result in poor unit performance and possible nuisance tripping of high pressure switches If an airflow is not specified use the nominal airflow from Table 2 and adjust the fan speed to compensate for actual job conditions Use Table 5 to determine proper fan speed If the unit trips on high pressure due to high condensing tem perature then it may be necessary to increase the fan speed and condenser airflow SERVICE Cleaning Condenser Coils A CAUTION Do not use high pressure water or air Damage to fins may result Clean coils with a vacuum cleaner fresh water com pressed air or a bristle brush not wire Backflush coil to remove debris Commercial coil cleaners may also be used to help remove grease and dirt Steam cleaning is NOT rec ommended Units installed in corrosive environ
23. ient damper may be required The low ambient kit con trols head pressure by discharge dampers on the condenser fan The dampers are actuated by a refrigerant operated pis ton connected to the discharge line of the condenser If low ambient accessory will be used install it at this time before final refrigerant and ductwork connections are made An accessory filter rack may also be installed on the con denser air inlet to help keep the coil clean This filter rack should be installed before the ductwork is attached to the unit and before unit is mounted against a wall louver if required in your specific application Refer to installation instructions provided with the acces sories for installation details Step 4 Install Rain Drain See Fig 7 IMPORTANT A rain drain connection MUST BE USED if any possibility exists of rain water entering the unit The O9BY unit provides a choice of 2 drain locations Rain drain connection can be made on either side of the unit Block whichever drain is not being used but DO NOT BLOCK BOTH drain locations FROM CONDENSATE PAN PLUG PLUG 3 MIN ve Y PLUG PLUG EXISTING FLOOR DRAIN SINK OR HOPPER UNIT CONDENSATE CONN 3 MIN 76 1 MIN pot ADM NOT LESS THAN 18 457 LONG AND TWO SIZES LARGER THAN WASTE PIPE TRAP TRAP SEWER NOTE Dimensions in millimeters Fig 7 Rain Drains A drain kit
24. ime specifications or designs without notice and without incurring obligations Book 2 4 PC 111 Catalog No 530 969 Printed in U S A Form 09 251 Pg 18 9 96 Replaces O9BY 1SI Tab 4 4 START UP CHECKLIST A Preliminary Information COMPRESSOR BEARING UNIT MODEL NO SERIAL NO 09BY UNIT MODEL NO SERIAL NO FIELD INSTALLED ACCESSORIES B Pre Start Up CONDENSING UNIT IS THERE ANY SHIPPING DAMAGE __ Y N IF SO WHERE WILL THIS DAMAGE PREVENT UNIT START UP Y N CHECK POWER SUPPLY DOES IT AGREE WITH UNIT Y N __ HAS THE GROUND WIRE BEEN CONNECTED YN HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY Y N ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY Y N HAVE DRAINAGE CONNECTIONS BEEN COMPLETED Y N __ HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT Y N __ DO THE FAN BELTS HAVE PROPER TENSION Y N ___ HAS CORRECT FAN ROTATION BEEN CONFIRMED Y N __ HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE Y N __ ARE PROPER AIR FILTERS IN PLACE Y N __ CONTROLS HAVE THERMOSTAT AND INDOOR FAN CONTROL WIRING CONNECTIONS BEEN MADE AND CHECKED Y N ARE ALL WIRING TERMINALS including main power supply TIGHT Y N HAS CRANKCASE HEATER IF EQUIPPED ON UNIT BEEN ENERGIZED FOR 24 HOURS Y N 09BY UNIT HAS WATER BEEN PLACED IN DRAIN PAN IF REQUIRED TO CONFIRM PROPER DRAINAGE Y N ARE PROPER AIR FILTERS IN PLACE Y N
25. ion 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 Step 6 Ductwork The 09BY unit is designed for use either with or without ductwork or rain louvers If either Is used care must be taken to eliminate air recirculation Re circulation can be minimized by blocking the front dis charge and discharging through an extension elbow When properly designed hinged discharge louvers can be applied to ductwork and to the condenser air discharge Fixed rain louvers over discharge outlets can cause excessive recircu lation and nuisance high pressure switch cutouts Obstruc tions closer than 10 ft to the discharge air pattern can cause significant recirculation See Fig 9 for ductwork installation to prevent recirculation of air DISCHARGE LOUVER LOUVER G ACCESS PANEL FOR CONDENSER COIL CLEANI z If ductwork is used from standard discharge openings and another bird screen is provided remove factory supplied screen to reduce static pressure loss Units 09BY006 014 have factory installed flange to connect ductwork to the con denser air inlet Units 09BY016 and 024 are provided with flanges taped inside the unit for shipping To attach the duct to the unit inlet mount the flange by removing the screws that hold the condenser coil Insert the flange and replace the screws See Fig 10 Take
26. is not functioning correctly 3 Check damper operation and adjust as required high pressure switch if equipped or high discharge 4 Dirty coil or plugged or restricted air filter and or 4 Check and clean coil filter and louver as required pressure is noted louvers 5 Service valve s is closed 5 Open valve s and check for restrictions in refrigerant lines Compressor or 1 or plugged or restricted air filter and or 1 Check and clean coil filter and louver as required evaporator is Aa ad losing capacity 2 Airflow is not adequate 2 creak aimo and determine if proper subcooling provided 1 Airflow is turned too high 1 Slow down motor and check discharge pressure Unit is noisy 2 Belt and pulley are not properly aligned 2 Check and adjust alignment 3 Proper vibration isolation has not been applied 3 Isolate unit properly Water drips from 1 Rain water drain not functioning properly 1 Clean drain and check drain operation the unit 2 Unit is not insulated to prevent condensation 2 Insulate unit as required Fan motor trips Slow motor down check discharge on internal Qupd de ie motor motor amps ex pressure protection p Airflow should be within the range shown in Table 2 and should also be as close as possible to nominal airflow shown in Table 2 for optimum performance 16 Copyright 1996 Carrier Corporation Manufacturer reserves the right to discontinue or change at any t
27. lied to the unit terminals is within listed minimum and maximum limits 11 Determine maximum deviation from average voltage AB 243 239 4 239 2362 3 239 238 1 v Maximum deviation is then 4 To determine the percentage of voltage imbalance 4 Volt Imbal 100 Voltage Imbalance X 239 1 7 This amount of phase imbalance is satisfactory since it is below the allowable maximum of 2 IMPORTANT If supply voltage phase imbalance is more than 2 contact your local electric utility com pany immediately Condenser operation on improper line voltage or exces sive phase imbalance may be considered abuse and any re sulting damage may not be covered by Carrier warranty All wiring must be in accordance with local or NEC National Electrical Code regulations Refer to Fig 11 for combination field wiring 24 VOLT TO INDOOR UNIT FIELD WIRING LEGEND EQUIP Equipment FMC Fan Motor Contactor GND Ground Field Wiring Factory Wiring B Field Splice O Marked Terminal TO MOTOR JUNCTION BOX DISCONNECT FACTORY WIRING FIELD WIRING MAIN POWER WIRING 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
28. ments 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 Lubrication Fan motors have permanently lubricated bearings 13 Condenser Fan Adjustment CAUTION 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 TO CHANGE FAN SPEED 1 Shut off unit power supply 2 Loosen fan belt by loosening fan motor from mounting bracket Do not loosen fan motor mounting bracket from unit 3 Loosen movable pulley flange setscrew Fig 12 4 Screw movable flange toward fixed flange to increase fan speed and away from fixed flange to decrease speed In creasing fan speed increases load on motor Do not ex ceed maximum allowable fan speed Table 2 or motor full load amps indicated on motor nameplate and in Table 4 5 Set movable flange setscrew at nearest flat of pulley hub and tighten setscrew 6 Check pulley alignment and belt tension adjustment as described below 7 Check fan operation Repeat above procedure as required PULLEY ALIGNMENT Shut off unit power supply Loosen fan motor pulley setscrews and slide fan pulley along fan shaft Make angular alignment by loosening motor from mount ing bracket see Fig 12 Check alignment with a straightedge BELT TENSION ADJUSTMENT Shut off unit power sup ply Loos
29. nnels under the entire width of the unit allowing them to protrude beyond the width of the unit so that supporting rods can be installed on the channel ends Attach minimum J in threaded sup porting rods field supplied to channels through a rubber or spring isolator See Fig 5 A CAUTION DO NOT use rods smaller than 1 diameter Smaller rods may not be strong enough to support the unit Rods must be securely anchored in ceiling joists Use a double hex nut when attaching hanger rods to brack ets A single nut could loosen from vibration of the unit Pitch unit approximately 4 in toward drain in both directions length wise and widthwise to aid in condensate and or rain removal Before sliding unit into final position check for clearance to access panels and service area to install piping VERTICAL DISCHARGE The 09BY units can be mounted on a field supplied stand as shown in Fig 6 for vertical dis charge Also provide a rain drain on the back of the unit 1 2 THREADED 09BY ROD UNIT PROTRUDING CHANNEL END RUBBER ISOLATOR WASHER DOUBLE HEX NUT FIELD SUPPLIED BRACKET Field supplied Fig 5 Threaded Rod Installed in Bracket ELECTRICAL JUNCTION FIELD SUPPLIED STAND Fig 6 O9BY Vertical Discharge Step 3 Install Accessory Low Ambient Kit or Inlet Filter Kit If Required If the unit will be op erated with inlet air to the condenser below 50 F a low amb
30. om Table 3 Use refrigerant grade piping If tubing size is other than unit connection sizes use adapter fittings Refer to 50BZ or other compressor bearing unit base unit installation instructions to determine refrigerant charge ad justment for remote and special piping applications NOTE When installing 09BY units in systems add charge for other components 1 filter drier moisture indicator etc to determine system charge quantity Record charge MANIFOLDING CIRCUITS The 09BY units with 2 or 3 circuits 012 024 units may be manifolded together to be used as a single circuit condenser See Fig 8 for a typical connection of a 2 circuit condenser for use on one circuit Three circuit units 024 may be manifolded in any combi nation of 1 2 or 3 circuits per compressor When manifold ing circuits NEVER CONNECT TWO SEPARATE COM PRESSOR EVAPORATOR CIRCUITS TOGETHER ON THE SAME CONDENSER CIRCUIT Pipe sizes for the com bined circuit should be no smaller than the sizes shown in Table 3 MANIFOLDED HEADERS SCHRADER PORT RECOMMENDED COMBINED DISCHARGE LINE SCHRADER PORT RECOMMENDED COMBINED LIQUID LINE Fig 8 Typical 2 Circuit Condenser Manifolded For Single Circuit Use Table 3 Minimum Refrigerant Line Size Data LENGTH OF PIPE 16 TO 25 Pr Circuits may be manifolded to a single compressor Multiple con denser circuits should be on the s
31. ser air is prevented Placement area must be level and strong enough to support operating weight of the unit Table 2 Bolt unit securely in place when unit is positioned and leveled Fasteners for mounting unit are field supplied NOTE It will be necessary to drill holes in the unit base or side wall where bolts are to be mounted IMPORTANT Use care if rain will enter the unit if unit is located fully or partially outdoors DO NOT drill through the unit drain pan or leaks will result VIBRATION ISOLATION Units mounted in or above occupied spaces should employ some type of vibration iso lation For units that are floor mounted rubber pads may be located under each unit corner or unit may be mounted on rubber shear isolators or on spring isolators Unit may be supported by its 4 corners or a field supplied support rail may be used for each side Size isolators with the corner weights shown in Fig 3 Units may also be suspended from above See Positioning the 09 Unit section below and Fig 5 for recommended support and isolator mounting Ductwork attached to the condenser should be isolated from the unit with a flexible collar on the inlet and outlet ducts SPREADER BAR SUPPORTS UNDER SKID Fig 4 Unit Rigging POSITIONING THE 09BY UNIT Refer to notes in Fig 3 for typical service clearances To suspend the unit use 4 field supplied 2 in diameter or larger threaded rods Mount 2 heavy cha
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