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Carrier 09DPS018 030 Installation Instructions PDF
Summary of Content for Carrier 09DPS018 030 Installation Instructions PDF
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-530900013-01 Printed in U.S.A. Form 09DP-3SI Pg 1 612 9-11 Replaces: 09DP-1SI
Installation, Start-Up and Maintenance Instructions
CONTENTS Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Step 1 Inspect Shipment . . . . . . . . . . . . . . . . . . . . . . 2 Step 2 Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . 2 DOMESTIC UNITS EXPORT UNITS PLACING UNITS Step 3 Complete Refrigerant Piping . . . . . . . . . . 19 GENERAL EVACUATION AND DEHYDRATION REFRIGERANT LINE SIZING PRESSURE RELIEF REFRIGERANT RECEIVER LIQUID LIFT Step 4 Make Electrical Connections . . . . . . . . . . 23 GENERAL POWER WIRING CONTROL CIRCUIT WIRING FIELD CONTROL WIRING Step 5 Check Condenser Fans. . . . . . . . . . . . . . . . 30 Step 6 Configure Optional Motormaster V Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Step 7 Install Accessories . . . . . . . . . . . . . . . . . . . . 34 LOW-AMBIENT OPERATION MISCELLANEOUS ACCESSORIES START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37,38 System Evacuation and Dehydration . . . . . . . . . . . . 37 Preliminary Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Adjust Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . 37 Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 37 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Recommended Maintenance Schedule . . . . . . . . . . 39 Microchannel Heat Exchanger (MCHX) Condenser Coil Maintenance and Cleaning Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should install, start up, and service this equipment.
Untrained personnel can perform basic maintenance func- tions, such as cleaning coils. All other operations should be performed by trained service personnel.
When working on the equipment, observe precautions in the literature, and on tags, stickers, and labels attached to the equipment and any other safety precautions that may apply. Follow all safety codes. Wear safety glasses and work gloves.
Use care in handling, rigging, and setting bulky equipment.
WARNING
Open all remote disconnects before servicing this equip- ment. Failure to do so could result in personal injury from electric shock.
DANGER
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. Failure to do so could result in personal injury from electric shock.
WARNING
DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective gloves and gog- gles and proceed as follows: a. Shut off electrical power to unit. b. Recover refrigerant to relieve all pressure from sys-
tem using both high-pressure and low pressure ports. c. Traces of vapor should be displaced with nitrogen
and the work area should be well ventilated. Refrig- erant in contact with an open flame produces toxic gases.
d. Cut component connection tubing with tubing cutter and remove component from unit. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when nec- essary. Oil can ignite when exposed to torch flame.
Failure to follow these procedures may result in personal injury or death.
CAUTION
DO NOT re-use compressor oil or any oil that has been exposed to the atmosphere. Dispose of oil per local codes and regulations. DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed. Failure to follow these proce- dures may result in damage to equipment.
GEMINI SELECT 09DPS018-030, 09DPM035-130 Air-Cooled Condensing Units
50/60 Hz
2
INSTALLATION
Step 1 Inspect Shipment Inspect unit for dam- age upon arrival. If damage is found, immediately file a claim with the shipping company. Verify proper unit delivery by checking unit nameplate data and the model number nomen- clature shown in Fig. 1. See Tables 1-6 for unit physical data.
Step 2 Rig and Place Unit All units are de- signed for overhead rigging, and it is important that this meth- od be used. Lifting holes are provided in the frame base rails. It is recommended to use shackles in the lifting holes (see rigging label on the unit and Fig. 2 and 3 for rigging weights and center of gravity). All panels must be in place when rigging.
Use spreader bars or frame to keep the cables, chains, and straps clear of the unit sides. Leave standard coil protection packaging in place during rigging to provide protection to coils. Remove and discard all coil protection after rigging ca- bles are detached.
IMPORTANT: To maintain unit stability while lifting, use 4 cables, chains or straps of equal length. Attach one end of each cable to shackle attachment point and the other end of each cable to the overhead rigging point.
CAUTION
All panels must be in place when rigging. Failure to com- ply could result in equipment damage.
CAUTION
For unit sizes 018 to 060 when handling with a forklift, handle only through fork pocket holes. Failure to follow this caution could result in equipment damage or personal injury.
CAUTION
For unit sizes 065 to 130, do not forklift the unit unless unit is attached to a skid designed for forklifting. Failure to fol- low this caution could result in equipment damage or per- sonal injury.
09DP M 035 6 4 0 0 0 0 0
09DP Split System Condenser Packaging/Security Options 0 Std Packaging 4 Security Grilles/Hail Guards Only 8 Bottom Skid Only
Ambient/SCCR Options 0 Std Ambient, Std Interrupt 3 Std Ambient, High Interrupt 6 Low Ambient, Std Interrupt 9 Low Ambient, High Interrupt
Not Used
Electrical Options 0 Single Point Power, Terminal Block 1 Single Point Power, Non-Fused Disconnect
Refrigeration Circuit Options* M Multiple Refrigeration Circuit S Single Refrigeration Circuit
Revision Level Current Revision Level
ylppuS rewoP 1 575-3-60 2 380-3-60 5 208/230-3-60 6 460-3-60 9 380/415-3-50
Condenser Coil/Low Sound Options 4 MCHX, No Sound Treatment 5 E-coat, MCHX, No Sound Treatment C MCHX, Low Sound Fan(s) D E-coat MCHX, Low Sound Fan(s)
Unit Size
D Bottom Skid, Security Grilles/Hail Guards J Bottom Skid, Top Crate, Bag N Bottom Skid, Top Crate, Bag, Security Grilles/Hail Guards
018
040 085
020 050 095
030 065 035 075
060 115 130
Not Used
LEGEND
*09DPS units available in sizes 018-030. 09DPM units available in sizes 035-130.
Quality Assurance Certified to ISO 9001:2000
MCHX Microchannel Heat Exchanger
a09-575
Fig. 1 Model Number Nomenclature
3
Table 1 Physical Data, 09DP018-040 Units English
LEGEND
*Nominal heat rejection based on optimum refrigerant charge of R-410A with 15 F subcooling at 30 F temperature difference.
Condenser fan airflow and power are for units operating at full load and 95 F ambient.
09DP UNIT SIZE 09DPS018 09DPS020 09DPS030 09DPM035 09DPM040
CAPACITY, 60 Hz (tons)* 20.7 33.1 37.7 43.3 55.0
CAPACITY, 50 Hz (tons)* 17.2 27.6 31.4 36.1 45.8
CIRCUIT Single Circuit Single Circuit Single Circuit Dual Circuit Single Circuit Dual Circuit Single Circuit
OPERATING WEIGHTS (lb) Standard 638 719 869 1126 1204 With Low Sound Option 656 755 905 1162 1258
APPROXIMATE TOTAL REFRIGERANT CHARGE R-410A (lb) 9.6 12.0 12.0 24.0 24.0
APPROXIMATE TOTAL REFRIGERANT CHARGE R-134a (lb) 11.1 13.9 13.9 27.7 27.7
NITROGEN SHIPPING CHARGE 5 psig
CONDENSER FANS Standard Propeller Type - Direct Drive
Quantity 1 2 2 2 2 3 3 Motor Hp (per fan) 1 1 1 1 1 1 1 RPM 1140 (60 Hz), 950 (50 Hz) Diameter (in.) 30 Airflow (cfm) (60 Hz) 11,300 18,500 20,900 22,700 32,000 Airflow (cfm) (50 Hz) 9420 15,420 17,420 18,920 26,670 Total Watts (60 Hz) 1600 3200 3200 3100 4800 Total Watts (50 Hz) 1333 2667 2667 2583 4000
Low Noise Plastic Type - Direct Drive Quantity 1 2 2 2 2 3 3 Motor Hp (per fan) 1 1 1 1 1 1 1 RPM 850 (60 Hz), 700 (50 Hz) Diameter (in.) 30 Airflow (cfm) (60 Hz) 10,450 17,500 19,400 21,000 29,600 Airflow (cfm) (50 Hz) 8710 14,580 16,170 17,500 24,670 Total Watts (60 Hz) 1300 2600 2600 2500 3900 Total Watts (50 Hz) 1083 2167 2167 2083 3250
MCHX COIL No. Coils per Circuit (Ckt A/Ckt B) 1 1 2 1 2 Circuit % (Ckt A/Ckt B) 100 50/50 100 50/50 100 Total Coils 1 2 2 2 2 sq ft 27.1 27.1 33.9 54.2 54.2 54.2 54.2
PIPING Pressure Relief Fusible Plug on liquid lines of both circuits - 210 F
Hot Gas Connection Line Size (in.) 13/8 13/8 13/8 13/8 + 13/8 15/8 13/8 + 13/8 15/8 Liquid Connection Line Size (in.) 5/8 5/8 5/8 5/8+ 5/8 7/8 5/8 + 5/8 7/8
CHASSIS DIMENSIONS (ft-in.) Length 7-5 7-5 7-5 7-9 7-9 7-9 7-9 Width 3-5 3-5 3-5 7-5 7-5 7-5 7-5 Height Standard 5-1 5-1 6-2 5-1 5-1 5-1 5-1 Low Sound 5-7 5-7 6-7 5-7 5-7 5-7 5-7
MCHX Microchannel Heat Exchanger
4
Table 2 Physical Data, 09DP050-075 Units English
LEGEND
*Nominal heat rejection based on optimum refrigerant charge of R-410A with 15 F subcooling at 30 F temperature difference.
Condenser fan airflow and power are for units operating at full load and 95 F ambient.
09DP UNIT SIZE 09DPM050 09DPM060 09DPM065 09DPM075
CAPACITY, 60 Hz (tons)* 66.4 75.3 85.8 107.6
CAPACITY, 50 Hz (tons)* 55.3 62.7 71.5 89.7
CIRCUIT Dual
Circuit Single Circuit
Dual Circuit
Single Circuit
Dual Circuit
Single Circuit
Dual Circuit
Single Circuit
OPERATING WEIGHTS (lb) Standard 1282 1524 1622 1846 With Low Sound Option 1354 1596 1694 1936
APPROXIMATE TOTAL REFRIGERANT CHARGE R-410A (lb) 24.0 24.0 35.2 44.0
APPROXIMATE TOTAL REFRIGERANT CHARGE R-134a (lb) 27.7 27.7 40.7 50.8
NITROGEN SHIPPING CHARGE 5 psig
CONDENSER FANS Standard Propeller Type - Direct Drive
Quantity 4 4 4 4 4 4 5 5 Motor Hp (per fan) 1 1 1 1 1 1 1 1 RPM 1140 (60 Hz), 950 (50 Hz) Diameter (in.) 30 Airflow (cfm) (60 Hz) 39,250 41,800 45,000 56,250 Airflow (cfm) (50 Hz) 32,710 34,830 37,500 46,870 Total Watts (60 Hz) 6500 6400 6400 8000 Total Watts (50 Hz) 5417 5333 5333 6667
Low Noise Plastic Type - Direct Drive Quantity 4 4 4 4 4 4 5 5 Motor Hp (per fan) 1 1 1 1 1 1 1 1 RPM 850 (60 Hz), 700 (50 Hz) Diameter (in.) 30 Airflow (cfm) (60 Hz) 36,300 38,800 41,600 52,000 Airflow (cfm) (50 Hz) 30,250 32,330 34,670 43,330 Total Watts (60 Hz) 5300 5200 5200 6500 Total Watts (50 Hz) 4417 4333 4333 5417
MCHX COIL No. Coils per Circuit (Ckt A/Ckt B) 1 2 1 2 2 4 3/2 5 Circuit % (Ckt A/Ckt B) 50/50 100 50/50 100 50/50 100 60/40 100 Total Coils 2 2 2 2 4 4 5 5 sq ft 54.2 54.2 67.8 67.8 99.8 99.8 124.7 124.7
PIPING Pressure Relief Fusible Plug on liquid lines of both circuits - 210 F
Hot Gas Connection Line Size (in.) 13/8 + 13/8 15/8 13/8 + 13/8 15/8 13/8 + 13/8 15/8 15/8 + 13/8 21/8 Liquid Connection Line Size (in.) 5/8 + 5/8 7/8 5/8 + 5/8 7/8 7/8 + 7/8 11/8 7/8 + 7/8 11/8
CHASSIS DIMENSIONS (ft-in.) Length 7-9 7-9 7-9 7-9 9-3 9-3 12-8 12-8 Width 7-5 7-5 7-5 7-5 7-5 7-5 7-5 7-5 Height Standard 5-1 5-1 6-2 6-2 6-1 6-1 6-1 6-1 Low Sound 5-7 5-7 6-7 6-7 6-7 6-7 6-7 6-7
MCHX Microchannel Heat Exchanger
5
Table 3 Physical Data, 09DP085-130 Units English
LEGEND *Nominal heat rejection based on optimum refrigerant charge of R-410A with 15 F subcooling at 30 F temperature difference.
Condenser fan airflow and power are for units operating at full load and 95 F ambient.
09DP UNIT SIZE 09DPM085 09DPM095 09DPM115 09DPM130
CAPACITY, 60 Hz (tons)* 115.6 129.4 149.4 172.0
CAPACITY, 50 Hz (tons)* 96.3 107.8 124.5 143.3
CIRCUIT Dual
Circuit Single Circuit
Dual Circuit
Single Circuit
Dual Circuit
Single Circuit
Dual Circuit
Single Circuit
OPERATING WEIGHTS (lb) Standard 1933 1933 2447 2533 With Low Sound Option 2041 2041 2573 2677
APPROXIMATE TOTAL REFRIGERANT CHARGE R-410A (lb) 52.8 52.8 61.6 70.4
APPROXIMATE TOTAL REFRIGERANT CHARGE R-134a (lb) 61.0 61.0 71.1 81.3
NITROGEN SHIPPING CHARGE 5 psig
CONDENSER FANS Standard Propeller Type - Direct Drive
Quantity 6 6 6 6 7 7 8 8 Motor Hp (per fan) 1 1 1 1 1 1 1 1 RPM 1140 (60 Hz), 950 (50 Hz) Diameter (in.) 30 Airflow (cfm) (60 Hz) 67,500 67,500 78,750 90,000 Airflow (cfm) (50 Hz) 56,250 56,250 65,620 75,000 Total Watts (60 Hz) 9600 9600 11200 12800 Total Watts (50 Hz) 8000 8000 9333 10667
Low Noise Plastic Type - Direct Drive Quantity 6 6 6 6 7 7 8 8 Motor Hp (per fan) 1 1 1 1 1 1 1 1 RPM 850 (60 Hz), 700 (50 Hz) Diameter (in.) 30 Airflow (cfm) (60 Hz) 62,400 62,400 72,800 83,200 Airflow (cfm) (50 Hz) 52,000 52,000 60,670 69,330 Total Watts (60 Hz) 7800 7800 9100 10400 Total Watts (50 Hz) 6500 6500 7583 8667
MCHX COIL No. Coils per Circuit (Ckt A/Ckt B) 3/2 5 3/3 6 4/3 7 5/3 8 Circuit % (Ckt A/Ckt B) 60/40 100 50/50 100 57/43 100 63/37 100 Total Coils 5 5 6 6 7 7 8 8 sq ft 124.7 124.7 149.6 149.6 174.6 174.6 199.5 199.5
PIPING Pressure Relief Fusible Plug on liquid lines of both circuits - 210 F
Hot Gas Connection Line Size (in.) 15/8 + 13/8 21/8 15/8 + 15/8 21/8 15/8 + 15/8 21/8 15/8 + 15/8 21/8 Liquid Connection Line Size (in.) 7/8 + 7/8 11/8 7/8 + 7/8 11/8 7/8 + 7/8 11/8 11/8 + 7/8 13/8
CHASSIS DIMENSIONS (ft-in.) Length 12-8 12-8 12-8 12-8 16-0 16-0 16-0 16-0 Width 7-5 7-5 7-5 7-5 7-5 7-5 7-5 7-5 Height Standard 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-1 Low Sound 6-7 6-7 6-7 6-7 6-7 6-7 6-7 6-7
MCHX Microchannel Heat Exchanger
6
Table 4 Physical Data, 09DP018-040 Units SI
LEGEND
*Nominal heat rejection based on optimum refrigerant charge of R-410A with 8.3 C subcooling at 16.7 C temperature difference.
Condenser fan airflow and power are for units operating at full load and 35 C ambient.
09DP UNIT SIZE 09DPS018 09DPS020 09DPS030 09DPM035 09DPM040
CAPACITY, 60 Hz (kW)* 72.8 116.4 132.6 152.3 193.4
CAPACITY, 50 Hz (kW)* 60.7 97.0 110.5 126.9 161.2
CIRCUIT Single Circuit Single Circuit Single Circuit Dual Circuit Single Circuit Dual Circuit Single Circuit
OPERATING WEIGHTS (kg) Standard 289 326 394 511 546 With Low Sound Option 298 342 411 527 571
APPROXIMATE TOTAL REFRIGERANT CHARGE R-410A (kg) 4.4 5.4 5.4 10.9 10.9
APPROXIMATE TOTAL REFRIGERANT CHARGE R-134a (kg)
5.0 6.3 6.3 12.6 12.6
NITROGEN SHIPPING CHARGE 0.35 bar
CONDENSER FANS Standard Propeller Type - Direct Drive
Quantity 1 2 2 2 2 3 3 Motor kW (per fan) 0.75 0.75 0.75 0.75 0.75 0.75 0.75 r/s 19 (60 Hz), 16 (50 Hz) Diameter (mm) 762 Airflow (l/sec) (60 Hz) 5333 8731 9864 10 713 15 102 Airflow (l/sec) (50 Hz) 4444 7276 8220 8928 12 585 Total Watts (60 Hz) 1600 3200 3200 3100 4800 Total Watts (50 Hz) 1333 2667 2667 2583 4000
Low Noise Plastic Type - Direct Drive Quantity 1 2 2 2 2 3 3 Motor kW (per fan) 0.75 0.75 0.75 0.75 0.75 0.75 0.75 r/s 14 (60 Hz), 12 (50 Hz) Diameter (mm) 762 Airflow (l/sec) (60 Hz) 4932 8260 9156 9911 13 971 Airflow (l/sec) (50 Hz) 4110 6883 7630 8259 11 643 Total Watts (60 Hz) 1300 2600 2600 2500 3900 Total Watts (50 Hz) 1083 2167 2167 2083 3250
MCHX COIL No. Coils per Circuit (Ckt A/Ckt B) 1 1 2 1 2 Circuit % (Ckt A/Ckt B) 100 50/50 100 50/50 100 Total Coils 1 2 2 2 2 sq m 2.5 2.5 3.1 5.0 5.0 5.0 5.0
PIPING Pressure Relief Fusible Plug on liquid lines of both circuits - 99 C
Hot Gas Connection Line Size (in.) 13/8 13/8 13/8 13/8 + 13/8 15/8 13/8 + 13/8 15/8 Liquid Connection Line Size (in.) 5/8 5/8 5/8 5/8+ 5/8 7/8 5/8 + 5/8 7/8
CHASSIS DIMENSIONS (mm) Length 2242 2242 2242 2340 2340 2340 2340 Width 1025 1025 1025 2242 2242 2242 2242 Height Standard 1550 1550 1857 1550 1550 1550 1550 Low Sound 1690 1690 1997 1690 1690 1690 1690
MCHX Microchannel Heat Exchanger
7
Table 5 Physical Data, 09DP050-075 Units SI
LEGEND
*Nominal heat rejection based on optimum refrigerant charge of R-410A with 8.3 C subcooling at 16.7 C temperature difference.
Condenser fan airflow and power are for units operating at full load and 35 C ambient.
09DP UNIT SIZE 09DPM050 09DPM060 09DPM065 09DPM075
CAPACITY, 60 Hz (kW)* 233.5 264.8 301.8 378.5
CAPACITY, 50 Hz (kW)* 194.6 220.7 251.5 315.4
CIRCUIT Dual
Circuit Single Circuit
Dual Circuit
Single Circuit
Dual Circuit
Single Circuit
Dual Circuit
Single Circuit
OPERATING WEIGHTS (kg) Standard 582 691 736 837 With Low Sound Option 614 724 768 878
APPROXIMATE TOTAL REFRIGERANT CHARGE R-410A (kg) 10.9 10.9 16.0 20.0
APPROXIMATE TOTAL REFRIGERANT CHARGE R-134a (kg) 12.6 12.6 18.4 23.1
NITROGEN SHIPPING CHARGE 0.35 bar
CONDENSER FANS Standard Propeller Type - Direct Drive
Quantity 4 4 4 4 4 4 5 5 Motor kW (per fan) 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 r/s 1140 (60 Hz), 950 (50 Hz) Diameter (mm) 30 Airflow (l/sec) (60 Hz) 18 524 19 727 21 238 26 547 Airflow (l/sec) (50 Hz) 15 437 16 439 17 698 22 123 Total Watts (60 Hz) 6500 6400 6200 8000 Total Watts (50 Hz) 5417 5333 5167 6667
Low Noise Plastic Type - Direct Drive Quantity 4 4 4 4 4 4 5 5 Motor kW (per fan) 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 r/s 14 (60 Hz), 12 (50 Hz) Diameter (mm) 762 Airflow (l/sec) (60 Hz) 17 132 18 314 19 633 24 541 Airflow (l/sec) (50 Hz) 14 277 15 262 16 361 20 451 Total Watts (60 Hz) 5300 5200 5200 6500 Total Watts (50 Hz) 4417 4333 4333 5417
MCHX COIL No. Coils per Circuit (Ckt A/Ckt B) 1 2 1 2 2 4 3/2 5 Circuit % (Ckt A/Ckt B) 50/50 100 50/50 100 50/50 100 60/40 100 Total Coils 2 2 2 2 4 4 5 5 sq m 5.0 5.0 6.3 6.3 9.3 9.3 11.6 11.6
PIPING Pressure Relief Fusible Plug on liquid lines of both circuits - 99 C
Hot Gas Connection Line Size (in.) 13/8 + 13/8 15/8 13/8 + 13/8 15/8 13/8 + 13/8 15/8 15/8 + 13/8 21/8 Liquid Connection Line Size (in.) 5/8 + 5/8 7/8 5/8 + 5/8 7/8 7/8 + 7/8 11/8 7/8 + 7/8 11/8
CHASSIS DIMENSIONS (mm) Length 2340 2340 2340 2340 2816 2816 3838 3838 Width 2242 2242 2242 2242 2242 2242 2242 2242 Height Standard 1550 1550 1857 1857 1855 1855 1855 1855 Low Sound 1690 1690 1997 1997 1994 1994 1994 1994
MCHX Microchannel Heat Exchanger
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Table 6 Physical Data, 09DP085-130 Units SI
LEGEND
*Nominal heat rejection based on optimum refrigerant charge of R-410A with 8.3 C subcooling at 16.7 C temperature difference.
Condenser fan airflow and power are for units operating at full load and 35 C ambient.
09DP UNIT SIZE 09DPM085 09DPM095 09DPM115 09DPM130
CAPACITY, 60 Hz (kW)* 406.6 455.1 525.5 605.0
CAPACITY, 50 Hz (kW)* 338.8 379.2 437.9 504.2
CIRCUIT Dual Circuit
Single Circuit
Dual Circuit
Single Circuit
Dual Circuit
Single Circuit
Dual Circuit
Single Circuit
OPERATING WEIGHTS (kg) Standard 877 877 1110 1149 With Low Sound Option 926 926 1167 1214
APPROXIMATE TOTAL REFRIGERANT CHARGE R-410A (kg)
23.9 23.9 27.9 31.9
APPROXIMATE TOTAL REFRIGERANT CHARGE R-134a (kg)
27.7 27.7 32.3 36.9
NITROGEN SHIPPING CHARGE 0.35 bar
CONDENSER FANS Standard Propeller Type - Direct Drive
Quantity 6 6 6 6 7 7 8 8 Motor kW (per fan) 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 r/s 1140 (60 Hz), 950 (50 Hz) Diameter (mm) 30 Airflow (l/sec) (60 Hz) 31 856 31 856 37 166 42 475 Airflow (l/sec) (50 Hz) 26 547 26 547 30 972 35 396 Total Watts (60 Hz) 9600 9600 11 200 12 800 Total Watts (50 Hz) 8000 8000 9333 10 667
Low Noise Plastic Type - Direct Drive Quantity 6 6 6 6 7 7 8 8 Motor kW (per fan) 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 r/s 14 (60 Hz), 12 (50 Hz) Diameter (mm) 762 Airflow (l/sec) (60 Hz) 29 450 29 450 34 358 39 266 Airflow (l/sec) (50 Hz) 24 541 24 541 28 632 32 722 Total Watts (60 Hz) 7800 7800 9100 10 400 Total Watts (50 Hz) 6500 6500 7583 8667
MCHX COIL No. Coils per Circuit (Ckt A/Ckt B) 3/2 5 3/3 6 4/3 7 5/3 8 Circuit % (Ckt A/Ckt B) 60/40 100 50/50 100 57/43 100 63/37 100 Total Coils 5 5 6 6 7 7 8 8 sq m 11.6 11.6 13.9 13.9 16.2 16.2 18.5 18.5
PIPING Pressure Relief Fusible Plug on liquid lines of both circuits - 99 C
Hot Gas Connection Line Size (in.) 15/8 + 13/8 21/8 15/8 + 15/8 21/8 15/8 + 15/8 21/8 15/8 + 15/8 21/8 Liquid Connection Line Size (in.) 7/8 + 7/8 11/8 7/8 + 7/8 11/8 7/8 + 7/8 11/8 11/8 + 7/8 13/8
CHASSIS DIMENSIONS (mm) Length 3838 3838 3838 3838 4860 4860 4860 4860 Width 2242 2242 2242 2242 2242 2242 2242 2242 Height Standard 1855 1855 1855 1855 1855 1855 1855 1855 Low Sound 1994 1994 1994 1994 1994 1994 1994 1994
MCHX Microchannel Heat Exchanger
9
DOMESTIC UNITS Standard 09DP unit packaging con- sists of coil protection only. Skids are not provided. If overhead rigging is not available at the jobsite, place the unit on a skid or pad before dragging or rolling. When rolling, use a minimum of 3 rollers. When dragging, pull the pad or skid. Do not apply force to the unit. When in final position, raise from above to lift unit off the pad or skid. EXPORT UNITS All export units are mounted on skids with vertical coil protection. Leave the unit on the skid until it is in final position. While on the skid, the unit can be rolled or skidded. Apply force to the skid, not to the unit. Use a mini- mum of 3 rollers when rolling. When in final position, raise from above to remove the skid. PLACING UNITS When considering location of the unit, be sure to consult National Electrical Code (NEC, U.S.A.) and local code requirements. Allow sufficient space for airflow, wiring, piping, and service. The placement area must be level and strong enough to support the operating weight of the unit. (See Fig. 2.) When unit is in proper location, use of mounting
holes in base rails is recommended for securing unit to supporting structure. Fasteners for mounting unit are field sup- plied. See Fig. 4.
Refer to Fig. 5-9 for airflow clearances. Recommended minimum clearances are 6 ft (1829 mm) for unrestricted air- flow and service on sides of unit, 4 ft (1219 mm) on ends, and unrestricted clear air space above the unit. Provide ample space to connect refrigerant lines to indoor unit. For multiple units, allow 10 ft (3048 mm) separation between airflow surfaces. If walls surround the unit, wall height should not exceed the top of the unit fan discharge. Installation in a pit is not recommend- ed.
Refer to Fig. 10 for outdoor fan and compressor layout. Refer to Fig. 11 and 12 for unit piping installation.
09DP Unit (lb) 09DP Unit (kg)
IMPORTANT: Be sure to mount unit level to ensure proper oil return to compressors.
09DP UNIT SIZE
TOTAL WEIGHT
OPERATIONAL CORNER WEIGHT
A B C D E F
018 638 153 149 166 171 020 719 173 169 186 191 030 869 208 203 226 231 035 1126 290 289 273 274 040 1204 319 317 283 285 050 1282 331 329 310 312 060 1524 392 390 370 372 065 1622 413 409 398 403 075 1846 471 465 452 457 085 1933 493 487 474 479 095 1933 493 487 474 479 115 2447 418 414 397 402 405 410 130 2533 429 424 416 420 420 425
09DP UNIT SIZE
TOTAL WEIGHT
OPERATIONAL CORNER WEIGHT
A B C D E F
018 289 69 67 75 77 020 326 79 77 84 87 030 394 94 92 103 105 035 511 132 131 124 124 040 546 145 144 128 129 050 582 150 149 141 141 060 691 178 177 168 169 065 736 187 185 181 183 075 837 214 211 205 207 085 877 224 221 215 217 095 877 224 221 215 217 115 1110 285 282 270 273 250 248 130 1149 292 289 283 286 262 258
A
B C
D
C O
N T
R O
L B
O X
A
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TOP VIEW, SIZES 065 TO 130TOP VIEW, SIZES 018 TO 030
TOP VIEW, SIZES 035 TO 060
Fig. 2 Corner Weights
a09-584
10
Fig. 3 Rigging Labels
Fig. 4 Perimeter Support Channel
SIZES 018 TO 060 SIZES 065 TO 130
a09-587
a09-586a09-585
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a09-614
16
X
OFM1
OFM3
OFM1
X OFM1 X OFM1 OFM2
weiV poTweiV poTweiV poTweiV poT 040 eziS530 eziS030-020 seziS810 eziS
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OFM5
OFM6
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OFM4OFM2
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weiV poTweiV poT Sizes 050-065 Size 075
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weiV poTweiV poT 511 eziS590-580 seziS
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Top View Size 130
Fig. 10 Outdoor Fan Layouta09-615
LEGEND OFM Outdoor Fan
17
FIELD POWER SUPPLY
CONTROL WIRING
CONTROL WIRING
09DP CONDENSER
DOUBLE HOT GAS RISER MAY BE REQUIRED
LIQUID LINE
RELIEF VALVE (IF REQUIRED BY CODE)
HOT GAS LINE
a38-7098_gs
Fig. 11 Typical 30MPA Refrigerant Piping to 09DP Remote Condenser (30MPA030 and 09DPS030 Units Shown)
NOTES: 1. Chiller and condenser must be installed levelly to maintain proper
compressor oil return. 2. Wiring and piping shown are general points-of-connection guides
only and are not intended for a specific installation. Wiring and piping shown are for a quick overview of system and are not in accordance with recognized standards.
3. All wiring must comply with applicable local and national codes. 4. All piping must follow standard piping techniques. Refer to Carrier
System Design Manual part 3, Carrier E20-II software Refrigerant Piping program, or appropriate ASHRAE (American Society of Heating, Refrigerating, and Air Conditioning Engineers) hand- book for details on proper piping sizes and design.
5. See Tables 1-6 for approximate refrigerant charge. 6. Double discharge riser may be required; check unit minimum
capacity. 7. Trap should be installed on hot gas lines to prevent condenser oil
and refrigerant vapor migration from accumulating in the com- pressor during off cycle.
8. Pitch all horizontal lines downward in the direction of refrigerant flow.
9. For piping lengths greater than 100 ft (30 m), provide discharge line check valve.
10. For pressure relief requirements, see latest revision of ASHRAE Standard 15, Safety Code for Mechanical Refrigeration.
11. All 09DP units have factory-installed contactors.
a09-589
18
30HXA CONDENSERLESS LIQUID CHILLER
09DPM050 CONDENSER
09DPM050 CONDENSER
Fig. 12 Typical 30HXA Condenserless Liquid Chiller Refrigerant Piping to 09DP Remote Condensers (30HXA076 and 09DPM050 Units Shown)
NOTES: 1. Chiller and condenser must be installed levelly to maintain proper
compressor oil return. 2. Wiring and piping shown are general points-of-connection guides
only and are not intended for a specific installation. Wiring and piping shown are for a quick overview of system and are not in accordance with recognized standards.
3. All wiring must comply with applicable local and national codes. 4. All piping must follow standard piping techniques. Refer to Carrier
System Design Manual part 3, Carrier E20-II software Refrigerant Piping program, or appropriate ASHRAE (American Society of Heating, Refrigerating, and Air Conditioning Engineers) hand- book for details on proper piping sizes and design.
5. See Tables 1-6 for approximate refrigerant charge. 6. Double discharge riser may be required; check unit minimum
capacity. 7. Trap should be installed on hot gas lines to prevent condenser oil
and refrigerant vapor migration from accumulating in the com- pressor during off cycle.
8. Pitch all horizontal lines downward in the direction of refrigerant flow.
9. For pressure relief requirements, see latest revision of ASHRAE Standard 15, Safety Code for Mechanical Refrigeration.
10. All 09DP units have factory-installed contactors. a09-590
19
Step 3 Complete Refrigerant Piping
GENERAL All field leak and pressure testing should be in accordance with local code requirements. If a local code does not exist, use ASHRAE (American Society of Heating, Refrig- erating, and Air Conditioning Engineers) Standard 15, Safety Code for Mechanical Refrigeration.
For leak testing procedures, refer to the Carrier Refrigerant Service Techniques book, Form SM-1A.
Perform phos-copper brazing on all field-made connections while protecting adjacent joints from heat.
Install or replace filter driers. If the chiller is above the condensing unit, the maximum al-
lowable vertical separation between the condensing unit and the evaporator. See Liquid Lift section on page 21.
Relieve the pressure caused by the nitrogen holding charge. Connect liquid line and discharge line to field piping. Refer to Fig. 5-9 for circuit orientation. Hot gas and liquid connections are located on the same end of the uit and are sealed with tube plugs.
Units are shipped standard with fan cycle pressure switches for use with R-410A refrigerant. Carrier 30HXA units are shipped with fan cycles pressure switches for use with R-134a condensing units.
Fan cycle pressure switches are to be installed on the dis- charge lines. Do not remove Schraeder valves from fittings. See Fig. 13-15 for unit piping. See Fig. 16 for switch details.
A tubing package for converting dual circuit units into sin- gle circuit units is shipped with all 09DP035-130 units. The kit is field installed. See Fig. 17.
The refrigerant system must not be opened and exposed to atmosphere for longer than 15 minutes. Connection and pump- down should be made as soon as possible to avoid acids forming in the compressor POE (polyolester) oils, which could damage the compressors.
Leak test the entire system by using soap bubbles and nitro- gen and an electronic leak detector.
Purge nitrogen from system after completion of leak-check- ing procedure. Repair leak if one is found. When finished, evacuate and dehydrate system using the following method. EVACUATION AND DEHYDRATION Because the 30MPA and 30HXA systems use polyolester oil, which can ab- sorb moisture, it is important to minimize the amount of time that the system interior is left exposed to the atmosphere. Mini- mizing the exposure time of the oil to the atmosphere will min- imize the amount of moisture that needs to be removed during evacuation.
CAUTION
Do NOT bury refrigerant piping underground. Failure to comply could result in equipment damage.
CAUTION
The 09DP unit is shipped with a nitrogen holding charge. Use caution when relieving unit pressure to avoid possible equipment damage or personal injury.
IMPORTANT: Unit is compatible with various refriger- ants. Ensure fan cycle pressure switches and Motormas- ter option are installed correctly per unit refrigeration configuration.
IMPORTANT: Protect the liquid and suction service valves from the heat of brazing. Schrader valve cores must be removed from the liquid and suction service valves before brazing in field connection piping to avoid damage. Reinsert cores after brazing is completed.
MOTORMASTER TRANSDUCER LOCATION
Fig. 13 Unit Piping Sizes 018-030
a09-591
20
MOTORMASTER PRESSURE TRANSDUCER LOCATION CIRCUIT B FAN CYCLE
PRESSURE SWITCH LOCATIONS
MOTORMASTER PRESSURE TRANSDUCER LOCATION CIRCUIT A
Fig. 14 Unit Piping Sizes 035-060
a09-592
MOTORMASTER PRESSURE TRANSDUCER LOCATION CIRCUIT A
MOTORMASTER PRESSURE TRANSDUCER LOCATION CIRCUIT B
FAN CYCLE PRESSURE SWITCH INSTALLATION LOCATIONS
a09-593
Fig. 15 Unit Piping Sizes 065-130
21
Once all of the piping connections are complete, leak test the unit and then pull a deep dehydration vacuum. Connect the vacuum pump to the low side and high side of the system. For best results, it is recommended that a vacuum of at least 500 microns (0.5 mm Hg) be obtained. Afterwards, to ensure that no moisture is present in the system, perform a standing vacu- um-rise test.
With the unit in deep vacuum (500 microns or less), isolate the vacuum pump from the system. Observe the rate-of-rise of the vacuum in the system. If the vacuum rises by more than 50 microns in a 30-minute time period, then continue the dehy- dration process. Maintain a vacuum on the system until the standing vacuum requirement is met. This will ensure a dry system.
By following these evacuation and dehydration procedures, the amount of moisture present in the system will be mini- mized. It is required that liquid line filter driers be installed be- tween the condenser(s) and the expansion devices to capture
any foreign debris and provide additional moisture removal ca- pacity. Be sure to consider the pressure drop of the filter drier when determining piping requirements. REFRIGERANT LINE SIZING Sizing depends on length of lines between various sections of the refrigerant system. See Tables 2-6 for pipe connection details. Consider the amount of liquid lift and drop in the system as well as proper compressor oil return. See Liquid Lift section for more information. Con- sult Carrier System Design Manual, Part 3, or Carrier E20-II Refrigerant Piping Computer Program for proper piping sizes and design. PRESSURE RELIEF The ASHRAE Standard 15, Safety Code for Mechanical Refrigeration states: Every refrigerat- ing 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. The 09DP units are pro- vided with a 210 F temperature fusible plug on the liquid line of each circuit. This may or may not meet local code require- ments. REFRIGERANT RECEIVER A refrigerant receiver is not furnished with 09DP units and is not recommended for normal applications as its use will be detrimental to the desired effects of subcooling. However, if a particular application requires a receiver to increase refrigerant holding capacity of the con- denser, a receiver can be used. Recommended receiver and valve installation and piping are shown in Fig. 18. When a receiver is to be used year-round, it should be installed indoors. Procedure for Using the Refrigerant Receiver (Fig. 18)
1. During normal operation Valve A is open and valves B and C are closed. Receiver is isolated from the system.
2. 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.
3. 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 refrig- erant from the receiver, throttle valve B while noting con- dition of refrigerant in the liquid line sight glass; also, watch the suction pressure. A sudden surge of bubbles in the sight glass and a rapid decrease in suction pressure indicate 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 un- der normal operation.
LIQUID LIFT Amount of liquid lift available before refrig- erant flashing occurs depends on amount of liquid sub-cooling in the system.
All 09DP 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 (due to elevation of the liquid metering device above the condenser).
When 09DP 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 liquid suction interchanger.
The average amount of liquid lift available is shown in Tables 7 and 8 for refrigerants R-410A and R-134a. It is rec- ommended that the evaporator be at the same level as the con- denser, or lower.
LEGEND SAE Society of Automotive Engineers
Fig. 16 Fan Cycle Pressure Switch
a9- 248tf.tif
TUBING PACKAGE
Fig. 17 Tubing Package Installed in Unit
WARNING
Do not apply pumpdown cycle with MCHX (microchannel heat exchanger) condensers. Damage to unit or personal injury may occur.
a09-594
22
Table 7 Available Liquid Lift (ft)* English
*Allows 7 psi drop for liquid line accessories with maximum charge. Saturated Condensing Temperature (entering) Entering Air Tem- perature (dry bulb) F.
NOTES: 1. Data based on 15 F subcooling. 2. Subcooling = Saturated condensing temperature of refrigerant
Actual temperature of refrigerant leaving the coil.
Table 8 Available Liquid Lift (m)* SI
*Allows 48 kPa drop for liquid line accessories with maximum charge. Saturated Condensing Temperature (entering) Entering Air Tem- perature (dry bulb) C.
NOTES: 1. Data based on 8.3 C subcooling. 2. Subcooling = Saturated condensing temperature of refrigerant
Actual temperature of refrigerant leaving the coil.
UNIT
REFRIGERANT R-410A R-134a
Temperature Difference (F) 20 30 20 30
09DPS018
75 75
60 45 09DPS020 50 35 09DPS030 45 30 09DPM035 55 40 09DPM040 50 35 09DPM050 50 35 09DPM060 45 30 09DPM065 55 40 09DPM075 50 35 09DPM085 50 35 09DPM095 50 35 09DPM115 50 35 09DPM130 50 35
UNIT
REFRIGERANT R-410A R-134a
Temperature Difference (C) 11.1 16.6 11.1 16.6
09DPS018
23 23
18 14 09DPS020 15 11 09DPS030 14 9 09DPM035 17 12 09DPM040 15 11 09DPM050 15 11 09DPM060 14 9 09DPM065 17 12 09DPM075 15 11 09DPM085 15 11 09DPM095 15 11 09DPM115 15 11 09DPM130 15 11
23
Step 4 Make Electrical Connections
GENERAL Verify nameplate electrical requirements match available power supply. Voltage at condenser must be within the minimum and maximum shown in Tables 9 and 10. Phases must be balanced within 2%. 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 voltage imbalance:
Example: Supply voltage is 240-3-60. AB = 243 volts BC = 236 volts AC = 238 volts
Determine maximum deviation from average voltage: (AB) 243 239 = 4 volts (BC) 239 236 = 3 volts (AC) 239 238 = 1 volt Maximum deviation is then 4 volts. To determine the percent- age of voltage imbalance:
This amount of phase imbalance is satisfactory since it is below the maximum allowable of 2%.
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 local or NEC regulations. POWER WIRING All field power wiring must comply with applicable local and national codes. Install field-supplied branch circuit fused disconnect per NEC of a type that can be locked OFF or OPEN. Disconnect must be within sight and readily accessible from the unit in compliance with NEC Arti- cle 440-14. General Wiring Notes:
1. A terminal strip is provided for field-wired control devices.
2. Power entry is at one end only. 3. All field power enters the unit through a hole located in
the corner post of the unit or the bottom of the control box shelf. Refer to Fig. 19 for field power wiring details. Re- fer to Fig. 5-9 for exact location of field power entry. See Table 11 for incoming power wiring options.
4. Terminals for field power supply are suitable only for copper conductors. Insulation must be rated 75 C minimum.
5. Units with high short circuit ratings require that only RK1, RK5, or J type fuses be used.
WARNING
Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury.
IMPORTANT: When starting up this equipment for operation, be sure to check tightness of all electrical ter- minal connections, clamps, screws, etc., as they may have become loose during shipment. It is also advisable to re-tighten all electrical connections after equipment has been in operation and components have reacted to operating temperature.
IMPORTANT: Operating unit on improper supply voltage or with excessive phase imbalance constitutes abuse and may adversely affect Carrier warranty.
CAUTION
Proper rotation of condenser fan(s) MUST be verified. Failure to comply could result in possible equipment damage.
RELIEF VALVE
*Field-supplied service valves.
Fig. 18 Piping for Field-Supplied Receiver
A Bypass valve B Receiver inlet valve C Receiver outlet valve
a09-595
% Voltage Imbalance = 100 x
max voltage deviation from average voltage
Average voltage
Average Voltage = 243 + 236 + 238 3
= 717 3
= 239
% Voltage Imbalance = 100 x 4 239
= 1.7%
IMPORTANT: If supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.
24
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25
Table 9 09DP Electrical Data Standard Fan
LEGEND
1. Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed minimum and maximum limits. Maximum allowable phase imbalance is voltage 2% and amps 10%.
2. All units or modules have single point primary power connec- tion. Main power must be supplied from a field-supplied disconnect.
3. All terminal block units should be capable of handling 14 AWG to 2 AWG.
4. Disconnect units with MOCP of greater than 40 require 8 AWG to 1 AWG.
5. Disconnect units with MOCP less than 40 require 14 AWG to 6 AWG.
6. For all high short circuit capable FIOP units, fuses must be used for overload protection.
09DP UNIT SIZE V-Ph-Hz SUPPLY VOLTAGE CONDENSER FAN
MCA MOCP Min Max TOTAL QTY FLA
018
208/230-3-60 187 254
1
6.6 8.3 15 380-3-60 342 418 3.9 4.9 15 460-3-60 414 506 3.3 4.1 15 575-3-60 518 632 2.6 3.3 15
380/415-3-50 342 440 3.3 4.1 15
020
208/230-3-60 187 254
2
6.6 14.9 20 380-3-60 342 418 3.9 8.8 15 460-3-60 414 506 3.3 7.4 15 575-3-60 518 632 2.6 5.9 15
380/415-3-50 342 440 3.3 7.4 15
030
208/230-3-60 187 254
2
6.6 14.9 20 380-3-60 342 418 3.9 8.8 15 460-3-60 414 506 3.3 7.4 15 575-3-60 518 632 2.6 5.9 15
380/415-3-50 342 440 3.3 7.4 15
035
208/230-3-60 187 254
2
6.6 14.9 20 380-3-60 342 418 3.9 8.8 15 460-3-60 414 506 3.3 7.4 15 575-3-60 518 632 2.6 5.9 15
380/415-3-50 342 440 3.3 7.4 15
040
208/230-3-60 187 254
3
6.6 21.5 25 380-3-60 342 418 3.9 12.7 15 460-3-60 414 506 3.3 10.7 15 575-3-60 518 632 2.6 8.5 15
380/415-3-50 342 440 3.3 10.7 15
050
208/230-3-60 187 254
4
6.6 28.1 30 380-3-60 342 418 3.9 16.6 20 460-3-60 414 506 3.3 14.0 15 575-3-60 518 632 2.6 11.1 15
380/415-3-50 342 440 3.3 14.0 15
060
208/230-3-60 187 254
4
6.6 28.1 30 380-3-60 342 418 3.9 16.6 20 460-3-60 414 506 3.3 14.0 15 575-3-60 518 632 2.6 11.1 15
380/415-3-50 342 440 3.3 14.0 15
AWG American Wire Gage FIOP Factory-Installed Option FLA Full Load Amps MCA Minimum Circuit Amps, complies with NEC, Article 430-24 MOCP Maximum Overcurrent Protection (Amps) NEC National Electrical Code
26
Table 9 09DP Electrical Data Standard Fan (cont)
LEGEND
1. Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed minimum and maximum limits. Maximum allowable phase imbalance is voltage 2% and amps 10%.
2. All units or modules have single point primary power connec- tion. Main power must be supplied from a field-supplied disconnect.
3. All terminal block units should be capable of handling 14 AWG to 2 AWG.
4. Disconnect units with MOCP of greater than 40 require 8 AWG to 1 AWG.
5. Disconnect units with MOCP less than 40 require 14 AWG to 6 AWG.
6. For all high short circuit capable FIOP units, fuses must be used for overload protection.
09DP UNIT SIZE V-Ph-Hz SUPPLY VOLTAGE CONDENSER FAN
MCA MOCP Min Max TOTAL QTY FLA
065
208/230-3-60 187 254
4
6.6 28.1 30 380-3-60 342 418 3.9 16.6 20 460-3-60 414 506 3.3 14.0 15 575-3-60 518 632 2.6 11.1 15
380/415-3-50 342 440 3.3 14.0 15
075
208/230-3-60 187 254
5
6.6 34.7 40 380-3-60 342 418 3.9 20.5 25 460-3-60 414 506 3.3 17.3 20 575-3-60 518 632 2.6 13.7 15
380/415-3-50 342 440 3.3 17.3 20
085
208/230-3-60 187 254
6
6.6 41.3 45 380-3-60 342 418 3.9 24.4 25 460-3-60 414 506 3.3 20.6 25 575-3-60 518 632 2.6 16.3 15
380/415-3-50 342 440 3.3 20.6 25
095
208/230-3-60 187 254
6
6.6 41.3 45 380-3-60 342 418 3.9 24.4 25 460-3-60 414 506 3.3 20.6 25 575-3-60 518 632 2.6 16.3 15
380/415-3-50 342 440 3.3 20.6 25
115
208/230-3-60 187 254
7
6.6 47.9 50 380-3-60 342 418 3.9 28.3 30 460-3-60 414 506 3.3 23.9 25 575-3-60 518 632 2.6 18.9 20
380/415-3-50 342 440 3.3 23.9 25
130
208/230-3-60 187 254
8
6.6 54.5 60 380-3-60 342 418 3.9 32.2 35 460-3-60 414 506 3.3 27.2 30 575-3-60 518 632 2.6 21.5 25
380/415-3-50 342 440 3.3 27.2 30
AWG American Wire Gage FIOP Factory-Installed Option FLA Full Load Amps MCA Minimum Circuit Amps, complies with NEC, Article 430-24 MOCP Maximum Overcurrent Protection (Amps) NEC National Electrical Code
27
Table 10 09DP Electrical Data Low Sound Fan
LEGEND
1. Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed minimum and maximum limits. Maximum allowable phase imbalance is voltage 2% and amps 10%.
2. All units or modules have single point primary power connec- tion. Main power must be supplied from a field-supplied disconnect.
3. All terminal block units should be capable of handling 14 AWG to 2 AWG.
4. Disconnect units with MOCP of greater than 40 require 8 AWG to 1 AWG.
5. Disconnect units with MOCP less than 40 require 14 AWG to 6 AWG.
6. For all high short circuit capable FIOP units, fuses must be used for overload protection.
09DP UNIT SIZE V-Ph-Hz SUPPLY VOLTAGE CONDENSER FAN
MCA MOCP Min Max TOTAL QTY FLA
018
208/230-3-60 187 254
1
6.0 7.5 15 380-3-60 342 418 3.9 4.9 15 460-3-60 414 506 2.9 3.6 15 575-3-60 518 632 2.4 3.0 15
380/415-3-50 342 440 2.9 3.6 15
020
208/230-3-60 187 254
2
6.0 13.5 15 380-3-60 342 418 3.9 8.8 15 460-3-60 414 506 2.9 6.5 15 575-3-60 518 632 2.4 5.4 15
380/415-3-50 342 440 2.9 6.5 15
030
208/230-3-60 187 254
2
6.0 13.5 15 380-3-60 342 418 3.9 8.8 15 460-3-60 414 506 2.9 6.5 15 575-3-60 518 632 2.4 5.4 15
380/415-3-50 342 440 2.9 6.5 15
035
208/230-3-60 187 254
2
6.0 13.5 15 380-3-60 342 418 3.9 8.8 15 460-3-60 414 506 2.9 6.5 15 575-3-60 518 632 2.4 5.4 15
380/415-3-50 342 440 2.9 6.5 15
040
208/230-3-60 187 254
3
6.0 19.5 25 380-3-60 342 418 3.9 12.7 15 460-3-60 414 506 2.9 9.4 15 575-3-60 518 632 2.4 7.8 15
380/415-3-50 342 440 2.9 9.4 15
050
208/230-3-60 187 254
4
6.0 25.5 30 380-3-60 342 418 3.9 16.6 20 460-3-60 414 506 2.9 12.3 15 575-3-60 518 632 2.4 10.2 15
380/415-3-50 342 440 2.9 12.3 15
060
208/230-3-60 187 254
4
6.0 25.5 30 380-3-60 342 418 3.9 16.6 20 460-3-60 414 506 2.9 12.3 15 575-3-60 518 632 2.4 10.2 15
380/415-3-50 342 440 2.9 12.3 15
AWG American Wire Gage FIOP Factory-Installed Option FLA Full Load Amps MCA Minimum Circuit Amps, complies with NEC, Article 430-24 MOCP Maximum Overcurrent Protection (Amps) NEC National Electrical Code
28
Table 10 09DP Electrical Data Low Sound Fan (cont)
LEGEND
1. Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed minimum and maximum limits. Maximum allowable phase imbalance is voltage 2% and amps 10%.
2. All units or modules have single point primary power connec- tion. Main power must be supplied from a field-supplied disconnect.
3. All terminal block units should be capable of handling 14 AWG to 2 AWG.
4. Disconnect units with MOCP of greater than 40 require 8 AWG to 1 AWG.
5. Disconnect units with MOCP less than 40 require 14 AWG to 6 AWG.
6. For all high short circuit capable FIOP units, fuses must be used for overload protection.
Table 11 Unit Incoming Power Options
LEGEND NOTES: 1. Terminal block high SCCR option units must use approved
fuses to meet high SCCR rating. 2. High SCCR disconnect option units can use either approved
fuse or circuit breaker for incoming power protection. 3. Time delay fuse type required.
09DP UNIT SIZE V-Ph-Hz SUPPLY VOLTAGE CONDENSER FAN
MCA MOCP Min Max TOTAL QTY FLA
065
208/230-3-60 187 254
4
6.0 25.5 30 380-3-60 342 418 3.9 16.6 20 460-3-60 414 506 2.9 12.3 15 575-3-60 518 632 2.4 10.2 15
380/415-3-50 342 440 2.9 12.3 15
075
208/230-3-60 187 254
5
6.0 31.5 35 380-3-60 342 418 3.9 20.5 25 460-3-60 414 506 2.9 15.2 20 575-3-60 518 632 2.4 12.6 15
380/415-3-50 342 440 2.9 15.2 20
085
208/230-3-60 187 254
6
6.0 37.5 40 380-3-60 342 418 3.9 24.4 25 460-3-60 414 506 2.9 18.1 20 575-3-60 518 632 2.4 15.0 15
380/415-3-50 342 440 2.9 18.1 20
095
208/230-3-60 187 254
6
6.0 37.5 40 380-3-60 342 418 3.9 24.4 25 460-3-60 414 506 2.9 18.1 20 575-3-60 518 632 2.4 15.0 15
380/415-3-50 342 440 2.9 18.1 20
115
208/230-3-60 187 254
7
6.0 43.5 45 380-3-60 342 418 3.9 28.3 30 460-3-60 414 506 2.9 21.0 25 575-3-60 518 632 2.4 17.4 20
380/415-3-50 342 440 2.9 21.0 25
130
208/230-3-60 187 254
8
6.0 49.5 50 380-3-60 342 418 3.9 32.2 35 460-3-60 414 506 2.9 23.9 25 575-3-60 518 632 2.4 19.8 20
380/415-3-50 342 440 2.9 23.9 25
AWG American Wire Gage FIOP Factory-Installed Option FLA Full Load Amps MCA Minimum Circuit Amps, complies with NEC, Article 430-24 MOCP Maximum Overcurrent Protection (Amps) NEC National Electrical Code
MOCP VALUE
UNIT INCOMING POWER OPTION Standard Terminal
Block Option High SCCR Terminal Block Option Standard and High SCCR Disconnect Option
Max Wire Size
Min Wire Size
Max Wire Size
Min Wire Size
High SCCR Fuse Type Max Wire Size Min
Wire Size 100 A or less 2/0 AWG 14 AWG 2/0 AWG 6 AWG J, RK1, or RK5 1/0 AWG 14 AWG Greater than
100 A and Less than or Equal to 200 A
2/0 AWG 14 AWG 2/0 AWG 6 AWG J or RK1 350 kcmil 6 AWG
Greater than 200 600 kcmil 2 AWG 600 kcmil 3/0 AWG J or RK1 500 kcmil (1) 500 kcmil (2) 3/0 AWG
AWG American Wire Gage kcmil Thousand Circular Mills MOCP Maximum Overcurrent Protection SCCR Short Circuit Current Rating
29
CONTROL CIRCUIT WIRING 09DP018-030 Units The units require a 24-volt externally supplied power to energize the control circuit connected to TB2 terminal 1 and 2 shown in Fig. 20. 09DP035-0130 Units Size 035 to 130 units are designed to operate with a 24-v field-supplied control power or can be powered by internal control transformer using contact closures to energize each control circuit. The 035-130 size units are de- signed to operate with either single, dual circuit or multiple unit applications.
When 24-v control power is supplied from external source (30MP application), this application requires the 24-v external- ly supplied power to energize the control relays for each circuit. Unit 1/Cir A should be connected to TB2 terminal 1 and 2. Unit 2/Cir B should be connected to TB2 terminal 3 and 4. See Fig. 21. FIELD CONTROL WIRING With 24-v internally sup- plied power applications (30HX applications), the application requires field-supplied control relay(s) to energize contacts to energize the 09DP control relays for each circuit.
1. Install field-supplied jumpers between terminals 2, 3 and 6 of TB2. See Fig. 22.
2. Connect field-supplied wiring and relay for Unit 1/Cir- cuit A. Contacts should be connected between TB2 terminal 1 and 5.
3. For single unit applications a jumper should be installed between TB2 terminals 1 and 4. See Fig. 23.
4. Connect field-supplied wiring and relay for Unit 2/Cir- cuit B. Contacts should be connected between TB2 ter- minals 4 and 5.
Fan Cycling Pressure Switches (FCPS) Unit sizes 040- 060 and 075-130 require fan cycling pressure switches to be in- stalled and wired into the control circuit. See Fig. 14 and 15 for mounting location of FCPS.
For sizes 040-060: 1. The FCPS wires should be routed through bushing
located in bottom of control box as shown in Fig. 24. 2. The FCPS1 and FCPS2 switches are wired in parallel
into the control circuit as shown in Fig. 25. The VIO and PNK wires are wired together when shipped from the factory. The connectors should be removed and the FCPS wired in using wire nuts.
Fig. 20 09DP018-030 Control Circuit Wiring
a09-596
Fig. 21 09DP035-130 with 30MP Control Circuit Wiring
a09-597
CAUTION
Since the 09DP units are compatible with multiple refriger- ants, the correct FCPS must be installed for proper opera- tion of unit. Damage to unit could result.
Fig. 22 09DP035-130 with 30HX Control Circuit Wiring
a09-598
JUMPER REQUIRED FOR SINGLE CIRCUIT APPLICATIONS
Fig. 23 Single Circuit 09DP035-130 with 30HX Control Circuit Wiring
a09-599
30
For sizes 075-095: 1. The FCPS wires should be routed through bushing
located in bottom of control box as shown in Fig. 24. 2. Remove the factory-supplied red jumper wire between
terminals 3 and 4 of TB3. 3. The FCPS1 and FCPS2 switches are wired in Parallel
into the control circuit as shown in Fig. 26. The VIO and ORN wires are wired together when shipped from the factory. The connectors should be removed and one end of the FCPS wired together with the RED and ORN wire using wire nuts and the other end connected to TB3 terminal 4.
For sizes 115-130: 1. The FCPS wires should be routed through bushing
located in bottom of control box as shown in Fig. 24. 2. Remove the red jumper wire between terminals 3 and
4 of TB3 that is supplied from the factory. This is installed for test purposes only.
3. Disconnect the VIO and ORN FCPS1 and FCPS2 wires that are connected together when shipped from the factory.
4. Connect FCPS1 between to the violet wire labeled FCPS1 and TB3 terminal 4 per Fig. 27.
5. Connect FCPS2 between to the orange wire labeled FCPS2 and pink wire labeled FC4 coil per Fig. 27.
Step 5 Check Condenser Fans Each fan is supported by a formed wire mount bolted to a fan deck and covered with a wire guard. METAL FANS The exposed end of fan motor shaft is pro- tected from weather by grease and a rubber boot. If fan motor must be removed for service or replacement, be sure to re- grease fan shaft and reinstall fan guard. For proper perfor- mance, fan web should be 0.32 in. (8 mm) below top of orifice on the fan deck to top of the fan hub. (See Fig. 28.) Tighten set screws to 15 1 ft-lb (20 1.3 N-m). Figure 28 shows the proper position of mounted fan.
LOW SOUND FAN A shroud and a wire guard provide protection from the rotating fan. The exposed end of the fan motor shaft is protected from weather by grease. If fan motor must be removed for service or replacement, be sure to re- grease fan shaft and reinstall fan guard. The fan motor has a step in the motor shaft. For proper performance, fan should be
FCPS AND MOTORMASTER TRANSDUCER WIRING
CONTROL WIRING
MAIN POWER WIRING
FCPS AND MOTORMASTER TRANSDUCER WIRING
CONTROL WIRING
MAIN POWER WIRING
09DP018-060 UNITS
09DP065-130 UNITS
Fig. 24 Control Box Entry Points
a09-600
Fig. 25 Fan Cycle Pressure Switch Wiring 09DP040-060 Units
IMPORTANT: Check for proper fan rotation (clockwise when viewed from above). If necessary, switch any 2 power leads to reverse fan rotation.
Fig. 26 Fan Cycle Pressure Switch Wiring 09DP075-095 Units
Fig. 27 Fan Cycle Pressure Switch Wiring 09DP115,130 Units
a09-603
Fig. 28 Mounted Fan Position
fan height.eps in job folder (WIP)
a09-601
a09-602
31
positioned such that it is securely seated on this step. Tighten the bolt to 15 1 ft-lb (20 1.3 Nm).
Step 6 Configure Optional Motormaster V Controller The optional or accessory Motormaster V controller uses a 0 to 5 vdc signal from a pressure transducer to control the speed of the fans controlled by the Motormaster control. The Motormaster V control is applied in 3 different ap- plications on the 09DP product and must be configured for the proper refrigerant application. SINGLE CIRCUIT APPLICATIONS (09DPS018-030) One Motormaster control is used to control the speed of the motor attached to the Motormaster V control based on the sig- nal from the liquid line transducer. DUAL CIRCUIT APPLICATIONS (09DPM065-130) There is one Motormaster control for each circuit and the speed output of each Motormaster control is controlled independently by the liquid line transducer reading for each circuit. SINGLE CIRCUIT APPLICATIONS (09DPM065-130) There are two Motormaster drives in the unit; one is the lead Motormaster control and the other is the follower Motormaster control. The units are shipped from the factory for independent Motormaster control. This application requires modification to the unit wiring during initial installation. This application MM- A controls the speed of both MM-A and MM-B based on the pressure transducer connected to MM-A.
Perform the following wiring modifications: 1. Remove the wiring to the Circuit B pressure transducer
connected to terminals 2, 5 and 6 on the terminal board of the controller per Fig. 29.
2. The units are shipped with a package required for modifying the unit for single circuit application. The package is located in the bottom of the control box below the Motormaster controllers.
3. Install the wire between MM-A terminal 2 and MM-B terminal 2.
4. Install the wire with the resistor between MM-A termi- nal 30 and MM-B terminal 25.
MOTORMASTER V REFRIGERANT CONFIGURA- TION The units are shipped from the factory for applica- tion with R-410A refrigerant. When applying on R-134a sys- tems, a jumper must be installed between terminal 2 and 12 of MM-A and MM-B.
Once the controller is wired properly it is configured for the application and no other adjustments are required. If the drive does not function properly, the information in this book and in Tables 12 and 13 can be used to troubleshoot.
IMPORTANT: Check for proper fan rotation (counter- clockwise when viewed from above). If necessary, switch any 2 power leads to reverse fan rotation.
CAUTION
If input power has not been applied to the drive for a period of time exceeding three years (due to storage, etc.), the electrolytic DC bus capacitors within the drive can change internally, resulting in excessive leakage current. This can result in premature failure of the capacitors if the drive is operated after such a long period of inactivity or storage. In order to reform the capacitors and prepare the drive for operation after a long period of inactivity, apply input power to the drive for 8 hours prior to actually operating the motor. Before attempting to operate the drive, motor, and driven equipment, be sure all procedures pertaining to installation and wiring have been properly followed. Fail- ure to comply could result in equipment damage.
Fig. 29 Motormaster V Wiring (09DP115,130 Units Shown)a09-604
32
Table 12 Fault Codes
DRIVE PROGRAMMING
To enter password and change program values: 1. Press Mode. 2. Upper right decimal point blinks. 3. Display reads 00. To enter the PROGRAM mode to ac-
cess the parameters, press the Mode button. This will ac- tivate the PASSWORD prompt (if the password has not been disabled). The display will read 00 and the upper right-hand decimal point will be blinking. (See Fig. 30.)
4. Use the and buttons to scroll to the password value (the factory default password is 111) and press the Mode button. Once the correct password value is entered, the display will read P01, which indicates that the PROGRAM mode has been accessed at the beginning of the parameter menu (P01 is the first parameter).
NOTE: If the display flashes Er, the password was incorrect, and the process to enter the password must be repeated.
5. Press Mode to display present parameter number. Upper right decimal point blinks. Use the and buttons to scroll to the desired parameter number.
Once the desired parameter number is found, press the Mode button to display the present parameter setting. The up- per right-hand decimal point will begin blinking, indicating that the present parameter setting is being displayed, and that it can be changed by using the up and down buttons. Use and to change setting. Press Mode to store new setting.
Pressing the Mode will store the new setting and also exit the PROGRAM mode. To change another parameter, press the Mode key again to re-enter the PROGRAM mode (the param- eter menu will be accessed at the parameter that was last viewed or changed before exiting). If the Mode key is pressed within two minutes of exiting the PROGRAM mode, the pass- word is not required to access the parameters. After two min- utes, the password must be entered in order to access the pa- rameters again.
To change password: first enter the current password then change parameter P44 to the desired password.
To disable automatic control mode and enter manual speed control mode:
1. Change P05 to 01- keypad. 2. Push UP and DOWN arrow key to set manual speed. 3. Set P05 to 04 - 4-20mA control to restore 4 to 20 mA
control. Fault Codes The drive is programmed to automatically re- start after a fault and will attempt to restart three times after a fault (the drive will not restart after CF, cF, GF, F1, F2-F9, or Fo faults). If all three restart attempts are unsuccessful, the drive will trip into FAULT LOCKOUT (LC), which requires a manual reset.
FAULT CODE DESCRIPTION SOLUTION AF High Temperature Fault: Ambient temperature is too high; Cooling
fan has failed (if equipped). Check cooling fan operation
CF Control Fault: A blank EPM, or an EPM with corrupted data has been installed.
Perform a factory reset using Parameter 48 PROGRAM SELECTION.
cF Incompatibility Fault: An EPM with an incompatible parameter ver- sion has been installed.
Either remove the EPM or perform a factory reset (Parameter 48) to change the parameter version of the EPM to match the parameter version of the drive.
CL CURRENT LIMIT: The output current has exceeded the CURRENT LIMIT setting (Parameter 25) and the drive is reducing the output frequency to reduce the output current. If the drive remains in CUR- RENT LIMIT too long, it can trip into a CURRENT OVERLOAD fault (PF).
Check for loose electrical connections. Check for faulty condenser fan motor. Check Parameter P25 from Table 13 is set correctly.
GF Data Fault: User data and OEM defaults in the EPM are corrupted. Restore factory defaults P48, see section above. If that does not work, replace EPM.
HF High DC Bus Voltage Fault: Line voltage is too high; Deceleration rate is too fast; Overhauling load.
Check line voltage set P01 appropriately
JF Serial Fault: The watchdog timer has timed out, indicating that the serial link has been lost.
Check serial connection (computer) Check settings for PXX. Check settings in communication software to match PXX.
LF Low DC Bus Voltage Fault: Line voltage is too low. Check line voltage set P01 appropriately OF Output Transistor Fault: Phase to phase or phase to ground short
circuit on the output; Failed output transistor; Boost settings are too high; Acceleration rate is too fast.
Reduce boost or increase acceleration values. If unsuccessful, replace drive. Check for incorrect wiring T1, T2, T3.
PF Current Overload Fault: VFD is undersized for the application; Mechanical problem with the driven equipment.
Check line voltage set P01 appropriately Check for dirty coils Check for motor bearing failure
SF Single-phase Fault: Single-phase input power has been applied to a three-phase drive.
Check input power phasing
F1 EPM Fault: The EPM is missing or damaged. F2-F9, Fo Internal Faults: The control board has sensed a problem Consult factory Drive display = 60.0 even though it is cold outside and it should be running slower
Feedback signal is above set point Check for proper set point Check liquid line pressure
Drive display = --- even though drive should be running
Start jumper is missing Replace start jumper. See section above
Drive display = 8.0 even though fan should be running faster
Feedback signal is below set point and fan is at minimum speed Check for proper set point Check liquid line pressure
VFD flashes 57 and LCS Feedback or speed signal lost. Drive will operate at 57 Hz until reset or loss of start command. Resetting requires cycling start command (or power).
In stand alone mode: Check transducer wiring and feedback voltage. Feedback voltage displayed on P-69. Pin 6 should be 5 v output. Pin 5 (feedback) should be somewhere between 0 and 5 v.
CAUTION
It is strongly recommended that the user NOT change any programming without consulting Carrier service personnel. Unit damage may occur from improper programming.
LEGEND EPM Electronic Programming Module
33
MANUAL RESET If the fault condition has been re- moved, cycle power to the Motormaster to reset the drive. TROUBLESHOOTING Troubleshooting the Motormaster V control requires a combination of observing system opera- tion and VFD (variable frequency drive) information. Refer to Fig. 29 for the low ambient wiring diagram. The drive provides 2 kinds of troubleshooting modes: a status matrix using the 3- digit display (P57, P58) and real time monitoring of key inputs and outputs. The collective group is displayed through parame- ters 50 to 71 and all values are read-only. The key read-only outputs are: P50: FAULT HISTORY - This displays the last 8 faults. P51 : SOFTWARE VERSION - This displays the Soft-
ware version number.
P52: DC BUS VOLTAGE - This displays the DC bus voltage in percent of nominal. It is usually rated input voltage x 1.4.
P53: MOTOR VOLTAGE - This displays the motor voltage in percent of rated output voltage.
P54: LOAD - This displays the motor load in percent of the drive's rated output current rating.
P55: VDC INPUT - This displays the VDC input in per- cent of maximum input. A display of 100 will indicate full scale, which is 5 v.
P56: 4-20 mA INPUT - This displays the 4 to 20 mA input in percent of maximum input. A value of 20% = 4 mA and a value of 100% = 20 mA. Refer to Tables 12 and 13 for more troubleshooting
information.
L1 L2 L3
Mode
DANGER
T1 T2 T3 B+B-
DISPLAYBUTTONS
Mode
MMV TERMINAL BLOCK
Fig. 30 Motormaster V Mode Buttons and Mode Display
LEGEND MMV Motormaster V Control
a09-605
34
Table 13 Motormaster V Program Parameters for Operating Modes
LEGEND
Step 7 Install Accessories LOW-AMBIENT OPERATION If operating temperatures below those found in Tables 14 and 15 are expected, Motor- master V fan motor control is recommended.
MISCELLANEOUS ACCESSORIES Energy manage- ment module, Navigator display, remote enhanced display, Touch Pilot display, BACnet* translator control, LON (local operating network) translator control, and long line accessory kit are available for special applications.
*Sponsored by ASHRAE (American Society of Heating, Refrigerat- ing and Air Conditioning Engineers).
CODE DESCRIPTION MODE 1
MODE 2
MODE 3
MODE 4
MODE 5
MODE 6
MODE 7
MODE 8
MODE 9
MODE 10
MODE 11
MODE 12
P01 Line Voltage: 01 = low line, 02 = high line 01 02 01 02 01 02 01 02 01 02 01 02
P02 Carrier Freq: 01 = 4 kHz, 02 = 6 kHz, 03=8 kHz 01 01 01 01 01 01 01 01 01 01 01 01
P03 Startup mode: flying restart 06 06 06 06 06 06 06 06 06 06 06 06
P04 Stop mode: coast to stop 01 01 01 01 01 01 01 01 01 01 01 01
P05 Standard Speed source: 01= keypad, 04=4-20mA (NO PI), 05= R410A, 06=R134a 05 05 05 05 04 04 04 04 06 06 06 06
P06 TB-14 output: 01 = none 01 01 01 01 01 01 01 01 01 01 01 01
P08 TB-30 output: 01 = none 01 01 01 01 01 01 01 01 01 01 01 01
P09 TB-31 Output: 01 = none 01 01 01 01 01 01 01 01 01 01 01 01
P10 TB-13A function sel: 01 = none 01 01 01 01 01 01 01 01 01 01 01 01
P11 TB-13B function sel: 01 = none 01 01 01 01 01 01 01 01 01 01 01 01
P12 TB-13C function sel: 01 = none 01 01 01 01 01 01 01 01 01 01 01 01
P13 TB-15 output: 01 = none 01 01 01 01 01 01 01 01 01 01 01 01
P14 Control: 01 = Terminal strip 01 01 01 01 01 01 01 01 01 01 01 01
P15 Serial link: 02 = enabled 9600,8,N,2 with timer 02 02 02 02 02 02 02 02 02 02 02 02
P16 Units editing: 02 = whole units 02 02 02 02 02 02 02 02 02 02 02 02
P17 Rotation: 01 = forward only, 03 = reverse only 01 01 01 01 01 01 01 01 01 01 01 01
P19 Acceleration time: 10 sec 10 10 10 10 10 10 10 10 10 10 10 10
P20 Deceleration time: 10 sec 10 10 10 10 10 10 10 10 10 10 10 10
P21 DC brake time: 0 0 0 0 0 0 0 0 0 0 0 0 0
P22 DC BRAKE VOLTAGE 0% 0 0 0 0 0 0 0 0 0 0 0 0
P23 Min freq = 8 Hz ~ 100 160 rpm 8 8 8 8 8 8 8 8 8 8 8 8
P24 Max freq 60 60 50 50 60 60 50 50 60 60 50 50
P25 Current limit: (%) 125 110 125 110 125 110 125 110 125 110 125 110
P26 Motor overload: 100 100 100 100 100 100 100 100 100 100 100 100 100
P27 Base freq: 60 or 50 Hz 60 60 50 50 60 60 50 50 60 60 50 50
P28 Fixed boost: 0.5% at low frequencies 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
P29 Accel boost: 0% 0 0 0 0 0 0 0 0 0 0 0 0
P30 Slip compensation: 0% 0 0 0 0 0 0 0 0 0 0 0 0
P31 Preset spd #1: speed if loss of control signal 57 57 47 47 57 57 47 47 57 57 47 47
P32 Preset spd #2: 0 0 0 0 0 0 0 0 0 0 0 0 0
P33 Preset spd #3: 0 0 0 0 0 0 0 0 0 0 0 0 0
P34 Preset spd 4 default R410A setpoint. TB12-2 open 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0
P35 Preset spd 5 default R134a setpoint. TB12-2 closed 12.6 12.6 12.6 12.6 12.6 12.6 12.6 12.6 12.6 12.6 12.6 12.6
P36 Preset spd 6 default 0 0 0 0 0 0 0 0 0 0 0 0
P37 Preset spd 7 default 0 0 0 0 0 0 0 0 0 0 0 0
P38 Skip bandwidth 0 0 0 0 0 0 0 0 0 0 0 0
P39 Speed scaling 0 0 0 0 0 0 0 0 0 0 0 0
P40 Frequency scaling 50 or 60 Hz 60 60 50 50 60 60 50 50 60 60 50 50
P41 Load scaling: default (not used so NA) 200 200 200 200 200 200 200 200 200 200 200 200
P42 Accel/decel #2: default (not used so NA) 60 60 60 60 60 60 60 60 60 60 60 60
P43 Serial address 1 1 1 1 1 1 1 1 1 1 1 1
P44 Password:111 111 111 111 111 111 111 111 111 111 111 111 111
P45 Speed at min signal: 8 Hz; used when PID mode is disabled and 4-20mA input is at 4 mA 8 8 8 8 8 8 8 8 8 8 8 8
P46 Speed at max feedback: 60 or 50 Hz. Used when PID disabled and 4-20mA input is at 20 mA 60 60 50 50 60 60 50 50 60 60 50 50
P47 Clear history? 01 = maintain. (set to 02 to clear) 01 01 01 01 01 01 01 01 01 01 01 01
P48 Program selection: Program 1 12 01 02 03 04 05 06 07 08 09 10 11 12
P61 PI Mode: 05= reverse, 0-5V, 01 = no PID 05 05 05 05 01 01 01 01 05 05 05 05
P62 Min feedback = 0 (0V *10) 0 0 0 0 0 0 0 0 0 0 0 0
P63 Max feedback = 50 (5V * 10) 50 50 50 50 50 50 50 50 50 50 50 50
P64 Proportional gain = 4% 4 4 4 4 4 4 4 4 4 4 4 4
P65 Integral gain = .2 .2 .2 .2 .2 .2 .2 .2 .2 .2 .2 .2 .2
P66 PI acell/decel (setpoint change filter) = 5 5 5 5 5 5 5 5 5 5 5 5 5
P67 Min alarm 0 0 0 0 0 0 0 0 0 0 0 0
P68 Max alarm 0 0 0 0 0 0 0 0 0 0 0 0
NA Not Applicable PID Proportional Integral Derivative TB Terminal Block
35
Table 14 Minimum Outdoor-Air Operating Temperature English
LEGEND
NOTES: 1. Based on 80 F condensing temperature at 100% and 75%
capacity and a 75 F condensing temperature at 50% and 25% capacity.
2. Unit sizes 035 to 130 are based on dual circuit operation. Dual circuit low ambient option should be based on circuit with low- est TD.
3. Operation below minimum ambient temperatures listed will require Motormaster control.
UNIT 09DP TD MINIMUM AMBIENT (F) WITHOUT MOTORMASTER CONTROL
100% Capacity 75% Capacity 50% Capacity 25% Capacity
018 30 58 62 62 64 25 63 66 65 66 20 67 70 68 68
020 30 44 51 54 59 25 51 58 58 62 20 58 63 64 66
030 30 27 38 45 54 25 37 47 51 58 20 47 55 58 63
035 30 41 48 50 58 25 47 53 55 60 20 53 59 60 63
040 30 32 41 45 55 25 39 47 50 57 20 46 53 56 61
050 30 20 35 45 52 25 25 42 50 56 20 31 50 56 60
060 30 20 30 45 50 25 25 37 50 54 20 31 47 56 58
065 30 19 32 41 51 25 30 42 47 56 20 42 51 55 62
075 30 24 36 43 53 25 35 45 50 57 20 45 54 57 63
085 30 16 29 39 50 25 28 40 46 55 20 39 49 54 61
095 30 15 26 37 49 25 25 38 44 54 20 37 48 53 61
115 30 15 24 35 48 25 22 36 43 54 20 35 46 52 60
130 30 15 25 36 49 25 23 36 43 54 20 36 47 52 60
TD Temperature Difference (F)
36
Table 15 Minimum Outdoor-Air Operating Temperature SI
LEGEND NOTES: 1. Based on 26.7 C condensing temperature at 100% and 75%
capacity and a 23.9 C condensing temperature at 50% and 25% capacity.
2. Unit sizes 035 to 130 are based on dual circuit operation. Dual circuit low ambient option should be based on circuit with low- est TD.
3. Operation below minimum ambient temperatures listed will require Motormaster control.
UNIT 09DP TD MINIMUM AMBIENT (C) WITHOUT MOTORMASTER CONTROL
100% Capacity 75% Capacity 50% Capacity 25% Capacity
018 16.6 14.2 16.7 16.6 17.6 13.9 16.9 19.1 18.2 18.7 11.1 19.7 21.3 20.1 20.1
020 16.6 6.4 10.6 12.3 15.1 13.9 10.5 14.2 14.7 16.8 11.1 14.5 17.4 17.5 18.8
030 16.6 -2.8 3.3 7.2 12.2 13.9 2.8 8.3 10.6 14.4 11.1 8.3 12.8 14.4 17.2
035 16.6 5.0 8.9 10.2 14.2 13.9 8.2 11.8 12.7 15.5 11.1 11.6 14.8 15.4 17.1
040 16.6 0.1 4.9 7.2 12.5 13.9 3.8 8.4 10.2 14.1 11.1 7.9 11.9 13.4 16.0
050 16.6 -6.7 1.7 7.2 11.1 13.9 -3.9 5.6 10.0 13.3 11.1 -0.6 10.0 13.3 15.6
060 16.6 -6.7 -1.1 7.2 10.0 13.9 -3.9 2.8 10.0 12.2 11.1 -0.6 8.3 13.3 14.4
065 16.6 -7.3 -0.2 4.7 10.8 13.9 -1.0 5.5 8.5 13.3 11.1 5.3 10.5 12.9 16.5
075 16.6 -4.4 2.1 6.3 11.7 13.9 1.4 7.3 9.8 14.0 11.1 7.3 12.0 13.9 17.0
085 16.6 -9.0 -1.6 3.8 10.2 13.9 -2.4 4.4 7.7 12.9 11.1 4.2 9.6 12.4 16.2
095 16.6 -9.4 -3.1 2.7 9.6 13.9 -4.0 3.2 6.9 12.4 11.1 2.9 8.7 11.7 15.9
115 16.6 -9.4 -4.3 1.9 9.1 13.9 -5.3 2.2 6.2 12.0 11.1 1.9 7.9 11.2 15.6
130 16.6 -9.4 -3.9 2.1 9.3 13.9 -5.0 2.5 6.4 12.1 11.1 2.2 8.1 11.4 15.7
TD Temperature Difference (C)
37
START-UP
System Evacuation and Dehydration Refer to GTAC II (General Training Air Conditioning), Module 4, De- hydration for Proper Evacuation and Dehydration Techniques.
Preliminary Charge Refer to GTAC II, Module 5, Charging, Recovery, Recycling, and Reclamation for charging procedures. Using the liquid charging method and charging by weight procedure, charge each circuit with the amount of re- frigerant (R-410A or R-134a depending on unit configuration) listed in Table 16.
Adjust Refrigerant Charge
Table 16 Preliminary Refrigerant Charge, lb (kg)
NOTES: 1. Preliminary charge does not take into account interconnecting piping
between indoor and outdoor units. 2. For liquid line piping longer than 25 ft (7.6 m) with R-410A refrigerant, use
the following information: 1/2 in. (12.7 mm) liquid line 0.6 lb per 10 linear ft (0.27 kg per 3 m) 5/8 in. (15.9 mm) liquid line 1.0 lb per 10 linear ft (0.45 kg per 3 m) 7/8 in. (22.2 mm) liquid line 2.0 lb per 10 linear ft (0.91 kg per 3 m) 11/8 in. (28.6 mm) liquid line 3.5 lb per 10 linear ft (1.59 kg per 3 m)
3. For liquid line piping longer than 25 ft (7.6 m) with R-134a refrigerant, use the following information: 1/2 in. (12.7 mm) liquid line 0.7 lb per 10 linear ft (0.32 kg per 3 m) 5/8 in. (15.9 mm) liquid line 1.2 lb per 10 linear ft (0.53 kg per 3 m) 7/8 in. (22.2 mm) liquid line 2.4 lb per 10 linear ft (1.06 kg per 3 m) 11/8 in. (28.6 mm) liquid line 4.1 lb per 10 linear ft (1.80 kg per 3 m)
Due to the compact design of microchannel heat exchang- ers, refrigerant charge is reduced significantly. As a result, charging procedures for MCHX units require very accurate measurement techniques. Charge should be added in small increments. Add or remove refrigerant until conditions are met. As conditions get close to the desired point, add or remove charge in 1/4 lb (100 gram) increments until complete. Ensure that all fans are on and all compressors are running when charging. If charging at low outdoor ambient, the con- denser coil can be partially blocked in order to increase head pressure.
With all fans operating and all compressors on the circuit being serviced operating at full capacity, adjust the refrigerant charge to obtain desired subcooling. Charge vapor into com- pressor low-side service port. Measure pressure at the liquid line port, making sure a Schrader depressor is used. Also, mea- sure liquid line temperature as close to the liquid service port as possible.
If the sight glass is cloudy, check refrigerant charge again. Ensure all fans and compressors on the circuit being serviced are operating. Also ensure maximum allowable liquid lift has not been exceeded. If the sight glass is cloudy, a restriction could exist in the liquid line. Check for a plugged filter drier or partially open solenoid valve. Replace or repair, as needed.
Head Pressure Control The head pressure control reduces condensing capacity under low ambient temperature conditions. FAN CYCLING The 09DP units are shipped from the fac- tory equipped to work down to ambient temperatures listed in Tables 14 and 15. This is accomplished by cycling condenser fans based on ambient temperature switch (ATS) and fan cy- cling pressure switches. The ATS opens at approximately 60 F and closes at approximately 65 F. The ATS is located below the control box behind the front access panel on the 020-060 and at the bottom of the control box on the 065-130 unit sizes.
The 040-060 and 075-130 size units need fan cycling pres- sure switches (FCPS) installed. The units are shipped from the factory with switches for use with R-410A. The switches are set to open at 289 psig (1993 kPa) and close at 445 psig (3068 kPa). The 30HXA units which are designed for use with R-134a are shipped from the factory with FCPS to be used with the 09DP units. The R-134a switch open point is 97 psig (669 kPa) and close point is 185 psig (1275 kPa).
Fan contactor and fan motor operation is shown in Tables 17 and 18. LIQUID LINE PRESSURE SET POINT ADJUST- MENT Adjusting the set point may be necessary to avoid interaction with other head pressure control devices. If adjust- ment is necessary, use the set point parameter found in P34 for R-410A or P35 for R-134a. A lower value will result in a lower liquid line set point. As an example for R-410A, decreasing the P34 from 24 to 23 will decrease the liquid line pressure by ap- proximately 15 psig (103 kPa). As an example for R-134a, de- creasing the P35 from 12.6 to 11.6 will decrease the liquid line pressure by approximately 15 psig (103 kPa). It is recommend- ed to adjust P34 for R-410A units by 1 and P35 for R-134a units by 0.5 increments.
CAUTION
Never charge liquid into the low pressure side of system. Do not overcharge. During charging or removal of refriger- ation, be sure indoor fan system is operating. Failure to comply could result in personal injury or equipment damage.
CAUTION
Charging procedures for MCHX (microchannel heat exchanger) units require very accurate measurement tech- niques. Charge should be added in small increments. Using cooling charging charts provided, add or remove refriger- ant until conditions of the chart are met. As conditions get close to the point on the chart, add or remove charge in 1/4 lb (100 gram) increments until complete. Ensure that all fans are on and all compressors are running when using charging charts. Failure to comply may result in equipment damage.
UNIT SIZE R-410A R-134a
Circuit A Circuit B Circuit A Circuit B 09DPS018 9.6 11.1 09DPS020 12.0 13.9 09DPS030 12.0 13.9 09DPM035 12.0 12.0 13.9 13.9 09DPM040 12.0 12.0 13.9 13.9 09DPM050 12.0 12.0 13.9 13.9 09DPM060 12.0 12.0 13.9 13.9 09DPM065 17.6 17.6 20.3 20.3 09DPM075 26.4 17.6 30.5 20.3 09DPM085 31.7 21.1 36.6 24.4 09DPM095 26.4 26.4 30.5 30.5 09DPM115 35.2 26.4 40.6 30.5 09DPM130 44.0 26.4 50.8 30.5
38
Table 17 Fan Control without Motormaster V Control
LEGEND
Table 18 Fan Control with Motormaster V Control
LEGEND
09DP UNIT SIZE
CR1 CR2 ATS FCPSA FCPSB
FC FM FC FM FC FM FC FM FC FM
018 FC1 OFM1 020-030 FC1 OFM1 FC2 OFM2
035 FC1 OFM3 FC1 OFM3 FC2 OFM1 040 FC1 OFM3 FC1 OFM3 FC2 OFM1 FC3 OFM2 FC3 OFM2
050,060 FC1 OFM3 FC1 OFM3 FC2 OFM1 FC3 OFM4, OFM2 FC3 OFM4, OFM2 065 FC2 OFM1 FC1 OFM5 FC6/FC5 OFM2/OFM4 075 FC2 OFM1 FC1 OFM5 FC6/FC5 OFM2/OFM6 FC3 OFM3 085 FC2 OFM1 FC1 OFM5 FC3/FC5 OFM2/OFM3 FC6 OFM4 FC6 OFM4 095 FC2 OFM1 FC1 OFM5 FC3/FC5 OFM2/OFM6 FC6 OFM4 FC6 OFM4 115 FC2 OFM1 FC1 OFM5 FC5/FC3 OFM4/OFM8 FC6 OFM2, OFM3 FC4 OFM7
130 FC2 OFM1 FC1 OFM5 FC5/FC3 OFM4/OFM8 FC6 OFM2, OFM3, OFM6 FC4 OFM7
ATS Ambient Temperature Switch CR Control Relay FC Fan Contactor FCPS Fan Cycling Pressure Switch FM Fan Motor OFM Outdoor Fan Motor
09DP UNIT SIZE
CR1 CR2 ATS FCPSA FCPSB
RC MMA RC MMB FC FM FC FM FC FM
018 FRA OFM1 020-030 FRA OFM1 FC2 OFM2
035 FRA OFM3 FRA FC2 OFM1 040 FRA OFM3 FRA FC2 OFM1 FC3 OFM2 FC3 OFM2
050,060 FRA OFM3 FRA FC2 OFM1 FC3 OFM4, OFM2 FC3 OFM4, OFM2 065 FRA OFM1 MMB OFM5 FC6/FC5 OFM2/OFM4
075 FRA OFM1, OFM3 MMB OFM5 FC6/FC5 OFM2/OFM6
085 FRA OFM1, OFM3 MMB OFM5 FC3/FC5 OFM2/OFM3 FC6 OFM4 FC6 OFM4
095 FRA OFM1, OFM3 MMB OFM5 FC3/FC5 OFM2/OFM6 FC6 OFM4 FC6 OFM4
115 FRA OFM1, OFM3 MMB OFM5,
OFM7 FC5/FC3 OFM4/OFM8 FC6 OFM2 FC4
130 FRA OFM1, OFM3 MMB OFM5,
OFM7 FC5/FC3 OFM4/OFM8 FC6 OFM2, OFM6 FC4
ATS Ambient Temperature Switch CR Control Relay FC Fan Contactor FCPS Fan Cycling Pressure Switch FM Fan Motor FR Fan Relay MM Motormaster OFM Outdoor Fan Motor RC Relay Control
39
MAINTENANCE
Recommended Maintenance Schedule The fol- lowing are only recommended guidelines. Jobsite conditions may dictate that maintenance schedule is performed more often than recommended. Every month: Check condenser coils for debris, clean as necessary. Every 3 months: Check all refrigerant joints and valves for refrigerant
leaks, repair as necessary. Check condenser coils for debris. Check all condenser fans for proper operation. Every 12 months: Check all electrical connections, tighten as necessary. Inspect all contactors and relays, replace as necessary. Check condition of condenser fan blades and ensure they
are securely fastened to the motor shaft.
Microchannel Heat Exchanger (MCHX) Con- denser Coil Maintenance and Cleaning Recommendations
Routine cleaning of coil surfaces is essential to maintain proper operation of the unit. Elimination of contamination and
removal of harmful residues will greatly increase the life of the coil and extend the life of the unit. The following steps should be taken to clean MCHX condenser coils:
1. Remove any foreign objects or debris attached to the coreface or trapped within the mounting frame and brackets.
2. Put on personal protective equipment including safety- glasses and/or face shield, waterproof clothing and gloves. It is recommended to use full coverage clothing.
3. Start high pressure water sprayer and purge any soap or industrial cleaners from sprayer before cleaning condens- er coils. Only clean, potable water is authorized for clean- ing condenser coils.
4. Clean condenser face by spraying the core steady and uniformly from top to bottom while directing the spray straight toward the core. Do not exceed 900 psig or 30 de- gree angle. The nozzle must be at least 12 in. from the core face. Reduce pressure and use caution to prevent damage to air centers.
CAUTION
Do not apply any chemical cleaners to MCHX condenser coils. These cleaners can accelerate corrosion and damage the coil.
CAUTION
Excessive wa
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