Carrier CAS072 Installation, Start-up And Service Instructions Manual

CAS-072-153-01SI Rev. A 1-23Installation, Start-Up and Service InstructionsCONTENTSPageSAFETY CONSIDERATIONS . . . . . . . . . . . . . . . 1INSTALLATION GUIDELINES . . . . . . . . . . . . . . 2Replacement/Retrofit — R-22 to R-410ARefrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . 2Matching CAS Model to Evaporator Coil . . . . . 3INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . 6Step 1 — Plan for Unit Location . . . . . . . . . . . . 6Step 2 — Complete Pre-Installation Checks . . 7Step 3 — Prepare Unit Mounting Support . . . . 7Rig and Mount the Unit . . . . . . . . . . . . . . . . . . . 7Step 4 — Determine Refrigerant Line Sizes . . . 7Suction Riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Step 5 — Complete Refrigerant PipingConnections . . . . . . . . . . . . . . . . . . . . . . . . . 10Step 6 — Install Accessories . . . . . . . . . . . . . . 13Step 7 — Complete Electrical Connections . . 13Step 8 — Wind Baffles for Low AmbientControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . 18System Check . . . . . . . . . . . . . . . . . . . . . . . . . . 18Turn On Crankcase Heater . . . . . . . . . . . . . . . 18Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . 18START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Preliminary Checks . . . . . . . . . . . . . . . . . . . . . 18Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19OPERATING SEQUENCE . . . . . . . . . . . . . . . . . 25Base Unit Controls . . . . . . . . . . . . . . . . . . . . . . 25All Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 26Quarterly Inspection(and 30 days after initial start) . . . . . . . . . . . 26Seasonal Maintenance . . . . . . . . . . . . . . . . . . . 26SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Refrigeration System . . . . . . . . . . . . . . . . . . . . 27Comfort Alert Diagnostic Module . . . . . . . . . . 28Compressor Protection . . . . . . . . . . . . . . . . . . 31Routine Cleaning of Round-Tube Plate Fin(RTPF) Coils . . . . . . . . . . . . . . . . . . . . . . . . . 31Fastener Torque Values . . . . . . . . . . . . . . . . . . 32TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 32APPENDIX A — AIR CONDITIONER AND HEATPUMP WITH R-410A –QUICK REFERENCE GUIDE . . . . . . . . . . . . . 35APPENDIX B — WIRING DIAGRAMS . . . . . . . 35APPENDIX C — LOW AMBIENT OPTION . . . . 50START-UP CHECKLIST . . . . . . . . . . . . . . . . . CL-1SAFETY CONSIDERATIONSImproper installation, adjustment, alteration, service,maintenance, or use can cause explosion, fire, electricalshock or other conditions which may cause personal injuryor property damage. Consult a qualified installer, serviceagency, or your distributor or branch for information orassistance. The qualified installer or agency must usefactory-authorized kits or accessories when modifying thisproduct. Refer to the individual instructions packaged withthe kits or accessories when installing.Follow all safety codes. Wear safety glasses and workgloves. Use quenching cloths for brazing operations andhave a fire extinguisher available. Read these instructionsthoroughly and follow all warnings or cautions attached tothe unit. Consult local building codes and appropriatenational electrical codes (in U.S.A., ANSI/NFPA70, NationalElectrical Code (NEC); in Canada, CSA C22.1) for specialrequirements.It is important to recognize safety information. This is thesafety-alert symbol . When you see this symbol on theunit and in instructions or manuals, be alert to the potentialfor personal injury.Understand the signal words DANGER, WARNING,CAUTION, and NOTE. These words are used with thesafety-alert symbol. DANGER identifies the most serioushazards which will result in severe personal injury or death.WARNING signifies hazards which could result in personalinjury or death. CAUTION is used to identify unsafepractices, which may result in minor personal injury orproduct and property damage. NOTE is used to highlightsuggestions which will result in enhanced installation,reliability, or operation.DANGERELECTRICAL SHOCK HAZARDFailure to follow this warning will result in personal injuryor death.Before performing service or maintenance operationson unit, turn off main power switch to unit and installlock(s) and lockout tag(s). Ensure electrical service torooftop unit agrees with voltage and amperage listed onthe unit rating plate. Do not check compressor ohms atcompressor terminals. Unit may have more than onepower switch.WARNINGUNIT OPERATION AND SAFETY HAZARDFailure to follow this warning could cause personalinjury, death and/or equipment damage.R-410A refrigerant systems operate at higher pressuresthan standard R-22 systems. Do not use R-22 serviceequipment or components on R-410A refrigerantequipment.CAS072-153Air-Cooled Condensing Unitswith R-410A Refrigerant