Page 1: Table Of Contents
• REQUIRED EQUIPMENT Carrier AppController ......30 Application Instructions ..... . 60 Required Configurations .
Page 2: Introduction
Only trained, qualified installers and service mechanics should in- stall, start up, and service this equipment. CAUTION Untrained personnel can perform basic maintenance functions, such as cleaning coils. All other operations should be performed This unit uses a microprocessor control system. Do not short or by trained service personnel.
Page 3 Table 1 — Physical Data UNIT 09FC*020 09FC*030 09FC*040 09FC*050 09FC*060 09FC*070 09FC*080 Shipping Weight, lbs (kg) 3471 (1574) 4946 (2243) 6482 (2940) 8219 (3728) 9694 (4397) 11209 (5084) 12683 (5753) Operating Weight, lbs (kg) 4288 (1945) 6162 (2795) 8098 (3673) 10251 (4650) 12126 (5500) 14041 (6369)
Page 4 09FC Model Code 09FC Design Series Unit Sizes Power Supply (V-Ph-Hz) 1 = 575-3-60 2 = 380-3-60 5 = 208/230-3-60 6 = 460-3-60 9 = 400-3-50 G = 400-3-60 H = 380-3-50 J = 415-3-50 K = 440-3-50 Efficiency Tier S = Standard Tier Coil Options - = Cu Tube/Al Fin...
Page 5 — — — — — — — — OPERATING WEIGHT AT CORNER WEIGHTS, LBS UNIT SIZE — — — — 09FC040, 09FC050, 09FC060 09FC020, 09FC030 Control Control Panel Panel 09FC070 Control Panel 09FC080 Control Panel Fig. 2 — Corner Weights...
Page 6: Installation
INSTALLATION CAUTION Storage The 09FC free cooling units are designed for outdoor installations. For all unit sizes, do not forklift unit unless unit is attached to a At times, a delay in construction or other factors require that a unit skid designed for forklifting.
Page 7 1. 1.50 dia (38.1mm) lifting holes provided for field supplied clevis. 2. Rig with a minimum of 25 ft (7620mm) length chain or cables. 3. If central lifting point is used, it must be minimum of 13 ft. (3962mm) above the top of the unit. 4.
Page 8 Fig. 5 — 09FC 020 Unit Dimensions...
Page 9 Fig. 6 — 09FC 030 Unit Dimensions...
Page 10 Fig. 7 — 09FC 040 Unit Dimensions...
Page 11 Fig. 8 — 09FC 050 Unit Dimensions...
Page 12 Fig. 9 — 09FC 060 Unit Dimensions...
Page 13 Fig. 10 — 09FC 070 Unit Dimensions...
Page 14 Fig. 11 — 09FC 080 Unit Dimensions...
Page 15: Mounting Units
Fig. 11 — 09FC Unit Dimensions MOUNTING UNITS 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 supplied. See Fig. 5-11. Be sure unit is level to within in.
Page 16 5.35" [136 mm] 2.56" [65 mm] INNER SIDE OUTER SIDE 2.46" [63 mm] OF UNIT OF UNIT BASE RAIL BASE RAIL 4.87" [124 mm] 5.12" [130 mm] 1.42" [36 mm] Fig. 12 — 09FC Base Rail Cross Section 1.50 DIA. [ø38 mm] 0'–...
Page 17: Step 3 - Connect Chilled Water Loop
Improperly designed or installed systems may cause unsatisfacto- ry operation and/or system failure. Consult a water treatment spe- cialist or appropriate literature for information regarding filtration, water treatment, and control devices. Figure 16 show a typical in- stallation and components. To facilitate servicing, it is recommended additional field-supplied air vents be installed.
Page 18: Field Piping
Distribution Pump Expansion Decoupler Tank(s) Air Separator with Vent NOTE: Expansion tanks for 30XV/09FC hydronic kits must be installed for chillers piped in parallel in the primary water loop. Fig. 16 — Typical Air Separator and Expansion Tank Location on Primary-Secondary Systems FIELD PIPING When facing the coil header side of the unit, the inlet (return) CAUTION...
Page 19: Modular Unit Series Piping (09Fc050 - 080)
INSERT THERMISTOR UNTIL O-RING MEETS THE THERMISTOR WELL BODY. 5/8 in. HEX 1/4-18 NPT WIRE TIE 6 in. MINIMUM 1.188 in. CLEARANCE FOR 2.315 in. THERMISTOR REMOVAL LOOP THERMISTOR WIRE AND SECURE TO CHILLED WATER PIPE Fig. 17 — Dual Chiller Accessory Kit Leaving Water Thermistor and Well (P/N 00EFN900044000A) MODULAR UNIT SERIES PIPING (09FC050 - 080) first circuit and the entering water connection of the second circuit.
Page 20 09FC Unit Chiller 24" Min (Note 2) 09FC Control Panel (Note 1) (Note 1) NOTES: 1. EWT and LWT thermistors must be installed in the ﬁeld. Thermistors are supplied inside control panel. Add 1/4 in. NPT hole in pipe for mounting. LWT thermistor well must be in mixed ﬂow piping.
Page 21: Step 4 - Fill The Chilled Water Loop
This may vary for different types of represents abuse and may impair or otherwise negatively affect chillers. Failure to maintain proper water quality may result in heat the Carrier product warranty. exchanger failure. Install a temporary bypass around the unit to avoid circulating dirty water and particulates into coils during the flush.
Page 22: Water Treatment
Also, be sure that there is capability to fully drain the system to protect the chilled water loop to a freeze protection (first crys- after cleaning. (See Fig. 23 and 24.) tals) concentration of at least 15°F (8.3°C) below the lowest de- sign ambient temperature.
Page 23 See the 09FC pressure drop Fig. 25-27 for reference. The the equation Rt=R1*R2/(R1+R2). Rt equals the equivalent 09FC020, 09FC030, and 09FC040 are shown. Larger units are pressure drop which R1 and R2 are the individual circuits. combinations of these piping systems. Combine pressures for Curves are for 30% Propylene Glycol (PG).
Page 24: Step 5 - Make Electrical Connections
Tag all disconnect locations IMPORTANT: Operating unit on improper supply voltage to alert others not to restore power until work is completed. or with excessive phase imbalance constitutes abuse and may affect Carrier warranty. Table 4 — Field Wire Sizes MAXIMUM NUMBER OF...
Page 25 Table 5 — 09FC Electrical Data POWER SUPPLY FAN MOTORS REC FUSE UNIT SIZE SUPPLY VOLTAGE MOCP SIZE VOLTAGE (EACH) 208/230 10.6 45.1 24.7 23.4 20.4 16.2 25.1 23.9 23.0 21.7 208/230 10.6 66.3 36.3 34.4 30.0 23.8 37.0 35.1 33.9 31.9 208/230...
Page 26 24V CONTROL LEGEND — Analog Output (0-10 Vdc) — Leaving Water Temperature ALM — Alarm Relay — Outdoor Air Temperature — Digital Output (Relay, 1A Max) — CW Valve Relay BMS — Building Manangement System — CCW Valve Relay — Circuit Breaker —...
Page 27: Power Wiring
POWER LEGEND — Analog Output (0-10 Vdc) — Alarm Relay — Digital Output (Relay, 1A Max) — Building Management System — Circuit Breaker — Entering Water Temperature — Fuse — Fan Motor — Ground — Thermistor or Dry Contact Input —...
Page 28: Enable Signal
ENABLE-OFF on the unit label diagram and by the switch) The 09FC may be kept independent from the chiller by placing allows the control circuit to be manually disconnected when SW2 in the local position. With the switch in this position, the unit necessary.
Page 29: Step 6 - Install Accessories/Optional Equipment
Table 6 — Wiring Specifications CABLE 22 AWG or 24 AWG, low capacitance, twisted stranded, shielded copper wire MAXIMUM LENGTH 2000 feet (610 meters) Set the communication type and baud rate. Set Communications For... Selection jumper to... Set DIP switches 1 and 2 to... Set DIP switches 3 and 4 to...
Page 30: Controls
Fig. 31 — Field-Fabricated and Field-Installed Wind Baffle CONTROLS Carrier AppController The Carrier AppController is the heart of the control system. It General contains the operating software and controls the operation of the The 09FC utilizes the Carrier AppController electronic control machine.
Page 31: Required Configurations
Carrier Equipment Touch Display Jumper settings for configurations are shown in Fig. 33. Equipment touch is the user interface for the Carrier AppControl- ler. Screen navigation is shown in Table 8. IN-2 should be set to the upper position for thermistor.
Page 32 Table 8 — App Controller Screen Navigation SCREEN NAMES DISPLAY DETAILS Standby Screen displays after the Inactive Timer expires (default is 5 minutes). Displays: • Leaving water temperature • Outdoor air temperature • Operating Mode • Run Command • Occupancy •...
Page 33 Table 8 — App Controller Screen Navigation (cont) SCREEN NAMES DISPLAY DETAILS Properties Menu Navigates to Property pages Login with one of the following passwords: User level - type user • • Admin level - type admin - Unit configuration - Sensor configuration - Setpoints Password Level: None - Alarm configuration...
Page 34 Table 8 — App Controller Screen Navigation (cont) SCREEN NAMES DISPLAY DETAILS Properties / Setpoints Default: 44°F Range: 15 to 75°F Password Level: Admin Properties / Alarm Configuration lo 42 (Range: –45 to 45°F) hi 125 (Range: –20 to 150°F) lo 42 (Range: –45 to 45°F) hi 125 (Range: –20 to 150°F) lo –65 (Range: –65 to 40°F)
Page 35 Table 8 — App Controller Screen Navigation (cont) SCREEN NAMES DISPLAY DETAILS Properties / Service Test This is service test. Defaults are shown. Password Level: Admin Properties / Alarms See page 47 for details on alarms. Password Level: None Alarms Views alarms from the controller.
Page 36 Table 8 — App Controller Screen Navigation (cont) SCREEN NAMES DISPLAY Properties / Alarms / Alarm Help (11 screens) Password Level: None...
Page 37 Table 8 — App Controller Screen Navigation (cont) SCREEN NAMES DISPLAY DETAILS Properties / Alarms / Alarm History Password Level: None Properties / Startup Wizard Password Level: Factory Properties / Startup Wizard / Fan Speed PID Password Level: Factory...
Page 38 Table 8 — App Controller Screen Navigation (cont) SCREEN NAMES DISPLAY DETAILS Properties / Startup Wizard / Mixing Valve PID Password Level: Factory...
Page 39 Table 8 — App Controller Screen Navigation (cont) SCREEN NAMES DISPLAY Properties / Startup Wizard / Help (11 screens) Password Level: Factory...
Page 40 Table 8 — App Controller Screen Navigation (cont) SCREEN NAMES DISPLAY DETAILS Properties / ET System Password Level: Factory Properties / ET System / Module Status Password Level: Factory Properties / ET System / Alarms Password Level: Factory Properties / ET System / Setup Password Level: Factory...
Page 41 Table 8 — App Controller Screen Navigation (cont) SCREEN NAMES DISPLAY DETAILS Properties / ET System / Setup / Module Setup Password Level: Factory Properties / ET System / Setup / Module Setup / Communication Password Level: Factory Properties / ET System / Browser Password Level: Factory Properties...
Page 42: Outdoor Fan Control
Outdoor Fan Control Outdoor fan layout shown in Table 9: Table 9 — Fan Motor Controls Fan Motor 09FC Volt-Hz 208/230-60 VFD 1 — — — — — — — — — — — — 380-50 VFD 1 — — —...
Page 43: Vfd Display Navigation
VFD DISPLAY NAVIGATION IMPORTANT: The VFDs are configured through the Car- rier Controller controls, and parameters should not be changed manually. This section is included for information and troubleshooting purposes only. NOTE: The following instructions apply to Danfoss VLT VFD. See Table 11 for voltage specific VFD parameters.
Page 44 to display mode from the Quick Menu Mode, the Main Menu Mode, or the Alarm Log mode. The operator can also use the Status key to toggle between single or double read-out mode. The Quick Menu key allows quick set-up of the frequency con- verter.
Page 45 nal is applied on the control terminals and/or the bus, the fre- The Reset key resets the frequency converter after an alarm (trip). quency converter starts. See Table 10 for a list of common VFD parameters. NOTE: An active HAND-OFF-AUTO signal via digital inputs has higher priority than the local control keys Hand On –Auto On.
Page 46: Vfd Alarms And Alerts
Table 11 — Voltage Specific VFD Parameters Voltage 208/230V-60 # of V's Drive Designation FVFD-1 FVFD-1 FVFD-1 FVFD-2 # of Connected Fans motor 1-22 motor volts dependent size 1-24 motor amperage 44.8 67.2 44.8 44.8 dependent Voltage 380V, 400V-60 # of V's Drive Designation FVFD-1 FVFD-1 FVFD-1 FVFD-1 FVFD-2 FVFD-1 FVFD-2 FVFD-1 FVFD-2 FVFD-1...
Page 47 Table 13 — Alarms List WARNING/ DOES MACHINE ACTION TO REFERENCE CODE DESCRIPTION POSSIBLE CAUSES ALARM SHUT DOWN BE TAKEN PARAMETER The control card voltage is <10 V from Remove the wiring from terminal 50. If the warning terminal 50. Remove some of the load from clears, the problem is with the wiring.
Page 48 Speed Low [Hz](except when starting or stopping), the frequency converter trips Current Limit The current is higher than the value in Ensure that motor data in parameters 1–20 to 1– Warning Exceeded parameter 4-18 Current Limit. 25 are set correctly. Contact Carrier Service...
Page 49 Check fan operation. • Check the power card Alarm Emergency Stop An unexpected combination of failures Contact Carrier Service Reset the clock in parameter 0-70 Date and Time. 0-7* Clock Warning Clock Fault Time is not set or the RTC clock has failed...
Page 50: Field Configuration
LEAVING WATER SETPOINT Field Configuration The following configurations must be set in the 09FC controls per OUTDOOR AIR SETPOINT the site application for proper operation. The Table 14 below is a reference for the major points in the con- trol. For a detailed list see appendix B. Table 14 —...
Page 51: Communication - Bacnet
Communication - BACnet See Table 15 for a list of BACnet Points. Addressing the controller may be done with or without power. Each time power is applied the controller reads the address. Address is set using rotary switches. Set the Tens (10’s) switch to the tens digit of the address, and the Ones (1’s) switch to the ones digit.
Page 52 Table 16 — Required Configurations SCREEN NAMES DISPLAY/DETAILS Communication Lets you edit the information below for the controller. Touch a field to tap in new information. BACnet Device Instance number Auto Generate Device ID - Enter No or Yes You can edit the following fields that pertain to the controller’s MS/TP network: Max Masters - Set this to the highest MAC address (up to 127) on the MS/TP network.
Page 53: Operation
Check inputs on the display to verify all temps are reading correct- drop and the LWT falls below setpoint with the fans at 0 Hz, the 3- ly. Reference the Carrier Equipment Touch section of this manual. way valve will adjust to mix return water and water from the coils to keep LWT from going too low.
Page 54: Thermistor Alarm
THERMISTOR ALARM OUTDOOR AIR TEMPERATURE ALARM Thermistor out of range. Detects failed thermistor. Close alarm Alarm Criteria: Outdoor air temperature is below the Low Out- contact, drive valves to bypass position, and disable fans. door Air Temp Alarm Limit or above the High Outdoor Air Temp Alarm Limit.
Page 55: Controller Troubleshooting
cation traffic based on the baud rate set. The higher the baud rate Controller Troubleshooting the more solid the LEDs become. See Table 17. The LED’s shown in Fig. 32 indicate if the controller is speaking Verify the LED patterns by cycling power to the controller and to the device on the network.
Page 56: To Restore Defaults
9.8" (Ref.) CL to CL of Pins guidance of Carrier Control Systems Support. To erase volatile memory data and restore factory default configu- ration settings: Turn off the AppController’s power switch.
Page 57: Thermistor
linkage to verify the “bypass valve” arm will not move any Replacing Thermistors (EWT, LWT) further in the CW direction. Add a small amount of thermal conductive grease to the thermis- tor well and end of probe. For all probes, tighten the retaining nut Add cotter pins to the clevis pin and tighten the adjuster nut.
Page 58 Table 18 — 5K Thermistor Temperature vs. Table 18 — 5K Thermistor Temperature vs. Resistance (cont) Resistance °F °C RESISTANCE, OHMS °F °C RESISTANCE, OHMS 5,972 –40 –40 166,781 5,710 –38 –39 156,158 5,461 –36 –38 146,275 5,225 –35 –37 137,078 5,000 –33...
Page 59: Fan Blade And Fan Motor Service
Table 18 — 5K Thermistor Temperature vs. Table 18 — 5K Thermistor Temperature vs. Resistance (cont) Resistance (cont) °F °C RESISTANCE, OHMS °F °C RESISTANCE, OHMS If a more accurate check is required, unit must be shut down and Fan Blade and Fan Motor Service thermistor removed and checked at a known temperature (freezing A formed metal mount bolted to the coil caps supports each fan point or boiling point of water) using either voltage drop measured...
Page 60: Round Tube Plate Fin Condenser Coil Cleaning
This cleaner is available Remove all surface loaded fibers and dirt with a vacuum from Carrier Replacement Components as part number P902- cleaner as described above. 0301 for a one-gallon container, and part number P902-0305 for a Thoroughly wet finned surfaces with clean water and a low 5-gallon container.
Page 61: Variable Frequency Drives
Finned surfaces should remain wet with cleaning solution for • Check heat exchanger coils for debris, clean as necessary. 10 minutes. Every 3 months: 10. Ensure surfaces are not allowed to dry before rinsing. Reap- • Check all joints and valves for leaks, repair as necessary. ply cleaner as needed to ensure 10-minute saturation is •...
Page 62: Appendix A - Control Panel Component Layout
APPENDIX A — CONTROL PANEL COMPONENT LAYOUT...
Page 63: Appendix B - 09Fc Free Cooling Module Controller
APPENDIX B — 09FC FREE COOLING MODULE CONTROLLER The following tables describe all of the possible settings for your controller on the i-Vu or Field Assistant Properties tab. ® NOTE: Some of the properties are available only when other set- tings have been enabled.
Page 64 APPENDIX B — 09FC FREE COOLING MODULE CONTROLLER (CONT) Setpoints Navigation: i-Vu / Field Assistant: Properties > Control Program ® > Configuration > Setpoints Point Name – Description Default/Range Leaving Water Temperature D: 44°F Leaving Water Temp Setpoint – The leaving water temperature setpoint maintained by the module. R: 15 to 75°F Leaving Water Temp Setpoint Offset –...
Page 65 APPENDIX B — 09FC FREE COOLING MODULE CONTROLLER (CONT) Service Configuration Navigation: i-Vu / Field Assistant: Properties > Control Program ® > Configuration > Service Configuration Point Name – Description Default/Range D: Open Remote Contact Normal Logic State – Specifies the remote contact's normal logic state. R: Open/Closed Fan VFD Run Status Normal Logic State –...
Page 66 Point Name – Description Default/Range D: Disable Fan VFD Enable Test – When set to Enable, Binary Output #4 is enabled for up to 5 minutes. R: Disable/Enable Fan VFD Speed % Test – When set to a value greater than 0, Analog Output #1 is enabled for up to 5 D: Disable minutes.
Page 67 APPENDIX B — 09FC FREE COOLING MODULE CONTROLLER (CONT) Alarms Navigation: i-Vu / Field Assistant: Properties > Control Program ® > Alarms Point Name – Description Range Equipment Alarm – Indicates if the unit is in a general equipment alarm. R: Normal/Alarm Leaving Water Temperature –...
Page 68 APPENDIX B — 09FC FREE COOLING MODULE CONTROLLER (CONT) 09FC Free Cooling Module Controller Start-Up Wizard Navigation: Equipment Touch Startup Wizard Point Name – Description Default/Range D: Enable Cool Enable – Enables or disables cooling operation. R: Disable/Enable Leaving Water Temp Setpoint – The leaving water temperature setpoint maintained by the D: 44°F module.
Page 70 © 2021 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53090030 -01 Printed in U.S.A. Form 09FC-1SI Pg 70 3-21 Replaces: NEW...
Page 71 START-UP CHECKLIST FOR 09FC WATERSIDE ECONOMIZER (Remove and use for Job File) NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere safety considerations/information outlined...
Page 72 Start-up Technician _________________________________________________________________Date__________________ Customer Representative _________________________________________________________________Date__________________ © 2021 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53090030 -01 Printed in U.S.A. Form 09FC-1SI Pg CL-2...

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