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Carrier FAS150 Installation, Start-Up And Service Instructions Manual

Packaged air-handling units with r-410a refrigerant 60 hz
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . 1
PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 2
Moving and Storage . . . . . . . . . . . . . . . . . . . . . . 2
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Uncrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . 10
Unit Positioning . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant Piping Access . . . . . . . . . . . . . . . . 11
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . 14
Fan Motors and Drives . . . . . . . . . . . . . . . . . . . . 15
Power Supply and Wiring . . . . . . . . . . . . . . . . . . 15
Variable Frequency Drive . . . . . . . . . . . . . . . . . 18
Connecting Ductwork . . . . . . . . . . . . . . . . . . . . 20
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . 21
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FAS/FHS ONLY . . . . . . . . . . . . . . . . . . . . . . . . . 22
Compressor Rotation . . . . . . . . . . . . . . . . . . . . 22
Indoor Fan Motor . . . . . . . . . . . . . . . . . . . . . . . 22
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fan Speed Set Up . . . . . . . . . . . . . . . . . . . . . . . 23
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 24
(and 30 days after initial start) . . . . . . . . . . . 24
Seasonal Maintenance . . . . . . . . . . . . . . . . . . . 24
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fan Motor Lubrication . . . . . . . . . . . . . . . . . . . 25
Fan Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . 25
Centering Fan Wheel . . . . . . . . . . . . . . . . . . . . 25
FAS/FHS150-180
Packaged Air-Handling Units
with R-410A Refrigerant
Installation, Start-up and
Service Instructions
Page
FASFHS150-180-01SI
60 Hz
Fan Shaft Position Adjustment . . . . . . . . . . . . 25
Individual Fan Wheel Adjustment . . . . . . . . . . 25
Fan Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fan Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fan Pulley Alignment . . . . . . . . . . . . . . . . . . . . 26
Pulley and Drive Adjustment . . . . . . . . . . . . . . 27
Variable Frequency Drive . . . . . . . . . . . . . . . . 32
Bypass the VFD . . . . . . . . . . . . . . . . . . . . . . . . 36
Condensate Drains . . . . . . . . . . . . . . . . . . . . . . 36
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . 36
Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cleaning Cooling Coil . . . . . . . . . . . . . . . . . . . 36
Cleaning Insulation . . . . . . . . . . . . . . . . . . . . . 36
Replacing Filters . . . . . . . . . . . . . . . . . . . . . . . 37
START-UP CHECKLIST. . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical
components. Only trained and qualified service personnel
should install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance
functions of cleaning coils and filters and replacing filters. All
other operations should be performed by trained service
personnel. When working on air-conditioning equipment,
observe precautions in the literature, tags and labels
attached to the unit, and other safety precautions that may
apply.
Follow all safety codes, including ANSI (American National
Standards Institute) Z223.1. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations. Have
fire extinguisher available for all brazing operations.
It is important to recognize safety information. This is the
safety-alert symbol
unit and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING,
CAUTION, and NOTE. These words are used with the
safety-alert symbol. DANGER identifies the most serious
hazards which will result in severe personal injury or death.
WARNING signifies hazards which could result in personal
injury or death. CAUTION is used to identify unsafe
. When you see this symbol on the
2-23

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  • Page 1: Table Of Contents

    FAS/FHS150-180 Packaged Air-Handling Units with R-410A Refrigerant 60 Hz Installation, Start-up and Service Instructions CONTENTS Fan Shaft Position Adjustment ... . 25 Individual Fan Wheel Adjustment ..25 Page Fan Belts .

  • Page 2: Pre-Installation

    practices, which may result in minor personal injury or PRE-INSTALLATION product and property damage. NOTE is used to highlight 1. The power supply (v, ph, and Hz) must correspond to suggestions which will result in enhanced installation, that specified on unit rating plate. reliability, or operation.
  • Page 3 Fig. 1 — Dimensions — Size 150 and 180...
  • Page 4 Fig. 1 —Dimensions — Size 150 and 180 (cont)
  • Page 5 MODEL SERIES Position Number F = R-410A Fan Coil Unit A = Air Conditioning (Cooling Only) H = Heat Pump Type S = Standard Efficiency Efficiency 150 = 12.5 Tons (2 circuit) (FAS units only) 180 = 15 Tons (2 circuit) Nominal Tonnage H = 208/230-3-60 L = 460-3-60...
  • Page 6 Table 1 — FAS150-180 Physical Data, English — Cooling Units UNIT FAS NOMINAL CAPACITY (tons) 12-1/2 OPERATING WEIGHT (lb) Base Unit with TXV Plenum FANS Qty...Diam. (in.) 2...15 2...15 Nominal Airflow (cfm) 5000 6000 Airflow Range (cfm) 3750-6250 4500-7500 Nominal Motor Hp (Standard Motor)
  • Page 7 Table 2 — FAS150-180 Physical Data, SI — Cooling Units UNIT FAS NOMINAL CAPACITY (kW) OPERATING WEIGHT (kg) Base Unit with TXV Plenum FANS Qty...Diam. (mm) 2...381 2...381 Nominal Airflow (L/s) 2360 2831 Airflow Range (L/s) 1770-2949 2124-3539 Nominal Motor Hp (Standard Motor) 208/230-3-60 and 460-3-60 2.16...
  • Page 8 Table 3 — FHS180 Physical Data, English — Heat Pump Units UNIT FHS NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Base Unit with TXV Plenum FANS Qty...Diam. (in.) 2...15 Nominal Airflow (cfm) 5625 Airflow Range (cfm) 4500-7500 Nominal Motor Hp (Standard Motor) 208/230-3-60 and 460-3-60 575-3-60 Motor Speed (rpm)
  • Page 9 Table 4 — FHS180 Physical Data, SI — Heat Pump Units UNIT FHS NOMINAL CAPACITY (kW) OPERATING WEIGHT (kg) Base Unit with TXV Plenum FANS Qty...Diam. (mm) 2...381 Nominal Airflow (L/s) 2655 Airflow Range (L/s) 2124-3539 Nominal Motor Hp (Standard Motor) 208/230-3-60 and 460-3-60 2.76 575-3-60...

  • Page 10: Rated Indoor Airflow (Cfm)

    Air Intake and Discharge efficiency rating for the units covered in this document. Fig. 4 — Typical Unit Positioning Table 5 — CAS****G/H/MN with FAS150-180 IMPORTANT: Do NOT attempt to install unit with return air MODEL NUMBER FULL LOAD AIRFLOW (CFM) entering top panel of unit.

  • Page 11: Refrigerant Piping

    4 o’clock or 8 o’clock position. (See Fig. 9.) knockouts provide sufficient access to the unit’s coils for all FAS150 and 180 units. FHS180 units require additional holes that must be field-fabricated to accommodate the pip- 1. Third-party trademarks and logos are the property of their respective ing.
  • Page 12 FEEDER TUBES PER DISTRIBUTOR NOZZLE UNIT COIL TYPE STD DISTRIBUTOR QTY...PART NO. QTY... PART NO. QTY...PART NO. QTY...SIZE (in.) 2...1178405 2...1178407 2...1178409 FAS150 4 Row 12...3/16 2...BBIZE— 5— GA 2...1113 2...G3 2...1178406 2...1178412 2...1178410 FAS180 4 Row 16...3/16 2...BBIZE— 6— GA 2...1136...
  • Page 13 1-1/8 Nipple, 7-5/8 L 1-1/8 Long Radius Elbow 5/8 Street Elbow Liquid Lower 5/8 Nipple, 1-7/16 L 5/8 Long Radius Elbow FAS150 5/8 Street Elbow Liquid Upper 5/8 Nipple, 11-1/2 L 5/8 Long Radius Elbow 1-1/8 Nipple, 5-5/8 L 1-1/8 Long Radius Elbow...

  • Page 14: Condensate Drain

    Condensate Drain Install a trapped condensate drain line to unit connection as shown in Fig. 10. The unit drain connection is a PVC stub. (See Fig. 11.) Some areas may require an adapter to con- nect to either galvanized steel or copper pipe. For these ap- plications, install a field-supplied threaded PVC adapter.

  • Page 15: Fan Motors And Drives

    1 — fan motor 1 — adjustable motor pulley 1 — fan pulley 2 — matched fan belts (FAS150/180, FHS180 units) For instructions on changing fan rotation, changing drive speeds and adjusting drives, see “Pulley and Drive Adjust- ment” on page 27.

  • Page 16: Three Stage Operation

    Install disconnect switch and power wiring in accordance with 2. Move orange wire from Thermostat CB terminal Y2 to all applicable local codes. See Fig. 12-13 and the unit label di- terminal X. agram. For units with motor sizes less than 5 Hp (3.7 kW), 3.
  • Page 17 NOTE: On select units, the black and blue IFM wires are reversed. Fig. 14 — Unit Wiring FASFHS150-180-01SI Specifications subject to change without notice.

  • Page 18: Variable Frequency Drive

    IDCB This wire is included in factory harness TSTAT TSTAT CB COMP Disconnect this wire from TSTAT CB-X and insulate. Fig. 15 — 3-Stage Cooling Diagram Variable Frequency Drive The unit is equipped with a Variable Frequency Drive (VFD) to control the indoor fan in sequence with the unit's ventila- tion, cooling, and heating operation.
  • Page 19 Fig. 17 — ACH550 Variable Frequency Drive (VFD) Variable Frequency Drive (VFD) Fig. 18 — ACS320 VFD Location for the following units: FAS150/180, FHS180 (208/230V and 460V only) FASFHS150-180-01SI Specifications subject to change without notice.

  • Page 20: Connecting Ductwork

    Variable Frequency Drive (VFD) Fig. 19 — ACH550 VFD Location for the following units: FAS150/180, FHS180 (575V only) Connecting Ductwork 2 flanges; each flange must be bent in the middle to con- form to the discharge opening. (See Fig. 21.) After flanges...

  • Page 21: Return-Air Filters

    Return-Air Filters a filter replacement tool (hook) is shipped inside the unit for field use when replacing filters. See the Service section for Type and size of filters are shown in Tables 1-4 and are instructions on filter element replacement. factory-supplied and factory-installed.

  • Page 22: Start-Up

    START-UP 3. Wait until suction pressure and superheat stabilize. This may take more than 30 minutes. Before starting unit, check the following and correct as 4. Continue adjustment until superheat reaches 10°F to necessary: 15°F (5.5°C to 8.3°C). • Is unit solidly supported? 5.

  • Page 23: Operating Fan For Test And Balance

    Table 11 — FAS/FHS Min CFM Per Fan Motor Type 2-SPEED FAN 2-SPEED FAN UNIT MOTOR (AT HIGH MOTOR (AT LOW SPEED) SPEED) FAS150 4056 2704 FAS/FHS180 4500 3000 Fan Speed Set Up These units contain a variable frequency drive (VFD) fan assembly.

  • Page 24: Maintenance

    MAINTENANCE Table 12 — Outdoor Unit Maintenance Checklist These items should be part of a routine maintenance pro- RECOMMENDED MAINTENANCE CHECKLIST gram, to be checked every month or two, until a specific INTERVAL schedule for each can be identified for this installation: Outdoor unit specific: Monthly Annual...

  • Page 25: Service

    SERVICE Inspection and maintenance should be performed at regular intervals and should include the following: • Complete cleaning of cabinet, fan wheel, cooling coil, Locking condensate pan and drain, heating coils, and return- Wheel Bolt air grille (if present). • Inspection of panels and sealing of unit against air Bearing leakage.

  • Page 26: Fan Rotation

    Pulley(s) Belts Motor Pulley(s) Slot Mounting Bolts Fig. 27 — Fan Motor Mounting Fan Rotation Correct fan rotation with respect to fan outlet is shown in Adjustable Flanges Fig. 28. To reverse the direction of rotation of a 3-phase fan motor, Setscrews reverse any 2 of the power leads.

  • Page 27: Pulley And Drive Adjustment

    Two Speed — SI To obtain desired fan speed, refer to the fan motor, drive data and performance data in Tables 15-34 and adjust fan UNIT FAS150 FAS180 motor pulley as follows: 208/230-3-60 and 460-3-60 1. Remove belt from fan motor pulley after loosening Speed (r/s) 28.92...
  • Page 28 Table 22 — Motor Efficiency FHS — Table 25 — Standard Drive Data, 60 Hz — English Two-Speed Motor UNIT FAS150 FAS/FHS180 MOTOR EFFICIENCY MOTOR DRIVE MOTOR HP EPACT MINIMUM (%) Motor Pulley Pitch Diameter (in.) 2.8-3.8 2.8-3.8 — 82.0 Pulley Factory Setting —...
  • Page 29 Table 27 — High-Static Drive Data, 60 Hz — English Table 29 — Medium-Static Drive Data, 60 Hz — SI UNIT FAS150 FAS/FHS180 UNIT FAS150 FAS/FHS180 MOTOR DRIVE MOTOR DRIVE Motor Pulley Pitch Diameter (in.) 3.7-4.7 4.3-5.3 Motor Pulley Pitch Diameter 86.4-111.8...
  • Page 30 EXTERNAL STATIC PRESSURE (in. wg) AIRFLOW UNIT (CFM) 3750 0.43 0.55 0.83 1.12 1.41 1.72 2.05 4300 0.62 0.74 1.05 1.38 1.70 2.04 2.39 FAS150 5000 0.92 1.06 1.39 1.76 2.14 2.52 2.91 5700 1.32 1.47 1.82 2.23 2.66 3.09 3.52 6250 1.71 1.87 2.24...
  • Page 31 1.05 13.13 1.28 14.19 1.53 2030 7.58 0.46 8.40 0.55 9.98 0.78 11.31 1.03 12.47 1.27 13.52 1.52 14.51 1.78 FAS150 2360 8.57 0.69 9.27 0.79 10.68 1.04 11.96 1.31 13.09 1.60 14.11 1.88 15.05 2.17 2690 9.59 0.99 10.20 1.10...

  • Page 32: Variable Frequency Drive

    Variable Frequency Drive Table 36 — ACH550 VFD Terminal Designations The VFD switches the indoor fan motor speed between full/ high speed (60 Hz motor operation) and reduced/low speed TERMINAL FUNCTION (40 Hz motor operation), as required by ASHRAE 90.1- 2016 and IECC-2015 requirements for two-stage HVAC Three-Phase main circuit input power supply units.

  • Page 33: Alarms

    ALARMS FAULTS Alarms are advisory in nature. These indicate a problem A fault is a significant internal situation for the VFD or its mo- has been detected by the VFD’s diagnostics but this prob- tor. If the motor was running when the fault was detected, it lem will not require that the VFD and its motor be shut was shutdown.
  • Page 34 Table 38 — Alarm Codes (cont) ALARM ALARM NAME IN PANEL DESCRIPTION AND RECOMMENDED CORRECTIVE ACTION CODE This alarm warns that the PFA interlocks are active, which means that the drive cannot start any motor 2015 PFA INTERLOCK (when Autochange is used), or a speed regulated motor (when Autochange is not used). 2016 —...

  • Page 35: Vfd Maintenance

    VFD MAINTENANCE If installed in an appropriate environment, the VFD requires very little maintenance. Table 40 lists the recommended routine maintenance. Captive Screw Table 40 — Maintenance Intervals MAINTENANCE INTERVAL Every 6 to 12 months Heat sink temperature check (depending on the dustiness of and cleaning the environment) HVAC control panel battery...

  • Page 36: Bypass The Vfd

    Bypass the VFD 7. Connect the ground wire from the indoor fan motor to the fan deck. 8. Restore power. WARNING Condensate Drains Bypassing the VFD is not recommended. This is a Keep condensate drains free of dirt and foreign matter. temporary procedure to provide cooling or heating Return-Air Filters operation when a new VFD is required.

  • Page 37: Replacing Filters

    Replacing Filters Filters can be removed and installed from either side of the unit. Install new filters in units that have one fan as follows: 1. Remove the side access panel (retain screws). 2. Remove the filter retainer clip (see Fig. 36). 3.

  • Page 38: Appendix A - Vfd Parameters

    APPENDIX A — VFD PARAMETERS Table A — ACS320 Common Parameters Table B — ACH550 VFD Common Parameters SETTING SETTING PARAMETERS DESCRIPTION PARAMETERS DESCRIPTION ACS320 ACH550 1001 EXT1 Commands 1001 EXT1 Commands 1102 EXT1/EXT2 Sel EXT1 1102 EXT1/EXT2 Sel EXT1 1103 REF1 Select AI-1...
  • Page 39 APPENDIX A — VFD PARAMETERS (cont) Table C — ACS320 VFD Parameters MOTOR CROSS MOTOR DRIVE VOLTAGE N. AMPS N. RPM N. HP MAX AMPS DESC. FREQ REFERENCE PARAMETERS PART NO. PART NO. (9905) (9906) (9908) (9909) (2003) ACS320 (Hz) EM_PKG (9907) FAS/FHS...
  • Page 42 © 2023 Carrier Lewisburg, TN 37091 USA Replaces: FAS-FHS-072-180-01SI FASFHS150-180-01SI Specifications are subject to change without notice.

  • Page 43: Start-Up Checklist

    START-UP CHECKLIST (SPLIT SYSTEMS WITH FAS/FHS UNITS) NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up check- list, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this Installation, Start-Up, and Service document.
  • Page 44 CHECK THE COMPRESSOR OIL LEVEL SIGHT GLASSES: ARE THE SIGHT GLASSES SHOWING OIL LEVEL AT 1/8 to 1/3 FULL? (Y/N)_______________ NOTES: ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ © 2023 Carrier Lewisburg, TN 37091 USA Replaces: FAS-FHS-072-180-01SI FASFHS150-180-01SI Specifications are subject to change without notice.

This manual is also suitable for:

Fas180Fas240Fhs180Fhs240

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