Carrier 40RFAA07 Installation, Start-Up And Service Instructions Manual
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Carrier 40RFAA07 Installation, Start-Up And Service Instructions Manual

Packaged air-handling units with puron® (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) . . . . . . . . . . . . . . . . . . . . . 9
Unit Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unit Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chilled Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fan Motors and Drives . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power Supply and Wiring . . . . . . . . . . . . . . . . . . . . . . . 13
Connecting Ductwork . . . . . . . . . . . . . . . . . . . . . . . . 18
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
40RFA and 40RFQ ONLY . . . . . . . . . . . . . . . . . . . . . 19
(40RFA and 40RFQ only) . . . . . . . . . . . . . . . . . . . 19
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SUPPLY FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Supply Fan (Direct-Drive) . . . . . . . . . . . . . . . . . . . . . 20
Condensate Drains . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Chilled Water Coil Freeze Protection . . . . . . . . . . . 26
Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cleaning Cooling Coil . . . . . . . . . . . . . . . . . . . . . . . . 26
Cleaning Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53400080-01
Installation, Start-up and
Service Instructions
Printed in U.S.A.
Form 40RF-7-12-02SI Rev. A
Packaged Air-Handling Units
with Puron
Replacing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Page
(and 30 days after initial start) . . . . . . . . . . . . . . .27
Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . .27
FAN PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . .28
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
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 practices, which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning will result in personal injury or
death.
Before performing service or maintenance operations on unit,
turn off main power switch to unit and install lock(s) and
lockout tag(s). Ensure electrical service to rooftop unit agrees
with voltage and amperage listed on the unit rating plate. Unit
may have more than one power switch.
Pg 1
40RF/A/S/Q 07-12
®
(R-410A) Refrigerant
. When you see this symbol on the unit and in
DANGER
2-23
Replaces: 40RU-7-16-01SI
60 Hz

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Summary of Contents for Carrier 40RFAA07

  • Page 1: Table Of Contents

    40RF/A/S/Q 07-12 Packaged Air-Handling Units with Puron ® (R-410A) Refrigerant 60 Hz Installation, Start-up and Service Instructions CONTENTS Replacing Filters ......26 MAINTENANCE .

  • Page 2: Pre-Installation

    The electrical supply provided by the utility must be suffi- cient to handle load imposed by this unit. WARNING Refer to Installation, General section (page 2) and Fig. 2 for UNIT OPERATION AND SAFETY HAZARD locations of electrical inlets, condensate drain, duct connec- tions, and required clearances before setting unit in place.
  • Page 3 Position: 9 10 11 12 13 14 15 16 17 18 Example: – Model Type Packaging Compliance Vane Axial Fan Packaged Air-Handling Unit 0 = Standard ® with Puron (R-410A) Refrigerant Future Use Type of Coil A = Standard A = Standard 4 Row DX S = Chilled Water Coil Cabinet Paint Q = Heat Pump Coil...
  • Page 4 Fig. 2 — 40RF 07-12 Base Unit Dimensions...
  • Page 5 Fig. 2 — 40RF 07-12 Base Unit Dimensions (cont)
  • Page 6 Table 1 — 40RFA 6-10 Ton Direct Expansion With Puron Refrigerant Units UNIT 40RFAA07 40RFAA08 40RFAA12 NOMINAL CAPACITY (Tons) 7-1/2 OPERATING WEIGHT (lb) Base Unit with TXV (4 Row) Plenum Economizer Hot Water Coil Steam Coil FANS Qty...Diam. (in.) 1…23 1…23...
  • Page 7 Table 2 — 40RFQ 6-10 Ton Heat Pump Units UNIT 40RFQA07 40RFQA08 40RFQA12 NOMINAL CAPACITY (Tons) 7-1/2 OPERATING WEIGHT (lb) Base Unit with TXV Plenum FANS Qty...Diam. (in.) 1…23 1…23 1…23 Nominal Airflow (cfm) 2400 2625 3000 Airflow Range (cfm) 1800-3000 2250-3750 3000-5000...
  • Page 8 Table 3 — 40RFS Physical Data — Chilled Water Units UNIT 40RFSA08 40RFSA10 40RFSA12 NOMINAL CAPACITY (Tons) 7-1/2 8-1/2 OPERATING WEIGHT (lb) Base Unit with TXV (4 Row) Plenum Economizer Hot Water Coil Steam Coil FANS Qty...Diam. (in.) 1…23 1…23 1…23 Nominal Airflow (cfm) 3000...

  • Page 9: Rated Indoor Airflow (Cfm)

    Unit Positioning Coil The unit can be mounted on the floor for vertical application with return air entering the face of the unit and supply air discharging vertically through the top of the unit. The unit can also be applied in a horizontal arrangement with return air entering horizontally and the supply air discharging horizontally.

  • Page 10: Refrigerant Piping

    Refrigerant Piping field-fabricated to accommodate the piping. See Fig. 6 for the positions and dimensions of the additional access holes required See Tables 1-3 for refrigerant pipe connection sizes. For ease in for 40RFS units. Recommended access hole use is also listed for brazing, it is recommended that all internal solder joints be made all units.
  • Page 11 Table 8 — Fitting Requirements UNIT ACCESS HOLE NO. CONNECTION TYPE CIRCUIT FITTING REQUIRED (in.) 1-1/8 Street Elbow Suction — 1-1/8 Nipple, 10-5/8 L 1-1/8 Long Radius Elbow 40RFA*07 40RFQ*07 5/8 Street Elbow Liquid — 5/8 Nipple, 8-5/8 L 5/8 Long Radius Elbow 1-1/8 Street Elbow Suction —...

  • Page 12: Chilled Water Piping

    40RFS chilled water piping. See Fig. 6, which lists recommended knockouts and access holes to use for each 40RFS unit size. To size, design, and install chilled water piping, consult the Carrier Condensate Drain Connection System Design manual. See Fig. 10 for an example of a typical in- stallation.

  • Page 13: Condensate Drain

    Condensate Drain Install a trapped condensate drain line to unit connection as shown in Fig. The unit drain connection is a PVC stub. (See Fig. 12.) Some areas may require an adapter to connect to either galvanized steel or copper pipe. For these applications, install a field-supplied threaded PVC adapter.
  • Page 14 Table 9 — Electrical Data, Standard Motors — Two Speed UNIT VOLTAGE FAN MOTOR POWER SUPPLY RANGE NOMINAL Maximum UNIT Minimum V-PH-Hz* TYPE Overcurrent Min. Max. Circuit Amps Protection (MCA) (MOCP) 1.76 6.4/5.8 15/15 208/230-3-60 HIGH 2.24 7.5/6.7 10/9 15/15 1.76 40RFA*07 460-3-60...
  • Page 15 Install disconnect switch and power wiring in accordance with all applicable local codes. See Fig. 13-15 and the unit wiring diagram label (Fig. 16). For units with motor sizes less than 5 Hp (3.7 kW), connect power wiring to unit with no. 10 ring terminal. For units with motor sizes of 5 Hp (3.7 kW) or more, connect power wiring with 1/4 in.
  • Page 16 Fig. 16 — Unit Wiring Diagram...

  • Page 17: Three Stage Operation

    THREE STAGE OPERATION Make connections of blue wire included in factory harness. Connect one end to Thermostat CB terminal Y2 and the other All units are factory shipped for 2-stage cooling operation. To con- to Indoor Connection Board terminal Y2. vert a unit to 3-stage operation, see Fig.

  • Page 18: Connecting Ductwork

    It is important that this connection be properly fabricated to prevent high air fric- Refer to the Carrier System Design Manual for the recommended tion losses and air noise. design and layout of ductwork.

  • Page 19: Start-Up

    START-UP Continue adjustment until superheat reaches 10°F to 15°F (5.5°C to 8.3°C). Before starting unit, check the following and correct as necessary: Replace the seal cap; tighten. • Is unit solidly supported? • Is fan adjusted for speed and pulley alignment? INSTALLER / INSTALLATEUR •...

  • Page 20: Supply Fan (Direct-Drive)

    SELECTING FAN SPEED CAUTION All units come factory-set for the corresponding voltage at 400 CFM per ton and either 1.2 in. wg (medium static units) or UNIT OPERATION HAZARD 2 in. wg (high static units) of external static pressure specific to each unit.

  • Page 21: Fan Fault Detection

    Low Speed Fan Adjustment 2-Pin DIP Switch The Low Speed 2-Pin DIP switch is located near the center of the UCB. See Fig. 23. When replacing UCB, the board will be shipped as default without a low speed selected. For all 40RF units, set both dip switches to “OFF”...

  • Page 22: Service Access For Supply Fan And Motor

    ESP in. wg Factory Setting: Calculator 9.0 V 1500 Field Setting: 1625 Record field setting here 1750 1875 2000 Switch Range: 2125 10.0 2250 4.1 - 7.5 2375 6.9 - 8.7 2500 7.7 - 10.0 Field Accessories: Economizer * Overlap in A, B, C switch range 1 Stage E Heat designed for maximum field adjustment potential.
  • Page 23 Quarter Round Stator Retention Brackets Fig. 26 — Quarter Round Stator Retention Brackets Fig. 27 — Fan Assembly, Side Panel Access (Side Panel Removed) Disassembling Motor and Fan Assembly See Fig. 28 for 2.4 Hp motor units; see Fig. 29 for 3 Hp motor units.
  • Page 24 Reassembly of Motor and Fan Assembly See Fig. 28 for 2.4 Hp motor units; see Fig. 29 for 3 Hp motor units. Place motor on flat surface. If required, install stator limit switch on the stator with two plastic push rivets (P/N: HH18HA597). Fit motor wire harness into keyhole feature on the side of the stator and pull wire harness out prior to fixing the motor to the stator.

  • Page 25: Vertical Applications

    Adjust the orientation of the stator so that it aligns with the embossed recess in the fan deck. Reconnect wires for stator temperature limit switch. Pull motor harness tight through grommet and plug it in to the control box harness and secure in the corner with snap-in wire tie.

  • Page 26: Condensate Drains

    Install three 1/4-20 x 1-in. hex head machine screws Cleaning Insulation (P/N: AC67AP170) through the holes in the rotor. Tighten The insulation contains an immobilized antimicrobial agent that to 50 in.-lb (5.65 Nm) helps inhibit the growth of bacteria and fungi. Clean the inner sur- face of the insulation according to the separate maintenance Align holes of composite fan inlet casing with screw wells on instructions shipped with the unit.

  • Page 27: Maintenance

    NOTE(S): a. The above list may not include all maintenance items. Inspection intervals may vary depending on climate and opening hours. Consult your Carrier dealer about a service contact for seasonal inspections Fig. 35 — Filter Removal/Replacement b.

  • Page 28: Fan Performance

    General Fan Performance Notes motor/drive combinations would work, Carrier recommends See Tables 14-40 for fan performance data. the lower horsepower option. Interpolation is permissible. Do not extrapolate. The EPACT (Energy Policy Act of 1992) regulates energy External static pressure is the static pressure difference requirements for specific types of indoor fan motors.
  • Page 29 1852 2.45 1925 2.76 High Static 788-1925 RPM, 2.76 Max BHP Medium Static 788-1695 RPM, 1.86 Max BHP Table 15 — 40RFAA07 Medium Static Fan Data (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1800 1081 1202 1308 1950...
  • Page 30 Table 16 — 40RFAA07 High Static Fan Data (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1800 1081 1202 1308 1950 1107 1227 1333 2100 1005 1134 1252 1358 2250 1040 1163 1278 1383 2400 1077 1194 1305 1409...
  • Page 31 Table 17 — 40RFAA08 Fan Data (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 2250 0.23 1009 0.37 1131 0.54 1247 0.74 1354 0.95 2440 0.27 1053 0.42 1168 0.59 1279 0.79 1383 1.01 2625 0.32 1099 0.47 1206 0.64 1311 0.84...
  • Page 32 Table 19 — 40RFAA08 High Static Fan Data (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 2250 1009 1131 1247 1354 2440 1053 1168 1279 1383 2625 1099 1206 1311 1412 2815 1048 1149 1249 1348 1445 3000 1103 1199 1293 1386...
  • Page 33 Table 20 — 40RFAA12 Fan Data (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 3000 1080 0.40 1175 0.55 1268 0.72 1361 0.92 1453 1.14 3250 1154 0.48 1243 0.64 1329 0.81 1415 1.01 1501 1.24 3500 1229 0.57 1312 0.74 1393...
  • Page 34 Table 22 — 40RFAA12 High Static Fan Data (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 3000 1080 1175 1268 1361 1453 3250 1154 1243 1329 1415 1501 3500 1229 1312 1393 1473 1553 3750 1305 1384 1459 1534 1609 4000 1381...
  • Page 35 Table 23 — 40RFQA07 Fan Data (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1800 0.18 0.31 1081 0.48 1202 0.67 1308 0.88 1950 0.20 0.34 1107 0.52 1227 0.71 1333 0.92 2100 0.23 1005 0.37 1134 0.55 1252 0.75 1358 0.97...
  • Page 36 Table 25 — 40RFQA07 High Static Fan Data (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1800 1081 1202 1308 1950 1107 1227 1333 2100 1005 1134 1252 1358 2250 1040 1163 1278 1383 2400 1077 1194 1305 1409 2550 1004 1115...
  • Page 37 Table 26 — 40RFQA08 Fan Data (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 2250 0.23 1009 0.37 1131 0.54 1247 0.74 1354 0.95 2440 0.27 1053 0.42 1168 0.59 1279 0.79 1383 1.01 2625 0.32 1099 0.47 1206 0.64 1311 0.84...
  • Page 38 Table 28 — 40RFQA08 High Static Fan Data (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 2250 1009 1131 1247 1354 2440 1053 1168 1279 1383 2625 1099 1206 1311 1412 2815 1048 1149 1249 1348 1445 3000 1103 1199 1293 1386...
  • Page 39 Table 29 — 40RFQA12 Fan Data (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 3000 1080 0.40 1175 0.55 1268 0.72 1361 0.92 1453 1.14 3250 1154 0.48 1243 0.64 1329 0.81 1415 1.01 1501 1.24 3500 1229 0.57 1312 0.74 1393...
  • Page 40 Table 31 — 40RFQA12 High Static Fan Data (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 3000 1080 1175 1268 1361 1453 3250 1154 1243 1329 1415 1501 3500 1229 1312 1393 1473 1553 3750 1305 1384 1459 1534 1609 4000 1381...
  • Page 41 Table 32 — 40RFSA08 Fan Data (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 2250 0.20 0.33 1096 0.49 1210 0.67 1315 0.87 2440 0.24 1017 0.37 1130 0.53 1239 0.71 1342 0.92 2625 0.27 1060 0.41 1167 0.57 1270 0.76 1369...
  • Page 42 Table 34 — 40RFSA08 High Static Fan Data (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 2250 1096 1210 1315 2440 1017 1130 1239 1342 2625 1060 1167 1270 1369 2815 1004 1107 1207 1305 1400 3000 1056 1154 1248 1341 1432...
  • Page 43 Table 35 — 40RFSA10 Fan Data (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 2550 0.26 1041 0.39 1151 0.55 1256 0.74 1357 0.94 2765 0.30 1093 0.44 1195 0.61 1294 0.80 1390 1.00 2975 1048 0.36 1146 0.50 1241 0.67 1335...
  • Page 44 Table 37 — 40RFSA10 High Static Fan Data (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 2550 1041 1151 1256 1357 2765 1093 1195 1294 1390 2975 1048 1146 1241 1335 1426 3190 1110 1202 1291 1379 1465 3400 1171 1257 1342...
  • Page 45 Table 38 — 40RFSA12 Fan Data (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 3000 1049 0.36 1146 0.50 1240 0.67 1333 0.85 1424 1.06 3250 1120 0.43 1211 0.58 1299 0.75 1385 0.94 1470 1.15 3500 1193 0.51 1278 0.67 1360...
  • Page 46 — — — High Static 1049-2060 RPM © 2023 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53400080-01 Printed in U.S.A. Form 40RF-7-12-02SI Rev. A...

  • Page 47: Start-Up Checklist

    START-UP CHECKLIST (SPLIT SYSTEMS WITH 40RF 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 48 ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ © 2023 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53400080-01 Printed in U.S.A. Form 40RF-7-12-02SI Rev. A Pg CL-2...

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