Carrier CAS072 Installation, Start-Up And Service Instructions Manual
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Carrier CAS072 Installation, Start-Up And Service Instructions Manual

Carrier CAS072 Installation, Start-Up And Service Instructions Manual

Air-cooled condensing units with r-410a refrigerant
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Installation, Start-Up and Service Instructions
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . 1
INSTALLATION GUIDELINES . . . . . . . . . . . . . . 2
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 1 - Plan for Unit Location . . . . . . . . . . . . 6
Rig and Mount the Unit . . . . . . . . . . . . . . . . . . . 7
Suction Riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connections . . . . . . . . . . . . . . . . . . . . . . . . . 10
Step 6 - Install Accessories . . . . . . . . . . . . . . 13
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Turn On Crankcase Heater . . . . . . . . . . . . . . . 18
Preliminary Charge . . . . . . . . . . . . . . . . . . . . . . 18
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . 18
Start Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATING SEQUENCE . . . . . . . . . . . . . . . . . 25
Base Unit Controls . . . . . . . . . . . . . . . . . . . . . . 25
All Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 26
(and 30 days after initial start) . . . . . . . . . . . 26
Seasonal Maintenance . . . . . . . . . . . . . . . . . . . 26
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Refrigeration System . . . . . . . . . . . . . . . . . . . . 27
Comfort Alert Diagnostic Module . . . . . . . . . . 28
Compressor Protection . . . . . . . . . . . . . . . . . . 31
(RTPF) Coils . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fastener Torque Values . . . . . . . . . . . . . . . . . . 32
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 32
QUICK REFERENCE GUIDE . . . . . . . . . . . . . 35
START-UP CHECKLIST . . . . . . . . . . . . . . . . . CL-1
CAS072-153
Air-Cooled Condensing Units
with R-410A Refrigerant
Page
CAS-072-153-01SI Rev. A

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
shock or other conditions which may cause personal injury
or property damage. Consult a qualified installer, service
agency, or your distributor or branch for information or
assistance. The qualified installer or agency must use
factory-authorized kits or accessories when modifying this
product. Refer to the individual instructions packaged with
the kits or accessories when installing.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloths for brazing operations and
have a fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions attached to
the unit. Consult local building codes and appropriate
national electrical codes (in U.S.A., ANSI/NFPA70, National
Electrical Code (NEC); in Canada, CSA C22.1) for special
requirements.
It is important to recognize safety information. This is the
safety-alert symbol
. When you see this symbol on the
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
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. Do not check compressor ohms at
compressor terminals. Unit may have more than one
power switch.
WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal
injury, death and/or equipment damage.
R-410A refrigerant systems operate at higher pressures
than standard R-22 systems. Do not use R-22 service
equipment or components on R-410A refrigerant
equipment.
DANGER
1-23

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  • Page 1: Table Of Contents

    CAS072-153 Air-Cooled Condensing Units with R-410A Refrigerant Installation, Start-Up and Service Instructions CONTENTS SAFETY CONSIDERATIONS Page Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical SAFETY CONSIDERATIONS ....1 shock or other conditions which may cause personal injury INSTALLATION GUIDELINES .

  • Page 2: Installation Guidelines

    Inspect all tube segments and joints for signs of dam- age, corrosion or poor brazing. Flush the interconnecting MODEL NUMBERS FULL LOAD AIRFLOW (CFM) piping system with dry Nitrogen to eliminate as much trace CAS072 — F*X072 2400 of mineral oil as possible. CAS091 — F*X091 3000 Same tube sizes are capable of handling higher flow rates CAS121 —...

  • Page 3: Matching Cas Model To Evaporator Coil

    The Model CAS123/153 CANNOT be field- converted to a single-circuit design. See Table 3. The CAS072/091/121/151 units have a single-circuit de- sign, requiring one set of refrigeration piping. This model Before unpacking this new CAS model, compare the evapo- can be connected to an evaporator coil with one circuit or rator coil design to the CAS model.
  • Page 4 Fig. 2 — CAS072-153 Base Unit Dimensions...
  • Page 5 24 [609.6] 50 3/8 [1279.2] CAS153 20 [508.0] 25 [635.0] 24 [609.6] 50 3/8 [1279.2] NOTE(S): Dimensions are in inches [mm]. Table 5 — CAS072/091/121/151 Single Circuit Models — Physical Data UNIT CAS072 CAS091 CAS121 CAS151 NOMINAL CAPACITY (tons) 12.5...

  • Page 6: Installation

    Table 6 — CAS123/153 Two Circuit Models – Physical Data UNIT CAS123 CAS153 NOMINAL CAPACITY (tons) 12.5 OPERATING WEIGHT (lb) Refrigeration System # Circuits / # Comp. / Type 2 / 2 / Scroll 2 / 2 / Scroll Refrigerant Type R-410A R-410A R-410A Shipping Charge A/B (lb)

  • Page 7: Step 2 - Complete Pre-Installation Checks

    Select recommended line sizes its final location. CAS072/091/121/151 and CAS123/153 unit from the ap- propriate tables. INSPECT SHIPMENT Determine the linear length of interconnecting piping re- File a claim with shipping company if the shipment is dam- quired between the outdoor unit and indoor unit (evapora- aged or incomplete.
  • Page 8 (feet of elevation) that a liquid line size can door unit to reduce the equivalent line length or the lift requirement. Table 8 — CAS072/091/121/151 Piping Recommendations (Single-Circuit) MODEL & LINEAR LINE (FT) 0 - 24...

  • Page 9: Suction Riser

    Table 10 — CAS Maximum Suction Pipe Size cal Riser Segments MODEL AND UNIT SIZE MAXIMUM TUBE SIZE (in.) Select Circuit 1 suction line size from NO VAPOR RISER line. CAS072 1-1/8 CAS091 1-1/8 Vertical Separation (outdoor unit above indoor unit) CAS121...

  • Page 10: Step 5 - Complete Refrigerant Piping

    Circuit 1 is on the right- hand side of the service valve compartment; Circuit 2 is on The CAS units include one (CAS072/091/121/151) or two the left. (CAS123/153) R-410A-duty filter drier(s), shipped in cartons attached to the unit basepan (see Table 12).
  • Page 11 MODEL SIZE NUMBER OD (in.) VOLUME REF. Fig. 8 — Location of Sight Glass(es) and Filter Driers CAS072 8 cu in. KH43LG091 Typical CAS072/091/121/151 Systems CAS091 16 cu in. KH43LG085 CAS121 16 cu in. KH43LG085 EQUALIZER LINE CAS151 30 cu in.
  • Page 12 Control the power to the liquid line solenoid through a Sole- noid Valve Relay (SVR) in all units. Use part number HN61PC005 (field-supplied, installed). CAS072/091/121/151 unit requires one SVR; CAS123/153 unit requires two relays. A unit with two liquid line solenoid valves also requires a...

  • Page 13: Step 6 - Install Accessories

    60 ft (18.3 m) linear line length field power connections directly to line connection pressure Equivalent line length 90 ft (27.4 m) lugs only. Liquid Lift: 20 ft (6.1 m) Select line sizes from Table 8 (CAS072/091/121/151): WARNING Liquid 1/2 in. FIRE HAZARD Suction 1-1/8 in.
  • Page 14 Non-Powered Type Units Without Disconnect Option This type requires the field installation of a general- purpose 125-volt 15-A circuit powered from a source else- where in the building. Observe national and local codes when selecting wire size, fuse or breaker requirements and disconnect switch size and location.
  • Page 15 Fig. 16 — Single Circuit Thermostat Connections — GFCI Receptacle CAS072/091/121/151 Fig. 15 — Weatherproof Cover Installation CAS072/091/121/151 is a single circuit, two-stage cooling ALL UNITS unit. Select a two-stage cooling thermostat. Voltage to compressor terminals during operation must be The CAS123/153 is a dual-circuit, three-stage cooling unit.
  • Page 16 1. Typical multi-function marking. Follow manufacturer’s configuration instructions to select Y2. 2. Connect only if thermostat requires 24-vac power source. Fig. 17 — Dual Circuit Thermostat Connections — CAS123/153 Table 14 — CAS072/091/121/151 Single Circuit Electrical Data without Powered Convenience Outlet COMPRESSOR VOLTAGE POWER SUPPLY...
  • Page 17 Table 15 — CAS072/091/121/151 Single Circuit Electrical Data with Powered Convenience Outlet COMPRESSOR VOLTAGE POWER SUPPLY DISCONNECT SIZE NOMINAL RANGE NUMBER No. 1 No. 2 POWER UNIT SIZE Fuse or SUPPLY STAGES FLA (ea) HACR V-Ph-Hz Brkr 575-3-60 — —...

  • Page 18: Step 8 - Wind Baffles For Low Ambient

    LEGEND AND NOTES FOR TABLES 14-17 System Check 1. The electrical power source must agree with the LEGEND — Full Load Amps unit’s nameplate rating. 2. Check all air handler(s) and other equipment auxil- — Locked Rotor Amps iary components. Consult the manufacturer’s instruc- MOCP —...

  • Page 19: Start Unit

    5. Ensure that the preliminary charge has been added Protection will reset automatically before the motor protector resets, which may take up to 2 hours. as described in the Pre-Start-Up section, Preliminary Charge. 6. All internal wiring connections must be tight, and all barriers and covers must be in place.
  • Page 20 Remove Charge if Below the Curve 1050 1400 1750 2100 2450 2800 3150 3500 3850 Pressure at Liquid Valve (PSIG / kPa) PN: 38AU000484 REV - Fig. 20 — CAS072 Charging Chart (RTPF) CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 21 7.5 Ton Dual Stage Charging Chart R410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve 1050 1400 1750 2100 2450 2800 3150 3500 3850 Pressure at Liquid Valve (PSIG / kPa) 38AU000028 Fig. 21 — CAS091 Charging Chart (RTPF) CAS-072-153-01SI Rev.
  • Page 22 10 Tons R410A CHARGING CHART 59.9 48.8 Add Charge if Above the Curve 37.7 26.6 15.5 Remove Charge if Below the Curve -6.7 1034 1379 1723 2068 2413 2758 3102 3447 3792 4136 Compressor Discharge Pressure, [psig/kPa] 38AU001204 Rev. - Fig.
  • Page 23 12.5 Ton Charging Chart R-410A Refrigerant Add Charge if Above the Curve Remove Charge if Below the Curve 1050 1400 1750 2100 2450 2800 3150 3500 3850 Pressure at Liquid Valve (PSIG / kPa) 38AU501048 Fig. 23 — CAS151 Charging Chart (RTPF) CAS-072-153-01SI Rev.
  • Page 24 10 Ton Circuit A Charging Chart R-410A Refrigerant 10 Ton Circuit B Charging Chart R-410A Refrigerant Add Charge if Add Charge if Above the Curve Above the Curve Remove Charge if Remove Charge if Below the Curve Below the Curve 100 150 200 250 300 350 400 450 500 550 600 100 150 200 250 300 350 400 450 500 550 600 350 700 1050 1400 1750 2100 2450 2800 3150 3500 3850...

  • Page 25: Operating Sequence

    SVR1 and compressor contactor C1 are energized; liq- uid line solenoid valve LLSV1 opens and Circuit 1 compres- CAS072/091, CAS121 (Single Circuit/2-Stage) sor starts. All outdoor fan motors start, subject to ambient On a thermostat call for Cooling, the indoor (supply) fan temperature (refer to Fan Cycling section).

  • Page 26: Maintenance

    COOLING, UNIT WITH ECONOMIZER Table 19 — Outdoor Unit Maintenance Checklist Refer to fan coil unit installation instructions and economizer RECOMMENDED accessory installation instructions for operating sequences MAINTENANCE CHECKLIST INTERVAL when system is equipped with accessory economizer. Outdoor unit specific: Monthly Annual HEATING...

  • Page 27: Service

    SERVICE FIELD REFRIGERANT ACCESS PORTS Field service access to refrigerant pressures is through the Refrigeration System access ports located at the service valves (see Fig. 26 and 27). These ports are 1/4-in. SAE Flare couplings with Schrader check valves and service caps. Use these ports to WARNING admit nitrogen to the field tubing during brazing, to evacuate the tubing and evaporator coil, to admit initial refrigerant...

  • Page 28: Comfort Alert Diagnostic Module

    FACTORY HIGH-FLOW ACCESS PORTS replace the entire core body if necessary. Service tools are available from Fast Parts that allow the replacement of the There are two additional access ports in the system - on the check valve core without having to recover the entire sys- suction tube between the compressor and the suction ser- tem refrigerant charge.
  • Page 29 The POWER LED indicates the presence of control power The TRIP LED indicates either a time-delay period is cur- to the CADM. rently active (RED LED is blinking) or the module has locked out the compressor (RED LED is on steady). A lock- The ALERT LED indicates an abnormal condition exists in out condition will occur when the CADM detects a thermo- the system through a flash code.
  • Page 30 Table 22 — LED Status Codes STATUS LED STATUS LED DESCRIPTION STATUS LED TROUBLESHOOTING INFORMATION Green “POWER” Module has power Supply voltage is present at module terminals 1. Compressor protector is open 2. Condensing unit power disconnect is open Thermostat demand signal Y is 3.

  • Page 31: Compressor Protection

    Compressor Protection Routine Cleaning of Round-Tube Plate Fin (RTPF) Coils COMPRESSOR OVER-TEMPERATURE INTERNAL Periodic cleaning with Totaline environmentally balanced ® PROTECTION coil cleaner is essential to extend the life of RTPF coils. This A thermostat installed on the compressor motor winding re- cleaner is available from Fast Parts as part number P902- acts to excessively high winding temperatures and shuts off 0301 for a one gallon container, and part number P902-...

  • Page 32: Fastener Torque Values

    6. Thoroughly apply Totaline environmentally balanced coil cleaner solution to all coil surfaces including the finned area, tube sheets and coil headers. 7. Hold garden sprayer nozzle close to finned areas Rigid and apply cleaner with a vertical, up-and-down Support motion.
  • Page 33 Table 25 — Troubleshooting PROBLEM SOLUTION COMPRESSOR DOES NOT RUN Contactor Open 1. Power off. 1. Restore power. 2. Fuses blown in field power circuit. 2. After finding cause and correcting, replace with correct size fuse. 3. No control power. 3.
  • Page 34 Table 25 — Troubleshooting (cont) PROBLEM SOLUTION COMPRESSOR RUNNING BUT COOLING INSUFFICIENT Suction Pressure Low 1. Refrigerant charge low. 1. Add refrigerant. 2. Head pressure low. 2. Check refrigerant charge. Check outdoor-air fan thermostat settings. 3. Air filters dirty. 3. Clean or replace filters. 4.

  • Page 35: Appendix A - Air Conditioner And Heat Pump With R-410A - Quick Reference Guide

    72 hours. • POE oils absorb moisture rapidly. Do not expose oil to atmosphere. APPENDIX B — WIRING DIAGRAMS ELECTRICAL UNIT DIAGRAM NUMBER PAGE NUMBER CHARACTERISTICS 208/230-3-60 38AU000441 CAS072 460-3-60 38AU000441 575-3-60 38AU000442 208/230-3-60 38AU000759 CAS091 460-3-60 38AU000760 575-3-60 38AU000758...
  • Page 36 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. A — Single Circuit/Two-Stage Wiring Diagram, 6 Ton — 208/230-3-60 and 460-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 37 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. B — Single Circuit/Two-Stage Wiring Diagram, 6 Ton — 575-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 38 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. C — Single Circuit/Two-Stage Wiring Diagram, 7.5 Ton — 208/230-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 39 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. D — Single Circuit/Two-Stage Wiring Diagram, 7.5 Ton — 460-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 40 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. E — Single Circuit/Two-Stage Wiring Diagram, 7.5 Ton — 575-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 41 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. F — Single Circuit/2-Stage Wiring Diagram, 10 Ton — 208/230-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 42 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. G — Single Circuit/2-Stage Wiring Diagram, 10 Ton — 460-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 43 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. H — Single Circuit/2-Stage Wiring Diagram, 10 Ton — 575-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 44 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. I — Single Circuit/2-Stage Wiring Diagram, 12.5 Ton — 208/230-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 45 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. J — Single Circuit/2-Stage Wiring Diagram, 12.5 Ton — 460-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 46 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. K — Single Circuit/2-Stage Wiring Diagram, 12.5 Ton — 575-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 47 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. L — Dual Circuit/3-Stage Wiring Diagram, 10-12.5 Ton — 208/230-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 48 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. M — Dual Circuit/3-Stage Wiring Diagram, 10-12.5 Ton — 460-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 49 APPENDIX B — WIRING DIAGRAMS (CONT) Fig. N — Dual Circuit/3-Stage Wiring Diagram, 10-12.5 Ton — 575-3-60 Units CAS-072-153-01SI Rev. A Specifications subject to change without notice.

  • Page 50: Appendix C - Low Ambient Option

    A temperature sensor, mounted on OBSERVATION POSSIBLE REMEDY either circuit 1 (CAS072/091/121/151 units) or both circuits All fans: 1 and 2 (CAS123/153 units) of the outdoor coil controls the Check power and wiring...
  • Page 51 Header Tube and Tube Sheet 6-7.5 TON SINGLE CIRCUIT UNITS 10 TON SINGLE CIRCUIT UNIT 12.5 TON SINGLE CIRCUIT UNIT Fig. O — CAS072/091/121/151 Single Circuit Low Ambient Control Sensor Locations (RTPF) CAS-072-153-01SI Rev. A Specifications subject to change without notice.
  • Page 52 APPENDIX C — LOW AMBIENT OPTION (CONT) Low Ambient Sensor 2 must be positioned on Feeder Tube (second from top on the Top Header) between Header Tube and Tube Sheet Low Ambient Sensor 2 must be positioned on Feeder Tube (second from top on the Top Header) between Header Tube and Tube Sheet...
  • Page 53 APPENDIX C — LOW AMBIENT OPTION (CONT) Fig. Q — Wind Baffles...
  • Page 54 1035 1054 1095 LEFT SIDE 1022 1041 1060 1095 1049 CAS123 CAS151 BACK 1016 1035 1054 1095 CAS153 RIGHT SIDE 1095 © 2023 Carrier Lewisburg, TN 37091 USA Replaces: 50101300801 CAS-072-153-01SI Rev. A Specifications are subject to change without notice.

  • Page 55: Start-Up Checklist

    START-UP CHECKLIST (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 to the safety considerations/information as outlined in preceding sections of this Installation, Start-Up, and Service document.
  • Page 56 __________ / __________ / __________ NOTES: ______________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ ______________________________________________________________________________________________ © 2023 Carrier Lewisburg, TN 37091 USA Replaces: 50101300801 CAS-072-153-01SI Rev. A CL-2 Specifications are subject to change without notice. 1-23...

This manual is also suitable for:

Cas091Cas121Cas151Cas123Cas153

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