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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
Detection of Flammable Refrigerants . . . . . . . . . . . . 2
Ignition Source Mitigation . . . . . . . . . . . . . . . . . . . . . 2
Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . 3
Evacuation, Removal, and Recovery . . . . . . . . . . . . 3
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Moving and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Checks to Refrigerating Equipment . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Uncrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . 11
Unit Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unit Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant and Chilled Water Piping Access . . . . 12
Chilled Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . 14
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fan Motors and Drives . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Supply and Wiring . . . . . . . . . . . . . . . . . . . . . . . 15
Leak Dissipation System . . . . . . . . . . . . . . . . . . . . . 20
Connecting Ductwork . . . . . . . . . . . . . . . . . . . . . . . . 23
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
40RLA and 40RLQ ONLY . . . . . . . . . . . . . . . . . . . . . 24
(40RLA and 40RLQ only) . . . . . . . . . . . . . . . . . . . 24
Fan Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
(and 30 days after initial start) . . . . . . . . . . . . . . . 24
Seasonal Maintenance . . . . . . . . . . . . . . . . . . . . . . . 25
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53400091-01
Installation, Start-up and
Service Instructions
Printed in U.S.A.
Form No. 40RL-7-12-01SI
Packaged Air-Handling Units
with Puron Advance™ (R-454B) Refrigerant
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Page
SUPPLY FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Supply Fan (Direct-Drive) . . . . . . . . . . . . . . . . . . . . .26
Service Access for Supply Fan and Motor . . . . . . .30
Condensate Drains . . . . . . . . . . . . . . . . . . . . . . . . . .33
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Chilled Water Coil Freeze Protection . . . . . . . . . . . .33
Coil Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Cleaning Cooling Coil . . . . . . . . . . . . . . . . . . . . . . . .33
Cleaning Insulation . . . . . . . . . . . . . . . . . . . . . . . . . .34
Replacing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
FAN PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . .34
General Fan Performance Notes . . . . . . . . . . . . . . .34
DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . .53
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
40RL/A/S/Q 07-12
. When you see this symbol on the unit and in
Pg 1
1-25
60 Hz
Replaces: NEW
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Summary of Contents for Carrier 40RLAA07
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Page 1: Table Of Contents
40RL/A/S/Q 07-12 Packaged Air-Handling Units with Puron Advance™ (R-454B) Refrigerant 60 Hz Installation, Start-up and Service Instructions CONTENTS SERVICE ........25 Panels . -
Page 2: Electrical Shock Hazard
suggestions which will result in enhanced installation, reliability, or operation. WARNING RISK OF FIRE — FLAMMABLE REFRIGERANT DANGER Do not use means to accelerate the defrosting process or to ELECTRICAL SHOCK HAZARD clean, other than those recommended by the manufacturer. Failure to follow this warning will result in personal injury or Do not pierce or burn. -
Page 3: Ventilation Requirements
shall be as short as possible to minimize the amount of re- Ventilation Requirements frigerant contained in them. Ensure that the area is in the open or that it is adequately ventilated • Cylinders shall be kept in an appropriate position accord- before breaking into the system or conducting any hot work. -
Page 4: Installation
INSTALLATION Uncrating Move unit as near as possible to final location before removing General shipping skid. Allow the following clearances for service access and airflow: Remove metal banding, top skid, and plastic wrap. Examine unit • Rear: 2-1/2 ft (762 mm) for shipping damage. - Page 5 Position: 9 10 11 12 13 14 15 16 17 18 Example: – Model Type Packaging Compliance 40RL = Vane Axial Fan Packaged Air-Handling 0 = Standard Puron Advance™ R-454B Refrigerant Future Use Type of Coil A = Standard A = Standard 4 Row DX S = Chilled Water Coil Cabinet Paint Q = Heat Pump Coil...
- Page 6 Fig. 2 — 40RL 07-12 Base Unit Dimensions...
- Page 7 Fig. 2 — 40RL 07-12 Base Unit Dimensions (cont)
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Page 8: Direct-Expansion Coil
Table 1 — 40RLA 6-10 Ton Direct Expansion with Puron Advance™ Refrigerant Units UNIT 40RLAA07 40RLAA08 40RLAA12 NOMINAL CAPACITY (Tons) 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 9 Table 2 — 40RLQ 6-10 Ton Heat Pump Units UNIT 40RLQA07 40RLQA08 40RLQA12 NOMINAL CAPACITY (Tons) 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 Nominal Motor HP (Standard Motor)
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Page 10: Chilled Water Coil
Table 3 — 40RLS Physical Data — Chilled Water Units UNIT 40RLSA08 40RLSA10 40RLSA12 NOMINAL CAPACITY (Tons) 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 3400 4000... -
Page 11: Rated Indoor Airflow (Cfm)
Coil Unit Positioning The unit can be mounted on the floor for vertical application with return air entering the face of the unit and supply air dis- charging vertically through the top of the unit. The unit can also be applied in a horizontal arrangement with return air en- tering horizontally and the supply air discharging horizontally. -
Page 12: Refrigerant Piping
Refrigerant Piping Refrigerant and Chilled Water Piping Access See Tables 1-3 for refrigerant pipe connection sizes. For ease in The 40RL Series units come with standard knockouts for re- brazing, it is recommended that all internal solder joints be made frigerant and chilled water piping. - Page 13 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 40RLA*07 40RLQ*07 5/8 Street Elbow Liquid — 5/8 Nipple, 8-5/8 L 5/8 Long Radius Elbow 1-1/8 Street Elbow Suction —...
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Page 14: Chilled Water Piping
40RLS chilled water piping. See Fig. 6, which lists recommended knockouts and access holes to use for each 40RLS unit size. To size, design, and install chilled water piping, consult the Carrier System Design manual. See Fig. 10 for an example of a typical in- Condensate Drain Connection stallation. -
Page 15: Condensate Drain
Condensate Drain Install a trapped condensate drain line to unit connection as shown in Fig. 11. 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 16 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 40RLA*07 460-3-60...
- Page 17 The control box contains a Unit Control Board (UCB) that re- Table 10 — Recommended Torque of ceives thermostat commands from the thermostat (through the Ground Lug Field Connection Thermostat Connection Board) and, outputs these commands to the condensing unit (through the Indoor Connection Board) as TORQUE (in.-lb) well as a high voltage terminal block.
- Page 18 Fig. 16 — Unit Wiring Diagram...
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Page 19: 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 20: Leak Dissipation System
sensor that detected the refrigerant. See Fig. 22 — on page 22 for Leak Dissipation System the full text on the Dissipation Control box cover label. 40RL units use R-454B refrigerant. These units are equipped When the sensor signal indicates the refrigerant has dissipated, with a factory installed R-454B leak dissipation system to ensure the dissipation board yellow status LED will display a flash safe operation in the event of a refrigerant leak. - Page 21 Detail A Detail B Detail A — Test Button Detail B — Status LED Fig. 21 — Dissipation Control Board — Shown without Dust Cover Press the Test button on the dissipation system control board to en- Ensure that the unit is able to meet the minimum required dissipa- sure proper dissipation system operation under each test condition tion mode airflows.
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Page 22: Troubleshooting
Table 13 details the required operational checks to ensure proper TROUBLESHOOTING dissipation system function. For all flash codes, first try power cycling the system to remove the code. Table 13 — Dissipation System Required Operational No Power Checks Verify the wiring to/from pins 1 and 8 on the power harness plug. Check the 24V system wiring the IDCB terminal in the main con- NORMAL OPERATION trol box. -
Page 23: Connecting Ductwork
It is important Connecting Ductwork 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 24: Start-Up
UPPER SPLIT SIGHT GLASS BULB BLOC SUPÉRIEUR drive recommendations. In cases when two motor/drive com- HUBLOT CAPTEUR TXV binations would work, Carrier recommends the lower horse- AIR FLOW power option. CIRCULATION D'AIR 15 DIAMS MIN 10 DIAMS 10 x DIA. MIN 15 x DIA. -
Page 25: Seasonal Maintenance
Repair or replace as necessary. a. The above list may not include all maintenance items. Inspection intervals may vary depending on climate and opening hours. Consult your Carrier dealer Inspect electrical wiring and connections. about a service contact for seasonal inspections. -
Page 26: Supply Fan
SELECTING FAN SPEED SUPPLY FAN All units come factory-set 8.9 vdc or approximately 89% of the motor's maximum speed.. Fan speed should be set per job specifi- WARNING cation CFM (cubic feet per minute) and ESP (external static pres- ELECTRICAL SHOCK HAZARD sure) required and per Fan Speed Set Up label mounted on the control box. -
Page 27: Fan Fault Detection
FREEZE PROTECTION On select models (40RLAA07 and 40RLAA12), there is a facto- ry-installed and wired temperature switch (P/N HH18HB016) to protect the compressor(s) in the condensing unit when frost build- up is present on the indoor coil. - Page 28 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.
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Page 29: Troubleshooting The Ecm Motor
TROUBLESHOOTING THE ECM MOTOR as the voltage/speed programming will not be the same as that on an original factory motor. EcoBlue™ motors are designed with several built-in protections included in the motor software. If the motor detects a fault it will safely shut down. -
Page 30: Service Access For Supply Fan And Motor
Service Access for Supply Fan and Motor HORIZONTAL APPLICATIONS Removing the Motor and Fan Assembly NOTE: Due to press fit design of composite Rotor on Motor, it is highly recommended that any time a motor is replaced the fan ro- tor is replaced as well. - Page 31 Fig. 34 — Fan Assembly for Units with 2.4 Hp Motor Fig. 35 — Fan Assembly for Units with 3 Hp Motor...
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Page 32: Vertical Applications
Reassembly of Motor and Fan Assembly Adjust the orientation of the stator so that it aligns with the embossed recess in the fan deck. See Fig. 34 for 2.4 Hp motor units; see Fig. 35 for 3 Hp motor units. Place motor on flat surface. Reconnect wires for stator temperature limit switch. -
Page 33: Condensate Drains
Install three 1/4-20 x 1-in. hex head machine screws (P/N: AC67AP170) through the holes in the rotor. Tighten to 50 in.-lb (5.65 Nm) Align holes of composite fan inlet casing with screw wells on the top flange of the fan stator. 10. -
Page 34: Cleaning Insulation
Clip The fan performance tables (see Tables 18-44) offer motor/ drive recommendations. In cases when two motor/drive com- binations would work, Carrier recommends the lower horse- power option. The EPACT (Energy Policy Act of 1992) regulates energy requirements for specific types of indoor fan motors. - Page 35 1852 2.45 1925 2.76 Medium Static 788-1695 rpm, 1.86 Max bhp High Static 788-1925 rpm, 2.76 Max bhp Table 19 — 40RLAA07 Medium Static Fan Data (rpm - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1800 1081 1202 1308 1950...
- Page 36 Table 20 — 40RLAA07 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 37 Table 21 — 40RLAA08 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 23 — 40RLAA08 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 24 — 40RLAA12 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 26 — 40RLAA12 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 27 — 40RLQA07 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 42 Table 29 — 40RLQA07 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 43 Table 30 — 40RLQA08 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 44 Table 32 — 40RLQA08 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 45 Table 33 — 40RLQA12 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 46 Table 35 — 40RLQA12 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 47 Table 36 — 40RLSA08 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 48 Table 38 — 40RLSA08 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 49 Table 39 — 40RLSA10 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 50 Table 41 — 40RLSA10 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 51 Table 42 — 40RLSA12 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 52 Table 44 — 40RLSA12 High Static Fan Data (rpm - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 3000 1049 1146 1240 1333 1424 3250 1120 1211 1299 1385 1470 3500 1193 1278 1360 1440 1520 3750 1266 1346 1423 1499 1574 4000 1340...
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Page 53: Decommissioning
If a vacuum is not possible, make a manifold so that refriger- DECOMMISSIONING ant can be removed from various parts of the system. Before carrying out this procedure, it is essential that the techni- Make sure that the cylinder is situated on the scales before cian is completely familiar with the equipment and all its detail. - Page 54 © 2025 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53400091-01 Printed in U.S.A. Form No. 40RL-7-12-01SI Pg 54 1-25 Replaces: NEW...
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Page 55: Preliminary Information
START-UP CHECKLIST (SPLIT SYSTEMS WITH 40RL 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 56 ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ ________________________________________________________________________________________________ © 2025 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53400091-01 Printed in U.S.A. Form No. 40RL-7-12-01SI Pg CL-2...
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