Carrier FHS150 Installation, Start-Up And Service Instructions Manual
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Carrier FHS150 Installation, Start-Up And Service Instructions Manual

Carrier FHS150 Installation, Start-Up And Service Instructions Manual

Packaged air-handling units with r-410a refrigerant 60 hz
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . 2
PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 3
Moving and Storage . . . . . . . . . . . . . . . . . . . . . . 3
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Uncrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . 11
Unit Positioning . . . . . . . . . . . . . . . . . . . . . . . . 11
Unit Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant Piping Access . . . . . . . . . . . . . . . . 12
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . 15
Fan Motors and Drives . . . . . . . . . . . . . . . . . . . . 16
Power Supply and Wiring . . . . . . . . . . . . . . . . . . 16
Variable Frequency Drive . . . . . . . . . . . . . . . . . 20
Connecting Ductwork . . . . . . . . . . . . . . . . . . . . 22
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . 22
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FAS150-180 and FHS180 . . . . . . . . . . . . . . . . . 23
(FAS150-180 and FHS180) . . . . . . . . . . . . . . 24
Compressor Rotation . . . . . . . . . . . . . . . . . . . . 24
Indoor Fan Motor . . . . . . . . . . . . . . . . . . . . . . . 24
Fan Speed Set Up . . . . . . . . . . . . . . . . . . . . . . . 25
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 26
(and 30 days after initial start) . . . . . . . . . . . 26
Seasonal Maintenance . . . . . . . . . . . . . . . . . . . 26
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fan Motor Lubrication . . . . . . . . . . . . . . . . . . . 27
Fan Shaft Bearings . . . . . . . . . . . . . . . . . . . . . . 27
Centering Fan Wheel . . . . . . . . . . . . . . . . . . . . 27
Fan Shaft Position Adjustment . . . . . . . . . . . . 27
Form No. FASFHS150-180-02SI
FAS/FHS150-180
Packaged Air-Handling Units
with R-410A Refrigerant
Installation, Start-up and
Service Instructions
Page
60 Hz
Individual Fan Wheel Adjustment . . . . . . . . . . 27
Fan Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fan Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fan Pulley Alignment . . . . . . . . . . . . . . . . . . . . 28
Pulley and Drive Adjustment . . . . . . . . . . . . . . 29
Variable Frequency Drive . . . . . . . . . . . . . . . . 33
VFD REMOTE KEYPAD . . . . . . . . . . . . . . . . . . 35
ACS320 VFD Modes . . . . . . . . . . . . . . . . . . . . . 35
ACS320 VFD Diagnostics . . . . . . . . . . . . . . . . 37
Correcting Faults . . . . . . . . . . . . . . . . . . . . . . . 38
Correcting Alarms . . . . . . . . . . . . . . . . . . . . . . 38
ACH580 VFD Modes . . . . . . . . . . . . . . . . . . . . . 42
ACH580 VFD Diagnostics . . . . . . . . . . . . . . . . 44
VFD MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 47
Heat Sink Cleaning . . . . . . . . . . . . . . . . . . . . . . 47
Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . 47
Pg 1
2-24

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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 Individual Fan Wheel Adjustment ..27 CONTENTS Fan Belts ......27 Page Fan Rotation .

  • Page 2: Safety Considerations

    • ACH580 MAIN FAN REPLACEMENT • ACH580 AUXILIARY COOLING FAN REPLACEMENT WARNING • ACS320 FAN REPLACEMENT Bypass the VFD ......50 UNIT OPERATION AND SAFETY HAZARD Condensate Drains .

  • Page 3: Pre-Installation

    PRE-INSTALLATION INSTALLATION 1. The power supply (v, ph, and Hz) must correspond to General that specified on unit rating plate. Allow the following clearances for service access and 2. The electrical supply provided by the utility must be airflow: sufficient to handle load imposed by this unit. •...
  • Page 4 Fig. 1 — Dimensions – Size 150 and 180...
  • Page 5 Fig. 1 — Dimensions – Size 150 and 180 (cont)
  • Page 6 MODEL SERIES Position Number F = R-410A Fan Coil Unit A = Air Conditioning (Cooling Only) H = Heat Pump (size 180 only) 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 7 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 / Diameter (in.) 2 / 15 2 / 15 Nominal Airflow (cfm) 5000 6000 Airflow Range (cfm) 3750-6250 4500-7500...
  • Page 8 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)
  • Page 9 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...
  • Page 10 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...

  • Page 11: 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 hori- zontally.

  • Page 12: Refrigerant Piping

    Overhead Suspension Accessory with 7' 11-1/2" Hot Water Coil [2425.7] 3/8" Threaded Rod (Field-Supplied) NOTE: Dimensions in [ ] are millimeters. Fig. 5 — Preferred Suspension Technique Refrigerant Piping dimensions of the additional access holes required for FHS180 units. Recommended access hole use is also See Tables 1-4 for refrigerant pipe connection sizes.
  • Page 13 FIELD-FABRICATED HOLE DIAMETERS FIELD-FABRICATED HOLE POSITION USE HOLE in. (mm) DIMENSIONS, in. (mm) UNIT NUMBERS NO. 5 NO. 6 NO. 7 FAS150-180 1, 2, 3, 4 — — — — — — FHS180 , 5, 6, 7 1-1/8 (28.6) 1-1/8 (28.6) 1-3/4 (44.5) 3.25 (82.6) 6.125 (155.6)
  • Page 14 Table 9 — Fitting Requirements (cont) UNIT ACCESS HOLE NO. CONNECTION TYPE CIRCUIT FITTING REQUIRED (in.) 1-1/8 Nipple, 3 L Suction Lower 1-1/8 Long Radius Elbow 5/8 Nipple, 2-7/8 L 5/8 45° Elbow Suction Lower 5/8 Nipple, 1-5/8 L 5/8 Long Radius Elbow 5/8 Nipple, 2-7/8 L FHS180 5/8 45°...

  • Page 15: 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 16: Fan Motors And Drives

    Fan Motors and Drives Motor and drive packages are factory installed in all units. The motor and drive packages consist of the following items: 1 — fan motor 1 — adjustable motor pulley 1 — fan pulley 2 — matched fan belts (FAS150-180, FHS180) For instructions on changing fan rotation, changing drive speeds and adjusting drives, see “Pulley and Drive Adjust- ment”...
  • Page 17 max voltage deviation from average voltage % Voltage = 100 x Imbalance average voltage Example: Supply voltage is 230-3-60 AB = 224-v BC = 231-v AC = 226-v MOTOR Unit Control (224 + 231 + 226) Board Average Voltage = Indoor Connection Board...
  • Page 18 NOTE: On select units, the black and blue IFM wires are reversed. Fig. 14 — Unit Wiring...

  • Page 19: Three Stage Operation

    THREE STAGE OPERATION The 3-stage system will run the fan at low speed with a G, Y1, and Y1+Y2 call, and at high speed with a call for Y1, Y2, All units are factory shipped for 2-stage cooling operation. and Y3. A thermostat with 3 cooling stage capability is re- To convert a unit to 3-stage operation, see Fig.

  • Page 20: Variable Frequency Drive

    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. The VFD is controlled through a 0-10vdc signal that is provided by the Unit Control Board (UCB) in the control box.
  • Page 21 Variable Frequency Drive (VFD) Fig. 18 — ACS320 VFD Location for the following units: FAS150-180(H/L), FHS180(H/L) (208/230V and 460V only) Variable Frequency Drive (VFD) Fig. 19 — ACH580 VFD Location for the following units: FAS150-180(S), FHS180(S) (575V only)

  • Page 22: Connecting Ductwork

    Connecting Ductwork are installed, connect them to the supply duct using a can- vas connection to prevent vibration. It is important that this Figure 20 shows recommended duct connection to units connection be properly fabricated to prevent high air friction with 2 fans.

  • Page 23: Start-Up

    Duct Flanges Fig. 21 — Duct Flange Installation START-UP Before starting unit, check the following and correct as nec- 40RU500072 2.0 essary: IMPORTANT! / IMPORTANT • Is unit solidly supported? EQUALIZER LINE CONDUITE D'ÉQUILIBRAGE • Is fan adjusted for speed and pulley alignment? SENSING UPPER SPLIT SIGHT GLASS...

  • Page 24: Adjusting Txv For Superheat (Fas150-180 And Fhs180)

    Adjusting TXV for Superheat Cooling with 2-Stage Indoor Fan Motor (FAS150-180 and FHS180) FIRST STAGE (Y1) The unit-mounted thermostatic expansion valve(s) is/are Set the thermostat FAN switch to AUTO and the SYSTEM factory set to provided superheat at the bulb location in switch to COOL.

  • Page 25: Fan Speed Set Up

    To restore the unit to ready-to-start condition, disconnect the unit power and lock-out/tag-out, set the space thermostat to FAN AUTO, remove the test pressure ports from the exter- nal duct locations, and re-set Low Speed 2-Pin DIP switch- es to factory setting (refer to wiring diagram on control box cover).

  • Page 26: Quarterly Inspection

    MAINTENANCE Table 13 — Indoor Unit Maintenance Checklist These items should be part of a routine maintenance pro- gram, to be checked every month or two, until a specific RECOMMENDED MAINTENANCE CHECKLIST INTERVAL schedule for each can be identified for this installation: Indoor unit specific: (for accessories Monthly Annual...

  • Page 27: Fan Motor Lubrication

    Fan Motor Lubrication Fan Shaft Position Adjustment Fan motor supplied with unit is permanently lubricated and Loosen setscrew or locking collar of each fan shaft bear- requires no further lubrication. ing. Slide shaft into correct position and replace locking collar. (See Fig. 26.) To replace locking collar, push collar Fan Shaft Bearings up against inner face of bearing.

  • Page 28: 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 29: Pulley And Drive Adjustment

    Pulley and Drive Adjustment Table 18 — Fan Motor Data, FAS Standard Motor, Two Speed — SI To obtain desired fan speed, refer to the fan motor, drive data and performance data in Tables 15-36 and adjust fan UNIT FAS150 FAS180 motor pulley as follows: 208/230-3-60 and 460-3-60...
  • Page 30 Table 22 — Motor Efficiency FHS — Table 26 — Medium-Static Drive Data, 60 Hz — Two-Speed Motor English MOTOR EFFICIENCY FAS180/ MOTOR HP EPACT MINIMUM (%) UNIT FAS150 FHS180 — 82.0 MOTOR DRIVE — 80.0 Motor Pulley Pitch Diameter (in.) 3.4-4.4 3.7-4.7 —...
  • Page 31 Table 29 — Medium-Static Drive Data, 60 Hz — SI Table 30 — High-Static Drive Data, 60 Hz — SI FAS180/ FAS180/ UNIT FAS150 UNIT FAS150 FHS180 FHS180 MOTOR DRIVE MOTOR DRIVE Motor Pulley Pitch Diameter (mm) 94.0-119.4 109.2-134-.6 Motor Pulley Pitch Diameter (mm) 86.4-111.8 94.0-119.4 Pulley Factory Setting Full Turns...
  • Page 32 Table 33 — Fan Performance Data — FAS/FHS 0-300 kPa ESP, 60 Hz — SI a,b,c EXTERNAL STATIC PRESSURE (Pa) AIRFLOW UNIT (L/s) 1770 6.84 0.32 7.78 0.41 9.46 0.62 10.82 0.83 12.02 1.05 13.13 1.28 14.19 1.53 2030 7.58 0.46 8.40 0.55...

  • Page 33: Variable Frequency Drive

    Variable Frequency Drive Table 38 — ACH580 VFD Terminal Designations The VFD switches the indoor fan motor speed between TERMINAL FUNCTION full/high speed (60 Hz motor operation) and reduced/low speed (40 Hz motor operation), as required by ASHRAE Three-Phase main circuit input power supply 90.1-2016 and IECC-2015 requirements for two-stage HVAC units.

  • Page 34: 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 35: Vfd Remote Keypad

    VFD REMOTE KEYPAD START UP WITH ASSISTANT Initial start-up has been performed at the factory. Use of the NOTE: The following only applies when a unit with the start up assistant will override factory VFD configurations. factory-installed 2-Speed Indoor Fan Motor System option is equipped with the field-installed Remote VFD Keypad (Part Number: CRDISKKIT001A00) ACS320 or (Part CAUTION...

  • Page 36: Parameters Mode

    7. Choose another parameter or press EXIT (SOFT KEY 1) to return to the listing of parameter groups. 60.0Hz Continue until all the parameters have been config- 100.0 %SP ured and then press EXIT (SOFT KEY 1) to return to the main menu.

  • Page 37: Clock Set Mode

    Download All Parameters 5. Use the UP or DOWN keys to highlight TIME FOR- MAT and press SEL (SOFT KEY 2). Use the UP or To download all parameters from the control panel to the DOWN keys to change the parameter setting. Press VFD, perform the following procedure: OK (SOFT KEY 2) to save the configuration and 1.

  • Page 38: Alarms (Green Led Flashing)

    ALARMS (GREEN LED FLASHING) the power for 5 minutes. Depending on the value of parame- ter 1604 (FAULT RESET SELECT), digital input or serial For less severe errors, called alarms, the diagnostic display communication could also be used to reset the drive. When is advisory.
  • Page 39 Table 41 — ACS320 Fault Codes FAULT FAULT NAME IN PANEL DESCRIPTION AND RECOMMENDED CORRECTIVE ACTION CODE Output current is excessive. Check for excessive motor load, insufficient acceleration time (parameters 2202 ACCELER OVERCURRENT TIME 1, default 30 seconds), or faulty motor, motor cables or connections. Intermediate circuit DC voltage is excessive.

  • Page 40: Reset After Using Start-Up Assistant

    Table 41 — ACS320 Fault Codes (cont) FAULT FAULT NAME IN PANEL DESCRIPTION AND RECOMMENDED CORRECTIVE ACTION CODE Parameter values for power control are inconsistent: Improper motor nominal kVA or motor nominal power. Check the following parameters: 1005 PAR PCU 2 1.1 <...

  • Page 41: Ach580 Operation With Remote Keypad

    ACH580 Operation with Remote Keypad FIRST START ASSISTANT The VFD keypad is shown in Fig. 35 and 36. The functions Initial start-up has been performed at the factory. Use of the of the Left and Right Softkeys ( ) change de- start up assistant will override factory VFD configurations.

  • Page 42: Start Up By Changing Parameters

    START UP BY CHANGING PARAMETERS The bottom corners of the LCD display show the functions currently assigned to the two soft keys. The lower middle INDIVIDUALLY displays the current time (if configured to show the time). Initial start-up is performed at the factory. To start up the The first time the drive is powered up, it is in the OFF VFD by changing individual parameters, perform the follow- mode.

  • Page 43: Parameters Mode

    PARAMETERS MODE Upload All Parameters To upload and store parameters in the control panel from The Parameters mode is used to change the parameters the VFD insert the Keypad into the VFD slot (Fig. 39) and on the drive. To change parameters, perform the following animation will appear loading the VFD configuration.

  • Page 44: Clock Set Mode

    CLOCK SET MODE ACH580 VFD Diagnostics Use the clock set mode to set the date and time for the in- The drive detects error situations and reports them using: ternal clock of the VFD. In order to use the timer functions of •...
  • Page 45 Table 42 — Fault and Alarm Codes for ACH580 VFD CODE (HEX) WARNING / AUX. CODE CAUSE WHAT TO DO Check motor load. Check acceleration times in parameter group 23 Speed reference ramp (speed control) or 28 Frequency reference chain (frequency control).
  • Page 46 Table 42 — Fault and Alarm Codes for ACH580 VFD (cont) CODE (HEX) WARNING / AUX. CODE CAUSE WHAT TO DO The start delay is active and the Check that it is safe to continue operation. Then return AFE9 Start delay drive will start the motor after a emergency stop push button to normal position.

  • Page 47: Vfd Maintenance

    VFD MAINTENANCE If installed in an appropriate environment, the VFD requires very little maintenance. Table 43 lists the recommended routine maintenance intervals. Table 43 — Maintenance Intervals MAINTENANCE INTERVAL Every 6 to 12 months Heat sink temperature check (depending on the dustiness of and cleaning the environment) Remote keypad battery change Every ten years...
  • Page 48 Fig. 42 — Remove Main Fan Fingerguard Fig. 44 — Open Keypad Cover and Remove Keypad Fig. 43 — Remove Main Fan ACH580 AUXILIARY COOLING FAN REPLACEMENT To replace the internal enclosure fan for frame sizes R1 and R2 perform the following (see Fig. 44, 45, and 46): 1.
  • Page 49 Fig. 47 — Remove Fan Holder and Free Fan Cable 5. Disconnect the fan cable. The fan cable connector is located on the control board that is against the front Fig. 46 — Remove Auxiliary Fan of the drive. ACS320 FAN REPLACEMENT 6.

  • Page 50: Coil Removal

    Bypass the VFD IMPORTANT: It is recommended NOT to bypass the WARNING ACH580 VFD on FAS/FHS 575-3-60 units. Bypassing the VFD is not recommended. This is a Condensate Drains temporary procedure to provide cooling or heating operation when a new VFD is required. When in this Keep condensate drains free of dirt and foreign matter.

  • Page 51: 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. 50). 3.

  • Page 52: Appendix A - Vfd Parameters

    APPENDIX A — VFD PARAMETERS Table A — ACS320 Common Parameters Table B — ACH580 VFD Common Parameters PARAMETERS DESCRIPTION SETTING ACS320 PARAMETERS DESCRIPTION SETTING ACH580 1001 EXT1 Commands 10.30 Relay out 3 (15) FAULT (–1) 1102 EXT1/EXT2 Sel EXT1 12.17 Minimum AI1 0.2V...
  • Page 53 APPENDIX A — VFD PARAMETERS (cont) Table C — ACS320 VFD Parameters, for FAS/FHS Units with Electromechanical Controls VFD PARAMETERS PKG ABB ACS320 MOTOR PART NUMBER VFD PART NUMBER DRIVE HP DESC 40RU000130-DATA 40RU000130 HD56FR233 HK30WA523 40RU 1.7 HP 230V 40RU000131-DATA 40RU000131 HD56FR463...

  • Page 54: Replaces: Fasfhs150-180-01Si

    4kHz (1) AUTO (1) Coast Not Sel 30 sec 10.0 sec © 2024 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Form No. FASFHS150-180-02SI Pg 54 2-24...

  • Page 55: Start-Up Checklist

    START-UP CHECKLIST Split Systems with FAS/FHS Units (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 Check the compressor oil level sight glasses: are the sight glasses showing oil level at 1/8 to 1/3 full? (Y/N)___________ NOTES: ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ © 2024 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Form No. FASFHS150-180-02SI Pg CL-2 2-24 Replaces: FASFHS150-180-01SI...

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