40LC-006SDR (3BL5-10-000) /38LH-066SDR (2AL5-50-000)

AIR COOLED DUCTED AIR CONDITIONER

Nominal cooling capacity 5.5 TR

Installation, Start-Up and Service Instruction

INDEX

Contents P. No.

Safety considerations 2

Introduction 2

General description 2

Installation 2-12

Pre start up 12-16

Start up and operation 17-26

Service and maintenance 26-39

Warranty 40-41

Tables and Figures

Table: Technical data 4-5

Figures: Mounting details 6-7

Table: Ducting specifications 9

Table: Selection chart for grilles/diffusers 10

Figures: Wiring diagram 16

Figure: Control Box details 25-26

Exploded views & Spare part list 31-32

Table: Troubleshooting chart 33-36

Table: Start-up checklist 37

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SAFETY CONSIDERATIONS

Installation, start-up and servicing of the equipment can be hazardous due to system pressures, electrical
components and locations of equipment (roofs etc.).

Only trained, qualified installers and service mechanics should install start-up and service this equipment.
Trained service personnel should perform all operations except basic maintenance.

When working on the equipment, follow all safety codes. Use proper tools, tackles and necessary
instruments. Use safety glasses, gloves, boots, valves and regulators etc. Be sure power to the equipment
is off before performing maintenance or service.

INTRODUCTION

These instructions cover installation, start-up and service of 40LC-006SDR/38LH-066SDR Air Cooled
DUCTED air-conditioning units.

GENERAL DESCRIPTION

The Air Cooled DUCTED system is composed of two units, one installed outside and the other inside,
which are interconnected after positioning. The outdoor unit is the condensing unit incorporating
condenser coil, fan and fan motor & Scroll compressor, Electrical panel. where as indoor unit contains
filter drier, evaporator coil, expansion valve, distributor, air filter, blower & blower motor & Handset
controller.

INSTALLATION
PRE-DELIVERY INSPECTION

This applies to the condensing and indoor units both.

1. Open packing carefully ensuring unit in upright position.

2. Check the unit thoroughly for dents, paint discrepancies, fins damage, pinching of tubes etc. Check
coil / copper tubes for any dents, pinching or cuts, especially near tube sheets. Ensure all parts /
components, electrical wiring and connections are visibly in order.

3. Rotate fan / blower for any bearing or touching noise.

4. Check and test fans / blower as per the rated supply for Indoor and Outdoor if possible.

5. Check coil and piping for leaks.

6. If any damage is found, rectify / take the necessary action and repack the unit in upright position.

RIGGING

These units are designed to be handled by forklift trucks. Use the unit skid for placing on the forks of the
lift-truck.

PLACEMENT
Out door Units are shipped mounted on wooden members & Indoor unit packed in carton box. These
should be removed only when the unit is in its final position.
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The unit may be lifted, dragged or rolled into place while the wooden supports are still in place. When
rolling, use a minimum of three rollers and pull / push the wooden members not the unit frame.

Once the unit is in place, lift and remove pad or roller, unbolt wooden supports and lower to ground.

LOCATION AND MOUNTING

A. CONDENSING UNIT

Location

Locate the unit so that airflow through the condenser coil is unrestricted. Provide clearance for wiring and
piping. There should be ample space for service requirements.
Install the outdoor unit in well-ventilated space. Avoid wet locations to prevent water entry. The unit should
be placed preferably in shaded areas, and places exposed to direct sunlight should be avoided.
The unit should be installed in a location so as to minimize refrigerant and drain pipe length.

Mounting

The unit should be mounted to prevent corrosion of sheet steel base on

(a) Prefabricated angle iron frame, or

(b) 3 raised concrete platform.

These should be designed to take care of vibratory operating loads.

Placement area must be level and strong enough to support operating weight of the unit. Check that the
unit is mounted level to ensure proper oil return to compressor.

Units mounted on walls must be provided with a platform having space for service (if otherwise not easily
accessible for service).

B) INDOOR UNIT

Location
These units are designed specially for applications where piping is fully concealed.

Locate unit ensuring adequate space for supply / return air, service purposes and connections.

The location of the unit should be such that there is no ingress of fresh air as this would cause
condensation / sweating. Location should be near a drain point for easy drainage, and in a location to
simplify refrigerant piping.
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! " # $
$
MODEL No (INDDOR / OUTDOOR) 40LC006SDR/ 38LH066S DR
TR 5.5
BTU/HR 66000
NOMINAL REFRIGERATION CAPACITY Kcal/hr 16500
RATED POWER CONSUMPTION Kw H/Hr 5.6
RATED POWER SUPPLY Volts/Hz/Ph 400 +/-10% / 50 / 3
INDOOR UNIT
OVERALL SIZE (Width x Length x Height) mm 750x1250x345
NET WEIGHT kg 62
CASING MATERIAL duly phosphate for increased
CASING

CASING THICKNESS mm 1.0/1.2

THERMAL INSULATION (Type / Thickness) mm Polyethylene (6.0 / 12.0 mm Thick)
TYPE Air-cooled
FACE AREA sft 4.46
FACE VELOCITY m/sec 2.51
CMH 3740
AIR FLOW RATE CFM 2200
No OF ROWS Nos. 3
No OF CIRCUITS / COIL Nos. 8
EVAPORATOR

FIN SPACING FPI 16

TUBE SIZE (OD / Thickness) Inches 3/8" / .011"
TUBE (Material / Type) Copper / Internally Grooved
FIN (Material / Thickness) mm Aluminium / 0.11 mm
EXPANSION VALVE ( Sporlan-BBIVE-5 )
MAKE
TYPE Double inlet double w idth
TYPE OF DISCHARGE Front
No of impellers on same shaft 2
Total No of impeller 2
IMPELLER SIZE (Diameter / Width) Inches 8"x10"
EVAPORATOR FAN

AIR FLOW RATE CMH 3740

STATIC PRESSURE mm of WG 15
VELOCITY PRESSURE mm of WG 5
TOTAL PRESSURE mm of WG 20
AIR MOVING UNIT ASSEMBLY

OUTLET BLOWER VELOCITY m/sec 9.8

FAN SPEED RPM 1350
RATED POWER CONSUMPTION Kw H/Hr 0.49
DRIVE (Type) Direct
MATERIAL OF CONSTRUCTION(Housing ) G.I
IMPELLER Aluminum
SOUND PRESSURE LEVEL dB(A) 71
FAN MOTOR (Make) PSC / M/s GE/CG/PICL
FAN MOTOR (Type / Qty) Single phase / one
FAN MOTOR (Rating / Speed) KW / RPM 0.560/1350
INSULATION CLASS Class B
ELECT

RATED POWER CONSUM. / EVAPORATOR Kw H/Hr 0.49

RATED POWER SUPPLY VoltS/Hz/Ph 230 / 50 / 1
QUANTITY Nos. 1
MEDIA Non Wooven Synthetic Fibre
EFFICIENCY / SIZE 90% & 10 microns
CASING MATERIAL G.I
FILTER

OVERALL SIZE mm 1160x285x10

FACE AREA sft 3.55
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OVERALL SIZE (Width x Length x height) mm 410x1040x875

NET WEIGHT Kg 112
CASING MATERIAL GI
CASING

CASING THICKNESS mm 1.0/1.2mm

TYPE Floor
COMPRESSOR TYPE Type Scroll
MAKE Copeland
COMPRESSOR

MODEL ZR72KC-TFD
REFRIGERANT R-22
No OF CIRCUIT / UNIT 1
No OF COMPRESSORS / UNIT 1
RATED POWER SUPPLY VoltS/Hz/Ph 400 +/-10% / 50 / 3
TYPE
FACE AREA sft 11.15
FACE VELOCITY m/sec 1.94
CMH 7225
AIR FLOW RATE CFM 4250
Nos OF ROWS Nos. 2
Nos OF CIRCUIT / COIL Nos. 4
MOVIN CONDENSER

FIN SPACING FPI 18

TUBE SIZE (OD / Thickness) inches 3/8" & 0.011"
TUBE (Material / Type) Internally Grooved
FIN (Material / Thickness) Aluminium & 0.11mm
FAN (Type / Make) Centrifugal & M/sBlow tech
G UNIT

FAN (Size & Qty/Condenser) mm / nos. 610/1

AIR

SOUND PRESSURE LEVEL dB(A) 75.0 at 1mtr.

RATED POWER SUPPLY VoltS/Hz/Ph 230 +/-10% / 50 / 1
ELECT

FAN MOTOR (Rating / Speed) KW / RPM .37/930

RATED POWER CONSUMPTION / CONDENSER Kw H/Hr 0.37
%
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5.5 TR ODU BASE CHANNEL DIMENSIONS

5.5 TR ODU OUTER DIMENSIONS

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Unit Mounting dimensions

5.5 IDU OUTER DIMENSIONS

Duct opening domensions

5.5 DUCT GUIDE DIMENSION

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Air distribution

Install the air distribution system complete with ductwork, supply and return air grilles / diffusers, etc.
following recommended good practice.

Connect the supply air duct with double canvas cloth at the mouth of the unit for eliminating vibrations
and duct alignment problems, and as per recommended ducting practice.

I. Ducting system design

Design of ducts for normal applications may be done using the equal friction method. The method
employs the same friction loss per foot of length for the entire system. The procedure is outlined
below:

1) Sketch the air distribution layout complete with duct run lengths, location of supply registers and
return grilles, air quantities through each outlet and in each circuit, & fan location and static.

2) Knowing initial velocity and air quantity (CFM) of the machine, find friction rate using a Friction
Chart.

3) Select equivalent round duct area corresponding to this point from the Friction Chart. Use the
following relation to obtain rectangular duct dimensions.
[By substituting D, and a value of a or b in the relation to find the value of other side (depth /
width of duct)].

Equivalent Diameter -
D = 1.3 x (a x b) 0.623 / (a + b) 0.23

4) To determine the total friction loss the fan must overcome; calculate total equivalent length of the
circuit run having the longest length plus fittings equivalent length (largest friction drop). TOTAL
EQUIVALENT LENGTH may be roughly assumed as CIRCUIT STRAIGHT LENGTH + 50% OF
STRAIGHT LENGTH.

Find total pressure loss using the following relation:

TOTAL PRESSURE LOSS = TOTAL EQUIVALENT LENGTH X FRICTION RATE/100

5) Total pressures loss calculated must be less than fan static. If not, select a different initial velocity
and repeat from step 2.

6) Now, for each circuit part or air outlet, find out equivalent round duct area and rectangular duct
dimensions using Friction Chart and the relation given in step 4. Use a constant value of friction
rate (from step 3), and air quantity through the duct length (= original CFM - CFM delivered
through the outlet) to enter in Friction Chart to find duct dimensions.

II. Fabrication and installation of ducting

Refer Table 1 for ducting specifications for ducts of different sizes. Follow recommended ducting
principles.

All the angles iron flanges should be welded electrically and holes drilled. All the angle iron flanges
should be connected to the GSS duct by rivets at 4 centers.

All the flanged joints should have thick felt / foam gasket or sealed with silicon sealant. Felt should
be stuck with varnish and the hole in packing should be burnt through.
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The GSS duct should be lapped across the flange.

The duct should be supported by supports at a distance not exceeding 8 Feet. 24-G duct should be
supported by MS rod with 1 x 3/16 angle on which the ducts will be rested. felt / foam should
be provided between the duct bottom and support face of the angle. All support rods and angles should
be painted with red oxide primer.

For all branches, guide vanes / splitters / dampers should be provided. Provide straightening vanes for
collars and smooth bends. Interconnection of ducts between two units should have individual dampers
of opposed blades / sliding type.

Provide acoustic lining for the first 5 feet of ducting after fan outlet with 12 mm fiberglass rigid board
with RP tissue paper / 26 G perforated aluminum sheets.

In case plenums are used, the velocity in plenum should not exceed 300 FPM and the plenum should
be lined for acoustic purpose. If two branches are to be taken from the same plenum, the same should
be provided with dampers. These should be taken on the same side but opposite to the incoming duct
connection.

Provide for suitable fresh air arrangement.

Provide a straight duct length of at least 2D after the fan outlet for streamlining airflow; D is the
equivalent round duct diameter. This is VERY IMPORTANT.

III. Return and supply air grille sizing

Return air at the inlet of the indoor unit should not exceed 300 FPM. Return air path should be
designed for a maximum velocity of 1000 FPM.

Supply air grilles / diffusers should be sized as per manufacturers specification. A quick selection chart
for the purpose is given in Table 2.

TABLE 1 : DUCTING SPECIFICATIONS

S.NO. Maximum side Thickness (G) Type of connection Bracing

(for GSS duct)

1. UPTO 30" 24 24BG GSS flanges / Cross bracing

1 1/4"x3/16" angle iron
2. 32" to 40" 22 Flanges with 1/4" GI bolts &
Nuts at 5" center or slip joint

3. 41" to 60" 22 1 1/4"x3/16" angle iron Cross bracing

Flanges with 5/16" GI bolts &
Nuts at 5" centers.

4. 61" to 90" 20 1 1/2"x3/16" angle iron Diagonally with 1 "x1/8"

Flanges with 3/8" GI bolts & angle iron if the piece is more
Nuts at 5" centers. than 4'long.

5. 91" and above 18 2"x1/4" angle iron Diagonally with 1 "x1/8"

Flanges with 3/8" GI bolts & angle iron if the piece is more
Nuts at 5" centers. than 4'long.

NOTE: IF SHEET METAL USED IS ALUMINIUM, USE ONE GAUGE HIGHER.

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TABLE 2 : QUICK SELECTION CHART FOR GRILLES/DIFFUSERS

S.NO. Description Size CFM Throw

(feet)
1. Round Type/square 12" dia. or square 300 7
type (Flat type)
15" dia. or square 450 9
(Terminal velocity
100FPM and jet 18" dia. or square 750 11
velocity 1250 FPM)
21" dia. or square 1050 13

2. Double deflection 20"x6" 270 16

type grilles
24"x6" 325 18
(Outlet velocity 500
FPM straight vane 30"x6" 400 19
type)
36"x6" 500 19

24"x8" 480 26

30"x8" 580 27

36"x8" 700 27

24"x10" 600 30

30"x10" 750 32

36"x10" 900 33

24"x12" 740 25

30"x12" 925 31

36"x12" 1115 39

Refrigerant Piping

Piping

Since in the Unit Both Compressor & Suction Line are in outdoor. It fully complies general guideline of
Suction line.The cross-section of horizontal suction lines shall be such that the resulting gas velocity is at
least 4 m/s. Suction lines are insulated to limit suction gas superheat.

Indoor & Outdoor Unit are connected by Suction & Liquid Line Piping. Special Attention is required to
insulate Suction line whose temperature remain 5-20 deg. It is required to do insulation of proper grade
& thickness .

Do not run any Wiring with Suction or Liquid line.

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Routing

Liquid line (1/2) is suitable for flare connection & Suction line (7/8) is suitable for brazed connection.
Adaptors are given on Suction line & Discharge line in outdoor Unit for refrigerant charging and
evacuation operations. Flare connections are provided because they allow easy connection /
disconnection / reuse without additional piping / brazing work.

Indoor units have connection suitable for brazing in suction line and quick lock valve in liquid line.
Start refrigerant piping from outdoor unit first and connect indoor unit last. Run the piping along walls /
floors or on wooden beading with saddle / clamps and boxed up for protection. Clamp and run pipes
neatly and straight using unlamented good copper tubing. Recommended copper tubes sizes are for
liquid line and 7/8 for suction line (standard piping lengths).

The pipes should run as straight as possible, avoiding unnecessary turns and bends. The piping length
between indoor & outdoor unit should not exceed 24 feet and number of bends should be adhered to the
possible extent. In case if the piping length exceeds 24 feet, contact Carrier Air conditioning &
Refrigeration Limited for other length, pipe sizes and extra refrigerant charge for extra pipe length. If
brazing is done to connect two tube lengths, it should be carried out using proper flux and brazing rod
(7.25% Phosphorus, rest copper) with a constant purge of nitrogen through the piping to maintain a clear
system.

All connections must be leak tight.

Compressor oil

Oil in a refrigeration circuit is required to lubricate moving parts in the compressor. During normal
system operation small oil quantities will continuously leave the compressor, with the discharge gas.
With good system piping design this oil will return to the compressor. As long as the amount of oil
circulating through the system is small it will contribute to good system operation and improved heat
transfer efficiency.

However, too large amounts of oil in the system will have a negative effect on condenser and evaporator
efficiency. If, in a poorly designed system, the amount of oil returning to the compressor is lower than
the amount of oil leaving the compressor, the compressor will become starved of oil and the condenser,
evaporator and / or refrigerant lines will become filled with oil. In such situations, additional oil charge
will only correct the compressor oil level for a limited period of time and increase the amount of surplus
oil in the rest of the system.

Only correct piping design can ensure a good oil balance in the system.

The main difference in the scroll compressor regarding oil is the higher oil carry rate which is around 0.6
to 1% compare to 0.3 to 0.5% on reciprocating compressors.

Up to 20 meters of equivalent pipe length no oil addition is required, assuming that piping design ensure
good oil return to the compressor at minimum load (minimum refrigerant mass flow). For longer pipe
runs an oil addition should be needed, 1 to 2% of refrigerant charge (in weight) can be used as
approach. But in any case oil charge has to be adjusted on compressor oil level (the above percentage
does not take in consideration line accessories such as oil separators, oil traps etc.).
The recommended way to maintain the oil level in the compressor having oil sight glass is to see the
compressor oil sight glass during running after stabilized condition & adjust the oil level above 1/3rd in
sight glass.
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Clamping

Clamping is necessary to prevent vibrations from being transmitted. When passing the pipes through
walls, opening should be sealed to minimize vibration transmission. Some slack in pipes between
structure & unit should be left.

Insulation

Insulate Suction & liquid line properly. This is necessary safety. Use tubular foam of ID for liquid
line and 7/8 for Suction line.

CONDENSATE DRAIN PIPING

Install condensate drain pipe, with a U-trap of minimum height 16 mm at its end, in the indoor unit.

The pipe should be PVC Braided pipe 16 mm diameters.

The pipe should slope downwards. There should not be unnecessary bends or kinking in the connection
pipes. Horizontal T-joints in the pipe are not permitted, prefer vertical T-joints. Keep the pipe length
minimum.

Insulate the condensate drainpipe wherever required especially the portion within the room.

FIELD ELECTRICAL CONNECTIONS

Do the field wiring as per wiring diagram. Never bypass any electrical protections provided in the unit.

1. Recommended wire size for main power supply cable is 4 core 6 mm2 Copper.
2. Recommended wire size for compressor from main electrical panel is 3 core 4 mm2 copper.
3. Recommended wire size for all control wiring is 1.5 mm2

Unbalanced 3-phase supply voltage

Never operate unit when supply voltage unbalance is more than 2%.
% Voltage unbalance = (Max. voltage deviation from avg. voltage) / (avg. voltage) x 100

PRE-START UP

Outdoor unit is factory charge with R-22 Refrigerant (Charging Amount-4.9 Kg.)

PRE-PRESSURE TEST

Carry out a pressure test of the Indoor unit and interconnecting pipes at 300 PSIG by using dry nitrogen
through the adaptor which is being placed on the suction pipe. Hold this pressure for sometime to
ensure that there is no leakage in the system.
However, in case of leaks in the refrigerant circuit or breaking of joints etc., the valves have to be back
seated and the entire system of indoor and outdoor units with piping has to be pressure tested,
evacuated and charged.

After pressurizing the system, do the following:

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SOAP TEST
Apply soap solution at all flare connections and brazing point. If bubbles appear at some points, then
tighten the flare nut or braze the leaking points (after releasing the gas from the system). No bubbles
should finally appear.

PRESSURE DECAY TEST

After soap test, note the pressure and leave the system pressurized for 30 minutes. Note the pressure
again. There should be no pressure decay, recheck for leaks, remove them and do the pressure decay
test again.

EVACUATION

1600
1400 Leakage
Pressure in microns

1200
1000
Humidity
800
600
400 500 microns of Hg
Tight & dry
200
0
0 10 20 30 40 50 60 70 80
Time in minutes

Vacuum pump down and dehydration procedure

Moisture obstructs the proper functioning of the compressor and the refrigeration system. Air and
moisture reduce service life and increase condensing pressure.They also cause excessively high
discharge pressure and temperature, which can destroy the lubricating properties of the oil. Air and
moisture also increase the risk of acid formation, giving rise to copper plating and motor insulation
damage. All these phenomena can cause mechanical and electrical compressor failure. To eliminate
these factors, a vacuum pump down according to the procedure below is recommended.

Procedure

It is essential to connect the vacuum pump to both the liquid and suction valves in order to avoid dead-
ending parts of the system.

1) After the leak detection

2) Pull down the refrigeration circuit to a vacuum of 46 microns of Hg
3) When a vacuum level of 46 microns of Hg is reached, the circuit must be isolated from the pump.
4) Wait for 30 minutes.
5) If the pressure rapidly increases, then the circuit is not leak tight. Locate and repair leaks.
Restart from step 1.
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If the pressure slowly increases, then the circuit contains moisture. Break should be reached and
maintained lower than 700 microns for 1-hour minimum. It will guarantee that the circuit is both tight
and fully dehydrated. This pressure shall be measured at the refrigeration system, not at the vacuum
pump gauge.

Vacuum pump

A two-stage vacuum pump with gas ballast (0.04 mbar standing vacuum) shall be used with a capacity
consistent with the system volume. It is recommended to use connecting hoses with a large diameter to
avoid excessive pressure losses.

Warning

Do not use a manometer or apply power to the compressor while it is under vacuum. This may cause
motor winding damage. Never run the compressor under vacuum as it may cause compressor motor
burnout.

Note: - You are requested to use Electronic Vacuum Gauge.

OPENING OF VALVES / CHARGING

Open (backseat) the suction and liquid valve to allow refrigerant to flow through the system. The unit is
ready to be test started.

In case a leak has occurred the refrigerant system has to be repaired, pressure tested and evacuated,
recharging of R-22 will have to be done. For this, connect the refrigerant cylinder to the suction valve
and the gauge manifold to the liquid valve. Make sure to purge air from charging line prior to tightening
the connections.

Connect the cylinder to allow vapor refrigerant to flow.

Open the all shut-off valves and charge the correct amount of refrigerant through adaptor on suction
line as per any of the following indicators:

a) Charge the correct amount of refrigerant by maintaining superheat of 10 deg at Suction line.

b) Charge Amount by Weighting Machine

Refrigerant Charge
Amount
5.5TR 4.9 Kg Per Circuit

Please Charge extra refrigerant if Piping exceeds 13 mt. as follows.

Extra Refrigerant
Charge Amount per
meter
5.5TR 20 gms

Do not charge using the indication of sweating suction line or by only measuring the amperes drawn by
the machine as these may lead to incorrect charge amount along with the associated problems.
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Charging by weight should be done as far as possible, as charging i.e. one of the most important factors
governing system performance. Purging of air before tightening connections is necessary.

CHECK PRIOR TO START-UP

Do not attempt to start the unit following steps have been completed:

1. Check that unit is properly located and mounted.

2. Check that piping has been done as per the recommended practice.
3. Check that the insulation is adequately sized and properly applied on the piping.

4. Check that condensate drain pipe has been properly installed and insulated.

5. Be sure there are no refrigerant leaks.

6. Check the refrigerant standing pressure with a pressure gauge connected on the liquid valve gauge
port. Check if the charge is complete with R-22 charged.

7. Check tightness of all electrical connections.

8. Check the protective device (MCB or fuse switch) from which the supply is given to the unit. The
recommended rating of the protective device is 32A.

9. Electrical power supply must agree with unit nameplate rating. Check that field wiring electrical
switches and voltage stabilizers (in the case of low voltage power supply) are properly sized for the
unit. Check and ensure that 3-phase voltage unbalance is less than 2%.
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ELECTRICAL WIRING DIAGRAM FOR 5.5TR

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START-UP AND OPERATION

Actual start-up / full-fledged testing should be done only under supervision of a qualified person.

1. Make main power connections. If reverse phase indication is there on the Display Panel, then
interchange two of the phases. Make sure display panel shows healthy supply.

2. Switch on the ON/OFF switch of the controls; the unit will start on its previous setting.

3. In this Wiring HP& LP are in series when either of two is removed wire from the electrical panel.
Compressor, Evaporator Blower fan will go off simultaneously. & Display Panel will show HP/LP.
Please check to ensure its HP and LP working.

4. Run unit according to Remote Control features as described.

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REMOTE CONTROL

BUTTONS:
1. Graphical LCD with backlight.
2. Multi Functional Key.
3. UP Key.
4. ON/OFF key.
5. Down key.
6. Multi function key.
7. Left shift key.
8. Reset key.
9. Right shift key.
10. Slide able Top cover.

Display:

It is a graphical LCD with backlight, which displays all features of the product.

Function Keys:

1) Multi Function Key (2) & (6) : Press these keys according to the function displayed on LCD screen
at respective keys.

2) UP key (3): Press this key to scroll up the screen/cursor to select or view previous item.

3.) On/Off Key (4): Press this key to switch ON / OFF the product.

4.) Down Key (5): Press this key to scroll down the screen/cursor to select or view next item.

5.) Left Shift Key (7) : Press this key to shift cursor to the left.

6.) Reset Key (8): Press this key to reset all the settings.

7.) Right Shift Key (9): Press this key to shift cursor to the right.
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22
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ELECTRICAL PANEL (CDU 5.5TR REFRESH DUCTED

SCANNER

CONTACTOR

COMPRESSOR
WIRE

CONNECTORS
MCB
GROUND
INCOMING
SUPPLY
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Part Quantity Make

Gasket 01 PVC
Rubber Grommet 01 -
Wire Assembly Compressor 01 1 wire, 3 core- 6 mm2
Sticker earth sign 01 -
Ground terminal block 5 way with pin type 01 -
lug
Screw Self tapping 10 -
Label Connection 01 P.V.C. thk.-0.2+/- 0.02 mm
Terminal block mounting 01
End plate(4 nos) & Stopper (6 nos) 6mm2 10 Elmex / Connectwell
Terminal Block side entry 6 mm2 11 -
Wire Assembly Scanner 01 -
MTG. Plate scanner 01 -
Scanner 01 Minilec
Contactor MTG. 01 -
MCB-32A TPN 01 GE / Protec / Schneider
Contactor-MNX-25/3TR 33 AC 3 , 25 A 01 L&T / Siemens
Control Box 01 -

SERVICE AND MAINTENANCE

SAFETY CONSIDERATIONS

Turn off all power supply going to unit before servicing. Use field disconnections. Make sure that there
are no parts rotating and that discharge and liquid lines are cool.

GENERAL MAINTENANCE

1. Keep the unit and area around the unit clean.

2. Check the tightness of all bolts; nuts and screws correctly fastened hardware prevents damaging
vibration and eliminated leaks.

3. Ensure all insulations etc. are in place and in good condition.

4. Check protective devices are functional at setting. Check main switches and fuses. Tighten all
terminal connections.

5. From time to time, check that line voltage and phase unbalance is within specified limits.

6. Ensure mounting arrangement and base pan is intact and aesthetically & neatly installed.

CONDENSER AND EVAPORATOR COIL

Cleaning of coil is of utmost essence and should never be neglected. Cleaning of coils should
necessarily be done annually at the time of overhaul / shutdown, or more often depending on working
conditions.
Clean condenser / evaporator fins with a soft brush. If required, blow from inside with compressed air,
taking care not to damage fins. If the fins are dirty, clean using water or solvent. Protect amply the
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electrical connections while chemical or water cleaning. However, use of water or solvent for cleaning
should be avoided as far as possible.

For assessing condenser coil for cleaning:

1. Turn off unit power supply.

2. Disconnect the connections of fan motor from control box.

3. Unscrew and remove Fan deck panel.

4. Clean the coil. After cleaning the coil, reassemble the unit.

For accessing evaporator coil for cleaning:

1. Turn off unit power supply.

2. Remove Air filter.

3. Clean the coil and after cleaning; reassemble the unit.

AIR FILTER

Turn off the unit power supply.

Lift the straps of filter and pull it to remove. Put the filter on the floor to release dust, use vacuum
cleaner to suck-in-dust, and wash the filter under tap. Dry the filter. Reinstall the filter.

Cleaning of air filter in indoor units is to be done after every 100/150 hours of use for normal working
environment. More frequent cleaning may be required depending on the working environment.

Filter replacement once every year may be required, for, a normal environment. Never allow the unit to
function with torn or clogged filters.

Selection of filter media is very critical and it is recommended that filter be purchased only from Carrier
Air-conditioning & refrigeration Limited.

FAN MOTOR MAINTENANCE (OUTDOOR UNIT)

Condenser Fan motor replacement:

1. Turn off unit power supply.

2. Remove the electrical connections of fan motor from control box.

3. Open the fan grill.

4. Loosen grub screw with Allen key on motor shaft and remove the fan carefully. Fan blade unbalance
affects the product performance.

5. Remove motor from the mounting bracket and replace the motor.

6. Reassemble the unit.

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BLOWER / BLOWER MOTOR MAINTENANCE (INDOOR UNIT)

For Blower motor replacement:

1. Turn off unit power supply and remove electrical connections.

2. Remove bottom panel Screws Safely.

3. Remove the nuts from service panel, safely handle the service panel along with motor and blowers.

4. Unscrew the housings from service panel and loose the grub screws of impellers.

5. Loose bolts from bracket and remove motor from the service panel.

6. Replace motor and reassemble the unit.

For Impeller replacement:

1. Turn off unit power supply and remove electrical connections.

2. Remove bottom panel.

3. Remove the nuts from service panel safely and handle the service panel along with motor and
blowers.

4. Remove the ventures of the housing assemble and loose the Grub screw of damaged impeller by
Ellen key then remove it safely.

5. Replace the impeller then tight the side ventures check the impeller curves direction it should be in
forward position check the rotation and positioning of the impeller. Tight the grub screws by seeing
proper alignment of the impeller.

6. Reassemble the unit.

THERMOSTAT EXPANSION VALVE

It is factory set to maintain 4.4 to 5.5 degree C superheat of vapor leaving Evaporator coil. Superheat
can be reset but this should be done only if absolutely necessary. Check that TXV bulb is properly
secured.

REPLACEMENT OF FILTER DRIER

1. Collect the refrigerant in CDU and close service valves (Suction 7/8 & liquid ).

2. Turn off indoor & outdoor unit power supply.

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3. Remove the line refrigerant from service valve cores, if high pressure is observed from valve core the
refrigerant is not collected properly in CDU and repeat the same procedure as per Sr. no.1&2

4. Open the service Window of the site.

5. Loose the flare nuts of Filter drier and replace it.

6. Reassemble the filter drier and close the service window.

LIQUID LINE SERVICE VALVE

This valve is located just after the discharge from Condenser coil, further connecting the indoor with the
outdoor.

REFRIGERANT SYSTEM

Leak testing

Quarterly check joints at valves / flare connections for leaks. In case of any leaks, repair the leak and
evacuate and dehydrate the unit before charging.
Refrigerant charge

Charging with unit off and Evacuated:

Close Liquid line service valve before charging. Weight in the specified charge. Open liquid line service
valve; start unit and allow it to run several minutes fully loaded.

Charging the unit in running condition:

If charge is to be added while unit is operating, it will be necessary to have all fans, blower and
compressor operating. Final adjustment may be done after stabilization of temperatures.

Do not overcharge, and never charge liquid into low-pressure side of system.
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ASSEMBLED VIEW OF ODU

ASSEMBLED VIEW OF IDU

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EXPLODED VIEW OF ODU

7 5 4 3 2 1

12

13

14

15

16

17
8 10
7 9 12
PART DESCRIPTION ODU

Part No. SAP Code Description Quantity

1 1508850 Condenser coil 01
2 1018420 Corner post right 01
3 1018438 Control Box 01
4 1018419 Corner post left 01
5 1018422 Fan Deck 01
6 1018424 Fan Guard 01
7 1018435 Propeller Fan 24 01
8 1018421 Service Panel 01
9 1018423 Motor Mounting Bracket 01
10 1015577 Scroll Compressor ZR-72 Copeland 01
11 1018418 Valve Plate 01
12 1018434 Motor (1/2 hp, 930 rpm) PICL 01
13 1018430 Suction line (7/8) 01
14 1018431 Discharge Line (1/2) 01
15 1018417 Base Pan 01
16 1018332 Service Valve (7/8) 01
17 1015510 Service Valve (1/2) 01
1018440 Netlon Guard 01
1002415 Rubber grommet 01
1003997 High pressure switch 01
1001587 Low pressure switch 01
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EXPLODED VIEW OF IDU

8 9 10 11 12 13 14 15 16 17

1 2 3 4 5 6 7

PART DESCRIPTION IDU

Part No. SAP Code Description Quantity

1 1018389 Fan Deck 01
2 1018391 Service Panel 01
3 1018382 Bottom Panel 01
4 1018379 Drain Pan 01
5 1018386 Side Panel Right 01
6 1018258 Filter Drier (DCL-084) 01
7 1018394 Coil Bracket Right 01
8 1018406 Blower Housing(8x10) 02
9 1018405 Impeller(8x10) 02
10 1018388 Hanger Bracket 04
11 1018392 Motor mounting bracket 01
12 1018404 Motor (3/4 hp, 1350 rpm, 1 phase) 01
13 1018384 Side Panel Left 01
14 1017843 TXV (Sporlan) 01
15 1508853 Evaporator Coil 01
16 1018393 Coil Bracket Left 01
17 1018409 Tube liquid B 01
1018396 Top panel 01
1018412 Filter 01

1017170 Remote control Assembly 01

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TABLE 4: TROUBLESHOOTING CHART

SYMPTOMS CAUSE REMEDY

MECHANICAL :

Unit not operating and Propeller fan loose on fan motor Tighten fan on shaft
Tripping Shaft

Blower loose on shaft Tighten blower on shaft

Condenser coil clogged / High Clean coil as described in

pressure switch tripping service instruction

Evaporator coil / filter clogged clean coil / filter

Fan motor shaft / bearing failure Replace shaft / motor / bearing

as applicable

Compressor seized Replace compressor

Gas leakage / low pressure switch Locate leak, rectify, pressure test
Tripping evacuate, charge

Leak back / poor pumping in Replace compressor

Compressor

Noise and vibration Fan / blower loose Tighten fan / blower

Fan motor mounting bolts loose / Tighten bolts / bracket

loose bracket

Fan motor bearing worn out Replace fan motor / bearings

Compressor mounting bolts / Tighten bolts or replace grommets

grommets loose or worn out

Connecting pipes in tension / Cut, reorient and replace pipes

Undersized

Piping vibration Support piping as required. Check

for loose pipe connectors

Overcharged refrigerant Purge out excess refrigerant

Loosening of compressor Replace compressor

Components / parts
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Compressor motor rotates in Interchange any two wires at
Backward direction Terminal

Less oil return to compressor Investigate for wrong pipe sizes

Blockage, frosted coil. Identify and
Rectify

Liquid flood back Investigate reason. Dirty coil/filter,

Less air quantity, low temperature
Setting. Check, locate and rectify.

Expansion valve hissing Add refrigerant. Check for plugged

Liquid line strainer.

Thermostat set for close differential Avoid such setting and reset for
Correct differential

ELECTRICAL

Unit not operating Incoming supply faulty

- Blown fuse Replace
- Tripped circuit breaker Check power circuit and control circuit
For ground or short, Repair circuit
Breaker
- Loose connection Tighten connection
- Low / high voltage Use proper voltage stabilizer

Loose contacts / unit wiring faulty / Tighten contacts / replace wiring /

Wire terminal loose or out of Tighten or reposition wire terminals
place

Contactor stuck open Replace contactor

Defective control box Replace control box

Compressor no continuity / high Replace compressor

Current

Fan motor speed low / motor Replace fan motor

Defective

Condenser fan tripping Fan Contactor Faulty Replace Contactor

Compressor tripped with fan Loose connections Tighten all electrical connection in
running (compressor in build wiring box & comp. Terminal
safety may tripped)
Low refrigerant charge Add refrigerant
 35

Choked filter drier Replace filter drier

Discharge valve and/or liquid valve Open it totally

may close/partially open

Partially/fully plugged expansion Clean or replace with proper charging

valve Procedure

Unit draws high current High / low voltage supply Rectify voltage using proper stabilizer

Neutral not properly connected in Rectify

incoming supply or in domestic
wiring

Wrong unit wiring connections Rectify by following wiring diagram

High discharge pressure; fan motor Rectify / replace fan motor as

not working, condenser dirty, Applicable
incorrect installation

Overcharging of refrigerant Put out excess refrigerant. Ensure

correct charge by seeing sight glass

Compressor runs Controller sensor kept exposed Put sensor in correct place
continuously and does not to warm place
cut
Defective control box Replace control box

Thermostat by- passed Reconnect thermostat, check, replace

if found defective

SYSTEM

Unit does not cool Blocked air filter of indoor unit Clean the air filter
adequately
Controller setting improper Reset thermostat setting

Refrigerant leak Detect leak, rectify, pressure test,

evacuate, charge.

Compressor motor rotates in Interchange any two wire at

backward direction compressor terminal

Refrigerant undercharged Check for minute leaks. If found,

rectify, pressure test, evacuated,
recharge . Otherwise charge correct
amount

Partially plugged expansion valve Clean or replace with proper charging

procedure
 36

Compressor- poor pumping Replace or repair

Fan motor speed low or low air Replace motor / check blower
quantity installation

High discharge pressure / HP Check installation for air short cycling,

pressure switch tripped fan speed, fan loose on shaft,
overcharged system, condenser coil
Dirty

Overcharged system Purge system. Ensure correct charge

Refrigerant contaminated Evacuate and recharge with drier in

charging line.

Discharge valve and / or liquid valve Open it totally

may close / partially open

Very high ambient temperature Place outdoor in shade. Avoid west or

north-west direction of location

Very high heat load See if it is possible to reduce load by

reducing appliances etc.,or by putting
up vanetian blinds / curtains or by
closing doors and windows

Frosted or sweated suction Expansion valve admitting excess Adjust expansion valve (be careful)
line refrigerant

Frosted liquid line Restricted filter drier Remove restriction or replace filter
drier
 37

TABLE 6 : START-UP CHECKLIST

Equipment sold by:

Installed by:

Site address:

Equipment type and serial number:

Start-up date:

Refrigerant:

Condenser air entering temperature: 1 2 Deg. C / F

Condenser air leaving temperature: 1 2 Deg. C / F

Supply voltage: Phase 1 - V Phase 2 - VPhase 3 - V

Phase unbalance: Phase 1 - V Phase 2 - VPhase 3 - V

Current drawn:
Main: Phase 1 - A Phase 2 - APhase 3 - A
Compressor: Phase 1 - A Phase 2 - APhase 3 - A
Indoor unit blower motors: Phase 1 - A Phase 2 - APhase 3 - A
Condenser fan motor: Phase 1 - A Phase 2 - APhase 3 - A

Main circuit breaker rating : A

Suction pressure 1: kPa / psig, Discharge pressure 1: kPa / psig

Suction pressure 2: kPa / psig, Discharge pressure 2: kPa / psig

Room temperature: Dry bulb: Wet bulb: Deg C / F

Indoor unit return air temperature: Dry bulb: Wet bulb: Deg C / F

Indoor unit supply air temperature: Dry bulb: Wet bulb: Deg C / F

Supply air grill / diffuser temperature: Dry bulb: Wet bulb: Deg C / F

Suction line temperature: 1 2 Deg C / F

Commissioning Engineer (Name):

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TIPS

FOR MAXIMUM COMFORT AND POWER CONSUMPTION, FOLLOW THESE HELPFUL TIPS:

Frequent changing of the set temperature is not recommended.

Enjoy better cooling efficiency by cleaning filter once a fortnight.

Avoid direct sunlight in room. Use curtains and cover at windows and doors
but avoid obstacles. Dont cover the A/C.

Insulate the ceiling if it is exposed to sunlight and keep room closed.

LIQUID LINE Inches
SUCTION LINE Inches 7/8 7/8

Close seal all opening /crevices in conditioned space. Install outdoor in well
ventilated space to avoid short cycling of hot condenser air. Install unit with
minimum recommended clearances and within specified distance between
indoor/outdoor unit for optimum performance.
For exhaust purpose, switch ON only the FAN with doors /windows open for
ventilation. Do not run in COOL mode.

SERVICE AND MAINTENANCE

CLOGGED FILTERS:
A clean filter guarantees maximum cooling, uninterrupted operation, eliminates
Frost building up on evaporator coil and prevents blown fuses /circuit breakers .
So make sure unit filter is cleaned regularly.

HOW TO CLEAN CLOGGED FILTERS:

Slide up and Remove grill.

Pull out filter carefully.
Clean /wash filter. Replace by pull up carefully in position.
Reassemble grill.
For normal and efficient operation, get the unit periodically checked by
Qualified technician trained by Carrier.

SELF SERVICE: Before calling to the Carrier Service, there are certain things you can check by yourself.
Refer to the Table.1
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Problem Possible cause Solution

Unit does not start Blown fuse. Replace only once.

Circuit breaker tripped. Reset only once.

Unit cord unplugged. Re plug properly.

Unit does not cool properly Filter dirty. Clean filter.

Improper set temp value. Select proper value.

Ice of frost forms on indoor coil
Low outside temperature. Operate the unit in fan mode only until
ice disappears.

Filter dirty. Clean filter.

Infiltration of outside air. Close source of infiltration.

CARRIER SERVICE

REST ASSURED

Certain normal sounds made by the unit

Thermostat Relay Click

This happens when you change cooling levels or when the thermostat cuts off and comes on
for Compressor to operate.

Dripping noise

The sound of liquid refrigerant passing through the system

Humming noise

Motor noise when unit is in operation or when fan is working and the
fluctuation in voltage /frequency is more than normal .

All these sounds signify that the unit is working normally and room temperature is being monitored
as required. If ever your unit fails to operate properly, contact the Carrier Authorized Dealer. If you are still
dissatisfied, get in touch with the Carrier Service Center.

Carrier Air conditioning and Refrigeration Ltd.

Address..Tel:
Person to be contacted:Dealer address:.Tel:..
Person to be contacted
In all correspondence/communication state your name, address, the serial number of your air
conditioning unit, date of purchase and dealers name (include address), location of unit and
description of problem, for prompt and immediate attention
 40

CARRIER AIR CONDITIONING & REFRIGERATION LTD.

Air Cooled DUCTED unit

Name of Customer: ___________________________________

Address: ____________________________________________
____________________________________________

Sr.No. of the Unit:

Sr.No. of the Compressor: Date of purchase:

Invoice No:

Name & Address of the Dealer:

Signature of the Dealer with Seal.

CARRIER AIR CONDITIONING & REFRIGERATION LTD. (hereinafter referred to as the

company), guarantees to the customer mentioned as per the details of the unit given that for a
period of 12 Months, commencing from the date of purchase, to repair or replace, if so required
at the sole discretion of the company, free of charge any part or parts of the DUCTED air-
conditioner, for any faulty material or defective workmanship leading to the failure of the
equipment or components including the compressor, condenser and evaporator, provided the
company is fully satisfied in its sole discretion about such defect and the mentioned unit is
deemed to be still in the possession of and used by the purchaser mentioned.

Clauses on next page will form the terms and conditions for this warranty.
 41
TERMS & CONDITIONS

The Warranty will be applicable only for the specified period indicated above, irrespective of whether the air
conditioner has been in use for any reason whatsoever, including any break down, time taken for repairs
/replacements and transmit time etc. The warranties will automatically expire/terminate on completion of the
period indicated above and no notice whatsoever will be given to this effect.

All parts failing due to faulty material or defective workmanship pertaining to the above DUCTED air-
conditioner will be repaired /replaced within the warranty period by Carrier Air Conditioning & Refrigeration
Ltd. (C.A.R.L) or by the authorized Dealer as intimated by C.A.R.L.

During the period of warranty it will be obligatory on the part of customer that the air conditioning machine is
serviced /repaired /attended to/installed /reinstalled only by the authorized Dealer of C.A.R.L and in case the
unit is attended to by any other agency, the warranty stands automatically terminated.

For units installed beyond the Municipal limits of the jurisdiction of the authorized Dealer of C.A.R.L all
expenses incurred in collecting the unit or parts there of from the Service Station of the Dealer of C.A.R.L as
expenses incurred in connection with deputing of Service Personnel /technician towards to &fro travel,
conveyance and other incidentals etc., will be borne by the customer and payable in advance.

The guarantee extended here is in lieu of all implied conditions and warranties under the law and is
confirmed to the repair or replacement of defective parts and does not cover any consequential or resulting
liability damage or loss arising from such defects. Furthermore, the guarantee, in no case, shall extend to
the payment of any monetary consideration whatsoever, or the replacement or return of the AC as a whole.

It is obligatory on the part of the customer that in case there is any change in the location of the unit and /or
change in the ownership, he should immediately intimate in writing to C.A.R.L or its servicing Authorized
Dealer, at least a week before such change takes place. In such case, the warranty period will be reckoned
on pro-rate basis for the new location/ownership from the date of such changes as the case may be. Failure
to do so will totally absolve C.A.R.L /authorized dealer of their obligation under this warranty.

Further, for continuation of this warranty at the new location and /or new ownership, fresh installation
charges and inspection fee for the units as well as the cost of rectification of any damage in transit due to
mishandling shall be added to the customers account and shall be paid in advance .In case, for any reason,
the customer/owner does not want to carry the repairs after the inspection of the unit, the inspection fees will
not be refunded to the customer.

The decision of C.A.R.L /Authorized Dealer will be final as to whether to affect the repair or replace parts at
the new site /location.

Any loss of refrigerant due to sabotage, man handling, wrong installation by the user or damage caused due
to accidents, fires, floods or earthquakes etc. or for any other reason or any corrosive action on refrigerant
pipes, fitting, valves etc. are not covered under warranty free of cost replenishment of such refrigerant or
pipes, fitting & valves.

This warranty is applicable only when the purchaser has paid all money in relation to the purchase and
installation of this product to C.A.R.L. or to its channel partners.

The warranty will become null & void:

i. If the electrical power supply and voltage are not within the stipulated norms i.e., 230+/-10% volts
or 415+/-10% volts.
ii. If there is consistent power cut, load shedding etc. leading to erratic power supply.
iii. If the air conditioner is improperly installed or repaired by any other source/agency other than the
Authorized dealer of C.A.R.L.
iv. Any damage is caused during transshipment by accident fire, flood, abuse or misuse.
v. If the serial numbers of the unit and/or compressor are removed, altered, defaced or tampered.
vi. If accessories like voltage stabilizer water tank and proper electrical connections are not provided
as recommended by C.A.R.L on their authorized dealer.
vii. If the unit is installed in an environment of corrosive/polluted atmosphere.
viii. The accessories such as voltage stabilizer, water tank, any kind of aesthetic /decorative material
including grills, side panels, front louvers etc.are not covered under the warranty.
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