Air-Cooled Condenser Units
Installation, Start-Up and
Service Instructions
09DK020-044
50/60 Hz
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Step 1 — Complete Pre-Installation Checks . . . . . . 2
Step 2 — Locate and Rig Unit, Remove
Shipping Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
•LOCATION
• RIGGING
• PLACING UNIT
• MOUNTING UNIT
Step 3 — Complete Refrigerant Piping . . . . . . . . . . . 6
• GENERAL
• COIL CIRCUITING CONVERSION
INSTRUCTIONS
• REFRIGERANT LINE SIZING
• LIQUID SHUTOFF VALVE AND
SIGHT GLASS
• PRESSURE RELIEF
• REFRIGERANT RECEIVER
• COIL CONNECTIONS
Step 4 — Complete Electric Connections. . . . . . . . 18
• GENERAL
• CONNECTIONS
•POWER WIRING
• GENERAL WIRING NOTES
Step 5 — Add Accessories as Needed. . . . . . . . . . . 18
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-20
System Evacuation and Dehydration . . . . . . . . . . . . 18
Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Check Operation of Condenser Fan Motor
Controls and Rotation of Fans . . . . . . . . . . . . . . . . 18
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21,22
Fan Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fan Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning Standard Coils. . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning and Maintaining E-Coated Coils . . . . . . . 21
Fan Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 22
• FAN CYCLING
SAFETY CONSIDERATIONS
Installing, starting up, and servicing air-conditioning equip-
ment can be hazardous due to system pressures, electrical components and equipment location (roofs, elevated structures,
etc.).
Only trained, qualified installers and service mechanics
should install, start up, and service this equipment (Fig. 1).
Untrained personnel can perform basic maintenance func-
tions such as cleaning coils. All other operations should be performed by trained service personnel.
When working on the equipment, observe precautions in the
literature and on tags, stickers, and labels attached to the
equipment.
Follow all safety codes. Wear safety glasses and work
gloves. Keep quenching cloth and fire extinguisher nearby
when brazing. Use care in handling, rigging, and setting bulky
equipment.
ELECTRIC SHOCK HAZARD
Open all remote disconnects before servicing
this equipment.
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and goggles and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from sys-
tem using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen
and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic
gases.
d. Cut component connection tubing with tubing cutter
and remove component from unit. Use a pan to catch
any oil that may come out of the lines and as a gage
for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when nec-
essary. Oil can ignite when exposed to torch flame.
Failure to follow these procedures may result in personal
injury or death.
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes
and regulations. DO NOT leave refrigerant system open to
air any longer than the actual time required to service the
equipment. Seal circuits being serviced and charge with
dry nitrogen to prevent oil contamination when timely
repairs cannot be completed. Failure to follow these procedures may result in damage to equipment.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 530-917 Printed in U.S.A. Form 09DK-13SI Pg 1 612 11-99 Replaces: 09DK-11SI
INTRODUCTION
Fig. 1 — Model 09DK (Size 028 Shown)
Fig. 2 — Rigging with Spreader Bars
(Field Supplied)
UNIT
09DK
MAX. SHIP
WT
LIFTING
HOLES
CENTER OF
GRAVITY
D
ABC
lb kg in. mm in. mm in. mm in. mm
020,024 989 449 95.7 2432 55.2 1403 24.7 628 49.5 1256
028 1209 548 95.7 2432 54.7 1391 36.7 933 73.5 1867
034 1835 832 142.0 3608 80.0 2032 36.7 933 73.5 1867
044 2017 915 142.0 3608 80.0 2032 36.7 933 73.5 1867
These instructions describe installation, start-up, and service of 09DK020-044 air-cooled condensers (Fig. 1). See
Table 1 for general unit physical data.
INSTALLATION
Step 1 — Complete Pre-Installation Checks —
Examine for damage incurred during shipment. File claim
immediately with transit company if damage is found. Verify
that the nameplate electrical requirements match the available
power supply. Check the shipment for completeness.
Step 2 — Locate and Rig Unit, Remove Shipping Skid
LOCATION — If roof installation is specified, make certain
that roof structure can support the condenser weight. Refer to
Table 1.
Locate condenser where an adequate supply of inlet outdoor
air is available. Do not locate where the possibility of air recirculation exists, such as under a roof overhang.
Locate condenser in an area free from airborne dirt or other
foreign material which could clog condenser coils.
RIGGING — Preferred method is with spreader bars from
above the unit. Use 2-in. (50 mm) OD pipe or hooks in lifting
holes. Rig with 4 cables and spreader bars. All panels must be
in place when rigging. See rigging label on unit for details concerning shipping weights, distance between lifting holes, center of gravity, and spreader bar dimensions. Also see Fig. 2.
If overhead rigging is not possible, place unit on skid or pad
for rolling or dragging. When rolling, use minimum of 3 rollers. When dragging, pull the pad. Do not apply force to the
unit. When in final position, raise from above to lift unit off
pad.
All panels must be in place when rigging. Do not forklift
unit if no skid is supplied. If unit has skid, use forklift truck
from sides only.
PLACING UNIT — There must be 4 ft (1.22 m) for service
and for unrestricted airflow on all sides of unit, and a minimum
of 8 ft (2.44 m) clean air space above units. See Fig. 3, 4, and
5. For multiple units, allow 8 ft (2.44 m) separation between
units for airflow and service.
MOUNTING UNIT — When unit is in proper location, use
mounting holes in base rails for securing unit to supporting
structure. Fasteners for mounting unit must be field supplied. If
unit is to be mounted on vibration isolators, drill mounting
holes in bottom of base rail at support points 1-4 (shown in
Fig. 3, 4, and 5) and locate isolators at those points.
Table 1 — Physical Data — 50 and 60 Hz
UNIT 09DK 020 024 028 034 044
OPERATING WEIGHT, lb (kg)
Aluminum-Fin Units 797 (361.5) 797 (361.5) 983 (445.9) 1495 (678.1) 1676 (760.2)
Copper-Fin Units 921 (417.8) 921 (417.8) 1137 (515.7) 1700 (771.1) 1984 (900.0)
CONDENSER FANS, TYPE Propeller Type, Direct Driven
No. 22233
Diam, in. (mm) 30 (762)
Total Airflow cfm 10,600 13,500 15,700 21,100 23,700
Speed, Rpm (rps) 1140 (19), 60 Hz 950 (15.8), 50 Hz
CONDENSER COIL, TYPE Horizontal, Plate Fin
Rows 33223
Fins/in. (Fins/m) 17 (669) 17 (669) 19 (748) 17 (669) 17 (669)
Total Face Area, sq ft 23.5 23.5 39.2 58.4 58.4
L/s 5,000 6,370 7,400 9,950 11,200
sq m 2.18 2.18 3.64 5.43 5.43
2
Fig. 3 — Dimensions, 09DK020-028
DIMENSIONS — MM [FT-IN.]
NOTES:
1. There must be 1220 mm [4-0] for service and for unrestricted airflow on
all sides of unit.
2. There must be minimum 2440 mm [8-0] clear air space above unit.
3. The approximate operating weight of the unit follows:
4. Dimensions are in millimeters. Dimensions in [ ] are in feet-inches.
UNIT
09DK
ABCDEF
020,024
1131
[3-8
1
/2]
1007
[3-311/16]
240
[97/16]
432
[1-0]
228
[0-9]
559
[1-10]
028
1742
[5-8
5
/8]
1619
[5-33/4]
496
[1-79/16]
914
[3-0]
445
[1-51/2]
762
[2-6]
UNIT 09DK
TOTAL
WEIGHT
OPERATING WT. AT SUPPORT
POINTS
Lb Kg Lb Kg Lb Kg
020,024 797 361.5 186 84.4 212 96.2
020C,024C 921 417.8 215 97.5 245 111.1
028 983 445.9 229 103.9 262 118.8
028C 1137 515.7 268 121.6 300 136.1
C—Units with optional copper-fin coils
1&2
3&4
3
Fig. 4 — Dimensions, 09DK034
DIMENSIONS — MM [FT-IN.]
NOTES:
1. There must be 1220 mm [4-0] for service and for unrestricted airflow on
all sides of unit.
2. There must be minimum 2440 mm [8-0] clear air space above unit.
3. The approximate operating weight of the unit follows:
4. Dimensions are in millimeters. Dimensions in [ ] are in feet-inches.
UNIT
09DK
BCDE F
034
112
[1-2
7
/16]
496
[1-79/16]
914
[3-0]
445
[1-51/2]
762
[2-6]
UNIT 09DK
TOTAL
WEIGHT
OPERATING WT. AT SUPPORT
POINTS
Lb Kg Lb Kg Lb Kg
034 1495 678.1 349 158.3 399 181.0
034C 1700 771.1 396 179.6 454 205.9
C—Units with optional copper-fin coils
1&2
3&4
4
Fig. 5 — Dimensions, 09DK044
COIL CONNECTION DIMENSIONS — MM [IN.]
NOTES:
1. There must be 1220 mm [4-0] for service and for unrestricted airflow on
all sides of unit.
2. There must be minimum 2440 mm [8-0] clear air space above unit.
3. The approximate operating weight of the unit follows:
4. Dimensions are in mm. Dimensions in [ ] are in feet-inches.
5. Dimension “E” for 34.9 mm I.D. is 118 mm [4
5
/8].
Dimension “E” for 28.5 mm I.D. is 112 mm [4
7
/16].
UNIT
09DK
ABCD E
044
34.9 I.D.
[1
3
/8]
28.5 I.D.
[11/8]
22.2 I.D.
[7/8]
15.9 I.D.
[5/8]
SEE
NOTE #5
UNIT 09DK
TOTAL
WEIGHT
OPERATING WT. AT SUPPORT
POINTS
Lb Kg Lb Kg Lb Kg
044 1676 760.2 391 177.4 447 202.8
044C 1984 900.0 462 209.6 529 240.0
C—Units with optional copper-fin coils
1&2
3&4
5
Step 3 — Complete Refrigerant Piping
GENERAL — All field leak and pressure testing should be in
accordance with local code requirements. If no local code
exists, follow American National Standards Institute (ANSI)/
American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE) Safety Standard 15, latest
revision.
For leak testing procedures, refer to the Carrier Refrigerant
Service Techniques Manual.
COIL CIRCUITING CONVERSION INSTRUCTIONS —
See Table 2 for standard unit circuiting and for the circuiting
available by installing the supplied parts kits. Note that for
044 size units, all circuiting must be field installed using field
supplied parts. Field supplied and installed parts are also
required for 100% circuiting of all 020-034 size units.
The following sections describe how to modify the standard
unit circuiting (as shipped from the factory) for optional splits.
NOTE: All coils are purged with dry air and then capped prior
to shipment. The coils DO NOT contain a refrigerant holding
charge.
Table 2 — Coil Circuiting Options
UNIT 09DK
020 50/50% 67/33%*
024 50/50% 67/33%*
028 50/50% 60/40%* or 40/40/20%*
034 50/50% 60/40%* or 40/40/20%*
044 Uncircuited†
*Parts kits for field circuiting conversions are supplied with the unit. Replacement parts kits are available as follows:
For 020 and 024 size units, part no. 09DK400138; for 028 and 034 units, part no. 09DK400139. Replacement parts kits are not
available for 044 units.
†The 044 unit is shipped from the factory uncircuited, with plastic caps on all connections. The unit must be field converted to the
desired split with field supplied parts.
FAC TOR Y
CIRCUITING
FIELD-CONVERTED
CIRCUITING
100% or 74/26% or 66/34% or
60/40% or 53/47% or 40/13/13/34%
6
09DK020,024 67/33% Circuiting Modification
CA
AB
Fig. 6 — Parts Removed from 09DK020,024
(50/50%) Unit for 67/33% Circuiting
Fig. 7 — Parts Added to 09DK020,024 Unit
(To Obtain 67/33% Circuiting)
— To convert the 09DK020 or 09DK024 coil from the 50/50% to
67/33% circuiting, perform the following steps:
1. Use a mini tubing cutter to remove specified parts:
a. Both
3
/8-in. diam tube nipples connecting the left
hot gas header to the coil. See Fig. 6, Item A.
b. The
3
/8-in. diam tube nipple connecting the left
liquid header to the coil. See Fig. 6, Item B.
c. Caps, where 2 are located on the right gas header,
and one is located on the right liquid header. See
Fig. 6, Item C.
2. Attach following specified parts contained in the parts
kit. Perform phos-copper brazing on all field-made
connections while protecting adjacent joints from heat.
a. Cap the open stub tubes on the left headers, where
two are located on the gas header, and one on the
liquid header. See Fig. 7, Item A.
b. Insert both 3
5
/8-in. length tube nipples into the
open stub tubes located on the right side of the coil
to connect the right gas header to the top row of
the coil. See Fig. 7, Item B.
c. Insert the 4
11
/16-in. length tube nipple into the
open stub tubes on the right side of the coil to connect the right liquid header to the bottom row. See
Fig. 7, Item C.
3. Install or replace filter-drier(s). Before charging the
system, install or replace filter drier(s) connected to
the liquid line near the indoor unit to prevent contamination in the system.
7
09DK028,034 60/40% Circuiting Modification
B
C
A
C
B
A
C
A
Fig. 8 — Parts Removed from 09DK028,034 (50/50%) Unit for 60/40% Circuiting
Fig. 9 — Parts Added to 09DK028,034 Unit
(To Obtain 60/40% Circuiting)
— To convert the 09DK028 or 09DK034 coil from the 50/50% to
60/40% circuiting, perform the following steps:
1. Use a mini tubing cutter to remove specified parts:
a. Both
3
/8-in. diam tube nipples connecting the left
hot gas header to the coil. See Fig. 8, Item A.
b. The
3
/8-in. diam tube nipple connecting the left
liquid header to the coil. See Fig. 8, Item B.
c. Caps, where 2 are located on the right gas header,
and one is located on the right liquid header. See
Fig. 8, Item C.
2. Attach following specified parts contained in the parts
kit. Perform phos-copper brazing on all field-made
connections while protecting adjacent joints from heat.
a. Cap the open stub tubes on the left headers, where
two are located on the gas header, and one on the
liquid header. See Fig. 9, Item A.
b. Insert both 4
1
/16-in. length tube nipples into the
open stub tubes on the right side of the coil, connecting the gas header to the top row. See Fig. 9,
Item B.
c. Insert the 4
11
/16-in. length tube nipple into the
open stub tubes on the right side of the coil, connecting the liquid header to the bottom row. See
Fig. 9, Item C.
3. Install or replace filter-drier(s). Before charging the
system, install or replace filter drier(s) connected to
the liquid line near the indoor unit to prevent contamination in the system.
8
Loading...