39CCN,CCW
Indoor and Outdoor
Custom Air Handlers
Installation, Start-Up and Service Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PREINSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,3
Receiving and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
• SPLIT UNITS
Clearance Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Air Handler Unit Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Ceiling Suspended Units. . . . . . . . . . . . . . . . . . . . . . . . . . .3
Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Duct/Weather Hood Installation . . . . . . . . . . . . . . . . . . . . 4
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reassembly of Split Units . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reassembly of Stacked Unit Horizontal Splits. . . . . . 5
Trapping Drains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Connecting Ducts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting Rain Hoods. . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preliminary Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fan Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
• RECOMMENDED GREASE
Every Six Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
• BELT TENSIONING METHOD
Yearly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION AND STORAGE CHECKLIST. . . 10,11
SAFETY CONSIDERATIONS
Air-handling equipment is designed to provide safe and reliable service when operated within design specifications. To
avoid injury to personnel and damage to equipment or property
when operating this equipment, use good judgment and follow
safe practices as outlined below.
DANGER
NEVER enter an enclosed fan cabinet or reach into a unit
while the fan is running.
LOCK OPEN AND TAG the fan motor power disconnect
switch before working on a fan. Take fuses with you and
note removal on tag. Electric shock can cause personal
injury or death.
LOCK OPEN AND TAG the electric heat coil power disconnect switch before working on or near heaters.
Failure to follow these warnings could lead to personal
injury or death.
WARNING
CHECK the assembly and component weights to be
sure that the rigging equipment can handle them safely.
Note also, the centers of gravity and any specific rigging
instructions.
CHECK for adequate ventilation so that fumes will not
migrate through ductwork to occupied spaces when welding or cutting inside air-handling unit cabinet or plenum.
WHEN STEAM CLEANING COILS be sure that the area
is clear of personnel.
DO NOT attempt to handle access covers and removable
panels on outdoor units when winds are strong or gusting
until you have sufficient help to control them. Make sure
panels are properly secured while repairs are being made to
a unit.
DO NOT remove access panel fasteners until fan is completely stopped. Pressure developed by a moving fan can
cause excessive force against the panel which can injure
personnel.
DO NOT work on dampers until their operators are
disconnected.
BE SURE that fans are properly grounded before working
on them.
Failure to follow these warnings could result in personal
injury or equipment damage.
CAUTION
SECURE drive sheaves with a rope or strap before working on a fan to ensure that rotor cannot free-wheel.
DO NOT restore power to unit until all temporary walkways inside components have been removed.
NEVER pressurize equipment in excess of specified test
pressures.
PROTECT adjacent flammable material when welding or
flame cutting. Use sheet metal or asbestos cloth to contain
sparks. Have a fire extinguisher at hand and ready for
immediate use.
Failure to follow these warnings could result in personal
injury or equipment damage.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53390017-01 Printed in U.S.A. Form 39CC-1SI Pg 1 1-15 Replaces: New
INTRODUCTION
The 39CC custom air-handling units are designed for indoor
(39CCN) or outdoor (39CCW) installations. Modular design
allows for heating sections such as hot water coils, steam coil,
or electric heat. Cooling options include chilled water, DX
(direct expansion), or glycol. Filter options include bag, rigid,
HEPA, mini-pleat, vee, and others.
For further information on unit and component identification, contact your Carrier representative for the approved submittal.
PREINSTALLATION
Receiving and Inspection
1. Verify receipt of all parts by comparing items in the shipment with those listed on the bill of lading.
To facilitate inspection, a list of items shipped with the
units is included and attached to the inside access door of
the supply fan section. Among the items generally
shipped loose are the following:
Fan section: Split unit reassembly hardware (nuts, bolts,
caulking); replacement fan belts; lifting lugs.
Filter section: Filters; filter clips
2. Inspect the unit(s) for any damage that may have occurred during shipping.
3. Indicate any problems such as shortage, damage, or
breakage on the carrier’s freight bill and obtain the signature of the driver or carrier’s representative as verification.
4. Immediately report any damage detected after delivery to
the carrier and obtain a concealed damage inspection report upon their inspection of the shipment.
5. If considerable damage has been incurred and the situation is urgent, contact your sales representative for assistance. Please keep a written record of all communications.
Storage — If unit is to be stored for more than 2 weeks pri-
or to installation, note that improper storage will result in seriously reduced equipment reliability. It is likely that an electric
motor or fan that does not experience regular use while being
exposed to normally humid atmospheric conditions will encounter bearing degradation. In addition, the motor’s electrical
insulation may absorb an excessive amount of moisture leading
to the motor winding failing to ground. The following preparations should be followed:
• Minimize condensation in and around the fan and motor
by humidity controls.
• Coat all external machined surfaces with a material to
prevent corrosion.
• Measure and record the motor electrical resistance of
insulation with a Megger meter or a resistance meter.
The insulation resistance = kV rating + 1 Megohom.
Whenever possible, store equipment indoors in a dry area
and protect the fan shaft, bearings and fan wheel from dust and
corrosion.
If outdoor storage is necessary, be sure to close latches on
all access doors to prevent potential water and air leakage. Unit
should be placed on a level surface. Avoid setting the unit directly on water or wet ground. Supports should be placed at
6-ft intervals. Use a tarp or similar weatherproof cover to protect cabinet exterior against dust, dirt, moisture, and corrosion.
Cover the unit from the roof down to the base on each side. Inspect and ventilate each section every 2 weeks to prevent mold/
mildew growth, and to observe overall integrity of the unit.
To protect against excessive vibration and accidental im-
pact, never store other equipment inside or on top of the unit. If
unit must be stored for an extended period, be sure to protect
against bearing damage by manually rotating the fan wheels
and lightly greasing the fan and motor bearings every month.
Rigging — The air-handling unit may be shipped in one of
three ways:
• assembled
• subassemblies or groups of parts
• separate sections
To ensure safe lifting, estimate the unit’s center of gravity,
taking into account that the weight may be unevenly distributed
due to the placement of internal components (for example,
more weight in the coil and fan areas). In case where the unit’s
center of gravity is a concern, please contact your Carrier representative.
Prior to lifting, install the removable lugs shipped loose in
the fan section. Tie downs must be used only to tie the unit to
the truck during shipping. Never attempt to lift the unit using
the tie downs. See Fig. 1.
CHANNEL
LIFTING LUG
TIE DOWN FOR SHIPPING ONLY
a39-4462
Fig. 1 — Lifting Lug
During a lift, all lugs must be used. Spreader bars are re-
quired to prevent damage to the cabinet and protruding components. To distribute the load properly, the tension in each line
must also be adjusted. See Fig. 2.
a39-4463
Fig. 2 — Lifting with Spreader Bars
For smaller units when no lifting lugs are provided, use a
belt-type sling to raise the unit from the base, carefully avoiding door handles, electrical boxes, coil connections, and other
protrusions.
Never lift units or subassemblies without a base by attach-
ing bolts, clevises, pins, hooks, etc. to casing, casing hardware,
flanges, angles, or tabs. Only rig as shown here.
2
It is mandatory to use spreader bars for larger units with lifting lugs or slings for smaller units to prevent damage to the
casing of the units by rigging equipment. Only qualified rigging personnel should operate lift equipment.
Units can be lifted with forklifts as long as the forks are
40 inches and the end tips contact the bottom of the intermediate supports of the base rail. Additionally, a fork lift may be
used to lift small subassemblies or individual sections, but the
forks must reach the other side of the base rail. See Fig. 3.
To avoid damaging the air-handling unit, always lift in an
upright position, and never move or lift unit from a sideways or
upside-down position. Use extreme caution when moving an
air-handling unit with a forklift.
a39-4461
FORKS
Fig. 3 — Forklift
installer’s responsibility to secure the unit to the unit pad in accordance with all applicable building and earthquake codes.
After the unit has been installed, the base rail should be inspected for paint damage from chains in the tie down brackets,
use of the lifting lugs and fastening the unit down. This damage
must be repaired by cleaning down to bare metal and applying
two heavy coats of matching paint to stop corrosion and rust.
Ceiling Suspended Units — Ceiling suspended units
must be supported from the base. To fully support the unit, four
or more suspension points are required. The casing is not a support component. The exact number of support points is function of the unit length and weight. Please refer to submittal
drawings for lift locations. The installer is responsible for installing in accordance with applicable building and earthquake
codes. See Fig. 4.
a39-4460
SPLIT UNITS — Split units less than 102 in. may be shipped
loosely assembled. Disassembly is required, with each section
being lifted individually. The “loosely assembled” split sections are affixed using a minimum number of bolts for transit
and cannot be lifted while fastened together. Use all lifting lugs
to avoid unit damage and/or personal injury.
Clearance Requirements — As required by the state,
city or the national electrical code (NEC or CEC), the service
space between the face of any electrical enclosure and wall or
obstruction must be 42 inches minimum.
Sufficient clearances are also needed to open doors and install piping and ductwork. Airflow through the louvers of
hoods cannot be obstructed in any way. The distance between
the louver and any facing wall must be equal to the horizontal
width of the louver.
Space around the unit must allow easy removal of the access panels and parts such as the fan wheels, motors and belt
guards. To facilitate removal of coils, fan shaft, and fan wheel,
allow a minimum clearance equal to the width of the unit on
one side.
INSTALLATION
• The services of qualified field services personnel are
required for safe and proper installation of this equip-
ment.
• Do not operate this unit outside the listed nameplate rat-
ings for flow or static pressure.
• This unit is designed for installation on a level surface or
suspended on a level plane.
• Follow SMACNA (Sheet Metal and Air Conditioning
Contractors’ National Association) guidelines for sup-
ply/return/exhaust duct connections and minimal duct
obstruction clearances.
Air Handler Unit Pad — The foundation and floor
should be level (shim when necessary), rigid, and strong
enough to support the weight of the entire unit. It is the
Fig. 4 — Suspension Mounting
Roof Curb — Roof curbs are shipped either fully welded
or in split sections. Bolt together if roof curb is bolted construction. Follow this procedure to assemble roof curb, if required:
1. Arrange the 4 perimeter sidewalls so that pre-drilled holes
are aligned. Drive bolt each corner securely (bolts provided).
2. Drive bolt the remaining support members using the predrilled holes and provided drive bolts. Turn out the flanges before fastening. See Fig. 5.
SIDEWALL
a39-4464
PRE-DRILLED HOLES
(BOLTS SHIPPED LOOSE)
Fig. 5 — Roof Curb Assembly
3. Line up the assembled curb with the roof openings.
Square up the curb by measuring the diagonal distance
between opposite corners and adjust until the distances
are equal. Level the curb.
4. Install the foam rubber seal strip atop the installed curb.
This provides an airtight seal and isolates the roof from
vibration.
3
5. Roof the curb prior to setting the unit. Use standard 2 in. x
4 in. wood nailers (provided), insulate and flash (by others) as required.
6. Check to ensure that curb is level and securely attached to
structure.
7. Check for sufficient height between the unit base and the
roof to allow for drain trapping.
8. Use polyurethane caulking on top of the curb to seal between the unit base and the roof curb.
9. Safely lift the unit into place.
The installer is responsible for installing roof curb in accor-
dance with local building and earthquake codes.
Duct/Weather Hood Installation — Follow
SMACNA and industry guidelines for duct gages, sizing, materials, insulation and supports. Transition to and from units as
required for proper airflow. When installing ductwork or
weather hoods to unit exterior, use gaskets or caulking around
entire perimeter of flange. Align the duct or hood over the
opening. Check for adequate clearance to doors and other
openings. Install the duct of hood using sheet metal screws
through the unit casing. Carefully remove excess caulking, if
required, from around the flange.
Electrical Connections — Follow the latest NEC (Na-
tional Electrical Code) and/or other applicable codes for all
electrical wiring and connections, including grounding.
Nameplate data contains line voltage and minimum ampacity for this unit. Separate line voltage power supply should be
run directly from the building distribution panel to the electrical connection on the unit. Consult wiring diagrams provided
with the unit. Follow NEC and applicable codes for conduit
and wire ratings.
Coils
HEATING COILS (HOT WATER, STEAM) — Heating
coils are constructed of copper tube with corrugated fins. Maximum operating pressure is 150 psig. Coils are provided with
drain and vent connections. Do not block the air vent; this may
result in poor coil performance. Inlet line strainers are recommended to prevent debris from blocking coil tubes or valves.
Common causes of heating coil damage are:
• improper piping installation
• water hammer
• freezing
• control valve chattering
• internal corrosion from chemicals in fluid
• external corrosion from chemicals in the airstream
COOLING COILS (CHILLED WATER, DIRECT EXPAN-
SION, GLYCOL) — Cooling coils are constructed of copper
tube with corrugated fins. Maximum operating pressure is
150 psig. An IAQ 304SS (indoor air quality 304 stainless steel)
condensate drain pan is located under the coil with drain and
vent connections. Do not block the air vent; this may result in
poor coil performance. Inlet line strainers are recommended to
prevent debris from blocking coil tubes or valves.
Common causes of water cooling coil damage are:
• improper piping installation
• water hammer
• freezing
• control valve chattering
• internal corrosion from chemicals in fluid
• external corrosion from chemicals in the air stream
Direct expansion (DX) cooling coils are thermal counter-
flow construction with same end liquid and suction
connections.
Common causes of DX cooling coil damage are:
• improper piping installation
• freezing (due to excessively low pressure)
• internal corrosion
• external corrosion from chemicals in the air stream
Refrigerant distributors are brass, pressure type with copper
distributor tubes factory installed.
Reassembly of Split Units — To prevent air and wa-
ter leaks, all units shipped in sections must be carefully assembled and installed on a proper foundation. Split air units are assembled in one piece in the factory to make sure that all pieces
match and the bolt holes line up, and are then split prior to shipping.
• For proper reassembly, housekeeping pad or roof curb
must be level.
• All nuts, bolts, washers, and caulking required for
assembly of the unit are shipped in the supply fan section.
• Place all sections on level surface.
• Caulk where indicated on both sides of split panel and
roof flanges, and bolt the base together. See Fig. 6.
CAULKING
a39-4465
Fig. 6 — Caulking Split Panel Flanges
• A come-along or hand-operated winch can be used to
tighten the space between unit section.
• Bolt holes may not align as a result of racking during
transit to the job site. In such instances, lift one side with
jack to align holes on wall of the opposite side. After
bolting this wall, remove jack. Then proceed with bolting
the other side, base, floor, and roof. Any racking that is
out of square should realign as the unit settles.
• Check to make sure that all bolts are properly secured.
• Caulk exterior roof seams. See Fig. 7.
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