Carrier Cassette Sky 53QC 36 Installation Manual Download

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Rev. (0) - 2013

Quality

Management System

ISO 9001 : 2008

Certificate No.: QS-5519HH

Enviromental

Management System

ISO 14001 : 2004

Certificate No : 12 104 30334 TMS

Safety

Management System

BS OHSAS 18001 : 2007

Certificate No : 12 116 30334 TMS

03501149

Carrier is committed to continuously improving its products according to national and international standards

to ensure the highest quality and reliability standards, and to meet market regulations and requirements.
All specifications subject to change without prior notice according to Carrier policy of continuous development.

INSTALLATION MANUAL

Cassette

Sky

53QC 36 - 48

HEAT PUMP

220-240V ~ 50Hz 1Ph

380-420V ~ 50Hz 3Ph

R22

Summary of Contents for Cassette Sky 53QC 36

Page 1: ...S 03501149 Carrier is committed to continuously improving its products according to national and international standards to ensure the highest quality and reliability standards and to meet market regulations and requirements All specifications subject to change without prior notice according to Carrier policy of continuous development INSTALLATION MANUAL Cassette Sky 53QC 36 48 HEAT PUMP 220 240V ...

Page 2: ...LECTING INSTALLATION LOCATION OF OUTDOOR UNIT 8 10 INSTALLATION LOCATION CHECK LIST 12 11 INSTALLTION ACCESSORIES 13 12 INSTALLATION CHART 15 13 INDOOR UNIT INSTALLATION 16 14 REMOTE CONTROL INSTALLATION 19 15 OUTDOOR UNIT INSTALLATION 21 16 CONNECTING REFRIGERANT PIPING LINES 22 17 CONNECTING CONDENSATE DRAIN LINE 35 18 CONNECTING ELECTRICAL WIRING 36 19 FINISHING INSTALLATION 41 20 TEST RUNNING ...

Page 3: ...screw driver 11 Pipe bender 3 Hole core drill 12 Hexagonal wrench 4 Tape measure 13 Torque wrench 5 Water level 14 Vacuum pump 6 Pipe clamp 15 Gas leak detector 7 Pipe cutter 16 Manifold gauge 8 Spanner 17 Thermometer 9 Reamer 18 Electrical circuit tester After completion of installation perform a run test and give the customer full instructions on the correct operation of the air conditioner incl...

Page 4: ...re due to wrong electrical connections between the electrical power supply and circuit breaker of air conditioner leading to fire due to short circuiting As these electrical connections are owner s responsibility 2 Failure due to Misuse Abusing overloading negligence of air filters cleaning and negligence of instructions included in the owner s manual 3 Failure due to Accident Weather Natural cata...

Page 5: ...outlet 4 Air in grill 5 Air filter inside air in grill 6 Air inlet 7 Refrigerant piping lines and electrical cables 8 Condensate drain line 9 Drain pipe 10 Flare valves 11 Remote control signal receiver 12 Bracket of remote control 7 8 10 Outdoor Unit 2 11 1 3 8 5 4 6 9 12 Indoor Unit ...

Page 6: ...3 15 Indoor temperature Maximum 27 Outdoor temperature Maximum Minimum 46 20 Outdoor temperature Maximum Minimum 24 2 18 1 MAIN POWER SUPPLY System Model Nominal Power Supply V PH HZ Minimum Voltage Maximum Voltage 53QC36 708 200 240 1 50 198 254 53QC48 508 380 420 3 50 342 462 NOTES When the unit is operated above or below these limits for a long time system diagnostics may detect a malfunction a...

Page 7: ...QC36 708 30 6 42QC48 708 30 6 7 DIMENSIONS AND WEIGHTS OF OUTDOOR UNIT DIMENSIONS mm Weight Model Kg 38QC36 708 79 5 38QC48 508 90 38QC36 708 38QC48 508 Kg Kg 950 Panel 680 Hook location 840 Body 950 Panel Drain side Tubing side 350 384 720 860 665 371 350 860 1150 371 350 665 350 384 840 Body 780 Hook location ...

Page 8: ... of refrigerant piping lines to facilitate refrigerant leak testing and to facilitate service and maintenance Avoid installation location which can lead to excessive length of refrigerant piping lines between indoor and outdoor units Avoid installation location which can lead to excessive height difference between indoor and outdoor units 1000 mm 1000 mm 1000 mm 1000 mm Outlet Inlet Outlet 2500mm ...

Page 9: ...ffect performance of the unit Avoid installation location where there are obstacles such as curtains and such as curtains furniture near the air inlet or outlet that may affect air flow and performance of the unit Avoid an installation location which has an environment with oil vapors Avoid an installation location which has an environment affected by high frequency waves generated as from radio e...

Page 10: ...eating performance Avoid installation location which can lead to excessive height difference between indoor and outdoor units to avoid alteration on system cooling and heating performance Avoid installation location which can lead to unnecessary turns and bends in the refrigerant piping lines connecting outdoor unit with indoor unit Avoid installation location where there are obstacles near the ai...

Page 11: ...tallation location which is full of sulfuric gas which may result in malfunction Select installation location where the operation noise and discharged air are not disruptive to your neighbors When the installation is made on the rooftop or other places subject to strong wind When the outdoor unit is to be installed on the rooftop or at the places where there are no other buildings around it is req...

Page 12: ...t side of outdoor unit should by away from any obstacle by 400 mm or more to ensure easy access to refrigerant and electrical connections The right side of outdoor unit air inlet should be away from any obstacle by 250 mm or more to ensure free air circulation The top side of outdoor unit should be away from any obstacle by 400 mm or more to ensure easy access to the electrical components motor an...

Page 13: ...ll support to ensure free air circulation The left side of outdoor unit should by away from any obstacle by 400 mm or more to ensure easy access to refrigerant and electrical connections The right side of outdoor unit air inlet should be away from any obstacle by 250 mm or more to ensure free air circulation The top side of outdoor unit should be away from any obstacle by 400 mm or more to ensure ...

Page 14: ...power supply is close to the outdoor unit The installation location is close to the indoor unit The installation location is able to support operating weight of outdoor unit The installation location is far away from any sunlight The installation location is free of dust or any material which can cause clogging of outdoor coil The installation location allow sufficient space for air circulation ar...

Page 15: ... Manual 1 To illustrate installation instructions Installation paper board 1 Template for indoor unit installation Out let pipe clasp 1 To fix Soundproof insulation sheath 2 To insulate piping Expansible hook 4 To mount indoor unit Installation hook 4 To mount indoor unit Wall support for outdoor unit for size 36 Only for domestic market 1 To mount outdoor unit on the wall For Cassette 36K Floor s...

Page 16: ...ly connect the indoor unit the outdoor unit and circuit breaker ـ Wall Sleeve ـ Wall Cap ـ Sealer putty To fill the gap between the wall hole and the lump of refrigerant piping lines electrical connection cables and condensate drain line ـ Finishing tape PVC film To tie together the refrigerant piping lines electrical connection cables and condensate drain line ـ Vinyl tape To stick pipe insulatio...

Page 17: ...acuum pump 2 Drilling hole thru the wall 6 Connecting condensate drain line 10 Refrigerant leak test 3 Installing indoor unit 7 Connecting electrical wiring 11 Opening service valves 4 Pipes flaring 8 Finishing outer pipe covering 12 Finishing installation 13 Test Running 14 Description of operation Outdoor unit ...

Page 18: ...kage will be caused by the malfunction of the water level switch Adjust the position to ensure the gaps between the body and the four sides of ceiling are even The body s lower part should sink into the ceiling for 10 12 mm In general L is half of the screw length of the installation hook Locate the air conditioner firmly by wrenching the nuts after having adjusted the body s position well New bui...

Page 19: ...es to the hooks of corresponding water receiver item 1 on figure Then hang the other two panel hooks onto corresponding hangers of the body item 2 on figure Adjust the four panel hook screws to keep the panel horizontal and screw them up to the ceiling evenly item 3 on figure Regulate the panel in the direction of the arrow Slightly to fit the panel s center to the center of the ceiling s opening ...

Page 20: ...terminator of the swing motor and that of the control box with corresponding terminators on the body respectively 5 Relocate the return air grille in the procedure of reversed order 6 Relocate the installation cover Fasten the rope of installation cover on the bolt of the installation cover Press the installation cover into the panel slightly Air leakage Ceiling Pollution Condensation bead Bead dr...

Page 21: ...attery symbols indicated in batteries compartment NOTES 1 The remote control uses two alkaline batteries 1 5 Volts 2 Do not use old batteries or batteries of different types as this may cause the remote control to malfunction 3 If you do not use the remote control for more than a few weeks please remove the batteries Other wise battery leakage may damage the remote control 4 The average battery li...

Page 22: ... between the remote control and the receiver of indoor unit to avoid blocking the signals from the remote control to the indoor unit 4 The maximum operating distance for the remote control is approximately 8 meters 5 Keep the remote control away from water Do not let the remote control fall down 6 Never use objects with sharp point to press the button on the remote control 7 Prevent any liquid fro...

Page 23: ...2 by using 2 nuts item 5 and 2 spring washers item 6 2 Fix front angle item 4 with right side item 1 and left side item 2 by using 2 nuts item 5 and 2 spring washers item 6 3 Fix top angle item 4 with right side item 1 and left side item 2 by using 4 nuts item 5 and 4 spring washers item 6 Important Notes 1 Mount spring washer before mounting the nut 2 Tighten nut properly with torque wrench with ...

Page 24: ...22 16 CONNECTING REFRIGERANT PIPING LINES 16 1 REFRIGERANT CONNECTIONS CHART 1 Pipes Flaring 2 Pipes Connections 3 Air Purging 4 Leak Check 5 Pipes Insulation 6 Opening Valves ...

Page 25: ...nd insulation materials must be of refrigerant quality Select the pipe diameters to the size of system to be installed All bends must be considered when connecting indoor unit with outdoor unit by required length of refrigerant piping lines Do not remove the protective caps from the couplings until the refrigerant piping lines are ready for connection with both indoor and outdoor units This is to ...

Page 26: ...Indoor unit to facilitate oil return to the compressor to ensure efficiency of compressor mechanical parts If height is more than 4 meters more than one oil trap must exist at the gas line the first one will be at the gas line near to the indoor unit and the following one will be 4 meters from the first one and so on C OUTDOOR UNIT ON THE SAME LEVEL AS INDOOR UNIT An oil trap is preferred to be at...

Page 27: ... piping lines of length 4 meters and with added 50 grams for air and moisture purge from the system 2 For refrigerant piping lines of length more than 5 meters add in the field 25 grams of refrigerant per extra meter more than 4 meters Example 1 For 8 meter lines refrigerant added 8 4 x 25 100 grams Example 2 For 12 meter lines refrigerant added 12 4 x25 200 grams 3 NOTES Refrigerant overcharge ma...

Page 28: ...ne 2 Liquid piping line 16 9 CUTTING AND FLARING TOOLS Make sure that have the required tools available before preparing refrigerant piping lines 1 Gas flare valve 2 Gas service valve 3 Gas port to open close 4 Cap for gas service valve 5 Cap for gas port 6 Liquid flare valve 7 Liquid service valve 8 Liquid port to open close 9 Cap for liquid service valve 10 Cap for liquid port Half Union Gas Hal...

Page 29: ...d and be sure that no copper scraps fall into the pipe STEP 3 Mounting flare nuts on the ends of refrigerant piping Mount gas flare nut large nut on the end of gas refrigerant piping line Mount liquid flare nut small nut on the other side of liquid refrigerant piping line STEP 4 Flaring the Piping Use flare tool to flare ends of both gas and liquid piping lines and then slide a flare nut on to the...

Page 30: ...ng line STEP 6 Removing protective plastic nuts of gas and liquid connections of indoor units NOTES Do not remove protective plastic nuts from the indoor unit until refrigerant piping lines are ready for connections STEP 7 Removing protective plastic nuts of gas and liquid connections of outdoor unit NOTES Do not remove protective plastic nuts from the outdoor unit until refrigerant piping lines a...

Page 31: ...e careful not to damage the flare nut threads NOTES 1 Insufficient tightening torque will cause refrigerant leaks 2 Over tightening the torque will damage the pipe flaring and cause refrigerant leaks 16 12 STEPS OF CONNECTING REFRIGERANT PIPING LINES TO OUTDOOR UNIT Connecting the other ends of gas and liquid piping lines respectively with gas and liquid flare valves of the outdoor unit Repeat ste...

Page 32: ...have undesirable effects as indicated below Pressure in the system rises Operating current rises Cooling and heating efficiency drops Moisture in the refrigerant circuit may freeze and block capillary tubing Water may lead to corrosion of parts in the refrigeration system Be sure using a torque wrench to tighten the service port cap after using the service port so that it prevents the gas leakage ...

Page 33: ...wrench to press the valve core pin discharge for three seconds and then wait for one minute 5 Use torque wrench to tighten the service port cap to a torque of 1 8 kg m 18 Nm 6 Set the 3 way gas valve to the open position 7 Mount the valve stem nuts to the 2 way liquid and 3 way gas valves 8 Check for gas leakage At this time especially check for gas leakage from the 2 way and 3 way stem nuts and f...

Page 34: ...purging procedure using vacuum pump 1 Connect the vacuum pump to the charge set s centre hose 2 Evacuate for approximately one hour Confirm that the gauge needle has moved toward 0 1 Mpa 76 cmHg vacuum of 4 mmHg or less 3 Close the valve Low side on the charge set turn off the vacuum pump and confirm that the gauge needle does not move approximately 5 minutes after turning off the vacuum pump 4 Di...

Page 35: ...perate the system for 10 to 15 minutes 3 Stop operation and wait for 3 minutes then connect the charge set to the service port of the 3 way gas valve Connect the charge hose with the push pin to the gas service port 4 Air purging of the charge hose Open the low pressure valve on the charge set slightly to purge air from the charge hose 5 Set the 2 way liquid valve to the close position 6 Operate t...

Page 36: ... leakage of the connecting points of the piping If bubbles come out the pipes have leakage and must be repaired 2 Refrigerant leak detector method Use the leak detector to check for leakage 16 16 INSULATING REFRIGERANT PIPING LINES To conserve energy and prevent wet floors due to condensation the gas and liquid piping lines must be well insulated with a proper insulation material The thickness of ...

Page 37: ...he body s pump joint the pipe should be arranged as vertically as possible And the lift distance must be less than 200mm otherwise the water will overflow when the air conditioner stops The end of the drain pipe should be over 50mm higher than the ground or the bottom of the drainage chute and do not immerse it in water If you discharge the water directly into sewage be sure to make a U form aquas...

Page 38: ...ir conditioner a separate circuit breaker with its own overload should be installed on the electrical distribution box D Operation On Off Circuit Breaker The installation of two pole automatic circuit breaker is necessary to operate the air conditioner The circuit breaker must be installed to be far away from any flammable materials curtains etc The circuit breaker must be suitable for air conditi...

Page 39: ...extension cables If extension cables are needed use terminal block C Electrical Connections a Electrical connections must be performed in compliance with national and local wiring codes and standards b Check that the electrical connections between the terminal blocks of indoor and outdoor units are in accordance with the wiring diagrams and caution field electrical wiring contained in the manual M...

Page 40: ...l 53QC36 and 30 meter for model 53QC48 3 Operating Conditions Standard operating conditions in standard ambient for cooling Indoor 27 19 C DBT WBT Outdoor 35 C DBT High speed of indoor unit motor Maximum operating conditions in standard ambient for cooling Indoor 27 19 C DBT WBT Outdoor 46 C DBT High speed of indoor unit motor Standard operating conditions for heating Indoor 20 C DBT Outdoor 7 6 C...

Page 41: ...cable must be field connected to PCB of outdoor unit and must be also field connected to PCB of indoor unit at connect CN1 In case of requesting this cable of length more than 6 meter an additional cable with connector must be purchased from Carrier The two cables of 6 meter each must be connected together at field and connected to both outdoor and indoor units NOTES 1 Connect the power supply to ...

Page 42: ...ble must be field connected to PCB of outdoor unit at connector CN305 and must be also field connected to PCB of indoor unit In case of requesting this cable of length more than 6 meter an additional cable with connector must be purchased from Carrier The two cables of 6 meter each must be connected together at field and connected to both outdoor and indoor units NOTES 1 Connect the power supply t...

Page 43: ... of the front panel b Install service cover C Tie together refrigerant piping lines electrical connection cords and drain line Form the refrigerant piping in the required direction and bind the drain hose and electrical connection cords together with vinyl tape The drain hose should be always at the bottom of lump to assure smooth drainage The lump must be of circular shape D Fill the gap between ...

Page 44: ...gs at 220 volt and 27 ºC return air to indoor unit and high speed of indoor unit motor Readings at 380 volt and 27 ºC return air to indoor unit and high speed of indoor unit motor 20 3 STEPS FOR HEATING TEST RUNNING a Move circuit breaker to ON position b Operate the system for heating operation at high fan speed by using wireless remote control c After system operation becomes stabilized Measure ...

Page 45: ... refrigerant piping lines are tested for refrigerant leakage e The gas and liquid service valves in outdoor unit are open f The cap nuts for flare valves are properly tightened 21 4 CONDENSATE DRAIN LINE CONNECTIONS a The Condensate drain line from indoor unit is gradually inclined downwards to the outside b The Condensate water flow smoothly 21 5 ELECTRICAL CONNECTIONS a The operating voltage ele...

Page 46: ...y abnormal noise or vibration from the outdoor unit during operation c There is no any abnormal noise or vibration from the indoor unit during operation d The wireless remote control operate Correctly e Each lamp on the indoor unit lights normally 21 8 CUSTOMER GUIDANCE a The correct operation of the air conditioner has been explained to the customer including the following points Starting and sto...

Page 47: ...urn Air Sensor open or short circuit E2 Indoor Coil Sensor open or short circuit E3 Outdoor Coil Sensor open or short circuit E4 Outdoor Unit Protection Works E6 Electronic Control PCB EEPROM error E7 Water level alarm malfunction E8 Flash at 5Hz Protection function operates if a malfunction happens in the outdoor unit as below by leds of PCB of outdoor unit as follows Defect LED 1 LED 2 LED 3 No ...

Page 48: ... www miraco com eg ...

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