Modular Air Handling Unit

Installation and Maintenance Manual

39TC
 Contents

I. Safety Measures ........................................................................ 2

II. Model Description and Performance Characteristics ................. 5

III. Transportation and Storage ...................................................... 8

IV Installation .............................................................................. 10

V. Debugging .............................................................................. 21

VI. Routine Maintenance............................................................. 23

VII. Troubleshooting ................................................................... 31

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I. Safety Measures

CARRIER fully considers your safety during the design and manufacturing process. However, this
cannot prevent damages caused by accidents arising from unauthorized operations or improper
maintenance. The best way to ensure your safety is correct installation, proper operations and regular
maintenance.

1.1 Safe Operations

Please carefully read through the safe operation measures prior to operation of the unit.

The safe operation measures provided in this chapter must be observed strictly.

1. Description of signs:

Warning: The instructions must be observed; otherwise, it may cause personal injury due to
improper operations of the user.

Note: The instructions must be observed; otherwise, it may cause damage to the air
conditioning unit due to improper operations of the user.

Electric shock prevention: This sign applies to electrical installation, maintenance and related
operations. Only experienced and qualified electrician can undertake wiring work for this unit.

2. Installation precautions:

Warning: Installation and maintenance must be performed by qualified personnel who are
authorized by the supplier and are familiar with relevant local laws and regulations and have
experience in this type of equipment.
The customer cannot install the equipment independently. Improper installation will lead to
water leakage, electric shock and fire hazard.

Note: Please install the electric insulation device.

Grounding is required, but the grounding device cannot be connected to a gas pipeline, water
pipe, lightning arrester, etc. An improper grounding device can lead to electric shock and other
hazards.

3. User measures:

Warning: The instructions must be observed; otherwise, it may cause personal injury due to
improper operations of the user.
Operating machine and power supply are dangerous. They may lead to serious casualties.
Before maintenance, make sure to disconnect the power supply and confirm that all moving
parts have stopped.

2
 Note: To prevent electric shock, do not operate the air conditioner with wet hands. To avoid
electric shock and other damages and losses, do not spray water to clean the air conditioner
directly. Always keep the air inlet and supply paths unobstructed. Turn off the power supply if
the unit will not be used for a long time.

Note: Due to ordering difference, your unit may not have some functions contained in this manual. You
should inform CARRIER of the specific performance parameters before placing the order.

1.2 Warning Signs

Warning label for preventing electric shock

Motor grounding sign

Other warning signs:

3
4
 II. Model Description and Performance Characteristics
2.1 Set out below is the model designation of CARRIER's modular AHU:

39TC XX YY C H W

Application characteristics: Chilled water type air

conditioning unit

Characteristic H—Horizontal type V—Vertical type

C—Ceiling type; the default value is horizontal type.

Design S/N A, B, C...

Specifications XX—Height modulus YY—Width modulus

(100 mm per mode)

Carrier modular AHU, skin thickness is 25mm or 50 mm

For example: 39TC 0918 CHW
Skin thickness 50 mm, 9 modes for the height, 18 modes for the width, horizontal, chilled water type air
conditioning unit
External height of unit = Height modulus*100+T+Base height External width = Width modulus*100+T.
39TC series: T=100; when the total height modulus of the unit is greater than or equal to 25 or the
width modulus is greater than 25, the base height is 100 mm; the heights of other bases are 80 mm.

2.2 Performance Characteristics

The modular air conditioning unit is a kind of air handling equipment made by assembling all the air
handling function sections. The air handling function sections of the unit include the units such as the
mixing section, fan section, cooling coil section, coil heating section, electric heating section, filtering
section, humidifying section, water spray section, heat recovery function, etc. The above function
sections can be selected according to the customer's requirements.

2.2.1 Elimination of Cold Bridge

All the metals in the cabinet of CARRIER's labyrinth AHU are isolated from outside metals using
polyurethane foam and specially designed rubber sealing strips, putting an end to the thermal
insulation strips attached here and there inside the common AHU. Therefore, CARRIER's labyrinth
AHU can avoid cold bridge in a simple way.
2.2.2 No Air Leakage
Adopting CARRIER's patented labyrinth design, the aluminum profile and panel form a whole through
high-pressure polyurethane foam, and the aluminum profile is designed with a concave groove and a

5
convex groove. A tenon is formed when the concave groove and convex groove are joined. Thus, it
implements strict labyrinth sealing together with fastening of bolts and nuts.
2.2.3 Anti-rust Cabinet
Aluminum profile frames are set around four sides of all the panels, so all the sheet metal edges and
corners are isolated from wet air, preventing rust spots on the panels.
2.2.4 Firm Structure Design
CARRIER's labyrinth AHU contains an outer aluminum alloy frame and a hidden inner square steel
frame, and the outer aluminum alloy frame forms a rigid body with strong torsion resistance through
the tenon structure and fastening of bolts and nuts, but the final rigidity comes from the hidden square
steel frame.

Figure 2.1 39TC series modular AHUs

2.2.5 Flat Inside of Cabinet

CARRIER's labyrinth AHU is flat inside, and there are no thermal insulation strips and sealing strips
attached here and there and small spare parts that look cumbersome. Hot-dip galvanized or stainless
steel sheets can be selected for inner walls. The AHU proves to be the best choice for purifying air
conditioners and IAQ air conditioners.
2.2.6 Modular Cabinet
The modular cabinet is adopted. The standard modular cabinet and the bolts and nuts for fastening
make Completely Knock Down (CKD) very convenient.
2.2.7 Safe Handle
CARRIER's labyrinth AHU adopts dual door handles. The access door can be opened from both the
inside and outside of the cabinet, thus improving safety.
2.2.8 Leveling Device
A leveling device is attached to the unit base. The cabinet levelness can be adjusted before two
cabinets (function sections) are connected, thus ensuring seamless connection of cabinets.

2.2.9 Heat Recovery Device

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A heat recovery device can be configured for CARRIER's air conditioning cabinet according to the
user's requirements to implement energy recovery, saving both energy and the user's operating cost.
Currently four forms are available: plate heat recovery, rotary heat recovery, heat pipe type heat
recovery, and intermediate media type heat recovery.
2.2.10 Design of Positive Pressure Door and Negative Pressure Door
Positive pressure door: In addition to the negative pressure door opened outward, CARRIER's
labyrinth AHU is also designed with a positive pressure door opened inward, which can reduce the air
leakage rate of the positive pressure section and strengthen the safety performance.
2.2.11 Polyurethane for Thermal Insulation
The panel consists of the polyurethane foam with an extremely low thermal conductivity and the inner
layer and outer layer of steel sheets. Two kinds of standard panel thicknesses are available: 25 mm
and 50 mm.
2.2.12 Heat Exchanger
Mechanical expansion tubes are adopted in the manufacturing process of heat exchanger to ensure
good contact between the copper pipe and the copper pipe and aluminum foil fixing parts. Besides,
multiple options are provided, including hydrophilic aluminum foil, tinned copper foil, steel sheet of
steel pipe, aluminum sheet of steel pipe, and stainless steel coil. The cooling coil, hot water coil and
steam coil of air conditioning cabinet are all selected using special model selection software, which is
compiled strictly according to the law of thermal engineering. Moreover, the software has been
corrected in consideration of actual use conditions of coils to make it more reliable.
2.2.13 Low Noises
AHU is characterized by the high safety coefficient of motor and low noises. All the adopted low noise
fans have undergone a strict static and dynamic balance test and have been selected using special fan
application software to achieve the optimal fan operating point, fan efficiency and noise level. The fan
and motor components are all provided with unique vibration damping devices, and flexible connection
is adopted between the air outlet of fan and the panel, minimizing the unit vibration and noises. The
unique sealing structure further prevents noises coming out of the unit. Therefore, a unit operating
quietly is offered to you to meet the application requirements of respective industries in different
scenarios.
2.2.14 Filter
Air conditioning cabinet can be configured with primary/medium efficiency plate filters, primary/medium
efficiency bag filters and sub-high efficiency dense-pleated filters according to the user's handling
requirements, or filters of other forms can be configured according to the user's requirements. In the
purifying air conditioner field, our quality filters and advanced installation modes an ensure cleanness
of air conditioning units in various occasions.

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 III. Transportation and Storage
3.1 Packaging of the Unit
When CKD transportation is adopted for the unit, all the parts of the unit are packaged using wooden
boxes separately; when whole transportation is adopted for the unit, the top four corners are protected
using corrugated paper, and the whole unit is wrapped using plastic film after assembly.

Figure 3.1 Packaging of the modular AHU

3.2 Transportation of the Unit

Due to the big size, usually the modular air conditioning unit is transported by segment, and CKD
transportation can be adopted if the unit size is especially large or there is special requirement. Carrier
recommends CKD transportation for the unit higher than 2.5 m.

3.3 Handling and Lifting of the Unit

Properties of the crane or forklift used for unit transportation and handling tools must comply with
safety requirements, and the quality and transportation method must accord with local laws and
regulations, with a view to avoiding accidents. The unit or packaging box should be kept horizontal
when being handled and lifted, avoiding unwanted damages to the parts. The forklift loading and
unloading port and lifting hole are reserved for the unit or packaging box before delivery. Operate
according to the method shown in the figure during lifting, without causing danger or damaging the unit.
Before lifting, insert materials such as hard cardboard at the position where the wire rope comes into
contact with the cabinet, preventing the wire rope from scratching the unit.
Hanger
Stay bar

Wire rope

Steel pipe

Figure 3.2 Unit lifting method

Warning: No person can stand under the unit during handling and lifting.

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3.4 Storage of the Unit
If the unit needs to be kept outdoors before being installed in the equipment room, prevent the unit
from being affected by dirt, rain and snow or destroyed by animals, and do not damage the protective
film on the surface of the unit. Do not expose the unit under direct sunshine in summer; otherwise, the
thermal insulation board will be deformed. If the unit needs to be installed outdoors, specify this
requirement when placing the order so that Carrier can take special treatment measures. Units should
be stacked according to the outer package label.
Units and their parts should be stored in the following indoor environment:
Relative humidity:  <80%
Ambient temperature: -30℃ - +50℃.
Units and their parts should be kept far from dust, gas, steam or any other chemicals that may affect
their performance.

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 IV Installation
4.1 Inspection and Acceptance
After arrival of goods and before installation on the site, check whether all the function sections and
parts of the units are intact, and whether all the accessories are complete and in good conditions.
Notify the distributor in writing immediately upon finding material shortage or damage.

4.2 Foundation Settings

(1) Levelness of the foundation directly affects installation and operation of the unit. If the
foundation is not horizontal, installation will become difficult, the thermal insulation board joint is
too large and leads to air leakage, condensate water cannot be discharged smoothly, and the
installed fan tilts, leading to imbalance, etc. CARRIER recommends that the levelness error of
the unit foundation should not exceed ±3 mm. The unit for lifting installation should also be kept
horizontal.
(2) The foundation can be made by pouring concrete or welding channel steel. The channel steel
surface should be kept flat during welding. The foundation height should not be less than 150
mm. Trench and floor drain should be reserved around the foundation so that condensate water
and sewage after unit flushing can be discharged.
(3) The bearing capacity of floor should be ensured for the unit to be installed on the floor. It is
advised to place a damping rubber pad under the unit base to reduce vibration. For the lifting
unit, the hanger must have sufficient strength to bear the unit weight, and a damping device
should be set on the hanger rod.

4.3 Assembly of the Unit

Field installation needs to be completed under instructions of professional technicians who are familiar
with the product and have received training. Pay attention to the following aspects during installation:
(1) The unit should be installed strictly according to the drawing provided by CARRIER;
(2) A space for troubleshooting of each function section should be reserved during installation;
(3) The unit cannot bear the weight of external pipe and air duct;
(4) Flexible connection should be adopted between the air conditioning unit and external air duct to
avoid vibration transmission;
(5) Unit cabinet plates must be connected tightly. If rubber sealing strips are adopted, they must be
pressed to prevent air leakage;
(6) The air filter should be installed after other parts of the unit have been installed;
(7) During unit installation, clear foreign matters from the unit in time, use compressed air or a hair
brush to remove dust from the coil fin, and correct the deformed pin.

4.4 Pipeline Installation

The pipeline system must be installed in accordance with local laws and regulations. Bends and
up/down displacements should be minimized in pipeline design to reduce the cost and maintain the
optimal unit performance. The pipeline must undergo insulation treatment. Proper installation includes
the following items:

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1) A damping device: It can reduce the vibration and prevent the pipeline from getting loose due to
vibration and leading to water leakage.
2) A repair valve: It can be closed during maintenance to separate the unit from the pipeline system.
3) A sufficient water pressure should be maintained for the system, and the coil resistance should
be subject to the nameplate label of the corresponding unit. The maximum operating pressure of
CARRIER's coil is 1.6 MPa. If the operating pressure exceeds 1.6 MPa, inform CARRIER of it
when placing the order so that CARRIER can take special treatment measures.
4) A water filter should be installed before the water pump to remove impurities from water.
5) For connection to the unit coil, the pipe should be connected according to the unit label (the cold
water coil of CARRIER's air conditioning unit adopts the top outlet and bottom inlet mode usually,
and the steam coil adopt the top inlet and bottom outlet mode) to avoid connection error. During
connection, the unit pipe connector must be fixed to prevent twisting of the copper tube and lead
to rupture.
6) The steam coil produced by CARRIER employs steel sheet of steel pipe or other forms. Besides,
a steam trap should be installed at the steam coil outlet to facilitate smooth drainage in the coil.
7) Water seal for the unit
Water seal must be installed for the condensate pipe of unit. The water seal height should comply with
the requirements shown in the figure:
In the figure, H = Internal negative pressure (mmH2O)+20
Note: The internal negative pressure refers to the negative pressure of the coil section.

Figure 4.1 Water seal installation for the unit

8) Piping requirements for the steam coil

(1) The steam pipe must be installed in compliance with the national standard, ensuring that
saturated steam is sent to the steam coil and preventing water hammer in the coil.
(2) The coil and pipeline should be supported separately, and the load cannot be placed on the coil
directly.
(3) The steam coil is connected to a steam trap:

11
a. A steam trap should be installed at the steam coil outlet and the lowest position of the steam
pipeline.
b. A collecting pipe should be set between the coil outlet and the steam trap. Before each time of
steam supply, the collecting pipe should be opened to drain remaining condensate water; after
the unit is stopped in winter, the collecting pipe should be opened to drain condensate water
from the coil, preventing frost crack of the coil.
c. A filter should be set before the steam trap. It may not be set if the steam trap has the filtering
function meeting requirements.
d. The installation height difference between the coil outlet and steam trap cannot be less than
300 mm.

Steam
inlet pipe
The products in
the dashed line
box are
provided by factory
Steam Steam coil
outlet pipe

Filter
Condensate
return

Steam Collecting
trap pipe

Figure 4.2 Requirements for connecting the steam coil to the steam trap

e. The actual operating pressure difference and hydrophobic ratio coefficient of the installation site
should be considered when the drainage capacity of steam trap is selected. The condensate
water displacement of coil is calculated as follows:
Condensate water displacement (kg/h) = Safety factor (4)*Steam flow (kg/h)
f. For the heating equipment for production that cannot interrupt steam supply, the bypass pipe and
valve should be installed so that the steam trap can be checked and repaired. However, the
bypass pipe cannot be opened during operation of the coil, lest steam would run into the water
return system.
g. When the pipeline behind the steam trap is higher than the steam trap, a one-way valve should be
installed behind the steam trap, but the pipeline height must ensure smooth discharge of
condensate water.

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 Steam
inlet pipe
The products
in the dashed
line box are
provided by
factory
Steam Steam coil
outlet
pipe

Steam
of e trap Filter
pe at
pi ns
r y e
D ond rn
c tu
re

One-way
valve

Collecting
pipe

Figure 4.3 Installation of the steam trap for steam coil attached with a
bypass pipeline and a check valve

h. The diameter of the pipeline from the coil outlet to the steam trap should be the same as that of
the coil outlet pipe.
i. When more than two steam coils are installed, if the capacity and pressure loss of each coil are
the same and these coils are regulated using the same control valve, the steam trap can be
shared, as shown in Figure 4.4. The requirements not indicated in Figure 4.4 are the same as
those indicated in Figure 4.2 and Figure 4.3.
The products in the dashed line box are
provided by factory

Pressure
gauge

Steam
inlet pipe

Steam coil Control

valve

Steam
Steam main pipe
outlet pipe

Steam coil
Steam trap Filter

Condensate
return

Collecting
pipe

Figure 4.4 Installation of the steam coils sharing the same steam trap

j. The preheating coil and reheating coil cannot share the same steam trap; when different coils are
combined, the control valve and steam trap should be set separately.

4.5 Electrical Installation

All the wiring and grounding must comply with the related electrical regulations. To prevent excessive

13
voltage fluctuation, the power cord should be separated from the transformer line of welding
equipment; every air conditioning unit should be configured with an independent power supply
equipped with a current circuit breaker.

4.5.1 Wiring of Lighting Lamp

If the customer requires that lighting lamps should be configured, we will configure the standard 36V
waterproof lamps. No transformer is configured for the unit before delivery. The customer needs to
configured transformers independently during installation. During wiring, check whether the power
voltage is correct.

4.5.2 Motor Starting Modes

A. Direct starting
The motor winding can adopt the Y or △ connection method, but must comply with the motor
nameplate. For example, 380VY of the nameplate indicates the voltage 380V, and Y connection
method is adopted; 380V △ of the nameplate indicates the voltage 380V, and the △ connection
method is adopted. The connection method in Figure A is adopted.
B. Reduced voltage starting
The power voltage must be the rated voltage of motor during normal operation, that is, the △
connection method is adopted. The power cord lead-out mode for motor shown in Figure B is adopted
when the motor starts according to this method. CARRIER recommends reduced voltage starting for
the motor of 11.0 kW or above, and the connection method in Figure B is adopted. The motor should
be grounded safely.

Figure A Figure B

Figure 4.5 Motor starting modes

C. For starting wiring of double speed motor, the following figure can be used as a reference:

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 Low speed
operation

High speed
operation

Low speed
operation indicator
High speed operation
indicator
Power indicator

Wiring diagram

Low speed High speed

Figure 4.6 Starting wiring diagram of double speed motor

In the figure: QF: Circuit breaker; FU: Fuse; KM1: Low speed contactor of fan; KM2 and KM3: High
speed contactor of fan; FR1: Low speed thermal relay; FR2: High speed thermal relay; SBO: Stop
button; SB1: Low speed start button; SB2: High speed start button; HL1: Low speed operation
indicator; HL2: High speed operation indicator; HL3: Power indicator.

D. For control wiring of the inverter motor, refer to the figure below:

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 380V/3N /50Hz
PE

Inverter parameter setting

R S T N table

Parameter Setting
QF
HL1
01-00 50
Fire valve, which can be short-circuited when not used
FU1 RA1 RC1
01-01 50
380

KA2
01-02
01-07 50
SB2
01-08 30
SA1 (local) SB1
01-09 10
KA3 KA1 01-10 10

KA3
02-00 01
KM
02-01 02
R/L1 U/T1
SA1 (remote) Remote startup signal 02-02 00
S/L2 V/T2 FAN
VVVF KA2
HL2 02-04 01
T/L3 W/T3 FR
03-00 16
KA3
+24V VFD-F
FWD 03-01 23
RA1
REV FM 04-00 00
RB1 Operation
EF 00
RC1
04-01
Mi1 04-02 00

KM
RA2
Mi2 04-03 00
RB2 Failure
Mi3
Mi4 RC2 RA2 RC2 04-04 00
Mi5

KA1
Mi6
AFM1 04-05 00
Mi7 AFM2 FAN2 FR
HL3 04-06 00
Mi8 ACM
FR 04-07 00
DCM
E
E
+10V
SA 0-5V 0-10V KA2

100 AVI SW2

SA ACi1 Notes:
0~10VDC R
KA1
ACi2 Dotted line - Customer connection
KM: AC contactor QF: Low-voltage circuit breaker FU: Fuse
101 ACM
SA: Changeover switch KA: Intermediate relay HL: Indicator
KA1
WVF: Inverter FR: Thermal relay

Figure 4.7 Control wiring diagram of the inverter motor

This figure applies to the inverter of Delta brand. For other brands, the connecting terminal for inverter
varies, but the other functions are the same.

4.5.3 Wiring of Electric Heater

An overall framework has been made for the electric heater before delivery, internal wiring has been
completed, and a power access port is reserved. It is only required to connect to the power supply
according to the unit label. For control wiring of the electric heater, refer to the figure below:

16
 Temperature
Fuse controller

Figure 4.8 Control wiring diagram of the PTC electric heater

Notes: 1. For the electric heater under 150 kW, install two temperature controllers; for the electric
heater of 150 kW or above, install three temperature controllers.
2. Do not debug or use the electric heater when the fan is not operating. The electric heating
frame (terminal-E) must be grounded reliably.
3. The electric heater needs to be connected to the control circuit (closed normally); otherwise,
the high temperature protection function cannot take effect.
4. For selection of the protective earth wire, refer to the national standard GB 7251.1-2005/IEC
60439-1:1999. When the AC phase line diameter S is less than 16 mm 2,
the selected protective earth wire diameter is the same as the phase line diameter; when the AC phase
line diameter S is equal to or greater than 16 mm 2 but equal to or less than 35 mm 2, the selected
protective earth wire diameter is 16 mm 2; when the AC phase line diameter S is greater than 35 mm 2,
the selected protective earth wire diameter is one half of the selected phase line diameter (note: The
AC phase line diameter here refers to the required phase line diameter selected for the electric heating
power of whole set).
5. Null line diameter selection: The phase line section (copper stranded conductor, 35 mm 2) is
taken as the boundary. When the AC phase line diameter S is less than or equal to 35 mm 2,
the selected null line diameter is the same as the phase line diameter; when the AC phase
line diameter S is greater than 35 mm 2, the selected null line diameter is one half of the
phase line diameter but not less than 35 mm 2 (note: It is required to lead out a group of null

17
 lines for each step according to the grading; when the customer adopts controlled silicon
control, the null line should be selected according to two times of the live line current).
6. The power cord should be selected according to the table below:
Specific
ation 12 15 18 24
mm2 1.5 2.5 4 6 10 16 25 35 50 70 95 0 0 5 0
Current 12 15 18 21 25 28 34
A 10 15 20 30 45 59 78 97 0 3 4 4 0 5 4
Power 10 12 14 16 18 22
kW 7 10 13 20 30 39 51 64 79 1 1 1 5 8 7
7. The control circuit diagram of electric heater is shown below:
380V/3N~/50Hz

R
S
T
N

：
：

Figure 4.9 Control circuit diagram of electric heater

Warning: The electric heater is a high temperature operating part, and improper circuit
handling will lead to a fire or personal injury. Before use, ask a professional to carefully read
through the manual and check to confirm the following functions:
(1) Confirm that the overheating protection switch (closed normally) of electric heater has been
installed.
(2) Confirm that the overheating switch action of electric heater is normal.
(3) Confirm that the overheating switch of electric heater has been connected to the electric heating
control loop, and wiring is correct.

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(4) Confirm that the main loop of electric heating is configured with a circuit breaker (with a shunt
release). When the electric heater fails, make sure that the main loop of electric heating is
powered off.
(5) Confirm no-wind power-off protection (wind break switch) for the electric heater. The electric
heater is linked with the fan. The electric heater can start only when the fan operates normally and
maintains the stable air flow as needed.
(6) When the system is stopped, the electric heater is turned off first, and the fan will stop after a
delay of five minutes (when the electric heater is too large, the delay time should be prolonged
properly), making sure that the electric heating margin is taken away.

4.5.4 Installation and Wiring of Other Electric Appliances

During the control solution design, the electrical wiring of other parts such as humidifiers is subject to
the wiring diagram attached to the unit. Pay attention to the following items:
A. The humidifier must be linked with the fan, that is, the humidifier is started after the fan; the fan can
be turned off only after the humidifier is turned off; B. If there are electric air valves in the air inlet
and outlet and the air system pipeline of the unit, the air valve actuator should be started before the
fan starts and stopped after the fan stops, that is, all the air valves in the pipeline are normally open
when the fan is operating.

Warning: All the electric appliances must be grounded safely according to the labels and
cannot be connected to the null line instead of being connected to the ground. A wiring error will
lead to severe explosion, fire, or personal injury accident.

4.6 Installation and Debugging of the Differential Pressure Switch

The differential pressure switch is used to check the fan pressure difference to protect the unit. The
difference between the negative pressure section of fan and the atmospheric pressure is calculated.
The negative pressure section of fan in the unit is adopted for the pole of negative pressure end ( “-”
used as the sensor mark); the atmospheric pressure is adopted for the pole of positive pressure end
(“+” used as the sensor mark). Debugging method: After the differential pressure switch is wired
correctly according to the electrical drawing, adjust the pressure difference value to 50 Pa. After the
unit operates normally for 3 minutes, take the pressure tube for the negative pressure end of
differential pressure switch from the unit. Now, the unit sends an alarm and stops, and prompts "Fan
failure or wind loss protection". The alarm is reset after the pressure tube of differential pressure switch
is reinstalled. Start the unit again. The unit operates normally, and the debugging work is finished.

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 Differential pressure switch

Negative pressure
section of fan

C
Installation position diagram of the
differential pressure switch

Figure 4.10 Installation position of the differential pressure switch

Note: Since the specification, model and brand may change, the instructions related to
unit accessories and humidifier in this manual are used for reference only. The specific using
methods are subject to the accessory instructions attached to the unit.

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 V. Debugging
5.1 Check
Before debugging and operation, the unit should be checked comprehensively. The check work should
include the following aspects at least:

 Check whether the unit has been installed completely and whether foreign matters have been
removed from the inside.

 Check whether the filter material of filter is damaged or contaminated. Cover a layer of nylon filter
mesh before the filter of air inlet section, preventing dust in the pipeline from contaminating the
filter. The medium/high efficiency filter can be installed after debugging is completed. When
conditions permit, the customer can prepare one set of primary efficiency filters to be used during
debugging.

 Check whether the spring pressing device has been removed. To prevent vibration during
transportation of the unit delivered as a whole, a spring pressing device is configured on the fan
motor base. Remove this device before the unit operates.

 Check whether the fan impeller of the rotating part rotates flexibly and whether it comes into
contact with the shell, check the lubrication condition, and check whether all the regulating
devices are flexible.

 Check whether all the air valves in the air system pipeline are opened according to the designed
position, and whether the locking mechanism has been locked.

 Check whether the water system has been cleaned and air has been exhausted from the system.
The pipeline should be rinsed after the pipeline system has been installed. During cleaning, be
sure to close the valve connected to the unit, lest foreign matters in the pipeline would be flushed
into the coil and block the loop. Before filling water for use, open the exhaust valve first to drain
the air from the pipeline, and close it when water is discharged.

 Check whether the motor insulation is qualified. The winding may be damped when the motor
stops operation for a long term. Before use, use a megohm meter to measure its insulation
resistance. The insulation resistance at 25°C should exceed 2 MΩ.

 Note: After measurement, the winding must be discharged immediately to avoid electric
shock. If the insulation resistance does not reach the reference value, the winding must be dried.

 Check whether the power voltage meets the requirement, whether the three-phase voltage is
balanced, and whether the circuit wiring is correct. Before formal startup, the motor switch can be
pressed for a trial to check whether the fan rotation direction is correct.

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5.2 Trial Operation
The unit can be started after the above check work is completed. After the unit starts, monitor whether
the motor operating current is normal and whether the unit sends abnormal sound. Check whether the
unit air flow and air pressure are normal. The cooling capacity and humidifying capacity should be
regulated according to different operating conditions.

The following situation should be regarded as normal:

Noises
Noises will be generated when air flows at a high speed or the fan motor operates. Noises can be
regarded as normal so long as it is not higher than the value specified for the product sample or in the
nameplate or other contract documents.
Vibration
Certain vibration is generated when the fan motor rotates at a high speed. Vibration should be
regarded as normal when it is not higher than the value specified by the national standard or other
contract documents.

22
 VI. Routine Maintenance
Check the unit operating status on an irregular basis, and implement long-term and effective
maintenance for the unit so as to greatly improve the unit operation reliability and service life.

6.1 Rinse the unit coil regularly to remove dust accumulated outside the coil. After the coil has been
used for 2-3 years, clear the water scale inside. If possible, use softened water to produce
cold/hot water for the unit coil.

6.2 When the unit stops operation in winter or operates in the non-heating mode, exhaust water
from the coil (system); otherwise it will lead to frost crack of the coil.

6.3 Check the dust accumulation status on the unit filter screen regularly (twice per month
recommended). If a differential pressure detection device is installed, the user needs to clean or
replace the filter in time when the final resistance reaches the defined value. CARRIER
recommends the following final resistance values:
Filtering efficiency specification Recommended final resistance (Pa)
G3 (primary efficiency) 100-200
G4 (primary efficiency) 150-250
F5-F6 (medium efficiency) 250-300
F7-F8 (medium/high efficiency) 300-400
F9-H11 (sub-high efficiency) 400-450
High efficiency and ultrahigh efficiency 400-600

6.4 After the unit has operated for one week, readjust tightness of the belt. After that, perform
routine check every three months.

6.5 After the unit has operated for a period of time, the wiring pile head of electric wire will get loose.
Check and tighten the wiring pile head in three days after the unit is turned on for the first time.

6.6 The fan and motor bearings need to be checked regularly (three times per month
recommended). Check the motor bearing sealing ring (e.g., V-sealing ring), and replace it when
necessary; check whether the installed and connected parts get loose; check the bearing
operating status by listening to abnormal noises, detecting vibration, and monitoring the oil
consumption or bearing vibration measuring element. In case of any abnormality, stop the unit
immediately, and locate and eliminate the cause in time. Take heating measures or use special
tools to install, remove or replace bearings. Do not knock or pry bearings.

6.7 Fan Bearing Maintenance

(1) For the fan with an oil injection nozzle, lubricating grease should be filled for the bearing
regularly: clean lithium based grease No. 2.
(2) If the user selects the grease of a brand for filling, the grease of this brand should be always
used.
(3) The validity period of lubricating grease depends on the grease type, bearing rotating speed,
shaft diameter and operating environment. Normally, the lubricating grease should be replaced
after the fan has operated for about 1500 hours; if the fan operates continuously for 24 hours,
replace the lubricating grease every 500 - 700 hours of operation.

23
(4) How to fill lubricating grease: Keep the shaft rotating when filling lubricating grease, stop filling
when seeing one layer of fresh grease overflowing, and use hand to rotate the wind wheel fast
to discharge excess grease.

6.8 Check the access door sealing strip and flexible connector of air duct regularly (once a month
recommended). If finding air leakage, replace them in a timely manner.

6.9 Humidifier Maintenance

6.9.1 Dry Steam Humidifier

1. Installation and use precautions of the humidifier

(1) Before installing the humidifier, use tap water or other methods to rinse and remove dirts such
as welding slag, rust and sediment from the steam pipe, lest they would stuck the electric valve.
(2) A filter (120 meshes) and a stop valve must be installed before the air inlet of humidifier.
(3) Install trap and sewage valve horizontally at the water outlet of humidifier.
(4) The humidifier can be connected only after the connection power supply is verified consistent
with the power supply (signal) of electric regulating valve.
(5) When the steam pressure of pipeline is greater than 0.4 MPa, a pressure relief valve must be
installed.
(6) When introducing steam to the humidifier, open the stop valve to increase pressure slowly to
prevent stalling of the electric valve. Meanwhile, open the water drain valve to discharge
condensed water from the pipeline.

Stop valve 120-mesh filter

Humidifier steam entrance

Spray bar
The product in
Steam water
separator the dashed line
Humidifier box are provided
water outlet
by factory.
Install a variable
Trap connector as needed
Used as sewage valve
and water drain valve

Figure 6.1 Installing the humidifier

(7) If humidifier will not be used for a long term, cut off the power supply, and perform regular
maintenance according to the ambient humidity. Connect the corresponding power supply
signal for 5-10 minutes every about two months to run the motor.
(8) The distances from the jet nozzle of humidifier to the elbow, variable diameter tube and air
supply outlet in the air system are not less than 1.2 m, and the distances from the temperature
controller and humidity test point are not less than 1.5 m.

24
2. Troubleshooting for the dry steam humidifier
Symptom Cause Troubleshooting solution
There is no steam in the main
Check air supply of the pipeline.
pipeline.
The dry steam The steam pipeline valve cannot be
Open the main pipeline valve.
humidifier fails to opened.
work. The manual regulating valve is not Open the manual regulating
opened. valve.
The electric valve is not opened. Open the electric valve.
The humidity of The valve opening degree is too large. Reduce the valve opening.
air conditioning
The steam pressure is too high. Reduce the steam pressure.
room is too high.
The diameter of steam transportation
Replace it.
pipeline is a little small.
Increase it to a value not
The steam pressure is relatively low.
exceeding 0.4 MPa.
The valve opening of each link is not
The humidifying Increase the valve opening.
enough.
capacity of the
Clean or replace the filter
humidifier is The filter is clogged with dirt.
cartridge.
insufficient.
The air duct leaks air. Seal the air duct.
The exhaust volume of air
Reduce the exhaust volume.
conditioning room is too large.
The selected humidifier model is a
Increase holes or humidifiers.
little small.
Use pipe wrench and spanner to
The connector gets loose.
tighten it.
The connection sealing ring is Replace it or re-wind the sealing
The humidifier damaged. material.
leaks air. Damage or deformation is caused
Repair or replace parts.
during transportation.
Air holes and sand holes stay in the
Weld them.
raw material.
The steam transport pipe is too long,
Reinforce thermal insulation of
so the thermal insulation is poor and
the pipeline.
steam is cooled to water.
The installed steam supply pipe is not Install steam supply pipe
The humidifier
horizontal, and condensed water in horizontal or add a trap device to
sprays water.
the pipeline flows to the humidifier. the upstream of humidifier.
Install the humidifier according
The installation method is not correct. to the correct installation
method.

25
 The steam trap cannot drain water in
Open the water drain valve, and
time because too much water is
close it after the water is
accumulated in the pipeline when the
drained.
unit is powered on.
The drainage capacity of steam trap is
Replace the steam trap with
too small or the steam trap is
one with a large capacity.
damaged.
The drain hole of steam trap is
Clean the steam trap.
clogged by dirt.
The humidifying capacity is too large
Reduce the humidifying
and the dry air absorption is
capacity of the humidifier.
over-saturated.
The humidity in the air conditioning Turn off or reduce the
cabinet is too high. humidifying capacity.
Increase the humidifying
The humidifying section distance is section distance in
too small. consideration of local
conditions.
Connect wires according to the
Wiring is wrong.
correct method.
The actuator signal is not matched
Adjust the control signal.
with the controller signal.
The actuator switching switch position Dial the switching switch
is incorrect. position.
The electric valve
The actuator control panel is
does not work. Replace it.
damaged.
The motor is damaged. Replace it.
The rotary gear is damaged. Replace it.
Add lubricating oil for
The actuator valve plug is stuck.
maintenance.
The valve body is corroded seriously. Repair or replace it.
The valve port is blocked by foreign Disassemble the valve to rinse
The electric valve
matters of the steam pipeline. it.
leaks air or
The valve seat is worn by sharp and
cannot be closed Replace the valve seat.
hard objects.
tightly.
The valve body screw gets loose. Tighten the screw.

6.9.2 High-pressure Spray Humidifier

1. Use conditions
Water supply quality: Tap water, purified water or similar water;
Water supply pressure: 0.05 MPa to 0.3 MPa;
Water supply temperature: 4°C—60°C

26
2. Troubleshooting
Symptom Cause Troubleshooting solution
After the The power supply is not
switch is connected.
turned on,
the indicator
Connect the power supply as
is not turned
required.
on and the The power supply is not matched.
main unit
does not
operate.
The fuse is damaged. Replace the fuse.
After the
The water source pressure is not
switch is Increase the water pressure.
enough or there is no water.
turned on,
The humidity reaches the set
the indicator It is normal.
value.
is turned on
The humidity controller is in poor Reinstall the humidity controller
and the main
contact. connector.
unit does not
The main control circuit is
operate. Replace the control panel.
damaged.
When the The water source is not
Connect the water source.
switch is connected.
turned on, Remove the connector and
The water line is blocked.
the main unit rinse the pipeline.
operates, but Disassemble the filter to clean
The Y-shaped filter is blocked.
the spraying the filter screen and inner wall.
function does
The solenoid valve is damaged. Replace the solenoid valve.
not work.
The water source pressure is too Increase the water pressure of
The pressure
low. water source.
is too low
The booster pump is worn down. Replace the pump impeller.
after the unit
Repair or replace the water
is turned on. The pipeline is broken and leaks.
pipe.
Some The nozzle is blocked. Clean and dredge the nozzles.
nozzles do
not spray or
The nozzle is worn down. Replace the nozzle.
spraying is
abnormal.
The pressure
gauge does
not display
The pressure gauge is damaged. Replace the pressure gauge.
value after
the unit is
turned on.

27
 The nozzle
still sprays
water after The solenoid valve is damaged. Replace the solenoid valve.
the unit is
turned off.
Note: When the humidifier is not used for a long term, turn it on for 5—10 minutes every
about two months.

6.9.3 Electrode Type Humidifier

1. Use conditions
Water supply quality: Only clean tap water and civil softened water can be used. Deionized water and
distilled water are forbidden.
Electric conductivity: 125-900 μs/cm 2
Water hardness: not greater than 30 Germanic degrees; otherwise a water purifier must be installed.
Water supply pressure: 0.1 MPa—0.35 MPa
Water supply temperature: 1°C—45°C
Power supply: AC380V, 50Hz.

2. Installation and maintenance

1) The joint of the steam outlet and jet nozzle should be connected reliably, without twisting.
2) The main unit should be installed stable, vertically and reliably.
3) Galvanized pipe and other high temperature resistant materials should be adopted for drain pipes.
4) The water supply pipeline must undergo insulation treatment; otherwise water leakage may be
caused by condensation. The water drain pipeline must undergo insulation treatment; otherwise
scald may be caused.
5) Be sure to clean the water inlet pipe before connecting it to the humidifier. A failure will arise if dirt
and foreign matters flow from the pipe to the humidifier.
6) For the steam tank detachable, clean it every 200 hours, and check the steam tank sealing,
electrode and other components on a monthly basis. Replace the electrode every 2000 hours.
Clean the steam tank according to the procedure below: Press the water drain switch manually to
drain water from the steam tank, turn off the humidifier power supply, remove the plug on the
electrode, make a mark, remove the steam tank, pour the debris out of the tank, use water to rinse
the tank, and install it at the original position. Note to ensure good sealing at the sealing position,
and connect the electrode plug according to the mark. Maintenance and cleaning method of the
integrated humidification tank non-detachable: After use for 150 hours, press the water drain
switch manually to drain water from the tank, press the water drain switch again to close the water
drain valve, and replenish water to the humidifier. Repeat the procedure for two or three times.
Replace the steam tank when the electrode rod is corroded.

28
 Above 20%

Above 5% Hose connection end raised

Hose connection end lowered

Correct installation method I Correct installation method II

Figure 6.2 Pipe connection diagram of the electrode type humidifier

6.10 Instructions of Mark Ⅱ Differential Pressure Gauge

1. Debugging and maintenance

Check the instrument oil (red camphor oil) position, and use the zero adjusting knob to set zero. In the
zero adjusting process, make sure that the press leading tube has no connection pressure, and this
differential pressure gauge is in the atmospheric pressure. Use soft soap water to clean the gauge
body. Do not use liquid that may harm the gauge.
2. Filling instrument oil (red camphor oil)
Rotate the zero adjusting knob anticlockwise till it cannot be rotated anymore, and then rotate it
clockwise for three circles (in this way, the zero adjusting knob is approximately in the middle position
of the adjustment scope). Now, remove the plug of filling hole, fill red camphor oil in the gauge till the
oil level reaches the zero graduation, use the zero adjusting knob to carry out fine tuning, and finally
install the plug of filling hole. If excessive liquid is filled, pour out excess red camphor oil and then
install the plug.

Note: Since the specification, model and brand may change, the instructions related to unit
accessories such as differential pressure gauge and humidifier in this manual are used for reference
only. The specific using methods are subject to the accessory instructions attached to the unit.

6.11 Consumables and Wearing Parts

The following accessories are consumables or wearing parts:
a. Air filter
b. Belt
c. Steam tank of the electrode humidifier
d. Fan bearing

29
The user needs to replace them according to use conditions, lest an equipment fault may occur.

30
 VII. Troubleshooting
Common Cause Solution
Fault
1. The impeller or fan bearing gets loose. 1. Lock the bearing seat.
2. There is foreign matter in the impeller or volute. 2. Clear the foreign matter.
3. The installed air duct and regulating valve get loose. 3. Fasten them.
4. The two V pulleys are not at the same central line, 4. Readjust the V pulley or V belt.
and the V belt is too loose or too tight.
5. The motor, fan or motor seat bolt gets loose, leading 5. Fasten the bolt.
to the loosening problem.
Abnormal 6. The flexible connector of fan outlet is too tight. 6. Replace it with a proper flexible
sound connector.
7. The fan rotation speed is too high, and the operating 7. Match the belt pulley again.
point is not proper.
8. The bearing contains dirt due to poor quality of the 8. Use quality lubricating oil and
lubricating oil. clean the bearing.
9. Noises are caused because the deflector is too small 9. Replace the deflector.
or the air duct turning is too sharp.
10. The selected fan is too small. 10. Replace the fan.
1. The filter screen is too dirty. 1. Clean the filter screen.
2. The air duct sealing is poor. 2. Check the air duct and plug the
pipeline leakage.
The rotation
3. There is an obstacle in the air duct or the air valve is 3. Check the pipeline and make it
speed is
not opened. smooth.
correct, but
4. The fan rotates inversely. 4. Change the power phase
the air flow
sequence of motor.
rate is
5. The belt gets loose or the motor and fan belt pulley 5. Adjust the belt and belt pulley.
insufficient.
are not at the same straight line.
6. The selected fan is improper. 6. Select the proper fan and air flow
rate.
The rotation 1. The selected fan is improper. 1. Select the proper fan and air flow
speed is rate.
correct, but 2. The air return pipe leaks air severely. 2. Check the pipe and plug the
the air flow pipeline leakage.
rate is too
large.
The air flow 1. The wind speed of the air outlet is too high. 1. Increase the air supply outlet
rate in the air area.
conditioning 2. The air flow organization is not reasonable. 2. Change the air outlet form or add
room is too a wind shield to make the air flow
large. organization reasonable.

31
The air in the 1. Increase the fresh air valve.
air 2. Clean the fresh air filter screen.
conditioning 3. Increase the cross sectional area
room the air The fresh air volume is not enough. of fresh air duct.
conditioning
room is not
fresh.

32
 Table of AHU Function Section Names and Icons

Function Section
No. Function Section Name Icon No. Icon
Name

1 Fan section 5 Intermediate section

Mixing section Plate filter

Air inlet section Bag filter

Air supply section Plate bag type filter

6
Dense-pleated filter
New exhaust section
section

High-pressure spray Unified as High-efficiency filter

humidification section humidification section
section

Wet-membrane Humidifier Activated carbon

humidification section filter section

Flow equalization
3 Steam humidifier section 7
section

Electrode humidification
8 Silencing section
section

Direct humidification Water retaining

9
section section

33
 Indirect humidification Dehumidification
10
section section

Heat recovery
Spray section 11
section

Cooling coil section 12 Empty section

Hot water heating

13 Inflamer section
section

Compression
4 Steam heating section 14
condensing section

Electronic
Electric heating section 15
purification section

Direct expansion section

34