Alarko Carrier AIROStar 39SQ Manual

39SQ/39SQR/39SQP
Airostar Air Handling Units
Installation, operation and maintenance instructions

CONTENTS
1 - SAFETY CONSIDERATIONS .................................................................................................................................... 3
1.1 - General .................................................................................................................................................................. .3
1.2 - Applications ........................................................................................................................................................... .3
1.3 - Instruction types ..................................................................................................................................................... .3
1.4 - Disposal of parts/materials ..................................................................................................................................... .5
2 - TRANSPORT AND LIFTING INSTRUCTIONS.......................................................................................................... 5
2.1 - General .................................................................................................................................................................. .5
2.2 - Transport and storage ............................................................................................................................................ .5
2.3 - Offloading and hoisting ........................................................................................................................................... .5
2.4 - Horizontal transport ................................................................................................................................................ .6
2.5 - Storage .................................................................................................................................................................. .6
2.6 - Warranty ................................................................................................................................................................ .6
2
2.7 - Placement ............................................................................................................................................................... 6
2.8 - Schematic diagram of an air handling unit ............................................................................................................... 6
3 - CHECKLIST OF START-UP CHECK POINTS .......................................................................................................... 9
3.1 - Checklist of start-up check points .......................................................................................................................... .9
4 - START-UP INSTRUCTIONS ................................................................................................................................... 10
4.1 - Casing ................................................................................................................................................................. .10
4.2 - Dampers .............................................................................................................................................................. .12
4.3 - Air filters ............................................................................................................................................................... .13
4.4 - Heaters ................................................................................................................................................................ .13
4.5 - Coolers ................................................................................................................................................................ .14
4.6 - DX Coils ............................................................................................................................................................... .15
4.7 - Heat recovery wheel ............................................................................................................................................. .15
4.8 - Plate heat exchanger ............................................................................................................................................ .16
4.9 - Recirculation damper ........................................................................................................................................... .16
4.10 - Fan .................................................................................................................................................................... .16
4.11 - Silencers ........................................................................................................................................................... .19
4.12 - Lighting .............................................................................................................................................................. .19
4.13 - Control panel ..................................................................................................................................................... .20
4.14 - Installation of external sensors included ............................................................................................................. .21
4.15 - Sensor Replecament ......................................................................................................................................... .22
5 - MAINTENANCE CHECKLIST ................................................................................................................................. 23
5.1 - Checklist of check points and maintenance intervals ............................................................................................ .23
6 - MAINTENANCE AND OPERATING INSTRUCTIONS ............................................................................................ 23
6.1 - General ................................................................................................................................................................ .24
6.2 - Casing panels ...................................................................................................................................................... .24
6.3 - Doors and access covers ..................................................................................................................................... .24
6.4 - Flexible connections ............................................................................................................................................. .24
6.5 - Earthing ............................................................................................................................................................... .24
6.6 - Dampers .............................................................................................................................................................. .24
6.7 - Outside air intake ................................................................................................................................................. .24
6.8 - Filters ................................................................................................................................................................... .24
6.9 - Heaters ................................................................................................................................................................ .24
6.10 - Coolers .............................................................................................................................................................. .25
6.11 - Heat recovery wheel ........................................................................................................................................... .25
6.12 - Plate heat exchanger .......................................................................................................................................... .26
6.13 - Recirculation damper ......................................................................................................................................... .26
6.14 - Fan .................................................................................................................................................................... .26
6.15 - Silencers ............................................................................................................................................................ .27
6.16 - Control ............................................................................................................................................................... .27
7 - OPEN AND CLOSED INSTRUCTIONS .................................................................................................................. 28
Abbreviations
AHU - Air handling unit
PED - Pressure Equipment Directive
SUP - Supply air
ETA - Extract air
BMS - Building management system
HMI - Human machine interface
ODA - Outdoor air
EHA - Exhaust air
rh - Relative humidity
6
7

3
1 - SAFETY CONSIDERATIONS
1.1 - General
Air Handling unit (AHU) is a device used to regulate and
circulate air as part of a heating, ventilating, and air-
conditioning (HVAC) system. So it can not be used for
differents purposes. The 39SQ air handling units (AHUs)
has been designed and manufactured in accordance with
the CE machine directive. In order to guarantee safe
operation and use of the unit, please carefully read and
observe the instructions in this document and pay special
attention to the warnings that apply to this unit. Any
modifications in the design and/or installation of the AHU
that are carried out without discussion with Carrier and
without advance written agreement will result in the loss of
the right to any warranty claims and any claim for injury to
personnel as a result of these modifications.
All work must be carried out by sufficiently trained
personnel.
All applicable personal safety devices must be used to
ensure safe working conditions. Safety gloves, glasses and
shoes must be worn for all maintenance operations. A
respiratory protection mask must be worn when changing
the filters. This pictogram shows the safety requirements
for all maintenance operations.
The technical staff should be use the most suitable
lightining for maintenence and startup. The unit should be
lighted according to EN12100.
The A weighted equivalent continuous
sound pressure level is between 70 and
85 dB(A), depending on the motor size,
fan size and fan speed. This means that
ear defenders must be worn, when the
fan is running.
All doors and hatches must have at
least one lock that can only be opened
with a special device.
Heating and cooling coils are
manufactured and supplied in
accordance with guidelines of the
Pressure Equipment Directive (PED).
Do not walk on the roof panels of units
installed inside or
outside.
Technical staff who is responsible for startup and
maintanence, has to take occupational health and safety
trainings according to the relevant national laws and
obligations. Only technical staff who fits this definition is
allowed to work on (electrical) components. All power
supplies to the unit must be disconnected, before any work
can be carried out.
Switch off the supply voltage using the main disconnect
switch /emergency stop switch.
CAUTION: Electric heaters have a separate supply and
must be switched off separately.
Use of electical equipment with a voltage above 48 V is
only permitted if an earth leakage switch is installed that
complies with local and national regulations.
1.2 - Applications
The AHU is designed for the movement and conditioning of
air, unless otherwise agreed during the design stage.
Lifting point
This pictogram shows where the AHU must be lifted and is
positioned on the support beam.
Lifting prohibited
This pictogram shows that no horizontal transport devices
must be placed under this frame section, such as pallet
lifters or the forks of fork lift trucks. It is also forbidden to
place lifting devices for transport and storage under this
frame element.
1.3 - Instruction types
The following warning pictograms and labels with text are
used.
Earthing
This pictogram indicates where the AHU can be earthed
and is on one of the support beams beneath the casing in
the fan section. If a unit consists of several sections, only
one section needs to be earthed, provided the sections are
connected in the correct way.
• The electrical components in the AHU must be
earthed, except for components with double insulation
and/or components with a supply voltage below 50 V.
• The electrical components must be installed in
accordance with national and local regulations.

4
Central data
This label contains the data for the AHU, such as order
number, position number etc. If present, the label is
normally located on the access cover or the door of the fan
assembly.
If the AHU consists of several parts, each part must
have a label with the required data.
Hot surfaces
This pictogram indicates that there are components behind
this access cover, door or panel that can cause serious
burns when touched.
The surfaces that may be hot are the heater surfaces. If
there are special special customer-specific components
behind doors, access covers or panels that have hot
surfaces and pose a potential risk, this is also indicated by
this pictogram.
Electrical voltage
This pictogram indicates that there are electrical
components behind this access cover, door or panel that
may be dangerous for the user/installer. Only qualified
electrician is permitted to carry out work on these
components. Do not work on electrical components including
control panels, switches, VFD untill you are sure ALL POWER
IS OFF and no residual voltage can leak from capacitors or
solid state components. Lock open and tag electrical circuits
during servicing ( see annex1 for lock out tag out instructions).
If the operation is interrupted, confirm that all circuits are
deenergized before the operation is resumed. For this work
the regulations of the applicable international (a.o. IEC
61557, EN 50110 and ES 59009) and national (e.g. BS
7671) standards must be observed. The pictogram is
attached to the access cover for the electric heater control
box.
Rotating parts
This pictogram indicates that there are rotating parts
behind this access cover, door or panel which may cause
injury. The components that include rotating parts are the
fan and heat recovery wheel. If there are special customer-
specific components behind doors, access covers or panels
that include rotating parts and pose a potential risk, this is
also indicated by this pictogram.

5
Opening the fan door
This pictogram is positioned on the outside of the door or access cover of the fan assembly. This pictogram warns that the
fan must have been switched off and deenergised for a minimum of two minutes before the door or access cover is
opened. This pictogram also indicates that transport brackets must be removed before the fan is started up. This warning
also important for safety. Because of the positive pressure, fan doors can hit the technical personnel who opens the doors.
Other warning labels
CAUTION: All doors and access covers must be closed
before starting up the AHU.
Lifting and transport
An instruction is attached to the AHU that describes the
procedures that must be followed for lifting and transport.
The following chapter contains further details.
1.4 - Disposal of parts/materials
• The packaging material must be disposed of in a
responsible manner and in accordance with local
regulations.
• Components that are replaced, must be disposed of
as described above.
2 - TRANSPORT AND LIFTING INSTRUCTIONS
2.1 - General
Transport and lifting of the AHU must always be in
accordance with the instructions below. If these
instructions are not observed, the unit may be irreparably
damaged, and people in the immediate vicinity of the unit
are endangered. Carrier does not accept any responsibility
if these instructions are not observed. Transport and lifting
must be carried out by qualified personnel. The AHU must
only be lifted with lifting bars supplied by Carrier (box profile
30 x 30 x 4 mm). Lifting must be carried out in accordance
with local regulations and with the help of certified lifting
aids.
Only one set of lifting bars is supplied per order/position
number per unit width (if ordered). These lifting bars are
suitable for single use and only for the parts of this order/
position number. The lifting bars are certified by an
authorised person using a type test.
2.3 - Offloading and hoisting
Depending on the dimensions of the AHU and the situation
on site, the AHUs are supplied in previously agreed
transport sections.
Before proceeding with the transport and installation of the
casing sections, always consult the applicable dimensional
drawing that give the dimensions and weights of the
sections, as well as the installation sequence.
The weight is given on each transport section. Each
transport section is equipped with a subframe with four
lifting points. These points are marked by the label shown
below.
2.2 - Transport and storage
During transport and storage the air handling unit must only
be supported under the designated lifting points.
Supporting and lifting under the cross beams is prohibited.

6
2.4 - Horizontal transport
For horizontal movement pallet lifters or transport skids can
be placed under the installation frame or under the lifting
bars. It is important that these support the lifting points. At
no time should the cross beams at the ends of the unit
sections be used for jacking or tracking the AHU. FOR
HORIZONTAL TRANSPORT ALWAYS PROVIDE SUPPORT
UNDER THE LIFTING POINTS. The use of bars as rollers
can result in damage to the installation frame.
For offloading as well as hoisting lifting cables can be
attached to the lifting bars. Evenly positioned spacer bars
should be used between the lifting cables to prevent
damage to the top of the unit and ensure that no excess
pressure is applied to the side panels. For hoisting please
ensure that the weight is evenly distributed. And please use
CE marked hooks.
The AHU should not be lifted or moved under the cross
beams.
2.5 - Storage
The packaging in which the AHU is supplied can cause
condensation to be formed between the packaging and
the AHU, if the unit is stored in an unconditioned place.
Storage temperature will be between –25 to 55 oC
according to EN 60204-1. If the AHU is not immediately
used it is recommended to store it in a conditioned location
on-site. If the AHU is kept outside for a short period direct
sun radiation must be avoided.
If the fans are shut down for a longer period (longer than
three months) bearing damage can occur. To prevent this it
is recommended to loosen the belt tension or to
temporarily remove the fan belts. When the fans are
re-started the belt tension must be reset to the specified
tension. Controlled rotation of the fan impeller can also
prevent this type of damage. This is also recommended for
direct-drive fans.
2.6 - Warranty
The units will 2 years warranty after invoice date if startup,
storage and maintenance are made according to this
manuel.
2.7 - Placement
The unit have to be placed on a dry floor surface which can
handle the weight and do not give permission to slide or
vibrate. Anti vibration pads can be used if needed.
2.8 - Schematic diagram of an air handling unit
The two versions of the 39SQ with heat recovery shown
here in schematic diagrams with a short description.
The drawings in this document are for information only and
show the various versions. They do not include possible
external sensors or control devices. The air flow direction
shown is from LEFT to RIGHT.
The dimensions given in the drawings (H and W) refer to
the outside dimensions of the
AHU casing (excl.
connections and additional components). Dimension
W1min is the required service clearance in front of the
AHU. W1rec is the recommended service clearance in front
of the AHU to replace components.
For horizontal movement pallet lifters or transport skids can
2.7 - Placement
The unit have to be placed on a dry floor surface which can
handle the weight and do not give permission to slide or
vibrate. Anti vibration pads can be used if needed.
2.8 - Schematic diagram of an air handling unit
The two versions of the 39SQ with heat recovery shown
here in schematic diagrams with a short description.
The drawings in this document are for information only and
show the various versions. They do not include possible
external sensors or control devices. The air flow direction
shown is from LEFT to RIGHT.
The dimensions given in the drawings (H and W) refer to
the outside dimensions of the
AHU casing (excl.
connections and additional components). Dimension
W1min is the required service clearance in front of the
AHU. W1rec is the recommended service clearance in front
of the AHU to replace components.
2.6
2.7

7
39SQR with high-efficiency heat recovery wheel
Sizes 0606, 0707, 0808, 0909, 1010, 1111, 1212, 1412 and 1416
Dimensions
39SQR Dimensions in mm
H W W1min W1rec
0606 1120 1148 700 1190
0707 1280 1308 700 1350
0808 1440 1483 700 1525
0909 1600 1643 700 1685
1010 1760 1803 700 1845
1111 1920 1963 700 2005
1212 2080 2138 700 2180
1412 2080 2458 700 2500
1416 2720 2458 700 2500
W1 min= minimum service distance
W1 rec= recommended service distance,
Recommended service distance on top of the unit is 1.5 meter.
If the customer doesn’t leave sufficient service distance,
Alarko Carrier does not accept any responsibility about commissioning
or service problems.
Legend
A. Exhaust air damper
B. Outdoor air intake damper
C. Electric pre-heater (hot water)
D. Supply air filter
E. Extract air fan
F. Control panel
G. Motor, heat recovery wheel
H. Heat recovery wheel
I. Recirculation damper
J. Supply air fan
K. Extract air filter
L. Electric reheater (hot water)
M. Cooling coil with changeover
N. Supply air damper
O. Extract air damper
Legend
1. Actuator, outdoor air damper
2. Pressure sensor, extract air fan
3. Frequency converter, extract air fan
4. Actuator, recirculation air damper
5. Frequency converter, supply air fan
6. Pressure sensor, supply air fan
7. Actuator, extract and supply air damper (2 x)
8. Main disconnect switch (supply), electric heater
9. Electrical heater switching components
10. Fuses, electric heate
11. Pressure switch, supply air filter
12. Controller, heat recovery wheel
13. Main supply connection, control panel
14. Main disconnect switch / emergency stop switch
(excl. electric heater)
15. Connection terminals
16. Pro-Dialog control
17. Reset button
18. Temperature sensor, air intake
19. Temperature sensor, extract air
20. Pressure switch, extract air filter
21. Relay
22. Frost protection thermostat, heating coil
23. Temperature sensor, DX coil inlet
24. Temperature sensor, supply air

8
39SQP with cross-flow plate heat exchanger
Sizes 0405, 0506, 0606, 0707, 0808, 0909 and 1010
Dimensions
39SQP Dimensions in mm
H W W1min W1rec
0405 960 813 600 855
0506 1120 973 700 1015
0606 1120 1148 700 1190
0707 1280 1308 700 1350
0808 1440 1483 700 1525
0909 1600 1643 700 1685
1010 1760 1803 700 1845
W1 min= minimum service distance
W1 rec= recommended service distance,
Recommended service distance on top of the unit is 1.5 meter.
If the customer doesn’t leave sufficient service distance,
Alarko Carrier does not accept any responsibility about commissioning
or service problems.
Legend
A. Outdoor air intake damper
B. Extract air damper
C. Electric pre-heater (hot water)
D. Supply air filter
E. Extract air filter
F. Recirculation damper, plate heat exchanger
G. Plate heat exchanger, incl. face/bypass damper
H. Control panel
I. Supply air fan
J. Extract air fan
K. Electric reheater (hot water)
L. Cooling coil with changeover
M. Supply air damper
N. Exhaust air damper
Legend
1. Actuator, outdoor air, extract air damper (2 x)
2. Actuator, face/bypass and/or recirculation air damper, plate heat
exchanger
3. Frequency converter, extract/supply air fan (2 x)
4. Pressure sensor supply/extract/supply air fan (2 x)
5. Actuator, supply/exhaust air damper (2 x)
6. Main disconnect switch (supply), electric heater
7. Electrical heater switching components
8. Fuses, electric heater
9. Pressure switch, supply air filter
10. Pressure switch, extract air filter
11. Temperature sensor, air intake
12. Temperature sensor, extract air
13. Relay
14. Pro-Dialog control
15. Main supply connection, control panel
16. Main disconnect switch, / emergency stop switch
AHU (excl. electric heater)
17. Connection terminals
18. Reset button
19. Frost protection thermostat, heating coil
20. Temperature sensor, DX coil inlet
21. Temperature sensor, supply air

9
3 - CHECKLIST OF START-UP CHECK POINTS
3.1 - Checklist of start-up check points
Before commissioning the unit, all functions below and the associated components must be checked, using the check list below.
The table below shows a general overview of the planning required to facilitate the installation of the AHU. The following pages give
a more detailed description of the individual components. The unit should be lighted according to EN12100 during maintenance
operation.
CAUTION: “Technical staff who is responsible from startup and maintenence, has to take occupational health and safety
trainings according to the relevant national laws and obligations.” Do not work on electrical components including control
panels, switches, VFD untill you are sure ALL POWER IS OFF and no resudual voltage can leak from capasitors or solid state
components. Lock open and tag electrical circuits during servicing. If work is interrupted, confirm that all circuits are deenegized
before resuming work. Before starting up the AHU ensure that the components have the correct connection voltage and
connect them in accordance with the regulations. The doors and access covers must be closed and the AHU must be earthed
.
Start-up check points
Function Components Check points Start-up
General All functions Remove obstacles and loose debris from compartment
All functions Check for possible condensate and if necessary dry the parts
indoor installation/
outdoor installation
Internal and external panels Damage
Internal and external panels Damage
Joints Cracks
Doors/access covers Must be closed and locked before start-up
Flexible connections Correct installation
Earthing Correct earthing in accordance with regulations
Roof covering (outdoor installation) Check if roof is completely watertight
dampers Correct operation
Blades fully closed and at zero position
Actuators Correct operation
Check rotation direction
Actuator end position same as damper end position
Filters Correct filter type
Are the filters correctly installed
Pressure differential gauge Correct operation
Pressure differential switch Correct operation/set-up
Heaters Hot-water coil Correct connections
Air vent the coil
Leakage
Frost protection thermostat connected
Electric heater Check heater earth
Check hatch earth
Correct fuse size
Check wiring diagram
Check for possible condensate and if necessary dry the heater
Coolers Chilled-water coil Correct connections
Air vent the coil
Leakage
Droplet eliminator Correct alignment
Drain trap Correct connection
Heat recovery wheel Rotor Check rotation direction
Seal Correct seal towards wheel
Drive Check connection voltage
Correct connection
Check current in all phases
Drive belt Check tension
Rotation monitor Correct connection
Controller Correct connection
Plate heat exchanger Damper (if used) Correct operation
Actuator (if used) Correct operation
Fan Transport protection brackets Remove
Fan housing and fan compartment Remove obstacles and loose debris from the fan and fan compartment
Fan compartment, fan, motor, frequency converter Check for possible condensate and if necessary dry the parts
Impeller Check rotation direction
Motor Check connection voltage
Correct connection
Check current in all phases
Drive belt Check tension
Flexible connections Correct installation
Operating switch Check connection
Ensure switch is locked off during checks
Frequency converter Connections Correct connection/complies with EMC
Frequency converter Check for possible condensate and if necessary dry the converter
Voltage Check connection voltage
Settings Check correct settings
Phases Check voltage in all phases
Lighting Lamp Check connection voltage
Control panel Components Check for possible condensate and if necessary dry the components
Power supply Check power supply voltage
Check neutral
Correct earthing in accordance with regulations
Power supply with correctly sized fuses
External sensors/control devices Connect according to wiring diagram
Alarms Connect to BMS or external panel
Controller Parameters Set all specific project parameters

10
4 - START-UP INSTRUCTIONS
4.1 - Casing
The unit data, such as order number, position number etc.
is given on the nameplate.
Note: Making a hole or mounting different components
on panel while start up, can affect the air handling unit
mechanical classes
4.1.1 - Casing panels
Check the AHU panels for any damage. Any dirt or stains
must be removed from the surface to prevent possible
long-term damage. Dirt can be removed with water and a
mild house-hold soap solution. Damage can be repaired by
throughly cleaning the affected surface, then treat and paint
as necessary. If applicable check the sealing joints and
repair if required.
4.1.2 - Doors and access covers
Check the operation of door handles, locks and movement
of the hinges. Check if the door closure (on the inside of the
door) is tightly fitted, so that there are no excessive air leaks
at the doors. For outside installation of the AHU check the
storm cord.
CAUTION: Doors and access covers must always be
closed before starting the unit.
4.1.3 - Flexible connections
• Check that all flexible connections are attached to the
AHU. If necessary, tighten loose screws.
• The stretched length of a single-skin flexible
connection is 170 mm, but a flexible connection must
NOT be installed stretched between the AHU and the
duct. Once installed the operating length of the flexible
connection must be 100 mm.
4.1.4 - Earthing
Ensure that the AHU has been earthed correctly and in
accordance with local regulations. A label on the support
frame indicates where the unit should be earthed.
4.1.5 - Connected ducts
• Inlet and outlet sections could be full face opening or
full face damper with flanges. For all fan types
(forward, backward or plug) duct have to be fixed
from flanges.
• It is recommended to use Europrofile connections
(type E30) at the corner frame as well as at the
duct to be connected.
• The Europrofile connections are available in fixed
lengths and can be cut to the required length with
a saw. These profiles can easily be placed over the
corner frame. Allow for a maximum profile height
of 30 mm, so that ducts that are positioned one
above the other can be installed correctly.
• The four corners between the profilles can be
completed with a corner piece (type H30).
• The profile at the corner frame can be attached to
the profile on the duct using a drive slip (type SR).
• Attaching self-adhesive tape between the two profiles
ensures an air-tight seal, as shown in the drawing
below.
8.5 mm
27 mm
27 mm
15 mm
105 mm
ø 11 mm
30 mm