Carrier 42DH 06, 42DH 12, 42DH 16, 42DH 20, 42DH 08 Installation, Start-up And Service Instructions Manual

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Page 1

42DH 06-30

Horizontal Direct Drive Blower Fan

Coils

Installation, Start-Up, and Service Instructions

CONTENTS

PAGE

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1

AHRI Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

C-ETL-US Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . 3

Prepare Job Site for Unit Installation . . . . . . . . . . . . 3

Identify and Prepare Units . . . . . . . . . . . . . . . . . . . . . 3

Protect Units from Damage . . . . . . . . . . . . . . . . . . . . 3

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 1 — Place Unit In Position . . . . . . . . . . . . . . . . . 3

Step 2 — Install Mixing Box . . . . . . . . . . . . . . . . . . . . 5

Step 3 — Connect Cooling/Heating Piping . . . . . . . . 7

Step 4 — Make Electrical Connections . . . . . . . . . . 12

Step 5 — Connect Ductwork . . . . . . . . . . . . . . . . . . 12

Step 6 — Make Final Preparations . . . . . . . . . . . . . 13

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Cooling/Heating System . . . . . . . . . . . . . . . . . . . . . . 13

Air Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Motor/Blower Assembly . . . . . . . . . . . . . . . . . . . . . . 14

Electronically Commutated Motor (ECM) . . . . . . . . 14

Control Board Adjustment . . . . . . . . . . . . . . . . . . . . 14

Water Balancing System . . . . . . . . . . . . . . . . . . . . . 15

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electric Resistance Heater Assembly . . . . . . . . . . . 16

Cabinet/Control Box Maintenance Light . . . . . . . . . 17

Electrical Wiring and Controls . . . . . . . . . . . . . . . . . 17

Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Filters — Throwaway . . . . . . . . . . . . . . . . . . . . . . . . 17

Filters — Replacement and Installation . . . . . . . . . 17

APPENDIX A — TYPICAL WIRING DIAGRAM

EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual

instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloths for brazing operations and have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and appropriate national electrical codes (in USA, ANSI/NFPA 70, National Electrical Code (NEC); in Canada, CSA C22.1) for special requirements.

It is important to recognize safety information. This is the safety-alert symbol . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices, which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

WARNING

ELECTRICAL SHOCK HAZARD Failure to follow this warning could cause personal injury

or death. Before performing service or maintenance operations on

unit, always turn off main power switch to unit and install lock(s) and lockout tag(s). Unit may have more than one power switch.

CAUTION

CUT HAZARD Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing, safety glasses and gloves when handling parts and servicing air-conditioning equipment.

Equipment is initially protected under the manufacturer’s standard warranty; however, this warranty is provided under the condition that the steps outlined in this manual for initial inspection, proper installation, commissioning, regular periodic maintenance, and everyday operation of the equipment be followed in detail. This manual should be fully reviewed and understood in advance of initial installation, start-up, and any maintenance. Should any questions arise, please contact your local Sales Representative or the factory BEFORE proceeding.

Catalog No. 04-53420019-01 Printed in U.S.A. Form 42DH-2SI Pg 1 8-19 Replaces: 42DH-1SI

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Page 2

CAUTION

WARNING

Disconnect all power prior to any installation or service (unit may use more than one power source; ensure all are disconnected). Power to remote mounted control devices may not be supplied by unit.

Install approved Lock-Out/Tag-Out protection devices on ALL incoming power sources to equipment being installed or serviced prior to beginning any work. Always verify all incoming power sources are de-energized using an electrical multi-meter.

WARNING

NO ATTEMPT SHOULD BE MADE TO HANDLE, INSTALL, OR SERVICE ANY UNIT WITHOUT FOLLOWING SAFE PRACTICES REGARDING MECHANICAL EQUIPMENT.

Always use proper equipment support. Secure all pre-installation supports.

CAUTION

Never wear bulky or loose fitting clothing when working on any mechanical equipment. Gloves should always be worn for protection against sharp sheet metal edges, heat, and other possible injuries. Safety glasses or goggles should always be worn, especially when drilling, cutting, or working with refrigerants, lubricants or cleaning chemicals.

CAUTION

Always protect adjacent flammable material when welding or soldering. Use a suitable heat shield material to contain sparks or drops of solder. Have a fire extinguisher readily available.

CAUTION

Always protect chilled and hot water valve bodies, strainers, ball valves, and other flow control related devices from heat caused by soldering or brazing processes.

Safety should always be first priority when handling, installing, operating or servicing mechanical equipment. Always follow all safety codes, procedures and protocols.

Consult applicable local building codes and National Electrical Codes (NEC) for special requirements. See Fig. 1 for Proposition 65 warning label. Be alert to safety information: symbols, words such as DANGER, WARNING and CAUTION.

Improper installation, adjustment, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions, which may result in personal injury or property damage. This product must be installed only by personnel with the training, experience, skills, and applicable licensing that makes him/her “a qualified professional HVACR installer.”

This product can expose you to chemicals including Acrylamide, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information, go to www.P65Warnings.ca.gov

AVERTISSEMENT

Ce produit peut vous exposer à des produits chimiques, y compris l’acrylamide, qui est connu dans l’État de Californie pour causer le cancer et des malformations congénitales ou d’autres problèmes de reproduction. Pour de plus amples informations, prière de consulter www.P65Warnings.ca.gov

ADVERTENCIA

Este producto puede exponerlo a productos químicos como la acrilamida, que en el estado de California es causante de cáncer y defects de nacimiento u otros daños reproductivos. Para mayor información, visite www.P65Warnings.ca.gov

343839-101 REV.A

Fig. 1 — Proposition 65 Warning Label

AHRI Certification

Carrier’s Horizontal Direct Drive Blower Coil units are certified in compliance with Air-Conditioning, Heating, and Refrigeration Institute (AHRI) industry standard AHRI-440 for room fan coil units.

C-ETL-US Listing

Carrier’s Direct Drive Series blower coil units are listed by Intertek Testing Services (ITS). ITS’s C-ETL-US listing signifies that Carrier’s blower coil units have been examined by ITS and comply with the minimum requirements of U.S. and Canadian national product safety standard, UL 1995/CSA C22.2 No. 236, and that Carrier’s manufacturing site has been audited. ITS’s re-examination service includes periodic visits to Carrier’s factory to ensure continued compliance for all listed products.

Introduction

Carrier fan coil units represent a prudent investment offering trouble free operation and long service with proper installation, operation, and regular maintenance. The equipment covered by this manual is available with a variety of options and accessories. Always consult the approved unit submittals, order acknowledgment, and other manuals for specific details on unit options and accessories. Always follow proper procedures related to safety, handling, installation, operation, and servicing of mechanical equipment as the manufacturer assumes no responsibility for personal injury or property damage resulting from improper or unsafe practices during the handling, installation, service, or operation of any equipment.

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ISOLATORS  4 PER UNIT FIELD FURNISHED AND INSTALLED

WASHER AND DOUBLE NUT FIELD FURNISHED AND INSTALLED

5/8” KNOCKOUTS FOR SUSPENSION RODS 4 PLACES TOP AND 4 PLACES BOTTOM OF UNIT

THREADED ROD SUSPENSION FIELD FURNISHED AND INSTALLED

TRAPEZE  RECOMMENDED ON UNIT SIZE 30

PRE-INSTALLATION

Unpacking and Inspection

All units are carefully inspected at the factory throughout the manufacturing process under a strict detailed quality assurance program. All major components and sub-assemblies are carefully tested for proper operation and verified for full compliance with factory standards. Operational testing of some customer-furnished components such as DDC (Direct-Digital Controls) controls, pneumatic control valves and switches may be a possible exception.

Each unit is carefully packaged for shipment to prevent damage during normal transit and handling. Equipment should always be stored in a dry and covered place, and in proper orientation marked on the carton.

All shipments are made F.O.B. ex-factory and it is the responsibility of the receiving party to inspect the equipment upon arrival. Any obvious damage to the packaging and/or its contents should be recorded on the bill of lading and a claim filed with the freight carrier.

After inspecting condition of packaging exterior, carefully remove each unit from the carton and inspect for hidden damage. Any hidden damage or missing components should be recorded and immediately reported to the carrier and a claim filed. In the event a claim for shipping damage is filed, the unit, shipping carton, and all packing must be retained for physical inspection by the freight carrier. All equipment must be stored in the factory shipping carton with internal packing in place until installation.

At time of receipt, equipment type and arrangement must be verified by review of order documents. Should any discrepancy be found, the local Sales Representative must be notified immediately so that proper action may be taken.

Should any questions arise concerning field warranty repairs, factory must be notified BEFORE any corrective action is taken.

When repairs or alterations can be accomplished locally, the factory must be fully informed of the extent and expected cost of repairs before work begins. When factory operations are required, the factory must be contacted for authorization to return equipment and a Return Authorization Number will be issued.

Unauthorized return shipments of equipment and shipments not marked with an authorization number will be refused. In addition, any claims for unauthorized expenses will not be accepted by the manufacturer.

Prepare Job Site for Unit Installation

To save time and to reduce the possibility of costly errors, set up a complete sample installation in a typical room at the job site. Check all the critical dimensions such as field piping, wiring, and duct connection to ensure they agree with job requirements. Refer to job drawings and product dimension drawings as required. Instruct all trades in their part of the installation. Should any discrepancies be discovered, contact your local representative before continuing with unit installations.

Identify and Prepare Units

For each unit, confirm incoming and control power requirements match available power source. Refer to unit nameplate and wiring diagram.

1. Review all tags on unit to determine if shipping screws are to be removed. Remove screws as directed.

2. Rotate fan wheel by hand to ensure that fan is unrestricted and can rotate freely. Inspect for shipping damage and fan obstructions. Adjust blower wheel as required.

Protect Units from Damage

Care must be taken to assure that no force or pressure is applied to the coil, piping or drain stub-outs during handling. The equipment covered in this manual IS NOT suitable for outdoor installations. The equipment is never to be stored or installed where it may be subjected to a hostile environment such as rain, snow, or extreme temperatures.

Before, during, and after installation, take specific caution to prevent foreign material such as paint, plaster, and drywall dust from being deposited in the drain pan, on the motor or blower wheels and cooling/heating coils. Failure to do so may have serious adverse effects on unit operation, and in the case of motor and blower assembly, may result in immediate or premature failure and voiding all manufacturers’ warranties. Some units and/or job conditions may require some form of temporary covering during construction. While the manufacturer is not involved in the design and selection of support methods and components, it shall be noted that unacceptable system operating characteristics and/or performance may result from improper or inadequate unit structural support. After mounting, the unit is then ready for the various service connections such as water, drain and electrical. Verify which proper type of services are actually provided to the unit. On units requiring chilled water and/or hot water, verify proper line size and water supply availability.

INSTALLATION

Step 1 — Place Unit In Position

Install mixing box when ordered with unit. Follow mixing box installation instructions outlined in the next section. The horizontal blower coil units have the top and bottom panels for 1/2 in. all threaded rods (not supplied with unit) to pass through (see Fig. 2). Always support the unit at the base until mounting is complete.

Fig. 2 — Unit Installation - Threaded Rod Suspension

Sufficient clearance must be kept for service and maintenance. Minimum recommended clearance for maintenance of the motor and blower wheel is 29 in. on the access side of the unit. Filters can be removed from both sides and the bottom of the filter frame. If side access to the filter is desired, the minimum clearance required is the width of the filter rack plus 6 inches.

See Fig. 3 for additional clearances information. For drain pan or coil removal, the recommended clearance should be no less than the width of the unit plus connections.

/8 in. knockouts in each corner of

Page 4

Fig. 3 — Unit Installation - Recommended Clearances (Top View)

MINIMUM RECOMMENDED

CLEARANCE

MINIMUM RECOMMENDED

CLEARANCE

ELECTRIC HEAT CONTROLS

AIRFLOW

FILTER

DRAIN PAN

ELECTRIC HEAT

ELEMENTS

29 IN.

MINIMUM RECOMMENDED

CLEARANCE

29 IN.

FAN MOTOR

PIPING PACKAGE

FAN

WASHER

DOUBLE NUTS

TRAPEZE

BOLT

The unit must be mounted level. DO NOT mount the unit on a slope. The drain pan has a built-in slope to ensure proper drainage. Mounting the unit on a slope may result in improper drainage. For threaded rod suspension see Fig. 4. Field-furnished and installed accessories such as ductwork, mixing boxes, economizers, dampers, etc. must be independently supported or suspended and must not rely on the unit for support.

Fig. 4 — Threaded Rod Suspension Mounting Details

TOTAL WEIGHT UNIT CORRECTION FACTOR (LB)

See Fig. 5 for 8-row water-filled coils and double wall construction (see Table 1). For a different number of rows, total unit weight can be determined by:

Total unit weight can be adjusted by:

1. Identify the size of unit and number of rows

2. From Fig. 5, identify the total weight of the unit

3. From Table 1, identify the correction factor and deduct this factor from the total weight.

See Fig. 5 for operating weight information. Weight information is based on 8-row water-filled coils and double wall cabinet construction. For a different coil and cabinet options, use the weight correction factor table.

Table 1 — Total Unit Weight Adjustment

42DH UNIT

OPTIONS

4-Row Coil –21 –21 –28 –28 –39 –46 –98 5-Row Coil –16 –16 –21 –21 –29 –35 –74 6-Row Coil –11 –11 –14 –14 –20 –23 –49 7-Row Coil –5 –5 –7 –7 –10 –12 –25 Single Wall

Construction

NOTES:

1. Unit weights (shown in pounds), ± 10%, are based on the largest water-filled coil.

2. The operating weight information is based on 8-row water-filled coils and double wall cabinet construction. For a different coil and cabinet options, use the weight adjustment table.

06 08 10 12 16 20 30

–31 –31 –40 –40 –47 –58 –67

Page 5

Step 2 — Install Mixing Box

1. Mixing boxes are pre-assembled from the factory for ease of installation. A linkage kit consisting of two crank arms, 2 swivels, and either a 25-in. (sizes 06-16) or a 34-in. (sizes 20-30) length of installation of an actuator.

2. Assemble the base rails (provided with mixing box, see Fig. 6). All hardware required for assembly is included and the base rails are letter coded for ease of assembly (as shown in Fig. 7).

/16 in. rod is provided for field

42DH UNIT

06 42 46 36 47 171 08 41 47 38 45 171 10 51 53 49 63 217 12 50 52 51 64 217 16 65 70 64 75 274 20 78 90 77 95 340 22 83 108 80 99 367 30 103 113 97 117 430

42DH UNIT

06 42 58 36 66 202 08 41 58 36 67 202 10 51 60 56 83 250 12 50 58 57 85 250 16 70 69 66 104 309 20 81 96 77 107 378 22 86 111 81 111 389 30 104 120 96 149 469

NO ELECTRIC HEAT (lb)

ABCDTotal

WITH ELECTRIC HEAT (lb)

ABCDTotal

Fig. 5 — Weight Distribution Calculations

Fig. 6 — Base Rails

Fig. 7 — Letter Coding on Base Rail Parts

3. Place unit on the base rails making sure that the unit is mounted flush to the outer edge of the end base rail at the aligning unit mounting holes (as shown in Fig. 8). It may be necessary to remove factory installed sheet metal screws to enable access to all mounting holes and to ensure proper fit. Do not remove screws unless necessary. Secure unit to base rail using No. 8 x

/2-in. fasteners at the

locations shown in Fig. 7 and 8, two per side.

Page 6

Fig. 8 — Horizontal Units with Mixing Box Option

DETAIL A

SEE DETAIL A

DETAIL A

42DH WITH 2" FILTER FRAME

42DH WITH 4" FILTER FRAME

SEE DETAIL BSEE DETAIL A

4. Place mixing box assembly onto frame rail. For units with 1-in. and 2-in. filters, mount mixing box flush to the outer edge of the end base rail, for units with 4-in. filters, the mixing box will over-hang the base rail by 2-in. Slide duct flanges of box over the flanges of the filter frame. It may be necessary to remove factory-installed sheet metal screws to enable access to all mounting holes and to ensure proper fit. Do not remove screws unless necessary. Secure base rail to mixing box with supplied #8 x

/2-in.

sheet metal screws, two per side (as shown in Fig. 9). For bottom-entering configurations, length adjustments to

the bottom damper shaft may need to be completed prior to final placement of the mixing box.

INLET AND OUTLET DAMPERS INSTALLATION

1. Install actuator per manufacturer's instructions.

2. Adjust damper shafts outward to extend past any obstacles that might cause interference. Do not adjust inward end of shaft within a distance of 2 inches of bronze bushing.

3. Position inlet damper and outlet damper to coincide with current or intended position of actuator arm, depending on actuator's position (opened/closed). Note rotation direction of each damper.

4. Install crank arms to each damper shaft approximately parallel to each other while maintaining state/position of dampers, as show in Fig. 10. Check for range of motion clearances before tightening.

Fig. 10 — Install Crank

5. Install swivels to crank arms and hand tighten. See Fig. 11.

SEE DETAIL A

DETAIL A

Fig. 9 — Horizontal Units with Mixing Box Option

5. Secure the mixing box to the filter frame using the sup-

/2-in. sheet metal screws at the mounting hole

plied #8 x located at the center of each duct flange. Seal the connection between the mixing box and the return duct flange with appropriate tape/sealant product. Be careful not to tape or seal the filter access panel.

Fig. 11 — Install Swivels

6. Insert

/16-in. damper rod through mounting hole of each swivel, as shown in Fig. 12. Position shaft to ensure there is not interference at any point during travel. Tighten rod clamp of swivel onto each damper rod.

Fig. 12 — Install Damper

7. Confirm correct operation of dampers. Adjust as needed. Tighten remaining fasteners.

Page 7

DIMENSIONS - INCHES (MILLIMETERS)

Unit Size H W A B C

3(76)

2.4(61)

4(102)

2.4(61)

3(76)

1(25)

2(51)

TOP VIEWS

BTM/REAR INLET - 42DH TOP/REAR INLET - 42DH

4(102)

2.4(61)

1(25)

2.4(61)

24 24

33 33

43 44 44

(610) (610) (838)

(838) (1092) (1118) (1118)

28 28

37 37

47 48 48

(711) (711) (940)

(940) (1194) (1219) (1219)

6 6

8 8 8 8

(711) (711) (940)

(940) (1194) (1219) (1219)

18.50

20.25

22.75

31.00

(470) (470) (514) (514) (514) (578) (787)

11 11 13 13 13 13 15

(279) (279) (330) (330) (330) (330) (381)

06 08 10 12 16

20/22

Fig. 13 — Optional Mixing Box

Step 3 — Connect Cooling/Heating Piping

Thoroughly review submittals and product literature detailing unit operation, controls, and connections BEFORE beginning the connection of the various cooling and/or heating mediums

CAUTION

to the unit. The supply and return connections are marked with

a “HS/CS” meaning Hot/Cold water Supply or inlet and “HR/ Residue and loose particles resulting from manufacturing and field piping techniques such as joint compounds, soldering flux, and metal shavings may be present in the unit and the piping system. This may cause damage to the unit. Ensure system cleanliness when connecting to solar, domestic or potable water systems.

CR” meaning Hot/Cold water Return or outlet indicating fluid

flow direction into and from the coil. Refer to Fig. 14-17 and

Tables 2 and 3 for details and DX (direct expansion) coils

marking and piping locations.

Page 8

COIL HEADER CONNECTION SIZE

Unit

Size

8 Row 6 Row 4 Row 2 Row HW 1 Row HW

Nom.

Size OD

Nom.

Size OD

Nom.

Size OD

Nom.

Size OD

Nom.

Size OD

CR - COLD WATER RETURN HR - HOT WATER RETURN CS - COLD WATER SUPPLY HS - HOT WATER SUPPLY RH - RIGHT HAND LH - LEFT HAND

Horizontal, left hand unit with re-heat coil shown.

Dimensions are in inches (mm).

2(51)

6-7/8(175)

8-5/8(219)

1-5/8(41)

06-12 1 1.1253/40.8753/40.8751/20.6251/20.625

16-22 1 1.125 1 1.125 1 1.125 1 1.125

/20.625

301

/21.625 1 1/21.625 1 1/21.625 1 1/21.6251/21.625

42DH UNIT

SIZE

06/08

10/12

20/22

Fig. 14 — Hydronic Coil Piping Connection Diagram

Table 2 — Hydronic Coil Piping Connections

COIL ROWS

Cool Heat

——

13 23

—— ———

13 23

8 —— ———10

——

15 25

—— ———

15 25

8 —— ———10

——7

212716

——7

212716

8——9

——7

2 11 9/

——7

2 11 9/

8——7

——

13 23

—— ———8

13 23

8 —— ———10

ABCDEFG

———

LH 10 RH 13

LH 10 RH 13 3/

LH 11

LH 11 RH 14 11/

7 3/

7 13/

7 7/

7 13/

7 7/

5 15/

12 3/

14 3/

15 5/

18 3/

26 5/

15 1/

15 13/

15 1/

15 13/

7 9/

9 3/

7 9/

9 3/

———

17 1/

17 7/

17 1/

17 7/

———

13 5/

7 9/

9 3/

9 9 5/

10 3/

7 9/

9 3/

7 9/

7 7

———

13 5/

11 13/

12 1/

9 3/ 9 3/

9 3/

———10 ———

13 5/

15 13/

9 5/

9 1/

7RH 14 11/

———

13 5/

15 13/

11 3/

11 1/

9 3/

———10 ———5

25 13/

9 1/

11 1/

11 5/

9 1/

8 1/

7 1/

Page 9

Horizontal, left hand unit with pre-heat coil shown.

Dimensions are in inches (mm).

HR - HOT WATER RETURN HS - HOT WATER SUPPLY LL - LIQUID LINE SL - SUCTION LINE

COIL HEADER CONNECTION SIZE (NOMINAL OD IN INCHES)

Unit

Size

LL SL 2 Row HW 1 Row HW

Nom.

Size OD

Nom.

Size OD

Nom.

Size OD

Nom.

Size OD

2(51)

8-5/8(219)

1-5/8(41)

06-12 1.125

/40.8751/20.6251/20.625

16-22 0.375

1 1.125 1 1.1251/20.625

30 0.625

1 1/21.125 1 1/21.625 1 1/21.625

Fig. 15 — DX Coil Piping Connection Diagram

Table 3 — DX Coil Piping Connection

42DH UNIT

SIZE

06/08

10/12

20/22

COIL ROWS

Water

Pre-Heat

—

DX Only

4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6 4 6

ABCDEFGH

——

5 1/

618

——

7 1/

17 1/

——

7 1/

5 3/

6 12 1/

17 1/

10 13 5/

——

11 5/

——

10 1/

19 3/

15 7/

25 7/

23 7/

2 3/

3 3/

2 3/

3 3/

6 6/

2 3/

3 3/

6 3/

2 3/

6 1/

6 3/

——

2 5/

3 1/

3 3/

2 5/

3 1/

2 5/

3 1/

—

2 5/

3 1/

——

2 5/

4 1/

2 5/

——

2 5/

4 1/

2 5/

——

4 1/

2 5/

Page 10

Drawing is not to scale and is provided for reference only.

Dimensions may vary with options ordered.

Size

Fan

Size

Depth Width Height

Supply Duct Return Duct

(Note 7)

Mounting Holes

Aux.Ctrl.

Box

ABCDE FG J K L

06 9 x 6

(914)28(711)

/

(502)

8 7/ (225)

10 7/

(276)

13 3/

(349)

2 1/

(57)

24 1/

(616)14(356)

2 3/

(70)

27 1/

(686)

35 1/

(895)

5 3/ (146)2(51)

08 9 x 6

(914)28(711)

/

(502)

8 7/ (225)

10 7/

(276)

13 3/

(349)

2 1/

(57)

24 1/

(616)14(356)

2 3/

(70)

27 1/

(686)

35 1/

(895)

5 3/ (146)2(51)

10 9 x 6

/

(953)37(940)

21 1/ (546)

8 7/ (225)

10 7/

(276)

14 1/

(368)

2 1/

(57)

33 1/

(845)

15 3/

(401)

2 7/

(73)

36 1/ (921)

(940)5(124)2(51)

12 9 x 6

/

(953)37(940)

21 1/ (546)

8 7/ (225)

10 7/

(276)

14 1/

(368)

2 1/

(57)

33 1/

(845)

15 3/

(401)

2 7/

(73)

/

(921)

(940)5(124)2(51)

16 10 x 7

/

(959)47(1194)

21 1/ (546)

10 3/

(264)12(305)

18 3/

(467)

2 1/

(57)

43 7/ (1115)

15 3/

(401)

2 7/

(73)

46 1/

(1175)37(940)

1 1/

(32)

1 1/ (38)

20/22 11 x 10

/

(1022)48(1219)

(610)

13 7/

(352)13(330)

17 1/

(438)

2 1/

(57)

44 1/ (1124)18(457)

2 7/

(73)

47 1/

(1200)

39 1/

(1033)

2 3/ (60)2(51)

30 12 x 12

/

(1022)48(1219)

32 1/

(819)

16 1/

(413)14(356)16(406)

7 1/ (181)

44 1/ (1124)

26 1/

(673)

1 1/

(32)

/

(1200)

39 1/

(1033)

3 3/ (95)2(51)

NOTES:

RH shown, LH opposite. All dimensions are ±

/ in. (6 mm). Product specifications are subject to changes without notice. Dimensions in parenthesis are shown in millimeters. Allow adequate spacing or maneuverability around unit to allow service through recommended access area. “C” dimension is measured from coil side of unit. Mixing Box option will vary return duct dimensions, refer to mixing box submittal. Auxiliary control box required with 3-speed EC motors and/or cabinet lighting option, not required with low voltage (0-10v) controls.

Fig. 16 — 42DH Unit Submittal Drawing

Page 11

NOTES:

RH shown, LH opposite. All dimensions are ± ¹/ in. (6 mm). Product specifications are subject to changes without notice. Dimensions in parenthesis are shown in (millimeters). Allow adequate spacing or maneuverability around unit to allow service through recommended access area. “C” dimension is measured from coil side of unit. Mixing Box option will vary return duct dimensions, refer to mixing box submittal. Mixing Box options include: a) Knockdown base rails for field assembly; b) Pre-assembled Mixing Box. Linkage kit supplied with Mixing Box is provided for field installation of actuator. Add 2-in. (51 mm) if using a Prefilter, or 4-in. (102 mm) filter. Auxiliary control box required with 3-speed EC motors and/or cabinet lighting option, not required with low voltage (0-10v) controls.

Drawing is not to scale and is provided for reference only.

Dimensions may vary with options ordered.

10.

11.

(Note 7)

Size

Fan Size

Depth

Unit

Depth

Width Height

Supply Duct

Return Duct

Mix Box

Mounting

Holes

Aux.Box

06 9 x 6

⁵/

(1311)36(914)28(711)

³/

(578)

8 ⁷/ (225)

⁷/

(276)

³/

(349)

¹/

(57)24(610)6(152)

¹/

(318)11(279)

¹/

(686)

¹/

(895)

³/

(146)

(51)

08 9 x 6

⁵/

(1311)36(914)28(711)

³/

(578)

8 ⁷/ (225)

⁷/

(276)

³/

(349)

¹/

(57)24(610)6(152)

¹/

(318)11(279)

¹/

(686)

¹/

(895)

³/

(146)

(51)

10 9 x 6

¹/

(1400)

¹/

(953)37(940)

¹/

(622)

⁷/

(225)

⁷/

(276)

¹/

(368)

¹/

(57)33(838)8(203)

¹/

(362)13(330)

¹/

(921)37(940)5(124)

(51)

12 9 x 6

¹/

(1400)

¹/

(953)37(940)

¹/

(622)

⁷/

(225)

⁷/

(276)

¹/

(368)

¹/

(57)33(838)8(203)

¹/

(362)13(330)

¹/

(921)37(940)5(124)

(51)

16 10 x 7

³/

(1407)

³/

(959)47(1194)

¹/

(622)

³/

(264)12(305)

³/

(467)

¹/

(57)43(1092)8(203)

¹/

(362)13(330)

¹/

(1175)37(940)

¹/

(32)

¹/

(38)

20/22 11 x 10

³/

(1467)

¹/

(1022)48(1219)27(686)

⁷/

(352)13(330)

¹/

(438)

¹/

(57)44(1118)8(203)

³/

(425)13(330)

¹/

(1200)

¹/

(1033)

³/

(60)

(51)

30 12 x 12

³/

(1518)

¹/

(1022)48(1219)

¹/

(895)

¹/

(413)14(356)16(406)

¹/

(181)44(1118)10(254)15(381)15(381)

¹/

(1200)

¹/

(1033)

³/

(95)

(51)

ABCDEF G H J K L

Fig. 17 — 42DH Unit with Mixing Box Submittal Drawing

Page 12

LEAK TESTING

Max Water Coil Leaving Air or Max Motor AMB: Max Fuse or Max Circ Breaker (HACR Type NEC):

Unit Intended for Indoor Use Only & Suited For 0.00 Clearance From Combustible Surfaces

25A - SCCR: 5KA

Unit Serial No:

Model No:

42DHA20 776004-60-1

ELECTRICAL ENV/PERF

Motor(s):

Motor VPH: Motor FLA:

Heater AMPS:

QTY of Motor(s):

Motor HP: Min Circ Amps:

Heater VPH:

E020-71537402

277/1/60

5.10A

18.1A

5.0 kW

1 HP

29.0A

277/1/60

Max ESP: Max Inlet Water Temp:

Coil Test:

High Side Coil Design:

Refrigerant Type:

1.65

300 PSIG

Max Outlet Air Temp: Max Hot Water or Steam:

ARI Model:

Low Side Coil Design:

42DHA20

190F

2 PSIG

Heater Kw:

Motor Current: 5.10A

Manufactured in the USA

After securing the connections, test the system for any leaks. Always test hydronic systems with water as some components are not designed to be inert gas pressurized.

Field pressure testing for leaks should not exceed 300 psi for hydronic coil and valve package components. Consult factory if higher limits are required.

CAUTION

Protect all water coils from freezing after initial filling with water. Even if the system is drained, unit coils may still hold enough water to cause damage when exposed to temperatures below freezing.

REFRIGERANT COIL TESTING

Test refrigerant systems with dry nitrogen rather than air to prevent the introduction of moisture into the system. In the event that leaking or defective components are discovered, notify the Sales Representative BEFORE any repairs are attempted. All leaks must be repaired before proceeding with the installation. In DX systems, adequate freeze protection should be field-installed.

PIPING INSULATION

After system integrity has been established, insulate the piping in accordance with the project specifications. This is the responsibility of the installing or insulation contractor.

CONDENSATE DRAIN

Any fan coil unit with a drain pan is recommended to be equipped with a drain trap to provide condensate drainage and prevent property damage.

The drain U-trap should be deep enough to offset maximum unit static pressure difference as shown at Fig. 18, to prevent condensate flowing back to drain pan.

DRAIN PAN

SAFETY MARGIN

TSP

Fig. 18 — Condensate Drain U-Trap

CONDENSATE FLOAT SWITCH

The condensate float switch is used to detect clogged or restricted condensate pan drains. The condensate switch uses a Normally Closed contact to allow the system control power to pass through the switch energizing the water valves and fans allowing normal operation. When an overflow condition is detected by the switch, it opens the NC contacts and de-energizes the water valves and fans.

Step 4 — Make Electrical Connections

The unit serial plate lists the unit electrical characteristics including the required supply voltage, fan and heater amperage and required circuit ampacity (See Fig. 19). The unit wiring diagram displays all unit and field wiring. Every project is different and each unit on a project may be different, the installer

TO DRAIN

must be familiar with the wiring diagram and serial plate on the unit BEFORE beginning any wiring.

Fig. 19 — Serial Plate Example

Ensure all field electrical connections are in accordance with unit wiring diagram and all applicable national and local code. The type and size of all wiring and other electrical components including circuit breakers, disconnect switches, etc. shall be determined by the individual job requirements. Verify conductor size is suitable for the distance to the equipment connection and will support the equipment electrical load. All installations including field wiring shall be made in compliance with all governing codes and ordinances. Compliance with all codes is the responsibility of the installing contractor.

All components furnished for field installation by either the factory or the controls contractor shall be located and checked for proper function and compatibility. Inspect all internal components for shipping damage. Inspect all electrical connections within the unit control box and accessories and tighten if necessary.

NOTE: All field wiring must be in accordance with governing codes and ordinances. Any modification of unit wiring without factory authorization will invalidate all factory warranties and nullify any agency listings. The manufacturer assumes no responsibility for any damages and/or injuries resulting from improper field installation and/or wiring.

CABINET/CONTROL BOX MAINTENANCE LIGHT

Optional Service Light provides a source of illumination in the main unit cabinet and the control box during routine maintenance and troubleshooting in the dark ceiling spaces. Light turns "ON" when access panel or control box door is open, but unit is not powered. (See Fig. 20.)

Step 5 — Connect Ductwork

All ductwork shall be installed in accordance with the project plans and specifications. See Fig. 16 and 17 for supply and return duct flanges location and dimensions.

NOTE: When installing units that attach to branch duct piping, use industry approved duct standards and configuration such as those published by Air Conditioning Contractors of America (ACCA) or American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE). The standards provide necessary information on sizing, layout and installing supply and return air duct systems.

Flexible duct connections should be used on all air handling equipment. All ductwork and insulation shall be installed to allow proper access to all components for service and repair such as filters, motor/blower assemblies, etc.

Page 13

Electric Heater

Manual Air Vent

Automatic Air Vent

Limit Switch

Knob

Disconnect Switch

Heater Fuses

Service Light

Strip

Auxillary Control Box (supplied when ordered with 3-speed controls and/or service light)

Service Light

Battery

24V Control

Fuse

Battery

Charger

Wrapper

Serial Plate

Wiring Diagram

(inside the door)

Above is the example of Control box for Size 20 unit with electric heat, disconnect switch and service light.

Contactors

Transformer

Fig. 20 — Control Box Layout

Step 6 — Make Final Preparations

1. Power unit(s) off (open unit electrical disconnect) and install lockout tags on all power supplies to the unit.

2. Install field-supplied thermostats and perform all other final wiring needed. Ensure all electrical connections are secure.

3. Perform final visual inspection. All equipment, ductwork, and piping should be inspected to verify all systems are complete and properly installed and mounted, and that no debris or foreign articles are left in the unit(s). Clean dirt, dust, and other construction debris from unit interior. Assess fan wheel and housing and clean if necessary.

4. Verify drain line is properly and securely positioned and that the line is clear. Pour water into drain to verify operation.

5. Rotate fan wheel by hand to be sure it is free and does not rub housing.

6. Install the filter into the filter frame. If field-supplied filters are used, verify filter size (see Table 4).

Table 4 — Filter Sizes

42DH UNIT

SIZE

06 1 16 08 1 16 10 1 18 12 1 18 16 2 18

20/22 2 20

30 2 29 x 22 (737 x 559)

7. Ensure all panels and filters are installed before checking fan operation. Turn on power to the unit.

8. Inspect the fan and motor operation.

FILTER

QUANTITY

NOMINAL FILTER SIZES —

in. (mm)

/2 x 24 (419 x 610)

/4 x 33 (464 x 838)

/4 x 21 1/2 (464 x 546)

/2 x 22 (521 x 559)

Bonded

Ground

Terminal Strip

Door Switch

Equipment

Ground

Terminal

Motor

Control

Board

general start-up procedures and have the appropriate start-up and balancing guides available for consultation.

The building must be completely finished including doors, windows, and insulation. All internal walls and doors should be installed. In some cases, the interior decorations and furniture may influence overall system performance. The entire building should be as complete as possible before beginning any system balancing.

Cooling/Heating System

Prior to the water system start-up and balancing, flush the chilled/hot water systems to clean out dirt and debris which may have collected in the piping during construction. During this procedure, all unit service valves must be in the closed position to prevent foreign matter from entering the unit and clogging the valves and metering devices. Strainers shall be installed in the piping mains to prevent such material from entering units during normal operation.

During system filling, air venting from the unit is accomplished by the use of the standard, manual air vent fitting, or the optional, automatic air vent fitting installed on the coil (Fig. 21). Manual air vents are basic Schrader valves that could be accessed from the coil side of the unit and are located between the coil header and end sheet. To vent the air from the coil, depress the valve until the air has vented the coil. When water begins to escape through the valve, release the valve.

Automatic air vents may be unscrewed one turn counterclockwise to speed initial venting, but should be screwed in for automatic venting after start-up operations.

START-UP

Before beginning any start-up operation, the start-up personnel shall familiarize themselves with the unit, options and accessories, and control sequence to understand the proper system operation. All personnel shall have a good working knowledge of

Fig. 21 — Air Vents

Page 14

IMPORTANT: The air vent provided on the unit is not intended to replace the main system air vents and may not release air trapped in other parts of the system. Independently inspect the entire system for potential air traps and vent those areas as required. In addition, some systems may require repeated venting over a period of time to properly eliminate air from the system.

Air Balance System

All ductwork must be complete and connected. All filters and access doors and panels must be properly installed to establish actual system operating conditions BEFORE beginning air balancing operations.

Each individual unit and the attached ductwork is a unique system with its own operating characteristics. For this reason, air balancing is normally done by balance specialists who are familiar with all procedures required to properly establish air distribution and fan-system operating conditions. These procedures shall not be attempted by unqualified personnel.

After proper system operation is established, the actual unit air delivery and the actual fan motor amperage draw for each unit should be recorded in a convenient place for future reference.

Motor/Blower Assembly

WARNING

Failure to follow this warning could result in personal injury or death. Please wait 5 minutes after disconnecting power before opening the motor.

Fan operation type is determined by the control components and their method of wiring. This may vary from unit to unit. Refer to the wiring diagram attached to each unit for individual operating characteristics. See Tables 5-7 for motor performance and heater availability.

All motors have permanently lubricated ball bearings. No field lubrication is required.

Should the motor/blower assembly require service, it may be removed from unit to facilitate operations such as motor or blower wheel/housing replacement, etc.

Dirt and dust must not be allowed to accumulate on blower wheel or housing. This can result in an unbalanced blower wheel condition which will damage a blower wheel or motor. The wheel and housing must be cleaned periodically using a vacuum cleaner and a brush taking care not to dislodge factory balancing weights on the blower wheel blades.

Electronically Commutated Motor (ECM)

All 42DH units are equipped with Electronically Commutated Motors (ECM) - constant speed brushless DC, which are easily adjustable in the field for desired performance. Motors are preprogrammed for constant speed mode. One-half HP and 1 HP motors have integrated control module with overload and short circuit protection. 1

/2 HP and 3 HP motors have remote mounted control module with overload and short circuit protection. Control module is mounted in the cabinet interior.

Control Board Adjustment

Adjusting the low, medium and high potentiometer requires the use of multi-meter capable of measuring 0-10 vdc. See Fig. 22.

CAUTION

Only trained and qualified individuals should attempt to adjust or service components on any energized electrical equipment. Failure to follow established safety rules and guidelines could result in serious injury or death.

VR3

VR2

VR1

CR1

COM

HIGH

MED

LOW

POTS

HIGH

MED

LOW

Fig. 22 — Motor Control Board

When the 42DH unit is shipped from the factory with motor control board (which has High, Med and Low airflow settings), it is pre-programmed at the factory to “High” speed and delivers the airflow and cooling/heating capacity specified at the time of order, while Medium and Low speeds are set to defaults based on High speed. Should airflow require adjustment after installation, the control board settings for Low, Medium and High could be adjusted by turning screws (as shown in Fig. 22) using a small Phillips screwdriver. It will adjust the control voltage to the motor. A clockwise rotation increases the voltage to the motor, while counter clockwise rotation reduces it.

IMPORTANT: On 42DH units with electric heat the factory default setting for low airflow prevents nuisance tripping of the electric heat protection circuit. Turning the low speed screw counter clockwise can cause interruptions in the heating performance of the unit due to the activation of this protective circuit.

CAUTION

Turning the voltage up past the setting for high speed may introduce the risk of condensate blow off which may result in damage to the unit.

Unit must be powered to perform the following procedure. Set the electrical multimeter to VDC. Attach black negative (–) lead of meter to the terminal labeled “L2” (shown above the potentiometers). Attach the RED positive (+) lead of the meter to the terminal labeled “L1” and confirm that there is approximately 5 to 10 vdc present.

Attach the RED positive (+) lead of the meter to the DC OUTPUTS. LOW, MED, and HIGH are typically connected together.

1. Close either the LOW, MED, or HIGH speed relay contacts by applying 24 VAC to the corresponding LOW, MED or HIGH 24 VAC INPUT and COM.

2. Measure voltage at the DC OUTPUTS and adjust the potentiometer for that speed. (VR1 LOW, VR2 MED, VR3 HIGH)

3. In order to achieve higher CFM, turn the potentiometer clockwise.

Page 15

NOTE: For specific voltages adjustment please contact Carrier factory representative.

When the 42DH unit is ordered with Proportional Control, no control board is required, and no field adjustments are possible. Motor uses a 0-10VDC signal directly. See control box label. Fan enabled at 1.5VDC.

Water Balancing System

A complete knowledge of the hydronic system, along with its components and controls, is essential to proper water system balancing. This procedure shall not be attempted by unqualified personnel. The system must be complete, and all components must be in operating condition BEFORE beginning water system balancing operations.

Table 5 — Motor Performance Data

(Full Load Amps)

Each hydronic system has different operating characteristics depending on the devices and controls used in the system. The actual balancing technique may vary from one system to another.

After the proper system operation is established, record the appropriate system operating conditions such as various water temperatures and flow rates in a convenient place for future reference.

Before, and during water system balancing, conditions may exist due to incorrect system pressures which may result in noticeable water noise or undesirable valve operation. After the entire system is balanced, these conditions will not exist on properly designed systems.

42DH UNIT SIZE

MOTOR TYPE VOLTAGE

1-PHASE

SINGLE SPEED

STANDARD

EFFICIENCY

3-PHASE

SINGLE SPEED

STANDARD

EFFICIENCY

NOTES:

1. Motor Full Load amps refer to National Electric Code (NEC) amps; actual motor nameplate amps may vary.

115V/1 PHASE/50-60 Hz 6.40 10.70 N/A N/A 208V/1 PHASE/50-60 Hz 3.80 6.30 N/A N/A 230V/1 PHASE/50-60 Hz 3.60 5.80 N/A N/A 277V/1 PHASE/50-60 Hz 3.20 5.10 N/A N/A 208V/3 PHASE/50-60 Hz 2.00 7.00 4.4 8.9 230V/3 PHASE/50-60 Hz 1.85 6.50 4.4 8.9

460V/3 PHASE/50-60 Hz 1.00 1.75 2.2 4.4

06, 08 08, 12, 16, 20 22 30

MOTOR HORSEPOWER AND FLA (HP)

2. Motors are UL recognized, constant speed brushless DC type, open drip proof, ball bearing, multi-voltage options, 0-10 V control.

Table 6 — Single Phase Electric Heater Availability

Electric Heater Amps 42DH UNIT SIZE (Heater Stages)

1.0 8.3 4.8 4.2 3.6 X —X —————————

1.5 12.5 7.2 6.3 5.4 X—X—X—X—————

2.0 16.7 9.6 8.3 7.2 X—X—X—X—————

2.5 20.8 12.0 10.4 9.0 X—X—X—X—X———

3.0 25.0 14.4 12.5 10.8 XXXXXXXXXX——

3.5 29.2 16.8 14.6 12.6 XXXXXXXXXXXX

4.0 33.3 19.2 16.7 14.4 XXXXXXXXXXXX

4.5 37.5 21.6 18.8 16.2 XXXXXXXXXXXX

5.0 — 24.0 20.8 18.1 XXXXXXXXXXXX

6.0 — 28.8 25.0 21.7 XXXXXXXXXXXX

7.0 — 33.7 29.2 25.3 ——XXXXXXXXXX

8.0 — 38.5 33.3 28.9 ——XXXXXXXXXX

9.9 ———35.7 ————XXXXXXXX

12.0 ———43.3 ——————X X X X X X

LEGEND NOTES:

X — Available Option –—Not Available

Single Phase (1 or 2 Stage) 06 08 10 12 16 20

120V 208V 240V 277V 1 stg 2 stg 1 stg 2 stg 1 stg 2 stg 1 stg 2 stg 1 stg 2 stg 1 stg 2 stg

1. Electric Heating Capacities BTUh)=Heater kW x 3413.

2. Electric Heater Amperage for Single-phase Power = (Heater kW x

1000)/Applied Voltage.

Page 16

Table 7 — Three Phase Electric Heater Availability

Electric Heater

Amps

1.0 2.8 2.4 1.2 X — X — ——————————————

1.5 4.2 3.6 1.8 X — X — X — X ———————————

2.0 5.6 4.8 2.4 X — X — X — X ———————————

2.5 6.9 6.0 3.0 X — X — X — X —— X ————————

3.0 8.3 7.2 3.6 X — X — X — X —— X ————————

3.5 9.7 8.4 4.2 X—X—X—X——X——X—————

4.0 11.1 9.6 4.8 XXXXXXXX—XX—XX————

4.5 12.5 10.8 5.4 XXXXXXXX—XX—XX————

5.0 13.9 12.0 6.0 XXXXXXXX—XX—XX————

6.0 16.7 14.4 7.2 XXXXXXXX—XX—XX—XX—

7.0 19.4 16.8 8.4 ——XXXXXX—XX—XX—XX—

8.0 22.2 19.2 9.6 ——XXXXXX—XX—XX—XX—

9.9 27.5 23.8 11.9 ———— X X X X — X X — X X—X X—

12.0 33.3 28.9 14.4 ——————X X X X X X X X X X X X

14.0 38.9 33.7 16.8 —————————X X X X X X X X X

15.0 41.6 36.1 18.0 —————————X X X X X X X X X

16.0 — 38.5 19.2 —————————X X X X X X X X X

18.0 ——21.7 ————————————X X X X X X

19.9 ——23.9 ————————————X X X X X X

25.0 ——30.1 ———————————————X X X

30.0 ——36.1 ———————————————X X X

LEGEND NOTES:

X — Available Option

–—Not Available

Three Phase

(1, 2 or 3 stage)

208V 240V 480V 1 stg 2 stg 1 stg 2 stg 1 stg 2 stg 1 stg 2 stg 3 stg 1 stg 2 stg 3 stg 1 stg 2 stg 3 stg 1 stg 2 stg 3 stg

06 08 10 12 16 20/22 20/22

UNIT SIZE (Heater Stages)

1. Electric Heating Capacities BTUh)=Heater kW x 3413.

2. Electric Heater Amp. for 3-phase Power = (Heater kW x 1000)/ (Applied Voltage x 1.73).

Water Treatment

Proper water treatment is a specialized industry. Carrier recommends consulting a water treatment expert to analyze water for compliance with water quality parameters listed below, and to recommend an appropriate water treatment regimen. Water treatment experts are able to recommend typical additives such as rust inhibitors, scaling preventative, antimicrobial growth agents, or algae preventatives. Anti-freeze solutions may also be used to lower the freezing point.

Carrier water coil tubes and headers are constructed of copper. Multiple brass alloys may be present in the valve package. It is the user’s responsibility to ensure tube and piping materials furnished by Carrier are compatible with treated water. See Table 8.

Failure to provide proper water quality may affect the fan coil units' warranty.

Table 8 — Water Quality Parameters

WATER CONTAINING REQUIRED CONCENTRATION

Sulphate Less than 200 ppm

pH 7.0-8.5

Chlorides Less than 200 ppm

Nitrate Less than 100 ppm

Iron Less than 4.5 mg/l

Ammonia Less than 2.0 mg/l

Manganese Less than 0.1 mg/l

Dissolved Solids Less than 1000 mg/l

CaCO3 Hardness 300-500 ppm

CaCO3 Alkalinity 300-500 ppm

Particulate Quantity Less than 10 ppm

Particulate Size 800 micron max

SERVICE

General

Each unit has an individual operating environment and conditions that dictate its maintenance schedule. A formal schedule of regular maintenance and an individual unit log should be established and maintained. This will achieve maximum performance and preserve the service life of each unit.

Observe and adhere to all safety precautions contained in the preface of this manual during all service and maintenance operations.

For more detailed information of service operations consult a Carrier Sales Representative or the factory.

Coils

Coils should be cleaned by brushing the entering air face between fins with a stiff brush. Brushing should be followed by cleaning with a vacuum cleaner. If a compressed air source is available, the coil may also be cleaned by blowing air through the coil fins from the leaving air face. This should again be followed by vacuuming. Units equipped with regularly replaced air filters will require less frequent coil cleaning.

Electric Resistance Heater Assembly

Electric resistance heaters typically require no scheduled maintenance when unit air filters are changed properly. The operation and service life may be affected by other conditions and equipment in the system. The two most important operating conditions for an electric heater are proper airflow and proper supply voltage. High supply voltage and/or poorly distributed or insufficient airflow over the element will result in element overheating and possible limit switch openings. See Tables 6 and 7.

This condition may result in the heater cycling on the high limit thermal cutout. Open-strip heaters have an automatic reset switch and high-limit thermal switch as a backup. Automatic reset limit switches reset after the heater has cooled down.

Page 17

High-limit thermal switches must be replaced once the circuit has been broken. The high-limit thermal cutout device is a safety device only, not intended for continuous operation. This device only operates when a problem exists; ANY condition that causes high-limit cutout MUST be corrected immediately. High supply voltage also causes excessive amperage draw, and may trip the circuit breaker or blow the fuse(s) on incoming power supply.

After proper airflow and supply power are assured, regular filter maintenance is important to provide clean air over the heater. Dirt allowed to deposit on the heating element will cause hot spots and eventual element burn through. These hot spots will normally not be enough to trip the high-limit thermal cutout device, and may not be evident until actual heater element failure.

Cabinet/Control Box Maintenance Light

An optional LED service light provides a source of illumination in the main unit cabinet and the control box during routine maintenance and troubleshooting in dark ceiling spaces.

When power is turned "OFF" for maintenance or troubleshooting, the control box/cabinet light will turn "ON" as soon as control box/cabinet door is open (see Fig. 20).

Electrical Wiring and Controls

Refer to wiring diagram attached to unit for type and number of controls provided on each unit.

Verify integrity of all electrical connections at least twice during the first year of operation. Subsequently, all controls must be inspected periodically for proper operation. Some components may experience erratic operation or failure due to age. Wall thermostats may also become clogged with dust and lint, and must be periodically inspected and cleaned to provide reliable operation.

When replacing any components such as fuses or relays, use only the exact type, size and voltage component as furnished from the factory. Any deviation without factory-authorization could result in personnel injury or damage to the unit. This will also void all factory warranties. Only factory supplied replacement parts ensure that the warranty and agency status remain in effect. All repair work shall be done in such a manner as to maintain the equipment in compliance with governing codes, ordinances and testing agency listings.

Drain

Inspect drain before initial start-up, and prior to each cooling season to assure that drain trap and line are clear. When clogged, clear the debris so condensate easily flows.

Periodically inspect drain during cooling season to maintain a free-flowing condensate. Units are provided with a secondary or “tell-tale” drain connection that will indicate a clogged main-drain line by flow from “tell-tale” connection.

Should algae and/or bacteria growth become a concern, consult an air conditioning and refrigeration supply organization

familiar with local conditions for chemicals, or other solutions available to control these agents.

Filters — Throwaway

Throwaway type filters; commonly used on fan coil units must be replaced on a regular basis. The time between replacement should be established based on regular inspection of filter, and also recorded in the log for each unit. Refer to Table 4 for appropriate filter dimensions compatible with each unit size. If replacement filters are not purchased from factory, filters used should be the same type and size as factory, or recommended by factory. Extended surface filters must not be used due to high air pressure drops encountered with these types of filters being incompatible with the type of fan coil unit covered in this manual. Consult factory for applications using filter types other than factory standard or optional product.

Filters — Replacement and Installation

Each unit is equipped with return air filters. Filters must be periodically replaced.

The 42DH units' filters are 1 in., 2 in., or 4 in. thick. Filters can be easily accessed from the side or bottom of the filter rack (see Fig. 23).

To remove filters from the side of the filter rack:

1. Remove the side access panel (A) of the filter rack by pulling tab at the bottom of the panel to free from magnets, and lower it out of the slot (B) in the top of the filter frame.

2. Pull out dirty filters.

3. Replace with new appropriate size filters.

4. To re-install side access panel into filter rack: a. Insert the tab of panel into the slot in filter frame's top

(B).

b. Rotate panel toward the frame, ensure magnets are

engaged.

To remove filters from the bottom of the filter rack:

1. Open hinged bottom access panel (C) - pull down to disengage magnets.

2. Pull out dirty filters.

3. Replace with new appropriate size filters.

4. Secure bottom access panels, make sure magnets are reengaged.

The 42DH units are designed to accept various filter sizes depending on job requirements. Each filter frame is equipped with filter support angle brackets (D) and 1 in. or 2 in. filter slots on all four sides of filter frame. The filter support angle brackets (D) are designed to provide guidance and support to the new filter as it is being inserted.

In order to accommodate 1 in. and 2 in. filters, the bracket should be inserted into corresponding slots on all sides of the filter frame (see Fig. 23) and secured with screws. When 4 in. filter is installed, the brackets should be stored for future use with different filter thickness, or discarded if 4 in. filter will be always used.

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D - FILTER SUPPORT ANGLE BRACKET

4” FILTER

1” FILTER MOUNTING HOLES

2” FILTER MOUNTING HOLES

DETAIL Y

SEE DETAIL X

DETAIL X

SEE DETAIL Y

1” FILTER

MAGNETS

2” FILTER

Fig. 23 — Filter Rack

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