Carrier 42KC user guide manual

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42KC, 45UC, 45XC, 35BF

Access Floor Terminal Units

Installation, Operation and

Configuration Instructions

AXIS™

CONTENTS

Page

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

GENERAL ...................................... 2-5

System Overview ................................ 2

System Architecture ............................. 3

PRE-INSTALLATION.............................. 6

Unpack and Inspect Units ........................ 6

Storage and Handling ............................ 6

Prepare Jobsite for Unit Installation.............. 6

45XC FAN-POWERED ZONE MIXING UNIT

INSTALLATION.............................. 6-27

45XC Hardware................................... 7

45XC Field-Supplied Hardware ................... 7

45XC Fan-Powered Zone Mixing Box

Installation ..................................... 9

45XC Sensor Installation ........................14

45XC Input and Output Connectors ............. 25

Connect to the CCN Communication Bus .......26

Connect Air Pressure Tubing.................... 26

45UC UNDERFLOOR SERIES FAN-POWERED

TERMINAL INSTALLATION ................. 27-35

45UC Hardware.................................. 27

45UC Field-Supplied Hardware .................. 27

45UC Underfloor Series Fan-Powered Unit

Installation ....................................29

45UC Sensor Installation ........................30

Connect to the CCN Communication Bus .......30

Modulating Baseboard Hydronic Heating........35

42KC PERIMETER FAN COIL UNIT

INSTALLATION............................. 36-45

42KC Hardware.................................. 36

42KC Field-Supplied Hardware .................. 37

42KC Perimeter Fan Coil Unit Installation ....... 37

Connect the Power Transformer................. 38

Fan Coil Controller Inputs and Outputs .........44

42KC Sensor Installation ........................44

35BF DIFFUSER INSTALLATION.............. 46-49

35BF-R Swirl Diffuser Installation ............... 46

35BF-CT,D,V Linear Diffuser Installation......... 46

OPERATION .................................. 50,51

Initial Start-Up Procedures ...................... 50

45XC Start-Up and Checkout Procedure......... 50

42KC Start-Up................................... 50

Page

CONFIGURATION ............................ 51-68

45XC Commissioning ........................... 51

45XC Set-Up and Configuration .................51

42KC Set-Up and Configuration .................57

42KC Fan Coil Airflow Adjustment .............. 57

Setting Fan Airflow with ECM ................... 57

Balancing Underfloor Fan Terminals ............ 57

Speed Controller ................................ 60

Set Points ....................................... 60

Testing and Start-Up ............................ 61

45XC Operation ................................. 62

42KC Fan Coil Sequence ........................ 66

45XC Application Considerations ............... 66

Maintenance ................................... 67

SAFETY CONSIDERATIONS

SAFETY NOTE

Air-handling equipment will provide safe and reliable service when operated within design specifications. The equipment should be operated and serviced only by authorized personnel who have a thorough knowledge of system operation, safety devices and emergency procedures.

Good judgement should be used in applying any manufacturer’s instructions to avoid injury to personnel or damage to equipment and property.

Disconnect all power to the unit before performing maintenance or service. Unit may automatically start if power is not disconnected. Electrical shock and personal injury could result.

If it is necessary to remove and dispose of mercury contactors in electric heat section, follow all local, state, and federal laws regarding disposal of equipment containing hazardous materials.

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

Book 3 3 Ta b 6 a 7 a

Catalog No. 04-53450001-01 Printed in U.S.A. Form 45-4SI Pg 1 11-05 Replaces: 45-2SI

GENERAL

The 45XC fan-powered mixing box provides plenum pressure and temperature control to the underfloor plenum. The 45XC mixing box is also equipped with a modulating primary air damper and a variable speed fan. Together, these features allow the 45XC unit to maintain plenum pressure at the desired pressure set point while adjusting the plenum temperature to match the load requirements.

The 45UC series underfloor fan-powered terminal and the 42KC fan coil unit are used to provide increased cooling or supplemental heating to perimeter zones. These units are available with factory-installed electric or hot water heating coils.

The controllers are factory-mounted. The 33ZCPLNCTL zone controller is supplied on the 45XC fan-powered mixing box. The 33ZCFANTRM underfloor controller is supplied on the 45UC underfloor fan-powered terminal. The 42KC fan coil units contain the 33ZCFANCOL perimeter fan coil controller. All are designed to be an integral part of the Carrier Direct Digital Controls (DDC) system. The controllers can communicate on the Carrier Comfort Network® (CCN) system while completely integrating with the building’s heating, ventilation and air conditioning (HVAC) system.

System Overview — Electronic control units feature a

factory-installed enclosure that provides easy access for field connections.

The 45XC zone controller is factory-supplied and factoryconfigured, and consists of a processor, pressure transducer and actuator. The controllers are configured to maintain the plenum

pressure between 0.01 and 1.0 in. wg and to control and maintain space temperature by measuring both plenum and space temperature. The space temperature set point may be adjusted by the user through the space temperature sensor without additional software.

Each 45XC zone controller also has the ability to function as a linkage coordinator for systems with up to 128 zones. As a linkage coordinator, a controller retrieves and provides system information to the air-handling equipment and other zone controllers. When a primary supply air sensor is installed, the controller can function as a stand-alone device. See Fig. 1 and 2.

The controller monitors differential pressure from two pressure probes: one mounted in the space and one in the pressurized plenum. It compares the resulting signal to a plenum pressure set point in order to provide pressure-independent control of the air passing through the mixing box into the plenum.

The controller is wired to a wall-mounted, field-supplied, space temperature sensor (SPT) in order to monitor zone temperature changes and satisfy zone demand.

The controller is designed to allow a service person or building owner to configure and operate the unit through the CCN user interface, however, a user interface is not required for day-to-day operation. All maintenance, configuration, setup, and diagnostic information is available through the Level II communications port to allow data access by an attached computer running Network Service Tool, ComfortVIEW™, or ComfortWORKS® software.

PMET

FAN MOTOR

INTERFACE

(

ECAP

ERUTARE

ROSNE

ROOLFREDNU

MUNELP

NOC ENOZ ROOLFREDNU

)LTCNLPCZ33

SPACE PRESSURE SENSOR

ELLORT

PRIMARY AIR TEMPERATURE SENSOR

AIRFLOW SENSOR

PRIMARY AIR DAMPER

GIH

WOL

DAMPER ACTUATOR

TROP

CONTROLS ENCLOSURE

PRIMARY

AIR DUCT

RAMIR

ROSNES ERUSSERP MUNELP

MIXED AIR

FAN

NRUTER / GNILI

RIA MUNELP

RETLIF

)deilppus-dleif(

RIA YLPPUS

ERUTAREPMET

FIELD-SUPPLIED FILTER MONITOR

ERUSSERP

HCTI

)deilppus-dleif(

RETURN DUCT

3 equivalent diameters of straight discharge duct

(minimum)

Fig. 1 — Typical Installation of Single 45XC Fan-Powered Mixing Unit

for Each Underfloor Zone

PMET

FAN MOTOR

INTERFACE

(

ECAP

ERUTARE

ROSNE

ROOLFREDNU

MUNELP

PRIMARY

RAMIR

TIC

)rosneS wolfriA(

than one

erom htiw snoitacilppa ni desu(

AIR DUCT

EBORP

)munelp nommoc a gnizirusserp tinu CX54

MIXED AIR

FAN

NRUTER / GNILI

RIA MUNELP

RETLIF

)deilppus-dleif(

RIA YLPPUS

ERUTAREPMET

FIELD-SUPPLIED FILTER MONITOR

ERUSSERP

HCTI

)deilppus-dleif(

RETURN DUCT

3 equivalent diameters of straight discharge duct

(minimum)

PRIMARY AIR TEMPERATURE SENSOR

AIRFLOW SENSOR

PRIMARY AIR DAMPER

DAMPER

NOC ENOZ ROOLFREDNU

ELLORT

)LTCNLPCZ33

ACTUATOR

HGIH

TROP

TOP

CONTROLS ENCLOSURE

OLEV DELLATSNI-DLEIF

Fig. 2 — Typical Installation for Multiple 45XC Fan-Powered Mixing Units

in a Larger Common Underfloor Zone (One 45XC Unit Shown)

System Architecture — Figure 3 shows the typical

control system architecture: a 45XC mixing box unit used to provide the main plenum pressure and temperature control and four 42KC fan coil units to provide supplemental heating and cooling.

Figure 4 shows an arrangement of underfloor and zone controllers and terminal units employed in the HVAC system of a large building. Though all controllers are connected to the same bus, controllers are configured to stand alone, satisfying the needs of individual zones. These are commonly used in perimeter zones. All underfloor controllers participate in linkage, with one configured as a linkage master; the rest are configured as slaves.

This arrangement, from the software point of view, gives the following information:

• All controllers may be configured to stand alone with their

own sensor OR they may share a temperature sensor

between themselves. The zone controllers do not share

sensor data with underfloor controllers.

• Controllers may have their own temperature sensor (located

near ceiling plenum) OR may share a single temperature

sensor.

• Controllers participate in linkage when sending the damper

position, occupancy, zone temperature and temperature set

point data to the master underfloor controller.

A bridge is recommended to isolate the underfloor control

system from the primary communication (comm) bus to:

• improve communication quality

• increase communication speed

Controllers use the underfloor plenum as the air source and control the diffusers to satisfy the space temperature needs. Controllers also make use of strip heaters for auxiliary heating.

POWER REQUIREMENTS — The power supply is 24 vac ± 10% at 40 va (50/60 Hz).

WIRING CONNECTIONS — Field wiring is 18-gage to 22-gage wire. The zone controller is a NEC (National Electrical Code) Class 2 rated device.

INPUTS

• space temperature sensor

• primary air damper position

• plenum sensor (factory-installed)

• supply air temperature sensor

• optional primary air temperature sensor (required for sys-

tems which do not utilize a linkage compatible air source)

• optional CO

sensor

• optional relative humidity sensor OUTPUTS

• internally factory-wired VAV (variable air volume) actuator

• internally factory-wired fan speed controller

ACCURACY — Terminal airflow pressure control is rated to 1 in. wg measured maximum pressure. The zone controller is capable of controlling from as low as 0.01 in. wg to as high as

1.0 in. wg nominal pressure with an accuracy of ± 3% (nominal) at any point within the range.

HARDWARE (MEMORY) — The hardware consists of FLASH EPROM memory.

DIFFERENTIAL PRESSURE SENSOR — Pressure range is

0.0 to 2.0 in. wg maximum for the onboard pressure sensor. SPECIFIED SENSING TEMPERATURE RANGE — The

controller space temperature measuring range is –40 to 245 F. This range applies to space temperature, supply-air temperature and primary air temperature sensors. The controller has an allowable control set point range from 40 to 90 F for heating and45to99Fforcooling.

COMMUNICATIONS — The maximum number of controllers is limited to 128 zones, with a limit of 8 systems (Linkage Coordinator configured for at least 2 zones). Carrier Comfort Network® (CCN) bus length may not exceed 4000 ft, with no more than 60 devices on any 1000 ft section. Optically isolated RS-485 repeaters are required every 1000 ft.

Exterior Zones

At 19,200 and 38,400 baud, the number of controllers is limited to 128 maximum, with no limit on the number of Linkage Coordinators. Bus length may not exceed 1000 ft.

ENVIRONMENTAL RATINGS — Operating Temperature is 32 to 140 F at 0 to 90% rh (relative humidity) (non-condensing).

Shipping Temperature is –40 to 185 F at 0 to 90% rh (non-condensing).

PERFORMANCE VIBRATION

• 0.014 in. peak-to-peak displacement measured at 5 to 31 Hz

• 0.75 G measured at 31 to 300 Hz CORROSION — Equipment intended for indoor use only. APPROVALS

• listed under UL 873

• conforms to requirements per European Consortium

standards EN50081-1 (CISPR 22, Class B) and EN50082-1

(IEC 801-2, IEC 801-3, and IEC 801-4) for CE mark

labeling

• UL94-5V plenum rated (housing and actuator)

35BF-D

42KC

Exterior Wall

LEGEND

42KC — Perimeter Fan Coil Unit with 33ZCFANCOL Fan Coil Controller 45XC — Fan-Powered Zone Mixing Unit with 33ZCPLNCTL Zone Controller T—Wall-Mounted Temperature Sensor

35BF-D Linear Diffuser

35BF-R Swirl Diffuser

42KC

45XC

35BF-R

Interior Zones

Fig. 3 — Typical System Layout (45XC and 42KC)

CCN PRIMARY BUS (BUS 0)

CCN

SYSTEM

MONITORING

SOFTWARE

FAN COIL CONTROLLER

45UC UNIT (33ZCFANTRM)

FULLY CCN

COMPATIBLE CARRIER

AIR HANDLER

SECONDARY BUS

CC6400 OR CSAM

EQUIPPED

NON-CARRIER

AIR HANDLER

COMFORT ID™

EQUIPPED

AIR TERMINAL

(1 OF UP TO 128)

ADDRESSED

SEQUENTIALLY

45XC UNIT (33ZCPLNCTL)

TYPICAL 42KC FAN COIL UNIT

BRIDGE

(RECOMMENDED)

FAN COIL CONTROLLER

(33ZCFANCOL)

TYPICAL 42KC

FAN COIL UNIT

LEGEND

CCN — Carrier Comfort Network® CSAM — Comfort System

Air

Manager™

Fig. 4 — Control System Architecture with Underfloor Terminal Units

DATA

COLLECTION

OPTION

42KC UNIT (33ZCFANCOL)

TO OTHER CONTROLLERS ON COMM BUS

PRE-INSTALLATION

Unpack and Inspect Units —

from all units. Check the shipment against shipping order. Inspect for damage upon receipt. If shipment is damaged or

incomplete, file claim with transportation company and advise Carrier immediately.

Remove shipping wraps

Storage and Handling — Store in a clean, dry and

covered location. Do not stack units. When unpacking units, care should be taken that the inlet collars and externally mounted components do not become damaged. Do not lift units using collars, sensors, or externally mounted components as handles. If a unit is supplied with electric or hot water heat, care should be taken to prevent damage to these devices. Do not lay uncrated units on end or sides. Do not stack uncrated units over 6 ft high. Do not handle control boxes by tubing connections or other external attachments.

PRIMARY AIR DUCT

Prepare Jobsite for Unit Installation — To s av e t im e

and to reduce the possibility of costly errors, set up a complete sample installation in a typical room at the jobsite. Check all critical dimensions. Refer to job drawings and product dimension drawings as required.

45XC FAN-POWERED ZONE MIXING UNIT

INSTALLATION

Physical components of the 45XC fan-powered zone mixing unit is detailed in Fig. 5. Figure 6 shows 45XC fanpowered zone mixing unit dimensions and weight data.

CEILING PLENUM RETURN AIR DUCT

CONTROL ENCLOSURE

42 in. MINIMUM - SIZE 04 54 in. MINIMUM - SIZE 07

LOW AND HIGH

PRESSURE PORT*

RAISED FLOOR

*Installation is shown for a single unit in a multiple unit/common plenum application.

High and low pressure ports piped to a discharge plenum. Refer to Fig. 2.

SUPPLY AIR TEMPERATURE PROBE

SUPPLY DUCT

Fig. 5 — 45XC Fan-Powered Zone Mixing Unit Physical Details

1/2" DIA.

PRIMARY AIR INLET

DAMPER SHAFT

1/2"

20"

ALLOW AT LEAST

24" CLEARANCE FOR CONTROLS

J 11 7/8"

6 1/4"

B 1-1/2"

INLET VIEW

45XC UNIT SIZE UNIT WEIGHT (lb) FILTER SIZE (in.) FILTER P/N FILTER KIT P/N

4 209 17 x 17 x 1 102649-1717 3503341717 7 269 22 x 19 x 1 102649-2219 3503342219

INLET

UNIT SIZE

*Estimated for rpm/torque controlled motor, at 0.1 in. wg static pressure under floor. NOTE: Inlet Size: 6-10, DD = 3

SIZE

(in.)

PRI.

CFM

6 500 1200 1700

8900 1200 21001/2361/8361/8181/16151/815 77/811 14 9 631/831/ 10 1400 1200 26001/2361/8361/8181/16151/815 97/811 14 9 731/831/ 12 2100 1200 33001/2361/8361/8181/16151/815 117/811 14 9831/

10 1400 2500 3900 1 42 12 2100 2500 4600 1 421/8461/8201/16201/817 117/815 17 10 8 51/241/ 14 2800 2500 5300 1 421/8461/8201/16201/817 137/815 17 10 10 51/ 16 3700 2500 6200 1 421/8461/8201/16201/817 157/815 17 10 101/451/

FA N

CFM*

/8in. Inlet Size: 12-16, DD = 57/8in.

1-1/4"

MAX

FLOW

RECIRCULATED AIR INLET

MOUNTING BRACKET - (4 PLCS)

SEE OPTIONAL FEATURES BELOW

PLAN VIEW – LEFT HAND UNIT

RIGHT HAND UNITS AVAILABLE - CONTROLS NOT SHOWN

LWH

/2361/8361/8181/16151/815 57/811 14 9 631/831/

/8461/8201/16201/817 97/815 17 10 7 51/241/

Recirc. Air

AB FG

Fig. 6 — 45XC Fan Powered Zone Mixing Unit Physical Data and Dimensions

45XC Hardware — The 45XC fan-powered mixing unit

contains the 33ZCPLNCTL zone controller.

Figure 7 shows the zone controller physical details.

SUPPLY-AIR TEMPERATURE (SAT) SENSOR (Fig. 9) — The zone controller must be connected to a field-supplied supply air temperature (SAT) sensor (P/N 33ZCSENSAT) to monitor the temperature of the air delivered by the fan coil.

45XC Field-Supplied Hardware — Each 45XC fan-

powered zone mixing unit requires the following field-supplied components to complete its installation:

• transformer — 24 vac, 40 va (standard applications)

• contactors (as required for electric heat)

•

/4-in. OD flame retardant polyethylene tubing (length not

toexceed25ft)

• space temperature sensor (33ZCT55SPT, 33ZCT56SPT, or 33ZCT57SPT)

• supply-air temperature sensor (33ZCSENSAT) with two no. 10 x supply duct)

• primary-air temperature sensor

• indoor-air quality (CO

• relative humidity sensor (optional)

SPACE TEMPERATURE SENSOR (Fig. 8) — Each 33ZCPLNCTL zone controller requires a field-supplied Carrier space temperature sensor. There are three sensors available for this application:

• 33ZCT55SPT, space temperature sensor with override button

• 33ZCT56SPT, space temperature sensor with override button and set point adjustment

/2-in. sheet metal screws (to secure SAT sensor to

) sensor (optional)

PRIMARY-AIR TEMPERATURE SENSOR (PAT) (Optional) — A field-supplied, primary air temperature (PAT) sensor (P/N 33ZCSENPAT) is used on a zone controller that is functioning as a linkage master for a non CCN/linkage compatible air source. See Fig. 10.

INDOOR-AIR QUALITY (CO indoor air quality sensor is required for IAQ monitoring. Three different CO2sensors are available for zone CO2level monitoring.

• The 33ZCSENCO2 sensor is an indoor, wall-mounted sensor with an LED (light-emitting diode) display.

• The 33ZCT55CO2 sensor is an indoor, wall-mounted sensor without display. The CO temperature sensor with override button.

• The 33ZCT56CO2 sensor is an indoor, wall-mounted sensor without display. The CO temperature sensor with override button and temperature offset.

RELATIVE HUMIDITY SENSOR (Fig. 12) — The relative humidity sensor (P/N 33AMSENRHS000) is an indoor, wallmounted sensor and is required for zone humidity control (dehumidification).

• 33ZCT57SPT, space temperature sensor with override button, set point adjustment, and manual fan speed control

DISCHARGE

DIMENSIONS (in.)

Discharge

F 2 9/16"

DISCHARGE VIEW

XY Z J

8 8 8

31/

41/

)SENSOR(Fig.11)—An

sensor also includes a space

HF23BJ042

Made in Switzerland by Belimo Automation

LR 92800

NEMA 2

LISTED 94D5 TENP IND & REG. EQUIP.

Class 2 Supply

WIP

yel

blu

ora

35 in-lb (4 Nm)

80...110s

24VAC/DC 50/60 Hz 3VA 2W

COM

red wht

blk

LOW

ZONE Controller

Part Number: 33ZCPLNCTL

S/N:

Bus#:

Element#:

Unit#:

HIGH

2 1

SEC DMP

CCW

COMCWHEAT1

24VAC

HEAT2

FAN AC

FAN

24VAC

N/A

HEAT3

COM

COW

RH/IAQ

GND

SECFLOW

+10V

DMPPOS

GND

TEST

GND

CCN

J2A

+24V

SPT

GND

SAT

T56

GND

PAT

REMOTE

24VAC

LEN

J2B

SRVC

Fig. 7 — 45XC Fan-Powered Zone Mixing Unit Controller Physical Details (33ZCPLNTCTL)

Cool

Warm

Fig. 8 — Space Temperature Sensor (P/N 33ZCT56SPT Shown)

.08

.39

FOAM GASKET

3.90

.40'' O.D.

.250 ±.01 Dia

.175 DIA

x .600

3.00

PLENUM RATED CABLE 114'' ±6

5.5 ±.5

NOTE: Dimensions are in inches.

Fig. 9 — Supply Air Temperature Sensor (33ZCSENSAT)

Fig. 10 — Primary Air Temperature Sensor

(33ZCSENPAT)

5.625 (14.3)

3.25 (8.3)

NOTE: Dimensions are in inches. Dimensions in () are in centimeters.

1.125 (2.9)

(12.7)

0.25

(0.8)

Fig. 11 — Indoor Air Quality (CO2) Sensor

(33ZCSENCO2)

Fig. 12 — Wall-Mounted Relative Humidity Sensor

(33AMSENRHS000)

45XC Fan-Powered Zone Mixing Box Installation

STEP 1 — SELECT LOCATION

1. Units should be installed so that they do not come in contact with obstacles such as rigid conduit, sprinkler piping, Greenfield flexible metal covering, or rigid pneumatic tubing; such contact can transmit vibration to the building structure, causing objectionable low frequency noise.

2. Units should never be installed tightly against concrete slabs or columns, as vibration transmission is amplified in this condition.

3. Fan-powered terminals require sufficient clearance for servicing the blower/motor assembly from the bottom of the unit, low voltage controls from the side and line voltage motor controls or electric heat (if equipped) from the rear (discharge end) of the unit. See Fig. 6.

Bottom access panel removal requires a minimum of 3-in. minimum clearance, in addition to substantial horizontal clearance, to slide the access panel out of the way for service. Actual horizontal dimensions will vary due to varying access panels for different sized units. See unit submittal drawings for detailed information.

NOTE: Be certain that accommodations for panel removal of unit casings are large enough to allow adequate internal service room once the panels are removed.

A clearance of 18 in. is recommended for control enclosure access. Unit control enclosure will vary depending on which control package is used. Control enclosure location is specified on unit submittals. Low voltage enclosure covers are removable, not hinged.

A clearance of 36 in. is recommended for line voltage motor controls and electric heat control access. High voltage motor controls or electric heat control access is supplied with hinged access doors for units with fused disconnect. Specific location is indicated on the unit submittal.

These recommendations do not supersede NEC (National Electrical Code) or local codes that may be applicable. Adherence to these codes are the responsibility of the installing contractor.

4. Whenever possible, fan-powered boxes should be installed over halls or passageways (rather than over occupied spaces) in order to limit the sound reaching occupants.

STEP 2 — POSITION UNIT

1. When moving boxes, use appropriate material handling equipment and avoid contact with shaft extensions, controls, wiring, piping, heaters, and control boxes.

2. Raise unit to position using safe mechanical equipment and support until hanging means are attached and box is level.

STEP 3 — INSTALL UNIT

1. Install field-supplied eyebolts, straphangers or bolt rod supports as desired. Figure 13 illustrates possible 45XC unit suspension methods. A typical underfloor installation is shown in Fig. 14.

2. Care should be taken to use hanging materials of sufficient stiffness and strength, rigidly attached to the unit. Straps should not be located on coil flanges, electric heat sections, or control boxes. When using trapeze supports, avoid areas where access is required to side mounted controls, or side or bottom access doors. For best installation with trapeze supports, provide elastomeric material between unit and supports.

3. Hangers should be securely attached to bar joist or mounting anchors properly secured to building structure with lugs or poured-in-place hangers. Percussion nails are not considered adequate anchors.

STEP 4 — MAKE DUCT CONNECTIONS

1. Check that the pressure pick-up in primary air collar is located properly and that air supply duct connections are airtight. Install supply ductwork on unit inlet collar, following all accepted medium-pressure duct installation procedures. Seal joints against leakage.

NOTE: For maximum efficiency in controlling radiated noise in critical applications, inlet ducts should be fabricated of 24-gage minimum sheet metal in place of flex connections. Flex duct is extremely transparent to radiated sound; consequently high inlet static pressure (Ps) or sharp bends with excessive pressure drop can cause a radiated noise problem in the space. If flex duct is used, it should be limited to the connection between the distribution duct and the boot diffuser.

2. Install the discharge duct, being careful not to reduce the face area of any electric heat section until several diameters away from the unit. It is strongly recommended that lined discharge duct be used downstream of the unit. Insulate duct as required.

3. Fan boxes should not be attached to octopus sections immediately downstream of the unit.

4. Install optional return-air filters before operating the unit.

5. Leave construction filters supplied with the box in place until installation is complete and building is cleared for occupancy.

STEP 5 — POWER WIRING

Disconnect electrical power before wiring or servicing the unit. All disconnect switches on the terminal (if equipped) should be in the OFF position while making power connections. Electrical shock, personal injury, or damage to the zone controller can result.

1. All power wiring must comply with local codes and with NEC ANSI/NFPA (American National Standards Institute/National Fire Protection Association) 70-1981. Disconnect switches are optional equipment. Electrical, control and piping diagrams are shown on the exterior labeling or on a diagram inside the control and highvoltage enclosure covers, unless otherwise specified in the order write-up. All units are wired for a single point electrical connection to the fan and electric heater (if equipped). Electric heaters provided by Carrier are balanced by kW per stage. The installing electrician should rotate incoming electric service by phase to help balance overall building load.

2. All field wiring must be provided with a safety disconnect per NEC 424-19, 20, and 21.

3. Units with electric heat should use copper wires rated at least 125% of rating plate amperage. Refer to the unit’s rating label and minimum supply circuit amps.

4. Observe wiring diagram and instructions attached to the unit. A Wye power source with a fourth (neutral) wire in addition to the full sized ground wire is required for 480-v, 3-phase units. All units must be grounded as required by NEC 424-14 and 250. See Fig. 15A and 15B.

ACCESSORY HANGER

SUPPORT ROD

FIELD-SUPPLIED BRACKET HANGER

DO NOT SUSPEND UNIT BY TRAPEZE HANGERS THAT INTERFERE WITH THE UNIT ACCESS PANEL

Fig. 13 — Typical 45XC Support Methods

ROOM SENSOR

45XC FAN POWERED ZONE MIXING BOX

Fig. 14 — Typical Underfloor Installation — 45XC Fan-Powered Mixing Box

35 BF-R SWIRL DIFFUSER

LEGEND

Factory Piping

Factory Wiring

Fig. 15A — 45XC Zone Controller Wiring — Control Package 4840

Field Wiring

to the fully closed position. Mount actuator over damper shaft and

secure to shaft enclosure. Engage clutch and rotate damper CCW to

AFS — Airflow Switch

COM — Common

CCW — Counterclockwise

CW — Clockwise

DMPPOS — Damper Position

ECM — Electronically Commutated Motor

GND — Ground

N.O. — Normally Open

PAT — Primary Air Temperature Sensor

SAT — Plenum Temperature Sensor

SPT — Space Temperature Sensor

UL — Underwriter’s Laboratories

NOTES:

the fully open position.

1. Verify actuator bushing is in the full CW position. Rotate damper CW

2. Use insulated quick connects.

Electric shock may result. Disconnect unit prior to servicing unit.

3. These controls have been wired to comply with UL-1995.

LEGEND

Factory Piping

Factory Wiring

Field Wiring

AFS — Airflow Switch

COM — Common

CCW — Counterclockwise

CW — Clockwise

DMPPOS — Damper Position

ECM — Electronically Commutated Motor

GND — Ground

N.O. — Normally Open

PAT — Primary Air Temperature Sensor

SAT — Plenum Temperature Sensor

SPT — Space Temperature Sensor

UL — Underwriter’s Laboratories

Electric shock may result. Disconnect unit prior to servicing

CW to the fully closed position. Mount actuator over damper

shaft and secure to shaft enclosure. Engage clutch and rotate

damper CCW to the fully open position.

NOTES:

1. Verify actuator bushing is in the full CW position. Rotate damper

2. Use insulated quick connects.

unit.

3. These controls have been wired to comply with UL-1995.

Fig. 15B — 45XC Zone Controller Wiring — Control Package 4841

45XC Sensor Installation

GENERAL SENSOR INSTALLATION — The sensor should be mounted:

• on an internal wall near a return air grille or duct

• at least 3 ft from any corner, 2 ft from an open doorway and 4 to 6 ft from the floor

• proximal to the wiring egress on the wall

• where temperature operating limits are 32 to 122 F

The sensor should NOT be mounted:

• close to a window, on an outside wall, or next to a door leading to the outside

• close to or in direct airflow of areas such as open windows, drafts or over heat sources

• in areas with poor air circulation, such as behind a door or in an alcove where there are dramatic temperature fluctuations or moisture accumulation

• where it is influenced by supply air as the sensor will give an inaccurate reading

• where it may be exposed to direct occupant breathing, such as near water coolers or coffee machines.

SPACE TEMPERATURE SENSOR INSTALLATION — A space temperature sensor must be installed for each zone controller. There are three types of SPT sensors available used with the 33ZCPLNCTL controller: 33ZCT55SPT space temperature sensor with timed override button, 33ZCT56SPT space temperature sensor with timed override button and set point adjustment, and 33ZCT57SPT space temperature sensor with timed override button, set point adjustment, and manual fan speed control. See Fig. 8 and 16.

The space temperature sensor is used to measure the build-

ing interior temperature and should be located on an interior building wall. The sensor wall plate accommodates the NEMA (National Electrical Manufacturers Association) standard 2 x 4 in. junction box. The sensor can be mounted directly on the wall surface if acceptable by local codes.

Do not mount the sensor in drafty locations such as near air

conditioning or heating ducts, over heat sources such as baseboard heaters or radiators, or directly above wall-mounted lighting dimmers. Do not mount the sensor near a window which may be opened, near a wall corner, or a door. Sensors mounted in these areas will have inaccurate and erratic sensor readings.

The sensor should be mounted approximately 5 ft from the

floor, in an area representing the average temperature in the space. Allow at least 4 ft between the sensor and any corner and mount the sensor at least 2 ft from an open doorway.

The sensor consists of the following hardware:

1 — sensor top 1 — sensor base 1 — mounting plate 2 — machine screws (6 x 32) 2 — locking screws

Install the sensor as follows (see Fig. 16):

1. Locate the two Allen type screws at the bottom of the sensor.

2. Turn the two screws clockwise to release the cover from the sensor wall mounting plate.

3. Lift the cover from the bottom and then release it from the top fasteners.

4. Feed the wires from the electrical box through the opening in the center of the sensor mounting plate.

5. Usingtwono.6-32x1machinescrews(providedwith the sensor), secure the sensor to the electrical box.

NOTE: Sensor may also be mounted directly on the wall using2plasticanchorsand2sheetmetalscrews (field-supplied).

6. Use 20-gage wire to connect the sensor to the controller. The wire is suitable for distances of up to 500 ft. Use a three-conductor shielded cable for the sensor and set point adjustment connections. The standard CCN communication cable may be used. If the set point adjustment (slidebar) is not required, then an unshielded, 18-gage or 20-gage, two-conductor, twisted pair cable may be used.

The CCN service jack requires a separate, shielded CCN communication cable. Always use separate cables for CCN communication and sensor wiring. (Refer to Fig. 17-19 for wire terminations.)

7. Replace the cover by inserting the cover at the top of the mounting plate first, then swing the cover down over the lower portion. Rotate the two Allen head screws counterclockwise until the cover is secured to the mounting plate and locked in position.

NOTE: Clean sensor with damp cloth only. Do not use solvents. See Table 1 for resistance vs temperature data.

Before performing service or maintenance operations on the system, turn off main power switches to the unit. Electric shock can cause personal injury.

NOTE: Dimensions are in inches.

Fig. 16 — Space Temperature Sensor and Wall-Mounted Humidity Sensor Mounting

Wiring the Space Temperature Sensor

(33ZCT55SPT, 33ZCT56SPT, 33ZCT57SPT) — The sensor wiring has the following requirements:

• Power requirements: 18 to 36 vac RMS 50/60 Hz at 4 va.

• All system wiring must be in compliance with all applicable

local and national codes.

• A dedicated power supply is required for this sensor.

• All sensor wiring should be color-coded for ease of mainte-

nance and service.

• Wiring should be 18 to 22 AWG (American Wire Gage)

stranded wire (20 AWG is recommended). To wire the sensor, perform the following (see Fig. 17-19):

1. Identify which cable is for the sensor wiring.

2. Strip back the jacket from the cables at least 3 inches.

Strip

/4-in. of insulation from each conductor. Cut the

shield and drain wire from the sensor end of the cable.

3. Connect the sensor cable as follows: a. Connect one wire from the cable (RED) to the SPT

terminal on the controller. Connect the other end of the wire to the left terminal on the SEN terminal block of the sensor.

b. Connect another wire from the cable (BLACK) to

the GND terminal on the controller. Connect the other end of the wire to the remaining open terminal on the SEN terminal block (COM on 33ZCT57SPT).

c. On 33ZCT56SPT and 33ZCT57SPT thermostats,

connect the remaining wire (WHITE/CLR) to the T56 terminal on the controller. Connect the other end of the wire to the SET terminal on the sensor.

d. In the control box, install a no. 10 ring-type crimp

lug on the shield drain wire. Install this lug under the mounting screw of the zone controller.

e. On 33ZCT56SPT thermostats, install a jumper

between the two center terminals (right SEN and left SET). See Fig. 18.

f. On 33ZCT57SPT thermostats, a separate

3-conductor, shielded cable is used to connect the fan speed wiring. Connect the SPD terminal on the thermostat to the SPEED terminal on the zone controller. Use the white/clear wire. Connect the COM terminal on the thermostat to the GND terminal on the zone controller. Use the black wire. Connect the 10V terminal on the thermostat to the +10V terminal on the zone controller. Use the red wire.

In the control box, install a no. 10 ring-type crimp lug on the fan speed wiring shield drain wire. Install this lug under the mounting screw of the zone controller.

Wiring the CCN Communication Service Jack

—See

Fig. 17-19. To wire the service jack, perform the following:

1. Strip back the jacket from the CCN communication cable(s) at least 3 inches. Strip

/4-in. of insulation from each conductor. Remove the shield and separate the drain wire from the cable. Twist together all the shield drain wires and fasten them together using a closed end crimp lug or a wire nut. Tape off any exposed bare wire to prevent shorting.

2. Connect the CCN + signal wire(s) (RED) to Terminal 5.

3. Connect the CCN – signal wire(s) (BLACK) to Terminal 2 .

4. Connect the CCN GND signal wire(s) (WHITE/CLR) to Terminal 4 .

Before wiring the CCN connection, refer to Connect the CCN Communication Bus section for communication bus wiring and cable selection. The cable selected must be identical to the CCN communication bus wire used for the entire network.

The other end of the communication bus cable must be connected to the remainder of the CCN communication bus. If the cable is installed as a T-tap into the bus, the cable length cannot exceed 50 ft. No more than 10 T-taps are allowed per bus. Wire the CCN service jack of the sensor in a daisy chain arrangement with other equipment. See Fig. 20. Refer to the Connect to the CCN Communication Bus section for additional details.

SW1

SEN

RED(+)

WHT(GND)

BLK(-)

BLK (GND)

RED (SPT)

CCN COM

SENSOR WIRING

Fig. 17 — Space Temperature Sensor Wiring

(33ZCT55SPT)

SEN

SW1

Cool Warm

RED(+)

WHT(GND)

BLK(-)

SET

WHT

(T56) BLK (GND) RED (SPT)

CCN COM

SENSOR WIRING

JUMPER TERMINALS AS SHOWN

Fig. 18 — Space Temperature Sensor Wiring

(33ZCT56SPT)

WHITE (SPEED)

3-CONDUCTOR SHIELDED CABLE

LEGEND

CCN — Carrier Comfort Network® SW1 — Switch Set Point — Set Point Adjust

NOTE: Do not connect white wire to SET terminal if set point adjustment is not needed.

3-CONDUCTOR SHIELDED CABLE

Fig. 19 — Space Temperature Sensor Wiring (33ZCT57SPT)

Table 1 — Thermistor Resistance vs Temperature Values for Space Temperature Sensor,

Return-Air Temperature Sensor, and Supply-Air Temperature Sensor

TEMP (C) TEMP (F) RESISTANCE (Ohms)

0 32 32,651

5 41 25,395 10 50 19,903 15 59 15,714 20 68 12,494 25 77 10,000 30 86 8,056 35 956,530 40 104 5,325 45 113 4,367 50 122 3,601

Wiring when distance between fan coil controller and space temperature sensor is 50 feet or less:

50 FT. MAXIMUM

FAN COIL PERIMETER CONTROLLER

3 COND COMM CABLE (TYP)

2 COND TWISTED CABLE OR 3 COND CABLE (TEMP SENSOR WIRING) (TYP)

45KC FAN COIL UNIT

CCN COMM BUS

Warm

Cool

SPACE

TEMPERATURE

SENSOR

Wiring when distance between fan coil controller and space temperature sensor is greater than 50 feet:

Warm

Cool

CCN COMM BUS

2 COND TWISTED CABLE OR 3 COND CABLE (TEMP SENSOR WIRING) (TYP)

Warm

Cool

SPACE

TEMPERATURE

SENSOR

DISTANCE GREATER

THAN 50 FT.

Fig. 20 — Communication Bus Wiring (42KC Perimeter Fan Coil Zone Controller Shown)

Warm

Cool

SUPPLY-AIR TEMPERATURE (SAT) SENSOR INSTALLATION — The SAT sensor is required and must be installed in the fan coil air outlet. The part number is 33ZCSENSAT.

The SAT sensor probe is 6 inches in length. See Fig. 9.

When using a ducted supply, the supply-air temperature sensor should be located in the supply duct downstream of the discharge of the fan coil to allow good mixing of the supply airstream.

See Fig. 21 for mounting location. See Fig. 22 for mounting hole requirements.

Disconnect electrical power before wiring the zone controller. Electrical shock, personal injury, or damage to the zone controller can result.

Do not run sensor or relay wires in the same conduit or raceway with Class 1 AC service wiring. Do not abrade, cut, or nick the outer jacket of the cable. Do not pull or draw cable with a force that may harm the physical or electrical properties. Avoid splices in any control wiring. Damage to the 33ZCPLNCTL zone controller can result.

Perform the following steps to connect the SAT sensor to the zone controller:

1. Locate the opening in the control box. Pass the sensor probe through the hole.

2. Drill or punch a

/2-in. hole in the fan coil unit. See

Fig. 22.

3. Use two field-supplied, self-drilling screws to secure the sensor probe to the fan coil unit.

4. Connect the sensor leads to the zone controller’s wiring harness terminal board at the terminals labeled SAT (RED) and GND (BLK).

Perform the following steps if state or local code requires the use of conduit, or if sensor installation requires a cable length of more than 8 ft:

1. Secure the probe to the fan coil unit with two fieldsupplied self-drilling screws.

2. If extending cable length beyond 8 ft, use plenum rated, 20 AWG, twisted pair wire.

3. Connect the sensor leads to the zone controller’s wiring harness terminal board at the terminals labeled SAT (RED) and GND (BLK).

4. Neatly bundle and secure excess wire.

INDOOR-AIR QUALITY (CO

) SENSOR INSTALLA-

TION — The indoor-air quality (CO2) sensor accessory monitors carbon dioxide levels, which provide information used to monitor indoor air quality. Three types of sensors are provided. The wall sensor can be used to monitor the conditioned air space. Sensors use infrared technology to measure the levels of CO

present in the air. The wall sensor is available with or

without an LCD readout to display the CO Fig. 11.

level in ppm. See

Sensor accessory descriptions and part numbers are shown in Table 2. To mount the sensor, refer to the installation instructions shipped with the accessory kit.

Table 2 — CO

CO2SENSOR ACCESSORY

PA RT N U MB ER S

33ZCSENCO2 Wall Mount Sensor (with display)

33ZCT55CO2

33ZCT56CO2

The CO

sensors listed in Table 3 are factory-set for a range

Sensor Accessories

DESCRIPTION

Wall Mount Sensor with 33ZCT55SPT space temperature sensor (no display)

Wall Mount Sensor with 33ZCT56SPT space temperature sensor and set point adjustment (no display)

of 0 to 2000 ppm and a linear voltage output of 0 to 10 vdc. Refer to the instructions supplied with the CO

sensor for

electrical requirements and terminal locations.

To accurately monitor the quality of the air in the conditioned air space, locate the sensor near a return air grille (if present) so it senses the concentration of CO

leaving the

space. The sensor should be mounted in a location to avoid direct breath contact.

Do not mount the CO

sensor in drafty areas such as near

supply ducts, open windows, fans, or over heat sources. Allow at least 3 ft between the sensor and any corner. Avoid mounting the sensor where it is influenced by the supply air; the sensor gives inaccurate readings if the supply air is blown directly onto the sensor or if the supply air does not have a chance to mix with the room air before it is drawn into the return airstream.

APROX

2 FT

SUPPLY DUCT

TYPICAL FAN COIL UNIT

SUPPLY AIR SENSOR

LEGEND

HC — Heating Coil

Fig. 21 — Supply Air Temperature Sensor

Mounting Location (42KC)

3.00

1.50

ø0.50

CLEARANCE HOLE

ENGAGEMENT HOLE FOR #10 SHEET METAL SCREW (2)

Fig. 22 — Supply Air Temperature

Sensor Mounting

Indoor-Air Quality Sensor Wiring

— To wire the sensors after they are mounted in the conditioned air space or outdoor location, see Fig. 23 and the instructions shipped with the sensors. For each sensor, use two 2-conductor 18 AWG twisted-pair cables (unshielded) to connect the separate isolated 24 vac power source to the sensor and to connect the sensor to the control board terminals. To connect the sensor to the control board, identify the positive (0-10 VDC) and ground (SIG COM) terminals on the sensor. Connect the –10 VDC terminal to terminal IAQ and connect the SIG COM terminal to terminal GND.

RELATIVE HUMIDITY SENSOR (WALL-MOUNTED) INSTALLATION — The relative humidity sensor accessory is installed on an interior wall to measure the relative humidity of the air within the occupied space. See Fig. 12.

Theuseofastandard2x4in.electricalboxtoaccommodate the wiring is recommended for installation. The sensor can be mounted directly on the wall, if acceptable by local codes.

If the sensor is installed directly on a wall surface, install the humidity sensor using 2 screws and 2 hollow wall anchors (field-supplied); do not overtighten screws. See Fig. 16.

Do NOT clean or touch the sensing element with chemical solvents; they can permanently damage the sensor.

The sensor must be mounted vertically on the wall. The Carrier logo should be oriented correctly when the sensor is properly mounted.

DO NOT mount the sensor in drafty areas such as near heating or air-conditioning ducts, open windows, fans, or over heat sources such as baseboard heaters, radiators, or wall-mounted light dimmers. Sensors mounted in those areas will produce inaccurate readings.

Avoid corner locations. Allow at least 4 ft between the sensor and any corner. Airflow near corners tends to be reduced, resulting in erratic sensor readings.

Sensor should be vertically mounted approximately 5 ft up from the floor, beside the space temperature sensor.

For distances up to 500 feet, use a 3-conductor, 18 or 20 AWG cable. A CCN communication cable can be used, although the shield is not required. The shield must be removed from the sensor end of the cable if this cable is used. See Fig. 24 for wiring details.

The power for the sensor is provided by the control board. The board provides 24 vdc for the sensor. No additional power source is required.

FRESH

AIR

DAMPER

FAN ON

FAN A C

LOW

MED

HIGH

24VAC

OAD

GND

IAQ

+10V

SPEED

GND

CONDSW

GND

R +

W GND

+24V DC

SPT

GND

SAT

T56

GND

CNGOVR

RMT/FS

24VAC

LINE VOLTAGE

SEPARATE

POWER SUPPLY

REQUIRED

NOT USED

CCN COMMUNICATIONS

VALV E

DX1

COM

VALV E

DX2

HEAT1

24VAC

HEAT2

Fig. 23 — CO2Sensor Wiring (42KC Controller Shown)

CCN COMMUNICATIONS

24 VAC

EQUIPMENT GROUND

LINE

VOLTAGE

To wire the sensor, perform the following:

1. At the sensor, remove 4-in. of jacket from the cable. Strip

/4-in. of insulation from each conductor. Route the cable through the wire clearance opening in the center of the sensor.

2. Connect the RED wire to the sensor screw terminal marked (+).

3. Install one lead from the resistor (supplied with the sensor) and the WHITE wire into the sensor screw terminal marked (–). After tightening the screw terminal, test the connection by pulling gently on the resistor lead.

4. Connect the remaining lead from the resistor to the BLACK wire and secure using a field-supplied closed end type crimp connector or wire nut.

5. Using electrical tape, insulate any exposed resistor lead to prevent shorting.

6. At the control box, remove the jacket from the cable.

7. Strip

/4-in. of insulation from each conductor.

8. Connect the RED wire to terminal 24 VDC on the control board.

NOTE: The 24 VDC terminal is used for rh sensor wiring only.

9. Connect the BLACK wire to terminal GND on the control board.

10. Connect the WHITE/CLEAR wire to terminal RH on the control board.

11. Connect shield to earth ground (if shielded wire is used).

HUMIDITY SENSOR

RED

WHITE

BLACK

SHIELD

(IF USED)

+24V DC

SPT

GND

IAQ

SAT

+10V

SPEED

GND

R +

W GND

T56

GND

CNGOVR

RMT/FS

VALVE

DX1

COM

VALVE

DX2

HEAT1

24VAC

HEAT2

FRESH

AIR

DAMPER

FAN

FAN A C

LOW

MED

HIGH

24VAC

OAD

CONDSW

Fig. 24 — Humidity Sensor Wiring (42KC Controller Shown)

499

NOT USED

CCN COMMUNICATIONS

24 VAC

LINE

VOLTAGE

EQUIPMENT

GROUND

AND SPACE TEMPERATURE SENSORS (Optional) —

The CO

and space temperature sensors are comprised of two

sensors housed in one unit. They are designed to monitor carbon dioxide (CO2) levels in the air and measure the interior building temperature.

Two models are available: P/N 33ZCT55CO2, and P/N 33ZCT56CO2, which has a set point adjustment potentiometer. Both models include a push-button override that may be disabled through controller software. See Table 3 for sensor specifications. To convert the CO CO

sensor, the duct-mounted aspirator (33ZCASPCO2) will

sensor into a duct-mounted

NOTE: There are 2 locking screws provided on the bottom of the cover for security. A special tool is required to remove and install the cover if the locking screws are used.

The sensor consists of the following hardware: 1 — sensor top 1 — sensor base 1 — mounting plate

2 — machine screws (6 x 32) 2 — locking screws

need to be purchased.

Refer to the instructions supplied with the CO electrical requirements and terminal locations. The zone controller requires 24 vac 25 va transformer to provide power to the sensor.

sensor for

Before performing service or maintenance operations on the system, turn off main power switches to the unit. Electric shock can cause personal injury.

IMPORTANT: The CO2and space temperature sensor should be wall-mounted in the occupied space to accurately measure the ventilation delivered to that zone.

Do NOT mount the sensor in the return air duct.

Table 3 — Performance Specification (P/N 33ZCT55CO2 and 33ZCT56CO2)

FEATURE SPECIFICATION

Sensing Method Single Beam Absor ption Infrared™

Sample Method Diffusion Measurement Range 0to2000ppm Sensitivity ± 20 ppm Accuracy ± 100 ppm

Pressure Dependency 0.13% of reading per mmHg Response Time 0 to 90% Step Change <2 minutes Warm-Up Time at 77 F (25 C) <2 minutes Operating Conditions 32 to 122 F (0° to 50 C)

Storage Temperatures –4 to +158 F (–20to70C) Agency Certification FCC Part 15 Class B/CE/CA Energy Commission Calibration/Interval Lifetime self-calibrating after 14 days of run time.* Power 18-30 vac RMS, 50/60 Hz —halfwave rectified (dedicated)

Analog CO Temperature Sensor 10 KΩ Thermistor, 10 KΩ ± 2.5% at 77 F (25 C) Temperature Control (P/N 33ZCT56CO2 only) Equipped with a slide potentiometer.

Override Control Equipped with a push button that, when depressed, shorts out its internal thermistor. Reliability Meets applicable Carrier reliability requirements

KΩ — Kilo-ohm (1000 ohms) RH — Relative Humidity RMS — Root Mean Square TEMA — Time Extended Measurement

Output 4-20 mA (Rlmax = 500 Ohms) and 0-10 V(Source 100 mA, Sink 10 mA)

LEGEND *Automatic background calibration (ABC Logic™) is a patented self-

Patented TEMA self calibration software and 10K temperature sensor

60 to 90 F: 760 mmHg (15 to 32 C)

0to99% RH, non-condensing

18-42 VDC polarity protected (dedicated)

1.75 VA maximum average power

2.75 VA peak power

Positions Resistance Left (Stop) 0 K(+5 K) Right (Stop) 100 K±10 K

calibration procedure that is designed to be used in applications where CO

concentrations will drop to outdoor ambient conditions (approxi-

mately 400 ppm) at least 3 times in a 14-day period (typically during unoccupied periods).

Step 1 — Space Temperature Sensor Location

— The sensor

should be mounted:

• on an internal wall near a return air grille or duct

• at least 3 ft from any corner, 2 ft from an open doorway and 4 to 6 ft from the floor

• proximal to the wiring egress on the wall

• where temperature operating limits are 32 to 122 F

The sensor should NOT be mounted:

• close to a window, on an outside wall, or next to a door leading to the outside

• close to or in direct airflow of areas such as open windows, drafts or over heat sources

• in areas with poor air circulation, such as behind a door or in an alcove in areas where there are dramatic temperature fluctuations or moisture accumulation

• where it is influenced by supply air as the sensor will give an inaccurate reading

• where it may be exposed to direct occupant breathing, such as near water coolers or coffee machines.

Step 2 — Mounting the Space Temperature Sensor

—The sensor can be mounted on a surface, wall or in a junction box. See Fig. 25-28.

NOTE: Before mounting the sensor, disassemble the sensor into three parts. See Fig. 27.

Surface or Wall Mounting

1. Place the mounting plate on the wall. Mark the desired location of the two mounting holes on the wall through the holes in the mounting plate. See Fig. 25.

2. Pull the wires through the wire hole in the middle of the mounting plate.

3. Drill two mounting holes in the wall in the location marked in Step 1.

4. Mount the sensor mounting plate with two wood screws and anchors (field-supplied).

Junction Box Mounting

1. Run wires through knockout in a 2x4in.junctionbox (field-supplied).

2. Pull wires through the wire hole in the middle of the mounting plate.

3. Secure the sensor mounting plate to the junction box usingthetwo6x32machinescrews(included).

Step 3 — Wiring the Space Temperature Sensor

— Perform

the following procedure to wire the sensor:

1. Run the wall wiring through the wire hole in the sensor base. See Fig. 26.

2. Align the top clips and secure the bottom clips of the sensor base to the wall mount plate. See Fig. 27.

3. Gently rock the case from top to bottom, using minimal pressure. A “snap” sound will indicate that the sensor is secure. See Fig. 27.

4. Separate the wires into two bundles. One bundle should contain the wires for the CO

sensor (J4 and J1) and the

other bundle should contain the wires for the temperature sensor and CCN (J5 and J6). See Table 4 and Fig. 28.

5. Terminate the wires to J1, J4, J5, and J6. See Table 4 and Fig. 28.

6. Push excess wire back through the hole. Align the sensor top over the sensor base.

7. Install the cover on the sensor. Two Allen wrench locking screws are provided to lock the cover onto the sensor for security reasons. They are located on the bottom of the cover. See Fig. 27.

Step 4 — Space Temperature Sensor Start-Up

— Perform the

following procedure to start up the sensor:

Once the installation is complete, apply power to the sensor. A two-minute warm-up will take place. After two minutes, the LED indicator light will be solid.

Measure and read the temperature and CO

sensor levels by

using a meter or checking the readings at the attached controller. Be sure the CO maximum acceptable level in the range.

5.25”

levels are above the minimum, up to the

3”

Fig. 25 — CO2and Space Temperature Sensor

Mounting Plate

3”

5.25”

3 2 1

OVERRIDE

LEGEND

1—3-Pin Terminal Block — Signal Out 2—3-Pin Terminal Block — Temp Sensor 3—3-Pin Terminal Block — CCN 4—Wiring Access — 1.21 in. x .75 in. 5—2-Pin Terminal Block — Power In 6—RJ14 Connector — Service Communication

Fig. 26 — CO2and Space Temperature

Sensor Base — Terminal Connections

MOUNTING HOLE

WIRE HOLE

MOUNTING HOLE

SENSOR MOUNTING PLATE

SENSOR BASE

SENSOR COVER

Fig. 27 — Sensor Assembly

ALLEN WRENCH LOCKING SCREWS (HIDDEN)

J1 J4

21 21

ISOLATED 24 VAC

OR 24 VDC

POWER SUPPLY

3 3

SHIELDED CABLE GROUNDED AT ONE LOCATION ONLY.

CCN (-)

CCN (GROUND)

CCN (+)

SETPOINT (T56) COMMON

SENSOR

TYPICAL

CARRIER

CONTROLLER

CO2 OUTPUT 4-20mA

GROUND

0-10 v

J6 J5

Fig. 28 — CO

and Space Temperature Sensors — Typical Field Wiring

(P/N 33ZCT55CO2, 33ZCT56CO2)

Table 4 — CO

and Space Temperature Sensors — Electrical Connections

(P/N 33ZCT55CO2, 33ZCT56CO2)

CONNECTOR TERMINAL DESIGNATION

J1 2-Pin Power Terminal

J3 RJ14 Connector

J4 3-Pin Terminal Signal Out

LEGEND

CCN — Carrier Comfort Network®

1—24VAC (+) (Dedicated Power Supply) 2—24VAC (–)(Dedicated Power Supply)

CCN Service Communication 1 — Not Used 2 — CCN (+) 3 — CCN Ground 4 — Not Used 5 — CCN (–) 6 — Not Used

1 — 4-20 mA CO 2 — Common CO2Output 3 — 0-10VDC CO

3-Pin Terminal Temp Sensor 1 — Thermistor 2—Common 3 — Temperature Offset

3-Pin Terminal CCN Communications 1 — CCN (–) 2 — CCN Ground 3 — CCN (+)

Output

45XC Input and Output Connectors — The 45XC

zone controller inputs are shown in Fig. 29. Outputs (fan,

staged heat) are shown in Fig. 30. All available controller outputs are factory wired.

Inputs (J4)

CHANNEL J4 PINS (+,–) DESCRIPTION CONTROL DEVICE

SPT 4, 6 Space Temperature 10K Thermistor

SAT 6, 8 Supply Air Temperature 10K Thermistor

SP_OFFSET 10, 12 Set Point Offset Adjust 100K Pot en tiometer

PAT EM P 12, 14 Primary Air Temperature 10K Thermistor

RH/IAQ

DMPPOS

PRIFLO N/A Plenum Pressure Sensor 0-5 VDC

REMTCIN 2 (24 VAC),6(–) Unoccupied Override Input 0/24 VAC

PRIMARY DAMPER POSITION

16 (24 VDC), 15 (+),13(–)

9(10 VDC)

7 (W+),5(–)

GROUND

PLENUM PRESSURE

GROUND

RH/IAQ Sensor 2-10 VDC

Damper Position 0-10 VDC

11 13

LEGEND

IAQ — Indoor Air Quality PAT EM P — Primary Air Temperature RH — Relative Humidity SAT — Supply-Air Temperature SP — Set Point SPT — Space Temperature

NOTE: The 24 v connection (J4-16) is required for RH sensor only.

+10 VDC SUPPLY

NOT USED

GROUND

RH/IAQ

REMTCIN/24 VAC

PATEMP

GROUND

T56 SETPOINT OFFSET

Fig. 29 — 45XC Input Connectors

Outputs (J5)*

CHANNEL J5 TERMINATIONS DESCRIPTION CONTROL DEVICE

DMPR_CCW 1, 2 Primary Damper CCW 24 VAC, 1A

DMPR_CW 2, 3 Primary Damper CW 24 VAC, 1A HEAT_ST1 4, 5 Fan 1 (Increase) 24 VAC, 1A HEAT_ST2 5, 6 Fan 1 (Decrease) 24 VAC, 1A

PRIMARY DAMPER ACTUATOR (OPEN)

PRIMARY DAMPER ACTUATOR (CLOSED)

GROUND

Fig. 30 — 45XC Output Connectors

12 14

LEGEND

CCW — Counterclockwise CW — Clockwise

* All outputs are factory wired.

HEAT CLOSE/ STAGE 2

COMMON (24VAC)

HEAT OPEN/ STAGE 1

+24VDC SUPPLY

SPT

GROUND

SAT

Connect to the CCN Communication Bus —

All controllers connect to the bus in a daisy chain arrangement. The zone controller may be installed on a primary CCN bus or on a secondary bus from the primary CCN bus. Connecting to a secondary bus is recommended.

At any baud (9600, 19200, 38400 baud), the number of controllers is limited to 239 zones maximum. When Carrier linkage thermostats are used on the same bus as fan coil units, no more than 128 fan coils and 12 linkage thermostats may be on the same bus. Bus length may not exceed 4000 ft, with no more than 60 total devices on any 1000 ft section. Optically isolated RS-485 repeaters are required every 1000 ft.

NOTE: Carrier thermostats operate at 9600 band.

The first zone controller in a network connects directly to the bridge and the others are wired sequentially in a daisy chain fashion. Refer to Fig. 20 for an illustration of CCN communication bus wiring.

The CCN communication bus may also connect to the zone controller space temperature sensor. Refer to the 45XC Sensor Installation section for sensor wiring instructions.

COMMUNICATION BUS WIRE SPECIFICATIONS — The CCN Communication Bus wiring is field-supplied and field-installed. It consists of shielded three-conductor cable with drain (ground) wire. The cable selected must be identical to the CCN Communication Bus wire used for the entire network. See Table 5 for recommended cable.

Table 5 — Recommended Cables

MANUFACTURER CABLE PART NO.

Alpha 2413 or 5463 American A22503 Belden 8772 Columbia 02525

NOTE: Conductors and drain wire must be at least 20 AWG (American Wire Gage), stranded, and tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –20 Cto60 Cisrequired.

CONNECTION TO THE COMMUNICATION BUS

1. Strip the ends of the red, white, and black conductors of the communication bus cable.

2. Connect one end of the communication bus cable to the bridge communication port labeled COMM2 (if connecting on a secondary bus).

When connecting the communication bus cable, a color code system for the entire network is recommended to simplify installation and checkout. See Table 6 for the recommended color code.

Table 6 — Color Code Recommendations

SIGNAL TYPE

+ Red 1

Ground White 2

– Black 3

CCN BUS WIRE

COLOR

3. Connect the other end of the communication bus cable to the terminal block labeled CCN in the zone controller of the first air terminal. Following the color code in Table 6,

PLUG PIN

NUMBER

connect the Red (+) wire to Terminal 1. Connect the White (ground) wire to Terminal 2. Connect the Black (–) wire to Terminal 3.

4. Connect additional zone controllers in a daisy chain fashion, following the color coded wiring scheme in Table 6. Refer to Fig. 20.

NOTE: The communication bus drain wires (shield) must be tied together at each zone controller. If the communication bus is entirely within one building, the resulting continuous shield must be connected to ground at only one single point. If the communication bus cable exits from one building and enters another building, connect the shields to ground at a lightning suppressor in each building where the cable enters or exits (one point only).

Connect Air Pressure Tubing

CONTROL PACKAGE 4840 — The underfloor controller measures the pressure differential between the plenum high and the occupied space low. See Fig. 1. The field-supplied and field-installed piping are connected to barb fittings on the underfloor controller with tubing. All piping for this purpose must be plenum rated and must conform to local codes.

Figure 15A indicates the positions of the two barb fittings. Perform the following steps to install and connect the air

pressure tubing:

1. Select a location where the airflow tube will be installed. The location should be one that is away from the unit’s discharge into the plenum and halfway between that point and the farthest diffuser. If this requirement is not met, stable airflow measurements may not be possible.

2. Mount the tubing in the plenum securely.

3. Use field-supplied to connect the high pressure airflow pickup to barb fitting P1 on the pressure transducer. At the underfloor controller, be careful to avoid sharp bends in the tubing, because malfunctions may occur if the tubing is bent too sharply. Use at least 2 ft of tubing for reading stability.

4. Use field-supplied to connect the low pressure fitting P2 on the pressure transducer to the occupied space. Be careful to avoid sharp bends in the tubing because malfunctions may occur if the tubing is bent too sharply. Use at least 2 ft of tubing for stability.

5. The

/8-in. OD tubing is limited to 25 ft maximum length for accurate measurement and response. For lengths up to 50 ft, use

/4-in. OD tubing. Do not exceed 50 ft tube

lengths for either the low or high pressure connections.

CONTROL PACKAGE 4841 (Fig. 31) — Locate the airflow probe as shown in Fig. 15B. Perform the following steps to install and connect the air pressure tubing:

1. Drill a rectangular shaped hole in the ductwork.

2. Securely mount the airflow probe with the high pressure side (black and red tubing) facing into the airflow from the 45XC terminal.

3. The probe is supplied with 10 ft of tubing from the factory. If required, it may be extended up to 25 ft using field-supplied

/4-in. flame retardant polyethylene

/4-in. tubing (rated for the application)

/4in. OD, flame retardant tubing.

AIR FROM 45XC

DISCHARGE

LEGEND

— Velocity Pressure

NOTE: Supply Duct View rotated to show component location.

Fig. 31 — Component Installation (Control Package 4841)

PLENUM TEMPERATURE SENSOR

24 in.

Size 04 - 34 in.

Size 07 - 46 in.

Size 04 - 42 in.

Size 07 - 54 in.

AIR INTO PLENUM

CENTERLINE

LOW Vp PRESSURE

HIGH Vp PROBE (Facing into Airflow)

NOTE - Supply Duct View rotated to show component location

45UC UNDERFLOOR SERIES

FAN-POWERED TERMINAL INSTALLATION

Physical components of the 45UC underfloor series fanpowered terminal is detailed in Fig. 32. Figure 33 shows 45UC underfloor terminal unit dimensions and weight data.

45UC Hardware — The 45UC underfloor fan-powered

unit contains the 33ZCFANTRM underfloor controller.

Figure 34 shows the underfloor controller physical details.

45UC Field-Supplied Hardware — Each 45UC un-

derfloor fan-powered unit requires the following field-supplied components to complete its installation:

• transformer — 24 vac, 40 va (standard applications)

• contactors (as required for electric heat)

• space temperature sensor (33ZCT55SPT, 33ZCT56SPT, or

33ZCT57SPT)

• supply-air temperature sensor (33ZCSENSAT) with two

no. 10 x

supply duct)

• primary-air temperature sensor

• changeover sensor (required for 2-pipe applications)

• indoor-air quality (CO

• relative humidity sensor (optional)

• valve and actuator for hot water heat (optional) SPACE TEMPERATURE SENSOR (Fig. 8) — Each under-

floor controller requires a field-supplied Carrier space temperature sensor. There are three sensors available for this application:

• 33ZCT55SPT, space temperature sensor with override

button

• 33ZCT56SPT, space temperature sensor with override

button and set point adjustment

/2-in. sheet metal screws (to secure SAT sensor to

) sensor (optional)

• 33ZCT57SPT, space temperature sensor with override button, set point adjustment, and manual fan speed control

SUPPLY-AIR TEMPERATURE (SAT) Sensor (Fig. 9) — The underfloor controller must be connected to a field-supplied supply air temperature (SAT) sensor (P/N 33ZCSENSAT) to monitor the temperature of the air delivered by the fan coil.

PRIMARY-AIR TEMPERATURE SENSOR (PAT) (Optional) — A field-supplied, primary air temperature (PAT) sensor (P/N 33ZCSENPAT) is used on an underfloor controller that is functioning as a linkage master for a non CCN/linkage compatible air source. See Fig. 10.

INDOOR-AIR QUALITY (CO

) SENSOR (Fig. 11) —

An indoor air quality sensor is required for indoor air quality monitoring. Three different CO

level monitoring.

sensors are available for zone

• The 33ZCSENCO2 sensor is an indoor, wall-mounted sensor with an LED (light-emitting diode) display.

• The 33ZCT55CO2 sensor is an indoor, wall-mounted sensor without display. The CO

sensor also includes a

space temperature sensor with override button.

• The 33ZCT56CO2 sensor is an indoor, wall-mounted sensor without display. The CO space temperature sensor with override button and tempera-

sensor also includes a

ture offset.

RELATIVE HUMIDITY SENSOR (Fig. 12) — The relative humidity sensor (P/N 33AMSENRHS000) is an indoor, wall-mounted sensor and is required for zone humidity control (dehumidification).

CHANGEOVER SENSOR — The underfloor controller uses the changeover sensor (33ZCSENCHG) in 2-pipe applications to determine if it is capable of providing heating or cooling to the space based on the temperature of the heating and cooling medium supplied to the unit from the building piping system. This value may be broadcast to other units.

Fig. 32 — 45UC Series Fan-Powered Underfloor Unit Physical Detail

45UC

UNIT SIZE

INLET SIZE

(in.)

HI-VOLTAGE CONTROL ENCLOSURE

Base

Unit

WEIGHT (lb)

With Hot Water Coil

1-Row 2-Row

OPTIONAL FILTER & ACCESS DOOR

3 9 120 132 136 150

9 128 140 146 158

10 128 140 146 158

With Electric Heat

1/4 " TURN FASTENER

LO-VOLTAGE CONTROL ENCLOSURE

INDUCED AIR INLET

3 8

PRIMARY AIR INLET WITH AeroCross MULTIPOINT CENTER AVERAGING FLOW SENSOR

™

45UC

UNIT SIZE

INLET SIZE

ABCDE FGHLW

3 9-in. Diameter 5 14 88

9-in. Diameter

10-in. Diameter 9

51412

NOTE: All dimensions are in inches.

Fig. 33 — 45UC Underfloor Unit Physical Data and Dimensions

DIMENSIONS (in.)

31/

55/

65/

710

714

48 21

DAMPER SHAFT

ACTUATOR CLAMP ASSEMBLY

LOW PRESSURE TUBING ROUTING

MECHANICAL STOP

ACTUATOR RELEASE BUTTON

HF23BJ042

Made in Switzerland by BelimoAutomation

LR 92800

NEMA2

LISTED 94D5 TENP IND & REG. EQUIP.

Class 2 Supply

yel

FAN A C

FAN

24VAC

N/A

HEAT3

COM

COW

SEC DMP

HEAT2

HIGH PRESSURE TUBING ROUTING

RH/IAQ

SECFLOW

DMPPOS

TEST

LOW

ZONE Controller

Part Number: 33ZCFANTRM

S/N:

Bus#:

Element#:

Unit#:

HIGH

red wht

35 in-lb (4 Nm)

80...110s

24VAC/DC 50/60 Hz 3VA 2W

COM

WIP

ora

blk

blu

2 1

CCW

COMCWHEAT1

24VAC

+24V

SPT

GND

SAT

+10V

T56

GND

PAT

REMOTE

GND

LEN

CCN

J2B

J2A

SRVC

24VAC

NOTE: Actuator clamp accepts dampers shafts with the following characteristics: Round — Square — Damper shaft must be a minimum of 1.5-in. (38 mm) long.

/4-in. to5/8-in. (6to16mm)

Fig. 34 — 45UC Underfloor Controller Physical Details (33ZCFANTRM)

GROMMET

ANTIRO TATIO N TAB

/4-in. to7/16-in. (6to11mm)

45UC Underfloor Series Fan-Powered Unit Installation

STEP 1 — POSITION UNIT

1. Units should be installed under raised access flooring so that they do not come in contact with obstacles such as rigid conduit, sprinkler piping, Greenfield flexible metal covering, or rigid pneumatic tubing; such contact can transmit vibration to the building structure, causing objectionable low frequency noise.

2. Fan-powered terminals require sufficient clearance for servicing the blower/motor assembly, low voltage controls from the side and line voltage motor controls or electric heat (if equipped) from the rear (discharge end) of the unit.

NOTE: Be certain that accommodations for panel removal of unit casings are large enough to allow adequate internal service room once the panels are removed.

These recommendations do not supersede NEC (National Electrical Code) or local codes that may be applicable, which are the responsibility of the installing contractor.

3. When moving boxes, use appropriate material handling equipment and avoid contact with shaft extensions, controls, wiring, piping, heaters, and control boxes.

4. Raise unit to position using safe mechanical equipment and support until hanging means are attached and box is level.

5. If necessary, use furring strips to level the unit, and anchor units to floor.

STEP 2 — MAKE DUCT CONNECTIONS

1. Check that the air supply duct connections are airtight. Install supply ductwork on unit discharge, following all accepted medium-pressure duct installation procedures. Seal joints against leakage.

3. Fan boxes should not be attached to octopus sections immediately downstream of the unit.

4. Protect units from damage caused by jobsite debris. Do not allow foreign material to fall into unit. Prevent dust and debris from being deposited on motor or fan wheels.

5. Install optional return-air filters before operating the unit.

6. Leave construction filters supplied with the box in place until installation is complete and building is cleared for occupancy.

STEP 3 — POWER WIRING

1. All power wiring must comply with local codes and with the NEC (National Electrical Code) ANSI/NFPA (American National Standards Institute/National Fire Protection Association) 70-1981. Disconnect switches are optional equipment. Electrical, control and piping diagrams are shown on the exterior labeling or on a diagram inside the control and high-voltage enclosure covers, unless otherwise specified in the order write-up. All units are wired for a single point electrical connection to the fan and electric heater (if equipped). Electric heaters provided by Carrier are balanced by kW per stage. The installing electrician should rotate incoming electric service by phase to help balance overall building load.

2. All field wiring must be provided with a safety disconnect per NEC 424-19, 20, and 21.

3. Units with electric heat should use copper wires rated at least 125% of rating plate amperage. Refer to the unit’s rating label and minimum supply circuit amps.

45UC Sensor Installation — See Sensor Installation

in 45XC Fan-Powered Zone Mixing Unit Installation.

Connect to the CCN Communication Bus —

See Connect to the CCN Communication Bus section in 45XC Fan-Powered Zone Mixing Unit Installation.

LINE

VOLTAGE

SPT

LINE

VOLTA GE

TRAN

GROUND

24 VAC

TRANSFORMER

GROUND

TERMINAL

NOT USED

COMMUNICATIONS

CCN

COMMUNICATIONS

CCN

FAN MOTOR

+24V

SPT

RH/IAQ

GND

FAN

CONTACTOR

GND

SECFLOW

T56

SAT

+10V

DMPPOS

FAN

GND

FAN

PAT

REMOTE

N/A

GND

24 VAC

NOT

USED

(+)

HEAT3

(GND)

COM

SECOND

(–)

CCW

DAMPER

HEAT2HEAT1 24VAC

RBW

LEGEND

CCN — Carrier Comfort Network®

SPT — Space Temperature Sensor

TRAN — Transformer

Field Wiring

Factory Wiring

LOW

WHTREDBLK

Fig. 35 — 45UC Underfloor Controller Wiring — Fan Powered Terminals, Cooling Only

COM

ORABLUYEL

HF23BJ042

LINE

VOLTAGE

SPT

SAT

PAT *

LINE

VOLTAGE

FAN MOTOR

FAN CONTACTOR

+24V

SPT

RH/IAQ

GND

SECFLOW

COMMUNICATIONS

NOT USED

T56

FAN AC

PAT

GND

REMOTE

N/A

GND

DMPPOS

FAN

24 VAC

USED

(+)

HEAT3

(GND)

(-)

COM

SECOND

DAMPER

SAT

+10V

CCN

COMMUNICATIONS

CCN

CCW

TRAN

GROUND

TRANSFORMER

24 VAC

GROUND

TERMINAL

HEAT2HEAT1 24VAC

RBW

LEGEND

24V*

COM

LOW

HWV

WHTREDBLK

COM

Field Wiring

ORABLUYEL

Factory Wiring

Fig. 36 — 45UC Underfloor Controller Wiring — Fan Powered Terminals, Modulating Hot Water Heat

HF23BJ042

PAT — Primary-Air Temperature Sensor

SAT — Supply-Air Temperature Sensor

SPT — Space Temperature Sensor

CCN — Carrier Comfort Network®

HWV — Hot Water Valve

TRAN — Transformer

*Required only on Linkage master if on a non-compatible air source.

LINE

VOLTAGE

FAN CONTACTOR

FAN MOTOR

+24V

SPT

RH/IAQ

GND

SECFLOW

SAT

PAT*

LINE

VOLTAGE

LEGEND

Field Wiring

Factory Wiring

TRAN

COMMUNICATIONS

CCN

COMMUNICATIONS

CCN

CCN — Carrier Comfort Network®

H—Heater Relay

PAT — Primary-Air Temperature Sensor

SAT — Supply-Air Temperature Sensor

SPT — Space Temperature Sensor

GROUND

TERMINAL

TRAN — Transformer

GROUND

TRANSFORMER

24 VAC

HEAT2HEAT1 24VAC

NOT USED

T56

DMPPOS

FAN AC

GND

FAN

PAT

N/A

24 VAC

REMOTE

GND

NOT USED

(GND)

(-)

COM

SECOND

DAMPER

CCW

(+)

HEAT3

SAT

+10V

RBW

LOW

WHTREDBLK

COM

H3 H2 H1

Fig. 37 — 45UC Underfloor Controller Wiring — Fan Powered Terminals, Staged Electric Heat

ORABLUYEL

HF23BJ042

*Required only on linkage master if on a non-compatible air source.

LINE

VOLTAGE

SPT

SAT

LINE

VOLTAGE

FAN MOTOR

FAN CONTACTOR

+24V

RH/IA

SPT

GND

NOT USED

SAT

+10V

SECFLOW

T56

FAN AC

GND

DMPPO

GND

FAN

PAT

REMOTE

N/A

GND

24 VAC

NOT USED

(+)

HEAT3

(GND)

(-)

M CO

SECOND

DAMPER

CCW

COMMUNICATIONS

CCN

COMMUNICATIONS

TRAN

GROUND

24 VAC

HEAT2HEAT1 24VAC

RBW

TRANSFORMER

GROUND

TERMINAL

LEGEND

LOW

HWV

WHTREDBLK

COM

ORABLUYEL

Field Wiring

Factory Wiring

Fig. 38 — 45UC Underfloor Controller Wiring — Fan Powered Terminals, Two-Position Hot Water Heat

HF23BJ042

SAT — Supply-Air Temperature Sensor

SPT — Space Temperature Sensor

CCN — Carrier Comfort Network®

TRAN — Transformer

HWV — Hot Water Valve

Modulating Baseboard Hydronic Heating —

Install the water valve on the leaving water end of the baseboard heater. See Fig. 39. Observe the fluid flow direction when mounting the valve. Be sure to properly heat sink the valve and direct the flame away from the actuator and valve body when sweating the valve connections. Install the leaving water temperature sensor (P/N 33ZCSENCHG) on the hydronic heating coil as shown. The sensor accommodates nominal copper pipe from

/8in.). It should be secured to the pipe with the clamp supplied. If piping is larger than 1 in. nominal size, a fieldsupplied clamp must be used. Use fiberglass pipe insulation to insulate the sensor assembly.

Refer to Fig. 36 to wire the modulating water valve and the sensor to the underfloor controller. Connect the leaving water temperature sensor to the controller using the wiring connections shown for the SAT sensor.

NOTE: The leaving water temperature sensor replaces the SAT sensor in this application.

Use 18 or 20 AWG wire for all connections. The water valve actuator housing may be used as a junction box if the leaving water temperature sensor cable is not long enough and the sensor cable must be extended to reach the controller.

/2to 1 in. (OD sizes from5/8to

For modulating hydronic heating applications, the default configuration must be changed to properly control the valve. Refer to the service configuration table and set the Heating Loop parameters as follows:

Proportional Gain = 20.0 Integral Gain = 0.5 Derivative Gain = 0.0 Start Value = 102.0

Also, set the Ducted Heat decision to YES and set the Maximum Duct Temperature decision equal to 200 F.

33ZCSENCHG (SENSOR)

FLOW

1/2” TUBE 3/4” TUBE 1” TUBE

Fig. 39 — Typical Water Valve and

Sensor Installation

42KC PERIMETER FAN COIL

UNIT INSTALLATION

Physical components of the 42KC fan coil unit is detailed in

Fig. 40. Refer to Fig. 41 for 42KC fan coil unit details.

Fig. 40 — 42KC Fan Coil Unit Physical Details

42KC Hardware — The 42KC perimeter fan coil unit

contains the 33ZCFANCOL zone controller.

Figure 42 shows the 42KC perimeter fan coil controller

physical details.

INLET VIEW

INLET SCREEN

TOP VIEW

DISCHARGE VIEW

NOTE: All dimensions are in inches.

42KC

UNIT SIZE

14 12 x 10 16 14 x 9

42KC

UNIT SIZE

14 12 10

16 14 97/

Fig. 41 — 42KC Fan Coil Unit Physical Data and Dimensions

INLET SIZE

(in.)

ABCEH LW

Base

Unit

120 132 136 150 128 140 146 158

DIMENSIONS (in.)

173/

WEIGHT (lb)

With Hot Water Coil

1-Row 2-Row

113/

133/

14 18 347/

16 19 347/

With Electric

Heat

ZONE Controller

Part Number: 33ZCFANCOL

S/N:

Bus#:

Element#:

Unit#:

VLV/DX1

COM

OAD ENA

VLV/DX2

HEAT1

24VAC

FAN A C FAN O N

24VAC

HEAT2

LOW

MED

HIGH

GND

+10V

SPEED

GND

CONDSW

GND

CCN

J2A

IAQ

CNGOVR

RMT/FS

SRVC

24VAC

+24V SPT GND

SAT

T56

GND

LEN

J2B

LED1

LED2

Fig. 42 — 42KC Perimeter Fan Coil Controller Physical Details (33ZCFANCOL)

42KC Field-Supplied Hardware — Each 42KC pe-

rimeter fan coil unit requires the following field-supplied components to complete its installation:

• transformer — 24 vac, 40 va (standard applications)

• contactors (as required for fan or electric heat)

• space temperature sensor (33ZCT55SPT, 33ZCT56SPT, or 33ZCT57SPT)

• supply-air temperature sensor (33ZCSENSAT) with two no. 10 x supply duct)

• changeover sensor (required for 2-pipe applications)

• indoor-air quality (CO

• linkage thermostat (optional)

• relative humidity sensor (optional)

• valve and actuator for hot water heat (optional)

SPACE TEMPERATURE SENSOR — Each zone controller requires a field-supplied Carrier space temperature sensor. There are four standard temperature sensors available for this application:

• 33ZCT55SPT, space temperature sensor with override button

• 33ZCT56SPT, space temperature sensor with override button and set point adjustment

• 33ZCT57SPT, space temperature sensor with override button, set point adjustment, and manual fan speed control

• 33ZC58SPT, space temperature sensor with override button, set point adjustment, and fan speed control, and LCD display

SUPPLY-AIR TEMPERATURE (SAT) SENSOR — The zone controller must be connected to a field-supplied supplyair temperature (SAT) sensor (P/N 33ZCSENSAT) to monitor the temperature of the air delivered by the fan coil.

CHANGEOVER SENSOR — The 33ZCSENCHG changeover sensor is used by the 42KC zone controller in 2-pipe applications to determine the temperature of the medium which is supplied to the fan coil by the building piping system. The controller can then determine if it is capable of providing heating or cooling to the space based on sensing the pipe water temperature. This value may be broadcast to other fan coils if a linkage thermostat is used or the controller is part of a CCN system with a comfort controller.

/2-in. sheet metal screws (to secure SAT sensor to

sensor (optional)

INDOOR-AIR QUALITY (CO

) SENSOR — An indoor-air

quality sensor is required for indoor air quality monitoring. Three different CO2sensors are available for zone CO2level monitoring. One is used to measure CO

only, while two other

models combine the CO2sensor with a space temperature sensor to eliminate the need for multiple sensors in each zone.

• The 33ZCSENCO2 sensor is an indoor, wall-mounted sensor with an LED (light-emitting diode) display.

• The 33ZCT55CO2 sensor is an indoor, wall-mounted sensor without display. The CO space temperature sensor with override button.

sensor also includes a

• The 33ZCT56CO2 sensor is an indoor, wall-mounted sensor without display. The CO

sensor also includes a space

temperature sensor with override button and temperature offset.

LINKAGE THERMO STAT — The linkage thermostat (33CSKITLST-01) can be used to control multiple 42KC units from a single thermostat. The linkage thermostat provides thermostat functions for up to 8 units serving a common zone. Thermostat functions include space temperature sensing, remote set point adjustment, and occupancy information. The linkage thermostat can be used in place of any space temperature sensor.

RELATIVE HUMIDITY — The relative humidity sensor (P/N 33AMSENRHS000) is an indoor, wall-mounted sensor and is required for zone humidity control (dehumidification).

42KC Perimeter Fan Coil Unit Installation

STEP 1 — POSITION UNIT

2. Fan-powered terminals require sufficient clearance for servicing the blower/motor assembly, low voltage controls from the side and line voltage motor controls or electric heat, if equipped, from the rear (discharge end) of the unit. See Fig. 43.

NOTE: Be certain that accommodations for panel removal of unit casings are large enough to allow adequate internal service room once the panels are removed.

1 IN.

AIR FLOW

DISCHARGE DUCT

ELECTRIC OR HOT WATER

ALLOW 1 IN. CLEARANCE FROM TOP OF UNIT TO BOTTOM OF FLOORING

FAN COIL UNIT

Fig. 43 — Service Clearance for Fan Coil

Unit Installation

These recommendations do not supersede NEC (National Electrical Code) or local codes that may be applicable, which are the responsibility of the installing contractor.

3. When moving boxes, use appropriate material handling equipment and avoid contact with shaft extensions, controls, wiring, piping, heaters, and control boxes.

4. Raise unit to position using safe mechanical equipment and support until hanging means are attached and box is level.

STEP 2 — INSTALL UNIT — If necessary, use furring strips to level the unit, and anchor units to floor.

STEP 3 — MAKE DUCT CONNECTIONS

NOTE: For maximum efficiency in controlling radiated noise in critical applications, inlet ducts should be fabricated of 24-gage minimum sheet metal in place of flex connections. Flex duct is extremely transparent to radiated sound; consequently, high inlet static pressure (Ps) or sharp bends with excessive pressure drop can cause a radiated noise problem in the space. If flex duct is used, it should be limited to the connection between the distribution duct and the boot diffuser.

3. Fan boxes should not be attached to octopus sections immediately downstream of the unit.

4. Protect units from damage caused by jobsite debris. Do not allow foreign material to fall into unit. Prevent dust and debris from being deposited on motor or fan wheels.

5. Install optional return-air filters before operating the unit.

6. Leave construction filters supplied with the box in place until installation is complete and building is cleared for occupancy.

STEP 4 — POWER WIRING

1. All power wiring must comply with local codes and with the NEC ANSI/NFPA (American National Standards Institute/National Fire Protection Association) 70-1981. Disconnect switches are optional equipment. Electrical, control and piping diagrams are shown on the exterior labeling or on a diagram inside the control and highvoltage enclosure covers, unless otherwise specified in the order write-up. All units are wired for a single point electrical connection to the fan and electric heater (if equipped). Electric heaters provided by Carrier are balanced by kW per stage. The installing electrician should rotate incoming electric service by phase to help balance overall building load.

2. All field wiring must be provided with a safety disconnect per NEC 424-19, 20, and 21.

3. Units with electric heat should use copper wires rated at least 125% of rating plate amperage. Refer to the unit’s rating label and minimum supply circuit amps.

4. Observe wiring diagram and instructions attached to the unit. A Wye power source with a fourth (neutral) wire, in addition to the full-sized ground wire, is required for 480-v, 3-phase units. All units must be grounded as required by NEC 424-14 and 250.

Connect the Power Transformer — An individual,

field-supplied, 24 vac power transformer is required for each zone controller. Transformers must be UL Class 2 rated. Standard applications require a 24 vac transformer, rated at 40 va minimum. All transformer secondaries are required to be grounded. Use only stranded copper conductors for all wiring to the zone controller. Wiring connections must be made in accordance with NEC and local codes. Ground one side of the transformer secondary at the transformer location. Connect the grounded side of the transformer to J1-2. Connect the hot side of the transformer secondary to J1-1. Connect an 18-gage, green ground wire from terminal J1-3 to the metal chassis of the unit.

For zone controllers, the power requirement sizing allows for a water valves accessory and for the fan contactor. Water valves are limited to 10 va on both two-position and modulating hot water. The fan contactor is limited to 3 va (holding) for each fan output.

NOTE: If a water valve contactor exceeds these limits, or external contactors are required for electric heat, then it is recommended that a 60 va transformer be used. The maximum rating for any single output is 20 va.

NOTE: Do not run sensor or communication wiring in the same conduit with line-voltage wiring.

NOTE: An accessory conduit box (P/N 33ZCCONBOX) is available for conduit wiring connections to the zone controller.

Perform the following steps to connect the power transformer:

1. Install the field-supplied transformer in an electrical enclosure that conforms to NEC and local codes.

2. Connect 24 vac from the transformer as shown in the applicable wiring diagram (Fig. 44-48). Be sure to observe polarity when connecting the transformer power.

LEGEND

AFS — Airflow Switch

CAP — Capacitor

COM — Common

DISC — Disconnect

N.O. — Normally Open

SCR — Electronic Speed Controller

Fan-Powered Units with Electric Heat

Fig. 44 — Typical 42KC 115/277 V, Single-Phase, 1-Stage, 1-Element Wiring Diagrams for

LEGEND

CAP — Capacitor

DISC — Disconnect

SCR — Electronic Speed Controller

Fan-Powered Units Without Electric Heat

Fig. 45 — Typical 42KC 208/240 V, Single-Phase Wiring Diagrams for

LEGEND

Field Wiring

Factory Wir ing

NOTE: These controls have been wired to

comply with UL-1995.

Fig. 46 — Typical Low Voltage Control Wiring Diagram for

42KC Fan-Powered Units with Up to 2 Stages of Electric Heat

LEGEND

Field Wiring

Factory Wir ing

NOTE: These controls have been wired to

comply with UL-1995.

42KC Fan-Powered Units with On/Off Hot Water Heat

Fig. 47 — Typical Low Voltage Control Wiring Diagram for

LEGEND

Field Wiring

Factory Wiring

NOTE: These controls have been wired to

comply with UL-1995.

42KC Fan-Powered Units with 3-Point Floating Valve

Fig. 48 — Typical Low Voltage Control Wiring Diagram for

Fan Coil Controller Inputs and Outputs — The

fan coil controller inputs and outputs are shown in Fig. 49 and 50.

CONNECT ACCESSORIES — Refer to accessory installation instructions for installation procedures. Fan coil controller

wiring is shown for the linkage thermostat, which is an optional accessory (Fig. 51).

42KC Sensor Installation — See 45XC Sensor Instal-

lation section on page 14.

Inputs (J4)

CHANNEL J4 PINS (+,–) DESCRIPTION CONTROL DEVICE

SPT 14, 12 Space Temperature 10K Thermistor SAT 10, 12 Supply Air Temperature 10K Thermistor

SP_OFFSET (T56/T57) 8, 12 Set Point Offset Adjust 100K Potentiometer

CNGOVR 4, 6 Changeover Sensor 10K Thermistor

SPEED 7 (+),5(–) Manual Speed Position 0-10 VDC

IAQ 11 (+),13(–) Indoor Air Quality Sensor 0-10 VDC

FS OR REMOTE S/S

16 (24 VDC), 15 (+),13(–)

2 (24 VDC),

J1Pin1(Gnd)

MANUAL SPEED

GROUND

NOT USED

GROUND

RH Sensor 2-10 VDC

Fan Status or

Remote Start/Stop

24 VAC (DI)

11 13

LEGEND

DI — Direct Input FS — Fan Status IAQ — Indoor Air Quality RH — Relative Humidity SAT — Supply-Air Temperature SPT — Space Temperature S/S — Start/Stop

NOTES:

1. Terminals 1 and 3 provide switched 24 VAC output power to the load.

2. Terminal 5 connects to field-supplied 24 vac.

3. The 24 v connection (J4-16) is required for RH sensor only.

NOT USED

IAQ

GROUND

FAN STATUS OR REMOTE S/S

CHANGEOVER SENSOR

GROUND

T56 SETPOINT OFFSET

12 14

Fig. 49 — 42KC Fan Coil Controller Inputs

+24VDC SUPPLY

SPT

GROUND

SAT

Daughter Board Outputs (J6, J7)

CHANNEL TERMINATIONS(+,–) DESCRIPTION CONTROL DEVICE

FAN AC J6-1, J1-1 Fan Input Power 24V,5A FAN ON J6-2, J1-2 Fan Start/Stop* 24V,5A

LOW J6-3, J1-2 Low Speed 24V,5A MED J6-4, J1-2 Med Speed 24V,5A

HI J6-5, J1-2 High Speed 24V,5A

OAD J7-1, J7-2 Outdoor Air Damper 24 VAC 1A

*For single-speed fan units, connect fan start/stop to control fan contactor. NOTE: J6-1 must be jumpered to 24 VAC +. (J1-1).

(-)

BLACK

(+)

RED

GREEN/

WHITE (GND)

CCN

FCC

FAN (24VAC)

FAN ON

LO SPEED

MED SPEED

HIGH SPEED

Fig. 50 — 42KC Fan Coil Controller Daughter Board Outputs

WIRENUT

(-)

BLACK

(+)

RED

GREEN/

WHITE

(GND)

TYPICAL FAN COIL UNIT

3-CONDUCTOR WIRE WITH SHIELD

CCN COMMUNICATION BUS

LINKAGE THERMOSTAT WIRING CONNECTION BLOCK

SHIELD

(-)

BLACK

(+)

RED

GREEN/

WHITE (GND)

WHT

RED

SHIELD

(-)

BLACK

(+)

RED

GREEN/

WHITE

(GND)

24VAC

OAD

COMMUNICATION BUS

COOL

24 VAC

TRANSFORMER

(SEPARATE

ISOLATED)

GND

RED

AC(+)

POWER SUPPLY

BOARD

W-

R+

MAXIMUM WIRE LENGTH OF 100 FT.

CCN — Carrier Comfort Network®

LEGEND

FCC — Fan Coil Controller

WHT

Fig. 51 — 42KC Wiring Connections (Linkage Thermostat Option)

35BF DIFFUSER INSTALLATION

35BF-R Swirl Diffuser Installation —

ings for diffusers are pre-cut in the floor panels at the factory. Removal of flooring is not necessary to install the diffusers.

Install diffusers after flooring and carpet installation is complete through the top panel by placing the unit into the gasketed positive compression quick mount underfloor ring.

Secure the gasketed quick mount underfloor ring to the trim ring on the underside of the raised panel. See Fig. 52.

Hole open-

CURVED SLOT HELICAL THROW DIFFUSER CORE 7 3/4” DIAMETER

MANUALLY ADJUSTED FLOW REGULATOR (OPTIONAL)

DIRT/DUST RECEPTACLE

35BF-CT, D, V Linear Diffuser Installation —

Removal of flooring is not necessary to install the 35BF-D linear floor diffuser plenum and 35BF-V variable volume diffuser plenum with damper; they can be installed into raised flooring from the top surface. See Fig. 53 and 54.

The 35BF-CT rectangular floor grilles/diffuser frame may be used with either of the linear floor diffusers. See Fig. 55 for dimension and deflection information.

9 3/ 4"

FLANGE

FLOOR TILE

TRIM RING WITH SPACE FLANGES (MUST BE USED WITH THIS ASSEMBLY)

5 3/4"

Open/Close indicator is raised from

trim ring and diffuser core

GASKETED POSITIVE COMPRESSION QUICK MOUNTED UNDERFLOOR RING 10 7/16” DIAMETER

Fig. 52 — 35BF-R Adjustable Swirl Diffuser

HOLE OPENING FOR DIFFUSER IS 8 5/8”

FLOOR TILE

PLENUM

ACCESS FLOORING

(BY OTHERS)

DIFFUSER CORE DIFFUSER FRAME

ATTACH DIFFUSER FRAM TO 35BF-CT WITH #8 SELF

DRILLING SCREWS. (FIELD-SUPPLIED)

FIELD INSTALLATION

DIFFUSER FRAME

(35BF-CT)

FLOOR PANEL

ATTACHMENT SCREWS (ASSEMBLED PRIOR TO INSTALLATION INTO FLOOR)

35BF-D ASSEMBLY

NOTE: 35BF-CT Diffuser Frame and 35BF-D plenum are sold as separate units.

85/8"

16 5/8"

16"

11/8"

12 1/2"

11 "

9" Ø INLET

Fig. 53 — 35BF-D Linear Floor Diffuser Plenum

VAV PLENUM

ACCESS FLOORING

(BY OTHERS)

16 5/8"

DIFFUSER CORE DIFFUSER FRAME

ATTACH DIFFUSER FRAME TO 35BF-V WITH #8 SELF DRILLING SCREWS. (FIELD-SUPPLIED)

FIELD INSTALLATION

DIFFUSER FRAME

(35BF-CT)

FLOOR PANEL

ATTACHMENT SCREWS (ASSEMBLED PRIOR TO INSTALLATION INTO FLOOR)

35BF-V ASSEMBLY

NOTE: 35BF-CT Diffuser Frame and 35BF-V plenum are sold as separate units.

85/8"

16"

11/2"

21/4"

31/2"

12"

Fig. 54 — 35BF-V Variable Volume Diffuser Plenum

35BF-CT ALUMINUM — FIXED BARS

CT-480 —1/4-in. SPACING,1/8-in. BARS, 0° DEFLECTION

CT-481 —1/4-in. SPACING,1/8-in. BARS, 15° DEFLECTION

CORE WITH HEAVY DUTY MOUNTING FRAME

FOR FLOOR APPLICATIONS

Type 5 heavy duty mounting frame is shown. NOTE: Core is furnished with additional reinforcing.

Frame Type 5

• 1 in. Flange

Removable core is furnished with frame. When spring clip is furnished, add an additional

FACE VIEW OF FRAME

17 3/8"

HEAVY DUTY MOUNTING FRAME

FOR FLOOR APPLICATIONS

/4in. to duct width.

9 3/8"

17/8"

1/8"

1 3/16"

11/32"

O=Dplus15/8"

D minus 3/8"

D = Duct Size

Check Selection

1/4 in. Spacing 1/8 in. Bars

MODEL CT-480

0° DEFLECTION

MODEL CT-481

15° DEFLECTION

AVAILABLE CORES

DUCT SIZE MINUS 3/4"

1/4"

SUPPORT BAR

DUCT SIZE

MINUS 3/4"

1/8"

OVERALL LENGTH AND WIDTH

1/8"

1 5/32"

TYPE D O C

51617

1/4"

1 5/32"

DUCT SIZE FRAME CORE

DOC

Fig. 55 — 35BF-CT Rectangular Floor Grille

Length

Core

DUCT SIZE FRAME CORE

153/

Width

/4in. SPACING

NUMBER OF

BLADES

73/

OPERATION

45XC Start-Up and Checkout Procedure

Initial Start-Up Procedures —

fan terminal units and 42KC perimeter fan coil units are designed to provide varying quantities of cold primary air to a space in response to a thermostat demand for cooling. For a heating demand, the fan will operate to supply ceiling plenum air to the space or for units equipped with a heating coil, the heater will operate as required to meet a heating demand.

The 45XC fan-powered mixing box is designed to provide airflow to an underfloor plenum at a specified pressure set point. The air supplied to the plenum is a mixture of primary air and ceiling plenum air. The fan speed is adjusted automatically by the control to provide the required airflow to maintain desired plenum temperature set point while the primary air damper will modulate to maintain the desired plenum pressure. In response to a cooling demand from a thermostat, the damper will increase the amount of cold primary air while the fan reduces the amount of ceiling plenum air to decrease the temperature of the air being delivered to the space. Typical plenum design temperatures are approximately 62 to 63 F, but the 45XC zone controller will automatically adjust the temperature to meet the load conditions and maintain the balance point.

The 45UC underfloor fan terminal control packages provide pressure independent operation of the primary air damper, regardless of changes to the available static pressure in the primary supply. To balance the unit, it is necessary to set both the minimum and maximum airflow set points of this controller. The many types of control options available each have specific procedures required for balancing. Refer to the submittal information for these requirements.

NOTE: The following steps MUST be followed in order to properly operate and service this unit.

1. Disconnect all electrical power to the unit.

Failure to disconnect the power to the fan box prior to checking and/or servicing the fan box could result in serious personal injury.

2. Verify that the fan box is installed level and that adequate mounting support has been provided.

3. Remove motor access panel from the bottom of the fan box, and also remove the control panel cover.

4. Test the fan motor setscrew. The setscrew should fit tightly, but it may have loosened during shipment or installation.

5. Rotate the blower by hand to ensure proper clearance between the blower and the blower housing.

6. Check the fan box for loose fiberglass insulation, especially on the electric heater elements or the hot water coils (if these accessories are installed).

7. Check the control enclosure and remove any debris.

8. Check the induction inlet filter (if provided) for obstructions, and verify the filter is securely in place.

9. Verify the main power supply to the connection to the fan box for proper voltage.

10. Identify the control system supplied.

11. Check all control connections (and/or electric) for proper installation.

12. Connect electrical power.

The 45UC underfloor

Before proceeding with start-up, be certain that voltage, frequency, and phase correspond to unit specifications. Unless noted, all fan motors are 60 Hz, 115, 208/240, or 277 vac electric heat. The electric heat voltage may exceed the blower motor voltage requirement. Excessive voltage to the fan box may seriously damage it. Verify that the DDC (if equipped) is receiving 24 vac, –15%, +20%.

All underfloor terminal units are shipped with cardboard packaging rings placed in one side of the blower housing internal to the blower/motor. These rings are provided to prevent damage to the motor during shipment. The rings MUST BE REMOVED prior to operation. The packing rings are accessible through the terminal’s plenum. Turn the fan wheel by hand to ensure that blower is free spinning. Carrier will not accept responsibility for any additional costs for removal of this packaging material. Failure to remove cardboard rings could result in damage to the unit.

Before balancing the system, the air handlers must be operating in accordance with the specifications for air capacity, static pressure, and temperature. The following items MUST be checked:

1. All fans must be running at calculated and specified rpm.

2. Permanent or temporary filters must be clean and installed where required.

3. All central station dampers must be adjusted and operating properly.

4. All thermostats must be calibrated and at the desired settings.

5. All ductwork must be tight.

6. All dirt or loose lining must be removed from inside ductwork.

7. Pumps and sprays, when used, must be in operation.

8. Connections to the coil, when used, must be checked.

9. Water control valve, if used, must be checked.

42KC Start-Up — Use the Carrier Comfort Network®

communication software to start up and configure the fan coil controller. All set-up and set point configurations are factoryset and field-adjustable.

Changes can be made using the ComfortWORKS® software, ComfortVIEW™ software, or Network Service Tool. The Network Service Tool is a portable interface device that allows the user to change system set-up and set points from a zone sensor or terminal control module. During start-up, the Carrier software can also be used to verify communication with each fan coil controller.

For specific operating instructions, refer to the literature provided with the software.

PERFORM SYSTEM CHECK-OUT

1. Check correctness and tightness of all power and communication connections.

2. At the fan coil, check fan and system controls for proper operation.

3. At the fan coil, check electrical system and connections of any optional electric reheat coil. If hot water reheat is used, check piping and valves against job drawings.

4. Ensure that area around the fan coil is clear of construction dirt and debris.

5. Check that final filters are installed in the fan coil. Dust and debris can adversely affect system operation.

6. Verify that the fan coil controller controls are properly connected to the CCN bus.

INITIAL OPERATION AND TEST — Perform the following procedure:

1. Apply power to the unit.

2. Connect the service tool to the phone jack service port of the controller.

3. Using the service tool, upload the controller from address 0,1. The address may be set at this time. Make sure that Service Tool is connected to this fan coil unit only when changing the address.

CONFIGURATION

45XC Commissioning —

tion permits the user to calibrate the damper position and zerocalibrate the pressure sensor. Commissioning is performed using points on the maintenance display (see Table 7).

Table 7 — Commissioning Function

FUNCTION CODE DESCRIPTION

CMODE Commissioning Mode CALIBRAT Damper/Transducer Cal MAXCOOL Maximum Cooling Pressure

INPUT

OUTPUT

PROCESS (ALGORITHM) — If the Calibration mode is set to Enable, the controller will interrupt its normal control to provide a means for an air balancer to easily test and commission the equipment. Once in the Commissioning mode, the control will remain in that mode until all tests are completed or for a maximum of 1 hour. During commissioning, the POINTS display screen MODE will indicate “COMMISS.”

If the Commissioning mode and the Damper/Transducer are both set to Enable, the controller will first test and calibrate the damper to verify the position feedback potentiometer is functioning and internally set the actuator full stroke time. A zero calibration will also be performed on the pressure transducer. If either test fails, the CAL (Auto Calibration) output will be set to alarm. When the test is completed successfully, the control will reset the Damper/Transducer Calibrate input to Disable.

The control will then provide a method to set, verify and test the cooling maximum and cooling minimum pressure limits. While in the Commissioning mode, if the Maximum Cooling input is set to Enable, the controller will recover the configured maximum cooling pressure limit as configured, and display the value as the pressure set point. If incorrect, the balancer can enter the correct value in the pressure set point, and this value will then be transferred back to the maximum cooling configuration limit. The control will then modulate the damper to achieve this set point and will display the resulting pressure as the actual pressure. If the pressure is incorrect, the balancer can enter the correct value as the actual pressure and the control will store this value. Once completed, or if the Minimum Cooling input is set to Enable, the Maximum Cooling input is reset to Disable. If the Minimum Cooling input is set to Enable, the

MINCOOL Minimum Cooling Pressure HEATOVER Maximum Heating Pressure COMCFM Pressure Set Point MVP Actual Plenum Pressure SAT Supply Air Temperature MODE Terminal Mode CAL Auto Calibration OFFSET Pressure Transducer Calibration

The Commissioning func-

Offset (internal point)

process is repeated except the minimum cooling pressure limit is used. If a correction is necessary, the control calculates an offset when the balancer enters the correct value.

If the heat override input is set to Enable, the pressure is modulated to the greater of the reheat airflow limit or the minimum cooling limit, and full heating is provided. Heating can be verified by the balancer through the Supply Air Temperature displayed value. Heating will be controlled during the test to avoid exceeding the maximum duct temperature. The 45XC configuration data is displayed in Tables 8-21.

ABNORMAL CONDITIONS AND RESPONSES — If the controller is unable to calibrate the open/close potentiometer readings or zero calibrate the pressure transducer during the commissioning function of damper/transducer calibration, an alarm indication will be set using the CAL point. A CCN alarm message will also be generated. The alarm condition is cleared when calibration is successfully accomplished.

45XC Set-Up and Configuration

1. With the primary airflow disabled (AHU OFF), select the Air Balancing Maintenance screen (ZNAIRBAL) and set the Commissioning Mode to ENABLE.

2. Set the Damper/Transducer Cal to ENABLE. Allow the primary air damper to fully close. After the controller calibrates the 0% open primary air damper position, the controller will fully open the damper and calibrate the 100% open primary air damper position. The primary air damper will fully close to the 0% position and the controller will zero calibrate the pressure transducer. When the test is complete, the Damper/Transducer Cal point will automatically revert back to DISABLE. Once this occurs, verify that the Auto-Calibration point at the bottom of the screen reads ‘NORMAL.’ If so, the terminal has been calibrated successfully. Force the Commissioning Mode point to DISABLE, then AUTO, which will remove the 45XC terminal controller from the commissioning mode.

3. Select the Set Point table (SETPOINT) and configure the desired Occ Heat set point, which should be set to the desired space temperature value. If the system (primary air source) is shut down at night during unoccupied times and an accelerated morning cool down is desired, configure the Occ Cool set point between 3 and 4º F above the Occ Heat set point. If this cycle is not desired, set the Occ Cool set point to 99.

4. In the Set Point table, configure the Unocc Heat set point and Unocc Cool set point to the same values as the occupied values unless a second space temperature set point is desired.

NOTE: Setting the unoccupied space heating set point lower than normal (below 70 F) consumes additional energy to maintain this lower temperature set point. The underfloor system is NOT designed for unoccupied operation at the terminals, but rather at the primary air source (AHU or RTU) or through a field-installed zone damper to disable primary airflow from the source to the 45XC mixing terminal. If a lower unoccupied heating set point is required, configure the Unocc Heat set point to that lower value. The 45XC mixing terminal should be set to occupied operation at all times to ensure maximum system efficiency. Again, if an accelerated cool down transition is desired, configure the Unocc Cool set point to a value approximately 4º F above the Unocc Heat set point. When an accelerated cool down transition is not used, the Unocc Cool set point is configured to 99.

5. In the Service Config Table (PRESS), configure the Cool Minimum Plenum Pressure set point, which is used for normal control.

6. If the Occ or Unocc Cool set points are used, configure the Cool Maximum Plenum Pressure set point; otherwise, set this value equal to the Cool Minimum value. The Cool Maximum value is the controlling plenum pressure set point used when the space temperature equals or exceeds the Cool set point. When the space temperature is between the heating and cooling set points, the plenum pressure is controlled to a linear interpolation between the two pressure set points.

7. In the Service Config table (PRESS), configure the Heat Minimum Plenum Pressure set point. This is the plenum pressure set point used whenever the central station equipment is in a heating mode, such as Morning Warm Up (as detected by the primary air temperature sensor). This value should be set lower than the Cool Minimum Plenum Pressure set point in order to reduce airflow to this zone when the space temperature has achieved the

Table 8 — 45XC Controller Identification Table

TABLE NAME CONTROLLER ID Device Name CID_UF

Description Underfloor Controller

Location —

Software Part Number CESR131317-01

Model Number —

Serial Number WWYYnnnnnn

Reference Number Version 1.0

LEGEND

CID_UF — Controller Identification — Underfloor ——Blank Field

heating set point. This will prevent overheating of the space.

NOTE: Only primary air, NOT return air, is used when the primary air source is operating in the heating mode. The terminal fan will only operate at minimum speed. The primary air damper will modulate as required to maintain the desired heating plenum pressure set point.

8. Configure the Heat Maximum Plenum Pressure set point. The controlling plenum pressure set point is used during morning warm up, when the space temperature falls below the heating set point and the primary air source is providing heated air. The value is usually set equal to the Cool Minimum Plenum Pressure set point in order to warm the space for occupancy and achieve the heating set point quickly.

Table 9 — 45XC Points Display Table

POINT DESCRIPTION STATUS/UNITS RANGE ACCESS MODE Terminal Mode MODE (1) R

TYPE Terminal Type UNDERFLR (2) R

CNTSP Controlling Set Point XXX.X F –40.0-245.0 R

SPT Space Temperature XXX.X F –40.0-245.0 R/W

MVP Plenum Pressure X.XXX wg 0.000-2.000 R/W

DMPPOS Damper Position XXX% OPEN 0-100 R

SAT Plenum Air Temperature XXX.X F –40.0-245.0 R/W

RH Relative Humidity XXX.X% 0.0-100.0 R/W AQ Air Quality (ppm)XXXX0-5000 R/W

PAT EMP Primary Temperature XXX F –40-245 (3) R/W

REMTCIN Unocc Override Off Off/On R/W

LEGEND NOTES:

R—Read R/W — Read/Write UNDERFLR — Underfloor

1. Modes = OFF [0], HEAT [1], COOL [5], VENT [3],FAN&VENT [4],DEHUMID [6],WARM-UP[2],REHEAT [7], PRESSURE [8],

EVAC [9],ZEROCAL[10],COMMISS[11]

2. UNDERFLR is equivalent to CID PAR_FAN Type and is fixed for this application.

3. Used by Linkage Master Zone for Mode determination, if configured as a system and no air source is specified, otherwise spare temperature sensor.

Table 10 — 45XC Pressure Set Point Service Configuration Table

POINT DESCRIPTION STATUS/UNITS RANGE DEFAULT

COOLMIN Cool Minimum X.XX wg 0.00-2.00 0.06

COOLMAX Cool Maximum X.XX wg 0.00-2.00 0.08

HEATMIN Heat Minimum X.XX wg 0.00-2.00 0.04

DB_PCT Deadband XX.X% 7.5-20.0 12.5

HEATMAX Heat Maximum X.XX wg 0.00-2.00 0.08

Table 11 — 45XC Terminal Service Configuration Table

POINT DESCRIPTION STATUS/UNITS RANGE DEFAULT

DAMPER PID

Kp Proportional Gain XXX.X –100.0-100.0 30.0

Ki Integral Gain XXX.X –5.0-5.0 2.5

Kd DerivativeGain XXX.X –20.0-20.0 0.0

STARTVAL Start Value XXXX.X% 0.0-100.0 10.0

DMPDIR CW Rotation Close/Open 0-1 0 (Close)

HEATING PID

Kp Proportional Gain XXX.X –100.0-100.0 4.0

Ki Integral Gain XXX.X –5.0-5.0 0.5

Kd DerivativeGain XXX.X –20.0-20.0 0.0 STARTVAL Start Value XXXX.X F 40.0-125.0 65.0 MAXTEMP Maximum Temperature XXX F 40-200 90

SPTTRIM SPT Trim XXXX.X^F–9.9-9.9 0.0

SATTRIM SAT Trim XXXX.X^F–9.9-9.9 0.0 RMTCFG Unocc. Override Configuration (Close) Open/Close 0-1 1

LEGEND

SAT — Space Air Temperature SPT — Space Temperature UNOCC — Unoccupied

Table 12 — 45XC Option Service Configuration Table

POINT DESCRIPTION STATUS/UNITS RANGE DEFAULT

SCH Occupancy Schedule #XXX64-99 64

GSM Global Schedule Master No/Yes 0-1 0 (No)

OVR Override (Hours: Minutes)XX:XX 00:00-24:00 00:00

SETT Set Point Group #XXX0-16 0

GSTM Global Set Point Master No/Yes 0-1 0 (No)

LIMT Maximum Offset Adjust XX.X^F 0-15.0 2.0

BROACK Broadcast Acknowledger No/Yes 0-1 0 (No)

SENSOPT Sensor Options*XXX0-2 0

*0 = None, 1 =Humidity, 2 = IAQ.

Table 13 — 45XC Alarm Configuration Table (Type 10H)

POINT DESCRIPTION STATUS/UNITS RANGE DEFAULT

ROUTING Alarm Routing Control XXXXXXXX 0-1 each pos 00000000

RETIME Re-alarm Time XXXX min 0-1440 0 (disabled)

SPTHYS SPT Occupied Hysteresis XX.X^F 1.0-100.0 5.0

UNOCCUPIED SPT

LOWLIM High Limit XXX.X F –40.0-245.0 40.0

HIGHLIM Low Limit XXX.X F –40.0-245.0 99.0

HIGHVP High Plenum Pressure X.XXX wg 0.000-2.000 0.200

OCCUPIED RH

LOWLIM High Limit XXX.X% 0.0-100.0 0.0

HIGHLIM Low Limit XXX.X% 0.0-100.0 100.0

UNOCCUPIED RH

LOWLIM High Limit XXX.X% 0.0-100.0 0.0

HIGHLIM Low Limit XXX.X% 0.0-100.0 100.0

AIR QUALITY

LOWLIM High Limit XXXX.X 0.0-5000.0 250.0

HIGHLIM Low Limit XXXX.X 0.0-5000.0 1200.0

Table 14 — 45XC Linkage Configuration Table

POINT DESCRIPTION STATUS/UNITS RANGE DEFAULT

ZONE LINKAGE

MZENA Linkage Master Zone No/Yes 0-1 0 (No) NSYSTZ Number of Zones XXX 1-239 1 ASBUSB Air Source Bus Number XXX 0-239 0

ASELEMN Air Source Element Number XXX 0-239 0

STATIC PRESSURE RESET

MINDP Reset Min Damper Position XX% 0-99 50

MAXDP Reset Max Damper Position XXX% 0-100 85

SPMAX Maximum Reset X.X wg 0.0-5.0 0.0 SPRVAR SP Reset Variable Name XXXXXXXX* A-Z, 0-9,blank,-,_ —

CCN-LINKAGE DATA

CCNVAR CCN-Variable Name XXXXXXXX* A-Z, 0-9,blank,-,_ —

CCNFUNC CCN Function Config† X 0-3 3

DATA RATE Data Transfer Rate XX min 1-15 10

CCNOUTP CCN Output Point XXXXXXXX* A-Z, 0-9,blank,-,_ — DESTBUSN Destination Bus Number XXX 0-239 0 DESTELEN Destination Element Number XXX 0-239 0 BRD_RECV Sensor Mode X 1-3 1

SENSCFG Listen Sensor Config X 1-2 1

BRDDEVID Broadcasting Element Number XXX 1-239 1

*ASCII text.

†0 = None

1 = Average 2 = Low 3 =High

1 = Local Sensor 2 = Broadcast 3 = Listen!

1 = SPT 2 = SPT & Offset

Table 15 — 45XC Set Point Table

DESCRIPTION POINT STATUS/UNITS RANGE DEFAULT

Occ Heat

Set Point

LEGEND

OCC — Occupied OCSP — Occupied Cool Set Point OHSP — Occupied High Set Point UCSP — Unoccupied Cool Set Point UHSP — Unoccupied High Set Point

OHSP XXX.X F40.0-90.0 72.0 OCSP XXX.X F45.0-99.9 74.0 UHSP XXX.X F40.0-90.0 72.0 UCSP XXX.X F45.0-99.990.0

Table 16 — 45XC Zone Linkage Maintenance Table

POINT DESCRIPTION STATUS/UNITS RANGE ACCESS ASBUSNUM Air Source Bus Number XXX —R ASDEVADR Air Source Element Number XXX —R MZDEVADR Master Zone Element Number XXX —R

ASOPMODE Operating Mode * —R

ASTEMP Air Source Supply Temp XXX.X F—R

STRTBIAS Start Bias Time XXX min — R

AOHS Average Occ Heat Set Point XXX.X F—R AOCS Average Occ Cool Set Point XXX.X F—R AUHS Average Unocc Heat Set Point XXX.X F—R AUCS Average Unocc Cool Set Point XXX.X F—R

AZT Average Zone Temp XXX.X F—R

AOZT Average Occ Zone Temp XXX.X F—R

CCCNVAL Composite CCN Value XXX.X F† — R

OCCSTAT Occupancy Status** X —R

NEXTOCCD Next Occupied Day XXX —R

NEXTOCCT Next Occupied Time XX:XX —R

NEXTUNOD Next Unoccupied Day XXX —R

NEXTUNOT Next Unoccupied Time XX:XX —R PREVUNOD Previous Unoccupied Day XXX —R PREVUNOT Previous Unoccupied Time XX:XX —R

MAXDMPOS Maximum Damper Position XXXXX.X% 0.0-100.0 R/W

PRESVAL Static Press Reset X.X wg 0.0-5.0 R/W

PRESDECR Pressure Decrease Value X.XXX wg 0.000-5.000 R/W

PRESINCR Pressure Increase Value X.XXX wg 0.000-5.000 R/W

LEGEND

R—Read R/W — Read/Write

*Modes = OFF [1], COOLING [4], HEATING [3], FREECOOL [5], PRESSURE

[6],EVAC [7].

†No units for this as this is varying in nature and depends on the CCN output

point name in config table.

**1=Occupied.

Table 17 — 45XC Zone Maintenance Table

POINT DESCRIPTION STATUS/UNITS RANGE ACCESS

ZONE_OCC Occupied No/Yes R

DAVCTL Linkage SlaveNo/Yes R

LINKMAST Linkage Master No/Yes R

TIMOV Timed Override in Effect No/Yes R

T56OFF Set Point Offset (T- 5 6 )XXX.X^F –20.0-20.0 R/W

CCMR Cool Master Reference XXX.X F 45.0-99.9 R/W

PPREF Plenum Pressure Reference X.XXX wg 0-2.000 R/W

HEATENA Fan Enable Ena/Disa R

HCMR Fan Master Reference XXX.X F 40.0-90.0 R/W HSMR Plenum Temperature Reference XXX F 0-200 R/W

TCA Temperature Control Airflow XXX% R

COOLFLAG Cooling in Effect No/Yes R

HEATFLAG HeatinginEffect No/Yes R

LEGEND

R—Read R/W — Read/Write

Table 18 — 45XC Air Balancing Maintenance Table

POINT DESCRIPTION STATUS/UNITS RANGE ACCESS

CMODE Commissioning Mode DIS/ENA 0-1 R/W

CALIBRAT Damper/Transducer Cal DIS/ENA 0-1 R/W

MAXCOOL Max Cooling Pressure DIS/ENA 0-1 R/W

MINCOOL Min Cooling Pressure DIS/ENA 0-1 R/W

HEATOVER Max Heating Pressure DIS/ENA 0-1 R/W

CONCFM Pressure Set Point X.XX wg 0-2.00 R/W

MVP Actual Plenum Pressure X.XXX wg 0.000-2.000 R/W

SAT Supply Air Temperature XXX.X F –40.0-245.0 R/W CAL Auto Calibration NORMAL/ALARM 0-1 R

LEGEND

DIS/ENA — Disable/Enable R—Read R/W — Read/Write

Table 19 — 45XC Holiday Configuration Tables

POINT DESCRIPTION STATUS/UNITS RANGE DEFAULT VALUE

MONTH Start Month XX 1-12 1

DAY Start Day XX 1-31 1

DURATION Duration XXX 0-365 0

Table 20 — 45XC Time Schedule Configuration Table

POINT DESCRIPTION STATUS/UNITS RANGE DEFAULT

OVR Manual Override Hours X hours 0-4 0

DOW1 Period 1: Day of Week XXXXXXXX 0/11’s

OCC1 Period 1: Occupied from XX:XX 0:00-24:00 0:00

UNOCC1 Period 1: Occupied to XX:XX 0:00-24:00 24:00

DOW2 Period 2: Day of Week XXXXXXXX 0/10’s

OCC2 Period 2: Occupied from XX:XX 0:00-24:00 0:00

UNOCC2 Period 2: Occupied to XX:XX 0:00-24:00 24:00

DOW3 Period 3: Day of Week XXXXXXXX 0/10’s

OCC3 Period 3: Occupied from XX:XX 0:00-24:00 0:00

UNOCC3 Period 3: Occupied to XX:XX 0:00-24:00 24:00

DOW4 Period 4: Day of Week XXXXXXXX 0/10’s

OCC4 Period 4: Occupied from XX:XX 0:00-24:00 0:00

UNOCC4 Period 4: Occupied to XX:XX 0:00-24:00 24:00

DOW5 Period 5: Day of Week XXXXXXXX 0/10’s

OCC5 Period 5: Occupied from XX:XX 0:00-24:00 0:00

UNOCC5 Period 5: Occupied to XX:XX 0:00-24:00 24:00

DOW6 Period 6: Day of Week XXXXXXXX 0/10’s

OCC6 Period 6: Occupied from XX:XX 0:00-24:00 0:00

UNOCC6 Period 6: Occupied to XX:XX 0:00-24:00 24:00

DOW7 Period 7: Day of Week XXXXXXXX 0/10’s

OCC7 Period 7: Occupied from XX:XX 0:00-24:00 0:00

UNOCC7 Period 7: Occupied to XX:XX 0:00-24:00 24:00

DOW8 Per io d 8: Day of Week XXXXXXXX 0/10’s

OCC8 Pe riod 8: Occupied from XX:XX 0:00-24:00 0:00

UNOCC8 Peri od 8: Occupied to XX:XX 0:00-24:00 24:00

LEGEND

DOW# — Peri od #: Day of Week OCC# — Pe riod #: Occupied from UNOCC# — Perio d #: Occupied to

Table 21 — 45XC Time Schedule Maintenance

POINT DESCRIPTION STATUS/UNITS RANGE ACCESS

TIME SCHEDULE

MODE Mode X 0-1 R

PERIOD Current Occupied Period X R

OVERLA ST Override in Progress No/Yes 0-4 R

OVERDURA Override Duration XHours 0-4 R

OCCSTART Occupied Start Time XX:XX 0:00-24:00 R

UNSTART Unoccupied Start Time XX:XX 0:00-24:00 R NXTOCCD Next Occupied Day X SUN-SAT, blank R

NXTOCCT Next Occupied Time XX:XX 0:00-24:00 R NXTUNOD Next Unoccupied Day X SUN-SAT, blank R

NXTUNOT Next Unoccupied Time XX:XX 0:00-24:00 R PRVUNOD Last Unoccupied Day X SUN-SAT, blank R

PRVUNOT Last Unoccupied Time XX:XX 0:00-24:00 R

LEGEND

R—Read

42KC Set-Up and Configuration

FAN, HEAT, AND COOL CONFIGURATION AND TEST — Reference Tables 22-28 to configure and test the fan, cool, and heat processes:

1. Display the Fan Coil Service Configuration screen to make sure the Cool Type, Heat Type, fan speeds, and other options are configured.

2. Display the Points Display table. In most cases, the fan will start up in low speed due to the default settings. If the fan does not come on, forcing the fan output to ON using the Points Display table will cause the fan to run at low speed. Check to ensure the fan is running.

3. Refer to 42KC Fan Coil Airflow Adjustment and set both SCR1 and SCR2 to deliver the desired airflow. With the fan running at low speed, bring up the Fan Coil Maintenance screen. Two points are available to change fan speed to Medium or High. Change the speeds by forcing the point. Make sure the fan runs at the correct speeds. Change the points back to AUTO after completing the test.

4. Heating operation can be tested with the fan running in the occupied mode by forcing the space temperature point. Force the point to a value 5° F above the cooling set point to test the fan speed control and 2° F below the heating set point to test heating.

42KC Fan Coil Airflow Adjustment

1. Using a CCN service interface tool, start the fan by placing the controller in the occupied mode. Adjust the occupied set points so that the current space temperature is at least 5° F above the heating set point and at least 5° F below the cooling set point (the satisfied Space Temperature condition).

2. As noted on the Points Display table, verify that Fan Mode is displaying “LOW.” Set SCR1 to adjust the lowest airflow, which will be provided under conditions where the space temperature is satisfied.

3. From the Maintenance screen, force the Fan Speed Medium point (FANSPD1) to ON. The fan will operate at medium speed. Adjust SCR2 to provide the required airflow on medium speed.

4. From the Maintenance screen, force the Fan Speed High point (FANSPD2) to ON. The fan will operate at high speed. There is no adjustment for high speed fan operation. The fan and motor will operate at full speed.

5. If high speed fan operation is not desired, then change the number of fan speeds (FAN_TYPE in the Service Configuration table) to 2. If electric heat is supplied, verify that the airflow provided at the medium speed setting of SCR 2 in step 2 above is sufficient to provide adequate airflow through the electric heater.

For additional information on the 42KC controller (P/N 33ZCFANCOL) and a full description of each value, default and range information, refer to the fan coil controller installation, start-up and configuration instructions.

Setting Fan Airflow with ECM (Electronically Commutated Motor) —

mixing boxes are equipped with ECMs and DO NOT require balancing. Fan speed is automatically adjusted to meet the temperature and pressure set points for the underfloor plenum. The ECM is programmed to provide a maximum airflow, depending on model and unit size. See Table 29 for airflow range.

The 45XC series fan-powered

Balancing Underfloor Fan Terminals — Carrier

45UC underfloor fan terminal units contain primary air dampers which, under the control of a volume controller, regulate the amount of primary air or plenum air (dependent on installation) distributed to the space.

The 45UC underfloor terminals direct all return plenum air through the unit fan. The terminal is designed to operate with the fan supplying airflow equal to or greater than the airflow supplied by the primary air source. To balance the unit, it is necessary to first set the fan flow, then the VAV damper (primary) flow.

Each control option has specific procedures required for balancing the unit, but some steps are common to all terminal units. The fan box adjustments described below must be made in conjunction with the adjustments described in the Speed Controller and Set Points sections. The VAV damper airflow may be set at the factory, but the fan airflow must be set in the field as described below. See Table 30.

Table 22 — 42KC Points Display Table

POINT DESCRIPTION DEFAULT UNITS

MODE Desired Mode Fan Only

ALARM Equipment Status Alarm

CSPT Controlling Set Point 70.0 dF

SPT Controlling Temperature 72.0 dF RAT Space Temperature 72.0 dF SAT Supply Air Temperature 68.2 dF

FANSTAT Fan Mode Low

CCAP Cooling Capacity 0.0 % HCAP Heating Capacity 0.0 %

FLTSTAT Filter Status Clean

CHGMODE Changeover Mode Heat

CON_PUMP Condensate Pump Off

REMOTE Remote Start Off

SFS Supply Fan Status On

AQ Air Quality (PPM) 0.0 RH Relative Humidity 0.0 %RH

OAT Outdoor Air Temperature 0.0 dF CCV1 Valve/DX1 Off CCV2 Valve/DX2 Off HCV1 Heating 1 Off HCV2 Heating 2 Off

DAMPER Damper Output Close

FAN Fan Output On

Table 23 — 42KC Unit with Modulating Hot Water

Heat Service Configuration Table

Table 24 — 42KC with 2 Position Hydronic Heat or

1-Stage Electric Heat Service Configuration Table

NAME DESCRIPTION DEFAULT UNITS

UNITTYPE 2-Pipe Changeover Disable

FAN CONTROL

FANOPR Fan Operation* 1

FAN_TYPE Number of Fan Speeds (1-3) 3

FAN PID

KP Proportional Gain 50.0

KI Integral Gain 0.0

KD Derivative0.0

STARTVAL Starting Value 100.0 %

COOL_TYP Cooling Type† 0

COOLING PID

KP Proportional Gain 8.0

KI Integral Gain 0.3

KD DerivativeGain 0.0

STARTVAL Starting Value 65.0 dF

STAGED COOLING

STAGES Number of Stages 1

TG1 Stage 1 Time Gard Enable

TG2 Stage 2 Time Gard Disable CLT1 2-Pos Valve Logic Type Normal CLT2 Stage 2 DX Logic Type Normal

HEAT_TYP Heating Type** 1

HEATING PID

KP Proportional Gain 13.0

KI Integral Gain 1.3

KD DerivativeGain 0.0

STARTVAL Starting Value 80.0 dF

HCROV Fan Off Value 55.0 dF

STAGED HEATING

STAGES Number of Stages 2

HLT1 2-Pos Valve Logic Type Normal

DMP 2-Position Damper No

AIR QUALITY

AQINLO AQ Low Voltage 0.0 Volts

AQINHI AQHigh Voltage 10.0 Volts

AQLO AQ Low Reference (PPM) 0.0

AQHI AQHigh Reference (PPM) 2000.0

FIL_TIMR Filter Timer hrs * 100 15

CPTIMR Condensate Pump Timer 10 min RATTRIM Space Temp Trim 0.0 ^F SATTRIM Supply Air Temp Trim 0.0 ^F

* 0=Auto, 1=Continuous.

†1=Mod, 2=2-Pos, 3=DX.

**1=Mod, 2=2Pos,3=Elec 4=2-Pipe Chg w/Elec Ht.

NAME DESCRIPTION DEFAULT UNITS

UNITTYPE 2-Pipe Changeover Disable

FAN CONTROL

FANOPR Fan Operation* 1

FAN_TYPE # Fan Speeds (1-3) 3

FAN P ID

KP Proportional Gain 40.0

KI Integral Gain 0.0

KD Derivative0.0

STARTVAL Starting Value 100.0 %

COOL_TYP Cooling Type† 0

COOLING PID

KP Proportional Gain 8.0

KI Integral Gain 0.3

KD DerivativeGain 0.0

STARTVAL Starting Value 65.0 dF

STAGED COOLING

STAGES Number of Stages 1

TG1 Stage 1 Time Gard Enable

TG2 Stage 2 Time Gard Disable CLT1 2-Pos Valve Logic Type Normal CLT2 Stage 2 DX Logic Type Normal

HEAT_TYP Heating Type **

HEATING PID

KP Proportional Gain 35.0

KI Integral Gain 0.0

KD DerivativeGain 0.0

STARTVAL Starting Value 105.0 dF

HCROV Fa n Of f Value 55.0 dF

STAGED HEATING

STAGES Number of Stages 1

HLT1 2-Pos Valve Logic Type Normal

DMP 2-Position Damper No

AIR QUALITY

AQINLO AQ Low Voltage 0.0 Volts

AQINHI AQHigh Voltage 10.0 Volts

AQLO AQ Low Reference (PPM) 0.0

AQHI AQHigh Reference (PPM) 2000.0

FIL_TIMR Filter Timer hrs * 100 15

CPTIMR Condensate Pump Timer 10 min RATTRIM Space Temp Trim 0.0 ^F SATTRIM Supply Air Temp Trim 0.0 ^F

0=Auto, 1=Continuous. †1=Mod, 2=2-Pos, 3=DX. **Enter Type 2 for two-position hot water/steam.

Enter Type 3 for 1 stage electric heat.

Table 25 — 42KC with 2-Stage Electric Heat

Service Configuration Table

NAME DESCRIPTION DEFAULT UNITS

UNITTYPE 2-Pipe Changeover Disable

FAN CONTROL

FANOPR Fan Operation* 1

FAN_TYPE # Fan Speeds (1-3) 3

FAN PID

KP Proportional Gain 40.0

KI Integral Gain 0.0

KD Derivative0.0

STARTVAL Starting Value 100.0 %

COOL_TYP Cooling Type† 0

COOLING PID

KP Proportional Gain 8.0

KI Integral Gain 0.3

KD DerivativeGain 0.0

STARTVAL Starting Value 65.0 dF

STAGED COOLING

STAGES Number of Stages 1

TG1 Stage 1 Time Gard Enable

TG2 Stage 2 Time Gard Disable CLT1 2-Pos Valve Logic Type Normal CLT2 Stage 2 DX Logic Type Normal

HEAT_TYP Heating Type** 1

HEATING PID

KP Proportional Gain 15.6

KI Integral Gain 1.6

KD DerivativeGain 0.0

STARTVAL Starting Value 93.0 dF

HCROV Fan Off Value 55.0 dF

STAGED HEATING

STAGES Number of Stages 2

HLT1 2-Pos Valve Logic Type Normal DMP 2-Position Damper No

AIR QUALITY

AQINLO AQ Low Voltage 0.0 Volts

AQINHI AQHigh Voltage 10.0 Volts

AQLO AQ Low Reference (PPM) 0.0

AQHI AQHigh Reference (PPM) 2000.0

FIL_TIMR Filter Timer hrs * 100 15

CPTIMR Condensate Pump Timer 10 min RATTRIM Space Temp Trim 0.0 ^F SATTRIM Supply Air Temp Trim 0.0 ^F

0=Auto, 1=Continuous.

†1=Mod, 2=2-Pos, 3=DX.

**1=Mod, 2=2Pos,3=Elec 4=2-Pipe Chg w/Elec Ht.

Table 26 — 42KC Set Point Table

NAME DESCRIPTION VALUE UNITS

SETPOINTS

OHSP Occupied Low Setpoint 70.0 dF OCSP Occupied High Setpoint 74.0 dF UHSP Unoccupied Low Setpoint 55.0 dF

UCSP Unoccupied High Setpoint 90.0 dF ORHH Occupied High Humidity 100.0 %RH URHH Unoc High Humidity 100.0 %RH

Table 27 — 42KC Fan Coil Maintenance Table

NAME DESCRIPTION VALUE UNITS

OCCSTAT Occupied Yes

DAVCL Linkage in Effect No

TIMOV Timed Override in Effect No

STRTBIAS Start Bias Time 0 min

T56OFF Setpoint Offset (T- 5 6 ) 0.0 F

T57STAT T57 Status 4

HCMR Heat Master Reference 70.0 dF

HCSR Heat Submaster Reference 150.0 dF

CCMR Cool Master Reference 74.0 dF

CCSR Cool Submaster Reference 150.0 dF

COOLFLAG Cooling in Effect No

HEATFLAG HeatinginEffect No REHTFLAG Reheat in Effect No

FANPCT Fan Speed 0 % FANSP D1 Fan Speed Medium Off FANSP D2 Fan Speed High Off

CHGTEMP Changeover Temperature 95.3 dF

CHANGOVR Changeover Status Heat

LINKAGE THERMOSTAT

LINKSTAT Linkage Status 2 SUPE-ADR Supervisory Element 0 SUPE-BUS Supervisory Bus 0

BLOCKNUM Supervisory Block 0

OCLOSTPT Average Occ Heat Setpt 0.0 dF

OCHISTPT Average Occ Cool Setpt 0.0 dF

UNLOSTPT Average Unoc Heat Setpt 0.0 dF

UNHISTPT Average Unoc Cool Setpt 0.0 dF

AZT Average Zone Temp 0.0 dF

AOZT Average Occ Zone Temp 0.0 dF

OCCSTAT Occupancy Status (1=occ) 1

Table 28 — 42KC Fan Coil Alarm Configuration

Table

NAME DESCRIPTION VALUE UNITS

ALARM CONTROL

ALRMCNT Alarm Routing Control 11010000

REALARM Realarm Time 0 min

SPTHYS Control Temp Hysteresis 5.0 ˆF

SUPPLY AIR TEMPERATURE

LOWLIM Low Limit 45.0 dF

HIGHLIM High Limit 150.0 dF

OCCUPIED RH

LOWLIM Low Limit 30.0 %RH

HIGHLIM High Limit 70.0 %RH

UNOCCUPIED RH

LOWLIM Low Limit 10.0 %RH

HIGHLIM High Limit 90.0 %RH

AIR QUALITY

LOWLIM Low Limit 0.0

HIGHLIM High Limit 1200.0

Table 29 — 45XC Fan-Powered Zone Mixing Unit (ECM)

UNIT

SIZE

ECM — Electronically Commutated Motor FLA — Full Load Amps

*Special order.

†This value is based on a signal of 0.03 in. wg differential pressure

of the linear averaging flow probe. Minimum Primary flow may be zero.

INLET

SIZE

10 1448 145 2648 12 2085208 3285 10 12 2085208 4585 14 2838 2845338 16 3706 371 6206

MOTOR

6 8927 932127

LEGEND

120 V FLA* 240 V FLA* 277 V FLA Max Min† Max Min

118.0 9.0 8.1

ECM MOTOR AMPS PRIMARY AIRFLOW ECM FAN AIRFLOW**

9.5 4.7 4.1

Table 30 — 45UC Underfloor Series Flow Fan Box (ECM)

UNIT SIZE

3 9

ECM — Electronically Commutated Motor

*Max based on 0.1 in. wg downstream static pressure.

Min based on 0.6 in. wg downstream static pressure.

INLET

SIZE

MOTOR

LEGEND

120 V 208/240 V 277 V Max Min Max Min**

MOTOR AMPS FAN AIRFLOW*

4.1 — 2.4 1000 280 900 203 0.10

3.9 — 2.3 1050 360 900 203 0.10

3.9 — 2.3 1050 360 1050 251 0.09

MAX

FLOW

521 52

1200 250

1448 145

2500 400

**Rpm/torque controlled motor, at 0.1 in. wg static pressure

underfloor.

NOTE: Data is based on tests conducted in accordance with ARI (Air Conditioning and Refrigeration Institute) Standard 880-98.

PRIMARY

AIRFLOW†

†Maximum primary airflows are set by the maximum induced air-

flow, which may vary as a function of downstream pressure.

**Some DDC controls supplied by others may have different

limitations.

MINIMUM

STATIC PRESSURE

(in. wg)

1721

3948

Speed Controller — Each 45UC fan-powered air termi-

nal unit is equipped with a fan SCR speed controller located on the bottom of the control box. The SCR can be adjusted in the field. (One SCR is located in the standard position at the bottom of the control box; the other is at the top of the control box.)

The minimum stop on the speed controller is factory set at an internal minimum stop to prevent damage to the motor. Do not attempt to override this minimum stop or electrical damage to the fan motor may result.

The fan airflow output is dependent on the setting of the

controller and the downstream static resistance.

To increase the fan speed, turn the slotted adjustment on the controller clockwise toward the “HI” marking printed on the controller faceplate (see Fig. 56). To decrease the fan speed, turn the slotted adjustment on the controller clockwise toward the “LO” marking (see Fig. 56).

Set Points

ADJUSTMENT OF SET POINTS — Each 45UC underfloor terminal unit, supplied with CCN controls, is equipped with an electronic volume controller which regulates the quantity of cold primary air entering the terminal and the conditioned space. If required airflow levels are specified with the job order, the minimum and maximum cfm levels will be set at the factory (where applicable). If minimum and maximum levels are not specified,

a default value of 0 is used for minimum setting at the factory. Other settings of minimum and maximum primary airflow must be set in the field. Airflow (cfm) ranges for the primary air damper and fans are shown in Table 30. The minimum primary airflow (other than zero) is the minimum flow rate controllable by the unit volume controller. The primary air damper can be set at zero for shutoff or at the minimum cfm listed.

Fig. 56 — 45UC Fan Speed Controller

FIELD ADJUSTMENT OF MINIMUM AND MAXIMUM AIRFLOW SET POINTS — Each 45UC underfloor terminal unit is equipped with a centerpoint averaging airflow sensor, which provides an amplified differential pressure that is proportional to the unit airflow. Output from this sensor is used to provide a flow signal to both pneumatic and electronic controls. Unit airflow (cfm) can be read directly from the airflow sensor labels on the unit. See Fig. 57 and Table 30.

1. With the unit airflow from the fan set, turn on primary (VAV) air supply.

2. To set cfm in the field, connect a gage to the flow probe at the provided ‘T’ taps, and check the differential pressure.

(Alternately, the total flow may be measured, and the previously determined fan induction flow rate may be subtracted from the total flow to determine VAV flow. However, for low primary settings, this may not be as accurate as the flow tap method.)

3. If a minimum VAV flow is required in heating mode, adjust the volume until the differential pressure corresponds to the cfm required.

4. Set the controller to provide maximum cooling demand. This is typically accomplished by first setting the thermostat to the lowest possible temperature setting.

a. In most series fan boxes, the primary airflow rate is

equal to the fan induction flow; in these cases, adjust the volume controller until a balance is achieved between fan-induced airflow and primary airflow. When a balance exists, a strip of paper hung at the induction port should hang straight down, and neither be blown in or out of the unit.

b. If the VAV airflow desired is less than the fan

induction flow, adjust the volume controller until the differential pressure (measured through the flow probe as described above) corresponds to the cfm required. Verify that induction exists through the inlet ports, using the paper strips as described above. When induction exists, the paper strip should be pulled into the unit.

5. Return all reheat options to normal connections.

6. Cap the ‘T’ taps.

7. Reset the thermostat to a normal setting.

NOTE: It is normal for the total airflow to the room to increase slightly in full cooling mode.

Testing and Start-Up

1. Place the 45XC controller in the Occupied mode. This action may be completed through the occupancy schedule or via the Occupancy Input point on the Point Display table.

2. Verify the required information was entered as specified in the 45XC Set-Up and Configuration section. Verify the primary air source is operating in a Cooling mode. Adjust the occupied heating set point to approximately 1º F above the current zone temperature and adjust the occupied cooling set point to the maximum value (99 F). From the Points Display Table, verify the Terminal Mode (MODE) is HEAT.

3. Allow the system to operate and determine the controlling pressure set point. The controlling plenum pressure reference (PPREF) can be found in the ZNMAIN table. Note the pressure reference value. Monitor the fan enable point (HEATENA) and verify that the status changes to ENA and the ‘Heating in effect’ flag is YES. Once this occurs, proceed to the plenum temperature reference point (HSMR) and FORCE this value to the design temperature that the system was selected for (approximately 62 F). Proceed to the Points Display Table (POINTS) and verify that the Actual Plenum Pressure (MVP) is at or near the noted reference and the plenum temperature is at the desired value that was previously entered (forced). If these values do not comply, the primary air damper (DMPPOS) should modulate to achieve this pressure set point while the fan speed will change to achieve the desired plenum temperature.

NOTE: If the damper position is at 100% and the Actual Plenum Pressure is still below the desired pressure set point, either the terminal has insufficient capacity to achieve the desired pressure set point, excessive leakage is occurring from the plenum, or the fan is not operating properly.

INLET AIRFLOW SENSOR

CFM at 1 in. wg SIGNAL

1.0

in. wg

INLET SIZES

INLET SENSOR P

.07

.05

.04

.03

358

300

515

500 700 1000

CFM

229

100

200

1432

916702

2062

116 0

2000

Fig. 57 — Inlet Airflow Sensor Cfm vs Signal Chart

3665

2806

3000

5000

7000

9.7

8.2

6.8

5.8

4.6

3.4

2.6

VOLTS (DC), ANALOG CONTROLS

2.0

1.8

1.4

7000

4. Verify that the fan can maintain the desired plenum pressure at minimum load conditions. Force the plenum temperature reference point (HSMR) to the maximum design temperature that the system was selected for (approximately 65 to 67 F). Verify return air to the terminal is at least at this temperature or greater. Allow sufficient time for the fan speed to increase. Verify that the primary air damper closes, then connect a Magnehelic gage to the terminal’s primary airflow pickup probes. Using Fig. 57 (provided with the terminal), manually adjust the primary air damper position to achieve the desired minimum primary airflow for ventilation. From the Points Display Table (POINTS), read the actual damper position (DMPPOS) and configure the minimum primary air damper position (MIN_VENT) in Table 9.

NOTE: If the Actual Plenum Pressure is below the desired pressure set point, either the terminal has insufficient fan capacity to achieve the desired pressure set point, excessive leakage is occurring from the plenum, or the fan is not operating properly.

5. While the Magnehelic gage is still connected, manually open the primary air damper in order to achieve the maximum rated box primary airflow. Set the primary air damper actuator’s mechanical stop so that the damper cannot exceed this position.

6. When completed, remove all forces previously applied for testing purposes.

45XC Operation — As the space temperature varies

around the space temperature set point, the fan speed is controlled to regulate the amount of return air allowed into the plenum, which in turn, the return air (hot) quantity is varied. The primary damper then adjusts to reduce the supply air (cold) in order to maintain a constant pressure in the duct. Underfloor plenum pressure is maintained at set point, which supplies air to the space through diffusers. The space air will heat up and hot air will reach the ceiling plenum. Several factors contribute to the heating of the space air: the occupancy, lighting loads, perimeter heating, mechanical heating by independent underfloor controller, etc. It is the job of the fan to introduce the proper proportion of ceiling plenum air to the supply air to maintain the space temperature at the configured heating set point.

These variable speed, parallel fan-powered terminals are designed to provide constant flow pressure and temperature control for a sealed underfloor plenum. These terminals are primarily used for plenums serving a single interior zone, where a combination of primary air mixed with recirculated air provides proper plenum pressure, temperature and ventilation. They may also be used in conjunction with a separate perimeter heating system to condition exterior zones. A typical application is shown in Fig. 1. Design load requirements and terminal fan capacity govern terminal selection and sizing. The control can provide variable air volume (VAV) control of the primary air during both cooling and heating. The fan provides plenum temperature control by varying the amount of recirculated air introduced into the plenum, while the primary air damper simultaneously maintains the plenum pressure by controlling the amount of primary air introduced into the plenum. As the zone’s cooling load decreases, the fan speed increases, which increases the amount of recirculated air drawn in from the ceiling plenum. Simultaneously, the amount of primary air is reduced to maintain a constant discharge pressure. A wall-mounted space temperature (SPT) sensor located in the zone will sense load requirements. The terminal fan will operate whenever the primary air source is operating.

FOR 45XC UNITS WITH CONTROL PACKAGE 4840 System Start-Up — Cooling (Refer to Numbers in Fig. 58)

1. Points 1 and 2 indicate that maximum cooling airflow is established by the user-defined maximum cooling plenum pressure set point until the zone comes under control

at 2 (this may be the same value as the minimum cooling pressure set point). The fan operates at minimum speed.

2. Beginning at 2, the plenum pressure is reduced by reducing the primary airflow until the minimum cooling plenum pressure set point is reached at 3.

Normal Operation — Cooling (Refer to Numbers in Fig. 58)

1. Point 3 indicates that the zone temperature is above the control (heating) set point, the plenum pressure is maintained at the user-defined minimum cooling plenum pressure set point.

2. At point 4, as the zone temperature decreases, the plenum temperature is increased by increasing the fan speed to introduce more recirculated air while simultaneously reducing the primary airflow. The plenum pressure remains constant at the user-defined minimum cooling plenum pressure set point.

3. As indicated by points 4 and 5, should the zone temperature continue to fall below the occupied control set point, the primary air damper will close but not below the userdefined minimum ventilation set point at point 5 (may be set to zero), while the fan provides recirculated air to maintain the plenum pressure set point.

Heating (When the Primary Air Source is Providing Heated Air, Refer to Numbers in Fig. 59)

1. Upon receiving a heating signal generated by the air source equipped with CCN controls (or a primary air temperature sensor is installed to detect that the air source is heating), the heating mode is automatically in effect.

2. If the zone temperature is above the occupied heating set point, the primary air damper is modulated to maintain the minimum heating plenum pressure set point at 4 ft-lb. The fan operates at minimum speed.

3. Should the zone temperature fall, the plenum pressure will increase up to the user-defined maximum heating plenum pressure set point at 5 ft-lb. The control may be configured to provide constant volume heating to provide a constant supply of heated air to the zone.

Morning Warm-Up (If Configured to Provide Variable Volume Heating, Refer to Numbers in Fig. 59) — Upon receiving a morning warm-up signal generated by the air source equipped with CCN controls, the primary air damper will modulate to maintain the maximum heating plenum pressure set point if the zone temperature is below the occupied heating set point at 5 ft-lb. This allows a maximum quantity of warm primary air to be delivered to the zone. As the zone’s temperature rises, the plenum pressure is reduced to the minimum heating plenum pressure 4 ft-lb. The terminal fan operates at minimum speed.

Cooling — Unoccupied Time Period (Optional) unoccupied period is reached, the user-defined occupied cooling set point can be reset upward to a user-defined unoccupied cooling set point. If the primary air source is operating, the primary air damper will throttle in the same manner (see System Start-Up — Cooling and Normal Operation — Cooling) during the unoccupied period, using the zone’s unoccupied cooling set point.

Heating — Unoccupied Time Period (Optional) unoccupied period is reached, the user-defined occupied heating set point can be reset downward to a user-defined unoccupied heating set point. If the primary air source is operating, the primary air damper will operate in the same manner (see Heating) during the unoccupied period, using the zone’s unoccupied heating set point.

Demand Controlled Ventilation Sensor (Optional) control provides an input for a ventilation sensor (CO2)thatcan be used to monitor the ventilation provided to the zone. The sensor value can also be used by a CCN system in order to modulate the mixed-air damper on the primary air source equipment and provide demand controlled ventilation.

— When the

—The

Damper Override

— The damper override function is energized through the use of a field-supplied smoke control panel connected to the air source equipped with CCN controls. The smoke control panel and installation must be in accordance with UL864 and local codes. The damper override function overrides the airflow setting used by the logic. It will cause the terminal to provide the configured maximum cooling plenum pressure when the air source is in the Pressurization mode, and fully close the primary air damper when the air source is in the

evacuation mode. The terminal fan is disabled only after the primary air is off.

If the Primary Air Source Shuts Off

— The primary air damper will fully close and the control will recalibrate the plenum pressure transducer. If the primary air source remains off (no primary air), the damper will be repositioned to at least 50% open to allow the air source to restart properly.

Plenum Pressure

(Maximum Cooling)

Maximum Fan Airflow

Plenum Pressure

(Minimum Cooling)

Minimum Ventilation

Minimum Fan Airflow

LEGEND

Warmer

OCCUPIED

CONTROL SETPOINT

HEATING &

MORNING WARM-UP

Cool

OCCUPIED

COOLING SETPOINT

PLENUM PRESSURE

PRIMARY AIRFLOW

PLENUM TEMPERATURE

FAN

Air Source Supplying Heated Air Air Source Supplying Cooled Air

Fig. 58 — Sequence of Operation — Equipment Cooling Mode (Control Package 4840)

Plenum Pressure

(Maximum Heating)

Maximum Heating Airflow

Warm

Minimum Heating Airflow

(Minimum Heating)

Minimum Fan Airflow

OCCUPIED

CONTROL SETPOINT

HEATING &

MORNING WARM-UP

OCCUPIED

COOLING

SETPOINT

PLENUM TEMPERATURE

PRIMARY AIRFLOW

PLENUM PRESSUREPlenum Pressure

FAN

LEGEND

Air Source Supplying Heated Air Air Source Supplying Cooled Air

Fig. 59 — Sequence of Operation — Equipment Heating Mode (Control Package 4840)

FOR 45XC UNITS WITH CONTROL PACKAGE 4841 System Start-Up — Cooling (Refer to Numbers in Fig. 60)

— Points 1-4 indicate that maximum cooling airflow is provided by primary air until the zone comes under control at 4. The fan operates at minimum speed.

Normal Operation — Cooling (Refer to Numbers in Fig. 60)

1. Points 1-3 indicate that if the zone temperature is above the control (heating) set point (typically 70 F), the terminal’s 55 F primary airflow from the air source is maximized to provide cold air to the plenum and cool the space. The fan is at minimum airflow and the total volume of air is maintained at the required constant airflow set point.

2. At point 4, as the zone temperature drops closer to the occupied heating set point, the discharge air temperature from the terminal into the plenum is increased by increasing the fan speed to introduce more recirculated air while simultaneously the primary airflow is reduced to maintain the total airflow into the access plenum. As indicated by points 4 and 5, should the zone temperature continue to fall, the primary air damper will close but not below the user defined minimum ventilation set point at 5 (may be set to zero), while the fan provides recirculated air from the return plenum, to maintain constant airflow into the underfloor plenum.

Heating (When the Primary Air Source [AHU] is Providing Heated Air, Fig. 61) — Upon receiving a heating signal generated by the air source equipped with CCN controls (or a primary air temperature sensor is installed to detect that the air source is heating), the heating mode is automatically in effect and the primary air damper is modulated to maintain constant airflow into the plenum. The fan operates at minimum speed.

Unoccupied Time Period (Optional)

— When an unoccupied period is reached, the user-defined occupied control set point (heating set point) can be reset upward to a user defined unoccupied set point to minimize the use of primary air during unoccupied periods. If the primary air source is operating, the primary air damper will close and the fan will maintain the desired airflow into the plenum. The control operates in the same manner (see Normal Operation — Cooling) during the unoccupied period, using the zone’s higher unoccupied control set point.

NOTE: In common plenum applications, unoccupied control is not recommended unless all terminals use the exact same time schedule and set points):

Demand Controlled Ventilation Sensor (Optional) trol provides an input for a ventilation sensor (CO

— The con) that can be

used to monitor the ventilation provided to the zone. The sensorvaluecanalsobeusedbyaCCNsysteminorderto modulate the mixed air damper on the primary air source equipment and provide demand controlled ventilation.

Damper Override

— The damper override function is energized through the use of a field-supplied smoke control panel connected to the air source equipped with CCN controls. The smoke control panel and installation must be in accordance with UL864 and local codes. The damper override function overrides the primary airflow setting used by the logic. It will cause the terminal to provide the configured maximum airflow into the plenum when the air source is in the Pressurization mode, and fully close the primary air damper when the air source is in the Evacuation mode. The terminal fan is disabled only if the primary air is off.

Primary Air Source Shuts Off

1. The primary air damper will fully close and the control will recalibrate the plenum pressure transducer.

2. If the primary air source remains off (no primary air), the damper will be repositioned to at least 50% open to allow the air source to restart properly.

Calibration of Airflow Sensors

—Inacommonplenum application with multiple terminals, all primary air sources supplying primary air to terminals feeding the common plenum must operate on the exact same schedule and must transition to “Off” at the same time at least once each day for 25 minutes to allow all airflow (pressure) transducers to recalibrate properly. Considering the amount of time required for recalibration, it is suggested that the recalibration period take place during the unoccupied period, if one exists. Sequentially, each primary air damper will fully close and each control will recalibrate its pressure transducer.

Typical Plenum

Pressure Setpoint

.10

Warmer

Maximum Fan Airflow

Maximum Primary Airflow

Resulting

Plenum Pressure

Temperature

.08

.06

Typical

Minimum Primary Airflow Ventilation

OCCUPIED

(CONFIGURED HEATING)

Cooler

Total Supply Airflow to Plenum

Plenum Temperature

Minimum Fan Airflow Fan

LEGEND

Air Source Supplying Heated Air Air Source Supplying Cooled Air

Fig. 60 — Sequence of Operation — Equipment Cooling Mode (Control Package 4841)

Plenum Pressure

(Maximum Heating)

Maximum Heating Airflow

PLENUM TEMPERATURE

PRIMARY AIRFLOW

PLENUM PRESSUREPlenum Pressure

FAN

Minimum Heating Airflow

(Minimum Heating)

Minimum Fan Airflow

Warm

OCCUPIED

CONTROL SETPOINT

HEATING &

MORNING WARM-UP

OCCUPIED

COOLING

SETPOINT

LEGEND

Air Source Supplying Heated Air Air Source Supplying Cooled Air

Fig. 61 — Sequence of Operation — Equipment Heating Mode (Control Package 4841)

42KC Fan Coil Sequence

CONTROL MODES — The control operating mode is determined based upon the fan coil’s mechanical configuration (heating coil type) and optional features, such as the T57 space temperature sensor’s fan speed switch selection. The fan will NOT operate and the mode will remain OFF if the T57’s fan speed selection is in the OFF position. Otherwise, the control will determine the operating mode as defined below.

Morning Start — Warm-up low the Occupied Heating Set Point, the unit will operated in the “Occupied Heating Mode” as described below.

Morning Start — Cooling above the Occupied Cooling Set Point, the unit will operated in the “Occupied Cooling Mode” as described below.

Occupied Heating Mode — Water/Steam temperature falls below the heating set point, the water valve will modulate (open for two position control valves) as required to maintain the heating set point. The valve is controlled to prevent the discharge air temperature from rising above 140 F at any time. During heating, if the fan has not been manually set (T57 only) to operate at a desired fixed speed, the fan will operate at the lowest speed necessary to meet the space load conditions in order to minimize fan noise. If the load increases, the fan speed will increase. When the load decreases and the space temperature rises, the fan speed is reduced. If the space temperature rises above the heating set point, the heating valve is closed.

Occupied Heating Mode — Electric Heat temperature falls below the heating set point, the electric heater stages are controlled to maintain the space temperature at the desired heating set point. During heating, if the fan speed has not been manually selected (T57 only) to operate at a desired speed, the fan will operate at the lowest speed necessary to meet the space load conditions, to minimize fan noise. If the supply air temperature should rise above 130 F while electric heat is operating, the fan speed is automatically increased (except if manually overridden from a T57 sensor). The fan will maintain high speed until all stages of electric heat have been disabled or the supply air temperature drops below 100 F. If the supply air temperature continues to increase above 140 F, the heater stages are deenergized. To protect against short cycling, the first heater stage is prevented from being restarted for a 5-minute period after being deenergized. If the space temperature rises above the heating set point, all heating stages are disabled.

Unoccupied Heating Mode the heat will be activated when the space temperature falls 1º F below the unoccupied heating set point. The heat is controlled in order to prevent the supply air temperature from rising above 140 F at any time. The fan will operate at low speed unless the low speed is unable to raise the space temperature to the unoccupied heating set point. The fan will be deenergized and the heat disabled when the space temperature rises above the unoccupied heating set point.

Occupied Cooling Mode above the cooling set point and the fan has not been manually set (T57 only) to operate at a desired speed, the fan will operated at the lowest speed necessary to meet the space load conditions in order to minimize fan and air noise. As the space load increases, the fan speed will increase to deliver more air from the underfloor plenum to the diffusers to balance the load as required. When the load decreases and the space temperature falls, the fan speed is reduced.

Unoccupied Cooling Mode cooled air in the underfloor plenum. No unoccupied cooling is provided. Unoccupied cooling should be disabled by setting the unoccupied cooling set point to the maximum value of 99 F.

— If the space temperature is be-

— If the space temperature is

—Ifthespace

— The fan will be energized and

— If the space temperature rises

— All cooling is provided by the

Unoccupied Fan Cycling been selected, the fan will start once an hour and operate for 1 minute to circulate the air in the space in order to avoid air stagnation and provide more accurate space temperature sensing. The actual start time for each unit will be determined by its address.

— If unoccupied fan cycling has

45XC Application Considerations

1. The 45XC fan-powered mixing box is used to mix primary air with ceiling plenum return air and deliver that air into an underfloor plenum supply distribution system. The 45XC mixing box maintains plenum pressure and temperature in order to meet the load requirements of the space. The pressure is maintained at set point by modulating the primary air damper to increase or decrease the flow of primary air into the underfloor plenum. This causes the resulting pressure to increase as the airflow increases or decrease as the airflow decreases. To maintain the proper plenum temperature, the parallel fan is used to modulate the flow of return air from the ceiling plenum into the plenum. This return airflow is a parallel airflow path to the primary airflow so the two work together, but oppositely, in order to maintain plenum pressure. For example, as the calculated plenum temperature set point increases due to a load decrease in the space, the parallel terminal fan increases its speed in order to introduce more return air into the plenum. This causes the plenum pressure to increase, therefore, the primary air damper closes to reduce the plenum pressure to coincide with the configured plenum pressure set point.

IMPORTANT: The terminal fan must be capable of supplying enough return air to maintain the configured plenum pressure set point. If the fan is not able to supply enough return air, additional primary air will be used to maintain the plenum pressure set point, resulting in a plenum temperature that is colder than required, which will overcool the space.

The terminal fan capacity and primary air damper size must both be accurately selected to achieve the complete range of plenum temperatures required, from the minimum plenum temperature at design space load to the maximum plenum temperature at minimum space load. The actual terminal capacity must meet or exceed the required plenum airflow over the full range of plenum temperatures. Refer to the 45X Underfloor Air Capacity Calculator program on the commercial marketing webpage (www.hvacpartners.com). To get to the calculator, select Carrier Commercial Marketing→Products→Airside Products→Air Terminals. Choose “45X” under the “Air Terminal Model” column, then “Documents and Downloads.” The calculator is found in the Miscellaneous section.

The 45X Underfloor Air Capacity Calculator uses specific input conditions for ceiling plenum temperature and primary air temperature to confirm that the airflow specified by the design engineers is available at the required underfloor plenum temperature.

2. The space temperature control set point for the 45XC underfloor system is ALWAYS the configured heating set point. This is the set point that the fan and primary air damper will maintain. During occupied periods, the occupied heating set point is used. The occupied cooling set point is only used to increase the plenum pressure and speed the space temperature recovery from an overtemperature condition caused by the space transitioning from unoccupied to occupied. The occupied cooling set point is NOT a temperature control set point, but rather the set point at which the control uses the maximum cooling pressure set point to increase airflow to the space. It should only be used if additional noise is acceptable in

order to expedite the space temperature recovery. The feature may be disabled by setting the maximum cooling plenum pressure set point to the same value as the minimum cooling pressure set point, or by setting the occupied space temperature set point to the maximum value.

3. The 45XC underfloor control is also equipped with unoccupied temperature set points. However, they do not function as typical unoccupied set point controls. The underfloor control always maintains the heating set point, therefore when transitioning to unoccupied operation, the unoccupied heating set point is used. If this set point is lower than the current space temperature, the fan return airflow will decrease and primary airflow will increase to lower the plenum temperature and satisfy the unoccupied heating space temperature set point while maintaining the plenum pressure set point. This causes energy consumption to increase. Conversely, if the unoccupied heating set point is raised, the primary air will be reduced while the fan speed will increase in an attempt to warm the space. Therefore, if a reduction in primary airflow is desired during unoccupied periods, then the unoccupied heating set point must be increased to the desired unoccupied space temperature set point and the unoccupied cooling set point must be set to maximum.

A more effective way to reduce energy consumption during unoccupied periods is to disable the primary airflow to the underfloor terminals via a field-supplied damper installed in the branch duct supplying the underfloor terminals or shutting down the primary air source fan. This will eliminate both the primary air consumption and will cause the underfloor terminal fan to shut down as well.

Unless two different temperature control set points are desired, the unoccupied set point should be set to the same values as the occupied set points. Underfloor controllers should have occupancy scheduled for 24 hours a day, 7 days a week (always occupied).

4. The Carrier Control Package 4840 is an underfloor plenum pressure control package that should only be used when one or two 45XC terminal discharges into an isolated or subdivided underfloor plenum (see 45XC Fan Speed and Temperature Control — For 45XC Units With Control Package 4840). When the plenum airflow requirements exceed the capability of two 45XC terminals, the 45XC terminals must be installed with a field-supplied velocity probe as shown in the Carrier Control Package 4841 (see 45XC Fan Speed and Temperature Control — For 45XC Units With Control Package 4841). This is done when multiple terminals are used to pressurize a common plenum. In this case, generally 70 to 80% of the total plenum airflow is controlled using the 4841 control package and 20 to 30% of the terminal airflow into the plenum is controlled using the 4840 package. The 4841 control package ensures that the common plenum is supplied evenly and that the airflow capability of a single terminal is not exceeded. Plenum pressure control is maintained by the terminal(s) using the 4840 control package.

NOTE: If the common plenum is large and more than one 4840 terminal is used, these should be located appropriately to ensure proper pressure control and to minimize interaction between the terminals.

The 45XC underfloor plenum control systems require the primary air source to be shut down in order to recalibrate the pressure transducers. These systems operate at extremely low pressures and must be recalibrated to provide accurate pressure and flow control. It is recommended that the primary airflow be shut down every 24 hours for

at least 30 minutes to allow recalibration. When 45XC underfloor terminals are fed primary air from a common primary air system that cannot be shut down, a twoposition branch damper MUST be installed to ensure the air can be closed off to the underfloor terminals for recalibration. This damper should be controlled to shut off the primary air to all underfloor terminals once every 24 hours, for 30 minutes, to allow recalibration. Additionally, if multiple 45XC terminals supply a common underfloor plenum, then the primary air must be shut off to these terminals simultaneously. Failure to provide a 30-minute recalibration period will result in incorrectly calibrated pressure transducers and a plenum pressure value at or near zero, eventually leading to a failure to calibrate transducer alarm.

Maintenance

MOTOR TROUBLESHOOTING — The PSC motors are equipped with long-life sleeve bearings with non-detergent SAE (Society of Automotive Engineers) 20 oil. Do not add oil to motors.

The ECM motor has permanently lubricated ball bearings

that require no maintenance.

The ECM motors are 277 v, single phase only and use a quick-connect type plug between the power source and the motor. No alternate wiring options are available.

To Check Wiring connect terminals to the capacitor (brown wire), the housing wire (green ground wire), and the control box (black wire and white wire). Verify that the fan motor wiring is correct as shown in Fig. 62-64.

To remove the fan motor and wheel:

1. Disconnect wiring at the quick-connect terminals located on the motor and the bell. Note connections.

2. The fan motor and wheel assembly is attached to the discharge panel with 4 hex nuts.

3. Remove the motor by removing the 3 screws that attach the torsion flex mounts to the inlet ring.

4. Remove wheel by unscrewing the hub set screws that are accessed through the open end of the wheel.

Refer to the fan motor wiring details shown on the wiring

diagram attached to the unit.

Failure to reconnect the fan properly can cause damage to the motor and/or serious personal injury.

FAN MOTOR MAINTENANCE — Unit motors are equipped with permanently lubricated bearings. Inspect fan and motor assembly accumulation of dust and dirt as required by operating environment. Clean as necessary.

If fan motor does not run:

1. Make sure that there is free rotation of blower wheel.

2. Remove fan packing.

3. Verify that there is no freight or installation damage.

4. Check for proper unit power.

5. Disconnects should be on, and check optional fusing.

6. Check for proper control signal, pie switch setting, proper air control 24 vac at fan contactor, and that the coil is energized.

If fan motor runs with excessive noise:

1. Make sure the blower, and all components have no clearance problems and are securely attached.

— The PSC motor is connected by quick-

2. Verify the integrity of ductwork, make sure there are no leaks or loose connections rattling diffusers or balancing dampers.

3. Confirm that the maximum cfm is not too high, or that discharge static pressure is not too low.

If fan motor runs with insufficient airflow:

1. Check for ductwork restrictions, dirty air filters, and clogged water coils.

2. Re-adjust fan speed control.

3. Discharge static pressure too high.

If repair or replacement is required:

1. Motor and fan should be removed as an assembly. Disconnect all power before servicing.

2. Remove the four hex nuts from the mounting lugs holding the fan assembly to the discharge panel, and lower the assembly.

NOTE: Do not allow assembly to hang from wiring.

3. Loosen the setscrew if removing motor from blower.

Brown to Capacitor

White #12 to Terminal Block /

Disconnect Switch

Black #12

Black #12 to SCR Controller

Green

ROTOM

132

Fig. 63 — PSC Motor Wiring Terminal Block —

208/240 V, Single Phase

Brown to Capacitor

654321

Black #12

ROTOM

White #12 to Terminal Block /

Disconnect Switch

Black #12 to

Crimp tie Wire 1 and Wire 4

Green

Fig. 62 — PSC Motor Wiring Terminal Block —

115 V, Single Phase

SCR Controller

Brown to Capacitor

White #12 to Terminal Block /

Disconnect Switch

ROTOM

421635

Green

Fig. 64 — PSC Motor Wiring Terminal Block —

277 V, Single Phase

Black #12

Black #12 to SCR Controller

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

Book 3 3 Ta b 6 a 7 a

Catalog No. 04-53450001-01 Printed in U.S.A. Form 45-4SI Pg 68 11-05 Replaces: 45-2SI

Carrier 42KC user guide manual

Specifications and Main Features

Frequently Asked Questions

User Manual