Carrier 42D Series Installation, Start-Up And Service Instructions Manual

Fan coil air conditioners

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Installation instructions manual (100 pages)

Installation and start-up instructions manual (20 pages)

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SAFETY CONSIDERATIONS

Installation of this unit can be hazardous due to electrical com-

ponents and equipment location (such as a ceiling or elevated

structure). Only trained, qualified installers and service

mechanics should install and service this equipment.

When installing this unit, observe precautions in the literature,

labels attached to the equipment, and any other safety precau-

tions that apply.

• Follow all safety codes.

• Wear safety glasses and work gloves.

• Use care in handling and installing this accessory.

WARNING

ELECTRIC SHOCK HAZARD To avoid the possibility of

electrical shock, open and tag all service switches before

installing this equipment.

INTRODUCTION

This document contains general installation instructions for

the 42C,D,S,V unit fan coils. Refer to the unit-wiring diagram

installed on the blower housing or specific manufacturer litera-

ture for any other type of factory-mounted controls.

See drawings for unit configurations, dimensions, clearances,

and pipe connections. Refer to unit wiring label for all electrical

connections; follow NEC (National Electrical Code) and local

codes.

PHYSICAL DATA

Component weight data, shipping weights, and filter data of

the 42C,D,S,V units are provided in Tables 1-4.

Pg 1

42C,D,S,V Series

12-09

Replaces: 42-2SI

Table of Contents

Summary of Contents for Carrier 42D Series

Page 1: Table Of Contents
Step 1 — Place Units in Position ....40 • 42C UNITS • 42V UNITS • 42D UNITS • 42S UNITS Step 2 — Make Piping Connections ... . . 42 •...
Page 2: Physical Data
UNIT SIZE 42C NOMINAL AIRFLOW (cfm) SHIPPING WEIGHT (lb)* 42CA 42CE 42CF 42CG 42CK COIL WATER WEIGHT (Approx lb per row of coil) 42CA, CE, CG, CK 42CF COILS Coil Face Area (sq ft)† MOTOR (qty) 42C Series BLOWER (qty) 42CA, CE, CG, CK 42CF FILTERS...
Page 3: Pre-Installation
Do not allow foreign material to fall into drain pan. Prevent dust and debris from being deposited on mo- tor and fan wheels. Manufacturer's warranty is void if foreign Table 3 — Physical Data — 42D Series Units 1000 1200...
Page 4 LEGEND 1 — Junction Box (remote mount) 2 — Flexible Metal Conduit 3 — Drain Conn, -in. OD 4 — Tell-Tale Drain Conn, -in. OD (optional) 5 — Drip Lip (optional) 6 — Hanger Slots (4), Rubber Grommet -in. Diameter Hole 7 —...
Page 5 LEGEND 1 — Junction Box (remote mount) 2 — Flexible Metal Conduit 3 — Strip Heater High Limit 4 — Electric Strip Heater Element 5 — Tell-Tale Drain Conn, -in. OD (optional) 6 — Drain Conn, -in. OD 7 — Drip Lip (optional) 8 —...
Page 6 LEGEND 1 — Junction Box, 4 in. x 4 in. 2 — Flexible Metal Conduit 3 — Mounting Bracket 4 — Drain Conn, -in. OD 5 — Tell-Tale Drain Conn, -in. OD (optional) 6 — Drip Lip (optional, shipped loose) 7 —...
Page 7 LEGEND 1 — Junction Box, 4 in. x 4 in. 2 — Flexible Metal Conduit 3 — Mounting Bracket 4 — Electric Strip Heater Element 5 — Drain Conn, -in. OD 6 — Strip Heater High Limit 7 — Tell-Tale Drain Conn, -in.
Page 8 LEGEND 1 — Junction Box, Installed with Plenum 2 — Flexible Metal Conduit 3 — Insulated Plenum 4 — Mounting Bracket 5 — Drain Conn, -in. OD 6 — Tell-Tale Drain Conn, -in. OD (optional) 7 — Drip Lip (optional, shipped loose) 8 —...
Page 9 LEGEND 1 — Junction Box, Installed with Plenum 2 — Plenum 3 — Flexible Metal Conduit 4 — Mounting Bracket 5 — Electric Strip Heater Element 6 — Drain Conn, -in. OD 7 — Drip Lip (optional, shipped loose) 8 — Tell-Tale Drain Conn, -in.
Page 10 LEGEND 1 — Junction Box, 4 in. x 4 in. 2 — Optional Return Air Location 3 — Optional Drip Lip, shipped loose 4 — Mounting Holes (4), Rubber Grommets have -in. Diameter Hole 5 — Electrical KO, -in. Diameter 6 —...
Page 11 LEGEND 1 — Junction Box, 4 in. x 4 in. 2 — Optional Stamped Rear Return Grille 3 — Optional Drip Lip, shipped loose 4 — Electric Strip Heater Element 5 — Mounting Holes (4), Rubber Grommets have -in. Diameter Hole 6 —...
Page 12 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Internal factory valve package and drains may not align with cabinet knockouts. 3. Dimensions shown in inches (mm). All dimensions are ± 4. Bottom panel is Arctic White polyester powder coat paint. UNIT AIRFLOW SIZE...
Page 13 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Internal factory valve package and drains may not align with cabinet knockouts. 3. Dimensions shown in inches (mm). All dimensions are ± 4. Bottom panel is Arctic White polyester powder coat paint. UNIT AIRFLOW SIZE...
Page 14 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Internal factory valve package and drains may not align with cabinet knockouts. 3. Dimensions shown in inches (mm). All dimensions are ± 4. Bottom panel is Arctic White polyester powder coat paint. UNIT AIRFLOW SIZE...
Page 15 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Internal factory valve package and drains may not align with cabinet knockouts. 3. Dimensions shown in inches (mm). All dimensions are ± 4. Bottom panel is Arctic White polyester powder coat paint. UNIT AIRFLOW SIZE...
Page 16 LEGEND 1 — Junction Box, 4 in. x 4 in. 2 — Optional Drip Lip, shipped loose 3 — Mounting Holes (4), Rubber Grommets have -in. Diameter Hole 4 — Piping KO, 1 -in. Diameter 5 — Electrical KO, -in. Diameter 6 —...
Page 17 LEGEND 1 — Junction Box, 4 in. x 4 in. 2 — Strip Heater High Limit 3 — Electric Strip Heater Element 4 — Optional Drip Lip, shipped loose 5 — Mounting Holes (4), Rubber Grommets have -in. Diameter Hole 6 —...
Page 18 LEGEND 1 — Optional Unit Mounted Control Box 2 — Wall Mounting Holes (4), -in. Diameter 3 — Drain, -in. MPT 4 — Drain Pan, Auxiliary, Shipped Loose 5 — Supply Conn, -in. OD 6 — Return Conn, -in. OD 7 —...
Page 19 LEGEND 1 — Standard Stamped Supply Grille 2 — Access Door, Fan Switch 3 — Supply Conn, -in. OD 4 — Return Conn, -in. OD 5 — Drain, -in. MPT 6 — Filter 7 — Air Vent, -in. MPT 8 — Front Panel Fastener 9 —...
Page 20 LEGEND 1 — Standard Stamped Supply Grille 2 — Access Door, Fan Switch 3 — Supply Conn, -in. OD 4 — Return Conn, -in. OD 5 — Drain, -in. MPT 6 — Filter 7 — Air Vent, -in. MPT 8 — Front Panel Fastener 9 —...
Page 21 LEGEND 1 — Optional Unit Mounted Control Box 2 — Drain Pan, Auxiliary, Shipped Loose 3 — Supply Conn, -in. OD 4 — Drain, -in. MPT 5 — Return Conn, -in. OD 6 — Air Vent, -in. MPT 7 — Discharge Opening 8 —...
Page 22 LEGEND 1 — Unit-Mounted Control Box (Optional) 2 — Drain Pan, Auxiliary, Shipped Loose 3 — Air Vent, -in. MPT 4 — Supply Conn, -in. OD 5 — Drain, -in. MPT 6 — Return Conn, -in. OD 7 — Filter 8 —...
Page 23 LEGEND 1 — Fan Switch, 3-Speed, behind Access Door 2 — Front Panel Fastener 3 — Stamped Supply Grille 4 — Supply Conn, -in. OD 5 — Return Conn, -in. OD 6 — Stamped Return Grille 7 — Filter 8 — Air Vent, -in.
Page 24 LEGEND 1 — Fan Switch, 3-Speed, behind Access Door 2 — Electrical Sheath Heater Element 3 — Stamped Supply Grille 4 — Supply Conn, -in. OD 5 — Return Conn, -in. OD 6 — Stamped Return Grille 7 — Filter 8 —...
Page 25 LEGEND 1 — Supply Conn, -in. OD 2 — Air Vent, -in. MPT 3 — Filter 4 — Return Air Grille, Stamped 5 — Stamped Supply Grille 6 — Return Conn, -in. OD 7 — Removable Front Panel 8 — Drain Conn, -in.
Page 26 DIMENSIONS (in. ± UNIT AIRFLOW SIZE A’ (cfm) 1000 1200 1400 1600 1800 2000 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ± 2.
Page 27 DIMENSIONS (in. ± UNIT AIRFLOW SIZE A’ D’ (cfm) 1000 1200 1400 1600 1800 2000 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ± 2.
Page 28: Filters
8. Units with internal factory valve packages have external connections located in triangular section above coil. 9. Consult Carrier for ducted front return air and external filter rack with 1-in. duct collar and throwaway filters. 10. Units with electric heat require additional access on the side of unit for servicing contactor box.
Page 29 DIMENSIONS (in. ± UNIT AIRFLOW SIZE (cfm) 1000 1200 1400 1600 1800 2000 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. NOTES: 1. Right hand unit shown; left hand unit opposite. 2.
Page 30 DIMENSIONS (in. ± UNIT AIRFLOW SIZE (cfm) 1000 1200 1400 1600 1800 2000 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. NOTES: 1. Right hand unit shown; left hand unit opposite. 2.
Page 31 LEGEND CR — Cold Water Return CS — Cold Water Supply — Drain HR — Hot Water Return HS — Hot Water Supply — Return — Supply ITEM DESCRIPTION Electrical Knockouts 3-in. Expanded Section Strip Heater (Optional) Limit Switch**†† (Optional) -in.
Page 32 LEGEND CR — Cold Water Return CS — Cold Water Supply — Drain HR — Hot Water Return HS — Hot Water Supply — Return — Supply ITEM DESCRIPTION Full Riser Chase Electrical Knockouts 3-in. Expansion Section Strip Heater (Optional) Limit Switch**††...
Page 33 LEGEND CR — Cold Water Return CS — Cold Water Supply D — Drain HR — Hot Water Return HS — Hot Water Supply R — Return S — Supply ITEM DESCRIPTION Electrical Knockouts Gypsum Board, -in. Type “X” 3-in. Expanded Section Strip Heater**(Optional) Limit Switch**††...
Page 34 LEGEND CR — Cold Water Return CS — Cold Water Supply D — Drain HR — Hot Water Return HS — Hot Water Supply R — Return S — Supply ITEM DESCRIPTION Electrical Knockouts 3-in. Expanded Section Strip Heater** (Optional) Limit Switch**††...
Page 35 LEGEND CR — Cold Water Return CS — Cold Water Supply D — Drain HR — Hot Water Return HS — Hot Water Supply R — Return S — Supply ITEM DESCRIPTION Electrical Knockouts Strip Heater** (Optional) Limit Switch**†† (Optional) -in.
Page 36 Item Description Float Switch (Optional) Drain Pan Flexible Drain Tube/P-Trap 1 each Drain Knockout (3 Sides) side Blower Riser Knockouts (3 Sides) 1/2 in. Flare Adaptor (SWT x 37.5) Coil, 1/2 in. OD Copper Tube 1 in. Throwaway Filter (Factory Installed) Manual Air Vent Return Air Opening Knockout (For Optional Thermostat...
Page 37 (76) (76) 3-5/8 3-5/8 (92) 1-1/4 (92) (32) CR CS (1600) LEGEND — Cold Water Return — Cold Water Supply — Drain — Hot Water Return — Hot Water Supply PSC — Permanent Split Capacitor SWT — Sweat NOTES: 1. Units are fabricated of 18-gage galvanized steel with a 16-gage galvanized fan deck. 2.
Page 38 PANEL DIMENSIONS (in.) PANEL NO. UNIT SIZE 03, 04 15.5 06, 08 19.5 10, 12 23.5 03, 04 15.5 06, 08 19.5 10, 12 23.5 03, 04 15.2 06, 08 19.2 10, 12 23.2 03, 04 15.5 06, 08 19.5 10, 12 23.5 03, 04...
Page 39 PANEL AND FRAME DIMENSIONS (in.) PANEL NO. UNIT SIZE 03, 04 15.1 06, 08 19.1 10, 12 23.1 03, 04 15.1 06, 08 19.1 10, 12 23.1 03, 04 15.1 06, 08 19.1 10, 12 23.1 NOTE: Dimensions in inches. A42-4168 54.7 PANEL NO.
Page 40: Installation
NOTE: For any unit without a return-air duct connection, applicable installation codes may limit unit to installation in single story residence only. 42D UNITS 1. Select the unit location. Allow adequate space for free air circulation, service clearances, piping and electrical con- nections, and any necessary ductwork.
Page 41: 42S Units
42S UNITS — A factory tag is on top of each unit. Tag states riser tier number, floor, room number if furnished and supply- air arrangement. Check unit for any other labels that apply to installation. Remove unit from pallet and take directly to assigned space for installation.
Page 42: Step 2 - Make Piping Connections
h. After all drywalling and painting is complete, install thermostats, supply air grilles and return air panels. 7. Attach unit risers: CAUTION Toxic residues and loose particles resulting from manufac- turing and field piping techniques such as joint compounds, soldering flux, and metal shavings may be present in the unit and the piping system.
Page 43: Valve Packages
Fig. 40 — Unit End Reference NOTE: Chilled water piping determines the hand of the unit. SAME END CONNECTION Valve Packages For 2-Pipe Systems — Valve packages for standard 2-pipe units are piped for same end connection (L.H. or R.H.). Valve Packages for 4-Pipe Systems —...
Page 44: Connections
Hydronic Coil Arrangement Field Piping Connections* VERTICAL FLOOR UNITS — 42VB, VE, VF Pipe into cabinet end compartment (opening in bottom and back). VERTICAL FLOOR UNITS — 42VA, VC Pipe to external connections (no cabinet). CEILING UNITS (EXPOSED) — 42CG, CK, DE, DF Pipe through knock-outs in rear of cabinet to coil and valve package connections.
Page 45: Piping
Coil Connections (Positions A & B) — When isolation valve only is added to supply or return line, the isolation valve will be factory brazed to the coil stub-out. Addition of any other component or connection to the supply or return line will change the respective coil connection(s).
Page 46: Valve Packages
The 2-way motorized valve motor drives valve open and a spring returns valve to normally closed position (no water flow with unit OFF). Supply connection at coil will be swage fit for field braze (standard) or union (option). Return connection at coil will be factory brazed if isolation valve only.
Page 47: Connections
On the 3-way motorized valve flow is normally closed to coil and open to system return. Motor closes bypass flow to sys- tem return while opening flow through coil. Water bypasses coil and flows directly to system return when unit is OFF. The aquastat (A) clips on supply line upstream from 3-way valve (as shown above).
Page 48 When isolation valves only are specified, they will be brazed to the coil stub-outs. Check job specifications for system pressure, pressure drop limitations and flow rate prior to selecting specific compo- nents or valve package size ( in., 2-PIPE SYSTEM ONLY (One Valve Package) Application: •...
Page 49: Valve Packages
Vent all coils at this time. Check interior unit piping for signs of leakage from shipping damage or mishandling. If leaks are found, notify a Carrier representative before initiating any repairs. Release trapped air from system (refer to Make Final Preparations section).
Page 50: Piping
SYMBOL/SKETCH MANUAL AIR VENT: Threaded brass needle valve with screwdriver slot for adjustment. Application — Body brazed into high point of heating and cooling coils for bleeding air from coil. Standard item on all hydronic coils (not used on steam or DX coils). Should not be used in lieu of main system air vents.
Page 51: Piping
SYMBOL/SKETCH PRESSURE TEST PORT: Brass body service access fitting with removable depres- sor type core. Application — Installed on both sides of the coil to allow for pressure sensing. Attach pressure gages to facilitate close tolerance water balancing. GAGE COCK: Brass shut-off valve with in.
Page 52: Piping
SYMBOL/SKETCH STRAINER: Y-type body with 50 mesh stain- less steel screen. Application — Used for removal of small parti- cles from system water during normal system operation. Should not be used in lieu of main system strainers. Strainer screen may have to be removed during initial high pressure sys- tem flushing during start-up.
Page 53: Valve Packages
SYMBOL/SKETCH 2-WAY MOTORIZED VALVE: Electric 2-position flow control valve (open/closed). Normally closed body with manual override lever. Installed in supply line to unit. Application — All standard control and valve pack- ages are based upon normally closed valves (valve electrically powered open and closed by spring return when electric power removed).
Page 54: Piping
IMPORTANT: THE ABOVE CHART IS FOR REFERENCE ONLY. Check all system component pressure ratings (coils, valves, pumps, etc.) and any applicable local or national piping codes prior to specifying system pressure rating. 50-50 Lead-Tin at 200 F 50-50 Lead-Tin at 150 F 50-50 Lead-Tin at 100 F NOTES: 1.
Page 55: Step 3 - Make Electrical Connections
Step 3 — Make Electrical Connections — to unit nameplate for required supply voltage, fan and heater amperage and required circuit ampacity. Refer to unit wire dia- gram for unit and field wiring. Make sure all electrical connec- tions are in accordance with unit wiring diagram and all appli- cable codes.
Page 56 Thermostatic Fan Control, 2-Pipe Systems — The thermo- stat cycles the fan on and off from any selected speed setting to maintain selected room temperature. Controls can be wired for heating-only, cooling-only or for heating/cooling by the addi- tion of an automatic changeover device that senses water tem- perature and changes the action of the thermostat as required.
Page 57 BLOWER H BLK MOTOR *WHT L2 or N EQUIPMENT GROUND Fig. 54 — 42C,S,V and 42D (600-1000) 2-Pipe Heating and Cooling with Automatic Changeover — Remote/Wall-Mounted Thermostat (Line Voltage) THERMOSTAT PART # 702893-36 *WHT a42-4060 NEC CLASS 1 WIRING RISE...
Page 58 Fig. 55 — 42SG,SH,SJ,VA,VB,VF 2-Pipe Heating and Cooling with Automatic Changeover — ® Unit-Mounted Debonair Thermostat (24-v), Duct Sensor a42-4061 NEC CLASS 2 WIRING Fig. 56 — 42C,S,V (except VG), and 42D (600-1000 cfm) 2-Pipe Heating and Cooling with ® Automatic Changeover — Remote/Wall-Mounted Debonair Thermostat (24-v)
Page 59 Thermostatic 2-Pipe Auxiliary Electric Heat with Valve Control — This system, also called twilight or intermediate season electric heat, goes a long way towards solving the spring and fall control problems of 2-pipe systems. Chilled water can be run late into the fall, turned on early in the spring and heat will still be available to all units whenever required.
Page 60 *WHT EQUIPMENT GROUND L2 or N LIMIT SWITCH Fig. 58 — 42C,S,V (except VG), and 42D (600-1000 cfm) 2-Pipe Heating and Cooling with Auxiliary Heat — Remote/Wall-Mounted Thermostat (Line Voltage) and Dual Power Source DUCT SENSOR 33CSSEN-DS VALVE TRANSFORMER EQUIPMENT...
Page 61 NEC CLASS 2 WIRING Fig. 60 — 42C,S,V (except VG), and 42D (600-1000 cfm) 2-Pipe Heating and Cooling with Auxiliary Heat — Remote/Wall-Mounted Debonair Thermostat 2-Pipe Total Electric Heat with Valve Con- trol — With this system, the complete heating requirement for the space is provided by the electric heater;...
Page 62 NEC CLASS 1 WIRING Fig. 61 — 42SG,SH,SJ,VA,VB,VC,VE,VF 2-Pipe Cooling with Total Electric Heat — Unit-Mounted Thermostat (Line Voltage) Fig. 62 — 42C,S,V (except VG), and 42D (600-1000 cfm) 2-Pipe Cooling with Total Electric Heat — Remote/Wall-Mounted Thermostat (Line Voltage)
Page 63 WHT/RED EQUIPMENT GROUND *WHT L2 or N EQUIPMENT GROUND Fig. 64 — 42C,S,V (except VG), and 42D (600-1000 cfm) 2-Pipe Cooling with Total Electric Heat — Remote/Wall-Mounted Debonair a42-4072 ® Thermostat (24-v) and Duct Sensor THERMOSTAT #33CSSN2-FC RS+5 H2O CK1...
Page 64 Thermostatic Valve Control, 4-Pipe — The 4-pipe system provides the ultimate in economy and room temperature con- trol. Both hot water and chilled water are available at any time. Normally an automatic changeover thermostat is used, but a manual changeover thermostat is also suitable. Two 2-way valves, two 3-way valves, or one 2-way plus one 3-way valve must be selected.
Page 65 ONLY 120V WHT/ALL OTHERS BLK Fig. 66 — 42C,S,V (except VG), and 42D (600-1000 cfm) 4-Pipe Heating and Cooling — Remote/Wall-Mounted Thermostat (Line Voltage) a42-4078 Fig. 67 — 42SG,SH,SJ,VA,VB,VC,VE,VF 4-Pipe Heating and Cooling — ® Unit-Mounted Debonair Thermostat (24-v) and Duct Sensor...
Page 66: Step 4 - Make Duct Connections
HEAT EQUIPMENT GROUND L2 or N Fig. 68 — 42C,S,V (except VG), and 42D (600-1000 cfm) 4-Pipe Heating and Cooling — Remote/Wall-Mounted Debonair Step 4 — Make Duct Connections — ductwork to and from unit in accordance with all applicable codes.
Page 67: Step 6 - Cut Out Openings For Grilles And
Step 6 — Cut out Openings for Grilles and On all units with optional supply-air or Thermostats — return-air grilles, dampers, thermostats, and switch plates, cut out openings where specified on the job plans. Be careful not to cut wires, piping or structural supports. For remote-mounted thermostats use a steel thermostat shield ring to protect drywall from thermostat wiring where applicable.
Page 68: Clean Fan Wheel
Standard motors are permanently sealed and lubricated. No lubrication is required unless special motors have been supplied or unusual operating conditions exist. Lock open and tag unit electrical Clean Fan Wheel — service switch. For access to fan assembly, remove front or bottom panel. Fan assembly may be removed from its tracks if unit has a long conduit lead.
Page 70 Copyright 2009 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420004-01 Printed in U.S.A. Form 42-3SI Pg 70 12-09 Replaces: 42-2SI...
Page 71: Start-Up Checklist For 42C,D,S,V Series Fan Coil Air Conditioners
START-UP CHECKLIST FOR 42C,D,S,V SERIES FAN COIL AIR CONDITIONERS I. Project Information Job Name _______________________________________________________________________ Address ________________________________________________________________________ City ______________________________________________State __________ Zip __________ Installing Contractor _______________________________________________________________ Sales Office _____________________________________________________________________ Start-up Performed By _____________________________________________________________ INSPECTION, INSTALLATION, AND START-UP CHECKLIST ITEM Receiving & Inspection 1.
Page 72 Copyright 2009 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420004-01 Printed in U.S.A. Form 42-3SI CL-2 12-09 Replaces: 42-2SI...

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Carrier 42D Series Installation, Start-Up And Service Instructions Manual

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SAFETY CONSIDERATIONS

INTRODUCTION

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Summary of Contents for Carrier 42D Series

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