Carrier 42DH Manual
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Carrier 42DH Manual

Carrier 42DH Manual

Direct drive blower fan coils
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Installation, Start-Up, and Service Instructions
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
AHRI Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C-ETL-US Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . 3
Prepare Job Site for Unit Installation . . . . . . . . . . . . 3
Identify and Prepare Units . . . . . . . . . . . . . . . . . . . . . 3
Protect Units from Damage . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 1 - Place Unit In Position . . . . . . . . . . . . . . . . . 3
Step 2 - Install Mixing Box . . . . . . . . . . . . . . . . . . . . 7
Step 5 - Connect Ductwork . . . . . . . . . . . . . . . . . . 19
Step 6 - Make Final Preparations . . . . . . . . . . . . . 20
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cooling/Heating System . . . . . . . . . . . . . . . . . . . . . . 20
Direct Expansion (DX) Systems . . . . . . . . . . . . . . . . 21
Air Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Motor/Blower Assembly . . . . . . . . . . . . . . . . . . . . . . 21
Control Board Adjustment . . . . . . . . . . . . . . . . . . . . 21
Water Balancing System . . . . . . . . . . . . . . . . . . . . . 22
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electric Resistance Heater Assembly . . . . . . . . . . . 23
Electrical Wiring and Controls . . . . . . . . . . . . . . . . . 24
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Filters - Throwaway . . . . . . . . . . . . . . . . . . . . . . . . 24
EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1

SAFETY CONSIDERATIONS

Improper
installation,
maintenance, or use can cause explosion, fire, electrical shock or
other conditions which may cause personal injury or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory-authorized kits or accessories
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53420022-01
adjustment,
alteration,
Printed in U.S.A.
Direct Drive Blower Fan Coils
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Page
Follow all safety codes. Wear safety glasses and work gloves. Use
quenching cloths for brazing operations and have a fire
extinguisher available. Read these instructions thoroughly and
follow all warnings or cautions attached to the unit. Consult local
building codes and appropriate national electrical codes (in USA,
ANSI/NFPA70, National Electrical Code (NEC); in Canada, CSA
C22.1) for special requirements.
It is important to recognize safety information. This is the safety-
alert symbol
instructions or manuals, be alert to the potential for personal
injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices, which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could cause personal injury or
death.
Before performing service or maintenance operations on unit,
turn off main power switch to unit and install lock(s) and lock-
out tag(s). Unit may have more than one power switch.
CUT HAZARD
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing, safety glasses and gloves
when handling parts and servicing air conditioning equipment.
Equipment is initially protected under the manufacturer's standard
warranty; however, this warranty is provided under the condition
that the steps outlined in this manual for initial inspection, proper
installation, commissioning, regular periodic maintenance, and
everyday operation of the equipment be followed in detail. This
manual should be fully reviewed and understood in advance of
service,
initial installation, start-up, and any maintenance. Should any
questions arise, please contact your local Sales Representative or
the factory BEFORE proceeding.
Form 42DHV-2SI
Pg 1
42DH, DV 06-30
. When you see this symbol on the unit and in
WARNING
CAUTION
1-22
Replaces: 42DHV-1SI

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  • Page 1: Table Of Contents

    42DH, DV 06-30 Direct Drive Blower Fan Coils Installation, Start-Up, and Service Instructions when modifying this product. Refer to the individual instructions CONTENTS packaged with the kits or accessories when installing. Page Follow all safety codes. Wear safety glasses and work gloves. Use SAFETY CONSIDERATIONS .

  • Page 2: Ahri Certification

    Have a fire extinguisher readily available. Carrier’s Direct Drive Series blower coil units are listed by Intertek Testing Services (ITS). ITS’s C-ETL-US listing signifies that Carrier’s blower coil units have been examined by ITS and comply with the minimum requirements of U.S. and Canadian CAUTION national product safety standard, UL 1995/CSA C22.2 No.

  • Page 3: Pre-Installation

    Step 1 — Place Unit In Position immediately reported to the carrier and a claim filed. In the event a Install mixing box when ordered with unit. Follow mixing box in- claim for shipping damage is filed, the unit, shipping carton, and stallation instructions outlined in the next section.
  • Page 4 Minimum Recommended Drain Pan Clearance Filter Minimum Recommended Clearance 29 In. Electric Heat Elements Airflow Airflow Electric Heat Controls Fan Motor Piping Package Minimum Recommended 29 In. Clearance Fig. 3 — 42DH Horizontal Unit Installation - Recommended Clearances (Top View)
  • Page 5 Filter Piping Package 29 In. 29 In. Minimum Recommened Minimum Recommened 29 In. Clearance Clearance Minimum Recommened Clearance (*) For drain pan or coil removal, the recommended clearance should be no less than the width of the unit plus connections. Fig.
  • Page 6 2. The operating weight information is based on 8-row water-filled coils and double wall cabinet construction. For a different coil and cabinet options, use the weight adjustment table. Fig. 6 — 42DH Horizontal Unit — Weight Distribution Calculations...

  • Page 7: Step 2 - Install Mixing Box

    2. The operating weight information is based on 8-row water-filled 42DH- Horizontal Units coils and double wall cabinet construction. For a different coil and Unit is mounted flush to the outer edge of the end base rail at the cabinet options, use the weight adjustment table (Table 1).
  • Page 8 (See Fig. 11.) Detail A Detail B Fig. 12 — 42DH Horizontal Units with Mixing Box Option 42DV With 2" Filter Frame 42DV With 4" Filter Frame See Detail A...
  • Page 9 4(102) 1(25) 2.4(61) 3(76) 2.4(61) 2.4(61) 3(76) 2.4(61) 1(25) 4(102) BTM/Rear Inlet - 42DH Top/Rear Inlet - 42DH Top/Front Inlet - 42DV DIMENSIONS in. (mm) 42DH, DV UNIT SIZE 18.50 (470) 28 (711) 6 (711) 24 (610) 11 (279) 18.50 (470)

  • Page 10: Step 3 - Connect Cooling/Heating Piping

    INLET AND OUTLET DAMPERS INSTALLATION Install actuator per manufacturer's instructions. Adjust damper shafts outward to extend past any obstacles that might cause interference. Do not adjust inward end of shaft within a distance of 2 inches of bronze bushing. Position inlet damper and outlet damper to coincide with cur- rent or intended position of actuator arm, depending on actua- tor's position (opened/closed).
  • Page 11 1. Horizontal, left hand unit with re-heat coil shown. RH TELL-TALE 2. Dimensions are in inches (mm). LH TELL-TALE Fig. 18 — 42DH Hydronic Coil Piping Connection Diagram, Left Hand Unit with Reheat Coil Shown LEGEND CR - Cold Water Return CS - C...
  • Page 12 Table 2 — Hydronic Coil Piping Connections COIL ROWS 42DH/DV UNIT SIZE Cool Heat — — — — — 3-1/2 15-1/2 5-15/16 3-13/16 15-13/16 7-9/16 7-9/16 06/08 — — 6-1/8 12-3/4 — — — 3-1/2 15-1/2 9-3/16 9-3/16 8-1/8 3-13/16...
  • Page 13 1-5/8 (41) 2. Dimensions are in inches (mm). LH TELL-TALE RH TELL-TALE Fig. 20 — 42DH DX Coil Piping Connection Diagram, Left Hand Unit with Preheat Coil Shown LEGEND HR - Hot Water Return HS - Hot Water Supply LL - Liquid Line...
  • Page 14 Table 3 — DX Coil Piping Connection COIL ROWS 42DH/DV UNIT WATER DX Only SIZE PRE-HEAT — — — 2-3/4 — — 06/08 4-3/4 5-1/2 12 1/2 3-3/4 2-5/8 2-5/8 4-7/8 3-1/4 3-1/4 — — — 2-3/4 — — 10/12...
  • Page 15 7. Mixing box option will vary return duct dimensions, refer to mixing box drawing. 8. Auxiliary control box required with 3-speed EC motors and/or cabinet lighting option; not required with low voltage (0-10v) controls. Fig. 22 — 42DH Unit Submittal Drawing...
  • Page 16 10. Add 2 in. if using a prefilter or 4 in. filter. 11. Auxiliary control box required with 3-speed EC motors and/or cabinet lighting option; not required with low voltage (0-10v) controls. Fig. 23 — 42DH Unit with Mixing Box Submittal Drawing...
  • Page 17 UNIT AUX. UNIT SIDE TO RETURN DUCT BOTTOM TO SUPPLY DUCT FLANGE CTRL. DUCT UNIT FLANGE DUCT DEPTH WIDTH HEIGHT FLANGE SIZE SIZE FLANGE 9 x 6 36-1/2 8-7/8 10-7/8 15-1/8 24-1/4 4-1/2 1-7/8 2-7/8 9 x 6 36-1/2 8-7/8 10-7/8 15-1/8 24-1/4...
  • Page 18 RETURN AUX. UNIT SIDE TO UNIT BOTTOM TO SUPPLY DUCT FLANGES DUCT CTRL. UNIT UNIT DUCT FLANGE DUCT FLANGE DEPTH DEPTH WIDTH HEIGHT FLANGES SIZE SIZE 9 x 6 35-1/2 36-1/2 8-7/8 10-7/8 15-1/8 4-1/2 1-7/8 2-7/8 9 x 6 35-1/2 36-1/2 8-7/8...

  • Page 19: Step 4 - Make Electrical Connections

    LEAK TESTING each unit on a project may be different, the installer must be famil- iar with the wiring diagram and serial plate on the unit BEFORE After securing the connections, test the system for any leaks. beginning any wiring. Always test hydronic systems with water as some components are Ensure all field electrical connections are in accordance with unit not designed to be inert gas pressurized.

  • Page 20: Step 6 - Make Final Preparations

    Strainers shall be installed in the Table 4 — Filter Sizes piping mains to prevent such material from entering units during normal operation. 42DH/DV FILTER NOMINAL FILTER SIZES During system filling, air venting from the unit is accomplished...

  • Page 21: Direct Expansion (Dx) Systems

    Fig. 30 — Motor Control Board fan-system operating conditions. These procedures shall not be at- When the 42DH/DV unit is shipped from the factory with motor tempted by unqualified personnel. control board (which has High, Med and Low airflow settings), After proper system operation is established, the actual unit air de- it is pre-programmed at the factory to “High”...

  • Page 22: Water Balancing System

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

  • Page 23: Water Treatment

    — — Not Available (Applied Voltage x 1.73). Water Treatment SERVICE Proper water treatment is a specialized industry. Carrier recom- General mends consulting a water treatment expert to analyze water for Each unit has an individual operating environment and conditions compliance with water quality parameters listed below, and to rec- that dictate its maintenance schedule.

  • Page 24: Cabinet/Control Box Maintenance Light

    The units' filters are 1 in., 2 in., or 4 in. thick. Filters can be easily accessed from the side or bottom (42DH - horizontal unit) or side Cabinet/Control Box Maintenance Light and top (42DV - vertical unit) of the filter rack (see Fig.
  • Page 25 See Detail Y 2” Filter Slot Filter Support Angle Bracket 1” Filter Detail X Magnet 2” Filter Detail Y Fig. 31 — 42DH Filter Rack 2" Filter Magnets 1" Filter See Detail X See Detail Y Detail X Filter Support Angle Bracket 4"...

  • Page 26: Appendix A - Typical Wiring Diagram Examples

    APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. A — No Electric Heat, Single Phase Power with Control Board WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig.
  • Page 27 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are pro- vided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. C — Single Element Heater, Single Stage Heat, Single Phase Power with Control Board...
  • Page 28 WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. D — Two Element Heater, Single Stage Heat, Single Phase Power with Control Board...
  • Page 29 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. E — Two Element Heater, Two-Stage Heat, Single Phase Power with Control Board...
  • Page 30 WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. F — Three Element Heater, Single Stage Heat, Three Phase Power with Control Board...
  • Page 31 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. G — Six Element Heater, Single Stage Heat, Three Phase Power with Control Board...
  • Page 32 WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. H — Six Element Heater, Two Stage Heat, Three Phase Power with Control Board...
  • Page 33 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. I — Nine Element Heater, Single Stage Heat, Three Phase Power with Control Board...
  • Page 34 WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. J — Nine Element Heater, Two Stage Heat, Three Phase Power with Control Board...
  • Page 35 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. K — Nine Element Heater, Three Stage Heat, Three Phase Power with Control Board WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit!
  • Page 36 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. M — No Electric Heat, Three Phase Power without Control Board WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig.
  • Page 37 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. O — Two Element Heater, Two Stage Heat, Single Phase Power without Control Board...
  • Page 38 WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. P — Three Element Heater, Single Stage Heat, Three Phase Power without Control Board...
  • Page 39 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. Q — Six Element Heater, Single Stage Heat, Three Phase Power without Control Board...
  • Page 40 WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. R — Six Element Heater, Two Stage Heat, Three Phase Power without Control Board...
  • Page 41 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. S — Nine Element Heater, Single Stage Heat, Three Phase Power without Control Board...
  • Page 42 WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. T — Nine Element Heater, Two Stage Heat, Three Phase Power without Control Board...
  • Page 43 APPENDIX A — TYPICAL WIRING DIAGRAM EXAMPLES (cont) WARNING: Wiring diagrams are provided as an example only, ALWAYS refer to WIRING DIAGRAM attached to the unit! Fig. U — Nine Element Heater, Three Stage Heat, Three Phase Power without Control Board...
  • Page 46 © 2022 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420022-01 Printed in U.S.A. Form 42DHV-2SI Pg 46 1-22 Replaces: 42DHV-1SI...

  • Page 47: Start-Up Checklist

    THE RELIABLE OPERATION AND LONG SERVICE LIFE OF THIS EQUIPMENT CAN BE IMPROVED WITH PROPER INSTALLATION, OPERATION AND REGULAR MAINTENANCE. THE EQUIPMENT IS INITIALLY PROTECTED UNDER CARRIER’S STANDARD WARRANTY. THIS WARRANTY IS PROVIDED UNDER THE CONDITION THAT THE FOLLOWING STEPS BE FOLLOWED IN DETAIL. SHOULD ANY QUESTIONS ARISE, PLEASE CONTACT YOUR LOCAL SALES REPRESENTATIVE OR THE FACTORY BEFORE ATTEMPTING ANY INSTALLATION OR OPERATION OF THE EQUIPMENT.
  • Page 48 CLEAN COIL AND DRAIN PAN __________ CLEAN BLOWER WHEEL AS NEEDED __________ © 2022 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420022-01 Printed in U.S.A.

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42dha20776004-60-1

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