Carrier 42S Series Instruction Manual
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Carrier 42S Series Instruction Manual

Stack model fan coil air conditioners
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Installation, Start-Up and Service
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PRE-INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unpack and Inspect Units . . . . . . . . . . . . . . . . . . . . . 2
Unit Protection from Damage . . . . . . . . . . . . . . . . . . 2
Prepare Jobsite for Unit Installation . . . . . . . . . . . . . 3
Identify and Prepare Units . . . . . . . . . . . . . . . . . . . . . 3
Unit Clearance and Service Access . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Step 1 - Place Units in Position . . . . . . . . . . . . . . . 17
Step 3 - Make Duct Connections . . . . . . . . . . . . . 26
Step 4 - Frame and Finish Unit . . . . . . . . . . . . . . . 26
Step 6 - Make Final Preparations . . . . . . . . . . . . . 27
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
COOLING/HEATING SYSTEM . . . . . . . . . . . . . . . . . 29
Direct Expansion (DX) Systems . . . . . . . . . . . . . . . . 29
Air System Balancing . . . . . . . . . . . . . . . . . . . . . . . . 29
Water System Balancing . . . . . . . . . . . . . . . . . . . . . 29
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Controls Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Excessive Condensation on Unit . . . . . . . . . . . . . . 30
To Clean Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Check Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fan Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 30
Motor/Blower Assembly . . . . . . . . . . . . . . . . . . . . . . 30
Clean Fan Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electric Resistance Heater Assembly . . . . . . . . . . . 31
Electrical Wiring and Controls . . . . . . . . . . . . . . . . . 31
Valves and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53420024-01
Instructions
Page
Printed in U.S.A.
Form 42S-5SI
Fan Coil Air Conditioners
Filters, Throwaway . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Filters, Permanent . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
• VARIABLE AIRFLOW FOR 0-10VDC
• ECM VARIABLE AIRFLOW FOR 0-10VDC
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
APPENDIX D-EVO/ECM 4-SPEED
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
IMPORTANT: Children should be supervised to ensure that
they do not play with appliance.

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components. Only
trained and qualified service personnel should install, repair, or
service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of
cleaning coils and filters and replacing filters. All other operations
should be performed by trained service personnel. When working
on air-conditioning equipment, observe precautions in the
literature, tags and labels attached to the unit, and other safety
precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves. Use
quenching cloth for unbrazing operations. Have fire extinguisher
available for all brazing operations.
It is important to recognize safety information. This is the safety-
alert symbol
. When you see this symbol on the unit and in
instructions or manuals, be alert to the potential for personal
injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices, which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
Pg 1
42S Series
Stack Model
9-22
Replaces: 42S-4SI

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Summary of Contents for Carrier 42S Series

  • Page 1: Table Of Contents

    Step 1 — Place Units in Position ....17 START-UP CHECKLIST FOR 42S SERIES FAN COIL AIR CONDITIONERS ......CL-1 •...

  • Page 2: Introduction

    Any hidden damage should be re- connu dans l’État de Californie pour causer corded and immediately reported to the carrier and a claim should le cancer et des malformations congénitales ou d’autres problèmes de reproduction. Pour be filed.

  • Page 3: Prepare Jobsite For Unit Installation

    or piping during handling. Never use the risers to lift the unit. Al- unit. However, the risers should be moved as little as possible to so, depending on the options and accessories, some units could avoid damage to the unit and internal components. contain delicate components that may be damaged by improper On certain units, shipping screws or braces must be removed after handling.
  • Page 4 Table 1 — Physical Data — 42S Series Units UNIT SIZE 42S NOMINAL AIRFLOW (cfm) 1000 1200 1400 1600 2000 SHIPPING WEIGHT (lb) 42SGA,SGM,SU — — — 42SH — — — 42SJ — — — 42SGS — — — 42SM —...
  • Page 5 6-5/8 6-5/8 1-1/4 [168] [76] [76] [168] [32] Control Box Option with E Heat [25] Note 7 Side panel removed for clarity. 3.00 [76.2] [229] [1599] [2233] ITEM DESCRIPTION [1372] Supply Opening [991] Duct Colar 1/2 [13] Ext (Typ) RA Acoustical Service Panel Riser, Supply and Return 3-1/2 Riser, Drain...
  • Page 6 Unit Width Riser Chase Depth (All model sizes) Risers 5-1/2 [141] Unit Depth Riser Chase Stack Unit Unit Height Fig. 4 — Riser Chase...
  • Page 7 6-5/8 6-5/8 [76] [168] [76] [168] 2-1/2 [64] Control Box Option with E Heat [127] 3.00 [76.2] NOTE 7 Side panel dimmed for clarity. [2235] [229] 1-1/2 [991] [38] 3-1/2 [88.9] [127] 4-Pipe panel shown. ITEM DESCRIPTION Tail D.D Steel Grille Assy Piece LEGEND Filter, Throwaway, 1 [25]...
  • Page 8 1 [25] 6-5/8 [168] 6-5/8 [168] [76] 6-1/4 [159] [76] [76] [27] [1599] [2233] 3.00 [76.2] Side panel dimmed for clarity. [229] Note 7 [1372] [991] 1-1/2 [38] See Note 13 3-1/2 [127] [127] [88.9] Tail 4-Pipe panel shown. Piece NOTE: Risers removed for clarity.
  • Page 9 6-5/8 6-5/8 1-1/4 [158] [76] [76] [168] [32] Control Box Option with E Heat [25] Note 7 Side panel removed for clarity. 3.00 [76.2] LEGEND CR— Cold Water Return [229] [1599] CS — Cold Water Supply [2233] D — Drain [1372] HR—...
  • Page 10 6-5/8 6-5/8 1-1/4 [76] [76] [168] [168] [32] Control Box Option with E Heat [25] Side panel removed for clarity. LEGEND 3.00 [76.2] CR— Cold Water Return CS — Cold Water Supply [229] D — Drain [1599] [2233] HR— Hot Water Return [1372] HS —...
  • Page 11 6-5/8 6-5/8 1-1/8 [76] [76] [168] [168] [27] Control Box Option with E Heat [25] 3.00 Side panel dimmed for clarity. [76.2] [1289] [2233] NOTE 7 [1598] [228] [991] 1-1/2 [38] [127] ITEM DESCRIPTION 3-1/2 4-Pipe panel shown. [126] Tail [88.9] Supply KO’s Top/Sides Piece...
  • Page 12 6-5/8 6/5-8 1-1/8 [168] [168] [76] [76] [27] Control Box Option with E Heat [25] 3.00 [76.2] [2233] [1289] Side panel dimmed for clarity. [1598] Note 7 [288] LEGEND CR— Cold Water Return CS — Cold Water Supply D — Drain HR—...
  • Page 13 6-5/8 6-5/8 [76] [76] [168] [168] [26] [279] Control Box Option with E Heat 24 [610] [76] 3.00 [76.2] [229] [1674] [991] 3-1/2 1-1/2 [88.9] [38] [127] 4-Pipe panel shown. NOTE: Risers removed for clarity. Standard heights and widths 28 [710] 24 [611] shown for riser penetration.
  • Page 14 1-1/4 [32] [279] [610] 3 [76] 3 [76] [610] 1-1/4 [32] 1-1/4 [32] [406] [406] [559] [559] [102] [102] [25] [25] [559] [762] [610] FRONT RIGHT NOTES: 1. Plenum box adds 22 in. (559 mm) to unit height, adds 26 lb (11.8 kg) to unit weight, and is factory installed.
  • Page 15 Panel and Frame Dimensions (in.) PANEL UNIT SIZE 03, 04 15.5 42SG,SJ, SU 06, 08 19.5 10, 12 23.5 42SM 14,16,20 29.5 03, 04 15.5 42SG,SJ 06, 08 19.5 10, 12 23.5 03, 04 15.2 42SG,SJ 06, 08 19.2 10, 12 23.2 61.1 55.5...
  • Page 16 Panel and Frame Dimensions (in.) PANEL UNIT UNIT SIZE 03, 04 15.1 42SG,SJ, SU 06, 08 19.1 10, 12 23.1 03, 04 15.1 42SG,SJ 06, 08 19.1 10, 12 23.1 03, 04 16.7 42SG,SJ 06, 08 20.7 10, 12 24.7 54.7 NOTE(S): a.

  • Page 17: Installation

    information. Figure 15 shows the 42SJ unit with standard risers INSTALLATION and with Siamese risers. Step 1 — Place Units in Position a. Lay out the control lines for the drywall track and studs A factory tag is on top of each unit. The tag states riser tier num- in the floor and ceiling (see Fig.
  • Page 18 NOTE: The studs may be mechanically fastened to the 42SJ fan a. Each riser has a 3 in. swaged portion at top and sufficient coil. Care should be taken, however, not to penetrate the supply or extension at bottom for an inserted length of approxi- return water risers or internal piping.

  • Page 19: 42Sua Universal Stack Arrangement

    air pressure in the riser. Pressure testing risers with water Unit orientation is determined based on the location of the risers in the building. The riser side of the universal stack unit always de- should be done with the unit service valves closed to prevent termines the rear of the unit.
  • Page 20 SIDE VIEW Drain Insulation Supply and Return Cut Line Insulation Cutline Side Supply Air Knockout (1 per side) Fig. 22 — 42SUA Unit Knockout Insulation Removal Optional Electrical CAUTION Knockouts Toxic residues and loose particles resulting from manufactur- ing and field piping techniques such as joint compounds, sol- dering flux, and metal shavings may be present in the unit and Riser Knockouts Return...
  • Page 21 Before anchoring the equipment in place, the unit must be leveled and the cabinet must be plumb and squared. The unit Unit Insulation Unit Wall may be anchored in place by bolting directly through the unit Riser Knockout Drain Pan floor or attaching to the cabinet in some location that will not interfere with drywall or other items such as the supply grille, thermostat, or return access panel.

  • Page 22: 42Sma Furred-In Mega Units

    prevent sweating and must be protected from wear or erosion at All installations should be made in compliance with all governing the joint between the insulation and the fireproofing material. codes and ordinances. Compliance with all codes is the responsi- bility of the installing contractor.
  • Page 23 Riser to Unit Installation connections on each end. The hose kits allow for riser fluctu- ations due to thermal expansion. Proper riser installation and vertical positioning in the unit pro- vides for a unit piping run-out to the service valves which are cen- Use a wrench to tighten the swivel connections.
  • Page 24 12. Test for leaks. Any and all leaks should be repaired before Repeat for all supply air tabs until all have been broken. proceeding with installation. When testing with air or some Discard center knockout piece. Be careful of sharp edges. other gas, it might be necessary to tighten stem packing nuts Use a sharp retractable knife to trim any excess insulation on some valves to maintain air pressure in the riser.

  • Page 25: Step 2 - Make Electrical Connections

    If the valve package is field-supplied, the aquastat must be installed in a location where it will sense the water temperature Duct Flange regardless of control valve position. A bleed bypass should be pro- vided for proper operation of aquastat. The bleed line allows a small amount of water to flow from supply to return piping when 90°...

  • Page 26: Step 3 - Make Duct Connections

    Thermostat 2-Pipe Total Electric Heat with Valve Control Step 4 — Frame and Finish Unit With this system, the complete heating requirement for the space Models 42SG, SH, SJ, SU and SM have factory enclosures and is provided by the electric heater; the water system is never may be finished with normally accepted wall covering.

  • Page 27: Step 6 - Make Final Preparations

    This prevents Carrier’s convention is to preset and wire Flo1 for high speed, foreign matter from entering the unit and clogging the Flo2 for medium, and Flo3 for low.

  • Page 28: Start-Up

    If a factory provided thermostat or DDC controller is utilized, then ture’s warranties. the unit is already correctly configured. Carrier recommends using Maximum operating altitude for units is 13,400 ft (4 km). All units the specified thermostat or DDC controller to commission the unit are IPX0 rated.

  • Page 29: Cooling/Heating System

    Anti-freeze solutions may also be used to lower the freezing point. IMPORTANT: Should the evaporator freeze due to inadequate Carrier water coil tubes and headers are constructed of pure cop- airflow for any reason, damage may occur to adjacent water or per.

  • Page 30: Controls Operation

    Other methods of control that avoid condensation problems are as Table 3 — Water Quality Parameters follows: Continuous fan operation with motorized chilled water valve WATER CONTAINING REQUIRED CONCENTRATION controlled by a thermostat. Sulphate Less than 200 ppm Continuous fan operation with thermostat control to switch 7.0 to 8.5 fan from high to low speed (instead of off).

  • Page 31: Electric Resistance Heater Assembly

    Electric Resistance Heater Assembly Filters, Permanent Electric resistance heaters typically require no normal periodic A maintenance schedule for permanent filters should be devel- maintenance when unit air filters are changed properly. The opera- oped in the same manner as throwaway filters. tion and service life may be affected by other conditions and Unlike throwaway filters, permanent filters may be cleaned and equipment in the system.

  • Page 32: Appendix A - Block-Out Construction

    APPENDIX A — BLOCK-OUT CONSTRUCTION This section provides rough guidelines for the block-out slot size Table B — Short 79 in. Cabinet, 2-pipe Units a,b,c,d for 42S units with risers included. Therefore, the floor block-out slot dimensions listed in this document should be considered esti- BLOCK-OUT CONSTRUCTION SIZE mates.
  • Page 33 APPENDIX A — BLOCK-OUT CONSTRUCTION (CONT) Table C — Standard 88 in. Cabinet Table D — Short 79 in. Cabinet (4-Pipe 42S Units) (4-Pipe 42S Units) a,b,c,d a,b,c,d BLOCK-OUT CONSTRUCTION SIZE BLOCK-OUT CONSTRUCTION SIZE TYPE OF INSTALLATION TYPE OF INSTALLATION TYPE 1 TYPE 2 TYPE 3...
  • Page 34 APPENDIX A — BLOCK-OUT CONSTRUCTION (CONT) Block-out Width Block-out Length Unit Riser Column Floor Penetration (Block-out) Standard 42SJ Floor Riser Length* Clear Height Floor To Floor Unit Siamese 42SJ Floor Slab Thickness NOTE: Riser Length = Floor-to-floor dimensions ± 2 in. (maximum riser length of 115 in.

  • Page 35: Appendix B - Potentiometer

    Failure to tion. Open the low speed relay. follow safety rules could result in electrical shock or hazard. NOTE: For specific voltages adjustment contact a Carrier repre- sentative. CAUTION Both of the procedures described below require the control box to be powered while adjustments are made.

  • Page 36: Adjustment

    Electric Heat OFF Power connector for 24V or Common-powered sensors d. Power to controller remains ON a. 24V Powered Sensors are applicable for Carrier-sup- BAS LED indication when BAS relay circuit activated. plied air sensor. b. Common-powered Sensors are applicable for thermo- stats by others.
  • Page 37 APPENDIX C — CONTROLS OPERATION (CONT) NOTE: Image depicts thermostat wired to control board. Fig. E — Mounted Thermostat Connection and Controls Fig. F — Thermostat Control Board (By Others or Remote Mounted) Table F — 0-10 Variable Airflow ECM Table E —...

  • Page 38: Adjustment

    VARIABLE AIRFLOW FOR 0-10VDC CN8 – INCOMING POWER If a factory provided thermostat or DDC controller is utilized, then the unit is already correctly configured. Carrier recommends using CN9 – PSC MOTOR the specified thermostat or DDC controller to commission the unit 3-Speed application whenever possible.
  • Page 39 APPENDIX C — CONTROLS OPERATION (CONT) Table G — LED Function and Outcomes (Sequence of Operation) ITEM DESCRIPTION OUTCOME OVF LED Shows Red Motor OFF Condensate Overflow Condensate switch is tripped by increasing water level in the drain pan. Actuator OFF Switch (OVF) Electric Heat Off Power to controller remains ON...
  • Page 40 APPENDIX C — CONTROLS OPERATION (CONT) Fig. H — Typical Wiring Diagram...
  • Page 41 For setting of Flo0 and Flo4, contact Carrier, otherwise these Attach the red (positive) lead of the meter to the high speed potentiometers should be set to full counter-clockwise “Flo1”...
  • Page 42 @ 2022 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420024-01 Printed in U.S.A. Form 42S-5SI Pg 42 9-22 Replaces: 42S-4SI...

  • Page 43: Start-Up Checklist For 42S Series Fan Coil Air Conditioners

    START-UP CHECKLIST FOR 42S SERIES FAN COIL AIR CONDITIONERS NOTE: To avoid injury to personnel and damage to equipment or prop- erty when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preceding sections of this Installation, Start-Up, and Service Instructions document.
  • Page 44 @ 2022 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420024-01 Printed in U.S.A. Form 42S-5SI Pg CL-2 9-22 Replaces: 42S-4SI...

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