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42C,D,S,V Series Fan Coil Air Conditioners Installation, Start-Up and Service Instructions CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,2 PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 PRE-INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Unpack and Inspect Units . . . . . . . . . . . . . . . . . . . . . . . . 4 Protect Units From Damage . . . . . . . . . . . . . . . . . . . . . . 4 Prepare Jobsite for Unit Installation . . . . . . . . . . . . . . 4 Identify and Prepare Units. . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-79 Step 1 — Place Units in Position . . . . . . . . . . . . . . . . 42 • 42C UNITS • 42V UNITS • 42D UNITS • 42S UNITS Step 2 — Make Piping Connections . . . . . . . . . . . . . 53 • VALVE PACKAGES • 42C,D,V DRAIN CONNECTIONS • 42C,D,V WATER SUPPLY/RETURN CONNECTIONS • 42C,D,V STEAM CONNECTIONS • 42C,D,V DIRECT EXPANSION (DX) REFRIGERANT PIPING • TEST AND INSULATE Step 3 — Make Electrical Connections . . . . . . . . . . 66 • FACTORY-INSTALLED OPTIONS • STANDARD WIRING PACKAGES Step 4 — Make Duct Connections . . . . . . . . . . . . . . . 77 Step 5 — Frame and Finish Unit. . . . . . . . . . . . . . . . . 77 Step 6 — Cut Out Openings for Grilles and Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Step 7 — Make Final Preparations. . . . . . . . . . . . . . . 77 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-81 Cooling/Heating System. . . . . . . . . . . . . . . . . . . . . . . . . 80 Air System Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Water System Balancing . . . . . . . . . . . . . . . . . . . . . . . . 80 Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Controls Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81,82 Excessive Condensation on Unit . . . . . . . . . . . . . . . . 81 To Clean Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Check Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Fan Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Clean Fan Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Clean Electric Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Clean or Replace Air Filters . . . . . . . . . . . . . . . . . . . . . 81 Electrical Wiring and Controls . . . . . . . . . . . . . . . . . . 82 Valves and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Page APPENDIX A — POTENTIOMETER ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 APPENDIX B — EVO/ECM 4-SPEED ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 START-UP CHECKLIST FOR 42C,D,S,V SERIES FAN COIL AIR CONDITIONERS. . . . . . . . .CL-1, CL-2 SAFETY CONSIDERATIONS Installation of this unit can be hazardous due to electrical components 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 precautions that apply. • Follow all safety codes. • Wear safety glasses and work gloves. Never wear bulky or loose fitting clothing when working on any mechanical equipment. Gloves should be worn for proper protection against heat and other possible injuries. Safety glasses or goggles should always be worn when drilling, cutting, or working with chemicals such as refrigerants or lubricants. • Use care in handling and installing this unit. • Never pressurize any equipment beyond specified test pressures. Always pressure test with an inert fluid or gas such as clear water or dry nitrogen to avoid possible damage or injury in the event of a leak or component failure during testing. Always protect adjacent flammable material when welding or soldering. Use a suitable heat-shield material to contain sparks or drops of solder. Have a fire extinguisher readily available. WARNING ELECTRIC SHOCK HAZARD. To avoid the possibility of electrical shock, open and tag all service switches before installing this equipment. INTRODUCTION Carrier fan coil units represent a prudent investment offering trouble-free operation and long service with proper installation, operation, and regular maintenance. Your 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, regular periodic maintenance, and everyday operation of the equipment be followed in detail. This manual should be fully reviewed in advance before initial installation, start-up, and any maintenance. Should any questions arise, please Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420010-01 Printed in U.S.A. Form 42-5SI Pg 1 1-14 Replaces: 42-4SI 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. contact your local sales representative or the factory BEFORE proceeding. 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 literature for any other type of factory-mounted controls. PHYSICAL DATA Component weight data, shipping weights, and filter data of the 42C,D,S,V units are provided in Tables 1-4. Table 1 — Physical Data — 42C Series Units UNIT SIZE 42C 02 03 04 06 08 10 12 NOMINAL AIRFLOW (cfm) 200 300 400 600 800 1000 1200 SHIPPING WEIGHT (lb)* 42CA 42CE 42CG 42CK 36 55 98 115 39 60 118 120 49 70 126 135 59 82 168 150 64 95 176 155 95 135 215 227 107 154 245 241 COIL WATER WEIGHT (Approx lb per row of coil) 42CA, CE, CG, CK 0.7 0.8 1.0 1.4 1.7 2.3 2.7 COILS FPI Coil Face Area (sq ft) 0.8 1.1 1.4 2.3 3.2 3.7 MOTOR (qty) 42C Series 1 1 1 1 1 2 2 BLOWER (qty) 42CA, CE, CG, CK 1 1 2 2 2 4 4 NA 10 x 18 NA 10 x 22 NA 10 x 28 NA 10 x 33 NA 10 x 40 NA 10 x 54 NA 10 x 62 10 x 231/2 8 x 231/2 10 x 28 8 x 28 10 x 321/2 8 x 321/2 10 x 37 8 x 37 10 x 41 8 x 41 10 x 541/2 8 x 541/2 10 x 63 8 x 63 10 x 28 7 x 21 1 10 x 28 7 x 21 1 10 x 33 7 x 27 1 10 x 45 7 x 38 1 10 x 45 7 x 38 1 10 x 62 7 x 52 1 10 x 62 7 x 52 1 FILTERS Nominal Size (in.) (1-in. thick) 42CA 42CE† 42CG Bottom Return Rear Return 42CK Bottom Return Rear Return Qty SUPPLY DUCT COLLAR 10 fins/inch 1.9 1-in. PIPING CONNECTIONS (Sweat) (in. OD) Coil Outlet and Inlet Drain Connection Tell-Tale Drain 5/ 8 7/ 8 5/ 8 *Calculate Operating Weight of Unit: Shipping Weight + Coil Water Weight x Number of Coil Rows. †Filter size if located in return-air plenum. 2 Table 2 — Physical Data — 42V Series Units UNIT SIZE 42V 01 02 03 04 06 08 10 12 NOMINAL AIRFLOW (cfm) 150 200 300 400 600 800 1000 1200 SHIPPING WEIGHT (lb)* 42VA 42VB 42VC 42VE 42VF 42VG — — — — — 40 42 63 50 72 64 — 47 68 60 100 69 74 57 82 72 108 83 — 77 99 110 154 100 — 79 101 — — 102 — 108 133 — — 135 — 127 154 — — 156 — COIL WATER WEIGHT (Approx lb per row of coil) 42VA, VB, VC†, VF 42VE 42VG — — 0.4 0.7 0.9 — 0.8 1.2 1.0 1.0 1.6 — 1.4 2.3 — 1.7 — — 2.3 — — 2.7 — — 12 fins/inch 10 fins/inch 1.4 1.9 2.3 3.2 3.7 COILS FPI (42VA, VB, VF) FPI (42VC, VE, VG) Coil Face Area (sq ft) 0.8 0.8 1.1 MOTOR (qty) 42VA, VB, VF 42VC, VE 42VG — — 1 1 1 — 1 1 2 1 1 — 1 2 — 1 — — 2 — — 2 — — BLOWER (qty) 42VA, VB, VF 42VC, VE 42VG — — 1 1 2 — 1 2 2 2 2 — 2 4 — 2 — — 4 — — 4 — — — — 10 x 141/2 1 73/4 x 213/4 7 x 213/4 — 1 73/4 x 213/4 7 x 263/4 10 x 28 1 73/4 x 313/4 7 x 343/4 — 1 73/4 x 413/4 7 x 483/4 — 1 73/4 x 433/4 — — 1 73/4 x 573/4 — — 1 73/4 x 653/4 — — 1 FILTERS Nominal Size (in.) (1-in. thick) 42VA, VB, VF 42VC, VE 42VG Qty SUPPLY DUCT COLLAR 1-in. PIPING CONNECTIONS (Sweat) (in.) Coil Outlet and Inlet Drain Connection 5/ OD 8 3/ MPT 4 *Calculate Operating Weight of Unit: Shipping Weight + Coil Water Weight x Number Of Coil Rows. †Available in sizes 02-06. Table 3 — Physical Data — 42D Series Units 06 08 10 12 14 16 18 20 NOMINAL AIRFLOW (cfm) UNIT SIZE 42D 600 800 1000 1200 1400 1600 1800 2000 SHIPPING WEIGHT (lb)* 42DA 42DC 42DD 42DE 42DF 64 94 135 150 157 79 107 145 160 167 90 150 155 170 177 108 169 180 195 202 119 174 190 205 215 124 178 200 215 225 141 195 215 230 240 151 220 230 235 255 COIL WATER WEIGHT (Approx lb per row of coil) 1.3 1.6 1.9 2.3 2.7 3.0 3.4 3.7 COILS FPI Coil Face Area (sq ft) 1.6 2.1 2.5 3.0 3.5 4.1 4.6 5.0 MOTOR (qty) 1 1 1 2 2 2 2 2 BLOWER (qty) 1 1 1 2 2 2 2 2 14 x 21 14 x 26 14 x 30 14 x 35 14 x 40 14 x 45 14 x 50 14 x 54 123/4 x 21 123/4 x 20 14 x 143/4 14 x 14 123/4 x 26 123/4 x 25 14 x 193/4 14 x 20 123/4 x 30 123/4 x 29 14 x 233/4 14 x 24 123/4 x 35 123/4 x 34 14 x 283/4 14 x 28 123/4 x 40 123/4 x 39 14 x 333/4 14 x 34 123/4 x 45 123/4 x 44 14 x 383/4 14 x 38 123/4 x 50 123/4 x 49 14 x 433/4 14 x 44 123/4 x 54 123/4 x 53 14 x 473/4 14 x 48 5/ 8 7/ 8 7/ 8 1 1 /8 1 1 /8 15/8 5/ 8 7/ 8 1 1 /8 1 1 /8 11/8 15/8 5/ 8 7/ 8 1 1 /8 1 1 /8 11/8 15/8 5/ 8 7/ 8 1 1 /8 1 1 /8 11/8 15/8 FILTERS Nominal Size (in.) (1-in. thick) 42DA 42DC 42DD (Front Return) (Bottom Return) 42DE 42DF Qty 10 fins/inch NA 1 SUPPLY DUCT COLLAR PIPING CONNECTIONS Coil Inlet/Outlet (in. OD) 1 and 2 Row 3 Row 4 Row 5 Row 6 Row 8 Row 1-in. 5/ 8 5/ 8 7/ 8 7/ 8 7/ 8 1 1 /8 5/ 8 5/ 8 7/ 8 7/ 8 7/ 8 1 1 /8 5/ 8 7/ 8 7/ 8 7/ 8 7/ 8 1 1 /8 5/ 8 7/ 8 7/ 8 7/ 8 7/ 8 1 1 /8 *Calculate Operating Weight of Unit: Shipping Weight + Coil Water Weight x Number of Coil Rows. 3 Table 4 — Physical Data — 42S Series Units UNIT SIZE 42S NOMINAL AIRFLOW (cfm) SHIPPING WEIGHT (lb)* 42SGA,SGM,SU 42SH 42SJ 42SGS 42SM COIL WATER WEIGHT (Approx lb per row of coil) COILS FPI BLOWER (qty) 42SGA,SH,SU,SGM,SGS,SM 42SJ FILTERS Nominal Size (in.) (1-in. thick) Qty PIPING CONNECTIONS Inlet (in. OD) 03 300 04 400 06 600 08 800 10 1000 12 1200 14 1400 16 1600 20 2000 180 202 360 162 — 225 247 450 203 — 240 262 480 216 — 260 286 520 234 — 280 311 560 252 — 305 336 610 275 — — — — — 390 — — — — 390 — — — — 390 4.09 4.09 4.39 1 — 1 — 1 — 1.79 2.63 3.45 14 fins/inch 1 2 1 2 121/2 x 241/4 1 2 1 2 161/4 x 263/4 1/ 2, 1 2 1 2 201/2 x 291/4 1† 241/2 x 291/2 261/2 x 291/2 unless larger size valve package is selected *Calculate Operating Weight of Unit: Shipping Weight + Coil Water Weight x Number of Coil Rows. †42SJ units require two filters. rugged appearance. Still, great care must be taken to assure that no force or pressure is applied to the coil, piping, or drain stub-outs during handling. Depending on the options and accessories, some units may contain delicate components that may be damaged by improper handling. All units shall be handled by the chassis or as close as possible to the unit mounting point locations. In the case of a full cabinet unit, the unit must be handled by the exterior casing. This is acceptable provided the unit is maintained in an upright position, and no force is applied that may damage internal components or painted surfaces. The equipment must always be properly supported. Temporary supports used during installation or service must be adequate to hold the equipment securely. Equipment should always be stored in the proper orientation as marked on the carton. To maintain warranty, protect units against hostile environment (such as rain, snow, or extreme temperatures), theft, vandalism, and debris on jobsite. Equipment covered in this manual is not suitable for outdoor installations. Do not allow foreign material to fall into drain pan. Prevent dust and debris from being deposited on motor, fan wheels and cooling/ heating coils. Failure to do so may have serious adverse effects on unit operation, and in the case of the motor and blower assembly, may result in immediate or premature failure. Manufacturer's warranty is void if foreign material is allowed to be deposited on the motor or blower wheels of any unit. Some units and/or job conditions may require some form of temporary covering during construction. PRE-INSTALLATION Unpack and Inspect Units — All units are carefully inspected at the factory throughout the manufacturing process under a strict detailed quality assurance program, and, where possible, ALL major components and sub-assemblies are carefully tested for proper operation and verified for full compliance with factory standards. Operational testing of some customer-furnished components such as electronic control valves and digital controllers may be a possible exception. Each unit is carefully packaged for shipment to avoid damage during normal transit and handling. Equipment should always be stored in a dry place, and in the proper orientation as marked on the carton. All shipments are made F.O.B. factory and are the responsibility of the receiving party to inspect the equipment upon arrival. Any obvious damage to the carton and/or its contents should be recorded on the bill of lading and a claim should be filed with the transportation company, and Carrier should be advised. After determining the condition of the carton exterior, carefully remove each unit from the carton and inspect for hidden damage. At this time, check to make sure that “furnished only” items such as thermostats, grilles etc. are accounted for whether packaged separately or shipped at a later date. Any hidden damage should be recorded and immediately reported to the transportation company, a claim should be filed with the transportation company, and Carrier should be notified. In the event a claim for shipping damage is filed, the unit, shipping carton, and all packing must be retained for physical inspection by the transportation company. All equipment should be stored in the factory shipping carton with internal packing in place until installation. At the time of receipt, the equipment type and arrangement should be verified against the order documents. Should any discrepancy be found, the local sales representative should be notified immediately so that proper action may be taken. Should any questions arise concerning warranty repairs, the factory must be notified BEFORE any corrective action is taken. Where local repairs or alterations can be accomplished, the factory must be fully informed of the extent and expected cost of those repairs before work is begun. Where factory operations are required, the factory must be contacted for authorization to return equipment and a Return Authorization Number will be issued. Unauthorized return shipments of equipment and shipments not marked with an authorization number will be refused. In addition, any claims for unauthorized expenses will not be accepted by the manufacturer. Prepare Jobsite for Unit Installation — To save time and to reduce the possibility of costly errors, set up a complete sample installation in a typical room at jobsite. Check all critical dimensions such as pipe, wire, and duct connection requirements. Refer to job drawings and product dimension drawings as required (see Fig. 1-38). Instruct all trades in their part of the installation. Identify and Prepare Units — Be sure power require- ments match available power source. Refer to unit nameplate and wiring diagram. 1. Check all tags on unit to determine if shipping screws are to be removed. Remove screws as directed. 2. Rotate the fan wheel by hand to ensure that the fan is unrestricted and can rotate freely. Check for shipping damage and fan obstructions. Adjust blower motor as required. 3. Perform "Dry Fit" of valve assembly that may be shipped unattached to unit coil assembly. Should any questions arise on fit up please contact your local representative. Protect Units from Damage — All equipment is de- signed and fabricated with robust materials and presents a 4 1 2 3 4 5 6 — — — — — — 7 — 8 — 9 — 10 — LEGEND Junction Box (remote mount) Flexible Metal Conduit Drain Conn, 7/8-in. OD Tell-Tale Drain Conn, 5/8-in. OD (optional) Drip Lip (optional, shipped loose) Hanger Slots (4), Rubber Grommet has 3/8-in. Diameter Hole Supply Duct Collar, 1-in. Air Vent, 1/8-in. MPT Return Conn, 5/8-in. OD Supply Conn, 5/8-in. OD NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ±5/8-inch. 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 3. Standard 3-row coil shown. 4. Overall unit dimension increases by 4 in. with optional electric heat. 5. Not shown: 3-speed fan switch; wall plate; closed cell foam on main drain pan. 6. Units have galvanized finish. 7. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. 8. Dimensions shown in inches (mm). a42-4099.eps UNIT SIZE NOM AIRFLOW (Cfm) DIMENSIONS (in.) A A’ B D’ E F G 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 211/4 251/4 311/4 361/4 431/4 571/4 651/4 311/4 361/4 431/4 431/4 571/4 651/4 751/4 16 20 26 31 38 52 60 13 14 15 10 17 11 13 181/4 221/4 281/4 331/4 401/4 541/4 621/4 61/4 61/4 61/4 71/2 71/2 71/2 71/2 83/4 83/4 83/4 10 10 10 10 H Blower QTY/UNIT Motor FACE AREA (sq ft) UNIT WEIGHT* (lb) 193/4 233/4 293/4 343/4 413/4 553/4 633/4 1 1 2 2 2 4 4 1 1 1 1 1 2 2 0.83 1.08 1.35 1.88 2.31 3.16 3.65 36 39 49 59 64 95 107 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 1 — 42CA Furred-In Horizontal Unit Dimensions 5 1 — 2 — 3 — 4 — 5 — 6 — 7 — 8 — 9 — 10 — 11 — 12 — NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ±5/8-inch. 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 3. Standard 3-row coil shown. 4. Overall unit dimension increases by 4 in. with optional electric heat. 5. Not shown: 3-speed fan switch; wall plate; closed cell foam on main drain pan. 6. Units have galvanized finish. 7. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. a42-4100.eps 8. Dimensions shown in inches (mm). LEGEND Junction Box (remote mount) Flexible Metal Conduit Strip Heater High Limit Electric Strip Heater Element Tell-Tale Drain Conn, 5/8-in. OD (optional) Drain Conn, 7/8-in. OD Drip Lip (optional, shipped loose) Supply Duct Collar, 1-in. Air Vent, 1/8-in. MPT Return Conn, 5/8-in. OD Supply Conn, 5/8-in. OD Hanger Slots (4), Rubber Grommet has 3/8-in. Diameter Hole UNIT SIZE NOM AIRFLOW (Cfm) DIMENSIONS (in.) QTY/UNIT A A’ B D’ E F G H Blower 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 211/4 251/4 311/4 361/4 431/4 571/4 651/4 311/4 361/4 431/4 431/4 571/4 651/4 751/4 16 20 26 31 38 52 60 13 14 15 10 17 11 13 181/4 221/4 281/4 331/4 401/4 541/4 621/4 6 1 /4 6 1 /4 6 1 /4 7 1 /2 7 1 /2 7 1 /2 7 1 /2 83/4 83/4 83/4 10 10 10 10 193/4 233/4 293/4 343/4 413/4 553/4 633/4 1 1 2 2 2 4 4 Motor FACE AREA (sq ft) UNIT WEIGHT* (lb) 1 1 1 1 1 2 2 0.83 1.08 1.35 1.88 2.31 3.16 3.65 38 41 51 61 66 97 109 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 2 — 42CA Furred-In Horizontal Unit with Electric Heat Dimensions 6 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — 12 — 13 — 14 — 15 — NOTES: 1. Right hand unit with standard 3-row coil shown; left hand unit opposite. Coil connection locations are ±5/8-inch. 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 3. Standard 3-row coil shown. 4. Unit available with bottom or rear return air. 5. Overall dimension increases by 4 in. with optional electric heat. 6. Not shown: 3-speed fan switch; wall plate; 1/2-in. fiberglass insulation on inside of plenum, closed cell foam on main drain pan. 7. Units have galvanized finish. 8. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. 9. Dimensions shown in inches (mm). LEGEND Junction Box, 4 in. x 4 in. Flexible Metal Conduit Mounting Bracket Drain Conn, 7/8-in. OD Tell-Tale Drain Conn, 5/8-in. OD (optional) Drip Lip (optional, shipped loose) Filter Return Duct Collar, 1-in. Filter Access Panel Access Panel Supply Duct Collar, 1-in. Air Vent, 1/8-in. MPT Return Conn, 5/8-in. OD Supply Conn, 5/8-in. OD Hanger Slots (4), Rubber Grommet has 3/ -in. Diameter Hole 8 a42-4101 UNIT SIZE NOM AIRFLOW (Cfm) A A’ B DIMENSIONS (in.) C D’ E F G H 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 211/4 251/4 311/4 361/4 431/4 571/4 651/4 311/4 361/4 431/4 431/4 571/4 651/4 751/4 16 20 26 31 38 52 60 181/4 221/4 281/4 331/4 401/4 541/4 621/4 13 14 15 10 17 11 13 193/4 233/4 293/4 343/4 413/4 553/4 633/4 61/4 61/4 61/4 71/2 71/2 71/2 71/2 83/4 83/4 83/4 10 10 10 10 153/8 193/8 253/8 303/8 373/8 513/8 593/8 QTY/UNIT FACE UNIT RETURN AIR AREA WEIGHT* DUCT Blower Motor (sq ft) (lb) (inches) 1 1 2 2 2 4 4 1 1 1 1 1 2 2 0.83 1.08 1.35 1.88 2.31 3.16 3.65 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 3 — 42CE Furred-In Horizontal Unit with Plenum Dimensions 7 55 60 70 82 95 135 154 101/2 x 181/4 101/2 x 221/4 101/2 x 281/4 101/2 x 331/4 101/2 x 401/4 101/2 x 541/4 101/2 x 621/4 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — 12 — 13 — 14 — 15 — 16 — 17 — NOTES: 1. Right hand unit with standard 3-row coil shown; left hand unit opposite. Coil connection locations are ±5/8-inch. 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 3. Standard 3-row coil shown. 4. Unit available with bottom or rear return air. 5. Overall dimension increases by 4 in. with optional electric heat. 6. Not shown: 3-speed fan switch; wall plate; 1/2-in. fiberglass insulation on inside of plenum, closed cell foam on main drain pan. 7. Units have galvanized finish. 8. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. 9. Dimensions shown in inches (mm). LEGEND Junction Box, 4 in. x 4 in. Flexible Metal Conduit Mounting Bracket Electric Strip Heater Element Drain Conn, 7/8-in. OD Strip Heater High Limit Tell-Tale Drain Conn, 5/8-in. OD (optional) Drip Lip (optional, shipped loose) Filter Return Duct Collar, 1-in. Filter Access Panel Access Panel Supply Duct Collar, 1-in. Air Vent, 1/8-in. MPT Return Conn, 5/8-in. OD Supply Conn, 5/8-in. OD Hanger Slots (4), Rubber Grommet has 3/ -in. Diameter Hole 8 A42-4102 UNIT SIZE NOM AIRFLOW (Cfm) A A’ B DIMENSIONS (in.) C D’ E F G H Blower QTY/UNIT Motor 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 211/4 251/4 311/4 361/4 431/4 571/4 651/4 311/4 361/4 431/4 431/4 571/4 651/4 751/4 16 20 26 31 38 52 60 181/4 221/4 281/4 331/4 401/4 541/4 621/4 13 14 15 10 17 11 13 193/4 233/4 293/4 343/4 413/4 553/4 633/4 61/4 61/4 61/4 71/2 71/2 71/2 71/2 83/4 83/4 83/4 10 10 10 10 153/8 193/8 253/8 303/8 373/8 513/8 593/8 1 1 2 2 2 4 4 1 1 1 1 1 2 2 FACE UNIT AREA WEIGHT* RETURN AIR DUCT (sq ft) (lb) 0.83 1.08 1.35 1.88 2.31 3.16 3.65 57 62 72 84 97 137 156 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 4 — 42CE Furred-In Horizontal Unit with Plenum and Electric Heat Dimensions 8 101/2 x 181/4 101/2 x 221/4 101/2 x 281/4 101/2 x 331/4 101/2 x 401/4 101/2 x 541/4 101/2 x 621/4 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — 12 — 13 — 14 — 15 — NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ±5/8-inch. 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 3. Cabinet has an Arctic White baked finish. 4. Refer to supply and return connections above for coil stub-out locations. 5. Not shown: optional drip lip, 3-speed fan switch; wall plate; 1/2-in. fiberglass insulation on inside of casing, closed cell foam on main drain pan. 6. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. 7. Valve package is factory-installed inside the cabinet when ordered with the unit (based on component size). 8. Dimensions shown in inches (mm). LEGEND Junction Box, 4 in. x 4 in. Optional Return Air Location Drip Lip (optional, shipped loose) Mounting Holes (4), Rubber Grommets have 3/8-in. Diameter Hole Electrical Knockout, 7/8-in. Diameter Return Knockout, 1-in. Diameter Supply Knockout, 11/2-in. Diameter Drain Knockout, 11/2-in. Diameter Supply, Return Connections, 5/8-in. OD Drain Connection, 7/8-in. OD Optional Valve Package (inside cabinet) Filter Standard Stamped-Return Air Grille Removable Hinged Access Panel Supply Grille, Stamped, Standard UNIT SIZE NOM AIRFLOW (Cfm) A B 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 38 42 48 53 60 74 82 171/8 211/2 257/8 345/8 39 521/8 607/8 A42-4105 DIMENSIONS (in.) C 107/16 101/4 111/16 93/16 101/2 1015/16 109/16 E F G Blower QTY/UNIT Motor FACE AREA (sq ft) UNIT WEIGHT* (lb) 34 38 44 49 56 70 78 53/4 53/4 53/4 63/4 63/4 63/4 63/4 11 11 11 12 12 12 12 1 1 2 2 2 4 4 1 1 1 1 1 2 2 0.83 1.08 1.35 1.88 2.31 3.16 3.65 98 118 126 168 176 215 245 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 5 — 42CG Horizontal Cabinet Unit Dimensions 9 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — 12 — 13 — 14 — 15 — 16 — NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ±5/8-inch. 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 3. Cabinet has an Arctic White baked finish. 4. Refer to supply and return connections above for coil stub-out locations. 5. Not shown: 3-speed fan switch; wall plate; 1/2-in. fiberglass insulation on inside of casing, closed cell foam on main drain pan. 6. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. 7. Valve package is factory-installed inside the cabinet when ordered with the unit (based on component size). 8. Dimensions shown in inches (mm). LEGEND Junction Box, 4 in. x 4 in. Optional Stamped Rear Return Grille Drip Lip (optional, shipped loose) Electric Strip Heater Element Mounting Holes (4), Rubber Grommets have 3/8-in. Diameter Hole Electrical Knockout, 7/8-in. Diameter Return Knockout, 1-in. Diameter Supply Knockout, 11/2-in. Diameter Drain Knockout, 11/2-in. Diameter Drain Connection, 7/8-in. OD Valve Package (optional, inside cabinet) Filter Standard Stamped-Return Air Grille Removable Hinged Access Panel Supply, Return Connections, 5/8-in. OD Supply Grille, Stamped, Standard UNIT SIZE NOM AIRFLOW (Cfm) A B 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 38 42 48 53 60 74 82 171/8 211/2 257/8 345/8 39 521/8 607/8 A42-4106 DIMENSIONS (in.) C 107/16 101/4 111/16 93/16 101/2 1015/16 109/16 QTY/UNIT E F G Blower 34 38 44 49 56 70 78 5 3 /4 5 3 /4 5 3 /4 6 3 /4 6 3 /4 6 3 /4 6 3 /4 11 11 11 12 12 12 12 1 1 2 2 2 4 4 Motor FACE AREA (sq ft) UNIT WEIGHT* (lb) 1 1 1 1 1 2 2 0.83 1.08 1.35 1.88 2.31 3.16 3.65 98 118 126 168 176 215 245 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 6 — 42CG Horizontal Cabinet with Electric Heat Dimensions 10 1 2 3 4 5 6 10 9 D 7 8 1 2 3 4 — — — — 5 6 7 8 9 10 — — — — — — 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 ±1/4 inches. 4. Bottom panel is Arctic White polyester powder coat paint. LEGEND Junction Box L-shape Drip Lip (optional, shipped loose) Chilled/Hot Water Supply and Return Connection Resilient Mounting Grommets with 3/8-in. Diameter Hole (typically 4) Electrical Knockout, 7/8-in. Diameter Drain Knockout, 11/2-in. Diameter Stamped Return Air Grille and 1-in. Filter Condensate Drain Connection, 7/8-in. OD Hinged Bottom Return Air Panel Supply Duct Collar, 1-in. OD A42-4149 DIMENSIONS (in.) QTY/UNIT UNIT SIZE NOM AIRFLOW (Cfm) A B C D E F Blower Motor 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 35 35 41 53 53 75 75 16 20 26 31 38 52 60 123/4 83/4 83/4 153/4 83/4 163/4 83/4 37 37 43 55 55 77 77 32 32 38 50 50 72 72 6 6 6 7 7 7 7 1 1 2 2 2 4 4 1 1 1 1 1 2 2 BOTTOM RETURN FILTER SIZE (in.) UNIT WEIGHT* (lb) 10 x 231/2 10 x 28 10 x 321/2 10 x 37 10 x 41 10 x 541/2 10 x 63 115 120 135 150 155 227 241 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 7 — 42CK Horizontal Cabinet Unit with Telescopic Access Panel, Front Supply, and Bottom Return Dimensions 11 12 11 9 13 10 a42-4150 1 2 3 4 5 6 — — — — — — 7 8 9 10 11 12 13 — — — — — — — LEGEND Contactor Box Strip Heater High Limit Electric Strip Heater Element L-shape Drip Lip (optional, shipped loose) Chilled/Hot Water Supply and Return Connection Resilient Mounting Grommets with 3/8-in. Diameter Hole (typically 4) Electrical Knockout, 7/8-in. Diameter Drain Knockout, 11/2-in. Diameter Stamped Return Air Grille and 1-in. Filter Condensate Drain Connection, 7/8-in. OD Hinged Bottom Return Air Panel Supply Duct Collar, 1-in. OD Drain Pan 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 ±1/4 inches. 4. Bottom panel is Arctic White polyester powder coat paint. DIMENSIONS (in.) QTY/UNIT UNIT SIZE NOM AIRFLOW (Cfm) A B C D E F Blower Motor 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 35 35 41 53 53 75 75 16 20 26 31 38 52 60 123/4 83/4 83/4 153/4 83/4 163/4 83/4 37 37 43 55 55 77 77 32 32 38 50 50 72 72 6 6 6 7 7 7 7 1 1 2 2 2 4 4 1 1 1 1 1 2 2 BOTTOM RETURN FILTER SIZE (in.) UNIT WEIGHT* (lb) 10 x 231/2 10 x 28 10 x 321/2 10 x 37 10 x 41 10 x 541/2 10 x 63 117 122 137 152 157 229 243 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 8 — 42CK Horizontal Cabinet Unit with Telescopic Access Panel, Front Supply, Bottom Return, and Heater Dimensions 12 2 1 3 4 5 6 7 8 11 10 9 1 2 3 4 5 — — — — — 6 7 8 9 10 11 — — — — — — LEGEND Junction Box 1-in. Ducted Rear Return and 1-in. Filter L-shape Drip Lip (optional, shipped loose) Chilled/Hot Water Supply and Return Connection Resilient Mounting Grommets with 3/8-in. Diameter Hole (typically 4) Electrical Knockout, 7/8-in. Diameter Drain Knockout, 11/2-in. Diameter 1-in. Ducted Rear Return and 1-in. Filter Condensate Drain Connection, 7/8-in. OD Hinged Bottom Return Air Panel Supply Duct Collar, 1-in. OD 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 ±1/4 inches. 4. Bottom panel is Arctic White polyester powder coat paint. a42-4151 UNIT SIZE NOM AIRFLOW (Cfm) DIMENSIONS (in.) QTY/UNIT A B C D E F Blower Motor REAR RETURN FILTER SIZE (in.) UNIT WEIGHT* (lb) 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 35 35 41 53 53 75 75 16 20 26 31 38 52 60 123/4 83/4 83/4 153/4 83/4 163/4 83/4 37 37 43 55 55 77 77 32 32 38 50 50 72 72 6 6 6 7 7 7 7 1 1 2 2 2 4 4 1 1 1 1 1 2 2 7 x 21 7 x 21 7 x 27 7 x 38 7 x 38 7 x 52 7 x 52 115 120 135 150 155 227 241 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 9 — 42CK Horizontal Cabinet Unit with Telescopic Access Panel, Front Supply, and Rear Return Dimensions 13 14 1 2 3 4 5 6 7 — — — — — — — 8 9 10 11 12 13 14 — — — — — — — LEGEND Contactor Box Strip Heater High Limit Electric Strip Heater Element 1-in. Ducted Rear Return and 1-in. Filter L-shape Drip Lip (optional, shipped loose) Chilled/Hot Water Supply and Return Connection Resilient Mounting Grommets with 3/8-in. Diameter Hole (typically 4) Electrical Knockout, 7/8-in. Diameter Drain Knockout,11/2-in. Diameter 1-in. Ducted Rear Return and 1-in. Filter Condensate Drain Connection, 7/8-in. OD Hinged Bottom Return Air Panel Supply Duct Collar, 1-in. OD Drain Pan 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 ±1/4 inches. 4. Bottom panel is Arctic White polyester powder coat paint. a42-4152 UNIT SIZE NOM AIRFLOW (Cfm) A B DIMENSIONS (in.) C D E F Blower QTY/UNIT Motor REAR RETURN FILTER SIZE (in.) UNIT WEIGHT* (lb) 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 35 35 41 53 53 75 75 16 20 26 31 38 52 60 123/4 83/4 83/4 153/4 83/4 163/4 83/4 37 37 43 55 55 77 77 32 32 38 50 50 72 72 6 6 6 7 7 7 7 1 1 2 2 2 4 4 1 1 1 1 1 2 2 7 x 21 7 x 21 7 x 27 7 x 38 7 x 38 7 x 52 7 x 52 117 122 137 152 157 229 243 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 10 — 42CK Horizontal Cabinet Unit with Telescopic Access Panel, Front Supply, Rear Return, and Heater Dimensions 14 LEGEND 1 — Junction Box, 4 in. x 4 in. 2 — Drip Lip (optional, shipped loose) 3 — Mounting Holes (4), Rubber Grommets have 3/8-in. Diameter Hole 4 — Piping Knockout, 11/2-in. Diameter 5 — Electrical Knockout, 7/8-in. Diameter 6 — Drain Knockout, 11/2-in. Diameter 7 — Supply Duct Collar 8 — Return Connection, 5/8-in. OD 9 — Optional Rear Return. Consult factory for collar dimensions 10 — Drain, 7/8-in. OD 11 — Stamped Bottom Return Air Grille 12 — Filter 13 — Stamped Air Supply Grille 14 — Hinged Bottom Access Panel 15 — Supply Connection, 5/8-in. OD NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ±5/8-inch. 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 3. Bottom access panel has an Arctic White baked finish. 4. Refer to supply and return connections above for coil stub-out locations. 5. Not shown: 3-speed fan switch; wall plate; 1/2-in. fiberglass insulation on inside of casing, closed cell foam on main drain pan. 6. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. 7. Valve package is factory-installed inside the cabinet when ordered with the unit (based on component size). 8. Bottom return or bottom supply is an ETO (engineering to order) request. A42-4107 9. Dimensions shown in inches (mm). UNIT SIZE NOM AIRFLOW (Cfm) DIMENSIONS (in.) A D 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 35 35 41 53 53 75 75 37 37 43 55 55 77 77 QTY/UNIT E Blower Motor FACE AREA (sq ft) UNIT WEIGHT* (lb) 32 32 38 50 50 72 72 1 1 2 2 2 4 4 1 1 1 1 1 2 2 0.83 1.08 1.35 1.88 2.31 3.16 3.65 115 120 135 150 155 227 241 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 11 — 42CK Horizontal Cabinet Unit with Telescopic Access Panel Dimensions 15 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — 12 — 13 — 14 — 15 — 16 — 17 — LEGEND Junction Box, 4 in. x 4 in. Strip Heater High Limit Electric Strip Heater Element Drip Lip (optional, shipped loose) Mounting Holes (4), Rubber Grommets have 3/8-in. Diameter Hole Piping Knockout, 11/2-in. Diameter Electrical Knockout, 7/8-in. Diameter Drain Knockout, 11/2-in. Diameter Supply Duct Collar Optional Rear Return. Consult factory for collar dimensions. Drain, 7/8-in. OD Stamped Bottom Return Air Grille Filter Stamped Air Supply Grille Hinged Bottom Access Panel Supply Connection, 5/8-in. OD Return Connection, 5/8-in. OD NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ±5/8-inch. 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 3. Bottom access panel has an Arctic White baked finish. 4. Refer to supply and return connections above for coil stub-out locations. 5. Not shown: 3-speed fan switch; wall plate; 1/2-in. fiberglass insulation on inside of casing; closed cell foam on main drain pan. 6. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. 7. Valve package is factory-installed inside the cabinet when ordered with the unit (based on component size). 8. Bottom return or bottom supply is an ETO (engineering to order) request. 9. Dimensions shown in inches (mm). A42-4108 DIMENSIONS (in.) QTY/UNIT UNIT SIZE NOM AIRFLOW (Cfm) A D E Blower Motor FACE AREA (sq ft) UNIT WEIGHT* (lb) 02 03 04 06 08 10 12 200 300 400 600 800 1000 1200 35 35 41 53 53 75 75 37 37 43 55 55 77 77 32 32 38 50 50 72 72 1 1 2 2 2 4 4 1 1 1 1 1 2 2 0.83 1.08 1.35 1.88 2.31 3.16 3.65 117 122 137 152 157 229 243 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 12 — 42CK Horizontal Cabinet with Telescopic Access Panel and Electric Heat Dimensions 16 FRONT VIEW a42-4381 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Dimensions shown in inches (mm). All dimensions are ±1/4 inches. DIMENSIONS (in.) QTY/UNIT UNIT SIZE A B C D Blower Motor UNIT WEIGHT* (lb) 02 03 04 06 08 10 12 243/16 243/16 343/16 443/16 463/16 603/16 683/16 22 22 32 42 44 58 66 23 23 33 43 45 59 67 16 18 26 36 38 52 60 1 1 2 2 2 4 4 1 1 1 1 1 2 2 42 47 57 77 79 108 127 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 13 — 42VA Furred-In Vertical Unit Dimensions 17 a42-4382 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Dimensions shown in inches (mm). All dimensions are ±1/4 inches. DIMENSIONS (in.) QTY/UNIT UNIT SIZE A B C D Blower Motor UNIT WEIGHT* (lb) 02 03 04 06 08 10 12 243/16 243/16 343/16 443/16 463/16 603/16 683/16 22 22 32 42 44 58 66 23 23 33 43 45 59 67 16 18 26 36 38 52 60 1 1 2 2 2 4 4 1 1 1 1 1 2 2 42 47 57 77 79 108 127 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 14 — 42VA Furred-In Unit with Electric Heat Dimensions 18 a42-4383 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Dimensions shown in inches (mm). All dimensions are ±1/4 inches. DIMENSIONS (in.) QTY/UNIT UNIT SIZE A B C D E Blower Motor UNIT WEIGHT* (lb) 02 03 04 06 08 10 12 41 41 51 61 63 77 85 22 22 32 42 44 58 66 23 23 33 43 45 59 67 171/4 171/4 26 39 39 521/8 61 31/8 31/8 33/4 21/4 31/4 35/8 31/4 1 1 2 2 2 4 4 1 1 1 1 1 2 2 63 68 82 99 101 133 154 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 15 — 42VB Vertical Cabinet Unit Dimensions 19 a42-4384 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Dimensions shown in inches (mm). All dimensions are ±1/4 inches. DIMENSIONS (in.) QTY/UNIT UNIT SIZE A B C D E Blower Motor UNIT WEIGHT* (lb) 02 03 04 06 08 10 12 41 41 51 61 63 77 85 22 22 32 42 44 58 66 23 23 33 43 45 59 67 171/4 171/4 26 39 39 521/8 61 31/8 31/8 33/4 21/4 31/4 35/8 31/4 1 1 2 2 2 4 4 1 1 1 1 1 2 2 63 68 82 99 101 133 154 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 16 — 42VB Vertical Cabinet Unit with Electric Heater Dimensions 20 a42-4385 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Dimensions shown in inches (mm). All dimensions are ±1/4 inches. DIMENSIONS (in.) QTY/UNIT UNIT SIZE A B C D E Blower Motor UNIT WEIGHT* (lb) 02 03 04 06 08 10 12 41 41 51 61 63 77 85 22 22 32 42 44 58 66 23 23 33 43 45 59 67 171/4 171/4 26 39 39 521/8 61 31/8 31/8 33/4 21/4 31/4 35/8 31/4 1 1 2 2 2 4 4 1 1 1 1 1 2 2 64 69 83 100 102 135 156 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 17 — 42VF Vertical Cabinet Unit with Slant Top Dimensions 21 a42-4386 NOTES: 1. Right hand unit shown; left hand unit opposite. 2. Dimensions shown in inches (mm). All dimensions are ±1/4 inches. DIMENSIONS (in.) QTY/UNIT UNIT SIZE A B C D E Blower Motor UNIT WEIGHT* (lb) 02 03 04 06 08 10 12 41 41 51 61 63 77 85 22 22 32 42 44 58 66 23 23 33 43 45 59 67 171/4 171/4 26 39 39 521/8 61 31/8 31/8 33/4 21/4 31/4 35/8 31/4 1 1 2 2 2 4 4 1 1 1 1 1 2 2 64 69 83 100 102 135 156 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 18 — 42VF Vertical Cabinet Unit with Slant Top and Electric Heater Dimensions 22 14-3/8 (368) 1 2 3 4 5 6 7 8 — — — — — — — — NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ± 5/8-inch. 2. Unit sizes 02 through 04 have one motor, 2 blowers; size 06 has 2 motors, 4 blowers. 3. Standard 2-row coil shown. 4. Optional unit-mounted switch box and controls, when specified, are installed on opposite side from cooling connections. 5. Height increases by 2 in. with electric heat. 6. Not shown: 3-speed fan switch, 1/2-in. fiberglass insulation on inside of casing, closed cell foam on main drain pan. 7. Units have galvanized finish. 8. For optional coil connections, view 42VC-203-1 using the Fan Coil Builder. A42-4112 9. Dimensions shown in inches (mm). LEGEND Optional Unit Mounted Control Box Drain Pan, Auxiliary, Shipped Loose Supply Conn, 5/8-in. OD Drain, 3/4-in. MPT Return Conn, 5/8-in. OD Air Vent, 1/8-in. MPT Discharge Opening Filter UNIT SIZE NOM AIRFLOW (Cfm) DIMENSIONS (in.) QTY/UNIT A B C Blower Motor FACE AREA (sq ft) UNIT WEIGHT* (lb) 02 03 04 06 200 300 400 600 23 28 36 50 22 27 35 49 17 22 30 44 2 2 2 4 1 1 1 2 1.18 1.53 2.08 3.06 50 60 72 110 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 19 — 42VC Furred-In Lowboy Unit Dimensions 23 1— 2— 3— 4— 5— 6— 7— 8— 9— LEGEND Unit-Mounted Control Box (Optional) Drain Pan, Auxiliary, Shipped Loose Air Vent, 1/8-in. MPT Supply Conn, 5/8-in. OD Drain, 3/4-in. MPT Return Conn, 5/8-in. OD Filter Electrical Sheath Heater Element Discharge Opening NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ± 5/8-inch. 2. Unit sizes 02 through 04 have one motor, 2 blowers; size 06 has 2 motors, 4 blowers. 3. Standard 2-row coil shown. 4. Optional unit-mounted switch box and controls, when specified, are installed on opposite side from cooling connections. 5. Height increases by 2 in. with electric heat. 6. Not shown: 3-speed fan switch, 1/2-in. fiberglass insulation on inside of casing, closed cell foam on main drain pan. 7. Units have galvanized finish. 8. For optional coil connections, view 42VC-203-1 using the Fan Coil Builder. 9. Dimensions shown in inches (mm). A42-4113 UNIT SIZE NOM AIRFLOW (Cfm) DIMENSIONS (in.) QTY/UNIT A B C Blower Motor FACE AREA (sq ft) UNIT WEIGHT* (lb) 02 03 04 06 200 300 400 600 23 28 36 50 22 27 35 49 17 22 30 44 2 2 2 4 1 1 1 2 1.18 1.53 2.08 3.06 50 60 72 110 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 20 — 42VC Furred-In Lowboy Unit with Electric Heat Dimensions 24 14-3/8 (368) NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ± 5/8-inch. 2. Unit sizes 02 through 04 have one motor, 2 blowers; size 06 has 2 motors, 4 blowers. 3. Cabinet has an Arctic White baked finish. 4. Height increases by 2 in. with electric heat. 5. Standard 2-row coil shown. 6. Not shown: 1/2-in. fiberglass insulation on inside of casing, closed cell foam on main drain pan. 7. For optional coil connections, view 42VC-203-1 using the Fan Coil Builder. 8. Valve package is factory-installed inside the cabinet when ordered with the unit (based on component size). A42-4114 9. Dimensions shown in inches (mm). LEGEND Fan Switch, 3-Speed, behind Access Door Front Panel Fastener Stamped Supply Grille Supply Conn, 5/8-in. OD Return Conn, 5/8-in. OD Stamped Return Grille Filter Air Vent, 1/8-in. MPT Optional Valve Package (inside cabinet) Drain Pan, Auxiliary, with 3/4-in. MPT Drain Connection 11 — Return Air Grille 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — UNIT SIZE NOM AIRFLOW (Cfm) DIMENSIONS (in.) QTY/UNIT A B C D Blower Motor 02 03 04 06 200 300 400 600 41 46 54 68 22 27 35 49 33/4 4 35/8 41/16 17 211/2 301/4 433/8 2 2 2 4 1 1 1 2 FACE AREA UNIT WEIGHT* (sq ft) (lb) *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 21 — 42VE Cabinet Lowboy Unit Dimensions 25 1.18 1.53 2.08 3.06 72 100 108 154 NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ± 5/8-inch. 2. Unit sizes 02 through 04 have one motor, 2 blowers; size 06 has 2 motors, 4 blowers. 3. Cabinet has an Arctic White baked finish. 4. Height increases by 2 in. with electric heat. 5. Standard 2-row coil shown. 6. Not shown: 1/2-in. fiberglass insulation on inside of casing, closed cell foam on main drain pan. 7. For optional coil connections, view 42VC-203-1 using the Fan Coil Builder. 8. Valve package is factory-installed inside the cabinet when ordered with the unit (based on component size). 9. Dimensions shown in inches (mm). A42-4115 LEGEND Fan Switch, 3-Speed, behind Access Door Electrical Sheath Heater Element Stamped Supply Grille Supply Conn, 5/8-in. OD Return Conn, 5/8-in. OD Stamped Return Grille Filter Air Vent, 1/8-in. MPT Front Panel Fastener Optional Valve Package (inside cabinet) Drain Pan, Auxiliary, with 3/4-in. MPT Drain Connection 12 — Return Air Grille 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — UNIT SIZE NOM AIRFLOW (Cfm) DIMENSIONS (in.) QTY/UNIT A B C D Blower 02 03 04 06 200 300 400 600 41 46 54 68 22 27 35 49 33/4 4 35/8 41/16 17 211/2 301/4 433/8 2 2 2 4 Motor FACE AREA (sq ft) UNIT WEIGHT* (lb) 1 1 1 2 1.18 1.53 2.08 3.06 72 100 108 154 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 22 — 42VE Cabinet Lowboy Unit with Electric Heat Dimensions 26 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — LEGEND Supply Conn, 5/8-in. OD Air Vent, 1/8-in. MPT Filter Return Air Grille, Stamped Stamped Supply Grille Return Conn, 5/8-in. OD Removable Front Panel Drain Conn, 7/8-in. OD Auxiliary Drain Pan Valve Compartment Junction Box NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations are ± 5/8-inch. 2. Front panel has an Arctic White baked finish. 3. Standard 2-row coil shown. 4. Unit size 01 has one motor, one blower; size 03 has 2 motors, 2 blowers. 5. Unit has 1/2-in. flanges for mounting to wall surface. 6. Front panel hooks at top of unit, swing down and snap in at bottom against a spring clip. 7. Not shown: 3-speed fan switch, wall plate, 1/2-in. fiberglass insulation on inside of casing, closed cell foam on main drain pan. 8. Dimensions shown in inches (mm). A42-4116 UNIT SIZE NOM AIRFLOW (Cfm) A B DIMENSIONS (in.) C D E Blower QTY/UNIT Motor UNIT WEIGHT* (lb) 01 03 150 300 253/4 393/4 153/4 293/4 14 28 11/2 115/16 123/4 257/8 1 2 1 2 40 74 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 23 — 42VG Furred-In Wall Unit Dimensions 27 a42-4120 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — LEGEND Motor Junction Box Motor-Blower Assembly Electric Strip Heater Element (optional) Auxiliary Drip Lip (optional, shipped loose) Tell-Tale Drain (optional) Drain Connection, 7/8-in. OD Air Vent, 1/8-in. MPT Supply Connection Supply Duct Collar, 1 in. Return Connection Mounting Holes (four, 3/4-in. diameter) have Rubber Grommets with 3/8-in. holes. UNIT SIZE 06 08 10 12 14 16 18 20 NOM AIRFLOW (cfm) 600 800 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 ± 5/8 inch. 2. Sizes 06, 08 and 10 have one motor, one blower; sizes 12 through 20 have 2 motors, 2 blowers. 3. Standard 4-row coil shown. Other coil option dimensional data available on request. 4. For optional coil connections, view 42DA-203-1 using the Fan Coil Builder. 5. Fan switch, wall plate not shown. 6. Galvanized finish provided as standard. 7. Dimensions are in inches (mm). DIMENSIONS (in. ± 1/8) QTY/UNIT A A’ B D’ E H Blower Motor UNIT WEIGHT* (lb) 23 28 32 37 42 47 52 56 32 37 42 47 52 56 62 66 14 19 23 28 33 38 43 47 131/2 131/2 141/2 141/2 141/2 131/2 141/2 141/2 17 22 26 31 36 41 46 50 181/2 231/2 271/2 321/2 371/2 421/2 471/2 511/2 1 1 1 2 2 2 2 2 1 1 1 2 2 2 2 2 64 79 90 108 119 124 141 151 Fig. 24 — 42DA Furred-In Ceiling Unit with Electric Heat Dimensions 28 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — 12 — 13 — 14 — 15 — 16 — UNIT SIZE 06 08 10 12 14 16 18 20 *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 ± 5/8 inch. 2. Sizes 06, 08 and 10 have one motor, one blower. Sizes 12 through 20 have 2 motors, 2 blowers. 3. Filter and filter rack are standard. 4. Standard 4-row coil shown. Other coil option dimensional data available on request. 5. For optional coil connections, view 42DA-203-1 using the Fan Coil Builder. 6. Fan switch, wall plate not shown. 7. Galvanized finish provided as standard. 8. Dimensions are in inches (mm). LEGEND Motor Junction Box Opposite Piping Insulated Return Air Plenum Mounting Clips (shipped loose) Electrical Strip Heater Element (optional) Auxiliary Drip Lip (shipped loose) with 3/8-in. Hole Tell-Tale Drain (optional) Drain Connection, 7/8-in. OD Filter Retainer Angle Access Panel Return Duct Collar, 21/2 in. Air Vent, 1/8-in. MPT Return Connection Filter, 1-in. Supply Duct Collar, 1 in. Supply Connection Mounting Holes (four, 3/4-in. diameter) with Rubber Grommet NOM AIRFLOW (cfm) 600 800 1000 1200 1400 1600 1800 2000 A42-4121 DIMENSIONS (in. ± 1/8) QTY/UNIT A A’ B D’ E F G H Blower Motor UNIT WEIGHT* (lb) 23 28 32 37 42 47 52 56 32 37 42 47 52 56 62 66 14 19 23 28 33 38 43 47 131/2 131/2 141/2 141/2 141/2 131/2 141/2 141/2 17 22 26 31 36 41 46 50 21 26 30 35 40 45 50 54 251/4 301/4 341/4 391/4 441/4 491/4 541/4 581/4 181/2 231/2 271/2 321/2 371/2 421/2 471/2 511/2 1 1 1 2 2 2 2 2 1 1 1 2 2 2 2 2 94 107 150 169 174 178 195 220 Fig. 25 — 42DC Furred-In Ceiling Unit with Plenum and Electric Heat Dimensions 29 A42-4122 SEE NOTE 8 1— 2— 3— 4— 5— 6— 7— 8— 9— 10 — 11 — 12 — LEGEND Motor Junction Box Air Vent, 1/8-in. MPT Return Connection Optional 6-in. Legs Bottom Return (optional) Return Air Opening Supply Connection Drain Connection, 7/8-in. OD Front Access Panel Filter, Throwaway Electric Strip Heater Element (optional) Supply Duct Connection, 1-in. UNIT SIZE 06 08 10 12 14 16 18 20 NOM AIRFLOW (cfm) 600 800 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 ± 5/8 inch. 2. Standard 4-row coil shown. Other coil option dimensional data available on request. 3. Sizes 06, 08 and 10 have one motor, one blower. Sizes 12 through 20 have 2 motors, 2 blowers. 4. Supply and return connections terminate within unit when valves are factory installed. 5. For optional coil connections, view 42DD-203-1 using the Fan Coil Builder. 6. Fan switch and wall plate are not shown. 7. Galvanized finish provided as standard. 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. 11. With bottom return, access to filter is through the front access panel. 12. Dimensions are in inches (mm). DIMENSIONS (in. ± 1/8) QTY/UNIT A B C Blower Motor 23 28 32 37 42 47 52 56 21 26 30 35 40 45 50 54 15 20 24 29 34 39 44 48 1 1 1 2 2 2 2 2 1 1 1 2 2 2 2 2 Fig. 26 — 42DD Vertical Unit with Full Casing and Electric Heat Dimensions 30 UNIT WEIGHT* (lb) 135 145 155 180 190 200 215 230 LEGEND 1 — Motor Junction Box 2 — Unit Mounting Channel (2), 14-gage; 4 Mounting Slots, 1/2-in. x 2-in. 3 — Auxiliary Drip Lip (optional, shipped loose) 4 — Side Access Panels 5 — Electrical Strip Heater Element (optional) 6 — Supply Air Duct Connection, 1 in. 7 — Manual Air Vent 8 — Filter, Throwaway, 1-in. 9 — Return Air Duct Connection, 21/2 in. 10 — Drain, 7/8-in. OD 11 — Bottom Access Panel 12 — Drain Pan 13 — Coil Inlet, Copper Sweat Connection 14 — Coil Outlet, Copper Sweat Connection UNIT SIZE NOM AIRFLOW (cfm) 06 08 10 12 14 16 18 20 600 800 1000 1200 1400 1600 1800 2000 A 31 36 40 45 50 55 60 64 *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. Coil stub-out location data available on request. 3. Unit fabricated of galvanized steel. 4. Internal parts fabricated of galvanized steel. 5. Sizes 06, 08 and 10 have one motor, one blower. Sizes 12 through 20 have 2 motors, 2 blowers. 6. Units must have drain line pitched and trapped externally. 7. For optional coil connections, view 42DA-203-1 using the Fan Coil Builder. 8. Fan switch, wall plate not shown. 9. Galvanized finished provided as standard. 10. Dimensions are in inches (mm). A42-4123 DIMENSIONS (in. ± 1/8) B C 15 15 20 20 24 24 29 29 34 34 39 39 44 44 48 48 QTY/UNIT D 26 31 35 40 45 50 55 59 Blower Motor UNIT WEIGHT* (lb) 1 1 1 2 2 2 2 2 1 1 1 2 2 2 2 2 150 160 170 195 205 215 230 235 Fig. 27 — 42DE Ceiling Unit with Full Casing and Electric Heat Dimensions 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 LEGEND —Junction Box —Return Air Grille, Hinged, Bar Type, with Filter Frame (Anodized Aluminum Only) —Unit Mounting Channel (2), 14-gage; 4 Mounting Slots, 1/2 in. x 2-in. —Auxiliary Drip Lip —Electric Strip Heater Element (optional) —Coil Inlet, Copper Sweat Connection —Coil Outlet, Copper Sweat Connection —Manual Air Vent —Filter, Throwaway —Bottom Access Panel —Drain, 7/8-in. OD —Drain Pan Insulated with Styrofoam —Side Access Panel (2) —Supply Air Grille (Double Deflection) UNIT SIZE NOM AIRFLOW (cfm) 06 08 10 12 14 16 18 20 600 800 1000 1200 1400 1600 1800 2000 A 31 36 40 45 50 55 60 64 *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. Coil stub-out connection data available on request. 3. Units fabricated of galvanized steel with an Arctic White baked finish. 4. Internal parts fabricated of galvanized steel. 5. Sizes 06, 08 and 10 have one motor, one blower. Sizes 12 through 20 have 2 motors, 2 blowers. 6. Units must have drain line pitched and trapped externally. 7. Stamped supply and return grilles are not available. 8. Bottom return air is not available. 9. For optional coil connections, view 42DA-203-1 using the Fan Coil Builder. 10. Fan switch and wall plate are not shown. 11. Dimensions are in inches (mm). A42-4124 DIMENSIONS (in. ± 1/8) B C D 14 26 131/2 181/2 20 31 221/2 24 35 28 40 271/2 321/2 34 45 371/2 38 50 44 55 421/2 461/2 48 59 E 81/2 8 8 81/2 8 81/2 8 8 QTY/UNIT Blower Motor 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 UNIT WEIGHT* (lb) 150 160 170 195 205 215 230 235 Fig. 28 — 42DF Exposed Ceiling Unit with Supply and Return Grille and Electric Heat Dimensions 32 24 CR CS D HR HS R S — — — — — — — ITEM 1 2 3 4 5 LEGEND Cold Water Return Cold Water Supply Drain Hot Water Return Hot Water Supply Return Supply DESCRIPTION Electrical Knockouts 3-in. Expanded Section Strip Heater (Optional) Limit Switch**†† (Optional) 1/ -in. 2 Isolation Ball Valves** QTY 1 3/5 1 1 2/4 6 Flexible Drain Tube/P-Trap 1 7 Coil 1/2-in. OD Copper Tube 1 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Filter, Throwaway, 1-in.** Return Air Opening Air Vent, Manual Molex Connector for Field-Installed Stat Control Box Knockout (For Optional Remote Mounting) Riser, Supply and Return (Copper) Riser, Drain (Copper) Drain Pan Acoustical Bypass Panel Blower Motor, 3-Speed, PSC, with Quick Connect Access Panel (Control Box) Control Opening (Surface Mount Stat) Duct Collar, 1/2-in. Extension (Typical) 23 Supply Air Opening(s) Top Supply Collar 1-in Extension (Optional) 24 1 1 1 1 1 2 2/4 1 1 1 1 1 1 1 *Drawing provided for reference only. Dimensions may vary with options ordered. NOTES: 1. Units are fabricated of galvanized steel with a 16-gage galvanized fan deck. 2. All risers are insulated with (1/2-in. or 3/4-in. thick) closed cell insulation. 3. Thermostats shipped loose for field connection. 4. Risers are piped to coil with valves as specified. 5. Blower, motor, valves, coil, and filter are accessible through the return air opening. 6. Unit and control box are insulated. 7. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 8. Maximum riser size is 21/2-in. diameter. If larger sizes are required, please consult the factory. 9. Expansion loops in hot water heating circuits as required. 10. A 9-in. x 21/4-in. slot is provided in the inside back panel for coil connection penetration to permit expansion and contraction of risers. Care must be taken to position the risers so that coil connection is at center of slot. 11. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 12. All dimensions are in inches. A42-4125 DIMENSIONS (in.) Double Supply Top Supply A B C D 14 6 14 10 UNIT SIZE NOM AIRFLOW (cfm) 03 300 04 400 14 12 14 6 14 10 06 600 18 10 18 6 16 08 800 18 12 18 6 10 1000 — — 22 12 1200 — — 22 Single Supply A B 14 8 E G H I UNIT WEIGHT† (lb) 17 11/2 11/2 14 180 17 11/2 11/2 14 225 12 20 1 2 18 240 16 12 20 1 2 18 260 8 18 16 24 1 3 22 280 8 18 16 24 1 3 22 305 1/2/3 1/2/3 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. 1 **Factory-Installed. ††Field-Installed. Fig. 29 — 42SG Furred-In Stack Dimensions 33 23 22 21 20 19 CR CS D HR HS R S — — — — — — — ITEM 1 LEGEND Cold Water Return Cold Water Supply Drain Hot Water Return Hot Water Supply Return Supply DESCRIPTION Full Riser Chase QTY 1 2 3 4 5 6 Electrical Knockouts 3-in. Expansion Section Strip Heater (Optional) Limit Switch**†† (Optional) 1/ -in. Isolation Ball Valves** 2 7 8 9 Flexible Drain Tube/P-Trap Drain Pan Coil 1/2-in. OD Tube 1 1 Filter, Throwaway, 1-in.** Air Vent, Manual Control Box Cabinet Camloc® Fasteners 1 1 1 14 3-Speed Switch (Optional) 15 16 17 18 19 20 21 22 23 Electrical Access Panel Riser, Supply and Return (Copper) Riser, Drain (Copper) Return Air Panel Motor, 3-Speed, PSC Blower Thermostat (Optional) Hinged Control Access Door Double Deflection Steel Core Grille Assembly 10 11 12 13 1 3/5 1 1 2/4 *Drawing provided for reference only. Dimensions may vary with options ordered. NOTES: 1. Units are fabricated of 18-gage galvanized steel with a 16-gage galvanized fan deck, painted with Arctic White. 2. Risers are piped to coil with valves as specified. 3. Blower, motor, valves, coil, and filter are accessible through the return air opening. 4. Unit and control box are insulated. 5. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 6. Maximum riser size is 21/2-in. diameter. If larger sizes are required, please consult the factory. 7. Expansion loops in hot water heating circuits as required. 8. A 9-in. x 21/4-in. slot is provided in the inside back panel for coil connection penetration to permit expansion and contraction of risers. Care must be taken to position the risers so that coil connection is at center of slot. 9. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 10. 42SHA available in front return only. 11. All dimensions are in inches. a42-4303 1 DIMENSIONS (in.) Double Supply C D A B 14 6 17 223/8 E F G UNIT WEIGHT† (lb) 21/2 221/8 143/4 202 17 223/8 21/2 221/8 143/4 247 8 20 253/8 21/2 265/8 173/4 262 14 10 20 253/8 21/2 265/8 173/4 286 16 14 12 24 293/8 21/2 311/8 173/4 311 16 14 12 24 293/8 21/2 311/8 173/4 336 UNIT SIZE NOM AIRFLOW (cfm) 1 03 300 1 2/4 1 1 1 1 1 1 1 04 400 14 12 14 8 06 600 14 12 14 08 800 14 16 10 1000 18 12 1200 18 2 Single Supply A B 14 8 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. **Factory-Installed. ††Field-Installed. Fig. 30 — 42SH Cabinet Dimensions 34 26 CR — CS — D — HR — HS — R — S — ITEM 1 LEGEND Cold Water Return Cold Water Supply Drain Hot Water Return Hot Water Supply Return Supply DESCRIPTION Electrical Knockouts QTY 6 2 Gypsum Board, 5/8-in. Type “X” 3 4 5 6 3-in. Expanded Section Strip Heater**(Optional) Limit Switch**†† (Optional) 3/5 2 2 1/ -in. 2 4/8 7 Thermafiber Insulation 2 8 9 Flexible Drain Tube/P-Trap Coil 1/2-in. OD Copper Tube 2 1 Isolation Ball Valves** 2 10 11 12 13 14 15 16 17 18 19 Filter, Throwaway, 1-in.** Return Air Opening Air Vent, Manual Knockout (For Optional Remote Mounting) Molex Connector for Field Installed Stat Control Box Riser, Drain (Copper) Riser, Supply and Return (Copper) Drain Pan Return Air Blockoff Panel (Optional) 2 2 2 2 2 2 1 2/4 2 20 21 22 23 24 Blower Motor, 3-Speed, PSC, with Quick Connect Access Panel (Control Box) Control Opening (Surface Mount Stat) Duct Collar, 1/2-in. Extension (Typical) 2 2 2 2 25 Supply Air Opening(s) Top Supply Duct Collar, 1-in. Extension (Optional) 26 1 *Drawing provided for reference only. Dimensions may vary with options ordered. NOTES: 1. Units are fabricated of 18-gage galvanized steel with a 16-gage galvanized fan deck. 2. All risers are insulated with closed cell insulation. 3. Thermostats shipped loose for field connection. 4. Risers are piped to coil with valves as specified. 5. Blower, motor, valves, coil, and filter are accessible through the return air opening. 6. Unit and control box are insulated. 7. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 8. Maximum riser size is 21/2-in. diameter. If larger sizes are required, please consult the factory. 9. Expansion loops in hot water heating circuits as required. 10. A 9-in. x 21/4-in. slot is provided in the inside back panel for coil connection penetration to permit expansion and contraction of risers. Care must be taken to position the risers so that coil connection is at center of slot. 11. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 12. All dimensions are in inches. A42-4304 DIMENSIONS (in.) Top Supply E C D 14 10 17 UNIT SIZE NOM AIRFLOW (cfm) 03 300 04 400 14 12 14 6 14 10 17 06 600 18 10 18 6 16 12 08 800 18 12 18 6 16 10 1000 — — 22 8 12 1200 — — 22 8 Single Supply A B 14 8 Double Supply A B 14 6 G H I J UNIT WEIGHT† (lb) 11/2 11/2 14 395/8 360 11/2 11/2 14 395/8 450 20 1 2 18 455/8 480 12 20 1 2 18 455/8 520 18 16 24 1 3 22 535/8 560 18 16 24 1 3 22 535/8 610 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. 1/2/3 1/2/3 1 **Factory-Installed. ††Field-Installed. Fig. 31 — 42SJ Back-to-Back Furred-In Stack Dimensions 35 24 CR — CS — D — HR — HS — R — S — ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 LEGEND Cold Water Return Cold Water Supply Drain Hot Water Return Hot Water Supply Return Supply DESCRIPTION Electrical Knockouts QTY 1 3-in. Expanded Section Strip Heater** (Optional) Limit Switch**†† (Optional) 1/ -in. Isolation Ball Valves** 2 Flexible Drain Tube/P-Trap Coil 1/2-in. OD Copper Tube 3/5 1 1 2/4 1 1 Filter, Throwaway, 1-in.** Return Air Opening Air Vent, Manual Knockout (For Optional Remote Mounting) Molex Connector for Field-Installed Thermostat Control Box Riser, Supply and Return (Copper) Riser, Drain (Copper) Drain Pan 1 1 1 2 1 1 2/4 1 1 *Drawing provided for reference only. Dimensions may vary with options ordered. NOTES: 1. Units are fabricated of 18-gage galvanized steel with a 16-gage galvanized fan deck. 2. All risers are insulated with closed cell insulation. 3. Thermostats shipped loose for field connection. 4. Risers are piped to coil with valves as specified. 5. Blower, motor, valves, coil, and filter are accessible through the return air opening. 6. Unit and control box are insulated. 7. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 8. Maximum riser size is 21/2-in. diameter. If larger sizes are required, please consult the factory. 9. Expansion loops in hot water heating circuits as required. 10. A 9-in. x 21/4-in. slot is provided in the inside back panel for coil connection penetration to permit expansion and contraction of risers. Care must be taken to position the risers so that coil connection is at center of slot. 11. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 12. All dimensions are in inches. A42-4128 DIMENSIONS (in.) Double Supply Top Supply A B C D 14 6 14 10 UNIT SIZE NOM AIRFLOW (cfm) 03 300 04 400 14 12 14 6 14 10 06 600 18 10 18 6 16 Single Supply A B 14 8 E G H I UNIT WEIGHT† (lb) 17 11/2 11/2 14 180 17 11/2 11/2 14 225 12 20 1 2 18 240 Acoustical Bypass Panel 1 08 800 18 12 18 6 16 12 20 1 2 18 260 18 19 20 21 22 Blower Motor, 3-Speed, PSC, with Quick Connect Access Panel (Control Box) Control Opening (Surface Mount Thermostat) Duct Collar, 1/2-in. Extension (Typical) 1 1 1 1 10 1000 — — 22 8 18 16 24 1 3 22 280 12 1200 — — 22 8 18 16 24 1 3 22 305 23 Supply Air Opening(s) Top Supply Duct Collar, 1-in. Extension (Optional) 24 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. 1/2/3 1/2/3 1 **Factory-Installed. ††Field-Installed. Fig. 32 — 42SGM Furred-In Master Stack Dimensions 36 23 CR — CS — D — HR — HS — R — S — ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 LEGEND Cold Water Return Cold Water Supply Drain Hot Water Return Hot Water Supply Return Supply DESCRIPTION Electrical Knockouts QTY 1 Strip Heater** (Optional) Limit Switch**†† (Optional) 1/ -in. Isolation Ball Valves** 2 Coil Stub Outs Shipping Brace Flexible Drain Tube/P-Trap Coil 1/2-in. OD Copper Tube 1 1 2/4 2/4 2/4 1 1 Filter, Throwaway, 1-in.** Return Air Opening Air Vent, Manual Knockout (For Optional Remote Mounting) Molex Connector for Field-Installed Stat Control Box Drain Pan Return Air Blockoff Panel (Optional) Blower Motor, 3-Speed, PSC, with Quick Connect Access Panel (Control Box) Control Opening (Surface Mount Thermostat) Duct Collar, 1/2-in. Extension (Typical) Supply Air Opening(s) Top Supply Duct Collar 1-in. Extension (Optional) 1 1 1 2 1 1 1 1 1 1 1 1 1/2/3 *Drawing provided for reference only. Dimensions may vary with options ordered. NOTES: 1. Units are fabricated of 18-gage galvanized steel with a 16-gage galvanized fan deck. 2. All risers are insulated with closed cell insulation. 3. Thermostats shipped loose for field connection. 4. Risers are piped to coil with valves as specified. 5. Blower, motor, valves, coil, and filter are accessible through the return air opening. 6. Unit and control box are insulated. 7. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 8. Maximum riser size is 21/2-in. diameter. If larger sizes are required, please consult the factory. 9. Expansion loops in hot water heating circuits as required. 10. A 9-in. x 21/4-in. slot is provided in the inside back panel for coil connection penetration to permit expansion and contraction of risers. Care must be taken to position the risers so that coil connection is at center of slot. 11. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 12. All dimensions are in inches. A42-4129 DIMENSIONS (in.) Double Supply Top Supply A B C D 14 6 14 10 UNIT SIZE NOM AIRFLOW (cfm) 03 300 04 400 14 12 14 6 14 10 06 600 18 10 18 6 16 08 800 18 12 18 6 10 1000 — — 22 12 1200 — — 22 Single Supply A B 14 8 E G H I UNIT WEIGHT† (lb) 17 11/2 11/2 14 162 17 11/2 11/2 14 203 12 20 1 2 18 216 16 12 20 1 2 18 234 8 18 16 24 1 3 22 252 8 18 16 24 1 3 22 275 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. 1/2/3 1 **Factory-Installed. ††Field-Installed. Fig. 33 — 42SGS Furred-In Slave Stack Dimensions 37 Item 1 2 3 Description Float Switch (Optional) Drain Pan Flexible Drain Tube/P-Trap 4 Drain Knockout (3 Sides) 5 6 7 8 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 Remote Mounting) Molex Connector for Field-Installed Thermostat Control Box Duct Collar Extension (1/2 in. Side, 1 in. Top) Outside Air Knockout (On Each Side Panel) Electrical Knockouts (Near Each Side) Service Switch (Optional) Motor, 3-Speed, PSC, with Quick Connect Access Panel for Motor and Blower Assembly Access Panel (Control Box) Control Opening Knockout (Surface Mount Thermostat) Supply Air Openings (4 Sides and Top, Stitch Cut) 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 3 (76) 3-5/8 (92) HR Qty 1 1 1 1 each side 1 2/4 2/4 1 D CR 1-1/4 (32) CS 1 C 16 H TOP VIEW A 23 4 DETAIL SIDE VIEW F 15 3 1 3 4 (102) 1-1/4 (32) 17 H 2 1-1/4 (32) D 1 1 1 HS 3 (76) 3-5/8 (92) B 1 1/2/3 1 1 14 22 13 21 18 1 1 88 (2235) 12 20 6 19 1 1 H H R S 1 C C R S 11 7 10 63 (1600) 1/2/3 5 51 (1295) 9 39 (991) 8 CR CS D HR HS PSC SWT — — — — — — — LEGEND Cold Water Return Cold Water Supply Drain Hot Water Return Hot Water Supply Permanent Split Capacitor Sweat I E E SIDE VIEW FRONT VIEW NOTES: 1. Units are fabricated of 18-gage galvanized steel with a 16-gage galvanized fan deck. 2. Thermostats shipped loose for field connection. 3. Blower, motor, valves, coil, and filter are accessible through the return air opening. 4. Unit and control box are insulated with 1/2-in. (13 mm) coated fiberglass insulation. 5. All risers will ship separately from units. Riser dimensions are measured from centerline of knockout. 6. Drain knockouts on three sides of cabinet. 7. Flex hoses ship with unit. 8. Thread fittings on both ends of flex hoses must be field tightened and leak tested. 9. Return air panel not shown. 10. All dimensions are in inches (mm). UNIT SIZE UNIT WEIGHT* (lb) 03 180 04 225 06 240 08 260 10 280 12 305 5 (127) 8 (203) a42-4305 DIMENSIONS (in.) A Side Supply B Size C D Size Top Supply E FILTER SIZE (in.) F H I 14 12 14 x 12 14 10 14 x 10 17 3 11/2 14 121/2 x 241/4 x 1 18 12 18 x 12 16 12 16 x 12 20 1 2 18 161/4 x 263/4 x 1 22 16 22 x 16 18 16 18 x 16 24 1 3 22 201/2 x 291/4 x 1 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 34 — 42SU Universal Furred-In Stack Dimensions 38 3 (76) 3-5/8 (92) HR HS D CR CS 3 (76) 3-5/8 (92) 1 1-1/4 (32) 2 1-1/4 (32) D 3 4 (102) 1-1/4 (32) 19 H C 18 H TOP VIEW A 25 4 DETAIL SIDE VIEW F 17 B 24 5 16 15 23 6 88 (2235) 14 20 7 8 22 21 H H R S 13 C C R S 11 51 (1295) 10 12 13 16 I E FRONT VIEW — — — — — — — Limit Switch (Factory Installed) Strip Heater 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 Remote Mounting) Molex Connector for Field-Installed Thermostat Control Box Duct Collar Extension (1/2 in. Side, 1 in. Top) Outside Air Knockout (On Each Side Panel) Electrical Knockouts (Near Each Side) Service Switch (Optional) Motor, 3-Speed, PSC, with Quick Connect Access Panel for Motor and Blower Assembly Access Panel (Control Box) Control Opening Knockout (Surface Mount Thermostat) Supply Air Openings (4 Sides and Top, Stitch Cut) 15 5 (127) 8 (203) CR CS D HR HS PSC SWT Drain Knockout (3 Sides) 5 6 7 8 9 10 14 39 (991) 17 18 E 19 SIDE VIEW 20 21 LEGEND Cold Water Return Cold Water Supply Drain Hot Water Return Hot Water Supply Permanent Split Capacitor Sweat 22 23 24 25 NOTES: 1. Units are fabricated of 18-gage galvanized steel with a 16-gage galvanized fan deck. 2. Thermostats shipped loose for field connection. 3. Blower, motor, valves, coil, and filter are accessible through the return air opening. 4. Unit and control box are insulated with 1/2-in. (13 mm) coated fiberglass insulation. 5. All risers will ship separately from units. Riser dimensions are measured from centerline of knockout. 6. Drain knockouts on three sides of cabinet. 7. Flex hoses ship with unit. 8. Thread fittings on both ends of flex hoses must be field tightened and leak tested. 9. Return air panel not shown. 10. All dimensions are in inches (mm). UNIT SIZE UNIT WEIGHT* (lb) 03 182 04 227 06 242 08 262 10 282 12 307 Description Float Switch (Optional) Drain Pan Flexible Drain Tube/P-Trap 4 11 9 12 63 (1600) Item 1 2 3 Qty 1 1 1 1 each side 1 1 1 2/4 2/4 1 1 1 1 3 1 1 1/2/3 1 1 1 1 1 1 1 1/2/3 a42-4306 DIMENSIONS (in.) A Side Supply B Size C D Size Top Supply E FILTER SIZE (in.) F H I 14 12 14 x 12 14 10 14 x 10 17 3 11/2 14 121/2 x 241/4 x 1 18 12 18 x 12 16 12 16 x 12 20 1 2 18 161/4 x 263/4 x 1 22 16 22 x 16 18 16 18 x 16 24 1 3 22 201/2 x 291/4 x 1 *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Fig. 35 — 42SU Universal Furred-In Stack with Heater Dimensions 39 3 (76) 3-5/8 (92) HR HS 3 (76) 3-5/8 (92) 3 (76) 3 (76) 1-1/4 (32) D CR CS 1-1/4 (32) HS D CR 11 (280) 11 (280) ELECTRICAL KNOCKOUTS 3 (76) 3 (76) 24 (610) 24 (610) 4-PIPE 4 (102) 4 22 (559) 2-PIPE 4 (102) 1 (25) SUPPLY PLENUM (OPTIONAL) 16 (406) CONTROL BOX MOTOR/BLOWER, 3 SPEED, PSC, HIGH STATIC RISER KNOCKOUTS 66* (1676) (OPTIONAL) RETURN AIR 59 PANEL (1499) 39 (991) SWT X 37.5 FLARE ADAPTER FILTER COIL FLEXIBLE DRAIN TUBE/P-TRAP 28 (711) 30 (762) CR — CS — D — HR — HS — PSC — SWT— 22 (559) 4-3/4 (121) ACOUSTICAL SERVICE ACCESS PANEL (OPTIONAL) INTERLOCKING DISCONNECT SWITCH 1 (25) 16 (406) SUPPLY TOP DUCT COLLAR, 1"(25) SUPPLY AIR OPENING 4-3/4 (121) 22 (559) LEGEND Cold Water Return Cold Water Supply Drain Hot Water Return Hot Water Supply Permanent Split Capacitor Sweat DRAIN PAN 5 (127) 24 (610) 5 (127) NOTES: 1. Unit measurements on drawings are shown in inches (millimeters). 2. Units are fabricated of galvanized steel with a 16 gage galvanized fan deck. 3. Blower, motor, valves, coil, and filter are accessible through the return air opening. 4. Unit and control box are insulated with 1/2-in. (13 mm) coated fiberglass insulation. 5. Maximum riser size is 21/2-in. (64 mm) diameter. If larger sizes are required, please consult the factory. 6. This drawing is pictorial. (See unit arrangements for actual supply and return air orientation.) 7. Riser length = [floor to floor + 2-in. (51 mm)]. Maximum riser length is 119-in. (3023 mm). 8. Unit shipping weight is approximately 390 lb (176 kg). Fig. 36 — 42SM Mega Furred-In Stack Dimensions 40 PANEL DIMENSIONS (in.) A42-4173 A a42-4167 A PANEL NO. UNIT UNIT SIZE A 1 42SG,SJ, SU 03, 04 06, 08 10, 12 15.5 19.5 23.5 42SM 14,16,20 29.5 2 42SG,SJ 03, 04 06, 08 10, 12 15.5 19.5 23.5 3 42SG,SJ 03, 04 06, 08 10, 12 15.2 19.2 23.2 A 61.1 NOTE: Dimensions in inches. 55.3 55.5 A42-4272 PANEL NO. 1 PANEL NO. 2 PANEL NO. 3 a42-4169 A A A A42-4275 A42-4274 60.5 61.1 52.5 PANEL NO. 2 WITHOUT DOOR PANEL NO. 1 FOR 42SU PANEL NO. 1 FOR 42SM Fig. 37 — Return-Air Wall Panels for Furred-In Units — Panels with No Frame Dimensions 41 PANEL AND FRAME DIMENSIONS (in.) PANEL NO. UNIT UNIT SIZE A 4 42SG,SJ, SU 03, 04 06, 08 10, 12 15.1 19.1 23.1 5 42SG,SJ 03, 04 06, 08 10, 12 15.1 19.1 23.1 A42-4273 NOTE: Dimensions in inches. A42-4168 A42-4276 A A A42-4277 A A 60.4 60.4 54.7 51.7 PANEL NO. 4 PANEL NO. 5 WITH CONTROL DOOR PANEL NO. 5 WITHOUT DOOR PANEL NO. 4 FOR 42SU Fig. 38 — Return-Air Wall Panels for Furred-In Units — Panels with Frame Dimensions unit. Hanger rods and fasteners and other required hardware must be field-supplied. 4. Move unit into position. Ensure unit is level or pitched towards drain to ensure proper drainage and operation. Pitch of suspended unit can change after coil is filled; recheck after filling coil. 5. Mounting unit: a. Use rods and fasteners to suspend the unit at the factory-provided mounting holes with rubber grommets on the top of the unit on 42CG, CK units. Reach into unit and attach unit to the ceiling using the 0.375-in. mounting holes (4) in top panel; do not use any other locations. INSTALLATION Step 1 — Place Units in Position 42C UNITS 1. Select the unit location. Allow adequate space for free air circulation, service clearances, piping and electrical connections, and any necessary ductwork. For specific unit dimensions, refer to Fig. 1-12. Allow clearances according to local and national electric codes. 2. Make sure ceiling is able to support the weight of the unit. See Table 1 for nominal unit weight. 3. Ensure bottom panel has been removed from 42CG, CK units with mounting holes. When unit is lifted, access to the 0.375-in. mounting holes is through the bottom of the 42 Fasteners, furring strips, and other seals (if required) must be field-supplied. 4. Remove all wall and floor moldings from behind the unit. 5. Ensure 42VA top panel (under window application) and 42VB, VF front panel has been removed from unit to obtain access to the four 0.75-in. mounting holes. Hanger rods and fasteners and other required hardware must be field-supplied. 6. Move unit into position. Ensure unit is level or pitched towards drain to ensure proper drainage and operation. Pitch of suspended unit can change after coil is filled; recheck after filling coil. 7. Adjust 42VA, VB, VC, VE, VF units leveling legs so unit is level. Unit must be level for proper operation and condensate drainage. 8. Mounting unit: The type of mounting device is a matter of choice, however, the mounting point shall always be that provided in the chassis or cabinet. a. Use rods and fasteners to suspend the unit at the factory-provided mounting holes with rubber grommets on the top of the unit on 42VA, VB, VF units. Reach into unit and attach unit to the wall using the 0.375-in. mounting holes (4) in top panel; do not use any other locations. The four mounting holes and hanger slots with rubber grommets are NOT for balancing unit. b. On 42VG unit ensure unit is placed snug within the wall. c. On 42VC, VE unit ensure unit is placed flush against the wall. NOTE: For any unit without a return-air duct connection, applicable installation codes may limit unit to installation in single-story residence only. b. Use rods and fasteners to suspend the unit at the factory-provided 0.375-in. hanger slots (4) with rubber grommets on the top of the unit on the 42CA and CE units. NOTE: The four mounting holes and hanger slots with rubber grommets are NOT for balancing unit. 6. The 42CA units without plenums and 42CE with bottom inlet may be installed in noncombustible areas only. NOTE: The installation of horizontal concealed units must meet the requirements of the National Fire Protection Association (NFPA) Standard 90A or 90B concerning the use of concealed ceiling space as return-air plenums. 42V UNITS — While the manufacturer is not involved in the design and selection of support methods and components, it shall be noted that unacceptable system operating characteristics and/or performance may result from improper or inadequate unit structural support. 1. Select the unit location. Allow adequate space for free air circulation, service clearances, piping and electrical connections, and any necessary ductwork. For specific unit dimensions, refer to Fig. 13-23. Allow clearances according to local and national electric codes. See Fig. 39 for minimum clearance recommendations. 2. Make sure the floor is able to support the weight of the unit. See Table 2 for nominal unit weight. Vertical units are designed to be floor mounted or otherwise supported from below, and bolted to the wall or floor structure through the mounting holes provided in the chassis. These units may be wall hung only when originally ordered from the factory for wall mount applications. 3. Ensure wall behind unit is smooth and plumb; if necessary, install furring strips on walls with irregular surfaces or mullions. Furring strips must be positioned behind mounting holes in unit (42VA, VB, VF units). 12" Level Unit ±¼" ½" Minimum ½" Minimum 30" Minimum per building code FRONT VIEW SIDE VIEW Fig. 39 — Clearance Recommendations 43 construction, floor plans, and unit configurations, each installation is different. The actual step-by-step method of installation may vary from unit to unit. However, the risers should be moved as little as possible to avoid damage to the unit and internal components. 42SG, SH, and SJ Units 1. Begin on lowest floor and progress upward, floor by floor, to top. 2. Examine drain line (Fig. 34 and 35). Be sure both ends are in place and that it forms a trap. Avoid pinching drain line. 3. Tip unit over riser hole in building floor. As unit is righted, align riser with unit below. NOTE: The unit must be lowered into the space taking care to properly align the risers to engage the riser swaged section on the unit below. The riser should never be bent or pushed together to be passed through the floor slot and should never be lifted up or pulled down to meet the riser on the floor below or above. 4. Install isolator pads beneath the four corners of unit if applicable. 5. Before anchoring the equipment in place, the unit must be leveled and the cabinet must be squared and brought into line with any adjacent or included walls. The unit may be anchored in place by bolting directly through the unit 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. When attaching to the unit cabinet, care must be taken to not penetrate the cabinet in locations that may damage internal components or wiring. The mounting technique is a matter of choice; however, the unit should always be anchored securely to prevent movement during construction and riser expansion and contraction. On certain units, shipping screws or braces must be removed after the unit is installed. Be sure to check all tags on the unit to determine which, if any, of these devices need to be removed. 6. If installing a 42SJ unit, follow Steps a-h. For 42SG and 42SH units, continue to Step 7. NOTE: The 42SJ back-to-back fan coils have been designed to serve two separate rooms. These products are classified by Underwriters Laboratories Inc. for use in penetration firestop systems, control number 27WL when ordered with 1-hr rated chase. See UL Fire Resistance Directory for more information. Figure 40 shows the 42SJ unit with standard risers and with Siamese risers. a. Lay out the control lines for the drywall track and studs in the floor and ceiling (see Fig. 41). NOTE: Tracking may be installed now or after the unit is set. b. Position the 42SJ fan coil assembly between two rooms with the unit drywall separation spotted over the wall control lines. 42D UNITS 1. Select the unit location. Allow adequate space for free air circulation, service clearances, piping and electrical connections, and any necessary ductwork. For specific unit dimensions, refer to the submittal drawings. Allow clearances according to the local and national electrical codes. 2. Be sure either the ceiling (42DA, DC, DE, and DF units) or floor (42DD unit) is able to support the weight of the unit. See Table 3 for nominal unit weight. 3. Move unit into position. Ensure unit is level or pitched towards drain to ensure proper drainage and operation. See Fig. 24-28. Pitch of suspended unit can change after coil is filled; recheck after filling coil. 4. Mounting units to the ceiling: a. When unit is lifted, access to the 0.375-in. mounting holes is on the top panel of the unit. Hanger rods and fasteners and other required hardware must be field-supplied. b. Use rods and fasteners to suspend the unit at the factory-provided mounting holes with rubber grommets on the top of the unit. Attach unit to the ceiling using the 0.375-in mounting holes (4) in top panel; do not use any other locations. c. Use the rods and fasteners to suspend the unit at the factory-provided 0.375-in. hanger slots (4) with the rubber grommets on the top of the unit on the 42DA, DC, DE, and DF units. NOTE: The four mounting holes and hanger slots with rubber grommets are NOT for balancing unit. d. Models 42DA and 42DC with bottom inlet may be installed in noncombustible return spaces only. 5. Mounting units on the floor: a. Ensure wall behind the unit is smooth and plumb; if necessary, install furring strips on walls with irregular surfaces or mullions. Furring strips must be positioned behind mounting holes on 42DD units. Fasteners, furring strips, and other seals (if required) must be field-supplied. b. If the unit has leveling legs, adjust them correctly to level the unit. 6. Protect units from damage caused by jobsite debris. Do not allow foreign material to fall in unit drain pan. Prevent dust and debris from being deposited on motor or fan wheels. 42S UNITS — A factory tag is on top of each unit. Tag states riser tier number, floor, room number if furnished and supplyair arrangement. Check unit for any other labels that apply to installation. Units should not be installed at locations other than that marked on the unit identification tag. If no specific detail is shown on tag for unit location then determine configuration for the Universal unit based on information within this manual. Should any questions arise regarding unit configuration, contact the sales representative or the factory BEFORE proceeding. Remove unit from pallet and take directly to assigned space for installation. While all equipment is designed and fabricated with sturdy materials and may present a rugged appearance, great care must be taken to assure that no force or pressure be applied to the coil, risers or piping during handling. Never use the riser to lift the unit. To maintain the straight and square cabinet alignment, avoid lifting or supporting the cabinet only at the top and bottom. For specific unit dimensions refer to Fig. 29-33. While the manufacturer does not become involved in the design and selection of support methods and components, it should be noted that unacceptable system operating characteristics and/or performance may result from improper or inadequate unit structural support. Due to variations in building 42SJA 42SJA 42SJB 42SJB Fig. 40 — 42SJ Unit with Standard and Siamese Risers 44 7. Attach unit risers: CAUTION CHASE SIDE PANEL DRYWALL TRACK AND STUD CONTROL LINES Toxic residues and loose particles resulting from manufacturing and field piping techniques such as joint compounds, soldering flux, and metal shavings may be present in the unit and the piping system. Special consideration must be given to system cleanliness when connecting to solar, domestic or potable water systems. Failure to heed this warning could result in equipment damage. INSTALL WALL STUD INTO POCKET FORMED BY CHASE SIDE PANEL NOTE: Submittals and product literature detailing unit operation, controls, and connections should be thoroughly reviewed BEFORE beginning the connection and testing of risers and piping. The supply and return connections are marked on the coil stub-outs and the valve package with an “S” meaning supply or inlet and “R” meaning return or outlet indicating flow direction to and from the coil. Blue letters mark the chilled water connections and red letters mark the hot water connections. a. Each riser has a 3-in. swaged portion at top and sufficient extension at bottom for an inserted length of approximately 2-inches. This unit-tounit joint is NOT intended for full bottoming in the joint, but allows for variations in floor-to-floor dimensions and for correct riser positioning. If job requires that unit risers be supplemented with between-the-floor extensions, pieces may be field-supplied or factory-supplied. If factorysupplied, insulation is also provided. b. Level unit to ensure proper coil operation and condensate drainage. Proper riser installation and vertical positioning in the unit provides for a unit piping run-out to the service valves which are centered in the access slots and level or sloping down slightly away from the riser. This prevents condensation from running back to the riser and possible damage from dripping at the bottom of a riser column. Each job has specific requirements, and satisfying those requirements is the responsibility of the installer. After units are positioned and riser centered in pipe chase, make unit plumb in two directions, using unit frame as a reference. c. Anchor unit to building. Use bolts or lag screws through holes provided in unit frame. d. After all units in a stack are anchored, make unitto-unit riser joints. First, center each coil-to-riser line within the expansion slot in the unit back panel. Each riser joint must be in vertical alignment with at least 1-in. penetration into the swaged joint. This condition is met if floor-tofloor dimension is as specified and coil-to-riser lines are properly centered. Wide variations in floor-to-floor dimensions may necessitate cutting off or extending individual risers. Such modifications are the full responsibility of the installing contractor. e. Before making the riser joints, the riser insulation must be pulled back away from the joint and protected from heat during the brazing process. The riser joint filler material must be selected to withstand the total operating pressure (both static and pumping head) to which the system will be subjected. Low temperature lead alloy solders such as “50/50” and “60/40” are normally not suitable. INSTALL STUDS FROM TOP OF UNIT TO CEILING (4 CORNERS) Fig. 41 — 42SJ Wall Board Installation c. If not already installed, install the floor and ceiling tracks up to and over the 42SJ fan coil unit. d. Position the vertical studs and fasten into each of the stud pockets formed into the chase side panels (see Fig. 41). NOTE: The studs may be mechanically fastened to the 42SJ fan coil. Care should be taken, however, not to penetrate the supply or return water risers or internal piping. Given the levelness of the floor and/or the fan coil assembly, some shimming may be necessary. e. Assemble the specified wall construction up to and over the top of the fan coil unit (see Fig. 42). f. With the fire-wall separation being complete, the drywall skin on the surface of the individual fan coils can be applied. Drywall can be applied directly to the surface, or, if necessary, studding may be installed on the corners for vertical control (see Fig. 42). g. For ease of installation of the access panel, apply drywall on the return air side directly to the surface of the unit (see Fig. 42). When applying the wall board directly to the unit cabinet, it may be necessary to shim the wall board in some areas to achieve the desired finished wall surface. h. After all drywalling and painting is complete, install thermostats, supply air grilles and return air panels. WALL STUDS INSTALL GYPSUM BOARD TO FACE OF UNIT WITH CUT OUTS FOR SUPPLY, RETURN AND THERMOSTAT INSTALL WALL GYPSUM BOARD (TO WALL AND OVER TOP OF UNIT) INSTALL GYPSUM BOARD TO UNIT SIDES Fig. 42 — 42SJ Unit Installation 45 Potential 42SU Unit Configurations Risers: Three Locations — The pre-installed supply, return, and drain risers (2-pipe or 4-pipe applications) can be oriented on any of three sides of the unit (see Fig. 43). NOTE: Risers cannot be installed on the return air side of the cabinet. IMPORTANT: Chilled water and hot water risers should never be piped to drain down into the condensate riser. Extensive water damage can occur due to drain overflow. Drain chilled and hot water risers to a remote location away from the unit such as sink, room or floor drains. a42-4283 HS D CR CS 42SU CABINET CS HR CR HS D D HS CR CS HR HR 8. Anchor risers as required: a. Do not fasten risers rigidly within each unit. Risers must be free to move within pipe chase in response to normal vertical expansion and contraction. The unit internal piping is designed to accommodate a total riser vertical movement of ± 3/4 in., due to thermal expansion and/or contraction, when positioned properly at the jobsite. b. Built-in risers must be anchored at some point to building structure. Unit design accommodates up to 11/2-in. expansion and contraction in riser assemblies when positioned properly at the jobsite. Risers must be anchored to the building structure to limit expansion and contraction movement to a maximum of 11/2 inches. Riser anchoring and expansion compensation is not included in the factory-supplied unit and must be field provided. While some special riser features are available from the factory, riser end caps, air vents, and/or flushing loops are normally provided on the job by the installer. 9. Test the system for leaks after the connections are completed. When testing with air or some other gas, it might be necessary to tighten stem packing nuts on some valves to maintain air pressure in the riser. Pressure testing risers with water should be done with the unit service valves closed to prevent flushing debris into the unit valve packages. This will also allow risers to be drained down after testing in the winter to avoid freeze-up problems. In the event that leaking or defective components are discovered, the sales representative must be notified before any repairs are attempted. All leaks should be repaired before proceeding with the installation. 10. After system integrity has been established, pull the riser insulation back into place over the joint and glue or seal to prevent sweating and heat loss or gain. Internal chilled water piping and valves are located over the drain pan and need not be insulated. 11. If required, fireproof where necessary. Any fireproofing requirements where risers or piping penetrate floors or walls are the responsibility of the installer. This work should be done only after all pressure testing is completed. The fireproofing method used must accommodate pipe expansion and contraction and the piping must be protected from abrasion and chemical attack. The pipe insulation also must be maintained to prevent sweating and must be protected from wear or erosion at the joint between the insulation and the fireproofing material. 42 SU Units — The unique design of the universal stack fan coil unit allows for field configuration for each unit. Air discharge, riser, drain, and outside air knockouts have been strategically located on each unit. Risers, shown with unit, are for reference only. All risers are factory fabricated and shipped loose for field installation. It is important that you identify all of the unit feature locations and which knockouts you intend to use before proceeding with the installation. See Fig. 43-47. Also, it must be determined whether your application requires a Mating Unit (primary/secondary) and its configuration. Consult your local sales representative or the factory for further details on primary/secondary arrangements. RETURN AIR R R = D = S = D S RETURN DRAIN SUPPLY 2- or 4-PIPE HR HR HS D CR CS HS = = = = = D CR CS HOT WATER RETURN HOT WATER SUPPLY DRAIN COLD WATER RETURN COLD WATER SUPPLY Fig. 43 — 42SU Unit Configuration Unit orientation is determined based on the location of the risers in the building. The riser side of the universal stack unit always determines the rear of the unit. See Fig. 44. a42-4284 REAR (RISER SIDE) LEFT 42SU CABINET RIGHT FRONT Fig. 44 — 42SU Unit Orientation Return Air: Single Location — The return air/access panel may then be oriented on the left, right, or front of the unit. Supply Air: Five Locations (4 sides and top) includes stitched design for 1/2-in. duct flanges. Outside Air: Two Locations — Either side adjacent to the return air opening. NOTE: Outside air opening may be used on a side if risers are configured on that same side. Supply, Return, and Drain Riser Installation 1. Three sides of each universal stack unit have four supply and return riser knockouts along the center and one drain knockout near the lower part of the unit (see Fig. 45). Identify whether your application uses a 2-pipe or 4-pipe configuration. a. Two-pipe configurations typically use the two inner riser knockouts. b. Four-pipe configurations will use all four riser knockouts. 46 2. Locate and mark the riser and drain knockouts that apply to your particular unit application, ensuring proper orientation of the return air opening in room. 3. Insert a flat head screw driver into knockout slot shown in Fig. 46. 4. Pry screw driver back and forth until knockout tabs break away from the unit. 5. Discard knockout. Be careful of sharp edges. 6. Use a sharp retractable knife (see Fig. 47) and vertically cut the insulation down the center of the riser and drain knockouts the full length of the knockout. 7. Use adhesive or glue to re-attach insulation that has pulled away from the unit during knockout removal process. a42-4285 a42-4309 SUPPLY AND RETURN KNOCKOUT KNOCKOUT TAB DRAIN KNOCKOUT KNOCKOUT SLOT KNOCKOUT TAB SIDE VIEW Fig. 46 — Remove 42SU Unit Knockouts a424287 SIDE SUPPLY AIR KNOCKOUT (1 PER SIDE) OPTIONAL ELECTRICAL KNOCKOUTS OUTSIDE AIR KNOCKOUT (2 SIDES ONLY, ADJACENT TO RETURN AIR OPENING) a42-4286 ELECTRICAL KNOCKOUTS Fig. 47 — 42SU Unit Knockout Insulation Removal Double Riser Swag Installation 1. The riser carton should contain: a. 2-pipe application: 1 supply riser with threaded ball valve stub-out 1 return riser with threaded ball valve stub-out 1 drain riser with copper stub-out b. 4-pipe application: 2 supply riser with threaded ball valve stub-out 2 return riser with threaded ball valve stub-out 1 drain riser with copper stub-out 2. Measure the building’s floor-to-floor height and refer to Table 5 for correct field supplied riser extension length required. RISER KNOCKOUTS (4 PER SIDE, EXCEPT ON RETURN AIR SIDE) RETURN AIR DRAIN INSULATION CUT LINE SUPPLY AND RETURN INSULATION CUT LINE DRAIN KNOCKOUT (1 PER SIDE, EXCEPT ON RETURN AIR SIDE) Table 5 — Recommended Extension Length TOP VIEW FLOOR-TO-FLOOR DIMENSION (in.) EXTENSION LENGTH REQUIRED (in.) 102 26 104 28 106 30 3. Before cutting riser extensions, make sure the piece of riser you are going to cut to make the extension matches the riser diameter that was ordered with unit. All transition pieces like riser reducers are field supplied and field installed. 4. Cut riser extensions using the recommended length from Table 5. 5. Identify and orient each unit riser so the installer knows which end is the top and which is the bottom. Use Fig. 48 and Table 6 for reference. TOP SUPPLY AIR KNOCKOUT Fig. 45 — Locate 42SU Unit Knockouts 47 SUPPLY/ RETURN TOP 9. Insert brazed extension/riser into the building’s floor block-out hole in the order specified in Fig. 48. Insert extension into swage of unit below, approximately 2-inches. 10. Verify the floor to riser stub-out and/or ball valve assembly dimension. For a return and supply riser, this dimension should be 39-inches. For a drain riser, this dimension should be 5-inches. (See Table 6.) 11. Verify riser stub-out is correctly aligned so that stub-out will penetrate through the riser knockout slot of the unit. 12. Secure the riser positions for final braze. 13. Make sure braze joint between riser and cut extension according to local building code specifications. 14. Repeat steps 2 through 13 for each floor as you move up the riser column. 15. Once all risers have been installed, the installer must perform a leak test for each riser column. 16. Once the riser column has passed its leak test inspection, each riser extension should be properly insulated. No exposed copper should be allowed for the riser columns. 17. Install the unit drain P-trap per unit instructions. 18. Prepare the unit for assembly per unit instructions. 19. Attach and install hose kits and P-trap to the unit per unit instructions. DRAIN TOP 26.75 60.75 53 19 CAUTION Fig. 48 — Riser Extension Toxic residues and loose particles resulting from manufacturing and field piping techniques such as joint compounds, soldering flux, and metal shavings may be present in the unit and the piping system. Special consideration must be given to system cleanliness when connecting to solar, domestic or potable water systems. Table 6 — Unit Riser Orientation BOTTOM STUB-OUT SWAGE TO HIGHT - AFF RISER (Above STUB-OUT (in.) Finished Floor) RISER TYPE TOP SWAGE TO RISER STUB-OUT (in.) Supply and Return Riser 26.75 53 39 Drain Riser 60.75 19 5 Submittals and product literature detailing unit operation, controls, and connections should be thoroughly reviewed BEFORE beginning the connection and testing of risers and piping. To assure optimal unit performance, the supply connection(s) are marked on the unit’s coil with an “S” meaning supply or inlet and “R” meaning return or outlet indicating flow direction to and from the coil. Blue letters mark the chilled water connections and red letters mark the hot water connections. The unit’s internal piping is designed to accommodate a total riser vertical movement of ±1½ in., due to thermal expansion and/or contraction, when positioned properly at the jobsite. Risers must be anchored to the building structure to limit expansion and contraction movement to a maximum of 3 inches. Riser anchoring and expansion compensation is not included in the unit and must be provided. Riser end caps, air vents, and/or flushing loops must be provided at the jobsite by the installer. Proper field riser installation and vertical positioning in the unit should have a pipe run-out to the service valves which are centered in the knockout access slots and that slope down slightly away from the riser (see Fig. 48). This prevents condensation from running back to the riser and possible damage from dripping at the bottom of a riser column. Each job has specific requirements and satisfying those requirements is the responsibility of the installer. 6. Insert cut riser extensions into the bottom swages of the risers to a penetration depth of 2-inches. 7. Invert the riser with extension to allow for an easier braze. Make the braze joint according to local building code specifications. 8. Identify and orient the brazed risers so that they will match the riser locations for the installed unit. Use Fig. 49 for reference. 42SU CABINET RETURN AIR R D S R = Return D = Drain S = Supply HR HS D CR CS Riser to Unit Installation — Before making the riser joints, the riser insulation must be pulled back away from the joint and protected from heat during the brazing process. Each riser joint must be in vertical alignment. Variations in floor-to-floor dimensions may require field work such as cutting off or extending the risers. This operation is the responsibility of the installer. The riser joint filler material must be selected to withstand the total operating pressure (both static and pumping head) to HR = Hot Water Return HS = Hot Water Supply S = Supply CR = Cold Water Return CS = Cold Water Supply Fig. 49 — Brazed Riser Orientation 48 which the system will be subjected. Low temperature lead alloy solders such as “50/50” and “60/40” are normally not suitable. Riser to Drain Installation 1. After the applicable supply, return, and drain knockouts have been removed, carefully position the unit so that the riser ball valves penetrate into the unit through the riser knockouts making sure the insulation penetrates into the unit as shown in Fig. 50-53. 2. Before anchoring the equipment in place, the unit must be leveled and the cabinet must be plumb and squared. The unit may be anchored in place by bolting directly through the unit 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. When attaching to the unit cabinet, care must be taken to not penetrate the cabinet in locations that may damage internal components or wiring. The mounting technique is a matter of choice; however, the unit should always be anchored securely to prevent movement during construction and riser expansion and contraction. After anchoring the unit, it is then ready for the various service connections such as riser connections and electrical. 3. The plastic flare caps on the end of the riser ball valves should be removed and discarded. 4. All universal stack units use reinforced braided stainless steel flexible hose kits for piping between field-installed risers and unit water coils as shown in Fig. 51. The hose kit design has threaded connections on each end. The hose kits allow for riser fluctuations due to thermal expansion. a42 4288 RISER STUBOUT INSULATION BALL VALVE RISER KNOCKOUT SLOT WRENCH SWIVEL CONNECTION BACK-UP WRENCH Fig. 52 — 42SU Unit Riser to Unit Installation (Tighten Swivel Connections) a42-4291 DRAIN PAN UNIT INSULATION UNIT WALL RISER KNOCKOUT RISER DRAIN CLAMP CLAMP P-TRAP RISER STUBOUT Fig. 53 — 42SU Unit Riser to Drain Installation 5. Use a wrench to tighten the swivel connections. Use a backup wrench to hold the riser ball valve stationary to prevent it from bending or twisting during installation as shown in Fig. 52. Be careful to not over tighten swivel connections. UNIT INSULATION OUTER CABINET a42-4290 BALL VALVE THREADED FLARE FITTING CAUTION Hose connection torque requirements are 350 in. lb +10/ –0 in. lb to prevent leaks. 6. Locate the unit’s coil fitting. 7. The plastic flare caps on the end of the coil fitting should be removed and discarded. 8. Use a wrench to tighten the swivel connections. The baffle acts as a secondary wrench. Be careful to not over tighten swivel connections. FLARE CAP Fig. 50 — 42SU Unit Riser to Unit Installation Setup a42-4289 FLEXIBLE HOSE KIT RISER STUBOUT INSULATION RISER CAUTION BALL VALVE Hose connection torque requirements are 350 in. lb +10/ –0 in. lb to prevent leaks. 9. Locate the p-trap drain and rubber hose factory installed to the drain pan connection in the bottom of the unit as shown in Fig. 53. 10. Push the rubber drain hose over the riser drain stubout. Be careful not to bend the drain stubout. 11. Adjust the hose clamp over the riser stubout and rubber hose to hold in place as shown in Fig. 53. 12. Test for leaks. Any and all leaks should be repaired before proceeding with installation. When testing with air or some other gas, it might be necessary to tighten stem packing nuts on some valves to maintain air pressure in the riser. Pressure testing risers with water should be done with the unit service valves closed to prevent flushing BAFFLE COIL CONNECTION POINT TO ANY FACTORY FURNISHED AND INSTALLED COMPONENTS. Fig. 51 — 42SU Unit Riser to Unit Installation 49 9. Use adhesive or glue to re-attach insulation that has pulled away from the unit during knockout removal process. 10. For ducted applications tape should be applied along and around all of the supply air opening knockouts to prevent air leakage. debris into the unit valve packages. This will also allow risers to be drained down after testing in the winter to avoid freeze-up problems. In the event that leaking or defective components are discovered, the sales representative must be notified BEFORE any repairs are attempted. All leaks should be repaired before proceeding with the unit installation. 13. After system integrity has been established, the riser insulation must be pulled back into place over the joint and glued or sealed to prevent sweating and heat loss or gain. All of the risers including the riser stubouts should be properly covered with insulation. Internally mounted chilled water piping and valves are located over the drain pan and need not be insulated. Any fireproofing requirements where risers or piping penetrate floors or walls are the responsibility of the installer. This work should be done only after all pressure testing is completed. The fireproofing method used must accommodate pipe expansion and contraction and the piping must be protected from abrasion and chemical attack. The pipe insulation also must be maintained to prevent sweating and must be protected from wear or erosion at the joint between the insulation and the fireproofing material. When no risers are ordered for the universal stack unit, it is the responsibility of the installer to make sure that an isolation ball valve is installed between each supply and return piping connection to the unit. Flare fittings are factory provided to allow connection between the ball valves and the hoses. Supply Air Installation — Each side of the unit has one supply air knockout as well as a supply air knockout on the top of the unit (see Fig. 45). 1. Determine which supply air opening/openings are required for your application. NOTE: The supply air opening on the riser side of the unit should not be used. 2. Use a sharp retractable knife to trim insulation using center knockout slot/trim line as pattern (see Fig. 54). 3. Use a sharp standard needle nose pliers and grab knockout tab (see Fig. 54). a42-4293 DUCT FLANGE UNIT WALL 90° UNIT INSULATION Fig. 55 — 42SU Supply Air Installation All installations should be made in compliance with all governing codes and ordinances. Compliance with all codes is the responsibility of the installing contractor. 42 SM Units — The unique design of the mega stack fan coil unit allows for field configuration of each unit. Risers, shown with unit, are for reference only. All risers are factory fabricated and shipped loose for field installation. It is important that you identify all of the unit feature locations before proceeding with the installation, see Fig. 36. Also, it must be determined whether your application requires a mating unit (primary/secondary) and its configurations. Consult your local sales representative or the factory for further details on primary/secondary arrangements. Unit orientation is determined based on the location of the risers in the building. Risers can only be installed on the rear side of the unit and always determine the rear of the mega stack unit. The return air is always on the front (see Fig. 56). HR HS D CR a42-4294 CS REAR KNOCKOUT TAB (10 PLACES) LEFT 42SM CABINET RIGHT FRONT DUCT BREAK (4 PLACES) RETURN AIR R KNOCKOUT TAB TRIM LINE R = D = S = a42-4291 Fig. 54 — 42SU Unit Supply Air Installation D S RETURN DRAIN SUPPLY 2- or 4-PIPE 4. Twist or pry pliers back and forth until knockout tab breaks away from unit. 5. Repeat for all supply air tabs until all have been broken. 6. Discard center knockout piece. Be careful of sharp edges. 7. Use a sharp retractable knife to trim any excess insulation using knockout hole as pattern. 8. Use duct pliers (hand seamers) to fold duct flange out of the unit 90 degrees for each side of the supply air opening along duct break (see Fig. 54). The 90-degree flanges can now be used as drywall stops to prevent coverage of discharge opening (see Fig. 55). HR HR HS D CR CS HS = = = = = D CR CS HOT WATER RETURN HOT WATER SUPPLY DRAIN COLD WATER RETURN COLD WATER SUPPLY Fig. 56 — 42SM Unit Installation Supply, Return, and Drain Risers CAUTION Toxic residues and loose particles resulting from manufacturing and field piping techniques such as joint compounds, soldering flux, and metal shavings may be present in the unit and the piping system. Special consideration must be given to system cleanliness when connecting to solar, domestic or potable water systems. 50 2. Before anchoring the equipment in place, the unit must be leveled and the cabinet must be plumb and squared. The unit may be anchored in place by bolting directly through the unit’s floor or attaching to the building walls through the cabinet walls in some location that will not interfere with drywall or other items such as the supply grille, thermostat, or return access panel. When attaching sheetrock to the unit cabinet, care must be taken to not penetrate the cabinet in locations that may damage internal components or wiring. The mounting technique is a matter of choice; however, the unit should always be anchored securely to the building to prevent movement during construction and riser expansion and contraction. After anchoring the unit, it is then ready for the various service connections such as riser connections and electrical. 3. The plastic flare caps on the end of the riser ball valves should be removed and discarded. 4. All mega stack units use reinforced braided stainless steel flexible hose kits for piping between field installed risers and unit water coils as shown in Fig. 58. Each hose has threaded connections on each end. The hose kits allow for riser fluctuations due to thermal expansion. 5. Use a wrench to tighten the swivel connections. Use a backup wrench to hold the riser ball valve stationary to prevent it from bending or twisting during installation as shown in Fig. 59. Be careful to not over tighten swivel connections. Submittals and product literature detailing unit operation, controls, and connections should be thoroughly reviewed BEFORE beginning the connection and testing of risers and piping. The supply and return connections are marked on the coil stubouts and the valve package depending on your configuration. “CS” means cold water supply, “CR” means cold water return, “HS” means hot water supply, and “HR” means hot water return to indicate flow direction to and from the coil. Blue letters mark the chilled water connections and red letters mark the hot water connections. The unit internal piping is designed to accommodate a total riser vertical movement of ±11/2 in., due to thermal expansion and/or contraction, when positioned properly at the jobsite. Risers must be anchored to the building structure to limit riser expansion and contraction movement to a maximum of 3 inches. Riser anchoring and expansion compensation is not included in the factory-supplied unit and must be field provided. While some special riser features are available from the factory, riser end caps, air vents, and/or flushing loops are normally provided on the job by the installer. Riser to Unit Installation — Proper riser installation and vertical positioning in the unit provides for a unit piping run-out to the service valves which are centered in the access slots and level or sloping down slightly away from the riser. This prevents condensation from running back to the riser and possible damage from dripping at the bottom of a riser column. Each job has specific requirements and satisfying those requirements is the responsibility of the installer. a42-4297 BALL VALVE Riser to Drain Installation 1. Carefully position the unit so that the riser ball valves penetrate into the unit through the riser slot making sure the insulation penetrates into the unit as shown in Fig. 57 and 58. WRENCH UNIT INSULATION OUTER CABINET a42-4295 BACK-UP WRENCH RISER STUBOUT INSULATION BALL VALVE RISER KNOCKOUT SLOT SWIVEL CONNECTION Fig. 59 — 42SM Riser to Unit Installation (Tighten Swivel Connections) THREADED FLARE FITTING CAUTION Hose connection torque requirements are 350 in. lb +10/ –0 in. lb to prevent leaks. FLARE CAP 6. Locate the unit’s coil fitting. 7. The plastic flare caps on the end of the coil fitting should be removed and discarded. 8. Use a wrench to tighten the swivel connections. The baffle acts as a secondary wrench. Be careful to not over tighten swivel connections. Fig. 57 — 42SM Riser to Unit Installation FLEXIBLE HOSE KIT RISER STUBOUT INSULATION RISER a42-4296 BALL VALVE CAUTION Hose connection torque requirements are 350 in. lb +10/ –0 in. lb to prevent leaks. BAFFLE COIL 9. Locate the p-trap drain and rubber hose factory installed to the drain pan connection in the bottom of the unit as shown in Fig. 60. 10. Push the rubber drain hose over the riser drain stubout. Be careful that you do not bend the drain stubout. 11. Adjust the hose clamp over the riser stubout and rubber hose to hold in place as shown in Fig. 60. CONNECTION POINT TO ANY FACTORY FURNISHED AND INSTALLED COMPONENTS. Fig. 58 — 42SM Riser to Unit Connection 51 Supply Air Installation 1. If the unit has been ordered with a supply air plenum, then each side of the unit has one supply air knockout as well as a supply air knockout on the top of the unit (see Fig. 61 and 62). 2. Determine which supply air opening/openings are required for your application. NOTE: The supply air opening on the riser side of the unit should not be used. 3. Use a sharp retractable knife to trim insulation using center knockout slot/trim line as pattern (see Fig. 63). 4. Use a sharp standard needle nose pliers and grab knockout tab (see Fig. 63). 5. Twist or pry pliers back and forth until knockout tab breaks away from unit. 6. Repeat for all supply air tabs until all have been broken. 7. Discard center knockout piece. Be careful of sharp edges. 8. Use a sharp retractable knife to trim any excess insulation using knockout hole as pattern. 9. Use duct pliers (hand seamers) to fold duct flange out of the unit 90 degrees for each side of the supply air opening along duct break (see Fig. 63). The 90-degree flanges can now be used as drywall stops to prevent coverage of discharge opening (see Fig. 64). a42-4298 UNIT INSULATION DRAIN PAN UNIT WALL RISER KNOCKOUT RISER DRAIN CLAMP CLAMP P-TRAP RISER STUBOUT Fig. 60 — 42SM Riser to Drain Installation 12. Test for leaks. Any and all leaks should be repaired before proceeding with installation. When testing with air or some other gas, it might be necessary to tighten stem packing nuts on some valves to maintain air pressure in the riser. Pressure testing risers with water should be done with the unit service valves closed to prevent flushing debris into the unit valve packages. These valves will also allow risers to be drained down after testing in the winter to avoid freeze-up problems. In the event that leaking or defective components are discovered, the sales representative must be notified BEFORE any repairs are attempted. All leaks should be repaired before proceeding with the unit installation. 13. After system integrity has been established, the riser insulation must be pulled back into place over the joint and glued or sealed to prevent sweating and heat loss or gain. All of the risers including the riser stubouts should be properly covered with insulation. Internally mounted chilled water piping and valves are located over the drain pan and need not be insulated. Any fireproofing requirements where risers or piping penetrate floors or walls are the responsibility of the installer. This work should be done only after all pressure testing is completed. The fireproofing method used must accommodate pipe expansion and contraction and the piping must be protected from abrasion and chemical attack. The pipe insulation also must be maintained to prevent sweating and must be protected from wear or erosion at the joint between the insulation and the fireproofing material. When no risers are ordered for the mega stack unit, it is the responsibility of the installer to make sure that a fieldsupplied isolation ball valve is installed between each supply and return piping connection to the unit. Flare fittings are factory provided to allow connection between the ball valves and the hoses. Variations in floor-to-floor dimensions may require field work such as cutting off or extending the risers. This operation is the responsibility of the installer. The riser joint filler material must be selected to withstand the total operating pressure (both static and pumping head) to which the system will be subjected. Low temperature lead alloy solders such as “50/50” and “60/40” are normally not suitable. Chilled water and hot water risers should never be piped to drain down into the condensate riser. Extensive water damage can occur due to drain overflow. Drain chilled and hot water risers to a remote location away from the unit such as sink, room, or floor drains. All installations should be made in compliance with all governing codes and ordinances. Compliance with all codes is the responsibility of the installing contractor. SIDE VIEW a42-4299 OPTIONAL SUPPLY PLENUM SIDE SUPPLY AIR KNOCKOUT (1 PER SIDE) MEGA MOD CABINET Fig. 61 — 42SM Unit Knockout Locations Side View (Typical) TOP VIEW ELECTRICAL KNOCKOUTS a42-4300 TOP SUPPLY AIR KNOCKOUT Fig. 62 — 42SM Unit Knockout Locations Top View (Typical) 52 with local and national codes must perform all piping connections. Refer to Tables 1-4 for piping connections. NOTE: It is important to have a common understanding of which side of the unit is the right hand side and which is the left hand side. When facing the supply air outlet from the front of the unit (air blowing in your face), your right hand will be on the right side of the unit and your left hand will be on the left side of the unit. See Fig. 65. Refer to Fig. 66 and 67 for typical piping connections. The supply and return piping connections of the factoryprovided valve package are either swaged for field brazing (standard) or union fitted (optional) for field connection to the coil. KNOCKOUT TAB (10 PLACES) DUCT BREAK (4 PLACES) a42-4301 KNOCKOUT TAB TRIM LINE Fig. 63 — 42SM Unit Supply Air Installation DUCT FLANGE 90º a42-4302 UNIT WALL Fig. 65 — Unit End Reference UNIT INSULATION VALVE PACKAGES — There are limitations on physical size of pneumatic valves, quantity and type of matching components, and required control interface. See Fig. 68. Consult factory before ordering any special valve package components that are not covered in this book. Valve packages are shipped with the units or in unit cartons. Valve packages include belled ends for field soldering to coil connections. All factory-furnished cooling valve packages are arranged to position as much of the package as possible over an auxiliary drain pan or drip lip. This helps minimize field piping insulation requirements. Refer to Fig. 69-72 for pipe connection configurations. See Table 7 for descriptions of common piping components. Fig. 64 — 42SM Unit Supply Air Installation 10. Use adhesive or glue to re-attach insulation that has pulled away from the unit during knockout removal process. 11. For ducted applications tape should be applied along and around all of the supply air opening knockouts to prevent air leakage. Step 2 — Make Piping Connections — Access to piping is available through the access panels at the side of the units or front of the unit. Qualified personnel in accordance 53 NOTE: Chilled water piping determines the hand of the unit. NOTE: Chilled water piping determines the hand of the unit. SAME END CONNECTION OPPOSITE 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 — Select 2 valve packages per unit. NOTE: Hot water valve package requirements may not be the same as chilled water valve package! SAME END CONNECTION OPPOSITE END CONNECTION LEGEND CW — Chilled Water HW — Hot Water LH — Left Hand RH — Right Hand Fig. 66 — Pipe Connection Configurations 54 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. CEILING UNITS (CONCEALED) — 42CA, CE, CF, DA, DC Pipe to connections extending from end of unit. 42VG VERTICAL UNITS — 42DD Pipe to stub connections extending from side of unit. a42-4177 42VG WALL UNITS, FURRED-IN Pipe to stub connections at the side of unit. or into optional piping compartment. Optional piping compartment is required if valves are factory installed. Factory-installed valve package is limited to one 2-way or 3-way motorized valve and 2 hand valves. *Location of field piping connections will vary depending on number of coil rows on factory-supplied coil or arrangement of factory-supplied valves. Fig. 67 — Piping Connection Positions 55 a42-213tf a42-4222 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). Service Fittings (Positions C & D) — Optional fittings for attaching pressure/temperature sensing devices to obtain pressure drop or temperature differential across coil. Used with ball valve or balance valve where extremely accurate water flow balancing is required. Water Flow Balancing (Positions E, F, & H) — Only one device per total valve package to be used for balancing water flow through the coil. When isolation valve (ball valve or ball valve with memory stop at position H) is used for water flow balancing, do not specify additional balancing device at position E or F. When balancing device is specified at position E or F, isolation valve does not require balancing feature at position H (with a 3-way motorized valve, a bypass balancing valve may be specified in the bypass line to permit equal flow balancing). Strainer (Position G) — Does not include blow down fitting and should not be used in lieu of main piping strainers. Isolation Valves (Positions H & J) — Normally requires one each on supply and return line (see exception under water flow balancing above). When position H is used for balancing (ball valve or ball valve with memory stop), check specifications for service valve requirements. Fig. 68 — Symbols and Placement of Valves 56 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. Addition of any other component will require swage fit for field braze or optional union connection. Check job specifications for system pressure, pressure drop imitations and flow rate prior to selecting valve package components or valve package size (1/2in., 3/4 in., etc.). 2-PIPE SYSTEM (One Valve Package) or 4-PIPE SYSTEM (Two Valve Packages) Application: • 2 Pipe — Hydronic Heating Only • 2 Pipe — Hydronic Cooling Only • 2 Pipe — Hydronic Cooling with Total Electric Heat • 4 Pipe — Hydronic Cooling and Heating a42-4174 MOTORIZED M BALL VALVE (2) BALL (1) 2-WAY MOTORIZED R COIL MOTORIZED 2-WAY VALVE BALL VALVE M S LEGEND BALL VALVE (WITH MEMORY STOP) Ball Valve M (2) BALL (ONE WITH MEMORY STOP) R (1) 2-WAY MOTORIZED Motorized 2-Way Valve COIL NOTE: A 1/4-in. bypass line is included in the piping package when a 2-way valve is specified with a control package containing an automatic changeover device. M MOTORIZED 2-WAY VALVE BALL VALVE M S a42-4308 Fig. 69 — Two-Way Motorized Control Valve Package a42-4175 The 2-way motorized valve motor drives valve open and a spring returns valve to normally closed position (no water flow through coil with unit OFF). The aquastat bleed bypass bleeds a small amount of water from supply to return when control valve is closed (required for system water temperature sensing by aquastat). Aquastat (A) clips on supply line upstream from aquastat bleed bypass (as shown at right). It senses system water temperature to prevent cooling operation with hot water in system piping or heating operation with chilled water in system piping. Additional aquastat is required to lock out the optional auxiliary electric heat when hot water is in the system. Supply and return connections at coil will be swage fit for field braze (standard) or unions (option). Check job specifications for system pressure, pressure drop limitations and flow rate prior to selecting valve package components or valve package size (1/2in., 3/4 in., etc.). 2-PIPE SYSTEM (One Valve Package) Application: • 2 Pipe — Hydronic Cooling and Heating • 2 Pipe — Hydronic Cooling and Heating with Auxiliary Electric Heat MOTORIZED M BALL VALVE (1) GATE (1) BALL (1) 2-WAY MOTORIZED R MOTORIZED 2-WAY VALVE M COIL S BYPASS BALL VALVE (2) BALL (1) BALANCING (1) 2-WAY MOTORIZED R COIL LEGEND BALANCING VALVE BALL VALVE M BYPASS S Balancing Valve MOTORIZED 2-WAY VALVE Ball Valve A CIRCUIT SETTER Circuit Setter (1) BALL (1) CIRCUIT SETTER (1) 2-WAY MOTORIZED Gate Shut Off Valve M GATE SHUT OFF A Motorized 2-Way Valve R MOTORIZED 2-WAY VALVE M COIL S NOTE: Additional aquastat required as noted above. BALL VALVE A BYPASS Fig. 70 — Two-Way Motorized Control Valve Package with Aquastat Bleed Bypass Line 57 On the 3-way motorized valve flow is normally closed to coil and open to system return. Motor closes bypass flow to system 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). It senses system water temperature to prevent cooling operation with hot water in system piping or heating operation with chilled water in system piping. Aquastat(s) required for 2-pipe cooling and heating with automatic changeover control and/or auxiliary electric heat. A bypass balancing valve may be specified in the bypass line to permit equal flow balancing. Supply and return connections at coil will be swage fit for field braze (standard) or unions (option). Check job specifications for system pressure, pressure drop limitations and flow rate prior to selecting valve package components or valve package size (1/2in., 3/4 in., etc.). 2-PIPE SYSTEM (One Valve Package) or 4-PIPE SYSTEM (Two Valve Packages) Application: • 2 Pipe — Hydronic Heating Only • 2 Pipe — Hydronic Cooling Only • 2 Pipe — Hydronic Cooling with Total Electric Heat • 2 Pipe — Hydronic Cooling and Heating • 2 Pipe — Hydronic Cooling and Heating with Auxiliary Electric Heat • 4 Pipe — Hydronic Cooling and Heating a42-4176 MOTORIZED M BALANCING VALVE (1) BALL (1) 3-WAY MOTORIZED MOTORIZED 3-WAY VALVE R M COIL (2) BALL (ONE WITH MEMORY STOP) (1) 3-WAY MOTORIZED S R (1) GATE (1) BALL (1) 3-WAY MOTORIZED LEGEND COIL Balancing Valve BYPASS BALL VALVE MOTORIZED 3-WAY VALVE M COIL BALL VALVE S BALL VALVE (WITH MEMORY STOP) M BYPASS BALL VALVE MOTORIZED 3-WAY VALVE BALL VALVE R M BYPASS GATE SHUT OFF VALVE S Ball Valve M Ball Valve with Memory Stop Circuit Setter BALL VALVE (2) BALL (1) BALANCING (1) 3-WAY MOTORIZED Gate Shut Off Valve M Motorized 3-Way Valve COIL R BALANCING VALVE M S BYPASS BALL VALVE MOTORIZED 3-WAY VALVE *When aquastat is used for automatic changeover, bypass is required as indicated by dashed line. NOTES: 1. Packages factory furnished and installed. 2. Valves are 5/8-in. ODS unless otherwise specified. 3. If an automatic flow control valve is added, it will be located on supply line between shutoff valve and coil (or motorized control valve, if supplied). (1) BALL (1) CIRCUIT SETTER (1) 3-WAY MOTORIZED MOTORIZED 3-WAY VALVE R M COIL S Fig. 71 — Three-Way Motorized Control Valve Package 58 CIRCUIT SETTER BYPASS BALL VALVE 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 components or valve package size (1/2 in., 3/4 in., etc.). 2-PIPE SYSTEM ONLY (One Valve Package) Application: • 2 Pipe - Hydronic Heating Only • 2 Pipe - Hydronic Cooling Only WITH HAND VALVES ONLY BALL VALVE LEGEND (2) BALL R Balancing Valve COIL Ball Valve Circuit Setter BALL VALVE S Gate Shut Off Valve *When aquastat is used for automatic changeover, bypass is required as indicated by dashed line. NOTES: 1. Continuous water flow, chilled water or hot water. 2. Not recommended for high humidity applications. 3. 2-Pipe System Only: Not recommended with unitmounted thermostat on vertical units. 4. The addition of any other component(s) wil require swage fitting for field braze or optional union connection. 5. Packages factory furnished and installed. 6. Valves are 5/8-in. ODS unless otherwise specified. 7. If an automatic flow control valve is added, it will be located on supply line between shutoff valve and coil (or motorized control valve, if supplied). BALL VALVE (1) BALL (1) GATE R GATE SHUT OFF VALVE COIL S BALL VALVE (2) BALL (1) BALANCING R BALANCING VALVE COIL BALL VALVE S CIRCUIT SETTER (1) BALL (1) CIRCUIT SETTER a42-4307 R COIL BALL VALVE S Fig. 72 — Valve Package without Motorized Control 42C,D,V DRAIN CONNECTIONS — Install drain line in accordance with all applicable codes. A continuous pitch of 1 in. per 10 ft of condensate drain line run is necessary for adequate condensate drainage. Insulate the drain line to prevent sweating. Extend the drain line straight from the drain pan before making any turns. The installer must provide proper support for the drain line to prevent undue stress on the auxiliary drain pan. A drain trap may be required by local codes and is recommended for odor control. The differential height inlet to outlet must be at least 1-in. wg greater than the total static pressure of the unit. The differential height of the outlet to the bottom of the trap must not be less than the total static pressure of the unit. See Fig. 73 (42D) and 74 (42V). Provide a trap of at least 2 in. near the end of the drain line to prevent odors from entering the rooms. 2 IN. MIN CONDENSATE PAN STUB-OUT TRAP 7/8 IN. FIELD-SUPPLIED DRAIN EXTENSION Fig. 73 — Typical Drain Line Details (42D Unit Shown) 59 NOTE: Field trim “P” trap as required to prevent kinking. Drain Pan Drain 42C,D,V STEAM CONNECTIONS — On units with steam heating coils, the maximum steam pressure applied to the unit should never exceed 10 psig. However, when steam is used on a 4-pipe application system with 1-row and 2-row coils the maximum steam pressure should never exceed 5 psig (suitable for only low pressure steam). Do not drain the steam mains or take-off through the coils. Drain the mains ahead of the coils through a steam trap to the return line. Overhead returns require 1 psig of pressure at the steam trap discharge for each 2 ft elevation to ensure continuous condensate removal. Proper steam trap selection and installation is necessary. As a guideline in creating a steam trap locate the steam trap discharge at least 12 in. below the condensate return connection. This provides sufficient hydrostatic head pressure to overcome trap losses and ensure complete condensate removal. 42C,D,V DIRECT EXPANSION (DX) REFRIGERANT PIPING — Use the condensing unit manufacturer's recommended line sizes and requirements. Suction line must be insulated for correct operation. Use refrigerant-grade copper lines only. The unit is not applied as a heat pump. Thermostatic expansion valve (TXV) and sensing bulb are factory-installed on units when DX coil option is chosen with distributor and TXV. NOTE: If a hot water coil is used in the reheat position, a fieldsupplied freezestat must be installed to protect the coil. TEST AND INSULATE — When all joints are complete, perform hydrostatic test for leaks. Vent all coils at this time. Check interior unit piping for signs of leakage from shipping damage or mishandling. If leaks are found, notify your Carrier representative before initiating any repairs. Release trapped air from system (refer to Step 7 — Make Final Preparations section). Never pressurize any equipment beyond specific test pressure. Always pressure test with an inert fluid or gas, such as clear water or dry nitrogen to avoid possible damage or injury in the event of a leak or component failure during testing. Unit Wall Clamp 2" Minimum Drain Clamp “P” Trap Fig. 74 — “P” Trap Minimum Configuration 42C,D,V WATER SUPPLY/RETURN CONNECTIONS — Install piping in accordance with all applicable codes. Position valves over the drain pan. Be sure valves are in proper operating position and are easily accessible for adjustment. See Fig. 69-72. Refer to Fig. 75 for copper water tube and joint material pressure ratings. If coil and valve package connections will be made with a solder joint, care should be taken to ensure that the components in the valve package are not subjected to high temperatures, which may damage seals or other materials. Protect all valve accessories with wet or damp rag wrapped around the body during soldering / brazing process. See Fig. 76. Many 2-position electric control valves are provided with a manual operating lever. This lever should be in the OPEN position during all soldering operations. If coil connection is made with a union, the coil side of the union must be prevented from turning (it must be backed up) during tightening. See Fig. 69-72 for common valve packages. The supply and return connections are marked and color coded on the coil stub out and valve package. Supply side is marked as 'S' and return side is marked as 'R.' A blue letter indicates cooling side and a red letter indicates heating side. In case of field-installed valves and piping, install chilled water valve components in a way that any condensate dripping or sweating caused is contained in the extended drain pan or auxiliary drain or drip lip (optional). Optional drip lip is field installed and may be packaged separately from the unit. CAUTION All water coils must be protected from freezing after initial filling with water. Even if system is drained, unit coils may still have enough water to cause damage when exposed to temperatures below freezing. CAUTION DO NOT OVERTIGHTEN! Overtightening will distort (egg shape) the union seal surface and destroy the union. Following the hydrostatic test, insulate all piping to prevent sweating. To ensure compliance with building codes, restore the structure's original fire resistance rating by sealing all holes with material carrying the same fire rating as the structure. NOTE: The project specifications for system pressure, pressure drop limitations, and flow rate should be checked prior to selection of specific components or the valve package size. 60 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. JOINT MATERIALS A 50-50 Lead-Tin at 200 F B 50-50 Lead-Tin at 150 F C 50-50 Lead-Tin at 100 F Note 1 D 95-5 Tin-Antimony at 200 F E 95-5 Tin-Antimony at 150 F F 95-5 Tin-Antimony at 100 F NOTES: 1. Not recommended for high system water pressures. 2. Standard factory joint material. Fig. 75 — Copper Water Tube and Joint Material Pressure Ratings 61 Note 2 Table 7 — Piping Components SYMBOL/SKETCH CV FACTOR 3/ 2 4 RATING* PSI F 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. N/A N/A 400 100 NO AUTOMATIC AIR VENT: Nickel plated brass valve, fiber-disc type, with positive shut-off ballcheck and quick vent feature via knurled vent screw. Application — Optional replacement for manual air vent. Automatically passes minute quantities of air through the fiber discs which expand upon contact with water, completely sealing the valve. As air accumulates, the fiber discs dry and shrink, repeating the cycle. Not recommended for removing large quantities of air encountered during initial start-up or subsequent draining and refilling. Should not be used in lieu of main system air vents. N/A N/A 125 240 NO SWAGE: Copper tube end expanded to accept a copper tube of the same size for factory or field brazing. Application — Used where possible for all tubing joints for best joint integrity. N/A N/A 300 200 YES UNION: Combination wrought copper/cast brass union assembly, solder by solder. Application — Used for quick connect (and disconnect) of valve package components to minimize field labor and facilitate servicing of unit. N/A N/A 300 200 YES INSERTION TEST PORT: Brass body valve for acceptance of test probe (up to 1/8 in. diameter). Application — Installed on one (or both) sides of the coil to allow for temperature or pressure sensing. Used for close tolerance water balancing and service analysis. N/A N/A 250 250 NO N/A N/A 400 210 NO 2.12 3.9 300 250 NO DESCRIPTION 1/ PRESSURE TEST PORT: Brass body 1/4 service access fitting with removable depressor type core. Application — Installed on both sides of the coil to allow for pressure sensing. Attach pressure gages to facilitate close tolerance water balancing. CIRCUIT SETTER: Variable water flow balancing valve with manual adjustment knob, pointer, percent-open scale, memory stop and integral pressure read-out ports. Application — Used for close tolerance water flow balancing. Positive shut-off ball valve feature allows usage as combination balancing and shut-off valve. LEGEND Cv — Coefficient of Velocity DX — Direct Expansion ETO — Engineering to Order *Check all system component pressure ratings (coils, values, pumps, etc.) with manufacturer and any applicable local or national piping codes prior to specifying system pressure rating. 62 STEAM USE Table 7 — Piping Components (cont) SYMBOL/SKETCH DESCRIPTION CV FACTOR 3/ 2 4 RATING* PSI F 4 300 250 NO 600 220 NO 1/ BALANCE VALVE: Variable water flow manual balancing valve with screwdriver slot adjustment screw. Application — Often used in conjunction with test port fittings for water flow balancing. Balance by temperature differential or coil pressure drop (check specifications for service fittings required if balancing by pressure drop). May be used in 3-way valve bypass line to permit equal flow balancing. FIXED FLOW VALVE: Flexible orifice type (non-adjustable). Application — Used for water flow balancing. Valve automatically adjusts the flow to within 10% of set point. a42-4282 STRAINER: Y-type body with 20 mesh stainless steel screen. Application — Used for removal of small particles 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 system flushing during start-up. Screen should be removed and cleaned per normal maintenance schedule (provisions for strainer blow-down not provided). BALL VALVE: Manual balance and shut-off valve. Application — Used for unit isolation and water flow balancing. Without memory stop feature water balance point must be marked by installer (if necessary). Check specifications for service fittings required when used for water balancing. BALL VALVE WITH MEMORY STOP: Manual balance and shut-off valve. Application — Used for unit isolation and water flow balancing. The adjustable memory stop feature allows return to the balance point after shut-off. Check specifications for service fittings required when used for water balancing. LEGEND Cv — Coefficient of Velocity DX — Direct Expansion ETO — Engineering to Order *Check all system component pressure ratings (coils, values, pumps, etc.) with manufacturer and any applicable local or national piping codes prior to specifying system pressure rating. 63 14 Valve orifice size determines CV factor. The orifice of these fixed flow valves changes as flow is regulated. As the water pressure increases, the orifice size decreases, thereby automatically limiting the flow rate to the specified gpm (±10%). STEAM USE 9.0 Clean 19.0 Clean 400 150 N/A 14.2 28.6 600 350 YES 14.2 28.6 600 350 N/A Table 7 — Piping Components (cont) SYMBOL/SKETCH DESCRIPTION CV FACTOR 1/ 2 3/ 4 RATING* PSI F STEAM USE 2-WAY MOTORIZED VALVE (25 PSI close off differential pressure): 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 packages are based upon normally closed valves (valve electrically powered open and closed by spring return when electric power removed). Manual override lever allows valve to be placed in the open position for secondary (unit) flushing, constant water flow prior to start-up, etc. Manual override is automatically disengaged when valve is electrically activated. Consult factory for normally open valve applications. 3.5 3.5 300 200 YES 15 PSI MAX. 2-WAY MOTORIZED VALVE (150 PSI close off differential pressure): 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 packages are based upon normally closed valves (valve electrically powered open and closed by spring return when electric power removed). Manual override lever allows valve to be placed in the open position for secondary (unit) flushing, constant water flow prior to start-up, etc. Manual override is automatically disengaged when valve is electrically activated. Consult factory for normally open valve applications. 4.9 10.3 300 240 NO 4.0 4.0 300 200 N/A 4.9 4.9 300 240 N/A 3-WAY MOTORIZED VALVE (25 PSI close off differential pressure): Electric 2-position flow control valve (closed to coil/open to bypass or open to coil/ closed to bypass). Normally closed with manual override lever. Installed in supply line to unit. Application — Same comments as 2-way motorized valve except with manual override lever engaged the valve is open to both ports and water flow will take the path of least resistance through the valve package (not necessarily 100% through the coil). 3-WAY MOTORIZED VALVE (150 PSI close off differential pressure): Electric 2-position flow control valve (closed to coil/open to bypass or open to coil/ closed to bypass). Normally closed with manual override lever. Installed in supply line to unit. Application — Same comments as 2-way motorized valve except with manual override lever engaged the valve is open to both ports and water flow will take the path of least resistance through the valve package (not necessarily 100% through the coil). LEGEND Cv — Coefficient of Velocity DX — Direct Expansion ETO — Engineering to Order *Check all system component pressure ratings (coils, values, pumps, etc.) with manufacturer and any applicable local or national piping codes prior to specifying system pressure rating. 64 Table 7 — Piping Components (cont) SYMBOL/SKETCH DESCRIPTION CV FACTOR 1/ 2 3/ 4 RATING* PSI F STEAM USE MODULATING VALVE (Optional) (Non-Spring Return, Floating Point Actuator): Modulating valves are designed to control the flow in the circuit by making incremental adjustments to the flow path within the valve. Application — To control fluid flow in fan coil units. On the 42DD,SG,SJ,SH commercial fan coil models, the factory provided modulating valve has application restrictions. In these models, the valve packages are located in the airstream, downstream of the coil. Due to the ambient temperature limitations of the modulating valves, the valves can only be used in the units listed above with 2-pipe cooling only systems. 4.0 300 200 N/A MODULATING VALVE (Optional) (Non-Spring Return, Proportional Type Actuator): Modulating valves are designed to control the flow in the circuit by making incremental adjustments to the flow path within the valve. Application — To control fluid flow in fan coil units. On the 42DD,SG,SJ,SH commercial fan coil models, the factory provided modulating valve has application restrictions. In these models, the valve packages are located in the airstream, downstream of the coil. Due to the ambient temperature limitations of the modulating valves, the valves can only be used in the units listed above with 2-pipe cooling only systems. 4.0 300 200 N/A MODULATING VALVE (Requires ETO) (Spring Return): Modulating valves are designed to control the flow in the circuit by making incremental adjustments to the flow path within the valve. Application — Same comments as non-spring return except when powered, the actuator moves to the desired position, at the same time tensing the spring return system. When power is removed for more than two minutes the spring returns the actuator to the normal position. 4.0 300 200 N/A AQUASTAT: Water temperature sensing electrical switch. (Line Voltage Controls) Application — Clips directly on nominal size 1/2 in. or 3/ in. copper tubing for water temperature sensing. 4 Must be correctly located for proper control operation. CHANGEOVER SENSOR: Water temperature sensor thermistor. Application — Sensor shall clamp on the outside diameter of the pipe. Sensor plate shall bend to allow its radius to be adjusted to fit the pipe. Sensor shall be secured to the pipe with mounting clamp. Insulate the mounting location of sensor on the pipe. LEGEND Cv — Coefficient of Velocity DX — Direct Expansion ETO — Engineering to Order *Check all system component pressure ratings (coils, values, pumps, etc.) with manufacturer and any applicable local or national piping codes prior to specifying system pressure rating. 65 Incoming Power Supply or Return Torch Field Tubing Stub From Coil Wet Rag Option 1 Adaptor (Factory Installed) Fig. 77 — High Voltage Wiring Service Switch (Side Location) Fig. 76 — Field Piping Connections Step 3 — Make Electrical Connections — Refer to unit nameplate for required supply voltage, fan and heater amperage and required circuit ampacity. Refer to unit wiring diagram for unit and field wiring. See Fig. 77-79. Since each project is different and each unit on a project may be different, the installer must be familiar with the wiring diagram and nameplate on the unit before beginning any wiring. Make sure all electrical connections are in accordance with unit wiring diagram and all applicable codes. The type and sizing of all wiring and other electrical components such as circuit breakers, disconnect switches, etc. should be determined by the individual job requirements, and should not be based on the size and/or type of connection provided on the equipment. All installations should be made in compliance with all governing codes and ordinances. Compliance with all codes is the responsibility of the installing contractor. The fan motor(s) should never be controlled by any wiring or device other than the factory-supplied switch or thermostat/ switch combination unless prior factory authorization is obtained. Fan motor(s) may be temporarily wired for use during construction only with prior factory approval and only in strict accordance with the instructions issued at that time. On 42S vertical stack units, the unit electrical supply is designed to enter through knockouts provided in the top of the unit and pass down through matching knockouts in the control section top. Where space allows, power may be pulled directly through the side of the cabinet into the control section. All components furnished for field installation by either the factory or the controls contractor should be located and checked for proper function and compatibility. All internal components should be checked for shipping damage, and any loose connections should be tightened to minimize problems during start-up. Any devices such as fan switches or thermostats that have been furnished from the factory for field installation must be wired in strict accordance with the wiring diagram that appears on the unit. Failure to do so could result in personal injury or damage to components, and will void all manufacturer's warranties. Units with factory-supplied and factory-installed aquastats may be shipped with the aquastats mounted on a coil stub-out. If this is the case, remove the aquastat before installing valve package. When reinstalling aquastats, consult the factorypiping diagram in the submittal for proper location. If the valve package is field-supplied, the aquastat must be installed in a location where it will sense the water temperature regardless of the control valve position. A bleed bypass may be required to guarantee proper aquastat operation. The aquastat bypass line allows a small amount of water to flow from the supply to the return piping when the control valve is closed. Incoming Power Option 2 Fig. 78 — High Voltage Power Connection (Unit Without Service Switch) Incoming Power Option 3 Fig. 79 — High Voltage Wiring Service Switch (Bottom Location) FACTORY-INSTALLED OPTIONS Condensate Overflow Switch — The condensate overflow switch is used to detect a clogged condensate drain pan. The condensate switch uses a normally closed contact to allow the system control power to pass through the switch energizing the water valves and fans allowing normal operation. When an overflow condition is detected by the switch, it opens the NC contact and de-energizes the water valve and fans. 66 Aquastat — The aquastat must be able to sense whether the flowing water is being chilled or heated and switches a contact closed to provide automatic summer or winter changeover for the system. When a two-pipe cooling/heating system with optional auxiliary electric heat is desired, an additional aquastat is required. Units with optional factory furnished and installed aquastats may be shipped with aquastats mounted on the coil stub out. In this situation, remove the aquatat before valve package installation. Refer Fig. 70 for factory piping diagram for proper location when reinstalling the aquastats. If the valve package is field supplied,the aquastat must be installed in a location where it will sense the water temperature regardless of control valve position. A bleed bypass should be provided for proper operation of aquastat. The bleed line allows a small amount of water to flow from supply to return piping when the control valve is closed for loop temperature sensing. All field wiring must be in accordance with governing codes and ordinances. Any modification of unit wiring without factory authorization will invalidate all factory warranties and nullify any agency listings. The manufacturer assumes no responsibility for any damages and/or injuries resulting from improper field installation and/or wiring. typical control sequences only. For detailed control operating sequence, refer to thermostat operating instructions. STANDARD WIRING PACKAGES Manual Fan Control — On vertical cabinet units, a fan-speed switch may be furnished unit-mounted and wired. See Fig. 80. On vertical furred-in units and horizontal units, the switch may be shipped separately on a decorative wall plate for field mounting and wiring. See Fig. 81. The standard switch has LOW, MEDIUM, HIGH and OFF positions plus an auxiliary contact to energize thermostats, valves, dampers, etc. NOTE: Wiring diagrams are for typical applications. If other voltages for heaters or controls are specified, wiring may differ from that shown. Refer to wiring diagram on unit blower housing for unit specific wiring. Thermostatic Electric Valve Control, 2-Pipe — A thermostatically controlled 2-position valve provides superior control to fan cycling. With this control, the fan runs continuously unless it is manually switched to the OFF or AUTO position. The fan must be on before the valve can be opened to supply water to the coil. This system can be used for normal 2-pipe changeover systems and can also be furnished for cooling-only or heating-only applications by omitting the changeover and specifying which application is intended. See Fig. 82 and 83 for line voltage control. See Fig. 84 and 85 for 24-v control. Wiring diagrams show typical applications. Refer to wiring diagram on unit blower housing for unit specific wiring. IMPORTANT: Wiring diagrams shown depict typical control functions. Refer to unit wiring label for specific functions. Units may be equipped with line voltage controls or 24 VAC control systems. The following descriptions are for Fig. 80 — No Controls — Unit-Mounted 3-Speed Switch Only 67 NOTES: 1. Motors are thermally protected. 2. Use copper conductors only. 3. See unit nameplate for power supply. Provide disconnect means and overload protection as required. 4. Unit-mounted thermostats are not recommended for fan control because of poor temperature sensing. Fan control not available on 42VC,VE lowboy units. Fig. 81 — No Controls — Wall-Mounted 3-Speed Switch Only '120-V WHT ALL OTHERS BLK NEC CLASS 1 WIRING a42-4223 Fig. 82 — 42SG,SH,SJ,VA,VB,VC,VE,VF 2-Pipe Heating and Cooling with Automatic Changeover — Unit-Mounted Thermostat (Line Voltage) 68 a42-4058 '120-V WHT ALL OTHERS BLK NEC CLASS 1 WIRING Fig. 83 — 42C,S,V and 42D (600-1000) 2-Pipe Heating and Cooling with Automatic Changeover — Remote/Wall-Mounted Thermostat (Line Voltage) a42-4059 Fig. 84 — 42SG,SH,SJ,VA,VB,VF 2-Pipe Heating and Cooling with Automatic Changeover — Unit-Mounted Debonair® Thermostat (24-v), Duct Sensor 69 a42-4061 NEC CLASS 2 WIRING Fig. 85 — 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) 70 Two control methods are available: 1. Use the standard automatic changeover thermostat with a dead band between heating and cooling. 2. Use a manual changeover thermostat. With this method only one changeover is required. Be sure to include a 2-way or 3-way electric valve with this system. NOTE: Wiring diagrams are for typical applications. If other voltages for heaters or controls are specified, wiring may differ from that shown. See Fig. 86 for line voltage control. See Fig. 87 and 88 for 24-v control. Refer to wiring diagram on unit blower housing for unit specific wiring. 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 electric heat will still be available to all units whenever required. In winter the system is switched over to hot water. Two changeover devices are required for this. One device switches the action of the thermostat and the other locks out the electric heat when hot water is in the coil. With this system, the fan runs continuously unless manually switched to OFF or AUTO position. Fan must be on before thermostat can send signal to open chilled water valve or turn on electric heater. THERMOSTAT PART # 702893-36 PUR ORG REMOTE DEVICE BOX COOL BLU HEAT RED L1 BLK L2 OR N YEL HI W/ORG W/RED LOW W/BRN UNIT MOUNTED J BOX AQUASTATS QUICK CONNECT OPTIONAL BLOWER BRN L RED RED M BLU BLU BLK RED H BLK MOTOR WHT COM RISE BLU PUR BLK BLK *WHT *WHT EQUIPMENT GROUND RED RED BRN BLU RED BLK *WHT WHT RISE L2 or N VALVE L1 *WHT CONTACTOR LIMIT SWITCH 1 BLK BLK BLK *WHT L1 L2 OR N GRN ONLY 120V WHT/ALL OTHERS BLK Fig. 86 — 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 71 THERMOSTAT #33CSSN2-FC R G Y1 G3 BLK DUCT SENSOR 33CSSEN-DS RS PUR RS+5 W1 G2 C H2O CK1 CHANGE OVER SENSOR RED YEL BLU BRN BLK RED ORG WHT BLK BLK VALVE BLK BLK 2 Q/C 1 YEL 33 YEL RED G QUICK CONNECT FAN BLU G2/(W) BLK G3/(Y) BLK COM (VALVE) RED 4 (COOL) 3 HI ORG (HEAT) YEL 24 RED L BLU M BLU BLK *WHT MED 2 1 BLOWER BLK H MOTOR WHT COM TRANSFORMER BLK EQUIPMENT GROUND L1 L2 or N LOW WHT/RED BLK BLK *WHT *WHT BRN YEL 0 YEL BLK L1 1 06 3 4 2 NC COM NO 7 LIMIT SWITCH 8 6 BLK N WHT BLK CONTACTOR EQUIPMENT GROUND ELEC. HEATER Fig. 87 — 42SG,SH,SJ,VA,VB,VC,VE,VF 2-Pipe Heating and Cooling with Auxiliary Heat — Unit-Mounted Debonair® Thermostat (24-v), Duct Sensor and Dual Power Source a42-4067 NEC CLASS 2 WIRING Fig. 88 — 42C,S,V (except VG), and 42D (600-1000 cfm) 2-Pipe Heating and Cooling with Auxiliary Heat — Remote/Wall-Mounted Debonair® Thermostat (24-v) 72 Normally, an automatic changeover thermostat with a dead band between heating and cooling is used, but a manual changeover thermostat is also suitable. A 2-way or 3-way valve must also be used so that the chilled water is off whenever the heater is on. No changeover device to sense water temperature is necessary. NOTE: Wiring diagrams are for typical applications. If other voltages for heaters or controls are specified, wiring may differ from that shown. See Fig. 89 for line voltage control. See Fig. 90 and 91 for 24-v control. Refer to wiring diagram on unit blower housing for unit specific wiring. Thermostat 2-Pipe Total Electric Heat with Valve Control — With this system, the complete heating requirement for the space is provided by the electric heater; the water system is never changed over for heating. It is therefore possible, just as with 4-pipe systems, to have heating or cooling at any time of the year. The fan runs continuously unless it is manually switched to OFF or AUTO position. Fan must be on before thermostat can send signal to open chilled water valve or turn on electric heater. Fig. 89 — 42C,S,V (except VG), and 42D (600-1000 cfm) 2-Pipe Cooling with Total Electric Heat — Remote/Wall-Mounted Thermostat (Line Voltage) 73 NOTE: Units may have 2 or 4 elements. Elements wired in parallel. a42-4072 Fig. 90 — 42SG,SH,SJ,VA,VB,VC,VE,VF 2-Pipe Cooling with Total Electric Heat — Unit-Mounted Debonair® Thermostat (24-v) and Duct Sensor THERMOSTAT #33CSSN2-FC REMOTE DEVICE BOX RS+5 RS R G Y1 G3 W1 G2 C H2O CK1 NEC CLASS 2 WIRING YEL BLU BRN BLK PUR RED ORG VALVE BLK COOL 2 Q/C 1 BLK YEL 33ZCRLYBRD G G2/(W) G3/(Y) COM YEL QUICK CONNECT FAN BLK (VALVE) RED 4 BLU (COOL) RED L BLU M 3 HI BLK BLOWER BLK H 2 ORG (HEAT) YEL 24 *WHT MED 1 MOTOR WHT COM TRANSFORMER EQUIPMENT GROUND L1 L2 or N BLK LOW WHT/RED BLK *WHT *WHT 0 YEL 1 06 EQUIPMENT GROUND 3 BLK 4 L1 2 NC 7 BRN LIMIT SWITCH COM 8 NO 6 BLK BLK WHT N ELEC. HEATER Fig. 91 — 42C,S,V (except VG), and 42D (600-1000 cfm) 2-Pipe Cooling with Total Electric Heat — Remote/Wall-Mounted Debonair® Thermostat (24-v) and Dual Power Source 74 With this system, the fan runs continuously unless it is manually switched to OFF/AUTO position. Fan must be on before thermostat can send signal to open the chilled water or hot water valve. NOTE: Wiring diagrams are for typical applications. If other voltages for heaters or controls are specified, wiring may differ from that shown. See Fig. 92 for line voltage control. See Fig. 93 and 94 for 24-v control. Refer to wiring diagram on unit blower housing for unit specific wiring. Thermostatic Valve Control, 4-Pipe — The 4-pipe system provides the ultimate in economy and room temperature control. 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. An automatic changeover device to sense water temperature is not required. ONLY 120V WHT/ALL OTHERS BLK Fig. 92 — 42C,S,V (except VG), and 42D (600-1000 cfm) 4-Pipe Heating and Cooling — Remote/Wall-Mounted Thermostat (Line Voltage) 75 a42-4078 Fig. 93 — 42SG,SH,SJ,VA,VB,VC,VE,VF 4-Pipe Heating and Cooling — Unit-Mounted Debonair® Thermostat (24-v) and Duct Sensor THERMOSTAT #33CSSN2-FC REMOTE DEVICE BOX RS+5 RS R G Y1 G3 W1 G2 C H2O CK1 NEC CLASS 2 WIRING YEL BLU BRN BLK PUR RED ORG VALVE BLK COOL BLK 2 Q/C 1 PUR YEL 33ZCRLYBRD VALVE BLK HEAT BLK 2 Q/C 1 BRN YEL G G2/(W) G3/(Y) COM QUICK CONNECT FAN BLK (VALVE) YEL RED BLU (COOL) HI YEL (HEAT) YEL 24 MED BLK 4 RED L BLU M 3 BLOWER BLK H 2 1 MOTOR WHT COM TRANSFORMER LOW EQUIPMENT GROUND L1 L2 or N BLK *WHT BLK *WHT Fig. 94 — 42C,S,V (except VG), and 42D (600-1000 cfm) 4-Pipe Heating and Cooling — Remote/Wall-Mounted Debonair® Thermostat (24-v) 76 Step 4 — Make Duct Connections — Install all ductwork to and from unit in accordance with project plans, specifications, and all applicable codes. Duct construction must allow unit to operate within duct external static pressure limits as shown on job submittals. Units designed to operate with ductwork may be damaged if operated without intended ductwork attached. Units provided with outside air should have some method of low-temperature protection to prevent freeze-up. This protection may be any of several methods, such as a low temperature thermostat to close the outside air damper or a preheat coil to temper the outside air before it reaches the unit. It should be noted that none of these methods will adequately protect the coil in the event of power failure. The safest method of freeze protection is to use glycol in the proper percent solution for the coldest expected air temperature. Insulate ductwork as required. Use flexible connections to minimize duct-to-unit alignment problems and noise transmission where specified. Set unit markings for minimum clearance to combustible materials and first 3 ft of ductwork. Install ductwork, accessory grilles and plenums so that they do not restrict access to filter. The manufacturer assumes no responsibility for undesirable system operation due to improper system design, equipment or component selection, and/or installation of ductwork, grilles, and other related components. CAUTION Proper safety procedures should be followed regarding ventilation and safety equipment during touch-up and repainting since materials may pose a health hazard. The manufacturer's directions should be followed for the products being used. To repaint the factory-baked enamel, the finish should be prepared by light sanding with no. 280 grit sand paper or no. 000 or no. 0000 fine steel wool. The surface may also be wiped with a liquid surface etch cleaning product such as “No Sand” or “Pasceo.” These items should be available at most paint product stores. It should be noted that the more conscientiously this preparation is done, the more effective it will be. After this preparation is accomplished, the factory finish should provide excellent adhesion for a variety of air-dried top coats. Enamel will give a more durable, higher gloss finish, while latex will not adhere as well and will give a dull, softer finish. Top coats involving an exothermic chemical process between two components, such as epoxies and urethanes, should be avoided. Factory aerosol touch-up paint may require a number of light “dust coats” to isolate the factory-baked enamel finish from the quick drying touch-up paint. Step 6 — Cut Out Openings for Grilles and Thermostats — On all units with optional supply-air or CAUTION 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. If not included on the unit or furnished from the factory, supply and return grilles should be provided as recommended in the product catalog. Prevent dust and debris from settling in unit. If wall finish or color is to be spray applied, cover all openings to prevent spray from entering unit. Failure to do so could result in damage to the unit and/or the reduction of unit efficiency. Step 5 — Frame and Finish Unit — Models 42SG, SH, SJ, SU and SM have factory enclosures and may be finished with normally accepted wall covering. However, drywall secured with adhesive bonding alone is not recommended. The 42S units are designed to have gypsum board or other types of wall board applied directly to the unit cabinet surface to a maximum combined thickness of 5/8-inch. Use low-profile sheet metal panhead screws to secure wallboard to unit frame. Fasteners may penetrate the cabinet no more than 1/2 inch. These fasteners must be located to avoid damage to internal components and wiring in the same manner as anchoring fasteners. Do not apply sheet metal screw or nails where they can penetrate coil, riser pipes, or electrical junction box and raceways. Do not secure wallboard to drain pan edges or to control box enclosure. Condensate leaks or electrical shorts may result. An alternate method of enclosing the unit is to frame one or more sides with studding and apply the wall board to this framing. This method requires specific unit features and return access panels when used on the return-air side of a unit. Units not properly equipped will exhibit poor cooling and/or heating performance and could experience excessive or premature component failures. Prevent sheetrock dust or other debris from settling on coil fins, motor-blower assembly or other unit interior surfaces. EXPOSED UNIT FINISH, TOUCH-UP AND REPAINT — Return access and exposed cabinet units may be furnished with a baked enamel finish. Small scratches in this finish may be repaired with touch-up paint available from the factory. Some colors of touch-up paint are available in aerosol containers and all touch-up paint is available in pint, quart, and gallon cans. Step 7 — Make Final Preparations 1. Turn off power to the unit (open unit electrical disconnect). 2. Install thermostats and perform any other final wiring as applicable. Check the unit for any loose wires. 3. Perform a final visual inspection. All equipment, plenums, ductwork, and piping should be inspected to verify that all systems are complete and properly installed and mounted, and that no debris or foreign articles such as paper or drink cans are left in the units or other areas. Clean dirt, dust, and other construction debris from unit interior. Be sure to check fan wheel and housing. 4. Rotate fan wheel by hand to be sure it is free and does not rub housing. Check that wing nuts securing fan assembly to fan deck are tight. 5. Ensure all panels and filters are installed before checking fan operation. Turn on power to the unit. 6. Install filter in frame at front of coil. If field-supplied filters are used, be sure size is as specified in Tables 1-4. CAUTION Do not start up or operate unit without filter. Be sure filter and unit interior are clean. Failure to do so could result in damage to the equipment or building and furnishings and/ or void all manufacturer's warranties. 7. ECM (Electronically Commutated) Blower: If the unit is equipped with an ECM blower, additional steps may be required during the air balancing process. 77 R The ECM blower is controlled by one of three control boards, depending on the options ordered with the unit. Review project submittals or order acknowledgement to determine which ECM control scheme the unit has. Alternatively, match the control board to the illustrations identified in the Control Board Type section. 8. Check the fan and motor operation. 9. Be sure drain line is properly and securely positioned and that the line is clear. Pour water into drain to check operation. 10. Prior to the water system start-up and balancing, the chilled/hot water systems should be flushed to clean out dirt and debris which may have collected in the piping during construction. During this procedure, the system should be flushed from the supply riser to the return riser through a cross-over loop at the end of the riser column, and all unit service valves must be in the closed position. This prevents foreign matter from entering the unit and clogging the valves and metering devices. Strainers should be installed in the piping mains to prevent this material from entering the units during normal operation. Vent all air from unit coil and related piping. Air venting from the unit is accomplished by the use of the standard manual air vent fitting, or the optional automatic air vent fitting installed on the coil. Venting can be accomplished by depressing the needle valve core. Automatic air vents may be unscrewed one turn counterclockwise to speed initial venting, but should be screwed in for automatic venting after start-up operations. When steady steam of water begins to escape, close valve. Vent release air slowly, usually dripping water into drain pan in the process. Make sure all service valves are open and that the motorized control valves, if supplied, are set for automatic operation. OUT R3 D10 D11 R C/B A B C D BK/ PWM 1 + – 1 ADJUST A B C D A B C D HIGH LOW SPEED A42-4310 SPEED MED SPEED 0 EM/W2 W/W1 Y/Y2 Y1 G Fig. 95 — ECM Jumper Speed Board (42SM Only) CAUTION Both of the procedures described below require the control box to be powered while adjustments are made. Line voltage components are concealed behind a secondary cover. However, installer should still take all reasonable precautions to prevent electrical shock. 3-Discrete Speed Rheostat Field Adjustment (42SM Only) (See Fig. 96)— The unit has been factory configured to produce PSC equivalent airflow on high speed, with medium and low speed set at 80% and 60% of high, respectively. If these setting are acceptable, then no further configuring is required. Board mounted rheostats are provided to adjust the airflow pertaining to each output. Each output can be adjusted from 0 to 100% of the motor’s factory programmed operating range. To set airflow, connect a volt-meter between “common” (near the red status LED) and Flo1 through Flo4. CAUTION The air vent provided on the unit is not intended to replace the main system air vents and may not release air trapped in other parts of the system. Inspect the entire system for potential air traps and vent those areas as required, independently. In addition, some systems may require repeated venting over a period of time to properly eliminate air from the system. Failure to properly vent system may negatively affect operation. Status 11. Check all control valves in the system for proper operation in accordance with valve manufacturer's instructions. 12. For units with factory-installed ball valves with lever handles — When handle is perpendicular to valve body, there is no flow through valve. Ball valves may be used as shutoff valves. ECM CONTROL OPTION 3-Speed Jumper Field Adjustment (42SM Only) (See Fig. 95) — The unit has been factory configured to produce PSC equivalent airflow on high speed, with medium and low speed set at 80% and 60% of high, respectively. If these setting are acceptable, then no further configuring is required. To adjust airflow, relocate board mounted jumpers as indicated on configuration chart. Chart is located on control box cover. U3 Rp1 Rp2 Rp3 Rp4 Rp5 Com Flo0 COMMON FLO1 Flo1 FLO2 Flo2 Flo3 FLO3 Flo4 FLO4 a Fig. 96 — ECM Rheostat Speed Board (42SM Only) Carrier’s convention is to preset and wire Flo1 for high speed, Flo2 for medium, and Flo3 for low. Flo4 is not used with any standard thermostat, but may be employed for a more advanced application. The chart on the control box cover associates airflow rates with the voltage indicated on your volt-meter. For each speed, adjust the rheostat until indicated voltage matches the desired value from the airflow table. If a factory provided thermostat or DDC (Direct Digital Controls) controller is utilized, then the unit is already correctly configured. A field furnished thermostat or control may require adjustment of board jumpers. 78 set at 80% and 60% of high, respectively. If these settings are acceptable, then no further configuring is required. Board mounted pots are provided to adjust the airflow pertaining to each output. Each output can be adjusted from 0 to 100% of the motor’s factory programmed operating range. Use voltmeter and airflow chart (on the control box cover) to set values. Refer to Appendix B for adjustment procedure. Variable Airflow for 0-10 Vdc Input (See Fig. 99) — If a factory provided thermostat or DDC controller is utilized, then the unit is already correctly configured. Carrier recommends using the specific thermostat or DDC controller to commission the unit whenever possible. However, the blower can be started and operated without the thermostat. To do so, locate jumper 7 near the large capacitor. Move J7 from 0-10 to Man. Once moved, the onboard pots control fan speed. To switch the fan in this configuration, place a dry contact inline or on the enable wire. Variable Airflow for 0-10 Vdc Input (42SM Only) (See Fig. 97) — Carrier recommends using the specified thermostat or DDC controller to commission the unit whenever possible. However, the blower can be started and operated without the thermostat. To do so, locate the airflow adjustment screw which is accessible from the inside of the control box. With service switch in the “ON” position, turn the adjustment screw. The unit has now been placed in manual override. Manual override will expire when one of the following conditions is satisfied: • Power to the unit is cycled • 15 minutes elapse with no change to adjustment screw • Unit receives a control signal from the thermostat or controller a42-4313 Fig. 97 — ECM Proportional Speed Board 3-Speed Jumper Field Adjustment (See Fig. 98) — The unit has been factory configured to produce PSC equivalent airflow on high speed, with medium and low speed set at 80% and 60% of high, respectively. If these settings are acceptable, then no further configuring is required. If alternative airflows are desired, use board mounted pots to adjust the airflow associated with each input. Each output can be adjusted from 0 to 100% of the motor’s factory programmed operating range. Use voltmeter and airflow chart (on control box cover) to set values. Refer to Appendix A for adjustment procedure. a42-4313 Fig. 99 — ECM Proportional Speed Board CAUTION Both of the start-up and servicing procedures described below require the control box to be powered while adjustments are made. Line voltage components are concealed behind a secondary cover. However, installer should still take all reasonable precautions. L2 START-UP Before beginning any start-up operation, the start-up personnel should familiarize themselves with the unit, options and accessories, and control sequence to understand the proper system operation. All personnel should have a good working knowledge of general start-up procedures and have the appropriate start-up and balancing guides available for consultation. The building must be completely finished including doors, windows, and insulation. All internal walls and doors should be in place and in the normal position. In some cases, the interior decorations and furniture may influence overall system performance. The entire building should be as complete as possible before beginning any system balancing. Except as required during start-up and balancing operations, no fan coil units should be operated without all the proper ductwork attached, supply and return grilles in place, and all access doors and panels in place and secure. C3 C2 VR2 CR1 VR1 K2 L1 LOW MED HIGH K3 VR3 C1 LOW MED HIGH COM POTS K1 Fig. 98 — 3-Speed Potentiometer Adjustment 4-Discrete Speed Potentiometer Field Adjustment, Solid State — The unit has been factory configured to produce PSC equivalent airflow on high speed, with medium and low speed 79 After proper system operation is established, the actual unit air delivery and the actual fan motor amperage draw for each unit should be recorded in a convenient place for future reference. Start-up procedures vary depending on time of year (summer or winter) and building characteristics (new building/old building, occupied/unoccupied, etc.) Start-up in the cooling mode requires that proper care be given to avoid condensation problems. Condensation forms on surfaces that are colder than the dew point of the surrounding air. If a unit is started and is piped with low-temperature chilled water in a hot, humid atmosphere, condensation will form on many parts of the unit. In order to avoid excessive condensation, higher temperature water should initially be used (approximately 65 to 70 F) and the fan coil control set at low or medium fan speed. Be sure the fan current does not exceed motor nameplate values. Also, outside air supply fans, and bathroom and kitchen exhaust fans should be off. As the building temperature drops, the chilled water temperature can be gradually reduced until it reaches 50 F. At this point the outside air fans can be turned on. When the chilled water temperature is reduced to its design point, the exhaust fans can be turned on. Water System Balancing — A complete knowledge of the hydronic system, along with its components and controls, is essential to proper water system balancing. This procedure should not be attempted by unqualified personnel. The system must be complete, and all components must be in operating condition BEFORE beginning water system balancing operations. Each hydronic system has different operating characteristics depending on the devices and controls used in the system. The actual balancing technique may vary from one system to another. After the proper system operation is established, the appropriate system operating conditions such as various water temperatures and flow rates should be recorded in a convenient place for future reference. Before and during water system balancing, conditions may exist due to incorrect system pressures which may result in noticeable water noise or undesired valve operation. After the entire system is balanced, these conditions will not exist on properly designed systems. Cooling/Heating System — Prior to the water system start-up and balancing, flush the chilled / hot water systems to clean out dirt and debris which may have collected in the piping during construction. During the process, all unit service valves must be in the closed position to prevent foreign matter from entering the unit and clogging the valves and metering devices. Strainers should be installed in the piping mains to prevent such material from entering units during normal operation. During system filling, air venting from the unit is accomplished by the use of standard manual air vent or optional automatic air venting installed on the coil. Manual air vents are basically Schrader valves. For air venting, depress the valve unit the air has vented the coil. When water begins to escape through the valve, release the valve. Automatic air vents may be unscrewed one turn counterclockwise to speed initial venting but should be screwed in for automatic venting after startup operation. See Fig. 100 and 101. Water Treatment — Proper water treatment is a specialized industry. Carrier recommends consulting an expert in this field to analyze the water for compliance with the water quality parameters listed in Table 8 and to specify the appropriate water treatment regimen. The expert may recommend typical additives such as rust inhibitors, scaling preventative, antimicrobial growth agents or algae preventatives. Anti-freeze solutions may be used to lower the freezing point. Carrier’s water coil tubes and headers are constructed of pure copper. Multiple brass alloys may be present in the valve package, depending on unit configuration. It is the user's responsibility to ensure the tube and piping materials furnished by Carrier are compatible with the treated water. Failure to provide proper water quality will void the fan coils unit's warranty. Table 8 — Water Quality Concentrations Fig. 100 — Manual Air Vent Fig. 101 — Automatic Air Vent Air System Balancing — All duct stubs, grilles, filters, and return-access panels must be properly installed to establish actual system operating conditions BEFORE beginning air balancing operations. Each individual unit and the attached ductwork is a unique system with its own operating characteristics. For this reason, air balancing is normally done by balance specialists who are familiar with all procedures required to properly establish air distribution and fan-system operating conditions. These procedures should not be attempted by unqualified personnel. Units with no ductwork have air volumes predetermined at the factory by supply grille size and normally do not require air balancing other than selecting the desired fan speed. Units furnished with optional dampers on supply grilles may require some small adjustments to “fine tune” the air delivery to each grille. Opposed blade balancing dampers are not available for all grilles on a unit with electric heat. WATER CONTAINING REQUIRED CONCENTRATION Sulphate Less than 200 ppm pH 7.0 to 8.5 Chlorides Less than 200 ppm Nitrate Less than 100 ppm Iron Less than 4.5 mg/l Ammonia Less than 2.0 mg/l Manganese Less than 0.1 mg/l Dissolved Solids Less than 1000 mg/l CaCO3 Hardness 300 to 500 ppm CaCO3 Alkalinity 300 to 500 ppm Particulate Quantity Less than 10 ppm Particulate Size 800 micron max Controls Operation — Before proper control operation can be verified, all other systems must be operating properly. The correct water and air temperatures must be present for the control function being tested. Some controls and features are designed to not operate under certain conditions. For example, on a two-pipe cooling/heating system with auxiliary electric heat, the electric heater cannot be energized with hot water in the system. A wide range of controls, electrical options and accessories may be used with the equipment covered in this manual. Consult the approved unit submittals, order acknowledgements, 80 wheel or motor. The wheel and housing may be cleaned periodically using a vacuum cleaner and a brush, taking care not to dislodge the factory balancing weights on the blower wheel blades. and other literature for detailed information regarding each individual unit and its controls. Since controls and features may vary from one unit to another, care should be taken to identify the controls used on each unit and their proper control sequence. Information provided by component manufacturers regarding installation, operation, and maintenance of their individual controls is available upon request. When changing from one mode to another (cooling to heating or heating to cooling), it may take some time to actually notice a change in the leaving air temperature. In addition, some units may be designed for a very low air temperature rise in heating. Before declaring a unit inoperative or a component defective, it may be necessary to verify operation by more than one method. Clean Electric Heater — Lock open and tag unit elec- trical service switch. 1. Remove dust, dirt, or foreign material before start-up. Do not block normal airflow to and from units; blockage may damage electric heaters. 2. Clean heater elements with soft brush or vacuum cleaner as necessary. 3. To replace blown fusible links (nichrome heaters only): a. Remove fan deck (horizontal units only) for access to heater. b. Remove nut securing link at each end; install new link; reinstall nuts. c. Reinstall fan deck (if removed). Electric resistance heaters typically require no normal periodic maintenance when unit air filters are changed properly. The operation and service life may be affected by other conditions and equipment in the system. The two most important operating conditions for an electric heater are proper airflow and proper supply voltage. High supply voltage and/or poorly distributed or insufficient airflow over the element will result in element overheating and possible limit switch opening. This condition may result in the heater cycling on the high-limit thermal cutout. Sheath heaters have automatic reset switches only. Open strip heaters have an automatic reset switch with a backup, high-limit thermal switch. Automatic reset switch resets automatically after the heater has cooled down. High limit thermal switch must be replaced once the circuit has been broken. The high-limit thermal cutout device is a safety device only and is not intended for continuous operation. With proper unit application and operation, the high-limit thermal cutout will not operate. This device only operates when a problem exists, and ANY condition that causes high-limit cutout MUST be corrected immediately. High supply voltage also causes excessive amperage draw and may trip the circuit breaker or blow the fuses on the incoming power supply. After proper airflow and supply power are assured, regular filter maintenance is important to provide clean air over the heater. Dirt that is allowed to deposit on the heating element will cause hot spots and eventual element burn through. These hot spots will normally not be enough to trip the high-limit thermal cutout device and may not be evident until actual heater element failure. SERVICE Excessive Condensation on Unit — Running chilled water through a fan coil unit with the unit fan off can cause excessive condensation. If fan cycling is used, a water flow control valve should be installed to shut off the water when the fan stops. Other methods of control that avoid condensation problems are as follows: 1. Continuous fan operation with motorized chilled water valve controlled by a thermostat. 2. Continuous fan operation with thermostat control to switch fan from high to low speed (instead of off). To Clean Coil 1. Be sure electrical service switch is open, locked, and tagged while working on unit. 2. Remove return-air grille access panel and brush between coil fins with stiff wire brush. Care should be taken to not damage coil fins. Follow-up by cleaning with vacuum cleaner. If coil is cleaned with air hose and nozzle, take care not to drive dirt and dust into other components. Blow air through the coil fins from the leaving air face. This should again be followed by vacuuming. Units provided with the proper type of air filters, replaced regularly, will require less frequent coil cleaning. 3. Install clean filter. Refer to Clean or Replace Air Filters section. Check Drain — Lock open and tag unit electrical service switch. Check drain pan, drain line and trap before initial start-up and at start of each cooling season. A standard type pipe cleaner for 3/4-in. ID pipe can be used to ensure that pipe is clear of obstruction so that condensate is carried away. Check the drain line at filter cleaning time during the cooling season. Be sure that debris has not fallen into unit through supply-air grille. Should the growth of algae and/or bacteria be a concern, consult an air conditioning and refrigeration supply organization familiar with local conditions for chemicals or other solutions available to control these agents. Clean or Replace Air Filters — Lock open and tag unit electrical service switch. At the start of each cooling season and after each month of operation (more or less depending on operating conditions) replace throwaway filter or clean permanent filter. THROWAWAY FILTER — The type of throwaway filter most commonly used on fan coil units should be replaced on a regular basis. The time interval between each replacement should be established based on regular inspection of the filter and should be recorded in the log for each unit. Replace filter with a good quality filter of the size shown in Tables 1-4. Do not attempt to clean and reuse disposable filters. If the replacement filters are not purchased from the factory, the filters used should be the same type and size as those furnished from or recommended by the factory. Consult the factory for applications using filter types other than the factory standard or optional product. Filters with high arc pressure drops are generally not compatible with the fan coil units in this manual. PERMANENT FILTER — A maintenance schedule for permanent filters should be developed in the same manner as throwaway filters. Unlike throwaway filters, permanent filters Fan Motor Bearings — Lock open and tag unit electrical service switch. Standard motors are permanently sealed and lubricated. No lubrication is required unless special motors have been supplied or unusual operating conditions exist. Clean Fan Wheel — Lock open and tag unit electrical 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. Dirt and debris should not be allowed to accumulate on the blower wheel or housing. This can result in an unbalanced blower wheel condition which can damage a blower 81 valve package from excessive heat should also be used during replacement. may be cleaned and re-installed in the unit instead of being discarded when dirty. 1. Tap on solid surface to dislodge heavy particles. 2. Wash in hot water. If needed, use mild solution of commercial solvent such as sal soda or trisodium phosphate. 3. Set filter on end so that water drains out through slots in frame. Allow filter to dry thoroughly. 4. Recharge filter with Film-Cor or similar recharging oil. Three ounces is sufficient for medium size filter. Oil may be applied by insect spray gun. For easier spraying, the oil can be warmed. If the filter is dipped in the recharging oil, remove it immediately and allow draining through slots in frame. 5. Replace filter in unit. If another type of filter is used, follow the filter manufacturer's instructions. Filters — The type of throwaway filter most commonly used on fan coil units should be replaced on a regular basis. The time interval between each replacement should be established based on regular filter inspection and should be recorded in the log for each unit. Refer to product catalog for recommended filter size for each product type and size. If the replacement filters are not purchased from the factory, the filter used should be of same type and size as those furnished from or recommended by the factory. Pleated media or extended surface filter should not be used since the high air pressure drop encountered with these type of filters is not compatible with the type of fan coil unit covered in the manual. A maintenance schedule for permanent filters should be developed in the same manner as throwaway filters. Unlike throwaway filters, permanent filters may be cleaned and reinstalled in the unit instead of being discarded when dirty. The optional factory permanent filter may be cleaned in hot soapy water to remove any trapped dirt the set aside on edge to dry. Before replacing the filter in the unit, it should be recharged with some type of entrapment film. The filter should be sprayed on both sides or submerged in the film to assure complete coverage. The filter should not be allowed to soak in the film but should be immediately removed and the excess film drained from the filter before reinstallation in the unit. NOTE: Permanent filters normally have less static pressure loss than throwaway filters. Electrical Wiring and Controls — The electrical operation of each unit is determined by the components and wiring of the unit. This may vary from unit to unit. Consult the wiring diagram attached to the unit for the actual type and number of controls provided on each unit. The integrity of all electrical connections should be verified at least twice during the first year of operation. Afterwards, all controls should be inspected regularly for proper operation. Some components may experience erratic operation or failure due to age. Wall thermostats may also become clogged with dust and lint and should be periodically inspected and cleaned to provide reliable operation. When replacing any components such as fuses, contractors, or relays, use only the exact type, size and voltage component as furnished from the factory. Any deviation without factory authorization could result in personal injury or damage to the unit. This will also void all factory warranties. Only factorysupplied replacement parts ensure that the warranty and agency status remain in effect. All repair work should be done in such a manner as to maintain the equipment in compliance with governing codes, ordinances and testing agency listings. More specific information regarding the use and operating characteristics of the standard controls offered by the manufacturer are contained in other manuals. Drain — The drain must be checked before initial start-up and at the beginning of each cooling season to assure that the drain trap and line are clear. If it is clogged, take steps to clear the debris so that condensate will flow easily. Make periodic checks of the drain during the cooling season to maintain a free flowing condensate. Units provided with secondary or tell-tale drain connection will indicate a clogged main line by flow from the tell-tale connection. NOTE: Should the growth of algae and/or bacteria be a concern, consult an air conditioning and refrigeration supply organization familiar with local conditions for chemical or other solution available to control these growths. Warranty — All equipment and components sold through Valves and Piping — No formal maintenance is re- the Parts Department are warranted under the same conditions as the standard manufacturer’s warranty with the exception that the warranty period is thirty (30) days unless the component is furnished as a warranty replacement. Parts furnished as warranty replacements are warranted for the remaining term of the original unit warranty or not less than thirty (30) days. quired on the valve-package components most commonly used with fan coil units other than a visual inspection for possible leaks in the course of other normal periodic maintenance. In the event that a valve should need replacement, the same precautions taken during the initial installation to protect the 82 APPENDIX A — POTENTIOMETER ADJUSTMENT 5. Attach the red (positive) lead of the meter to the red wire that bridges the 0-10 vdc outputs: high, medium, and low. 6. High Speed: Close high speed relay by applying 24-v to the high terminal. Using a small screwdriver turn the VR3 potentiometer so the meter measures 4.51 vdc. This will set the ECM speed to 90% of maximum for high speed. Open the high speed relay. 7. Medium Speed: close medium speed relay by applying 24-v to the medium terminal. Using a small screwdriver turn the VR2 potentiometer so the meter measures 3.53 vdc. This will set the ECM speed to 70% of maximum for medium speed. Open the medium speed relay. 8. Low Speed: Close low speed relay by applying 24-v to the low terminal. Using a small screwdriver turn the VR1 potentiometer so the meter measures 2.06 vdc. This will set the ECM speed to 40% of maximum speed for low speed operation. Open the low speed relay. Adjusting the low, medium, and high potentiometers requires the use of a multi-meter capable of measuring 0~5 vdc. 1. Only trained and qualified individuals should attempt to adjust or service components on any electrical component. Failure to follow safety rules could result in electrical shock or hazard. 2. Unit must be powered to perform the following procedure. If main power is not available, connecting a temporary 24V-40VA power supply to parallel with a secondary outputs of the unit’s transformer is recommended. 3. Set the electrical multi-meter to volts direct current (vdc) on the 0~5 or 0~20 vdc scale. 4. Attach black (negative) lead of meter to the DC common terminal, labeled “L2” above the potentiometer and to the left of the orange relay. 83 APPENDIX B — EVO/ECM 4-SPEED ADJUSTMENT 6. High Speed: Using a small screwdriver turn the Flo1 potentiometer so the meter measures 4.51 vdc. This will set the ECM speed to 90% of maximum for high speed operation. 7. Medium Speed: Using a small screwdriver turn the Flo2 potentiometer so the meter measures 3.53 vdc. This will set the ECM speed to 70% of maximum speed for medium speed operation. 8. Low Speed: Using a small screwdriver turn the Flo3 potentiometer so the meter measures 2.06 vdc. This will set the ECM speed to 40% of maximum speed for low speed operation. 9. For setting of Flo0 and Flo4 contact Carrier, otherwise these potentionmeters should be set to full counter-clockwise rotation. Adjusting the Flo1, Flo2, Flo3 potentiometers requires the use of a multi-meter capable of measuring 0~5 vdc. 1. Only trained and qualified individuals should attempt to adjust or service components on any electrical component. Failure to follow safety rules could result in electrical shock or hazard. 2. 24 vac power must be supplied to ECM board to make adjustments. 3. Set the electrical multi-meter to volts direct current (vdc) on the 0~5 or 0~20 vdc scale. 4. Attach black (negative) lead of meter to the “Com” terminal to the left of the potentiometers and below the status light. 5. Attach the red (positive) lead of the meter to the high speed “Flo1” terminal below the potentiometer. 84 © Carrier Corporation 2014 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420010-01 Printed in U.S.A. Form 42-5SI Pg 86 1-14 Replaces: 42-4SI 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. Unit received undamaged 2. Unit received complete as ordered 3. “Furnish only” parts accounted for 4. Unit arrangement/hand correct 5. Unit structural support complete and correct Handling & Installation 6. Mounting grommets/isolators used 7. Unit mounted level and square 8. Proper access provided for unit and accessories 9. Proper electrical service provided 10. Proper overcurrent protection provided 11. Proper service switch/disconnect provided 12. Proper chilled water line size to unit 13. Proper hot water line size to unit 14. Proper refrigerant line sizes to unit 15. Proper steam line sizes to unit 16. Proper steam condensate trap on return line 17. Proper steam supply pressure to unit (10 psi max) 18. All service to unit in code compliance 19. All shipping screws and braces removed 20. Unit protected from dirt and foreign matter Cooling/Heating Connections 21. Protect valve package components from heat 22. Mount valve packages 23. Connect field piping to unit 24. Pressure test all piping for leaks 25. Install drain line and traps as required 26. Insulate all piping as required 27. Install drip lip under piping as required 28. Connect risers from 42SGM to 42SGS models 29. Connect risers to unit coil valve package (if risers are shipped/installed separately) Ductwork Connections 30. Install ductwork, fittings, and grilles as required 31. Flexible duct connections at unit 32. Proper supply and return grille type and size used 33. Control outside air for freeze protection 34. Insulate all ductwork as required COMPLETE ITEM Electrical Connections 35. Refer to unit wiring diagram 36. Connection incoming power service(s) 37. Install and connect “furnish only” parts 38. All field wiring in code compliance Unit Start-Up 39. General visual unit and system inspection 40. Check for proper fan rotation 41. Record electrical supply voltage 42. Record ambient temperatures 43. Check all wiring for secure connections 44. Close all unit isolation valves 45. Flush water systems 46. Fill systems with water/refrigerant 47. Vent water systems as required 48. All ductwork and grilles in place 49. All unit panels and filters in place 50. Start fans, pumps, chillers, etc. 51. Check for overload condition of all units 52. Check all ductwork and units for air leaks 53. Balance air systems as required 54. Record all final settings for future use 55. Check piping and ductwork for vibration 56. Check all dampers for proper operation 57. Verify proper cooling operation 58. Verify proper heating operation 59. Reinstall all covers and access panels 60. Verify proper condensate drainage COMPLETE Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420010-01 Printed in U.S.A. Form 42-5SI CL-1 1-14 Replaces: 42-4SI Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53420010-01 Printed in U.S.A. Form 42-5SI CL-2 1-14 Replaces: 42-4SI SERIAL NUMBER RH LH CFM ESP WATTS FILTER TYPE EAT db/wb °F EWT °F GPM PD H2O COOLING SENSIBLE BTUH EWT °F GPM PD H2 O STEAM PSI HEATING BTUH kW VOLTAGE ____________________________________________________________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________________________________________________________ ____________________________________________________________________________________________________________________________________________________________________________ TOTAL BTUH EAT db/wb °F 42 Series Fan Coil Air Conditioner Maintenance Data Log FAN AND MOTOR NOTE: Indicate repairs made, refrigerant added or removed (include amounts), field controls and valve packages added. MODEL NUMBER QTY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE © Carrier Corporation 2014