Installation, Start-Up and Service Instructions

42C,D,S,V Series Fan Coil Air Conditioners

CONTENTS Page Page SAFETY CONSIDERATIONS ...... 1 APPENDIX A — POTENTIOMETER ADJUSTMENT...... 83 INTRODUCTION ...... 1,2 APPENDIX B — EVO/ECM 4-SPEED PHYSICAL DATA ...... 2-4 ADJUSTMENT...... 84 PRE-INSTALLATION...... 4-42 START-UP CHECKLIST FOR 42C,D,S,V SERIES Unpack and Inspect Units ...... 4 FAN COIL AIR CONDITIONERS...... CL-1, CL-2 Protect Units From Damage ...... 4 Prepare Jobsite for Unit Installation...... 4 Identify and Prepare Units...... 4 SAFETY CONSIDERATIONS INSTALLATION ...... 42-79 Installation of this unit can be hazardous due to electrical com- Step 1 — Place Units in Position ...... 42 ponents and equipment location (such as a ceiling or elevated • 42C UNITS structure). Only trained, qualified installers and service • 42V UNITS mechanics should install and service this equipment. • 42D UNITS When installing this unit, observe precautions in the literature, • 42S UNITS labels attached to the equipment, and any other safety precau- Step 2 — Make Piping Connections ...... 53 tions that apply. • VALVE PACKAGES • Follow all safety codes. • 42C,D,V DRAIN CONNECTIONS • Wear safety glasses and work gloves. Never wear bulky • 42C,D,V WATER SUPPLY/RETURN or loose fitting clothing when working on any mechani- CONNECTIONS cal equipment. Gloves should be worn for proper protec- • 42C,D,V STEAM CONNECTIONS tion against heat and other possible injuries. Safety • 42C,D,V DIRECT EXPANSION (DX) REFRIGERANT glasses or goggles should always be worn when drilling, PIPING cutting, or working with chemicals such as refrigerants • TEST AND INSULATE or lubricants. Step 3 — Make Electrical Connections ...... 66 • Use care in handling and installing this unit. • FACTORY-INSTALLED OPTIONS • Never pressurize any equipment beyond specified test • STANDARD WIRING PACKAGES pressures. Always pressure test with an inert fluid or gas Step 4 — Make Duct Connections ...... 77 such as clear water or dry nitrogen to avoid possible Step 5 — Frame and Finish Unit...... 77 damage or injury in the event of a leak or component Step 6 — Cut Out Openings for Grilles and failure during testing. Always protect adjacent flamma- Thermostats ...... 77 ble material when welding or soldering. Use a suitable Step 7 — Make Final Preparations...... 77 heat-shield material to contain sparks or drops of solder. START-UP ...... 79-81 Have a fire extinguisher readily available. Cooling/Heating System...... 80 Air System Balancing ...... 80 Water System Balancing ...... 80 WARNING Water Treatment...... 80 Controls Operation...... 80 ELECTRIC SHOCK HAZARD. To avoid the possibility of electrical shock, open and tag all service switches before SERVICE ...... 81,82 installing this equipment. Excessive Condensation on Unit...... 81 To Clean Coil...... 81 Check Drain ...... 81 INTRODUCTION Fan Motor Bearings ...... 81 Carrier fan coil units represent a prudent investment offer- Clean Fan Wheel ...... 81 ing trouble-free operation and long service with proper installa- Clean Electric Heater...... 81 tion, operation, and regular maintenance. Your equipment is Clean or Replace Air Filters ...... 81 initially protected under the manufacturer’s standard warranty; Electrical Wiring and Controls ...... 82 however, this warranty is provided under the condition that the Valves and Piping ...... 82 steps outlined in this manual for initial inspection, proper in- Filters ...... 82 stallation, regular periodic maintenance, and everyday opera- Drain ...... 82 tion of the equipment be followed in detail. This manual should Warranty ...... 82 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 contact your local sales representative or the factory BEFORE See drawings for unit configurations, dimensions, clearances, proceeding. and pipe connections. Refer to unit wiring label for all electrical This document contains general installation instructions for connections; follow NEC (National Electrical Code) and local the 42C,D,S,V unit fan coils. Refer to the unit wiring diagram codes. installed on the blower housing or specific manufacturer litera- PHYSICAL DATA ture for any other type of factory-mounted controls. 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 36 39 49 59 64 95 107 42CE 55 60 70 82 95 135 154 42CG 98 118 126 168 176 215 245 42CK 115 120 135 150 155 227 241 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 10 fins/inch Coil Face Area (sq ft) 0.8 1.1 1.4 1.9 2.3 3.2 3.7 MOTOR (qty) 42C Series 111 1 1 22 BLOWER (qty) 42CA, CE, CG, CK 112 2 2 44 FILTERS Nominal Size (in.) (1-in. thick) 42CA NA NA NA NA NA NA NA 42CE† 10 x 18 10 x 22 10 x 28 10 x 33 10 x 40 10 x 54 10 x 62 42CG 1 1 1 Bottom Return 10 x 23 /2 10 x 28 10 x 32 /2 10 x 37 10 x 41 10 x 54 /2 10 x 63 1 1 1 Rear Return 8 x 23 /2 8 x 28 8 x 32 /2 8 x 37 8 x 41 8 x 54 /2 8 x 63 42CK Bottom Return 10 x 28 10 x 28 10 x 33 10 x 45 10 x 45 10 x 62 10 x 62 Rear Return 7 x 21 7 x 21 7 x 27 7 x 38 7 x 38 7 x 52 7 x 52 Qty 111 1 1 11 SUPPLY DUCT COLLAR 1-in. PIPING CONNECTIONS (Sweat) (in. OD) 5 Coil Outlet and Inlet /8 7 Drain Connection /8 5 Tell-Tale Drain /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 — 42 47 57 77 79 108 127 42VB — 63 68 82 99 101 133 154 42VC — 50 60 72 110 — — — 42VE — 72 100 108 154 — — — 42VF — 64 69 83 100 102 135 156 42VG 40 — 74 — — — — — COIL WATER WEIGHT (Approx lb per row of coil) 42VA, VB, VC†, VF — 0.7 0.8 1.0 1.4 1.7 2.3 2.7 42VE — 0.9 1.2 1.6 2.3 — — — 42VG 0.4 — 1.0 — — — — — COILS FPI (42VA, VB, VF) 12 fins/inch FPI (42VC, VE, VG) 10 fins/inch Coil Face Area (sq ft) 0.8 0.8 1.1 1.4 1.9 2.3 3.2 3.7 MOTOR (qty) 42VA, VB, VF —111 1122 42VC, VE —1 1 1 2 — — — 42VG 1— 2 — — — — — BLOWER (qty) 42VA, VB, VF —112 2244 42VC, VE —2 2 2 4 — — — 42VG 1— 2 — — — — — FILTERS Nominal Size (in.) (1-in. thick) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 42VA, VB, VF —7/4 x 21 /4 7 /4 x 21 /4 7 /4 x 31 /4 7 /4 x 41 /4 7 /4 x 43 /4 7 /4 x 57 /4 7 /4 x 65 /4 3 3 3 3 42VC, VE —7 x 21/4 7 x 26 /4 7 x 34 /4 7 x 48 /4 ——— 1 42VG 10 x 14 /2 — 10 x 28 — — — — — Qty 1111 1111 SUPPLY DUCT COLLAR 1-in. PIPING CONNECTIONS (Sweat) (in.) 5 Coil Outlet and Inlet /8 OD 3 Drain Connection /4 MPT *Calculate Operating Weight of Unit: Shipping Weight + Coil Water Weight x †Available in sizes 02-06. Number Of Coil Rows. Table 3 — Physical Data — 42D Series Units

UNIT SIZE 42D0608101214161820 NOMINAL AIRFLOW (cfm) 600 800 1000 1200 1400 1600 1800 2000 SHIPPING WEIGHT (lb)* 42DA 64 79 90 108 119 124 141 151 42DC 94 107 150 169 174 178 195 220 42DD 135 145 155 180 190 200 215 230 42DE 150 160 170 195 205 215 230 235 42DF 157 167 177 202 215 225 240 255 COIL WATER WEIGHT (Approx lb per row of coil) 1.31.61.92.32.73.03.43.7 COILS FPI 10 fins/inch Coil Face Area (sq ft) 1.62.12.53.03.54.14.65.0 MOTOR (qty) 11122222 BLOWER (qty) 11122222 FILTERS Nominal Size (in.) (1-in. thick) 42DA NA 42DC 14 x 21 14 x 26 14 x 30 14 x 35 14 x 40 14 x 45 14 x 50 14 x 54 42DD 3 3 3 3 3 3 3 3 (Front Return) 12 /4 x 21 12 /4 x 26 12 /4 x 30 12 /4 x 35 12 /4 x 40 12 /4 x 45 12 /4 x 50 12 /4 x 54 3 3 3 3 3 3 3 3 (Bottom Return) 12 /4 x 20 12 /4 x 25 12 /4 x 29 12 /4 x 34 12 /4 x 39 12 /4 x 44 12 /4 x 49 12 /4 x 53 3 3 3 3 3 3 3 3 42DE 14 x 14 /4 14 x 19 /4 14 x 23 /4 14 x 28 /4 14 x 33 /4 14 x 38 /4 14 x 43 /4 14 x 47 /4 42DF 14 x 14 14 x 20 14 x 24 14 x 28 14 x 34 14 x 38 14 x 44 14 x 48 Qty 1 SUPPLY DUCT COLLAR 1-in. PIPING CONNECTIONS Coil Inlet/Outlet (in. OD) 5 5 5 5 5 5 5 5 1 and 2 Row /8 /8 /8 /8 /8 /8 /8 /8 5 5 7 7 7 7 7 7 3 Row /8 /8 /8 /8 /8 /8 /8 /8 7 7 7 7 7 1 1 1 4 Row /8 /8 /8 /8 /8 1 /8 1 /8 1 /8 7 7 7 7 1 1 1 1 5 Row /8 /8 /8 /8 1 /8 1 /8 1 /8 1 /8 7 7 7 7 1 1 1 1 6 Row /8 /8 /8 /8 1 /8 1 /8 1 /8 1 /8 1 1 1 1 5 5 5 5 8 Row 1 /8 1 /8 1 /8 1 /8 1 /8 1 /8 1 /8 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 03 04 06 08 10 12 14 16 20 NOMINAL AIRFLOW (cfm) 300 400 600 800 1000 1200 1400 1600 2000 SHIPPING WEIGHT (lb)* 42SGA,SGM,SU 180 225 240 260 280 305 — — — 42SH 202 247 262 286 311 336 — — — 42SJ 360 450 480 520 560 610 — — — 42SGS 162 203 216 234 252 275 — — — 42SM ——————390390390 COIL WATER WEIGHT (Approx lb per row of coil) 1.79 2.63 3.45 4.09 4.09 4.39 COILS FPI 14 fins/inch BLOWER (qty) 42SGA,SH,SU,SGM,SGS,SM 11111111 1 42SJ 222222——— FILTERS 1 1 1 3 1 1 1 1 1 1 Nominal Size (in.) (1-in. thick) 12 /2 x 24 /4 16 /4 x 26 /4 20 /2 x 29 /4 24 /2 x 29 /2 26 /2 x 29 /2 Qty 1† PIPING CONNECTIONS 1 Inlet (in. OD) /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.

PRE-INSTALLATION rugged appearance. Still, great care must be taken to assure that no force or pressure is applied to the coil, piping, or drain Unpack and Inspect Units — All units are carefully stub-outs during handling. Depending on the options and ac- inspected at the factory throughout the manufacturing process cessories, some units may contain delicate components that under a strict detailed quality assurance program, and, where may be damaged by improper handling. All units shall be han- possible, ALL major components and sub-assemblies are care- dled by the chassis or as close as possible to the unit mounting fully tested for proper operation and verified for full compli- point locations. In the case of a full cabinet unit, the unit must ance with factory standards. Operational testing of some cus- be handled by the exterior casing. This is acceptable provided tomer-furnished components such as electronic control valves the unit is maintained in an upright position, and no force is ap- and digital controllers may be a possible exception. plied that may damage internal components or painted Each unit is carefully packaged for shipment to avoid dam- surfaces. age during normal transit and handling. Equipment should al- The equipment must always be properly supported. Tempo- ways be stored in a dry place, and in the proper orientation as rary supports used during installation or service must be ade- marked on the carton. All shipments are made F.O.B. factory quate to hold the equipment securely. Equipment should al- and are the responsibility of the receiving party to inspect the ways be stored in the proper orientation as marked on the car- equipment upon arrival. Any obvious damage to the carton ton. To maintain warranty, protect units against hostile and/or its contents should be recorded on the bill of lading and environment (such as rain, snow, or extreme temperatures), a claim should be filed with the transportation company, and theft, vandalism, and debris on jobsite. Equipment covered in Carrier should be advised. After determining the condition of this manual is not suitable for outdoor installations. Do not al- the carton exterior, carefully remove each unit from the carton low foreign material to fall into drain pan. Prevent dust and de- and inspect for hidden damage. At this time, check to make bris from being deposited on motor, fan wheels and cooling/ sure that “furnished only” items such as thermostats, grilles etc. heating coils. Failure to do so may have serious adverse effects are accounted for whether packaged separately or shipped at a on unit operation, and in the case of the motor and blower as- later date. Any hidden damage should be recorded and imme- sembly, may result in immediate or premature failure. Manu- diately reported to the transportation company, a claim should facturer's warranty is void if foreign material is allowed to be be filed with the transportation company, and Carrier should be deposited on the motor or blower wheels of any unit. Some notified. In the event a claim for shipping damage is filed, the units and/or job conditions may require some form of tempo- unit, shipping carton, and all packing must be retained for rary covering during construction. physical inspection by the transportation company. All equipment should be stored in the factory shipping carton with inter- Prepare Jobsite for Unit Installation — To save nal packing in place until installation. time and to reduce the possibility of costly errors, set up a com- At the time of receipt, the equipment type and arrangement plete sample installation in a typical room at jobsite. Check all should be verified against the order documents. Should any critical dimensions such as pipe, wire, and duct connection discrepancy be found, the local sales representative should be requirements. Refer to job drawings and product dimension notified immediately so that proper action may be taken. drawings as required (see Fig. 1-38). Instruct all trades in their Should any questions arise concerning warranty repairs, the part of the installation. factory must be notified BEFORE any corrective action is tak- Identify and Prepare Units — Be sure power require- en. Where local repairs or alterations can be accomplished, the ments match available power source. Refer to unit nameplate factory must be fully informed of the extent and expected cost and wiring diagram. of those repairs before work is begun. Where factory operations are required, the factory must be contacted for authoriza- 1. Check all tags on unit to determine if shipping screws are tion to return equipment and a Return Authorization Number to be removed. Remove screws as directed. will be issued. Unauthorized return shipments of equipment 2. Rotate the fan wheel by hand to ensure that the fan is and shipments not marked with an authorization number will unrestricted and can rotate freely. Check for shipping be refused. In addition, any claims for unauthorized expenses damage and fan obstructions. Adjust blower motor as will not be accepted by the manufacturer. required. 3. Perform "Dry Fit" of valve assembly that may be shipped Protect Units from Damage — All equipment is de- unattached to unit coil assembly. Should any questions signed and fabricated with robust materials and presents a arise on fit up please contact your local representative.

4 LEGEND NOTES: 1—Junction Box (remote mount) 1. Right hand unit shown; left hand unit opposite. Coil connection 5 2—Flexible Metal Conduit locations are ± /8-inch. 7 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 3—Drain Conn, /8-in. OD 5 through 08 have one motor, 2 blowers; sizes 10 and 12 have 4 — Tell-Tale Drain Conn, /8-in. OD (optional) 5—Drip Lip (optional, shipped loose) 2 motors, 4 blowers. 6—Hanger Slots (4), Rubber Grommet 3. Standard 3-row coil shown. 3 4. Overall unit dimension increases by 4 in. with optional electric has /8-in. Diameter Hole 7—Supply Duct Collar, 1-in. heat. 1 5. Not shown: 3-speed fan switch; wall plate; closed cell foam on 8—Air Vent, /8-in. MPT 5 main drain pan. 9—Return Conn, /8-in. OD 10 — Supply Conn, 5/ -in. OD 6. Units have galvanized finish. 8 7. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. a42-4099.eps 8. Dimensions shown in inches (mm).

UNIT NOM DIMENSIONS (in.) QTY/UNIT FACE UNIT AIRFLOW AREA WEIGHT* SIZE (Cfm) AA’BD’E F GHBlower Motor (sq ft) (lb) 1 1 1 1 3 3 02 200 21 /4 31 /4 16 13 18 /4 6 /4 8 /4 19 /4 1 1 0.83 36 1 1 1 1 3 3 03 300 25 /4 36 /4 20 14 22 /4 6 /4 8 /4 23 /4 1 1 1.08 39 1 1 1 1 3 3 04 400 31 /4 43 /4 26 15 28 /4 6 /4 8 /4 29 /4 2 1 1.35 49 1 1 1 1 3 06 600 36 /4 43 /4 31 10 33 /4 7 /2 10 34 /4 2 1 1.88 59 1 1 1 1 3 08 800 43 /4 57 /4 38 17 40 /4 7 /2 10 41 /4 2 1 2.31 64 1 1 1 1 3 10 1000 57 /4 65 /4 52 11 54 /4 7 /2 10 55 /4 4 2 3.16 95 1 1 1 1 3 12 1200 65 /4 75 /4 60 13 62 /4 7 /2 10 63 /4 4 2 3.65 107

*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 LEGEND NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection 1—Junction Box (remote mount) 5 locations are ± /8-inch. 2—Flexible Metal Conduit 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 3 — Strip Heater High Limit through 08 have one motor, 2 blowers; sizes 10 and 12 have 4 — Electric Strip Heater Element 5 2 motors, 4 blowers. 5 — Tell-Tale Drain Conn, /8-in. OD (optional) 7 3. Standard 3-row coil shown. 6—Drain Conn, /8-in. OD 4. Overall unit dimension increases by 4 in. with optional electric 7—Drip Lip (optional, shipped loose) heat. 8—Supply Duct Collar, 1-in. 1 5. Not shown: 3-speed fan switch; wall plate; closed cell foam on 9—Air Vent, /8-in. MPT 5 main drain pan. 10 — Return Conn, /8-in. OD 5 6. Units have galvanized finish. 11 — Supply Conn, /8-in. OD 7. For optional coil connections, view 42CA-203-1 using the Fan Coil 12 — Hanger Slots (4), Rubber Grommet 3 Builder. has /8-in. Diameter Hole 8. Dimensions shown in inches (mm). a42-4100.eps

UNIT NOM DIMENSIONS (in.) QTY/UNIT FACE UNIT AIRFLOW AREA WEIGHT* SIZE (Cfm) AA’BD’E F GHBlower Motor (sq ft) (lb) 1 1 1 1 3 3 02 200 21 /4 31 /4 16 13 18 /4 6 /4 8 /4 19 /4 1 1 0.83 38 1 1 1 1 3 3 03 300 25 /4 36 /4 20 14 22 /4 6 /4 8 /4 23 /4 1 1 1.08 41 1 1 1 1 3 3 04 400 31 /4 43 /4 26 15 28 /4 6 /4 8 /4 29 /4 2 1 1.35 51 1 1 1 1 3 06 600 36 /4 43 /4 31 10 33 /4 7 /2 10 34 /4 2 1 1.88 61 1 1 1 1 3 08 800 43 /4 57 /4 38 17 40 /4 7 /2 10 41 /4 2 1 2.31 66 1 1 1 1 3 10 1000 57 /4 65 /4 52 11 54 /4 7 /2 10 55 /4 4 2 3.16 97 1 1 1 1 3 12 1200 65 /4 75 /4 60 13 62 /4 7 /2 10 63 /4 4 2 3.65 109

*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 LEGEND NOTES: 1. Right hand unit with standard 3-row coil shown; left hand unit opposite. Coil 1— Junction Box, 4 in. x 4 in. 5 2— Flexible Metal Conduit connection locations are ± /8-inch. 3— Mounting Bracket 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have 7 one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 4— Drain Conn, /8-in. OD 5 3. Standard 3-row coil shown. 5— Tell-Tale Drain Conn, /8-in. OD (optional) 6— Drip Lip (optional, shipped loose) 4. Unit available with bottom or rear return air. 5. Overall dimension increases by 4 in. with optional electric heat. 7— Filter 1 8— Return Duct Collar, 1-in. 6. Not shown: 3-speed fan switch; wall plate; /2-in. fiberglass insulation on 9— Filter Access Panel inside of plenum, closed cell foam on main drain pan. 10 — Access Panel 7. Units have galvanized finish. 11 — Supply Duct Collar, 1-in. 8. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. 1 9. Dimensions shown in inches (mm). 12 — Air Vent, /8-in. MPT 5 13 — Return Conn, /8-in. OD 5 14 — Supply Conn, /8-in. OD 15 — Hanger Slots (4), Rubber Grommet has a42-4101 3 /8-in. Diameter Hole

NOM DIMENSIONS (in.) QTY/UNIT FACE UNIT RETURN AIR UNIT AIRFLOW AREA WEIGHT* DUCT SIZE (Cfm) AA’BCD’EFGHBlower Motor (sq ft) (lb) (inches) 1 1 1 3 1 3 3 1 1 02 200 21 /4 31 /4 16 18 /4 13 19 /4 6 /4 8 /4 15 /8 1 1 0.83 55 10 /2 x 18 /4 1 1 1 3 1 3 3 1 1 03 300 25 /4 36 /4 20 22 /4 14 23 /4 6 /4 8 /4 19 /8 1 1 1.08 60 10 /2 x 22 /4 1 1 1 3 1 3 3 1 1 04 400 31 /4 43 /4 26 28 /4 15 29 /4 6 /4 8 /4 25 /8 2 1 1.35 70 10 /2 x 28 /4 1 1 1 3 1 3 1 1 06 600 36 /4 43 /4 31 33 /4 10 34 /4 7 /2 10 30 /8 2 1 1.88 82 10 /2 x 33 /4 1 1 1 3 1 3 1 1 08 800 43 /4 57 /4 38 40 /4 17 41 /4 7 /2 10 37 /8 2 1 2.31 95 10 /2 x 40 /4 1 1 1 3 1 3 1 1 10 1000 57 /4 65 /4 52 54 /4 11 55 /4 7 /2 10 51 /8 4 2 3.16 135 10 /2 x 54 /4 1 1 1 3 1 3 1 1 12 1200 65 /4 75 /4 60 62 /4 13 63 /4 7 /2 10 59 /8 4 2 3.65 154 10 /2 x 62 /4

*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 LEGEND NOTES: 1. Right hand unit with standard 3-row coil shown; left hand unit opposite. Coil 1— Junction Box, 4 in. x 4 in. 5 2— Flexible Metal Conduit connection locations are ± /8-inch. 3— Mounting Bracket 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 have 4— Electric Strip Heater Element one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 7 3. Standard 3-row coil shown. 5— Drain Conn, /8-in. OD 6— Strip Heater High Limit 4. Unit available with bottom or rear return air. 5 5. Overall dimension increases by 4 in. with optional electric heat. 7— Tell-Tale Drain Conn, /8-in. OD (optional) 1 8— Drip Lip (optional, shipped loose) 6. Not shown: 3-speed fan switch; wall plate; /2-in. fiberglass insulation on 9— Filter inside of plenum, closed cell foam on main drain pan. 10 — Return Duct Collar, 1-in. 7. Units have galvanized finish. 11 — Filter Access Panel 8. For optional coil connections, view 42CA-203-1 using the Fan Coil Builder. 12 — Access Panel 9. Dimensions shown in inches (mm). 13 — Supply Duct Collar, 1-in. 1 14 — Air Vent, /8-in. MPT 5 A42-4102 15 — Return Conn, /8-in. OD 5 16 — Supply Conn, /8-in. OD 17 — Hanger Slots (4), Rubber Grommet has 3 /8-in. Diameter Hole

NOM DIMENSIONS (in.) QTY/UNIT FACE UNIT UNIT AIRFLOW AREA WEIGHT* RETURN AIR SIZE DUCT (Cfm) AA’BCD’EFGHBlower Motor (sq ft) (lb) 1 1 1 3 1 3 3 1 1 02 200 21 /4 31 /4 16 18 /4 13 19 /4 6 /4 8 /4 15 /8 1 1 0.83 57 10 /2 x 18 /4 1 1 1 3 1 3 3 1 1 03 300 25 /4 36 /4 20 22 /4 14 23 /4 6 /4 8 /4 19 /8 1 1 1.08 62 10 /2 x 22 /4 1 1 1 3 1 3 3 1 1 04 400 31 /4 43 /4 26 28 /4 15 29 /4 6 /4 8 /4 25 /8 2 1 1.35 72 10 /2 x 28 /4 1 1 1 3 1 3 1 1 06 600 36 /4 43 /4 31 33 /4 10 34 /4 7 /2 10 30 /8 2 1 1.88 84 10 /2 x 33 /4 1 1 1 3 1 3 1 1 08 800 43 /4 57 /4 38 40 /4 17 41 /4 7 /2 10 37 /8 2 1 2.31 97 10 /2 x 40 /4 1 1 1 3 1 3 1 1 10 1000 57 /4 65 /4 52 54 /4 11 55 /4 7 /2 10 51 /8 4 2 3.16 137 10 /2 x 54 /4 1 1 1 3 1 3 1 1 12 1200 65 /4 75 /4 60 62 /4 13 63 /4 7 /2 10 59 /8 4 2 3.65 156 10 /2 x 62 /4

*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 LEGEND NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection locations 1— Junction Box, 4 in. x 4 in. 5 are ± /8-inch. 2— Optional Return Air Location 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 through 08 3— Drip Lip (optional, shipped loose) have one motor, 2 blowers; sizes 10 and 12 have 2 motors, 4 blowers. 4— Mounting Holes (4), Rubber Grommets 3 3. Cabinet has an Arctic White baked finish. have /8-in. Diameter Hole 7 4. Refer to supply and return connections above for coil stub-out locations. 5— Electrical Knockout, /8-in. Diameter 5. Not shown: optional drip lip, 3-speed fan switch; wall plate; 1/ -in. fiber- 6— Return Knockout, 1-in. Diameter 2 1 glass insulation on inside of casing, closed cell foam on main drain pan. 7— Supply Knockout, 1 /2-in. Diameter 1 6. For optional coil connections, view 42CA-203-1 using the Fan Coil 8— Drain Knockout, 1 /2-in. Diameter 5 Builder. 9— Supply, Return Connections, /8-in. OD 7 7. Valve package is factory-installed inside the cabinet when ordered with 10 — Drain Connection, /8-in. OD the unit (based on component size). 11 — Optional Valve Package (inside cabinet) 8. Dimensions shown in inches (mm). 12 — Filter 13 — Standard Stamped-Return Air Grille 14 — Removable Hinged Access Panel 15 — Supply Grille, Stamped, Standard A42-4105

UNIT NOM DIMENSIONS (in.) QTY/UNIT FACE UNIT AIRFLOW AREA WEIGHT* SIZE (Cfm) ABCEFGBlower Motor (sq ft) (lb) 1 7 3 02 200 38 17 /8 10 /16 34 5 /4 11 1 1 0.83 98 1 1 3 03 300 42 21 /2 10 /4 38 5 /4 11 1 1 1.08 118 7 1 3 04 400 48 25 /8 11 /16 44 5 /4 11 2 1 1.35 126 5 3 3 06 600 53 34 /8 9 /16 49 6 /4 12 2 1 1.88 168 1 3 08 800 60 39 10 /2 56 6 /4 12 2 1 2.31 176 1 15 3 10 1000 74 52 /8 10 /16 70 6 /4 12 4 2 3.16 215 7 9 3 12 1200 82 60 /8 10 /16 78 6 /4 12 4 2 3.65 245

*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 LEGEND NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection 1— Junction Box, 4 in. x 4 in. 5 locations are ± /8-inch. 2— Optional Stamped Rear Return Grille 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 3— Drip Lip (optional, shipped loose) through 08 have one motor, 2 blowers; sizes 10 and 12 have 4— Electric Strip Heater Element 2 motors, 4 blowers. 5— Mounting Holes (4), Rubber Grommets 3 3. Cabinet has an Arctic White baked finish. have /8-in. Diameter Hole 7 4. Refer to supply and return connections above for coil stub-out 6— Electrical Knockout, /8-in. Diameter locations. 7— Return Knockout, 1-in. Diameter 1 1 5. Not shown: 3-speed fan switch; wall plate; /2-in. fiberglass 8— Supply Knockout, 1 /2-in. Diameter 1 insulation on inside of casing, closed cell foam on main drain 9— Drain Knockout, 1 /2-in. Diameter 7 pan. 10 — Drain Connection, /8-in. OD 6. For optional coil connections, view 42CA-203-1 using the Fan 11 — Valve Package (optional, inside cabinet) Coil Builder. 12 — Filter 7. Valve package is factory-installed inside the cabinet when 13 — Standard Stamped-Return Air Grille ordered with the unit (based on component size). 14 — Removable Hinged Access Panel 5 8. Dimensions shown in inches (mm). 15 — Supply, Return Connections, /8-in. OD A42-4106 16 — Supply Grille, Stamped, Standard

NOM DIMENSIONS (in.) QTY/UNIT FACE UNIT UNIT SIZE AIRFLOW AREA WEIGHT* (Cfm) ABCEFGBlower Motor (sq ft) (lb) 1 7 3 02 200 38 17 /8 10 /16 34 5 /4 11 1 1 0.83 98 1 1 3 03 300 42 21 /2 10 /4 38 5 /4 11 1 1 1.08 118 7 1 3 04 400 48 25 /8 11 /16 44 5 /4 11 2 1 1.35 126 5 3 3 06 600 53 34 /8 9 /16 49 6 /4 12 2 1 1.88 168 1 3 08 800 60 39 10 /2 56 6 /4 12 2 1 2.31 176 1 15 3 10 1000 74 52 /8 10 /16 70 6 /4 12 4 2 3.16 215 7 9 3 12 1200 82 60 /8 10 /16 78 6 /4 12 4 2 3.65 245

*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

5 6

D 9 7

LEGEND NOTES: 1 — Junction Box 1. Right hand unit shown; left hand unit opposite. 2 — L-shape Drip Lip (optional, shipped loose) 2. Internal factory valve package and drains may not align with cabinet 3 — Chilled/Hot Water Supply and Return Connection knockouts. 3 3. Dimensions shown in inches (mm). All dimensions are ±1/ inches. 4 — Resilient Mounting Grommets with /8-in. Diameter Hole 4 (typically 4) 4. Bottom panel is Arctic White polyester powder coat paint. 7 5 — Electrical Knockout, /8-in. Diameter 1 6 — Drain Knockout, 1 /2-in. Diameter 7 — Stamped Return Air Grille and 1-in. Filter A42-4149 7 8 — Condensate Drain Connection, /8-in. OD 9 — Hinged Bottom Return Air Panel 10 — Supply Duct Collar, 1-in. OD

DIMENSIONS (in.) QTY/UNIT BOTTOM UNIT NOM RETURN UNIT WEIGHT* AIRFLOW SIZE (Cfm) ABCDEFBlowerMotorFILTER SIZE (lb) (in.) 3 1 02 200 35 16 12 /4 37 32 6 1 1 10 x 23 /2 115 3 03 300 35 20 8 /4 37 32 6 1 1 10 x 28 120 3 1 04 400 41 26 8 /4 43 38 6 2 1 10 x 32 /2 135 3 06 600 53 31 15 /4 55 50 7 2 1 10 x 37 150 3 08 800 53 38 8 /4 55 50 7 2 1 10 x 41 155 3 1 10 1000 75 52 16 /4 77 72 7 4 2 10 x 54 /2 227 3 12 1200 75 60 8 /4 77 72 7 4 2 10 x 63 241

*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 13 9 10

a42-4150

LEGEND NOTES: 1 — Contactor Box 1. Right hand unit shown; left hand unit opposite. 2 — Strip Heater High Limit 2. Internal factory valve package and drains may not align with 3 — Electric Strip Heater Element cabinet knockouts. 4 — L-shape Drip Lip (optional, shipped loose) 3. Dimensions shown in inches (mm). All dimensions are 1 5 — Chilled/Hot Water Supply and Return Connection ± /4 inches. 3 6 — Resilient Mounting Grommets with /8-in. Diameter Hole 4. Bottom panel is Arctic White polyester powder coat paint. (typically 4) 7 7 — Electrical Knockout, /8-in. Diameter 1 8 — Drain Knockout, 1 /2-in. Diameter 9 — Stamped Return Air Grille and 1-in. Filter 7 10 — Condensate Drain Connection, /8-in. OD 11 — Hinged Bottom Return Air Panel 12 — Supply Duct Collar, 1-in. OD 13 — Drain Pan

NOM DIMENSIONS (in.) QTY/UNIT BOTTOM UNIT RETURN UNIT WEIGHT* SIZE AIRFLOW FILTER SIZE (lb) (Cfm) ABCDEFBlowerMotor (in.) 3 1 02 200 35 16 12 /4 37 32 6 1 1 10 x 23 /2 117 3 03 300 35 20 8 /4 37 32 6 1 1 10 x 28 122 3 1 04 400 41 26 8 /4 43 38 6 2 1 10 x 32 /2 137 3 06 600 53 31 15 /4 55 50 7 2 1 10 x 37 152 3 08 800 53 38 8 /4 55 50 7 2 1 10 x 41 157 3 1 10 1000 75 52 16 /4 77 72 7 4 2 10 x 54 /2 229 3 12 1200 75 60 8 /4 77 72 7 4 2 10 x 63 243

*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

6 7

LEGEND NOTES: 1 — Junction Box 1. Right hand unit shown; left hand unit opposite. 2 — 1-in. Ducted Rear Return and 1-in. Filter 2. Internal factory valve package and drains may not align with 3 — L-shape Drip Lip (optional, shipped loose) cabinet knockouts. 4 — Chilled/Hot Water Supply and Return Connection 3. Dimensions shown in inches (mm). All dimensions are 3 ±1/ inches. 5 — Resilient Mounting Grommets with /8-in. Diameter Hole 4 (typically 4) 4. Bottom panel is Arctic White polyester powder coat paint. 7 6 — Electrical Knockout, /8-in. Diameter 1 7 — Drain Knockout, 1 /2-in. Diameter 8 — 1-in. Ducted Rear Return and 1-in. Filter 7 a42-4151 9 — Condensate Drain Connection, /8-in. OD 10 — Hinged Bottom Return Air Panel 11 — Supply Duct Collar, 1-in. OD

NOM DIMENSIONS (in.) QTY/UNIT UNIT AIRFLOW REAR RETURN UNIT WEIGHT* SIZE FILTER SIZE (in.) (lb) (Cfm) ABCDEFBlowerMotor 3 02 200 35 16 12 /4 37 32 6 1 1 7 x 21 115 3 03 300 35 20 8 /4 37 32 6 1 1 7 x 21 120 3 04 400 41 26 8 /4 43 38 6 2 1 7 x 27 135 3 06 600 53 31 15 /4 55 50 7 2 1 7 x 38 150 3 08 800 53 38 8 /4 55 50 7 2 1 7 x 38 155 3 10 1000 75 52 16 /4 77 72 7 4 2 7 x 52 227 3 12 1200 75 60 8 /4 77 72 7 4 2 7 x 52 241

*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

LEGEND NOTES: 1 — Contactor Box 1. Right hand unit shown; left hand unit opposite. 2 — Strip Heater High Limit 2. Internal factory valve package and drains may not align 3 — Electric Strip Heater Element with cabinet knockouts. 4 — 1-in. Ducted Rear Return and 1-in. Filter 3. Dimensions shown in inches (mm). All dimensions are 1 5 — L-shape Drip Lip (optional, shipped loose) ± /4 inches. 6 — Chilled/Hot Water Supply and Return Connection 4. Bottom panel is Arctic White polyester powder coat paint. 3 7 — Resilient Mounting Grommets with /8-in. Diameter Hole (typically 4) a42-4152 7 8 — Electrical Knockout, /8-in. Diameter 1 9 — Drain Knockout,1 /2-in. Diameter 10 — 1-in. Ducted Rear Return and 1-in. Filter 7 11 — Condensate Drain Connection, /8-in. OD 12 — Hinged Bottom Return Air Panel 13 — Supply Duct Collar, 1-in. OD 14 — Drain Pan

UNIT NOM DIMENSIONS (in.) QTY/UNIT REAR RETURN UNIT WEIGHT* AIRFLOW SIZE (Cfm) ABCDE FBlowerMotorFILTER SIZE (in.) (lb) 3 02 200 35 16 12 /4 37 32 6 1 1 7 x 21 117 3 03 300 35 20 8 /4 37 32 6 1 1 7 x 21 122 3 04 400 41 26 8 /4 43 38 6 2 1 7 x 27 137 3 06 600 53 31 15 /4 55 50 7 2 1 7 x 38 152 3 08 800 53 38 8 /4 55 50 7 2 1 7 x 38 157 3 10 1000 75 52 16 /4 77 72 7 4 2 7 x 52 229 3 12 1200 75 60 8 /4 77 72 7 4 2 7 x 52 243

*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 NOTES: 1— Junction Box, 4 in. x 4 in. 1. Right hand unit shown; left hand unit opposite. Coil connection 5 2— Drip Lip (optional, shipped loose) locations are ± /8-inch. 3— Mounting Holes (4), Rubber Grommets 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 3 through 08 have one motor, 2 blowers; sizes 10 and 12 have have /8-in. Diameter Hole 1 2 motors, 4 blowers. 4— Piping Knockout, 1 /2-in. Diameter 7 3. Bottom access panel has an Arctic White baked finish. 5— Electrical Knockout, /8-in. Diameter 1 4. Refer to supply and return connections above for coil stub-out 6— Drain Knockout, 1 /2-in. Diameter locations. 1 7— Supply Duct Collar 5. Not shown: 3-speed fan switch; wall plate; /2-in. fiberglass 5 8— Return Connection, /8-in. OD insulation on inside of casing, closed cell foam on main drain 9— Optional Rear Return. Consult factory for pan. collar dimensions 6. For optional coil connections, view 42CA-203-1 using the Fan 7 10 — Drain, /8-in. OD Coil Builder. 11 — Stamped Bottom Return Air Grille 7. Valve package is factory-installed inside the cabinet when 12 — Filter ordered with the unit (based on component size). 8. Bottom return or bottom supply is an ETO (engineering to order) 13 — Stamped Air Supply Grille request. 14 — Hinged Bottom Access Panel 9. Dimensions shown in inches (mm). A42-4107 5 15 — Supply Connection, /8-in. OD

UNIT NOM DIMENSIONS (in.) QTY/UNIT FACE AREA UNIT WEIGHT* AIRFLOW SIZE (Cfm) ADEBlower Motor (sq ft) (lb) 02 200 35 37 32 1 1 0.83 115 03 300 35 37 32 1 1 1.08 120 04 400 41 43 38 2 1 1.35 135 06 600 53 55 50 2 1 1.88 150 08 800 53 55 50 2 1 2.31 155 10 1000 75 77 72 4 2 3.16 227 12 1200 75 77 72 4 2 3.65 241

*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 LEGEND NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection 1— Junction Box, 4 in. x 4 in. 5 locations are ± /8-inch. 2— Strip Heater High Limit 2. Unit sizes 02 and 03 have one motor, one blower; sizes 04 3— Electric Strip Heater Element through 08 have one motor, 2 blowers; sizes 10 and 12 have 4— Drip Lip (optional, shipped loose) 2 motors, 4 blowers. 5— Mounting Holes (4), Rubber Grommets 3. Bottom access panel has an Arctic White baked finish. 3 have /8-in. Diameter Hole 4. Refer to supply and return connections above for coil stub-out 1 6— Piping Knockout, 1 /2-in. Diameter locations. 7 1 7— Electrical Knockout, /8-in. Diameter 5. Not shown: 3-speed fan switch; wall plate; /2-in. fiberglass 1 insulation on inside of casing; closed cell foam on main drain 8— Drain Knockout, 1 /2-in. Diameter 9— Supply Duct Collar pan. 6. For optional coil connections, view 42CA-203-1 using the Fan 10 — Optional Rear Return. Consult factory for Coil Builder. collar dimensions. 7 7. Valve package is factory-installed inside the cabinet when 11 — Drain, /8-in. OD ordered with the unit (based on component size). 12 — Stamped Bottom Return Air Grille 8. Bottom return or bottom supply is an ETO (engineering to order) 13 — Filter request. 14 — Stamped Air Supply Grille 9. Dimensions shown in inches (mm). 15 — Hinged Bottom Access Panel A42-4108 5 16 — Supply Connection, /8-in. OD 5 17 — Return Connection, /8-in. OD DIMENSIONS (in.) QTY/UNIT UNIT SIZE NOM AIRFLOW FACE AREA UNIT WEIGHT* (Cfm) ADEBlowerMotor(sq ft) (lb) 02 200 35 37 32 1 1 0.83 117 03 300 35 37 32 1 1 1.08 122 04 400 41 43 38 2 1 1.35 137 06 600 53 55 50 2 1 1.88 152 08 800 53 55 50 2 1 2.31 157 10 1000 75 77 72 4 2 3.16 229 12 1200 75 77 72 4 2 3.65 243

*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 NOTES: a42-4381 1. Right hand unit shown; left hand unit opposite. 2. Dimensions shown in inches (mm). All dimensions are 1 ± /4 inches.

UNIT DIMENSIONS (in.) QTY/UNIT UNIT WEIGHT* SIZE ABCDBlowerMotor(lb) 3 02 24 /16 22 23 16 1 1 42 3 03 24 /16 22 23 18 1 1 47 3 04 34 /16 32 33 26 2 1 57 3 06 44 /16 42 43 36 2 1 77 3 08 46 /16 44 45 38 2 1 79 3 10 60 /16 58 59 52 4 2 108 3 12 68 /16 66 67 60 4 2 127

*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.

*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.

UNIT DIMENSIONS (in.) QTY/UNIT UNIT WEIGHT* SIZE ABCDEBlowerMotor(lb) 1 1 02 41 22 23 17 /4 3 /8 1163 1 1 03 41 22 23 17 /4 3 /8 1168 3 04 51 32 33 26 3 /4 2182 1 06 61 42 43 39 2 /4 2199 1 08 63 44 45 39 3 /4 2 1 101 1 5 10 77 58 59 52 /8 3 /8 4 2 133 1 12 85 66 67 61 3 /4 4 2 154

*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.

*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.

UNIT DIMENSIONS (in.) QTY/UNIT UNIT WEIGHT* SIZE ABCDEBlowerMotor(lb) 1 1 02 41 22 23 17 /4 3 /8 1164 1 1 03 41 22 23 17 /4 3 /8 1169 3 04 51 32 33 26 3 /4 2183 1 06 61 42 43 39 2 /4 2 1 100 1 08 63 44 45 39 3 /4 2 1 102 1 5 10 77 58 59 52 /8 3 /8 4 2 135 1 12 85 66 67 61 3 /4 4 2 156

*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.

*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)

LEGEND NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection 1— Optional Unit Mounted Control Box 5 2— Drain Pan, Auxiliary, Shipped Loose locations are ± /8-inch. 5 2. Unit sizes 02 through 04 have one motor, 2 blowers; size 06 3— Supply Conn, /8-in. OD 3 has 2 motors, 4 blowers. 4— Drain, /4-in. MPT 5 3. Standard 2-row coil shown. 5— Return Conn, /8-in. OD 1 4. Optional unit-mounted switch box and controls, when specified, 6— Air Vent, /8-in. MPT 7— Discharge Opening are installed on opposite side from cooling connections. 5. Height increases by 2 in. with electric heat. 8— Filter 1 6. Not shown: 3-speed fan switch, /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). A42-4112

NOM DIMENSIONS (in.) QTY/UNIT FACE AREA UNIT WEIGHT* UNIT SIZE AIRFLOW (Cfm) ABCBlowerMotor(sq ft) (lb) 02 200232217211.1850 03 300282722211.5360 04 400363530212.0872 06 600 50 49 44 4 2 3.06 110

*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 LEGEND NOTES: 1— Unit-Mounted Control Box (Optional) 1. Right hand unit shown; left hand unit opposite. Coil connection 5 2— Drain Pan, Auxiliary, Shipped Loose locations are ± /8-inch. 1 3— Air Vent, /8-in. MPT 2. Unit sizes 02 through 04 have one motor, 2 blowers; size 06 has 5 4— Supply Conn, /8-in. OD 2 motors, 4 blowers. 3 5— Drain, /4-in. MPT 3. Standard 2-row coil shown. 5 6— Return Conn, /8-in. OD 4. Optional unit-mounted switch box and controls, when specified, 7— Filter are installed on opposite side from cooling connections. 8— Electrical Sheath Heater Element 5. Height increases by 2 in. with electric heat. 1 9— Discharge Opening 6. Not shown: 3-speed fan switch, /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

NOM DIMENSIONS (in.) QTY/UNIT FACE AREA UNIT WEIGHT* UNIT SIZE AIRFLOW (sq ft) (lb) (Cfm) ABCBlowerMotor 02 200 23 22 17 2 1 1.18 50 03 300 28 27 22 2 1 1.53 60 04 400 36 35 30 2 1 2.08 72 06 600 50 49 44 4 2 3.06 110

*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)

LEGEND NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection 1— Fan Switch, 3-Speed, behind Access Door 5 2— Front Panel Fastener locations are ± /8-inch. 3— Stamped Supply Grille 2. Unit sizes 02 through 04 have one motor, 2 blowers; size 06 has 5 2 motors, 4 blowers. 4— Supply Conn, /8-in. OD 5 3. Cabinet has an Arctic White baked finish. 5— Return Conn, /8-in. OD 6— Stamped Return Grille 4. Height increases by 2 in. with electric heat. 5. Standard 2-row coil shown. 7— Filter 1 1 6. Not shown: /2-in. fiberglass insulation on inside of casing, 8— Air Vent, /8-in. MPT 9— Optional Valve Package (inside cabinet) closed cell foam on main drain pan. 3 7. For optional coil connections, view 42VC-203-1 using the Fan 10 — Drain Pan, Auxiliary, with /4-in. MPT Drain Connection Coil Builder. 11 — Return Air Grille 8. Valve package is factory-installed inside the cabinet when ordered with the unit (based on component size). 9. Dimensions shown in inches (mm). A42-4114

NOM DIMENSIONS (in.) QTY/UNIT FACE AREA UNIT WEIGHT* UNIT SIZE AIRFLOW (sq ft) (lb) (Cfm) ABCDBlowerMotor 3 02 200 41 22 3 /4 17 2 1 1.18 72 1 03 300 46 27 421/2 2 1 1.53 100 5 1 04 400 54 35 3 /8 30 /4 2 1 2.08 108 1 3 06 600 68 49 4 /16 43 /8 4 2 3.06 154

*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 LEGEND NOTES: 1. Right hand unit shown; left hand unit opposite. Coil connection 1— Fan Switch, 3-Speed, behind Access Door 5 2— Electrical Sheath Heater Element locations are ± /8-inch. 3— Stamped Supply Grille 2. Unit sizes 02 through 04 have one motor, 2 blowers; size 06 has 5 2 motors, 4 blowers. 4— Supply Conn, /8-in. OD 5 3. Cabinet has an Arctic White baked finish. 5— Return Conn, /8-in. OD 6— Stamped Return Grille 4. Height increases by 2 in. with electric heat. 5. Standard 2-row coil shown. 7— Filter 1 1 6. Not shown: /2-in. fiberglass insulation on inside of casing, 8— Air Vent, /8-in. MPT 9— Front Panel Fastener closed cell foam on main drain pan. 10 — Optional Valve Package (inside cabinet) 7. For optional coil connections, view 42VC-203-1 using the Fan 3 Coil Builder. 11 — Drain Pan, Auxiliary, with /4-in. MPT Drain Connection 8. Valve package is factory-installed inside the cabinet when 12 — Return Air Grille ordered with the unit (based on component size). 9. Dimensions shown in inches (mm). A42-4115

NOM DIMENSIONS (in.) QTY/UNIT UNIT FACE AREA UNIT SIZE AIRFLOW (sq ft) WEIGHT* (Cfm) ABCDBlowerMotor (lb) 3 02 200 41 22 3 /4 17 2 1 1.18 72 1 03 300 46 27 4 21 /2 2 1 1.53 100 5 1 04 400 54 35 3 /8 30 /4 2 1 2.08 108 1 3 06 600 68 49 4 /16 43 /8 4 2 3.06 154

*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 LEGEND NOTES: 5 1. Right hand unit shown; left hand unit opposite. Coil connection 1— Supply Conn, /8-in. OD 1 locations are ± 5/ -inch. 2— Air Vent, /8-in. MPT 8 3— Filter 2. Front panel has an Arctic White baked finish. 4— Return Air Grille, Stamped 3. Standard 2-row coil shown. 5— Stamped Supply Grille 4. Unit size 01 has one motor, one blower; size 03 has 2 motors, 5 2 blowers. 6— Return Conn, /8-in. OD 1 7— Removable Front Panel 5. Unit has /2-in. flanges for mounting to wall surface. 8— Drain Conn, 7/ -in. OD 6. Front panel hooks at top of unit, swing down and snap in at bottom 8 against a spring clip. 9— Auxiliary Drain Pan 1 10 — Valve Compartment 7. Not shown: 3-speed fan switch, wall plate, /2-in. fiberglass insula- 11 — Junction Box tion on inside of casing, closed cell foam on main drain pan. 8. Dimensions shown in inches (mm). A42-4116

NOM DIMENSIONS (in.) QTY/UNIT UNIT UNIT SIZE AIRFLOW WEIGHT* (Cfm) ABCDEBlowerMotor(lb) 3 3 1 3 01 150 25 /4 15 /4 14 1 /2 12 /4 1140 3 3 15 7 03 300 39 /4 29 /4 28 1 /16 25 /8 2274

*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

LEGEND *Unit weights are based on dry coils and minimum rows. Weights 1— Motor Junction Box exclude packaging, valves, and other components. 2— Motor-Blower Assembly NOTES: 3— Electric Strip Heater Element (optional) 1. Right hand unit shown; left hand unit opposite. Coil connection 5 4— Auxiliary Drip Lip (optional, shipped loose) locations are ± /8 inch. 5— Tell-Tale Drain (optional) 2. Sizes 06, 08 and 10 have one motor, one blower; sizes 12 7 6— Drain Connection, /8-in. OD through 20 have 2 motors, 2 blowers. 1 7— Air Vent, /8-in. MPT 3. Standard 4-row coil shown. Other coil option dimensional data 8— Supply Connection available on request. 9— Supply Duct Collar, 1 in. 4. For optional coil connections, view 42DA-203-1 using the Fan 10 — Return Connection Coil Builder. 3 11 — Mounting Holes (four, /4-in. diameter) have Rubber 5. Fan switch, wall plate not shown. 3 Grommets with /8-in. holes. 6. Galvanized finish provided as standard. 7. Dimensions are in inches (mm).

1 NOM DIMENSIONS (in. ± /8) QTY/UNIT UNIT UNIT SIZE AIRFLOW WEIGHT* AA’BD’E HBlowerMotor (cfm) (lb) 1 1 06 600 23 32 14 13 /2 17 18 /2 11 64 1 1 08 800 28 37 19 13 /2 22 23 /2 11 79 1 1 10 1000 32 42 23 14 /2 26 27 /2 11 90 1 1 12 1200 37 47 28 14 /2 31 32 /2 2 2 108 1 1 14 1400 42 52 33 14 /2 36 37 /2 2 2 119 1 1 16 1600 47 56 38 13 /2 41 42 /2 2 2 124 1 1 18 1800 52 62 43 14 /2 46 47 /2 2 2 141 1 1 20 2000 56 66 47 14 /2 50 51 /2 2 2 151

Fig. 24 — 42DA Furred-In Ceiling Unit with Electric Heat Dimensions

28 LEGEND *Unit weights are based on dry coils and minimum rows. Weights exclude 1— Motor Junction Box Opposite Piping packaging, valves, and other components. 2— Insulated Return Air Plenum NOTES: 3— Mounting Clips (shipped loose) 1. Right hand unit shown; left hand unit opposite. Coil connection locations are 5 4— Electrical Strip Heater Element (optional) ± /8 inch. 3 2. Sizes 06, 08 and 10 have one motor, one blower. Sizes 12 through 20 have 5— Auxiliary Drip Lip (shipped loose) with /8-in. Hole 6— Tell-Tale Drain (optional) 2 motors, 2 blowers. 7 3. Filter and filter rack are standard. 7— Drain Connection, /8-in. OD 8— Filter Retainer Angle 4. Standard 4-row coil shown. Other coil option dimensional data available on 9— Access Panel request. 1 5. For optional coil connections, view 42DA-203-1 using the Fan Coil Builder. 10 — Return Duct Collar, 2 /2 in. 1 6. Fan switch, wall plate not shown. 11 — Air Vent, /8-in. MPT 12 — Return Connection 7. Galvanized finish provided as standard. 13 — Filter, 1-in. 8. Dimensions are in inches (mm). 14 — Supply Duct Collar, 1 in. 15 — Supply Connection 3 16 — Mounting Holes (four, /4-in. diameter) with Rubber Grommet A42-4121

1 DIMENSIONS (in. ± /8) QTY/UNIT UNIT UNIT NOM WEIGHT* SIZE AIRFLOW A A’ B D’ E F G H Blower Motor (cfm) (lb) 1 1 1 06 600 23 32 14 13 /2 17 21 25 /4 18 /2 11 94 1 1 1 08 800 28 37 19 13 /2 22 26 30 /4 23 /2 1 1 107 1 1 1 10 1000 32 42 23 14 /2 26 30 34 /4 27 /2 1 1 150 1 1 1 12 1200 37 47 28 14 /2 31 35 39 /4 32 /2 2 2 169 1 1 1 14 1400 42 52 33 14 /2 36 40 44 /4 37 /2 2 2 174 1 1 1 16 1600 47 56 38 13 /2 41 45 49 /4 42 /2 2 2 178 1 1 1 18 1800 52 62 43 14 /2 46 50 54 /4 47 /2 2 2 195 1 1 1 20 2000 56 66 47 14 /2 50 54 58 /4 51 /2 2 2 220

Fig. 25 — 42DC Furred-In Ceiling Unit with Plenum and Electric Heat Dimensions

29 A42-4122

SEE NOTE 8

LEGEND *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, 1— Motor Junction Box valves, and other components. 1 NOTES: 2— Air Vent, /8-in. MPT 3— Return Connection 1. Right hand unit shown; left hand unit opposite. Coil connection locations are 5 4— Optional 6-in. Legs ± /8 inch. 5— Bottom Return (optional) 2. Standard 4-row coil shown. Other coil option dimensional data available on 6— Return Air Opening request. 7— Supply Connection 3. Sizes 06, 08 and 10 have one motor, one blower. Sizes 12 through 20 have 7 2 motors, 2 blowers. 8— Drain Connection, /8-in. OD 9— Front Access Panel 4. Supply and return connections terminate within unit when valves are factory 10 — Filter, Throwaway installed. 11 — Electric Strip Heater Element (optional) 5. For optional coil connections, view 42DD-203-1 using the Fan Coil Builder. 12 — Supply Duct Connection, 1-in. 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).

NOM DIMENSIONS (in. ± 1/ ) QTY/UNIT UNIT UNIT 8 SIZE AIRFLOW WEIGHT* (cfm) ABCBlower Motor (lb) 06 600 23 21 15 1 1 135 08 800 28 26 20 1 1 145 10 1000 32 30 24 1 1 155 12 1200 37 35 29 2 2 180 14 1400 42 40 34 2 2 190 16 1600 47 45 39 2 2 200 18 1800 52 50 44 2 2 215 20 2000 56 54 48 2 2 230

Fig. 26 — 42DD Vertical Unit with Full Casing and Electric Heat Dimensions

30 LEGEND *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, 1— Motor Junction Box valves, and other components. 2— Unit Mounting Channel (2), 14-gage; 4 NOTES: 1 Mounting Slots, /2-in. x 2-in. 1. Right hand unit shown; left hand unit opposite. 3— Auxiliary Drip Lip (optional, shipped loose) 2. Coil stub-out location data available on request. 4— Side Access Panels 3. Unit fabricated of galvanized steel. 5— Electrical Strip Heater Element (optional) 4. Internal parts fabricated of galvanized steel. 6— Supply Air Duct Connection, 1 in. 5. Sizes 06, 08 and 10 have one motor, one blower. Sizes 12 through 20 have 7— Manual Air Vent 2 motors, 2 blowers. 8— Filter, Throwaway, 1-in. 6. Units must have drain line pitched and trapped externally. 1 9— Return Air Duct Connection, 2 /2 in. 7. For optional coil connections, view 42DA-203-1 using the Fan Coil Builder. 7 10 — Drain, /8-in. OD 8. Fan switch, wall plate not shown. 11 — Bottom Access Panel 9. Galvanized finished provided as standard. 12 — Drain Pan 10. Dimensions are in inches (mm). 13 — Coil Inlet, Copper Sweat Connection 14 — Coil Outlet, Copper Sweat Connection A42-4123

DIMENSIONS (in. ± 1/ ) QTY/UNIT UNIT SIZE NOM AIRFLOW 8 UNIT WEIGHT* (cfm) ABCDBlower Motor (lb) 06 600 31 15 15 26 1 1 150 08 800 36 20 20 31 1 1 160 10 1000 40 24 24 35 1 1 170 12 1200 45 29 29 40 2 2 195 14 1400 50 34 34 45 2 2 205 16 1600 55 39 39 50 2 2 215 18 1800 60 44 44 55 2 2 230 20 2000 64 48 48 59 2 2 235

Fig. 27 — 42DE Ceiling Unit with Full Casing and Electric Heat Dimensions

31 LEGEND *Unit weights are based on dry coils and minimum rows. Weights exclude packaging, 1—Junction Box valves, and other components. 2—Return Air Grille, Hinged, Bar Type, with NOTES: Filter Frame (Anodized Aluminum Only) 1. Right hand unit shown; left hand unit opposite. 3—Unit Mounting Channel (2), 14-gage; 4 2. Coil stub-out connection data available on request. 1 3. Units fabricated of galvanized steel with an Arctic White baked finish. Mounting Slots, /2 in. x 2-in. 4—Auxiliary Drip Lip 4. Internal parts fabricated of galvanized steel. 5—Electric Strip Heater Element (optional) 5. Sizes 06, 08 and 10 have one motor, one blower. Sizes 12 through 20 have 6—Coil Inlet, Copper Sweat Connection 2 motors, 2 blowers. 7—Coil Outlet, Copper Sweat Connection 6. Units must have drain line pitched and trapped externally. 8—Manual Air Vent 7. Stamped supply and return grilles are not available. 9—Filter, Throwaway 8. Bottom return air is not available. 10 —Bottom Access Panel 9. For optional coil connections, view 42DA-203-1 using the Fan Coil Builder. 7 10. Fan switch and wall plate are not shown. 11 —Drain, /8-in. OD 12 —Drain Pan Insulated with Styrofoam 11. Dimensions are in inches (mm). 13 —Side Access Panel (2) A42-4124 14 —Supply Air Grille (Double Deflection)

1 NOM AIRFLOW DIMENSIONS (in. ± /8)QTY/UNITUNIT WEIGHT* UNIT SIZE (cfm) ABCDEBlowerMotor (lb) 1 1 06 600 31 13 /2 14 26 8 /2 1 1 150 1 08 800 36 18 /2 20 31 8 1 1 160 1 10 1000 40 22 /2 24 35 8 1 1 170 1 1 12 1200 45 27 /2 28 40 8 /2 2 2 195 1 14 1400 50 32 /2 34 45 8 2 2 205 1 1 16 1600 55 37 /2 38 50 8 /2 2 2 215 1 18 1800 60 42 /2 44 55 8 2 2 230 1 20 2000 64 46 /2 48 59 8 2 2 235

Fig. 28 — 42DF Exposed Ceiling Unit with Supply and Return Grille and Electric Heat Dimensions

32 24

LEGEND CR — Cold Water Return CS — Cold Water Supply D—Drain HR — Hot Water Return HS — Hot Water Supply R—Return S—Supply

ITEM DESCRIPTION QTY *Drawing provided for reference only. Dimensions may vary with options ordered. 1 Electrical Knockouts 1 NOTES: 1. Units are fabricated of galvanized steel with a 16-gage galvanized fan deck. 2 3-in. Expanded Section 3/5 1 3 2. All risers are insulated with ( /2-in. or /4-in. thick) closed cell insulation. 3 Strip Heater (Optional) 1 3. Thermostats shipped loose for field connection. 4 Limit Switch**†† (Optional) 1 4. Risers are piped to coil with valves as specified. 5. Blower, motor, valves, coil, and filter are accessible through the return air opening. 1 5 /2-in. Isolation Ball Valves** 2/4 6. Unit and control box are insulated. 7. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 6 Flexible Drain Tube/P-Trap 1 1 8. Maximum riser size is 2 /2-in. diameter. If larger sizes are required, please consult the factory. 1 7 Coil /2-in. OD Copper Tube 1 9. Expansion loops in hot water heating circuits as required. 1 10. A 9-in. x 2 /4-in. slot is provided in the inside back panel for coil connection penetration to permit expansion 8 Filter, Throwaway, 1-in.** 1 and contraction of risers. Care must be taken to position the risers so that coil connection is at center of slot. 9 Return Air Opening 1 11. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 12. All dimensions are in inches. 10 Air Vent, Manual 1 A42-4125 11 Molex Connector for Field-Installed Stat 1 12 Control Box 1 NOM DIMENSIONS (in.) UNIT 13 Knockout (For Optional Remote Mounting) 2 UNIT AIRFLOW Single Supply Double Supply Top Supply WEIGHT† SIZE EGH I 14 Riser, Supply and Return (Copper) 2/4 (cfm) AB A BCD (lb) 15 Riser, Drain (Copper) 1 1 1 03 300 14 8 14 6 14 10 17 1 /2 1 /2 14 180 16 Drain Pan 1 1 1 04 400 14 12 14 6 14 10 17 1 /2 1 /2 14 225 17 Acoustical Bypass Panel 1 06 600 18 10 18 6 16 12 20 1 2 18 240 18 Blower 1 08 800 18 12 18 6 16 12 20 1 2 18 260 19 Motor, 3-Speed, PSC, with Quick Connect 1 20 Access Panel (Control Box) 1 10 1000 — — 22 8 18 16 24 1 3 22 280 21 Control Opening (Surface Mount Stat) 1 12 1200 — — 22 8 18 16 24 1 3 22 305 1 22 Duct Collar, /2-in. Extension (Typical) 1/2/3 23 Supply Air Opening(s) 1/2/3 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. Top Supply Collar 1-in Extension 24 (Optional) 1

**Factory-Installed. ††Field-Installed.

Fig. 29 — 42SG Furred-In Stack Dimensions

33 23

LEGEND CR — Cold Water Return CS — Cold Water Supply D—Drain HR — Hot Water Return HS — Hot Water Supply R—Return S—Supply

*Drawing provided for reference only. Dimensions may vary with options ordered. ITEM DESCRIPTION QTY NOTES: 1 Full Riser Chase 1 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. 2 Electrical Knockouts 1 3. Blower, motor, valves, coil, and filter are accessible through the return air opening. 3 3-in. Expansion Section 3/5 4. Unit and control box are insulated. 5. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 4 Strip Heater (Optional) 1 1 6. Maximum riser size is 2 /2-in. diameter. If larger sizes are required, please consult the factory. 5 Limit Switch**†† (Optional) 1 7. Expansion loops in hot water heating circuits as required. 8. A 9-in. x 21/ -in. slot is provided in the inside back panel for coil connection penetration to permit expansion and 1 4 6 /2-in. Isolation Ball Valves** 2/4 contraction of risers. Care must be taken to position the risers so that coil connection is at center of slot. 7 Flexible Drain Tube/P-Trap 1 9. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 10. 42SHA available in front return only. 8 Drain Pan 1 11. All dimensions are in inches. 1 9 Coil /2-in. OD Tube 1 a42-4303 10 Filter, Throwaway, 1-in.** 1 11 Air Vent, Manual 1 NOM DIMENSIONS (in.) UNIT 12 Control Box 1 UNIT AIRFLOW Single Supply Double Supply WEIGHT† SIZE CDEFG 13 Cabinet Camloc® Fasteners 2 (cfm) ABAB (lb) 14 3-Speed Switch (Optional) 3 1 1 3 1 03 300 14 8 14 6 17 22 /8 2 /2 22 /8 14 /4 202 15 Electrical Access Panel 1 3 1 1 3 04 400 14 12 14 8 17 22 /8 2 /2 22 /8 14 /4 247 16 Riser, Supply and Return (Copper) 2/4 3 1 5 3 06 600 14 12 14 8 20 25 /8 2 /2 26 /8 17 /4 262 17 Riser, Drain (Copper) 1 3 1 5 3 08 800 14 16 14 10 20 25 /8 2 /2 26 /8 17 /4 286 18 Return Air Panel 1 10 1000 18 16 14 12 24 293/ 21/ 311/ 173/ 311 19 Motor, 3-Speed, PSC 1 8 2 8 4 12 1200 18 16 14 12 24 293/ 21/ 311/ 173/ 336 20 Blower 1 8 2 8 4 21 Thermostat (Optional) 1 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. 22 Hinged Control Access Door 1 23 Double Deflection Steel Core Grille Assembly 1

**Factory-Installed. ††Field-Installed. Fig. 30 — 42SH Cabinet Dimensions

34 26

LEGEND CR — Cold Water Return CS — Cold Water Supply D—Drain HR — Hot Water Return HS — Hot Water Supply R—Return S—Supply

ITEM DESCRIPTION QTY *Drawing provided for reference only. Dimensions may vary with options ordered. NOTES: 1 Electrical Knockouts 6 1. Units are fabricated of 18-gage galvanized steel with a 16-gage galvanized fan deck. A42-4304 5 2. All risers are insulated with closed cell insulation. 2 Gypsum Board, /8-in. Type “X” 1 3. Thermostats shipped loose for field connection. 3 3-in. Expanded Section 3/5 4. Risers are piped to coil with valves as specified. 5. Blower, motor, valves, coil, and filter are accessible through the return air opening. 4 Strip Heater**(Optional) 2 6. Unit and control box are insulated. 5 Limit Switch**†† (Optional) 2 7. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 8. Maximum riser size is 21/ -in. diameter. If larger sizes are required, please consult the factory. 1 2 6 /2-in. Isolation Ball Valves** 4/8 9. Expansion loops in hot water heating circuits as required. 1 7 Thermafiber Insulation 2 10. A 9-in. x 2 /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. 8 Flexible Drain Tube/P-Trap 2 11. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 1 12. All dimensions are in inches. 9 Coil /2-in. OD Copper Tube 2 10 Filter, Throwaway, 1-in.** 2 11 Return Air Opening 2 12 Air Vent, Manual 2 NOM DIMENSIONS (in.) UNIT 13 Knockout (For Optional Remote Mounting) 2 UNIT AIRFLOW Single Supply Double Supply Top Supply WEIGHT† SIZE EGH I J 14 Molex Connector for Field Installed Stat 2 (cfm) ABA BCD (lb) 1 1 5 15 Control Box 2 03 300 14 8 14 6 14 10 17 1 /2 1 /2 14 39 /8 360 1 1 5 16 Riser, Drain (Copper) 1 04 400 14 12 14 6 14 10 17 1 /2 1 /2 14 39 /8 450 17 Riser, Supply and Return (Copper) 2/4 5 06 600 18 10 18 6 16 12 20 1 2 18 45 /8 480 18 Drain Pan 2 5 08 800 18 12 18 6 16 12 20 1 2 18 45 /8 520 19 Return Air Blockoff Panel (Optional) 1 5 10 1000 ——228181624132253/8 560 20 Blower 2 5 12 1200 ——228181624132253/8 610 21 Motor, 3-Speed, PSC, with Quick Connect 2 22 Access Panel (Control Box) 2 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. 23 Control Opening (Surface Mount Stat) 2 1 24 Duct Collar, /2-in. Extension (Typical) 1/2/3 25 Supply Air Opening(s) 1/2/3 Top Supply Duct Collar, 1-in. Extension 26 (Optional) 1 **Factory-Installed. ††Field-Installed. Fig. 31 — 42SJ Back-to-Back Furred-In Stack Dimensions

35 24

LEGEND CR — Cold Water Return CS — Cold Water Supply D—Drain HR — Hot Water Return HS — Hot Water Supply R—Return S—Supply

*Drawing provided for reference only. Dimensions may vary with options ordered. ITEM DESCRIPTION QTY NOTES: 1 Electrical Knockouts 1 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. 2 3-in. Expanded Section 3/5 3. Thermostats shipped loose for field connection. A42-4128 3 Strip Heater** (Optional) 1 4. Risers are piped to coil with valves as specified. 5. Blower, motor, valves, coil, and filter are accessible through the return air opening. 4 Limit Switch**†† (Optional) 1 6. Unit and control box are insulated. 5 1/ -in. Isolation Ball Valves** 2/4 7. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 2 1 8. Maximum riser size is 2 /2-in. diameter. If larger sizes are required, please consult the factory. 6 Flexible Drain Tube/P-Trap 1 9. Expansion loops in hot water heating circuits as required. 1 1 7 Coil /2-in. OD Copper Tube 1 10. A 9-in. x 2 /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. 8 Filter, Throwaway, 1-in.** 1 11. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 9 Return Air Opening 1 12. All dimensions are in inches. 10 Air Vent, Manual 1 11 Knockout (For Optional Remote Mounting) 2 DIMENSIONS (in.) UNIT NOM UNIT 12 Molex Connector for Field-Installed Thermo- 1 AIRFLOW Single Supply Double Supply Top Supply WEIGHT† stat SIZE EGH I (cfm) AB A BCD (lb) 13 Control Box 1 03 300 14 8 14 6 14 10 17 11/ 11/ 14 180 14 Riser, Supply and Return (Copper) 2/4 2 2 1 1 15 Riser, Drain (Copper) 1 04 400 14 12 14 6 14 10 17 1 /2 1 /2 14 225 16 Drain Pan 1 06 600 18101861612201218240 17 Acoustical Bypass Panel 1 08 800 18121861612201218260 18 Blower 1 10 1000 ——2281816241322280 19 Motor, 3-Speed, PSC, with Quick Connect 1 12 1200 ——2281816241322305 20 Access Panel (Control Box) 1 21 Control Opening (Surface Mount Thermostat) 1 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. 1 22 Duct Collar, /2-in. Extension (Typical) 1/2/3 23 Supply Air Opening(s) 1/2/3 Top Supply Duct Collar, 1-in. Extension 24 (Optional) 1 **Factory-Installed. ††Field-Installed.

Fig. 32 — 42SGM Furred-In Master Stack Dimensions

36 23

LEGEND CR — Cold Water Return CS — Cold Water Supply D—Drain HR — Hot Water Return HS — Hot Water Supply R—Return S—Supply

ITEM DESCRIPTION QTY *Drawing provided for reference only. Dimensions may vary with options ordered. NOTES: 1 Electrical Knockouts 1 1. Units are fabricated of 18-gage galvanized steel with a 16-gage galvanized fan deck. 2 Strip Heater** (Optional) 1 2. All risers are insulated with closed cell insulation. 3. Thermostats shipped loose for field connection. A42-4129 3 Limit Switch**†† (Optional) 1 4. Risers are piped to coil with valves as specified. 4 1/ -in. Isolation Ball Valves** 2/4 5. Blower, motor, valves, coil, and filter are accessible through the return air opening. 2 6. Unit and control box are insulated. 5 Coil Stub Outs 2/4 7. Riser length = [(floor to floor) +2 in.], maximum riser length = 119 inches. 1 6 Shipping Brace 2/4 8. Maximum riser size is 2 /2-in. diameter. If larger sizes are required, please consult the factory. 9. Expansion loops in hot water heating circuits as required. 1 7 Flexible Drain Tube/P-Trap 1 10. A 9-in. x 2 /4-in. slot is provided in the inside back panel for coil connection penetration to permit expansion and 8 Coil 1/ -in. OD Copper Tube contraction of risers. Care must be taken to position the risers so that coil connection is at center of slot. 2 1 11. Drawing is pictorial (see unit arrangements for actual supply and return air orientation). 9 Filter, Throwaway, 1-in.** 1 12. All dimensions are in inches. 10 Return Air Opening 1 11 Air Vent, Manual 1 NOM DIMENSIONS (in.) UNIT 12 Knockout (For Optional Remote Mounting) 2 UNIT AIRFLOW Single Supply Double Supply Top Supply WEIGHT† SIZE EGH I 13 Molex Connector for Field-Installed Stat 1 (cfm) ABABCD (lb) 14 Control Box 1 1 1 03 300 14 8 14 6 14 10 17 1 /2 1 /2 14 162 15 Drain Pan 1 1 1 04 400 14 12 14 6 14 10 17 1 /2 1 /2 14 203 16 Return Air Blockoff Panel (Optional) 1 06 600 18 10 18 6 16 12 20 1 2 18 216 17 Blower 1 08 800 18 12 18 6 16 12 20 1 2 18 234 18 Motor, 3-Speed, PSC, with Quick Connect 1 10 1000 — — 22 8 18 16 24 1 3 22 252 19 Access Panel (Control Box) 1 Control Opening (Surface Mount Thermo- 12 1200 — — 22 8 18 16 24 1 3 22 275 20 stat) 1 1 21 Duct Collar, /2-in. Extension (Typical) 1/2/3 †Unit weights are based on dry coils and minimum rows. Weights exclude packaging, valves, and other components. 22 Supply Air Opening(s) 1/2/3 Top Supply Duct Collar 1-in. Extension 23 (Optional) 1 **Factory-Installed. ††Field-Installed. Fig. 33 — 42SGS Furred-In Slave Stack Dimensions

37 3 Item Description Qty 3 (76) (76) 1 Float Switch (Optional) 1 3-5/8 3-5/8 (92) (92) 1-1/4 2 Drain Pan 1 HRHS D CR CS (32) 1 3 Flexible Drain Tube/P-Trap 1 2 1 each 4 Drain Knockout (3 Sides) side D 1-1/4 (32) 3 5 Blower 1 4 6 Riser Knockouts (3 Sides) 2/4 (102) 1-1/4 7 1/2 in. Flare Adaptor (SWT x 37.5) 2/4 17 (32) 8 Coil, 1/2 in. OD Copper Tube 1 1 in. Throwaway Filter HCH 16 9 (Factory Installed) 1 4 10 Manual Air Vent 1 TOP VIEW DETAIL SIDE VIEW 11 Return Air Opening 1 23 A F Knockout (For Optional Thermostat 15 12 Remote Mounting) 3 Molex Connector for Field-Installed 13 Thermostat 1 B 14 Control Box 1 Duct Collar Extension 15 (1/2 in. Side, 1 in. Top) 1/2/3 14 22 Outside Air Knockout 16 (On Each Side Panel) 1 13 Electrical Knockouts 17 (Near Each Side) 1 21 88 18 (2235) 18 Service Switch (Optional) 1 12 5 Motor, 3-Speed, PSC, with Quick 19 Connect 1 20 6 Access Panel for Motor and Blower 19 20 Assembly 1 21 Access Panel (Control Box) 1 H H C C 11 22 Control Opening Knockout 1 R S R S (Surface Mount Thermostat) 7 Supply Air Openings 63 10 23 (4 Sides and Top, Stitch Cut) 1/2/3 (1600) 51 (1295)

9 39 (991) 8 LEGEND 5 CR — Cold Water Return (127) CS — Cold Water Supply 8 D—Drain (203) HR — Hot Water Return HS — Hot Water Supply I PSC — Permanent Split Capacitor E E SWT — Sweat FRONT VIEW SIDE 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. 1 4. Unit and control box are insulated with /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. a42-4305 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).

DIMENSIONS (in.) UNIT UNIT FILTER SIZE SIZE WEIGHT* Side Supply Top Supply (in.) (lb) AB SizeCD SizeEFH I 03 180 1 1 1 14 12 14 x 12 14 10 14 x 10 17 3 1 /2 14 12 /2 x 24 /4 x 1 04 225 06 240 1 3 18 12 18 x 12 16 12 16 x 12 20 1 2 18 16 /4 x 26 /4 x 1 08 260 10 280 1 1 22 16 22 x 16 18 16 18 x 16 24 1 3 22 20 /2 x 29 /4 x 1 12 305

*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 3 (76) (76) 3-5/8 3-5/8 1 (92) (92) 1-1/4 HRHS D CR CS (32) 2 1-1/4 (32) 3 D 4 (102) 1-1/4 (32) 19

18 HCH 4 TOP VIEW DETAIL SIDE VIEW 25 A F 17 Item Description Qty B 1 Float Switch (Optional) 1 2 Drain Pan 1 5 3 Flexible Drain Tube/P-Trap 1 24 16 4 Drain Knockout (3 Sides) 1 each 15 side 6 5 Limit Switch (Factory Installed) 1 88 23 6 Strip Heater 1 20 14 (2235) 7 7 Blower 1 8 Riser Knockouts (3 Sides) 2/4 22 8 21 9 1/2 in. Flare Adaptor (SWT x 37.5) 2/4 10 Coil, 1/2 in. OD Copper Tube 1 H H C C 13 1 in. Throwaway Filter 11 1 R S R S (Factory Installed) 12 9 63 12 Manual Air Vent 1 (1600) 51 13 Return Air Opening 1 (1295) 11 14 Knockout (For Optional 3 Thermostat Remote Mounting) 39 Molex Connector for (991) 15 1 10 Field-Installed Thermostat 16 Control Box 1 5 Duct Collar Extension 17 1/2/3 8 (127) (1/2 in. Side, 1 in. Top) (203) Outside Air Knockout 18 (On Each Side Panel) 1 I E 19 Electrical Knockouts 1 (Near Each Side) E SIDE VIEW FRONT VIEW 20 Service Switch (Optional) 1 21 Motor, 3-Speed, PSC, 1 LEGEND with Quick Connect CR — Cold Water Return Access Panel for Motor and Blower CS — Cold Water Supply 22 Assembly 1 D—Drain 23 Access Panel (Control Box) 1 HR — Hot Water Return Control Opening Knockout HS — Hot Water Supply 24 1 PSC — Permanent Split Capacitor (Surface Mount Thermostat) SWT — Sweat Supply Air Openings 25 (4 Sides and Top, Stitch Cut) 1/2/3 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. 1 4. Unit and control box are insulated with /2-in. (13 mm) coated fiberglass insulation. 5. All risers will ship separately from units. Riser dimensions are measured from centerline of a42-4306 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).

DIMENSIONS (in.) UNIT UNIT FILTER SIZE Side Supply Top Supply SIZE WEIGHT* (in.) (lb) AB SizeCD SizeEFH I 03 182 1 1 1 14 12 14 x 12 14 10 14 x 10 17 3 1 /2 14 12 /2 x 24 /4 x 1 04 227 06 242 1 3 18 12 18 x 12 16 12 16 x 12 20 1 2 18 16 /4 x 26 /4 x 1 08 262 10 282 1 1 22 16 22 x 16 18 16 18 x 16 24 1 3 22 20 /2 x 29 /4 x 1 12 307

*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 3 3 3 (76) (76) (76) (76) 3-5/8 3-5/8 (92) (92) 1-1/4 1-1/4 HR HSD CR CS (32) HSD CR (32)

11 11 (280) (280) ELECTRICAL KNOCKOUTS

3 24 3 24 (76) (610) (76) (610)

4-PIPE 2-PIPE

22 1 (25) 22 1 (25) 4 (102) 4 4 (102) (559) (559) SUPPLY PLENUM (OPTIONAL) 16 16 (406) (406) 22 SUPPLY (559) SUPPLY AIR TOP DUCT 4-3/4 (121) OPENING COLLAR, 1"(25) 4-3/4 (121) ACOUSTICAL (OPTIONAL) SERVICE CONTROL BOX INTERLOCKING ACCESS PANEL DISCONNECT SWITCH MOTOR/BLOWER, 3 SPEED, PSC, HIGH STATIC RISER KNOCKOUTS 66* (OPTIONAL) (1676) RETURN AIR PANEL 59 SWT X 37.5 (1499) FLARE ADAPTER 39 FILTER (991)

COIL DRAIN PAN

FLEXIBLE 28 DRAIN TUBE/P-TRAP (711) 5 24 5 30 (127) (610) (127) (762)

LEGEND NOTES: 1. Unit measurements on drawings are shown in inches (millimeters). CR — Cold Water Return 2. Units are fabricated of galvanized steel with a 16 gage galvanized fan deck. CS — Cold Water Supply 3. Blower, motor, valves, coil, and filter are accessible through the return air opening. D—Drain 1 4. Unit and control box are insulated with /2-in. (13 mm) coated fiberglass insulation. HR — Hot Water Return 1 5. Maximum riser size is 2 /2-in. (64 mm) diameter. If larger sizes are required, please HS — Hot Water Supply consult the factory. PSC — Permanent Split Capacitor 6. This drawing is pictorial. (See unit arrangements for actual supply and return air SWT— Sweat 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 a42-4167 A A42-4173 PANEL DIMENSIONS (in.) A A PANEL NO. UNIT UNIT SIZE A 03, 04 15.5 42SG,SJ, 06, 08 19.5 1 SU 10, 12 23.5 42SM 14,16,20 29.5 03, 04 15.5 2 42SG,SJ 06, 08 19.5 10, 12 23.5 03, 04 15.2 3 42SG,SJ 06, 08 19.2 10, 12 23.2

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 03, 04 15.1 42SG,SJ, 4 SU 06, 08 19.1 10, 12 23.1 03, 04 15.1 5 42SG,SJ 06, 08 19.1 10, 12 23.1

NOTE: Dimensions in inches. A42-4273

A42-4276 A42-4168 A A A42-4277

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

INSTALLATION unit. Hanger rods and fasteners and other required hardware must be field-supplied. Step 1 — Place Units in Position 4. Move unit into position. Ensure unit is level or pitched 42C UNITS towards drain to ensure proper drainage and operation. 1. Select the unit location. Allow adequate space for free air Pitch of suspended unit can change after coil is filled; circulation, service clearances, piping and electrical recheck after filling coil. connections, and any necessary ductwork. For specific 5. Mounting unit: unit dimensions, refer to Fig. 1-12. Allow clearances ac- a. Use rods and fasteners to suspend the unit at the cording to local and national electric codes. factory-provided mounting holes with rubber 2. Make sure ceiling is able to support the weight of the unit. grommets on the top of the unit on 42CG, CK See Table 1 for nominal unit weight. units. Reach into unit and attach unit to the ceiling 3. Ensure bottom panel has been removed from 42CG, CK using the 0.375-in. mounting holes (4) in top units with mounting holes. When unit is lifted, access to panel; do not use any other locations. the 0.375-in. mounting holes is through the bottom of the

42 b. Use rods and fasteners to suspend the unit at the Fasteners, furring strips, and other seals (if required) must factory-provided 0.375-in. hanger slots (4) with be field-supplied. rubber grommets on the top of the unit on the 4. Remove all wall and floor moldings from behind the unit. 42CA and CE units. 5. Ensure 42VA top panel (under window application) and NOTE: The four mounting holes and hanger slots 42VB, VF front panel has been removed from unit to with rubber grommets are NOT for balancing unit. obtain access to the four 0.75-in. mounting holes. Hanger 6. The 42CA units without plenums and 42CE with bottom rods and fasteners and other required hardware must be inlet may be installed in noncombustible areas only. field-supplied. NOTE: The installation of horizontal concealed units must 6. Move unit into position. Ensure unit is level or pitched meet the requirements of the National Fire Protection Associa- towards drain to ensure proper drainage and operation. tion (NFPA) Standard 90A or 90B concerning the use of con- Pitch of suspended unit can change after coil is filled; cealed ceiling space as return-air plenums. recheck after filling coil. 42V UNITS — While the manufacturer is not involved in the 7. Adjust 42VA, VB, VC, VE, VF units leveling legs so unit design and selection of support methods and components, it is level. Unit must be level for proper operation and shall be noted that unacceptable system operating characteris- condensate drainage. tics and/or performance may result from improper or inade- 8. Mounting unit: quate unit structural support. The type of mounting device is a matter of choice, how- 1. Select the unit location. Allow adequate space for free air ever, the mounting point shall always be that provided in circulation, service clearances, piping and electrical the chassis or cabinet. connections, and any necessary ductwork. For specific unit dimensions, refer to Fig. 13-23. Allow clearances ac- a. Use rods and fasteners to suspend the unit at the cording to local and national electric codes. See Fig. 39 factory-provided mounting holes with rubber for minimum clearance recommendations. grommets on the top of the unit on 42VA, VB, VF units. Reach into unit and attach unit to the wall 2. Make sure the floor is able to support the weight of the using the 0.375-in. mounting holes (4) in top unit. See Table 2 for nominal unit weight. Vertical units panel; do not use any other locations. The four are designed to be floor mounted or otherwise supported mounting holes and hanger slots with rubber from below, and bolted to the wall or floor structure grommets are NOT for balancing unit. through the mounting holes provided in the chassis. These units may be wall hung only when originally or- b. On 42VG unit ensure unit is placed snug within dered from the factory for wall mount applications. the wall. 3. Ensure wall behind unit is smooth and plumb; if c. On 42VC, VE unit ensure unit is placed flush necessary, install furring strips on walls with irregular against the wall. surfaces or mullions. Furring strips must be positioned NOTE: For any unit without a return-air duct connection, behind mounting holes in unit (42VA, VB, VF units). applicable installation codes may limit unit to installation in single-story residence only.

12" Level Unit ½" ½" ±¼" Minimum Minimum 30" Minimum per building code

SIDE VIEW FRONT VIEW

Fig. 39 — Clearance Recommendations

43 42D UNITS construction, floor plans, and unit configurations, each installation is different. The actual step-by-step method of installation 1. Select the unit location. Allow adequate space for free air may vary from unit to unit. However, the risers should be circulation, service clearances, piping and electrical con- moved as little as possible to avoid damage to the unit and in- nections, and any necessary ductwork. For specific unit ternal components. dimensions, refer to the submittal drawings. Allow clearances according to the local and national electrical codes. 42SG, SH, and SJ Units 2. Be sure either the ceiling (42DA, DC, DE, and DF units) 1. Begin on lowest floor and progress upward, floor by or floor (42DD unit) is able to support the weight of the floor, to top. unit. See Table 3 for nominal unit weight. 2. Examine drain line (Fig. 34 and 35). Be sure both ends 3. Move unit into position. Ensure unit is level or pitched are in place and that it forms a trap. Avoid pinching drain towards drain to ensure proper drainage and operation. line. See Fig. 24-28. Pitch of suspended unit can change after 3. Tip unit over riser hole in building floor. As unit is coil is filled; recheck after filling coil. righted, align riser with unit below. 4. Mounting units to the ceiling: NOTE: The unit must be lowered into the space taking a. When unit is lifted, access to the 0.375-in. mount- care to properly align the risers to engage the riser swaged ing holes is on the top panel of the unit. Hanger section on the unit below. The riser should never be bent rods and fasteners and other required hardware or pushed together to be passed through the floor slot and must be field-supplied. should never be lifted up or pulled down to meet the riser on the floor below or above. b. Use rods and fasteners to suspend the unit at the factory-provided mounting holes with rubber 4. Install isolator pads beneath the four corners of unit if grommets on the top of the unit. Attach unit to the applicable. ceiling using the 0.375-in mounting holes (4) in 5. Before anchoring the equipment in place, the unit must be top panel; do not use any other locations. leveled and the cabinet must be squared and brought into c. Use the rods and fasteners to suspend the unit at line with any adjacent or included walls. The unit may be the factory-provided 0.375-in. hanger slots (4) anchored in place by bolting directly through the unit with the rubber grommets on the top of the unit on floor or attaching to the cabinet in some location that will the 42DA, DC, DE, and DF units. not interfere with drywall or other items such as the supply grille, thermostat, or return access panel. When at- NOTE: The four mounting holes and hanger slots taching to the unit cabinet, care must be taken to not pen- with rubber grommets are NOT for balancing unit. etrate the cabinet in locations that may damage internal d. Models 42DA and 42DC with bottom inlet may be components or wiring. The mounting technique is a mat- installed in noncombustible return spaces only. ter of choice; however, the unit should always be an- 5. Mounting units on the floor: chored securely to prevent movement during construction a. Ensure wall behind the unit is smooth and plumb; and riser expansion and contraction. On certain units, if necessary, install furring strips on walls with shipping screws or braces must be removed after the unit irregular surfaces or mullions. Furring strips must is installed. Be sure to check all tags on the unit to deter- be positioned behind mounting holes on 42DD mine which, if any, of these devices need to be removed. units. Fasteners, furring strips, and other seals (if 6. If installing a 42SJ unit, follow Steps a-h. For 42SG and required) must be field-supplied. 42SH units, continue to Step 7. b. If the unit has leveling legs, adjust them correctly NOTE: The 42SJ back-to-back fan coils have been de- to level the unit. signed to serve two separate rooms. These products are 6. Protect units from damage caused by jobsite debris. Do classified by Underwriters Laboratories Inc. for use in not allow foreign material to fall in unit drain pan. penetration firestop systems, control number 27WL when Prevent dust and debris from being deposited on motor or ordered with 1-hr rated chase. See UL Fire Resistance fan wheels. Directory for more information. Figure 40 shows the 42SJ unit with standard risers and with Siamese risers. 42S UNITS — A factory tag is on top of each unit. Tag states riser tier number, floor, room number if furnished and supply- a. Lay out the control lines for the drywall track and air arrangement. Check unit for any other labels that apply to studs in the floor and ceiling (see Fig. 41). installation. Units should not be installed at locations other NOTE: Tracking may be installed now or after the than that marked on the unit identification tag. If no specific unit is set. detail is shown on tag for unit location then determine configu- b. Position the 42SJ fan coil assembly between two ration for the Universal unit based on information within this rooms with the unit drywall separation spotted manual. Should any questions arise regarding unit configura- over the wall control lines. tion, 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 42SJA 42SJA 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 support- ing the cabinet only at the top and bottom. For specific unit dimensions refer to Fig. 29-33. 42SJB 42SJB 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 character- Fig. 40 — 42SJ istics and/or performance may result from improper or inade- Unit with Standard and Siamese Risers quate unit structural support. Due to variations in building

44 7. Attach unit risers:

CHASE SIDE CAUTION PANEL 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, DRYWALL INSTALL WALL domestic or potable water systems. Failure to heed this TRACK AND STUD INTO STUD POCKET warning could result in equipment damage. CONTROL FORMED BY LINES CHASE SIDE PANEL NOTE: Submittals and product literature detailing unit operation, controls, and connections should be thoroughly reviewed BEFORE beginning the connection and test- INSTALL STUDS FROM TOP OF ing of risers and piping. The supply and return connec- UNIT TO CEILING (4 CORNERS) tions are marked on the coil stub-outs and the valve pack- Fig. 41 — 42SJ Wall Board Installation age with an “S” meaning supply or inlet and “R” meaning c. If not already installed, install the floor and ceiling return or outlet indicating flow direction to and from the tracks up to and over the 42SJ fan coil unit. coil. Blue letters mark the chilled water connections and red letters mark the hot water connections. d. Position the vertical studs and fasten into each of the stud pockets formed into the chase side panels a. Each riser has a 3-in. swaged portion at top and (see Fig. 41). sufficient extension at bottom for an inserted length of approximately 2-inches. This unit-to- NOTE: The studs may be mechanically fastened unit joint is NOT intended for full bottoming in to the 42SJ fan coil. Care should be taken, how- the joint, but allows for variations in floor-to-floor ever, not to penetrate the supply or return water dimensions and for correct riser positioning. risers or internal piping. Given the levelness of the floor and/or the fan coil assembly, some shimming If job requires that unit risers be supplemented may be necessary. with between-the-floor extensions, pieces may be field-supplied or factory-supplied. If factory- e. Assemble the specified wall construction up to supplied, insulation is also provided. and over the top of the fan coil unit (see Fig. 42). b. Level unit to ensure proper coil operation and f. With the fire-wall separation being complete, the condensate drainage. Proper riser installation and drywall skin on the surface of the individual fan vertical positioning in the unit provides for a unit coils can be applied. Drywall can be applied piping run-out to the service valves which are cen- directly to the surface, or, if necessary, studding tered in the access slots and level or sloping down may be installed on the corners for vertical control slightly away from the riser. This prevents con- (see Fig. 42). densation from running back to the riser and pos- g. For ease of installation of the access panel, apply sible damage from dripping at the bottom of a drywall on the return air side directly to the sur- riser column. Each job has specific requirements, face of the unit (see Fig. 42). When applying the and satisfying those requirements is the responsi- wall board directly to the unit cabinet, it may be bility of the installer. After units are positioned necessary to shim the wall board in some areas to and riser centered in pipe chase, make unit plumb achieve the desired finished wall surface. in two directions, using unit frame as a reference. h. After all drywalling and painting is complete, c. Anchor unit to building. Use bolts or lag screws install thermostats, supply air grilles and return air through holes provided in unit frame. panels. d. After all units in a stack are anchored, make unit- to-unit riser joints. First, center each coil-to-riser INSTALL WALL line within the expansion slot in the unit back GYPSUM WALL STUDS BOARD panel. Each riser joint must be in vertical (TO WALL AND alignment with at least 1-in. penetration into the OVER TOP OF UNIT) swaged joint. This condition is met if floor-to- floor 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 modifica- tions are the full responsibility of the installing contractor. INSTALL GYPSUM e. Before making the riser joints, the riser insulation INSTALL BOARD TO must be pulled back away from the joint and pro- GYPSUM UNIT SIDES BOARD TO tected from heat during the brazing process. The FACE OF riser joint filler material must be selected to with- UNIT WITH stand the total operating pressure (both static and CUT OUTS FOR SUPPLY, pumping head) to which the system will be sub- RETURN AND jected. Low temperature lead alloy solders such as THERMOSTAT “50/50” and “60/40” are normally not suitable. Fig. 42 — 42SJ Unit Installation

45 Potential 42SU Unit Configurations IMPORTANT: Chilled water and hot water risers should never be piped to drain down into the condensate riser. Risers: Three Locations — The pre-installed supply, return, Extensive water damage can occur due to drain over- and drain risers (2-pipe or 4-pipe applications) can be oriented flow. Drain chilled and hot water risers to a remote loca- on any of three sides of the unit (see Fig. 43). tion away from the unit such as sink, room or floor NOTE: Risers cannot be installed on the return air side of the drains. cabinet. 8. Anchor risers as required: a42-4283 a. Do not fasten risers rigidly within each unit. HR HS D CR CS Risers must be free to move within pipe chase HR in response to normal vertical expansion and CS HS

contraction. The unit internal piping is designed to CR accommodate a total riser vertical movement of 42SU D

3 D ± /4 in., due to thermal expansion and/or contrac- CABINET tion, when positioned properly at the jobsite. CR HS

b. Built-in risers must be anchored at some point CS

to building structure. Unit design accommodates HR 1 up to 1 /2-in. expansion and contraction in riser assemblies when positioned properly at the jobsite. Risers must be anchored to the building struc- RETURN AIR ture to limit expansion and contraction movement R S HR HS CR CS 1 D D to a maximum of 1 /2 inches. Riser anchoring and expansion compensation is not included in the factory-supplied unit and must be field provided. R = RETURN HR = HOT WATER RETURN While some special riser features are available D = DRAIN HS = HOT WATER SUPPLY from the factory, riser end caps, air vents, and/or S = SUPPLY D = DRAIN flushing loops are normally provided on the job by 2- or 4-PIPE CR = COLD WATER RETURN the installer. CS = COLD WATER SUPPLY 9. Test the system for leaks after the connections are com- Fig. 43 — 42SU Unit Configuration pleted. When testing with air or some other gas, it might be necessary to tighten stem packing nuts on some valves Unit orientation is determined based on the location of the to maintain air pressure in the riser. Pressure testing risers risers in the building. The riser side of the universal stack unit with water should be done with the unit service valves always determines the rear of the unit. See Fig. 44. closed to prevent flushing debris into the unit valve packages. This will also allow risers to be drained down after a42-4284 REAR testing in the winter to avoid freeze-up problems. In the (RISER SIDE) 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 42SU proceeding with the installation. LEFT RIGHT 10. After system integrity has been established, pull the riser CABINET 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. FRONT 11. If required, fireproof where necessary. Any fireproofing Fig. 44 — 42SU Unit Orientation requirements where risers or piping penetrate floors or walls are the responsibility of the installer. This work Return Air: Single Location — The return air/access panel should be done only after all pressure testing is complet- may then be oriented on the left, right, or front of the unit. ed. The fireproofing method used must accommodate Supply Air: Five Locations (4 sides and top) includes stitched 1 pipe expansion and contraction and the piping must be design for /2-in. duct flanges. protected from abrasion and chemical attack. The pipe in- Outside Air: Two Locations — Either side adjacent to the sulation also must be maintained to prevent sweating and return air opening. must be protected from wear or erosion at the joint between the insulation and the fireproofing material. NOTE: Outside air opening may be used on a side if risers are configured on that same side. 42 SU Units — The unique design of the universal stack fan coil unit allows for field configuration for each unit. Air dis- Supply, Return, and Drain Riser Installation charge, riser, drain, and outside air knockouts have been strate- 1. Three sides of each universal stack unit have four supply gically located on each unit. Risers, shown with unit, are for and return riser knockouts along the center and one drain reference only. All risers are factory fabricated and shipped knockout near the lower part of the unit (see Fig. 45). loose for field installation. Identify whether your application uses a 2-pipe or 4-pipe It is important that you identify all of the unit feature loca- configuration. tions and which knockouts you intend to use before proceeding a. Two-pipe configurations typically use the two with the installation. See Fig. 43-47. Also, it must be deter- inner riser knockouts. mined whether your application requires a Mating Unit (prima- b. Four-pipe configurations will use all four riser ry/secondary) and its configuration. Consult your local sales knockouts. representative or the factory for further details on primary/secondary arrangements.

46 2. Locate and mark the riser and drain knockouts that apply to your particular unit application, ensuring proper orien- a42-4309 tation of the return air opening in room. SUPPLY AND RETURN DRAIN 3. Insert a flat head screw driver into knockout slot shown in KNOCKOUT KNOCKOUT KNOCKOUT Fig. 46. TAB 4. Pry screw driver back and forth until knockout tabs break away from the unit. KNOCKOUT 5. Discard knockout. Be careful of sharp edges. SLOT 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 KNOCKOUT process. TAB

a42-4285 SIDE VIEW Fig. 46 — Remove 42SU Unit Knockouts

a424287 SIDE SUPPLY AIR KNOCKOUT DRAIN (1 PER SIDE) SUPPLY AND RETURN INSULATION INSULATION CUT LINE CUT LINE

OPTIONAL ELECTRICAL KNOCKOUTS Fig. 47 — 42SU Unit Knockout Insulation Removal Double Riser Swag Installation 1. The riser carton should contain: RISER KNOCKOUTS RETURN (4 PER SIDE, a. 2-pipe application: AIR EXCEPT ON RETURN AIR SIDE) 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 OUTSIDE AIR Table 5 for correct field supplied riser extension length KNOCKOUT required. (2 SIDES ONLY, ADJACENT TO DRAIN KNOCKOUT RETURN AIR (1 PER SIDE, Table 5 — Recommended Extension Length OPENING) EXCEPT ON RETURN AIR SIDE) FLOOR-TO-FLOOR EXTENSION LENGTH DIMENSION (in.) REQUIRED (in.) 102 26 a42-4286 TOP VIEW 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 TOP SUPPLY the riser diameter that was ordered with unit. All transi- AIR KNOCKOUT ELECTRICAL tion pieces like riser reducers are field supplied and KNOCKOUTS 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 Fig. 45 — Locate 42SU Unit Knockouts and Table 6 for reference.

47 9. Insert brazed extension/riser into the building’s floor SUPPLY/ block-out hole in the order specified in Fig. 48. Insert ex- RETURN DRAIN TOP TOP tension 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 26.75 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. 60.75 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 ex- 53 posed 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 19 instructions.

CAUTION Fig. 48 — Riser Extension Toxic residues and loose particles resulting from manufacturing and field piping techniques such as joint compounds, Table 6 — Unit Riser Orientation soldering flux, and metal shavings may be present in the TOP SWAGE TO BOTTOM STUB-OUT unit and the piping system. Special consideration must be RISER SWAGE TO HIGHT - AFF TYPE RISER RISER (Above given to system cleanliness when connecting to solar, STUB-OUT (in.) STUB-OUT (in.) Finished Floor) domestic or potable water systems. Supply Submittals and product literature detailing unit operation, and Return 26.75 53 39 controls, and connections should be thoroughly reviewed BE- Riser FORE beginning the connection and testing of risers and piping. Drain 60.75 19 5 Riser To assure optimal unit performance, the supply connec- 6. Insert cut riser extensions into the bottom swages of the tion(s) are marked on the unit’s coil with an “S” meaning sup- risers to a penetration depth of 2-inches. ply or inlet and “R” meaning return or outlet indicating flow direction to and from the coil. Blue letters mark the chilled water 7. Invert the riser with extension to allow for an easier braze. connections and red letters mark the hot water connections. Make the braze joint according to local building code specifications. The unit’s internal piping is designed to accommodate a total riser vertical movement of ±1½ in., due to thermal expan- 8. Identify and orient the brazed risers so that they will sion and/or contraction, when positioned properly at the job- match the riser locations for the installed unit. Use Fig. 49 site. Risers must be anchored to the building structure to limit for reference. 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. 42SU Proper field riser installation and vertical positioning in the CABINET 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 RETURN AIR specific requirements and satisfying those requirements is the responsibility of the installer. R D S 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 R = Return HR = Hot Water Return D = Drain HS = Hot Water Supply protected from heat during the brazing process. Each riser joint S = Supply S = Supply must be in vertical alignment. Variations in floor-to-floor di- CR = Cold Water Return mensions may require field work such as cutting off or extend- CS = Cold Water Supply ing the risers. This operation is the responsibility of the installer. The riser joint filler material must be selected to withstand Fig. 49 — Brazed Riser Orientation the total operating pressure (both static and pumping head) to

48 which the system will be subjected. Low temperature lead al- BALL a42-4290 loy solders such as “50/50” and “60/40” are normally not suit- VALVE WRENCH able. 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 SWIVEL unit may be anchored in place by bolting directly through BACK-UP CONNECTION the unit floor or attaching to the cabinet in some location WRENCH that will not interfere with drywall or other items such as Fig. 52 — 42SU Unit Riser to Unit Installation the supply grille, thermostat, or return access panel. (Tighten Swivel Connections) When attaching to the unit cabinet, care must be taken to a42-4291 UNIT INSULATION not penetrate the cabinet in locations that may damage in- UNIT WALL ternal components or wiring. The mounting technique is a matter of choice; however, the unit should always be an- DRAIN PAN RISER KNOCKOUT chored securely to prevent movement during construction and riser expansion and contraction. After anchoring the unit, it is then ready for the various service connections DRAIN RISER such as riser connections and electrical. CLAMP 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 CLAMP steel flexible hose kits for piping between field-installed P-TRAP risers and unit water coils as shown in Fig. 51. The hose RISER STUBOUT kit design has threaded connections on each end. The hose kits allow for riser fluctuations due to thermal expansion. Fig. 53 — 42SU Unit Riser to Drain Installation a42 4288 5. Use a wrench to tighten the swivel connections. Use a OUTER UNIT INSULATION backup wrench to hold the riser ball valve stationary to CABINET prevent it from bending or twisting during installation as shown in Fig. 52. Be careful to not over tighten swivel RISER STUBOUT connections. INSULATION BALL VALVE RISER KNOCKOUT THREADED SLOT 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 FLARE CAP be removed and discarded. Fig. 50 — 42SU Unit Riser to Unit Installation 8. Use a wrench to tighten the swivel connections. The baf- Setup fle acts as a secondary wrench. Be careful to not over tighten swivel connections. FLEXIBLE a42-4289 HOSE KIT RISER STUBOUT CAUTION INSULATION BALL VALVE RISER 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 BAFFLE COIL shown in Fig. 53. 10. Push the rubber drain hose over the riser drain stubout. Be careful not to bend the drain stubout. CONNECTION POINT TO ANY FACTORY FURNISHED AND INSTALLED 11. Adjust the hose clamp over the riser stubout and rubber COMPONENTS. hose to hold in place as shown in Fig. 53. 12. Test for leaks. Any and all leaks should be repaired before Fig. 51 — 42SU Unit Riser to Unit Installation 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

49 debris into the unit valve packages. This will also allow 9. Use adhesive or glue to re-attach insulation that has risers to be drained down after testing in the winter to pulled away from the unit during knockout removal avoid freeze-up problems. In the event that leaking or de- process. fective components are discovered, the sales representa- 10. For ducted applications tape should be applied along and tive must be notified BEFORE any repairs are attempted. around all of the supply air opening knockouts to prevent All leaks should be repaired before proceeding with the air leakage. unit installation. 13. After system integrity has been established, the riser insu- DUCT FLANGE a42-4293 lation must be pulled back into place over the joint and glued or sealed to prevent sweating and heat loss or gain. UNIT All of the risers including the riser stubouts should be 90° WALL 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 UNIT work should be done only after all pressure testing is complet- INSULATION ed. The fireproofing method used must accommodate pipe expansion and contraction and the piping must be protected from Fig. 55 — 42SU Supply Air Installation abrasion and chemical attack. The pipe insulation also must be maintained to prevent sweating and must be protected from All installations should be made in compliance with all gov- wear or erosion at the joint between the insulation and the fire- erning codes and ordinances. Compliance with all codes is the proofing material. responsibility of the installing contractor. When no risers are ordered for the universal stack unit, it is 42 SM Units — The unique design of the mega stack fan coil the responsibility of the installer to make sure that an isolation unit allows for field configuration of each unit. Risers, shown ball valve is installed between each supply and return piping with unit, are for reference only. All risers are factory fabricat- connection to the unit. Flare fittings are factory provided to al- ed and shipped loose for field installation. low connection between the ball valves and the hoses. It is important that you identify all of the unit feature loca- Supply Air Installation — Each side of the unit has one sup- tions before proceeding with the installation, see Fig. 36. Also, ply air knockout as well as a supply air knockout on the top of it must be determined whether your application requires a mat- the unit (see Fig. 45). ing unit (primary/secondary) and its configurations. Consult your local sales representative or the factory for further details 1. Determine which supply air opening/openings are re- on primary/secondary arrangements. quired for your application. Unit orientation is determined based on the location of the NOTE: The supply air opening on the riser side of the risers in the building. Risers can only be installed on the rear unit should not be used. side of the unit and always determine the rear of the mega stack 2. Use a sharp retractable knife to trim insulation using cen- unit. The return air is always on the front (see Fig. 56). ter knockout slot/trim line as pattern (see Fig. 54). a42-4294 3. Use a sharp standard needle nose pliers and grab knock- HR HS D CR CS out tab (see Fig. 54). REAR

KNOCKOUT TAB 42SM (10 PLACES) LEFT CABINET RIGHT

FRONT

DUCT BREAK (4 PLACES) RETURN AIR

R S HR HS CR CS KNOCKOUT TAB D D TRIM LINE R = RETURN HR = HOT WATER RETURN a42-4291 D = DRAIN HS = HOT WATER SUPPLY S = SUPPLY D = DRAIN Fig. 54 — 42SU Unit Supply Air Installation 2- or 4-PIPE CR = COLD WATER RETURN 4. Twist or pry pliers back and forth until knockout tab CS = COLD WATER SUPPLY breaks away from unit. Fig. 56 — 42SM Unit Installation 5. Repeat for all supply air tabs until all have been broken. Supply, Return, and Drain Risers 6. Discard center knockout piece. Be careful of sharp edges. 7. Use a sharp retractable knife to trim any excess insulation CAUTION using knockout hole as pattern. 8. Use duct pliers (hand seamers) to fold duct flange out of Toxic residues and loose particles resulting from manufac- the unit 90 degrees for each side of the supply air opening turing and field piping techniques such as joint compounds, along duct break (see Fig. 54). The 90-degree flanges can soldering flux, and metal shavings may be present in the now be used as drywall stops to prevent coverage of dis- unit and the piping system. Special consideration must be charge opening (see Fig. 55). given to system cleanliness when connecting to solar, domestic or potable water systems.

50 Submittals and product literature detailing unit operation, 2. Before anchoring the equipment in place, the unit must be controls, and connections should be thoroughly reviewed BE- leveled and the cabinet must be plumb and squared. The FORE beginning the connection and testing of risers and unit may be anchored in place by bolting directly through piping. the unit’s floor or attaching to the building walls through The supply and return connections are marked on the coil the cabinet walls in some location that will not interfere stubouts and the valve package depending on your configura- with drywall or other items such as the supply grille, ther- tion. “CS” means cold water supply, “CR” means cold water mostat, or return access panel. When attaching sheetrock return, “HS” means hot water supply, and “HR” means hot wa- to the unit cabinet, care must be taken to not penetrate the ter return to indicate flow direction to and from the coil. Blue cabinet in locations that may damage internal compo- letters mark the chilled water connections and red letters mark nents or wiring. The mounting technique is a matter of the hot water connections. choice; however, the unit should always be anchored securely to the building to prevent movement during con- The unit internal piping is designed to accommodate a total 1 struction and riser expansion and contraction. After an- riser vertical movement of ±1 /2 in., due to thermal expansion choring the unit, it is then ready for the various service and/or contraction, when positioned properly at the jobsite. connections such as riser connections and electrical. Risers must be anchored to the building structure to limit riser expansion and contraction movement to a maximum of 3 inch- 3. The plastic flare caps on the end of the riser ball valves es. Riser anchoring and expansion compensation is not includ- should be removed and discarded. ed in the factory-supplied unit and must be field provided. 4. All mega stack units use reinforced braided stainless steel While some special riser features are available from the factory, flexible hose kits for piping between field installed risers riser end caps, air vents, and/or flushing loops are normally and unit water coils as shown in Fig. 58. Each hose has provided on the job by the installer. threaded connections on each end. The hose kits allow for Riser to Unit Installation — Proper riser installation and verti- riser fluctuations due to thermal expansion. cal positioning in the unit provides for a unit piping run-out to 5. Use a wrench to tighten the swivel connections. Use a the service valves which are centered in the access slots and backup wrench to hold the riser ball valve stationary to level or sloping down slightly away from the riser. This pre- prevent it from bending or twisting during installation as vents condensation from running back to the riser and possible shown in Fig. 59. Be careful to not over tighten swivel damage from dripping at the bottom of a riser column. Each connections. job has specific requirements and satisfying those requirements a42-4297 BALL is the responsibility of the installer. VALVE WRENCH 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.

OUTER UNIT INSULATION CABINET a42-4295 SWIVEL BACK-UP CONNECTION RISER STUBOUT WRENCH INSULATION BALL VALVE Fig. 59 — 42SM Riser to Unit Installation RISER KNOCKOUT THREADED (Tighten Swivel Connections) SLOT FLARE FITTING

CAUTION Hose connection torque requirements are 350 in. lb +10/ FLARE CAP –0 in. lb to prevent leaks. 6. Locate the unit’s coil fitting. Fig. 57 — 42SM Riser to Unit Installation 7. The plastic flare caps on the end of the coil fitting should be removed and discarded. FLEXIBLE HOSE KIT a42-4296 8. Use a wrench to tighten the swivel connections. The baffle acts as a secondary wrench. Be careful to not over RISER STUBOUT INSULATION BALL tighten swivel connections. VALVE RISER CAUTION Hose connection torque requirements are 350 in. lb +10/ BAFFLE –0 in. lb to prevent leaks. COIL 9. Locate the p-trap drain and rubber hose factory installed to the drain pan connection in the bottom of the unit as CONNECTION POINT TO ANY FACTORY shown in Fig. 60. FURNISHED AND INSTALLED COMPONENTS. 10. Push the rubber drain hose over the riser drain stubout. Be careful that you do not bend the drain stubout. Fig. 58 — 42SM Riser to Unit Connection 11. Adjust the hose clamp over the riser stubout and rubber hose to hold in place as shown in Fig. 60.

51 a42-4298 Supply Air Installation UNIT INSULATION UNIT WALL 1. If the unit has been ordered with a supply air plenum, RISER KNOCKOUT then each side of the unit has one supply air knockout as DRAIN PAN 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 re- DRAIN RISER quired for your application. CLAMP NOTE: The supply air opening on the riser side of the unit should not be used.

CLAMP 3. Use a sharp retractable knife to trim insulation using cen- P-TRAP ter knockout slot/trim line as pattern (see Fig. 63). RISER STUBOUT 4. Use a sharp standard needle nose pliers and grab knockout tab (see Fig. 63). Fig. 60 — 42SM Riser to Drain Installation 5. Twist or pry pliers back and forth until knockout tab breaks away from unit. 12. Test for leaks. Any and all leaks should be repaired before 6. Repeat for all supply air tabs until all have been broken. proceeding with installation. When testing with air or some other gas, it might be necessary to tighten stem 7. Discard center knockout piece. Be careful of sharp edges. packing nuts on some valves to maintain air pressure in 8. Use a sharp retractable knife to trim any excess insulation the riser. Pressure testing risers with water should be done using knockout hole as pattern. with the unit service valves closed to prevent flushing de- 9. Use duct pliers (hand seamers) to fold duct flange out of bris into the unit valve packages. These valves will also the unit 90 degrees for each side of the supply air opening allow risers to be drained down after testing in the winter along duct break (see Fig. 63). The 90-degree flanges can to avoid freeze-up problems. In the event that leaking or now be used as drywall stops to prevent coverage of dis- defective components are discovered, the sales represen- charge opening (see Fig. 64). tative must be notified BEFORE any repairs are attempted. All leaks should be repaired before proceeding with SIDE VIEW a42-4299 the unit installation. 13. After system integrity has been established, the riser insu-

lation must be pulled back into place over the joint and OPTIONAL glued or sealed to prevent sweating and heat loss or gain. SUPPLY All of the risers including the riser stubouts should be PLENUM SIDE SUPPLY AIR properly covered with insulation. Internally mounted KNOCKOUT chilled water piping and valves are located over the drain (1 PER SIDE) 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 MEGA MOD testing is completed. The fireproofing method used must CABINET 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 ero- Fig. 61 — 42SM Unit Knockout Locations sion at the joint between the insulation and the fireproof- Side View (Typical) ing material. When no risers are ordered for the mega stack unit, it is TOP VIEW a42-4300 the responsibility of the installer to make sure that a field- supplied 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. TOP SUPPLY Variations in floor-to-floor dimensions may require field AIR KNOCKOUT work such as cutting off or extending the risers. This op- ELECTRICAL eration is the responsibility of the installer. The riser joint KNOCKOUTS 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 Fig. 62 — 42SM Unit Knockout Locations damage can occur due to drain overflow. Drain chilled Top View (Typical) 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.

52 with local and national codes must perform all piping connec- KNOCKOUT TAB tions. Refer to Tables 1-4 for piping connections. (10 PLACES) 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. DUCT BREAK When facing the supply air outlet from the front of the unit (4 PLACES) (air blowing in your face), your right hand will be on the right a42-4301 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. KNOCKOUT TAB TRIM LINE The supply and return piping connections of the factory- provided valve package are either swaged for field brazing (standard) or union fitted (optional) for field connection to the coil. Fig. 63 — 42SM Unit Supply Air Installation

DUCT FLANGE a42-4302

UNIT 90º WALL

Fig. 65 — Unit End Reference UNIT INSULATION VALVE PACKAGES — There are limitations on physical size of pneumatic valves, quantity and type of matching Fig. 64 — 42SM Unit Supply Air Installation components, and required control interface. See Fig. 68. 10. Use adhesive or glue to re-attach insulation that has Consult factory before ordering any special valve package pulled away from the unit during knockout removal components that are not covered in this book. process. Valve packages are shipped with the units or in unit cartons. 11. For ducted applications tape should be applied along and Valve packages include belled ends for field soldering to coil around all of the supply air opening knockouts to prevent connections. air leakage. All factory-furnished cooling valve packages are arranged Step 2 — Make Piping Connections — Access to to position as much of the package as possible over an auxiliary piping is available through the access panels at the side of the drain pan or drip lip. This helps minimize field piping insula- units or front of the unit. Qualified personnel in accordance tion requirements. Refer to Fig. 69-72 for pipe connection configurations. See Table 7 for descriptions of common piping components.

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!

OPPOSITE END CONNECTION SAME 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 a42-4174 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. MOTORIZED Check job specifications for system pressure, pressure drop imitations and flow rate prior to selecting valve package M 1 3 components or valve package size ( /2in., /4 in., etc.). 2-PIPE SYSTEM (One Valve Package) or 4-PIPE SYSTEM (Two Valve Packages) Application: BALL VALVE • 2 Pipe — Hydronic Heating Only (2) BALL • 2 Pipe — Hydronic Cooling Only (1) 2-WAY MOTORIZED R MOTORIZED • 2 Pipe — Hydronic Cooling with Total Electric Heat 2-WAY VALVE COIL BALL VALVE • 4 Pipe — Hydronic Cooling and Heating M S

LEGEND BALL VALVE (WITH Ball Valve MEMORY STOP) (2) BALL (ONE WITH M MEMORY STOP) R M Motorized 2-Way Valve (1) 2-WAY MOTORIZED MOTORIZED 2-WAY VALVE BALL VALVE 1 COIL NOTE: A /4-in. bypass line is included in the piping package M when a 2-way valve is specified with a control package contain- S ing an automatic changeover device. 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). MOTORIZED

Aquastat (A) clips on supply line upstream from aquastat M 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. BALL VALVE (1) GATE Supply and return connections at coil will be swage fit for (1) BALL R (1) 2-WAY MOTORIZED field braze (standard) or unions (option). MOTORIZED 2-WAY VALVE GATE Check job specifications for system pressure, pressure drop COIL M SHUT OFF A limitations and flow rate prior to selecting valve package S 1 3 components or valve package size ( /2in., /4 in., etc.). BYPASS 2-PIPE SYSTEM (One Valve Package) Application: • 2 Pipe — Hydronic Cooling and Heating BALL VALVE • 2 Pipe — Hydronic Cooling and Heating with Auxiliary BALANCING (2) BALL VALVE Electric Heat (1) BALANCING R (1) 2-WAY MOTORIZED BALL VALVE LEGEND COIL M BYPASS S Balancing Valve A MOTORIZED Ball Valve 2-WAY VALVE Circuit Setter CIRCUIT SETTER Gate Shut Off Valve (1) BALL (1) CIRCUIT SETTER R (1) 2-WAY MOTORIZED M MOTORIZED Motorized 2-Way Valve 2-WAY VALVE BALL VALVE COIL M A NOTE: Additional aquastat required as noted above. S 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 sys- a42-4176 tem return while opening flow through coil. Water bypasses coil and flows directly to system return when unit is OFF. The aquastat (A) clips on supply line upstream from 3-way valve (as shown above). It senses system water tempera- MOTORIZED ture to prevent cooling operation with hot water in system piping or heating operation with chilled water in system pip- M ing. 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 BALANCING line to permit equal flow balancing. VALVE MOTORIZED BALL VALVE Supply and return connections at coil will be swage fit for (1) BALL 3-WAY VALVE field braze (standard) or unions (option). (1) 3-WAY MOTORIZED R Check job specifications for system pressure, pressure drop M BYPASS limitations and flow rate prior to selecting valve package COIL S BALL VALVE 1 3 components or valve package size ( /2in., /4 in., etc.). 2-PIPE SYSTEM (One Valve Package) or 4-PIPE SYSTEM (Two Valve Packages) Application: BALL VALVE • 2 Pipe — Hydronic Heating Only (WITH MEMORY STOP) • 2 Pipe — Hydronic Cooling Only MOTORIZED (2) BALL (ONE WITH 3-WAY VALVE • 2 Pipe — Hydronic Cooling with Total Electric Heat MEMORY STOP) R M (1) 3-WAY MOTORIZED • 2 Pipe — Hydronic Cooling and Heating M BYPASS • 2 Pipe — Hydronic Cooling and Heating with Auxiliary COIL S Electric Heat BALL VALVE • 4 Pipe — Hydronic Cooling and Heating

MOTORIZED BALL VALVE (1) GATE 3-WAY VALVE (1) BALL R (1) 3-WAY MOTORIZED LEGEND M BYPASS S GATE Balancing Valve COIL SHUT OFF VALVE Ball Valve M Ball Valve with Memory Stop Circuit Setter BALL VALVE BALANCING Gate Shut Off Valve (2) BALL VALVE (1) BALANCING R (1) 3-WAY MOTORIZED M M BYPASS Motorized 3-Way Valve COIL S BALL VALVE

*When aquastat is used for automatic changeover, bypass is MOTORIZED required as indicated by dashed line. 3-WAY VALVE

NOTES: CIRCUIT SETTER 1. Packages factory furnished and installed. MOTORIZED 2. Valves are 5/ -in. ODS unless otherwise specified. (1) BALL 3-WAY VALVE 8 (1) CIRCUIT SETTER R 3. If an automatic flow control valve is added, it will be (1) 3-WAY MOTORIZED located on supply line between shutoff valve and coil (or M BYPASS motorized control valve, if supplied). COIL S BALL VALVE

Fig. 71 — Three-Way Motorized Control Valve Package

58 When isolation valves only are specified, they will be brazed to the coil stub-outs. Check job specifications for system pressure, pressure drop limitations and flow rate prior to selecting specific compo- 1 3 nents or valve package size ( /2 in., /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 Balancing Valve R Ball Valve COIL BALL VALVE Circuit Setter S Gate Shut Off Valve

*When aquastat is used for automatic changeover, bypass is BALL VALVE required as indicated by dashed line. (1) BALL NOTES: (1) GATE R 1. Continuous water flow, chilled water or hot water. 2. Not recommended for high humidity applications. COIL GATE SHUT 3. 2-Pipe System Only: Not recommended with unit- OFF VALVE mounted thermostat on vertical units. S 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. 5 BALL VALVE 6. Valves are /8-in. ODS unless otherwise specified. 7. If an automatic flow control valve is added, it will be (2) BALL located on supply line between shutoff valve and coil (or (1) BALANCING R motorized control valve, if supplied). BALANCING COIL VALVE BALL VALVE S

CIRCUIT SETTER (1) BALL a42-4307 (1) CIRCUIT SETTER 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 2 IN. MIN the unit. The differential height of the outlet to the bottom of CONDENSATE the trap must not be less than the total static pressure of the PAN STUB-OUT TRAP 7/8 IN. FIELD-SUPPLIED unit. See Fig. 73 (42D) and 74 (42V). DRAIN EXTENSION Provide a trap of at least 2 in. near the end of the drain line to prevent odors from entering the rooms. Fig. 73 — Typical Drain Line Details (42D Unit Shown)

59 42C,D,V STEAM CONNECTIONS — On units with steam Unit NOTE: Field trim heating coils, the maximum steam pressure applied to the unit Wall Drain Pan “P” trap as required should never exceed 10 psig. However, when steam is used on to prevent kinking. a 4-pipe application system with 1-row and 2-row coils the maximum steam pressure should never exceed 5 psig (suitable Drain for only low pressure steam). Clamp 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 2" Minimum Drain steam trap discharge for each 2 ft elevation to ensure continu- Clamp ous condensate removal. “P” Trap Proper steam trap selection and installation is necessary. As Fig. 74 — “P” Trap Minimum Configuration 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 42C,D,V WATER SUPPLY/RETURN CONNECTIONS — trap losses and ensure complete condensate removal. Install piping in accordance with all applicable codes. Position valves over the drain pan. Be sure valves are in proper operat- 42C,D,V DIRECT EXPANSION (DX) REFRIGERANT ing position and are easily accessible for adjustment. See PIPING — Use the condensing unit manufacturer's recom- Fig. 69-72. Refer to Fig. 75 for copper water tube and joint mended line sizes and requirements. Suction line must be material pressure ratings. insulated for correct operation. Use refrigerant-grade copper lines only. The unit is not applied as a heat pump. If coil and valve package connections will be made with a solder joint, care should be taken to ensure that the components Thermostatic expansion valve (TXV) and sensing bulb are in the valve package are not subjected to high temperatures, factory-installed on units when DX coil option is chosen with which may damage seals or other materials. Protect all valve distributor and TXV. accessories with wet or damp rag wrapped around the body NOTE: If a hot water coil is used in the reheat position, a field- during soldering / brazing process. See Fig. 76. Many 2-posi- supplied freezestat must be installed to protect the coil. tion electric control valves are provided with a manual operat- TEST AND INSULATE — When all joints are complete, ing lever. This lever should be in the OPEN position during all perform hydrostatic test for leaks. Vent all coils at this time. soldering operations. Check interior unit piping for signs of leakage from shipping If coil connection is made with a union, the coil side of the damage or mishandling. If leaks are found, notify your Carrier union must be prevented from turning (it must be backed up) representative before initiating any repairs. Release trapped air during tightening. See Fig. 69-72 for common valve packages. from system (refer to Step 7 — Make Final Preparations The supply and return connections are marked and color section). coded on the coil stub out and valve package. Supply side is Never pressurize any equipment beyond specific test pres- marked as 'S' and return side is marked as 'R.' A blue letter indi- sure. Always pressure test with an inert fluid or gas, such as cates cooling side and a red letter indicates heating side. In case clear water or dry nitrogen to avoid possible damage or injury of field-installed valves and piping, install chilled water valve in the event of a leak or component failure during testing. 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 CAUTION may be packaged separately from the unit. All water coils must be protected from freezing after initial CAUTION filling with water. Even if system is drained, unit coils may still have enough water to cause damage when exposed to DO NOT OVERTIGHTEN! Overtightening will distort temperatures below freezing. (egg shape) the union seal surface and destroy the union. Following the hydrostatic test, insulate all piping to prevent sweating. NOTE: The project specifications for system pressure, pressure drop limitations, and flow rate should be checked prior to To ensure compliance with building codes, restore the struc- selection of specific components or the valve package size. ture's original fire resistance rating by sealing all holes with material carrying the same fire rating as the structure.

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 D 95-5 Tin-Antimony at 200 F B 50-50 Lead-Tin at 150 F Note 1 E 95-5 Tin-Antimony at 150 F Note 2 C 50-50 Lead-Tin at 100 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 Table 7 — Piping Components

CV FACTOR RATING* STEAM SYMBOL/SKETCH DESCRIPTION 1 3 /2 /4 PSI F USE 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 N/A N/A 400 100 NO 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. AUTOMATIC AIR VENT: Nickel plated brass valve, fiber-disc type, with positive shut-off ball- check 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 N/A N/A 125 240 NO 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 subse- quent draining and refilling. Should not be used in lieu of main system air vents. SWAGE: Copper tube end expanded to accept a copper tube of the same size for factory or field brazing. N/A N/A 300 200 YES Application — Used where possible for all tubing joints for best joint integrity. UNION: Combination wrought copper/cast brass union assembly, solder by solder. Application — Used for quick connect (and dis- N/A N/A 300 200 YES connect) of valve package components to minimize field labor and facilitate servicing of unit. INSERTION TEST PORT: Brass body valve 1 for acceptance of test probe (up to /8 in. diameter). Application — Installed on one (or both) sides N/A N/A 250 250 NO of the coil to allow for temperature or pressure sensing. Used for close tolerance water balancing and service analysis. 1 PRESSURE TEST PORT: Brass body /4 service access fitting with removable depressor type core. Application — Installed on both sides of the N/A N/A 400 210 NO 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. 2.12 3.9 300 250 NO 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 Table 7 — Piping Components (cont)

CV FACTOR RATING* STEAM SYMBOL/SKETCH DESCRIPTION 1 3 /2 /4 PSI F USE 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. Bal- 4 14 300 250 NO ance 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. Valve orifice size FIXED FLOW VALVE: Flexible orifice type determines CV fac- (non-adjustable). tor. The orifice of Application — Used for water flow balancing. these fixed flow Valve automatically adjusts the flow to within valves changes as 10% of set point. flow is regulated. As the water pressure increases, 600 220 NO the orifice size a42-4282 decreases, thereby automatically limiting the flow rate to the specified gpm (±10%). 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 9.0 19.0 main system strainers. Strainer screen may Clean Clean 400 150 N/A 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 14.2 28.6 600 350 YES 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 14.2 28.6 600 350 N/A stop feature allows return to the balance point after shut-off. Check specifications for service fittings required when used for water balancing.

63 Table 7 — Piping Components (cont)

CV FACTOR RATING* SYMBOL/SKETCH DESCRIPTION STEAM 1 3 USE /2 /4 PSI F 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 YES electrically powered open and closed by spring 3.5 3.5 300 200 15 return when electric power removed). Manual over- PSI ride lever allows valve to be placed in the open posi- MAX. tion 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. 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 4.9 10.3 300 240 NO 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-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 4.0 4.0 300 200 N/A 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 4.9 4.9 300 240 N/A 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).

64 Table 7 — Piping Components (cont)

CV FACTOR RATING* STEAM SYMBOL/SKETCH DESCRIPTION 1 3 /2 /4 PSI F 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, 4.0 300 200 N/A 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. 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, 4.0 300 200 N/A 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. 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 300 200 N/A except when powered, the actuator moves to the 4.0 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. AQUASTAT: Water temperature sensing electrical switch. (Line Voltage Controls) 1 Application — Clips directly on nominal size /2 in. or 3 /4 in. copper tubing for water temperature sensing. 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.

65 Supply Incoming Power or Return Torch Stub From Coil

Field Tubing Wet Rag

Adaptor Option 1 (Factory Installed) Fig. 77 — High Voltage Wiring Service Switch Fig. 76 — Field Piping Connections (Side Location) Step 3 — Make Electrical Connections — Refer to unit nameplate for required supply voltage, fan and heater Incoming Power 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. Compli- ance with all codes is the responsibility of the installing contractor. Option 2 The fan motor(s) should never be controlled by any wiring or device other than the factory-supplied switch or thermostat/ Fig. 78 — High Voltage Power Connection switch combination unless prior factory authorization is (Unit Without Service Switch) obtained. Fan motor(s) may be temporarily wired for use during construction only with prior factory approval and only Incoming Power 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 Option 3 on the unit. Failure to do so could result in personal injury or damage to components, and will void all manufacturer's Fig. 79 — High Voltage Wiring Service Switch warranties. (Bottom Location) Units with factory-supplied and factory-installed aquastats FACTORY-INSTALLED OPTIONS may be shipped with the aquastats mounted on a coil stub-out. If this is the case, remove the aquastat before installing valve Condensate Overflow Switch — The condensate overflow package. When reinstalling aquastats, consult the factory- switch is used to detect a clogged condensate drain pan. The piping diagram in the submittal for proper location. If the valve condensate switch uses a normally closed contact to allow the package is field-supplied, the aquastat must be installed in a system control power to pass through the switch energizing the location where it will sense the water temperature regardless of water valves and fans allowing normal operation. When an the control valve position. A bleed bypass may be required to overflow condition is detected by the switch, it opens the NC guarantee proper aquastat operation. The aquastat bypass line contact and de-energizes the water valve and fans. allows a small amount of water to flow from the supply to the return piping when the control valve is closed.

66 Aquastat — The aquastat must be able to sense whether the typical control sequences only. For detailed control operating flowing water is being chilled or heated and switches a contact sequence, refer to thermostat operating instructions. closed to provide automatic summer or winter changeover for STANDARD WIRING PACKAGES the system. When a two-pipe cooling/heating system with optional auxiliary electric heat is desired, an additional aqua- Manual Fan Control — On vertical cabinet units, a fan-speed stat is required. switch may be furnished unit-mounted and wired. See Fig. 80. On vertical furred-in units and horizontal units, the switch may Units with optional factory furnished and installed aquastats be shipped separately on a decorative wall plate for field may be shipped with aquastats mounted on the coil stub out. In mounting and wiring. See Fig. 81. this situation, remove the aquatat before valve package installation. Refer Fig. 70 for factory piping diagram for proper loca- The standard switch has LOW, MEDIUM, HIGH and OFF tion when reinstalling the aquastats. If the valve package is positions plus an auxiliary contact to energize thermostats, field supplied,the aquastat must be installed in a location where valves, dampers, etc. it will sense the water temperature regardless of control valve NOTE: Wiring diagrams are for typical applications. If other position. A bleed bypass should be provided for proper opera- voltages for heaters or controls are specified, wiring may differ tion of aquastat. The bleed line allows a small amount of water from that shown. Refer to wiring diagram on unit blower hous- to flow from supply to return piping when the control valve is ing for unit specific wiring. closed for loop temperature sensing. Thermostatic Electric Valve Control, 2-Pipe — A thermo- All field wiring must be in accordance with governing statically controlled 2-position valve provides superior control codes and ordinances. Any modification of unit wiring without to fan cycling. With this control, the fan runs continuously un- factory authorization will invalidate all factory warranties and less it is manually switched to the OFF or AUTO position. The nullify any agency listings. The manufacturer assumes no re- fan must be on before the valve can be opened to supply water sponsibility for any damages and/or injuries resulting from im- to the coil. proper field installation and/or wiring. This system can be used for normal 2-pipe changeover systems and can also be furnished for cooling-only or heating-only ap- IMPORTANT: Wiring diagrams shown depict typical plications by omitting the changeover and specifying which control functions. Refer to unit wiring label for specific application is intended. See Fig. 82 and 83 for line voltage con- functions. trol. See Fig. 84 and 85 for 24-v control. Wiring diagrams show typical applications. Refer to wiring diagram on unit blower Units may be equipped with line voltage controls or housing for unit specific wiring. 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 Thermostatic 2-Pipe Auxiliary Electric Heat with Valve Two control methods are available: Control — This system, also called twilight or intermediate 1. Use the standard automatic changeover thermostat with a season electric heat, goes a long way towards solving the dead band between heating and cooling. spring and fall control problems of 2-pipe systems. 2. Use a manual changeover thermostat. With this method Chilled water can be run late into the fall, turned on early in only one changeover is required. the spring and electric heat will still be available to all units whenever required. Be sure to include a 2-way or 3-way electric valve with this system. In winter the system is switched over to hot water. Two changeover devices are required for this. One device switches NOTE: Wiring diagrams are for typical applications. If other the action of the thermostat and the other locks out the electric voltages for heaters or controls are specified, wiring may differ heat when hot water is in the coil. from that shown. See Fig. 86 for line voltage control. See Fig. 87 and 88 for 24-v control. Refer to wiring diagram on With this system, the fan runs continuously unless manually unit blower housing for unit specific wiring. 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 ORG PUR

REMOTE DEVICE BOX HEAT RED COOL BLU L2 OR N YEL L1 BLK LOW W/BRN W/RED HI W/ORG

UNIT MOUNTED J BOX

QUICK CONNECT AQUASTATS OPTIONAL BRN BLK L RED RED RED M BLU BLU RISE BLOWER PUR BLU MOTOR HBLK BLK

WHT *WHT BLK COM *WHT RED RED EQUIPMENT RISE GROUND BRN BLU L2 or N

VALVE L1 RED BLK

CONTACTOR *WHT *WHT WHT LIMIT SWITCH 1 BLK BLK BLK

*WHT GRN L2 OR N L1

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

RS+5 RS RG3G Y1 W1G2 C H2O CK1

DUCT SENSOR 33CSSEN-DS RED CHANGE OVER ORG RED PUR BLK BRN BLU YEL WHT SENSOR BLK BLK

BLK

VALVE

BLK 2 Q/C BLK YEL 1

YEL QUICK CONNECT RED G FAN BLU G2/(W) BLK G3/(Y) BLK COM (VALVE) RED RED L 4 BLU BLU M (COOL) 3 BLOWER HI BLK BLK H MOTOR 2 (HEAT) ORG YEL *WHT WHT COM MED 1 24

TRANSFORMER LOW EQUIPMENT BLK WHT/RED GROUND

L1 BLK BLK *WHT L2 or N *WHT YEL BRN 0 1 YEL 06

NC 3 7 BLK COM LIMIT SWITCH L1 4 8 NO 2 6 BLK BLK

WHT N 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 Thermostat 2-Pipe Total Electric Heat with Valve Normally, an automatic changeover thermostat with a dead Control — With this system, the complete heating require- band between heating and cooling is used, but a manual ment for the space is provided by the electric heater; the water changeover thermostat is also suitable. A 2-way or 3-way valve system is never changed over for heating. It is therefore possi- must also be used so that the chilled water is off whenever the ble, just as with 4-pipe systems, to have heating or cooling at heater is on. No changeover device to sense water temperature any time of the year. is necessary. The fan runs continuously unless it is manually switched to NOTE: Wiring diagrams are for typical applications. If other OFF or AUTO position. Fan must be on before thermostat can voltages for heaters or controls are specified, wiring may differ send signal to open chilled water valve or turn on electric from that shown. See Fig. 89 for line voltage control. See heater. Fig. 90 and 91 for 24-v control. Refer to wiring diagram on unit blower housing for unit specific wiring.

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 RG3G Y1 W1G2 C H2O CK1

NEC CLASS 2 WIRING ORG RED PUR BLK BRN BLU YEL

VALVE BLK 2 Q/C COOL BLK YEL 1

33ZCRLYBRD QUICK CONNECT G FAN G2/(W) G3/(Y) BLK YEL COM (VALVE) RED RED L 4 BLU BLU M (COOL) 3 BLOWER HI BLK BLK H MOTOR 2 (HEAT) ORG YEL *WHT WHT COM MED 1 24

TRANSFORMER LOW EQUIPMENT BLK WHT/RED GROUND

BLK L1

*WHT L2 or N *WHT

0 YEL 1 BRN EQUIPMENT 06 NC GROUND 3 7 LIMIT SWITCH

BLK 4 COM 8 L1 2 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 Thermostatic Valve Control, 4-Pipe — The 4-pipe system With this system, the fan runs continuously unless it is provides the ultimate in economy and room temperature con- manually switched to OFF/AUTO position. Fan must be on be- trol. Both hot water and chilled water are available at any time. fore thermostat can send signal to open the chilled water or hot Normally an automatic changeover thermostat is used, but a water valve. manual changeover thermostat is also suitable. Two 2-way NOTE: Wiring diagrams are for typical applications. If other valves, two 3-way valves, or one 2-way plus one 3-way valve voltages for heaters or controls are specified, wiring may differ must be selected. An automatic changeover device to sense from that shown. See Fig. 92 for line voltage control. See water temperature is not required. Fig. 93 and 94 for 24-v control. Refer to wiring diagram on unit blower housing for unit specific wiring.

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 RG3G Y1 W1G2 C H2O CK1

NEC CLASS 2 WIRING ORG RED PUR BLK BRN BLU YEL

VALVE BLK PUR 2 Q/C COOL BLK YEL 1

33ZCRLYBRD QUICK CONNECT G FAN VALVE G2/(W) BLK BLK BRN G3/(Y) 2 YEL COM HEAT Q/C (VALVE) BLK YEL RED RED L 1 4 BLU BLU M (COOL) 3 BLOWER HI BLK BLK H MOTOR YEL 2 YEL (HEAT) WHT COM MED 1 24

TRANSFORMER LOW EQUIPMENT GROUND

BLK BLK L1

L2 or N *WHT *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, CAUTION specifications, and all applicable codes. Duct construction must allow unit to operate within duct external static pressure limits Proper safety procedures should be followed regarding as shown on job submittals. Units designed to operate with ventilation and safety equipment during touch-up and ductwork may be damaged if operated without intended duct- repainting since materials may pose a health hazard. The work attached. manufacturer's directions should be followed for the prod- Units provided with outside air should have some method ucts being used. of low-temperature protection to prevent freeze-up. This protection may be any of several methods, such as a low tempera- To repaint the factory-baked enamel, the finish should be ture thermostat to close the outside air damper or a preheat coil prepared by light sanding with no. 280 grit sand paper or to temper the outside air before it reaches the unit. It should be no. 000 or no. 0000 fine steel wool. The surface may also be noted that none of these methods will adequately protect the wiped with a liquid surface etch cleaning product such as “No coil in the event of power failure. The safest method of freeze Sand” or “Pasceo.” These items should be available at most protection is to use glycol in the proper percent solution for the paint product stores. It should be noted that the more conscien- coldest expected air temperature. tiously this preparation is done, the more effective it will be. Insulate ductwork as required. Use flexible connections to After this preparation is accomplished, the factory finish minimize duct-to-unit alignment problems and noise transmis- should provide excellent adhesion for a variety of air-dried top sion where specified. coats. Enamel will give a more durable, higher gloss finish, Set unit markings for minimum clearance to combustible while latex will not adhere as well and will give a dull, softer materials and first 3 ft of ductwork. Install ductwork, accessory finish. Top coats involving an exothermic chemical process be- grilles and plenums so that they do not restrict access to filter. tween two components, such as epoxies and urethanes, should The manufacturer assumes no responsibility for undesirable be avoided. system operation due to improper system design, equipment or Factory aerosol touch-up paint may require a number of component selection, and/or installation of ductwork, grilles, light “dust coats” to isolate the factory-baked enamel finish and other related components. from the quick drying touch-up paint. Step 6 — Cut Out Openings for Grilles and CAUTION Thermostats — On all units with optional supply-air or return-air grilles, dampers, thermostats, and switch plates, cut Prevent dust and debris from settling in unit. If wall finish out openings where specified on the job plans. Be careful not to or color is to be spray applied, cover all openings to pre- cut wires, piping or structural supports. vent spray from entering unit. Failure to do so could result in damage to the unit and/or the reduction of unit effi- For remote-mounted thermostats use a steel thermostat ciency. shield ring to protect drywall from thermostat wiring where applicable. Step 5 — Frame and Finish Unit — Models 42SG, If not included on the unit or furnished from the factory, SH, SJ, SU and SM have factory enclosures and may be fin- supply and return grilles should be provided as recommended ished with normally accepted wall covering. However, drywall in the product catalog. secured with adhesive bonding alone is not recommended. Step 7 — Make Final Preparations The 42S units are designed to have gypsum board or other types of wall board applied directly to the unit cabinet surface 1. Turn off power to the unit (open unit electrical disconnect). 5 to a maximum combined thickness of /8-inch. Use low-pro- 2. Install thermostats and perform any other final wiring as file sheet metal panhead screws to secure wallboard to unit applicable. Check the unit for any loose wires. 1 frame. Fasteners may penetrate the cabinet no more than /2 3. Perform a final visual inspection. All equipment, ple- inch. nums, ductwork, and piping should be inspected to verify These fasteners must be located to avoid damage to internal that all systems are complete and properly installed and components and wiring in the same manner as anchoring fas- mounted, and that no debris or foreign articles such as pa- teners. Do not apply sheet metal screw or nails where they can per or drink cans are left in the units or other areas. Clean penetrate coil, riser pipes, or electrical junction box and race- dirt, dust, and other construction debris from unit interior. ways. Be sure to check fan wheel and housing. Do not secure wallboard to drain pan edges or to control 4. Rotate fan wheel by hand to be sure it is free and does not box enclosure. Condensate leaks or electrical shorts may result. rub housing. Check that wing nuts securing fan assembly An alternate method of enclosing the unit is to frame one or to fan deck are tight. more sides with studding and apply the wall board to this fram- 5. Ensure all panels and filters are installed before checking ing. This method requires specific unit features and return ac- fan operation. Turn on power to the unit. cess panels when used on the return-air side of a unit. Units not 6. Install filter in frame at front of coil. If field-supplied properly equipped will exhibit poor cooling and/or heating per- filters are used, be sure size is as specified in Tables 1-4. formance and could experience excessive or premature component failures. Prevent sheetrock dust or other debris from settling on coil CAUTION fins, motor-blower assembly or other unit interior surfaces. Do not start up or operate unit without filter. Be sure filter EXPOSED UNIT FINISH, TOUCH-UP AND and unit interior are clean. Failure to do so could result in REPAINT — Return access and exposed cabinet units may be damage to the equipment or building and furnishings and/ furnished with a baked enamel finish. Small scratches in this or void all manufacturer's warranties. finish may be repaired with touch-up paint available from the factory. Some colors of touch-up paint are available in aerosol 7. ECM (Electronically Commutated) Blower: containers and all touch-up paint is available in pint, quart, and If the unit is equipped with an ECM blower, additional gallon cans. steps may be required during the air balancing process.

77 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. Alter- natively, match the control board to the illustrations iden- RR tified in the Control Board Type section. OUT 8. Check the fan and motor operation.

9. Be sure drain line is properly and securely positioned and D10 D11

that the line is clear. Pour water into drain to check R3 operation. 10. Prior to the water system start-up and balancing, the chilled/hot water systems should be flushed to clean out C/B A A 1 A dirt and debris which may have collected in the piping B B + B during construction. During this procedure, the system C C – C should be flushed from the supply riser to the return riser D D 1 D BK/ MED LOW ADJUST HIGH through a cross-over loop at the end of the riser column, PWM and all unit service valves must be in the closed position. SPEED SPEED A42-4310 SPEED This prevents foreign matter from entering the unit and 0 clogging the valves and metering devices. Strainers should be installed in the piping mains to prevent this ma- W/W1 Y/Y2 Y1 G terial 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 EM/W2 manual air vent fitting, or the optional automatic air vent fitting installed on the coil. Venting can be accomplished Fig. 95 — ECM Jumper Speed Board (42SM Only) 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 CAUTION venting after start-up operations. When steady steam of water begins to escape, close valve. Vent release air slow- Both of the procedures described below require the control ly, usually dripping water into drain pan in the process. box to be powered while adjustments are made. Line volt- Make sure all service valves are open and that the motor- age components are concealed behind a secondary cover. ized control valves, if supplied, are set for automatic However, installer should still take all reasonable precau- operation. tions to prevent electrical shock. 3-Discrete Speed Rheostat Field Adjustment (42SM Only) CAUTION (See Fig. 96)— The unit has been factory configured to produce PSC equivalent airflow on high speed, with medium and The air vent provided on the unit is not intended to replace low speed set at 80% and 60% of high, respectively. If these the main system air vents and may not release air trapped setting are acceptable, then no further configuring is required. in other parts of the system. Inspect the entire system for Board mounted rheostats are provided to adjust the airflow per- potential air traps and vent those areas as required, inde- taining to each output. Each output can be adjusted from 0 to pendently. In addition, some systems may require repeated 100% of the motor’s factory programmed operating range. To venting over a period of time to properly eliminate air from set airflow, connect a volt-meter between “common” (near the the system. Failure to properly vent system may negatively red status LED) and Flo1 through Flo4. affect operation. Status U3 11. Check all control valves in the system for proper opera- Rp1 Rp2 Rp3 Rp4 Rp5 tion in accordance with valve manufacturer's instructions. 12. For units with factory-installed ball valves with lever han- dles — When handle is perpendicular to valve body, there Com is no flow through valve. Ball valves may be used as Flo0 Flo1 Flo2 Flo3 Flo4 shutoff valves. ECM CONTROL OPTION COMMON FLO1 FLO2 FLO3 FLO4 a 3-Speed Jumper Field Adjustment (42SM Only) (See Fig. 95) — The unit has been factory configured to produce Fig. 96 — ECM Rheostat Speed Board (42SM Only) PSC equivalent airflow on high speed, with medium and low speed set at 80% and 60% of high, respectively. If these setting Carrier’s convention is to preset and wire Flo1 for high are acceptable, then no further configuring is required. speed, Flo2 for medium, and Flo3 for low. Flo4 is not used To adjust airflow, relocate board mounted jumpers as indi- with any standard thermostat, but may be employed for a more cated on configuration chart. Chart is located on control box advanced application. The chart on the control box cover asso- cover. ciates 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 Variable Airflow for 0-10 Vdc Input (42SM Only) (See set at 80% and 60% of high, respectively. If these settings are Fig. 97) — Carrier recommends using the specified thermostat acceptable, then no further configuring is required. or DDC controller to commission the unit whenever possible. Board mounted pots are provided to adjust the airflow per- However, the blower can be started and operated without the taining to each output. Each output can be adjusted from 0 to thermostat. To do so, locate the airflow adjustment screw 100% of the motor’s factory programmed operating range. Use which is accessible from the inside of the control box. With voltmeter and airflow chart (on the control box cover) to set service switch in the “ON” position, turn the adjustment screw. values. Refer to Appendix B for adjustment procedure. The unit has now been placed in manual override. Manual override will expire when one of the following conditions is Variable Airflow for 0-10 Vdc Input (See Fig. 99) — If a satisfied: factory provided thermostat or DDC controller is utilized, then the unit is already correctly configured. • Power to the unit is cycled • 15 minutes elapse with no change to adjustment screw Carrier recommends using the specific thermostat or DDC • Unit receives a control signal from the thermostat or controller to commission the unit whenever possible. Howev- controller er, 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.

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 a42-4313 on high speed, with medium and low speed set at 80% and Fig. 99 — ECM Proportional Speed Board 60% of high, respectively. If these settings are acceptable, then no further configuring is required. If alternative airflows are desired, use board mounted pots CAUTION to adjust the airflow associated with each input. Each output can be adjusted from 0 to 100% of the motor’s factory pro- Both of the start-up and servicing procedures described grammed operating range. Use voltmeter and airflow chart (on below require the control box to be powered while adjust- control box cover) to set values. Refer to Appendix A for ad- ments are made. Line voltage components are concealed justment procedure. behind a secondary cover. However, installer should still take all reasonable precautions. START-UP L2 POTS Before beginning any start-up operation, the start-up personnel should familiarize themselves with the unit, options and K3 COM C3 accessories, and control sequence to understand the proper sys- VR3

HIGH tem operation. All personnel should have a good working HIGH C2 VR2 knowledge of general start-up procedures and have the appro- MED MED C1 priate start-up and balancing guides available for consultation. VR1 K2 CR1 LOW LOW The building must be completely finished including doors, windows, and insulation. All internal walls and doors should K1

L1 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 Fig. 98 — 3-Speed Potentiometer Adjustment possible before beginning any system balancing. 4-Discrete Speed Potentiometer Field Adjustment, Solid Except as required during start-up and balancing operations, State — The unit has been factory configured to produce PSC no fan coil units should be operated without all the proper duct- equivalent airflow on high speed, with medium and low speed work attached, supply and return grilles in place, and all access doors and panels in place and secure.

79 Start-up procedures vary depending on time of year (sum- After proper system operation is established, the actual unit mer or winter) and building characteristics (new building/old air delivery and the actual fan motor amperage draw for each building, occupied/unoccupied, etc.) unit should be recorded in a convenient place for future refer- Start-up in the cooling mode requires that proper care be ence. given to avoid condensation problems. Condensation forms on Water System Balancing — A complete knowledge surfaces that are colder than the dew point of the surrounding of the hydronic system, along with its components and con- air. If a unit is started and is piped with low-temperature chilled trols, is essential to proper water system balancing. This proce- water in a hot, humid atmosphere, condensation will form on dure should not be attempted by unqualified personnel. The many parts of the unit. In order to avoid excessive condensa- system must be complete, and all components must be in oper- tion, higher temperature water should initially be used (approx- ating condition BEFORE beginning water system balancing imately 65 to 70 F) and the fan coil control set at low or medi- operations. um fan speed. Be sure the fan current does not exceed motor nameplate values. Also, outside air supply fans, and bathroom Each hydronic system has different operating characteristics and kitchen exhaust fans should be off. depending on the devices and controls used in the system. The actual balancing technique may vary from one system to As the building temperature drops, the chilled water temper- another. ature can be gradually reduced until it reaches 50 F. At this point the outside air fans can be turned on. When the chilled After the proper system operation is established, the appro- water temperature is reduced to its design point, the exhaust priate system operating conditions such as various water tem- fans can be turned on. peratures and flow rates should be recorded in a convenient place for future reference. Cooling/Heating System — Prior to the water system Before and during water system balancing, conditions may start-up and balancing, flush the chilled / hot water systems to exist due to incorrect system pressures which may result in no- clean out dirt and debris which may have collected in the pip- ticeable water noise or undesired valve operation. After the en- ing during construction. During the process, all unit service tire system is balanced, these conditions will not exist on prop- valves must be in the closed position to prevent foreign matter erly designed systems. from entering the unit and clogging the valves and metering devices. Strainers should be installed in the piping mains to pre- Water Treatment — Proper water treatment is a special- vent such material from entering units during normal opera- ized industry. Carrier recommends consulting an expert in this tion. field to analyze the water for compliance with the water quality During system filling, air venting from the unit is accom- parameters listed in Table 8 and to specify the appropriate wa- plished by the use of standard manual air vent or optional auto- ter treatment regimen. The expert may recommend typical ad- matic air venting installed on the coil. Manual air vents are ba- ditives such as rust inhibitors, scaling preventative, antimicro- sically Schrader valves. For air venting, depress the valve unit bial growth agents or algae preventatives. Anti-freeze solutions the air has vented the coil. When water begins to escape may be used to lower the freezing point. through the valve, release the valve. Automatic air vents may Carrier’s water coil tubes and headers are constructed of be unscrewed one turn counterclockwise to speed initial vent- pure copper. Multiple brass alloys may be present in the valve ing but should be screwed in for automatic venting after start- package, depending on unit configuration. It is the user's re- up operation. See Fig. 100 and 101. sponsibility 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 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 Fig. 101 — Automatic Air Vent Iron Less than 4.5 mg/l Ammonia Less than 2.0 mg/l Manganese Less than 0.1 mg/l Air System Balancing — All duct stubs, grilles, filters, Dissolved Solids Less than 1000 mg/l and return-access panels must be properly installed to establish CaCO3 Hardness 300 to 500 ppm actual system operating conditions BEFORE beginning air balancing operations. CaCO3 Alkalinity 300 to 500 ppm Particulate Quantity Less than 10 ppm Each individual unit and the attached ductwork is a unique system with its own operating characteristics. For this reason, Particulate Size 800 micron max air balancing is normally done by balance specialists who are Controls Operation — Before proper control operation familiar with all procedures required to properly establish air can be verified, all other systems must be operating properly. distribution and fan-system operating conditions. These proce- The correct water and air temperatures must be present for the dures should not be attempted by unqualified personnel. control function being tested. Some controls and features are Units with no ductwork have air volumes predetermined at designed to not operate under certain conditions. For example, the factory by supply grille size and normally do not require air on a two-pipe cooling/heating system with auxiliary electric balancing other than selecting the desired fan speed. Units fur- heat, the electric heater cannot be energized with hot water in nished with optional dampers on supply grilles may require the system. some small adjustments to “fine tune” the air delivery to each A wide range of controls, electrical options and accessories grille. Opposed blade balancing dampers are not available for may be used with the equipment covered in this manual. Con- all grilles on a unit with electric heat. sult the approved unit submittals, order acknowledgements,

80 and other literature for detailed information regarding each in- wheel or motor. The wheel and housing may be cleaned peri- dividual unit and its controls. Since controls and features may odically using a vacuum cleaner and a brush, taking care not to vary from one unit to another, care should be taken to identify dislodge the factory balancing weights on the blower wheel the controls used on each unit and their proper control blades. sequence. Information provided by component manufacturers regarding installation, operation, and maintenance of their indi- Clean Electric Heater — Lock open and tag unit elec- vidual controls is available upon request. trical service switch. When changing from one mode to another (cooling to heat- 1. Remove dust, dirt, or foreign material before start-up. Do ing or heating to cooling), it may take some time to actually no- not block normal airflow to and from units; blockage may tice a change in the leaving air temperature. In addition, some damage electric heaters. units may be designed for a very low air temperature rise in 2. Clean heater elements with soft brush or vacuum cleaner heating. Before declaring a unit inoperative or a component as necessary. defective, it may be necessary to verify operation by more than 3. To replace blown fusible links (nichrome heaters only): one method. a. Remove fan deck (horizontal units only) for access to heater. SERVICE b. Remove nut securing link at each end; install new Excessive Condensation on Unit — Running chilled link; reinstall nuts. water through a fan coil unit with the unit fan off can cause c. Reinstall fan deck (if removed). excessive condensation. If fan cycling is used, a water flow Electric resistance heaters typically require no normal peri- control valve should be installed to shut off the water when the odic maintenance when unit air filters are changed properly. fan stops. The operation and service life may be affected by other condi- Other methods of control that avoid condensation problems tions and equipment in the system. The two most important op- are as follows: erating conditions for an electric heater are proper airflow and 1. Continuous fan operation with motorized chilled water proper supply voltage. High supply voltage and/or poorly dis- valve controlled by a thermostat. tributed or insufficient airflow over the element will result in 2. Continuous fan operation with thermostat control to element overheating and possible limit switch opening. This switch fan from high to low speed (instead of off). condition may result in the heater cycling on the high-limit thermal cutout. Sheath heaters have automatic reset switches To Clean Coil only. Open strip heaters have an automatic reset switch with a 1. Be sure electrical service switch is open, locked, and backup, high-limit thermal switch. Automatic reset switch re- tagged while working on unit. sets automatically after the heater has cooled down. High limit thermal switch must be replaced once the circuit has been bro- 2. Remove return-air grille access panel and brush between ken. The high-limit thermal cutout device is a safety device coil fins with stiff wire brush. Care should be taken to not only and is not intended for continuous operation. With proper damage coil fins. Follow-up by cleaning with vacuum unit application and operation, the high-limit thermal cutout cleaner. If coil is cleaned with air hose and nozzle, take will not operate. This device only operates when a problem ex- care not to drive dirt and dust into other components. ists, and ANY condition that causes high-limit cutout MUST Blow air through the coil fins from the leaving air face. be corrected immediately. High supply voltage also causes ex- This should again be followed by vacuuming. Units pro- cessive amperage draw and may trip the circuit breaker or blow vided with the proper type of air filters, replaced regular- the fuses on the incoming power supply. ly, will require less frequent coil cleaning. After proper airflow and supply power are assured, regular 3. Install clean filter. Refer to Clean or Replace Air Filters filter maintenance is important to provide clean air over the section. heater. Dirt that is allowed to deposit on the heating element Check Drain — Lock open and tag unit electrical service will cause hot spots and eventual element burn through. These switch. hot spots will normally not be enough to trip the high-limit thermal cutout device and may not be evident until actual heat- Check drain pan, drain line and trap before initial start-up er element failure. and at start of each cooling season. A standard type pipe clean- 3 er for /4-in. ID pipe can be used to ensure that pipe is clear of Clean or Replace Air Filters — Lock open and tag obstruction so that condensate is carried away. Check the drain unit electrical service switch. line at filter cleaning time during the cooling season. Be sure At the start of each cooling season and after each month of that debris has not fallen into unit through supply-air grille. operation (more or less depending on operating conditions) re- Should the growth of algae and/or bacteria be a concern, con- place throwaway filter or clean permanent filter. sult an air conditioning and refrigeration supply organization familiar with local conditions for chemicals or other solutions THROWAWAY FILTER — The type of throwaway filter available to control these agents. most commonly used on fan coil units should be replaced on a regular basis. The time interval between each replacement Fan Motor Bearings — Lock open and tag unit electri- should be established based on regular inspection of the filter cal service switch. and should be recorded in the log for each unit. Replace filter Standard motors are permanently sealed and lubricated. No with a good quality filter of the size shown in Tables 1-4. Do lubrication is required unless special motors have been not attempt to clean and reuse disposable filters. If the replace- supplied or unusual operating conditions exist. ment filters are not purchased from the factory, the filters used should be the same type and size as those furnished from or Clean Fan Wheel — Lock open and tag unit electrical recommended by the factory. Consult the factory for applica- service switch. tions using filter types other than the factory standard or For access to fan assembly, remove front or bottom panel. optional product. Filters with high arc pressure drops are gen- Fan assembly may be removed from its tracks if unit has a long erally not compatible with the fan coil units in this manual. conduit lead. Dirt and debris should not be allowed to accumu- PERMANENT FILTER — A maintenance schedule for per- late on the blower wheel or housing. This can result in an un- manent filters should be developed in the same manner as balanced blower wheel condition which can damage a blower throwaway filters. Unlike throwaway filters, permanent filters

81 may be cleaned and re-installed in the unit instead of being dis- valve package from excessive heat should also be used during carded when dirty. replacement. 1. Tap on solid surface to dislodge heavy particles. Filters — The type of throwaway filter most commonly 2. Wash in hot water. If needed, use mild solution of com- used on fan coil units should be replaced on a regular basis. mercial solvent such as sal soda or trisodium phosphate. The time interval between each replacement should be estab- 3. Set filter on end so that water drains out through slots in lished based on regular filter inspection and should be recorded frame. Allow filter to dry thoroughly. in the log for each unit. Refer to product catalog for recommended filter size for each product type and size. If the replace- 4. Recharge filter with Film-Cor or similar recharging oil. ment filters are not purchased from the factory, the filter used Three ounces is sufficient for medium size filter. Oil may should be of same type and size as those furnished from or rec- be applied by insect spray gun. For easier spraying, the oil ommended by the factory. Pleated media or extended surface can be warmed. filter should not be used since the high air pressure drop en- If the filter is dipped in the recharging oil, remove it im- countered with these type of filters is not compatible with the mediately and allow draining through slots in frame. type of fan coil unit covered in the manual. 5. Replace filter in unit. A maintenance schedule for permanent filters should be de- If another type of filter is used, follow the filter manufacturer's veloped in the same manner as throwaway filters. Unlike instructions. throwaway filters, permanent filters may be cleaned and rein- stalled in the unit instead of being discarded when dirty. The Electrical Wiring and Controls — The electrical optional factory permanent filter may be cleaned in hot soapy operation of each unit is determined by the components and water to remove any trapped dirt the set aside on edge to dry. wiring of the unit. This may vary from unit to unit. Consult the Before replacing the filter in the unit, it should be recharged wiring diagram attached to the unit for the actual type and with some type of entrapment film. The filter should be number of controls provided on each unit. sprayed on both sides or submerged in the film to assure com- The integrity of all electrical connections should be verified plete coverage. The filter should not be allowed to soak in the at least twice during the first year of operation. Afterwards, all film but should be immediately removed and the excess film controls should be inspected regularly for proper operation. drained from the filter before reinstallation in the unit. Some components may experience erratic operation or failure NOTE: Permanent filters normally have less static pressure due to age. Wall thermostats may also become clogged with loss than throwaway filters. dust and lint and should be periodically inspected and cleaned to provide reliable operation. Drain — The drain must be checked before initial start-up When replacing any components such as fuses, contractors, and at the beginning of each cooling season to assure that the or relays, use only the exact type, size and voltage component drain trap and line are clear. If it is clogged, take steps to clear as furnished from the factory. Any deviation without factory the debris so that condensate will flow easily. authorization could result in personal injury or damage to the Make periodic checks of the drain during the cooling season unit. This will also void all factory warranties. Only factory- to maintain a free flowing condensate. Units provided with sec- supplied replacement parts ensure that the warranty and agency ondary or tell-tale drain connection will indicate a clogged status remain in effect. All repair work should be done in such main line by flow from the tell-tale connection. a manner as to maintain the equipment in compliance with NOTE: Should the growth of algae and/or bacteria be a con- governing codes, ordinances and testing agency listings. cern, consult an air conditioning and refrigeration supply orga- More specific information regarding the use and operating nization familiar with local conditions for chemical or other characteristics of the standard controls offered by the manufac- solution available to control these growths. turer are contained in other manuals. Warranty — All equipment and components sold through Valves and Piping — No formal maintenance is re- the Parts Department are warranted under the same conditions quired on the valve-package components most commonly used as the standard manufacturer’s warranty with the exception with fan coil units other than a visual inspection for possible that the warranty period is thirty (30) days unless the compo- leaks in the course of other normal periodic maintenance. In the nent is furnished as a warranty replacement. Parts furnished as event that a valve should need replacement, the same warranty replacements are warranted for the remaining term of precautions taken during the initial installation to protect the the original unit warranty or not less than thirty (30) days.

82 APPENDIX A — POTENTIOMETER ADJUSTMENT Adjusting the low, medium, and high potentiometers re- 5. Attach the red (positive) lead of the meter to the red wire quires the use of a multi-meter capable of measuring 0~5 vdc. that bridges the 0-10 vdc outputs: high, medium, and low. 1. Only trained and qualified individuals should attempt to 6. High Speed: Close high speed relay by applying 24-v to adjust or service components on any electrical compo- the high terminal. Using a small screwdriver turn the nent. Failure to follow safety rules could result in electri- VR3 potentiometer so the meter measures 4.51 vdc. This cal shock or hazard. will set the ECM speed to 90% of maximum for high 2. Unit must be powered to perform the following proce- speed. Open the high speed relay. dure. If main power is not available, connecting a tempo- 7. Medium Speed: close medium speed relay by applying rary 24V-40VA power supply to parallel with a secondary 24-v to the medium terminal. Using a small screwdriver outputs of the unit’s transformer is recommended. turn the VR2 potentiometer so the meter measures 3. Set the electrical multi-meter to volts direct current (vdc) 3.53 vdc. This will set the ECM speed to 70% of maxi- on the 0~5 or 0~20 vdc scale. mum for medium speed. Open the medium speed relay. 4. Attach black (negative) lead of meter to the DC common 8. Low Speed: Close low speed relay by applying 24-v to terminal, labeled “L2” above the potentiometer and to the the low terminal. Using a small screwdriver turn the VR1 left of the orange relay. 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.

83 APPENDIX B — EVO/ECM 4-SPEED ADJUSTMENT Adjusting the Flo1, Flo2, Flo3 potentiometers requires the 6. High Speed: Using a small screwdriver turn the Flo1 po- use of a multi-meter capable of measuring 0~5 vdc. tentiometer so the meter measures 4.51 vdc. This will set 1. Only trained and qualified individuals should attempt to the ECM speed to 90% of maximum for high speed oper- adjust or service components on any electrical compo- ation. nent. Failure to follow safety rules could result in electri- 7. Medium Speed: Using a small screwdriver turn the Flo2 cal shock or hazard. potentiometer so the meter measures 3.53 vdc. This will 2. 24 vac power must be supplied to ECM board to make set the ECM speed to 70% of maximum speed for medi- adjustments. um speed operation. 3. Set the electrical multi-meter to volts direct current (vdc) 8. Low Speed: Using a small screwdriver turn the Flo3 po- on the 0~5 or 0~20 vdc scale. tentiometer so the meter measures 2.06 vdc. This will set the ECM speed to 40% of maximum speed for low speed 4. Attach black (negative) lead of meter to the “Com” termi- operation. nal to the left of the potentiometers and below the status light. 9. For setting of Flo0 and Flo4 contact Carrier, otherwise these potentionmeters should be set to full counter-clock- 5. Attach the red (positive) lead of the meter to the high wise rotation. speed “Flo1” terminal below the potentiometer.

I. Project Information

Job Name ______

Address ______

City ______State ______Zip ______

Installing Contractor ______

Sales Office ______

Start-up Performed By ______

INSPECTION, INSTALLATION, AND START-UP CHECKLIST ITEM COMPLETE ITEM COMPLETE Receiving & Inspection Electrical Connections 1. Unit received undamaged 35. Refer to unit wiring diagram 2. Unit received complete as ordered 36. Connection incoming power service(s) 3. “Furnish only” parts accounted for 37. Install and connect “furnish only” parts 4. Unit arrangement/hand correct 38. All field wiring in code compliance 5. Unit structural support complete and correct Unit Start-Up Handling & Installation 39. General visual unit and system inspection 6. Mounting grommets/isolators used 40. Check for proper fan rotation 7. Unit mounted level and square 41. Record electrical supply voltage 8. Proper access provided for unit and accessories 42. Record ambient temperatures 9. Proper electrical service provided 43. Check all wiring for secure connections 10. Proper overcurrent protection provided 44. Close all unit isolation valves 11. Proper service switch/disconnect provided 45. Flush water systems 12. Proper chilled water line size to unit 46. Fill systems with water/refrigerant 13. Proper hot water line size to unit 47. Vent water systems as required 14. Proper refrigerant line sizes to unit 48. All ductwork and grilles in place 15. Proper steam line sizes to unit 49. All unit panels and filters in place 16. Proper steam condensate trap on return line 50. Start fans, pumps, chillers, etc. 17. Proper steam supply pressure to unit (10 psi max) 51. Check for overload condition of all units 18. All service to unit in code compliance 52. Check all ductwork and units for air leaks 19. All shipping screws and braces removed 53. Balance air systems as required 20. Unit protected from dirt and foreign matter 54. Record all final settings for future use Cooling/Heating Connections 55. Check piping and ductwork for vibration 21. Protect valve package components from heat 56. Check all dampers for proper operation 22. Mount valve packages 57. Verify proper cooling operation 23. Connect field piping to unit 58. Verify proper heating operation 24. Pressure test all piping for leaks 59. Reinstall all covers and access panels 25. Install drain line and traps as required 60. Verify proper condensate drainage 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

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 - BTUH kW VOLTAGE PSI STEAM O 2 PD H GPM °F ______EWT °F EAT db/wb ------BTUH SENSIBLE BTUH TOTAL O 2 PD H COOLING HEATING er Maintenance Data Log er Maintenance GPM °F EWT °F EAT db/wb TYPE FILTER 42 Series Fan Coil Air Condition 42 Series Fan Coil ------CUT ALONG DOTTED LINE DOTTED CUT ALONG LINE CUT ALONG DOTTED QTYMOTOR AND FAN RH LH CFM ESP WATTS SERIAL NUMBER SERIAL MODEL NUMBER ______NOTE: Indicate repairs made, refrigerant added or removed (include amounts), field controls and valve packages added. packages and valve controls field amounts), (include or removed added refrigerant repairs made, Indicate NOTE: ______