42EL Ducted Fan Coil Unit

Transcription

1 42EL Ducted Fan Coil Unit Supply Moduboot Installation Manual

2 The photograph on the front cover is for illustrative purposes only and is not part of any offer for sale or contract. The manufacturer reserves the right to change the design at any moment without prior warning.

3 Contents 1 - INTRODUCTION FEATURES Physical and electrical data Dimensional drawings Aqualia packaging Receiving a shipment - installation method SAFETY CONSIDERATIONS General Precautions against electrocution Installation recommendations Conformity INSTALLING THE AQUALIA Co-ordinating the unit with the false ceiling Installation precautions Installation procedure Removal procedure FRESH AIR Fresh air controller Fresh air duct accessory item FAN MOTOR ASSEMBLY Description Fan assembly removal procedure Capacitor replacement procedure ELECTRIC HEATER Description Electric heater replacement procedure DUCT CONNECTION SPIGOTS WATER COIL Description Coil removal procedure Coil inlet/outlet positions WATER FLOW CONTROL VALVES Electrothermal actuator (on/off) Actuator replacement procedure Actuator electrical connections Valve body replacement procedure Technical specification for the heating/cooling changeover switch FLEXIBLE WATER PIPES Two-way valves Three-way valves AIR FILTER AND ACCESS Description Air filter replacement CONTROLS MAESTRO numeric controller Carrier electronic thermostat Carrier EXCEL 10 controller ACCESSORIES Condensate drain pump Adjustable feet for installing Aqualia units in false floor voids AQUALIA PERFORMANCE DATA Electrical data Air flow data...44

4 1 - INTRODUCTION The Carrier 42EL Aqualia compact fan coil unit is available in two sizes and with two motor drive combinations and is capable of air conditioning rooms from 25 to 50 m 2 in area. The main components of each unit comprise a centrifugal fan, a fresh air inlet with an air flow regulator (option), a chilled water cooling coil and either a hot water heating coil or an electric heater. Connections between the unit and one or more linear boot diffusers (35BD/SR Moduboot range), installed in the false ceiling above the area to be air conditioned are made on site using thermally and acoustically insulated flexible ducting. The complete system comprises one or more Carrier air or watercooled chillers and one or more air handling units to supply fresh air to the 42EL Aqualia units. These may be installed in false ceiling or under floor voids (for size 1 only) where they can be connected to the fresh air supply and the hot and chilled-water circuits. With a low height of less than 230 mm (for size 1 only), the 42EL Aqualia can be installed in most areas. Its design allows for easy maintenance. Different duct connection spigot arrangements allow most site requirements to be accommodated. The supply and return air plenum connection spigots are sized for the connection of Ø 200 or 250 mm (depending on sizes) supply/return air ducts and the Ø 125 or 160 mm fresh air supply duct. The position and number of supply/return plenum connection spigots are configured to allow for the connection of 2 or 3 ducts for size 1, 3 or 5 ducts for size 2, for the supply as well as for the return, as shown below. An open (non ducted) return air inlet may be provided instead of a return plenum. 2 - FEATURES The modular design of the Carrier Aqualia allows it to meet the different heating or air conditioning requirements of mediumsized spaces. With an overall depth of only 230 mm (for size 1 only) including fixings, these units are easily installed in suspended false ceilings or false floor voids. The Aqualia casing is manufactured from 1.2 mm galvanised sheet steel lined internally with a 6 mm layer of melamine which is itself protected by an aluminium film in order to guarantee the thermal and acoustical insulation of the unit. Several Aqualia versions are available to meet different site requirements: Aqualia size 1 unit with ducted return air. Filter removal is either from below for ceiling void installations or from above for floor void installations. unit with open (non ducted) return air inlet. Filter removal is from the rear of the unit Aqualia size 2 Filter removal is from the unit side, independent of the configuration: with ducted return air or with open return air inlet. Operating limits: Cooling Mode: Supply air temperature 12 C, when the unit is installed in an ambient temperature of 27 C dry bulb and 65% relative humidity. Heating Mode: Maximum supply air temperature 60 C. The 42EL is designed for internal application in non corrosive, dust free and non marine urban environments. The concentrations of the following gases must not be exceeded: SO 2 < 0.02 ppm H 2 S < 0.02 ppm NO, NO 2 < 1.0 ppm NH 3 < 6.0 ppm N 2 O < 0.25 ppm It is strongly recommended to select more than 3 ducts at each adapter, for sizes 1.2 or 5.2. Noise or more precisely the absence of noise is a deciding factor in the selection of an air conditioning system. The Aqualia has been designed to be particularly quiet. Low noise levels and easy maintenance are key factors influencing the selection of an air conditioning system. 4

5 2.1 - Physical and electrical data 42EL Aqualia Size 1.1 or 5.1 Size 1.2 or 5.2 Size 2.3 Size 2.4 Nominal air flow l/s (m 3 /h) 204 (735) 254 (915) 442 (1590) 526 (1895) Total cooling capacity - chilled water coil (1) kw* Sensible capacity - chilled water coil (1) kw* Heating capacity - hot water coil (1) kw** Power supply 230 V - 1 ph - 50 Hz U% ± 10 ± 10 ± 10 ± 10 Operating weight (4-row water coil) kg Water coil 3/8 in. Ø copper tubes Aluminium fins, purge valve, female connection Test pressure kpa Operating pressure kpa row coil Connection 1/2 nut (gas) 3/4 nut (gas) Water content l Monobloc 4-row coil Cooling connection: 1/2 nut (gas) 3/4 nut (gas) Heating connection: 1/2 nut (gas) Water content - cooling l heating l Electric heater-resistance wire type Power supply: 230 V - 1 ph - 50 Hz U% ± 10 ± 10 ± 10 ± 10 Heating capacity - excluding fan heat (+5%; -10%) W Self-resetting safety thermostat cut out temperature C Over temperature thermofuse link, fusing temperature C Current absorbed A Minimum heater air flow required l/s (m 3 /h) 64 (230) 122 (440) 97 (350) 97 (350) Fan Forward curved centrifugal fan number of centrifugal wheels Nominal air flow l/s (m 3 /h) 204 (735) 254 (915) 442 (1590) 526 (1895) Static pressure available at nominal air flow (2) (unit without supply and return air octopus) Pa Motor Supply voltage: 230 V - 1ph - 50 Hz, 2-pole asynchronous, internal overload protection, permanent capacitor, class B winding insulation, varnish class F. Maximum absorbed power at 230 V ( 2) W Nominal current ( 2) A Starting current A Air filter Throwaway, fire rating medium: M1 (French standard) Dimensions mm 218 x x x x 1100 Filter efficiency: 65% (gravimetric) Fresh air connection Outside diameter mm / /159 Constant minimum air flow (-10%; + 20%) l/s (m 3 /h) 8.3 (30) 8.3 (30) 8.3 (30) 8.3 (30) Constant maximum air flow (-10%; + 20%) l/s (m 3 /h) 44.4 (160) 44.4 (160) 44.4 (160)/69.4 (250) 44.4 (160)/69.4 (250) P (upstream/downstream): - Controller 8.3 l/s (30 m 3 /h) Pa Controller 44.4 l/s (160 m 3 /h) or 69.4 l/s (250 m 3 /h) Pa Aqualia water connections The water circuit in the Aqualia units is guaranteed for an operating pressure of 1000 kpa, although the Aqualia units components are individually designed and tested for a pressure of 1600 kpa. For applications requiring an operating pressure of more than 1000 kpa, please contact your local Carrier representative. Legend: (1) At nominal air flow (2) Refer to performance data tables * Based on an entering water temperature of 7 C, entering air at 27 C dry bulb and 47% relative humidity, and a water temperature difference of 5 K at nominal air flow (EUROVENT conditions). ** Based on an entering water temperature of 50 C, entering air at 20 C and a water temperature difference of 10 K at nominal air flow (EUROVENT conditions). 5

6 2.2 - Dimensional drawings Maintenance access space required, mm Sizes 1.1 or 5.1 and 1.2 and Ducted return air - Non-ducted return air 6

7 Maintenance access space required, mm (continued) Sizes 2.3 and Non-ducted return air - Ducted return air 7

8 Filter access sizes 1.1 or 5.1 and 1.2 and 5.2 Ducted return air Non-ducted return air 8

9 Filter access sizes 2.3 and 2.4 9

10 Overall dimensions, mm Sizes 1.1 or 5.1 and 1.2 and Non-ducted return air - Ducted return air 10

11 Overall dimensions, mm (continued) Sizes 2.3 and 2.4 Non-ducted return air 11

12 Return Octopus 12

13 2.3 - Aqualia packaging Aqualia units are packed on wooden pallets, separated by spacers and protected by heat-shrunk or stretchable plastic film. For Export packing please contact your local Carrier representative. Pallet weight and dimensions N of units Length Width Height Weight per pallet (mm) (mm) (mm) (kg) Sizes 1.1 or 5.1 and 1.2 or Sizes 2.3 or Check the packaging for damage upon receipt of the equipment. Unpacking of the equipment should be left until just before final installation to avoid any damage or deterioration to the units on site Receiving a shipment - installation methods Check the condition of the equipment upon receipt, any damage due to transport should be notified in writing to the transporter. Unpacking of the equipment should be left until just before final installation and should be as close to the installation as possible. Avoid placing any heavy objects on the packing. WARNING: When moving the units do not use water pipe connections, condensate drain stubs, valves or flexible pipes as handles. The presence of electrical components creates hazards to those installing and servicing these units. Only properly qualified electricians may be authorised to instal, service and repair these units. Some routine maintenance such as cleaning of the coils and filter replacement may be entrusted to non-skilled personnel. Before carrying out any work, all personnel, including qualified technicians, must familiarise themselves with the contents of this manual and all name plates and labels attached to the units. It is essential to adhere to all applicable local safety regulations. Wear eye protectors, safety gloves and non-flammable clothing when soldering or brazing. Always have a fire extinguisher of the appropriate type close at hand. Disconnect the power supply to the unit and to any accessories before carrying out any work on a unit. Do not instal units in environments where flammable gases or products of an acidic or alkaline nature may be present. The copper/aluminium coil or plastic components inside the unit could suffer irreparable corrosion damage in their presence. WARNING: Failure to take proper account of the above advice and unauthorised modification of the electrical connections will render the warranty on the product null and void. 13

14 3 - SAFETY CONSIDERATIONS General Installing, commissioning and servicing of the various components which make up the different control loops can be dangerous unless certain aspects of the installation, such as the presence of mains electricity and hot or chilled-water in the air conditioning equipment, are taken into account. Only specially trained and qualified technicians and installers who have been fully trained on the product concerned are authorised to instal, commission and service this equipment. During servicing work, it is essential to apply all recommendations and instructions given in service leaflets, on labels or in the instructions delivered with the equipment, and to comply with any other relevant instructions. Definition of the pictograms used General installation recommendations IMPORTANT: The controllers must have an isolating device upstream (for example a double-pole circuit breaker). If necessary, an easily operated emergency stop device (such as a punchbutton switch) must cut off the power to all equipment. These safety devices shall be sized and installed in accordance with IEC Recommendation 364, corresponding to Europe HD 384, France NFC and UK IEE Wiring Regulations. These devices are not supplied by Carrier. In general terms the following rules must be applied: - Units must be provided with overvoltage protection upstream (not supplied by Carrier) Unit without electric heater Standard unit size 1 with electric heater Upstream overvoltage protection T2A T10A Standard unit size 2 with electric heater T16A Electrical Danger Caution hand hazard General Danger Comply with all the safety rules and regulations currently in force. Wear eye protectors and work gloves. Take care when moving or positioning equipment Precautions against electrocution Only electricians who are qualified to the level recommended by the IEC (International Electrotechnical Commission) in its standard IEC 364, corresponding to Europe HD 384, France NFC and UK IEE Wiring Regulations, may have access to electrical components. In particular it is obligatory to disconnect all electrical power supplies to the unit and its accessories before carrying out any work. Disconnect the main power supply with an isolating device (not supplied by Carrier). IMPORTANT: The components, which make up the different control loops described in this manual include electronic items. As such, they may generate or be harmed by electromagnetic interference unless they are installed and used in accordance with these instructions. The components making up these control systems conform to the requirements of electromagnetic compatibility in residential and industrial areas. They also comply with the low-voltage directive. - Units must be protected by a differential type earth leakage current device (not supplied by Carrier) - The power disconnexion device must be clearly labelled to identify which items of equipment are connected to it. - The wiring of the components which make up the different control systems and the communication buses must be carried out in accordance with the latest rules and regulations by professional installers. - The power supply cable must be doubly insulated and fixed using an appropriate cable clamp or the cable clamp supplied with the MAESTRO controller. The cable must be clamped on the outer insulation. - The control loop components must be installed in an environment, which conforms to their index of protection (IP). The maximum level of pollution is normally pollutant (level 2) and installation category II. - The low-voltage wiring (communication bus) must be kept physically separate from the power wiring. - In order to avoid interference with the communication links: Keep low-voltage wiring away from power cables and avoid using the same cable run (a maximum of 300 mm in common with the 230 VAC, 30 A cable) Do not pass low-voltage wires through loops in the power cables Do not connect heavy inductive loads to the same electrical supply (circuit breaker) used by the controllers, power modules or speed controllers. Use the screened cable type recommended by Carrier and make sure all cables are connected to the controllers and power modules Conformity This equipment has been declared to be in conformity with the main requirements of the directive by virtue of using the following standards: - Electromagnetic compatibility: 89/336/EEC - Low-voltage directive: 73/23/EEC 14

15 4 - INSTALLING THE AQUALIA Installing the unit in the false ceiling Before beginning the installation process it is advisable to become familiar with the overall installation drawing. A mounting template, available your local Carrier representative, will assist in planning the installation. Co-ordinate the installation of the Aqualia units and the 35BD/35SR Moduboots or other types of diffusers with the supply and return air ducts and the fitting of the false ceiling Installation precautions During the installation process, remove all debris and construction material from the ducts to prevent any damage to the unit Installation procedure a) Position the Aqualia on the floor close to where it is to be installed in the ceiling or floor void. WARNING: When moving a unit do not use the water pipe connections, condensate drain pan, valves, flexible pipes or electrical cables as handles. Lift the unit and align it on the threaded hangers. Screw the nuts on loosely to support the unit, but do not tighten. At this point do not tighten the nuts fully and do not clamp the unit up to the ceiling slab. The nuts will be finally adjusted after the pipework or flexible connections have been made and the unit has been levelled. d) Levelling the unit Adjust the unit so that the condensate drain pan is about 5 mm below the opposite side of the unit. To check that the slope is adequate connect a 2 m length of 16 mm transparent tubing to the drain stub. Empty some water into the drain pan until the water level in the pipe is at the bottom of the auxiliary drain pan, point B. Floor void installation for units sizes 5.1 or 5.2 Remove the unit packing. The adjustable rubber mounting feet are factory-installed. 31 to 43 The water level in the opposite end of the pipe, position A, should be about 5 mm below the bottom of the drain pan. Ceiling void installation: A hydraulic lift and a folding ladder will make the task easier. e) Condensate drain pipe b) Check that the clearances around the unit are sufficient to allow for easy maintenance. c) Offer the template up to the ceiling and mark the position of the threaded hangers. The method of fixing the threaded hangers, not supplied by Carrier, depends upon the ceiling type. The maximum diameter of the hangers is 8 mm. Use 16 mm internal diameter clear plastic cold water pipe arranged to provide a uniform fall of 2 cm/m over the horizontal pipe run. Instal a 50 mm (minimum) siphon to prevent waste water gases and odours from being drawn into the ceiling void. The condensate drain pipe is secured to the drain pan by a collar (not supplied by Carrier). 15

16 2% slope Do not forget to fit a sealing washer (not supplied by Carrier) between the flexible pipe connector and the isolating valve. i) When all units are installed, open the isolating valves on the manifolds, bleed and then pressurise the circuits. To bleed the coils slightly undo the bleed screws. j) Make the electrical connections. Do not switch on the power until all power and earth connections have been made. The installation can now be started Aqualia unit removal procedure 5 cm siphon When several units are connected to a common condensate collector, use the piping arrangement shown in the following diagram. f) Instal the diffusers as shown on the false ceiling layout drawing. Connect the supply and return air ducts to the corresponding spigot connections on diffuser and Aqualia plenums. When the unit and the false ceiling have been installed, and before startup, remove the protective film from the diffuser. Aqualia units are connected to the diffusers by ducts. The pressure drops in the ducts must be compatible with the capacity of the unit. The inner surfaces of the duct must be as smooth as possible. Avoid sharp bends. Check that there are no air leaks or kinks in the ducts. Ensure that there is no dirt or construction material inside the ducts that could be harmful to the mechanical components of the system such as the fan wheel and the diffuser damper actuators. Check the noise level requirements and if necessary, add sound attenuators. g) For Aqualia units with the fresh air inlet option, connect the fresh air supply duct. h) When installation is complete - i.e. the Aqualia is installed in the false ceiling or floor void, the air ducts are connected, the water manifolds are in position with isolating valves fitted to the connection stubs, and the electrical installation is ready - connect the flexible water pipes (refer to Flexible water pipes ). Each flexible pipe has a 1/2 or 3/4 BSP union nut, following the unit size WARNING: Disconnect the power supply before carrying out any work on an Aqualia unit. a) Switch off the power supply at the isolator provided for the purpose during installation (isolator not supplied by Carrier). b) Disconnect the power supply cables. Maestro Zone and Excel 10 controller Regarding the Excel 10 controller, remove the ABS protective cover secured by two hexagon head screws (8 mm AF). Disconnect the power supply cable and the earth wire fitted with a flat connector. Disconnect the quick connect coupler from the Zone User Interface for the Maestro controller, from the wallmounted thermostat for the Excel 10 controller. Where appropriate disconnect the quick connect cable for the BMS bus. Disconnect the quick connect coupler for the window contact. Carrier electronic wall-mounted thermostat Remove the ABS protective cover secured by two hexagon head screws (8 mm AF). Disconnect the power supply quick connect coupler and withdraw the earth wire complete with a flat connector. c) Close the isolating valves on the manifolds. d) Disconnect the flexible water pipes by unscrewing the union nuts. WARNING: Since the flexible water pipes do not have valves, a receiver must be provided to allow the coil to be drained. e) Disconnect the supply air and return air ducts and, if fitted, the fresh air duct. f) Disconnect the flexible condensate drain pipe. Drain the siphon into a suitable vessel. g) Support the unit and release it gently by unscrewing the four nuts on the screwed hangers. Lower the unit carefully. 16

17 2% slope 2% slope 5 cm siphon 17

18 5 - FRESH AIR Fresh air flow controller The Aqualia can be fitted with a constant fresh air flow controller allowing the introduction of fresh air and the air change rate to be controlled. It is essential that the selection of the regulator takes into account the intended usage of the room. The following range of fresh air controllers is available: Option a: 8.3 l/s or 30 m 3 /h (-10%; + 20%) (size 1) Option b: 16.6 l/s or 60 m 3 /h (-10%; + 20%) (sizes 1 and 2) Option c: 69.4 l/s or 250 m 3 /h (-10%; + 20%) (size 2) The fresh air supply is located upstream of the water coil. Options a and b: the 125 mm spigot housing the fresh air flow controller is made of ABS plastic. Two types of plastic spigot and one type of metallic spigot may be fitted to the Aqualia, depending on the capacity of the fresh air controller chosen. One plastic spigot can accept only the 8.3 l/s (30 m 3 /h) controller. The other one can accept only the field modifiable 16.6 l/s (60 m 3 /h) controller. This means there is no possibility of mixing up the two types of controller during installation or servicing. IMPORTANT: If the Aqualia is fitted with a return air temperature sensor, the constant fresh air flow rate must not exceed 50% of the supply air flow delivered by the unit at minimum speed. The /s (60 m 3 /h) fresh air controller may be modified on site by relocating or removing two plastic restrictors in order to increase the maximum constant fresh air flow capacity to /s (160 m 3 /h). A label on the 42EL shows how to adjust the two plastic restrictors. To operate correctly, the 8.3 l/s (30 m 3 /h) constant fresh air flow controller requires a differential pressure in the range 50 Pa to 200 Pa. The 16.6 l/s (60 m 3 /h) constant fresh air controller requires a differential pressure in the range 70 to 200 Pa Fresh air duct accessory Flexible fresh air duct, diameter 125 mm, maximum length 0.5 m, supplied with fixing collars at each end (fresh air duct fire rating: M1, French standard). Modification procedure Disconnect the fresh air duct from the spigot on the Aqualia. Remove or reposition the two plastic restrictors, following the fresh air flow controller. Reconnect the fresh air duct to the spigot. Option c: the 159 mm spigot housing the fresh-air flow controller is made of metal. 18

19 6 - FAN MOTOR ASSEMBLY Description Aqualia size 1 Aqualia size 1 has multi-speed fan-motor assemblies, with double-inlet forward-curved fans for unit size 1.1 or 5.1 (735 m 3 /h or 204 l/s with 50 Pa available pressure) or tripleinlet forward-curved fans for unit size 1.2 or 5.2 (915 m 3 /h or 254 l/s with 50 Pa available pressure). Motor supply voltage is single-phase 230 V ± 10%, 50 Hz An auto transformer provides the fan motor with 6 possible speeds, which allows the installer a large flexibility in setting the air flows. A selection of three of the six available speeds can be made taking into account the local electromechanical and electronic regulations in force. This adaptability is much appreciated by installers. Minimum speed: terminal 6 Maximum speed: terminal 1 As standard, 42EL units size 1 are prewired to the factory settings, for speeds 1, 3 and 5. For other fan motor speed wiring combinations refer to the unit codification Aqualia size 2 Aqualia size 2 has multi-speed fan-motor assemblies, with double-inlet forward-curved fans. Size 2.3: 1590 m 3 /h or 442 l/s with 65 Pa available pressure Size 2.4: 1895 m 3 /h or 526 l/s with 65 Pa available pressure The fan motor has four speeds, provided by a multi-winding electric motor. Three of four speeds must be selected to allow connection of the fan motor in accordance with the applicable electromechanical or electronic regulations (for fan coils). Minimum speed: terminal 4 Maximum speed: terminal 1 As standard, 42EL units size 2 are prewired to the factory settings, for speeds 1, 2 and 3. For other fan motor speed wiring combinations refer to the unit codification Fan assembly removal procedure WARNING: Disconnect the power supply to the Aqualia before carrying out any work on the unit. Identify and note the fan speeds wired to the autotransformer terminal block or to the multi-winding electric motor. If the fan develops a fault the whole assembly must be removed and replaced. a) Remove the filter b) Unscrew the fan access panel. Remove the panel. c) Disconnect the power supply cable, fitted with a quick connector, to the fan motor assembly. d) The fan assembly is held in place by one torx screw (T20) and several lugs. Remove this screw and slide the assembly free of the lugs. e) Remove the fan motor assembly. Be careful not to touch the fan blades during the removal process to avoid unbalancing the fans. In order to simplify maintenance, the fan motor assembly is fixed by 6 or 8 lugs (depending on the unit size) and a single screw. Electrical connections are made using quick connectors, preventing wiring errors and considerably reducing service and maintenance time. f) For units with the electric heater option, disconnect the power supply cable to the heater. Withdraw the cable through the cable gland. g) Unscrew the electric heater. h) Replacement of the fan motor assembly is by the reversal of the above procedure. 19

20 WARNING: The electrical connections to the fan motor must be made in accordance with the labels on the connector block. Red wire: low speed Grey wire: medium speed Black wire: high speed Earth connection: connect the yellow/green wire Capacitor replacement procedure a) Disconnect the power supply to the Aqualia before carrying any work on the unit. b) Remove the filter c) Remove the fan motor assembly access panel d) Unscrew the HM8 capacitor fixing screw. This is located on the fan motor assembly chassis e) Disconnect the capacitor by withdrawing the flat spade connectors from the back of the capacitor f) Replacement of the capacitor assembly is by the reversal of the above procedure. 20

21 7 - ELECTRIC HEATER 7.1- Description Electric heater-resistance wire type Supply voltage: 230 V (± 10%) - 1 ph - 50 Hz Capacity per coil: - Size 1: 500 W (+ 5%; - 10%) - Size 2: 1000 W (+ 5%; - 10%) Number of coils per unit: - Size 1.1 or 5.1: 2 - Size 1.2 or 5.2: 3 - Size 2.3 or 2.4: 2 Maximum unit heating capacity size 1.1 or 5.1: 1000 W Maximum unit heating capacity size 1.2 or 5.1: 1500 W Maximum unit heating capacity size 2.3 or 2.4: 2000 W Each heater is protected with double temperature protection: a) Safety thermostat - resettable type. Trip temperature 75 C. When the trip temperature is reached a thermostat heater is energised that prevents auto resetting of the thermostat as long as the power is switched on and there is no air flow. Resetting of the thermostat is achieved by switching off the power supply to the heater. The safety thermostat protects the unit against overheating due to the operation of the electric heater with no or low air flow. b) Thermofuse link - fusing temperature 150 C. Minimum air flow must be maintained to avoid damaging the electric heaters: Unit size 1.1 or 5.1: minimum air flow 64 l/s (230 m 3 /h) Unit size 1.2 or 5.2: minimum air flow 122 l/s (440 m 3 /h) Unit size 2.3 or 2.4: minimum air flow 97 l/s (350 m 3 /h) WARNING: Disconnect the power supply before carrying out any work on the unit. Screw Screw Electric heater replacement procedure WARNING: Disconnect the power supply before carrying out any work on the unit If the electric heater develops a fault, it must be replaced; this requires the removal of the fan motor assembly. CAUTION: Do not touch the live metal heater elements when the electric heater is connected to the power supply. a) Remove the filter b) Remove the fan motor assembly access panel c) Identify and note the fan speeds wired to the autotransformer terminal block or to the multi-winding electric motor. Disconnect the power supply cable, fitted with a quick connector, to the fan motor assembly d) The fan assembly is held in place by one torx screw (T20) and several lugs. Remove this screw and slide the assembly free of the lugs e) Remove the fan motor assembly Be careful not to touch the fan blades during the removal process to avoid unbalancing the fans. g) Unscrew the electric heater h) Replacement of the fan motor assembly is by the reversal of the above procedure. 21

22 8 - DUCT CONNECTION SPIGOTS These are manufactured from high density plastic with a VO fire rating, more or less equivalent to class M1 (French standard). The ducts should be fixed to these spigots using circular collars or adhesive. Screws and rivets should not be used. WARNING: In order to guarantee good air tightness, the duct should overlap the whole of the spigot. - Make sure that the maximum supply air temperature does not exceed 60 C. - Do not lift or support the unit using the spigots, place loads on the spigots or damage the spigots during installation or operation. 9 - WATER COIL Description The water coil has aluminium fins mechanically bonded by expansion onto copper tubes. Water inlet and outlet connections are 1/2 or 3/4 BSP union nuts (female) for the size 2 cooling coil. Air purge valves are standard. The coil is integral with the drain pan and coil access door to ease of removal during service and maintenance. Coils available are: 2 rows for two-pipe changeover systems or for use with electric heater. 4-row systems Coil removal procedure WARNING: Disconnect the power supply to the Aqualia before carrying out any work on the unit. a) Close the isolating valves on the manifolds. b) Unscrew the union nuts to disconnect the flexible water pipes. c) Remove the valve actuators taking care to identify the cooling and heating valves. d) Disconnect the flexible condensate drain pipe which is held in place by a collar (the collar is not supplied by Carrier). e) Remove the 4 hexagon head screws (8 mm AF) and slide out the coil and drain pan assembly. f) Remove the two-way or three-way water flow control valve bodies. Depending how the Aqualia is configured, the threeway valve coupling may be fitted with a heating/cooling changeover switch, if so do not remove it. g) Replacement is by the reversal of the procedure described above. Ensure that all gaskets are fitted and that the inlet and outlet connections to the coil are made correctly using an appropriate sealing compound applied to the valve body. WARNING: Bleed all air from the coil during refilling. 22

23 9.3 - Coil inlet/outlet positions Aqualia size 1 23

24 Aqualia size 2 3-way cooling valve 2-way cooling valve Cooling water outlet Cooling water outlet Cooling water inlet Cooling water inlet 3-way heating valve 2-way heating valve Heating water outlet Heating water outlet Heating water inlet Heating water inlet 24

25 10 - WATER FLOW CONTROL VALVES Top of the range Aqualia units will be fitted with a Carrier Maestro Zone Controller, an electronic thermostat or Excel 10 communicating controller to control the water flow control valve or valves. These valves are two-way or three-way type, with a body designed to withstand a 16 bar operating pressure Electrothermal actuator (On/Off) Actuator electrical connections Maestro Controls For further information, please refer to the selection manual and the Carrier Maestro Zone Controller installation, operation and maintenance instructions Carrier electronic thermostat This on/off type actuator is used with a Carrier electronic thermostat (wall-mounted) and the Maestro Zone Controller. The electrothermal actuator is delivered in the normally closed position regardless of the two-way or three-way valve body used (way A-AB closed in the case of a three-way valve). Therefore to enable the installation to be filled with water, the water circuits to be equalised and the units to be purged, the valves will have to be opened by sending a command either from the wall thermostats or from the BMS. CABLE LENGTH 1 m Actuator replacement procedure The actuators on both the chilled water and the hot water valves may be replaced if either develops a fault. a) Disconnect the power supply to the unit before carrying out any work on a unit. b) Disconnect the actuator power supply cable. 230 V On/Off type actuator used with a Maestro Zone Controller Disconnect the actuator power supply cable fitted with a quick connector. 230 V On/Off actuator used with an electronic thermostat Remove the plastic protection cap held in place with two hexagon head (8 mm AF) screws. Disconnect the actuator power supply cable connected to the quick connector. This can be done by pressing down the spring tongue using a screwdriver and pulling out the wire from the appropriate terminal. 24 V On/Off actuator used with Carrier Excel 10 controller Remove the plastic protection cap held in place with two hexagon head (8 mm AF) screws. Disconnect the actuator power supply cable fitted with a quick connector. c) Uncouple the faulty actuator. Refitting is by the reversal of the procedure described above. CARRIER ELECTRONIC THERMOSTAT CARRIER MAESTRO CONTROLLER Carrier Excel 10 controls WARNING: Ensure that the actuator is firmly screwed to the valve body (maximum torque 15 N/m). 25

26 Valve body replacement procedure a) Disconnect the power supply before carrying out any work on a unit. b) Close the isolating valves on the manifolds. c) Unscrew the union nuts to disconnect the flexible water pipes. d) Remove the valve actuators taking care to identify the cooling and heating valves. e) Disconnect the flexible condensate drain pipe which is held in place by a collar (the collar is not supplied by Carrier). f) Remove the 4 hexagon head screws (8 mm AF) and slide out the coil and drain pan assembly. g) Remove the two-way or three-way water flow control valve bodies. Depending how the Aqualia is configured, the threeway valve coupling may be fitted with a heating/cooling changeover switch, if so do not remove it. h) Fit the new valve body to the coil. Ensure that the connections to the coil are made correctly. i) Refit the coil and condensate assembly. j) Reconnect the flexible condensate drain pipe which is held in place by a collar (the collar is not supplied by Carrier). k) Refit the valve actuators taking care to ensure that they are correctly fixed to the valve body. l) Reconnect the flexible water pipes by tightening the union nuts. Retighten all the water connections and ensure that all seals are correctly installed (maximum torque 15 N/m). m) Open the isolating valves on the manifolds and purge all air from the system. n) Check that there are no leaks and reconnect the power to the Aqualia. WARNING: When replacing a valve always ensure that the direction of flow through the valve is as shown by the arrow on the valve body. If the direction of flow is wrong, the valve body will deteriorate rapidly. WATER OUTLET WATER OUTLET WATER INLET WATER INLET Two-way valve (Aqualia size 1) Three-way valve (Aqualia size 1) 3-way cooling valve 2-way cooling valve Cooling water outlet Cooling water outlet Cooling water inlet Cooling water inlet 3-way heating valve 2-way heating valve Heating water outlet Heating water outlet Heating water inlet Heating water inlet Aqualia size 2 26

27 2-way valve body 3-way valve body 27

28 Technical specification for the heating/cooling changeover switch The heating/cooling changeover switch is designed to be installed straight onto the couplings of the 3-port valves on the Carrier electronic thermostat. It detects temperature changes in the fluid circulating in the primary water circuit. A changeover switch operates according to the water temperature in accordance with the diagram below. When a heating/cooling changeover switch is connected between the room thermostat and the water flow control valve, the changeover between heating and cooling modes takes place automatically in accordance with the following diagram. 28

29 11 - FLEXIBLE WATER PIPES Size 1 coil Size 2 coil Materials Pipes: MEPD-based elastomer (modified ethylene-propylenediene) Braid: 304L stainless steel Insulation: cellular foam rubber with M1 (French standard) fire rating (9 mm thick, chilled water pipes only). Maximum hot water temperature 90 C Maximum operating pressure: 16 bar Test pressure: 24 bar Connections: 1/2 or 3/4 BSP union nuts (female) Length: 1 m for flexible pipes connected to the water coil and 930 mm for pipes connected to water valves. Characteristics Minimum bending radius: non-insulated 35 mm, insulated 75 mm The flexible water pipes are designed for treated or untreated water (maximum 40% ethylene glycol or propylene glycol) Aqualia size Two-way valve 29

30 Aqualia size 1, continued Three-way valve Aqualia size 2 3-way cooling valve 2-way cooling valve Cooling water outlet Cooling water outlet Cooling water inlet Cooling water inlet 3-way heating valve 2-way heating valve Heating water outlet Heating water outlet Heating water inlet Heating water inlet 30

31 12 - AIR FILTER AND ACCESS Description The Carrier Aqualia is fitted with a 65% gravimetric filter (G2). Medium fire rating M1 (French standard), metal wire frame Different filter access options are available to suit different site requirements: Aqualia size 1 Unit with ducted return air: - Filter removal is from above for floor void installations. - Filter removal is from below for ceiling void installations Air filter replacement Air filters should be changed regularly. Filter life depends on the rate at which the filter becomes clogged, which depends upon the cleanliness of the working environment. If clogged filters are not changed they can increase the air pressure drop, trapped dust particles may be given off and entrained in the air supply, and the general performance of the Aqualia may be degraded (as the air flow reduces). When installing an Aqualia in a ceiling void, check that no T- bars will obstruct filter access and removal. Unit with open (non ducted) return air inlet: - Filter removal is from the rear of the unit Aqualia size 2 Unit with ducted or non ducted return air: filter removable from the side. This filter is hinged at the centre to facilitate removal. 31

32 13 - CONTROLS numeric controller At the top of the range, each Aqualia is fitted with a Maestro programmable numeric controller to control each of the units installed in each air conditioned zone Carrier electronic thermostat Description The Aqualia may be provided with a 3-speed Carrier electronic wall thermostat. The main functions of the controller are: Controlling room temperature Raising, lowering and adjusting the angle of the blinds (optional) Switching the lights on and off (optional) Selecting occupied or unoccupied mode through a Zone User Interface SUPPLY AIR MODUBOOT With this option each Aqualia can be equipped with an on/off type water control valve and flexible water pipes to simplify the connection of units to the primary hot and/or chilled water. This electronic thermostat option also includes a male-female quick connect terminal block for connecting the different wires from the fan motor, valve actuators, the electric heater and the heating/cooling changeover switch for Aqualia units equipped with a single heating or cooling coil. The male-female quick connect terminal block is DIN rail mounted and protected by a recyclable plastic cover. The DIN rail is large enough to accept a two poledisconnecting switch with integral fuse holder (not supplied by Carrier). The quick connect terminal block and flexible water pipes will be appreciated during maintenance and servicing operations, since they enable significant time savings to be made. The replacing or moving of a unit is greatly simplified Location of the wall-mounted thermostat The thermostat is for indoor wall mounting only Mounting height: 1.5 m above floor level Locate the thermostat away from heat sources, avoid air convection from cables and avoid drafts (doors, windows, etc). For further information, please refer to the selection manual and the Carrier Maestro Zone Controller installation manual operation and maintenance instructions. 32

33 33

34 Carrier Excel 10 controller Output Options Introduction At the top of the range, 42EL Aqualia units can be supplied with Carrier Excel 10 numeric programmable controller to control the units located in each zone. The Carrier Excel 10 numeric controller can operate as standalone or be networked to a standard Echelon LonWorks communications bus. This controller can control a hot water coil and/or an electric heater (directly without a relay) and a chilled water cooling coil. The power supply to the Carrier Excel 10 numeric controller is 230 VAC (±10%) avoiding the need for a transformer. Each Aqualia can be supplied with on/off water flow control valves and flexible water pipes to simplify the connections to the hot and chilled water supplies. Heating Cooling Fan Electric heater Floating, electrothermal, PWM, On/Off, multi-stage electric heater Floating, electrothermal, PWM, On/Off On/Off, 2 or 3 speed On/Off Table 2 - Control outputs By default the valve actuators are of the electrothermal type. If proportional actuators (3 way, 24 VAC, floating) are required, please contact your local Carrier representative Control sequence The heating and cooling sequences can be selected to be active or inactive giving a total of 8 different control sequences (each with or without fan control): - heating only - cooling only - heating/cooling changeover - sequential heating and cooling - the above options with electric reheat Features LonMark HVAC profile N 8020 Stand-alone operation or with a high speed 78 kbits/s Echelon bus (E-bus) network. Uses Echelon LonTalk protocol Direct connections to the electrothermal valve actuators Direct connections to the fan speed switch (230 VAC) Direct connections to the electric heater (230 VAC) Factory configured default settings Interlocks and timers to protect equipment Controller supply 230 VAC (±10%) Description Excel 10 controllers are LonMark compliant fan coil controllers from the Excel 10 product range. They are used for controlling 2 or 4 -pipe fan coil units, with optional electric heater, and can control 3 fan speeds. The controllers are supplied with factory configured default settings and are fully operational once installed. The controller can be configured with job-specific settings using standard Echelon configuration tools. A variety of wall modules may be interfaced with the controller to provide some or all of the following features: set point adjustment, fan speed adjustment and occupancy override button. All the wall modules include a space temperature sensor. A remote return air sensor can also be used. Control sequence Operating modes The controller provides the following operating modes: Occupied mode This is the normal operating mode for a room or occupied zone. The controller can be put into this mode from a network command, or by the mode override button located on the wall module. In occupied mode the fan speed is controlled by the fan speed switch setting on the thermostat or the control algorithm speed setting if the fan speed switch is set to auto. The fan can be configured to remain on or turn off in the neutral zone. Standby mode The standby mode saves energy by reducing the demand for heating or cooling when the space is temporarily unoccupied. In this mode the fan is switched off in the neutral zone. 34

35 Night/Unoccupied mode This mode is used when the space is unoccupied for longer periods, for example at night, during the weekend or holidays. Window open If the controller is configured for window open detection, the controller will automatically disable the heating and cooling control until the window is shut. Frost protection remains active. CARRIER EXCEL 10 CONTROLLER WINDOW CONTACT WALL MOUNTED TEMPERATURE SENSOR Frost protection If the temperature drops below 8 C, the controller enables the heating mode as protection against freezing. Smoke control The fan can be turned on or off by network command for smoke control. E-BUS E-BUS Heating/Cooling changeover Typical application The controller can be used to control an Aqualia 2-pipe system unit using a changeover input Wall mounted controller wiring/layout diagram This wire is not provided for electrothermal type actuators. 35

36 CUT-OUT FOR EUROPEAN APPLICATION STANDARD FIXING 2 x 4 mm Ø SCREWS Specification Input/Outputs Inputs Function Characteristic On/Off Window/occupied/ Closed if 400 Ω Changeover/ Open if 10 kω air flow Analogue/ Fan speed/ Resistor On/Off 1 override Network Analogue Temperature sensor 20 kω NTC Analogue 1 Setpoint adjustment 10 kω Outputs Function Characteristic On/Off 1 Override LED 0/5 VAC Triac (2 pairs) 2 Heating and cooling 24 VAC, 250 ma max continuous, 650 ma max surge ( 30 s) Relay Fan command 20 to 253 VAC, 3 A max Power Electric heater 20 to 300 VAC relay (resistive load) 10 A max Table 3 - Inputs/Outputs characteristics Legend: 1 Wall module connection only 2 See table 2 for the types of output Supply 230 VAC ±10%, 50 Hz Power consumption 30 VA max Hardware design Processor: Neuron 3150 running at 5 MHz, with 2 Ko RAM and 0.5 Ko of EEPROM on chip. External memory: EPROM, 62 Ko x 8. Transformer (circuit board mounted): 16 VA with thermal fuse. Temperature sensing range 0 to 40 C Environmental Ratings Operating temperature: 0 to 50 C Shipping/storage temperature: - 40 to 70 C Relative humidity: 5% to 95% without condensation Dimensions 101 x 257 x 60 mm 36

37 Communication The Excel 10 controller uses a transformer coupled E-bus port to communicate at 78 kbits/s, the controllers use free topology transceivers (FTT). This interface assures galvanic insulation and strongly attenuates common mode transients. The E-bus is insensitive to polarity, which eliminates connection errors during installation. The recommended wire size to be used for the E-bus is level IV 22 AWG (0.34 mm 2 ) non-shielded, twisted pair, solid core wire (Belden reference H or 9D220150). An FTT network can be in bus, star or loop or any combination of these topologies. Mounting The Excel 10 controller is DIN rail mounted Conformity CE EN EN Meets the requirements of FCC chap 15, class B Accessory items Excel 10 wall-mounted thermostat Excel 10 terminal module FTT/LPT B Return air sensor. LonMark operating protocol Excel 10 controllers support the LonMark N 8020 functional profile version 2.0 (see diagram on page 38). 37

38 LonMark operating protocol The variables not used are shown in grey 38

39 14 - ACCESSORIES Condensate drain pump Introduction Aqualia units can be fitted with condensate drain pumps, preferably before but if necessary after the unit has been installed in the false floor or ceiling Procedure for installation a) Check the contents of the parts kit with those shown in Fig. 1. b) Installation of the detector block support bracket. Instal the aluminium detector block bracket on the condensate drain pan as shown in Fig. 2-A. The detector support bracket must be installed horizontally as shown in Fig. 2 (maximum angle 15 ). c) Installation of the pump support bracket Bend the support bracket into a right angle to suit the chosen location of the pump. d) Installation of the detector block Connect the detector to the condensate drain using the rubber tube supplied (Fig. 2-B). Connect the 6 mm bore flexible tube to the outlet stub on the detector. Connect the short 6 mm bore flexible tube to the detector vent. Attach the detector block support to the aluminium bracket with the double-sided adhesive pad supplied (Fig. 2-C), and then clip the detector block to the plastic bracket. The detector must be installed horizontally. The rubber tube must be secured to the outlet stub on the condensate drain pan by a collar (not supplied by Carrier). e) Installation of the pump The pump can be installed anywhere and can if necessary be located up to 2.5 m above the unit. Using the 2 screws supplied, fix the pump to the metal support bracket previously fitted to the Aqualia. A clearance space must be left around the pump in order to provide for cooling during long operating periods. Do not insulate the pump block. The pump unit must not be immersed or placed outside the building or in damp place. f) Connection between the detector and the pump Connect the RJ 11 (telephone type) connector to the pump. Connect the 6 mm bore flexible tube to the ribbed outlet on the pump as shown in Fig. 4. Respect the direction of water flow as shown by the arrow on the pump body. g) Connection of the pump Connect the 6 mm bore flexible tube between the ribbed outlet on the pump and the condensate drain. h) Electrical connection Connect to the power supply of the Aqualia or to the mains supply using: an interconnexion cable (HO VVF) with 0.75 mm 2 cores an electrical protection and isolating device (not supplied), conforming to IEC 345 standard, on the line (phase) and neutral a 630 ma fuse on the line (phase). i) Connection of the alarm The condensate level detector consists of a float, which can detect three different condensate levels: Pump on level: 17 mm ±2 mm of condensate. When this level is exceeded the pump will start automatically. Pump off level: 11 mm ±2 mm of condensate. When the pump has been operating, it will switch off when the level falls below this threshold. Alarm level: 21 mm ±2 mm of condensate. When this level is reached a volt free contact operates which can be connected to an external alarm. If the alarm threshold is reached or exceeded, the condensate drain pump keeps running. The alarm condition applies if the condensate level is above the alarm threshold. The alarm condition no longer applies when the level is below the alarm threshold. The device includes a volt-free changeover switch with a capacity of 8 A/250 V (resistive load) The alarm contact on the drain pump is a Normally Open or Normally Closed type, and therefore: If the condensate level is below the alarm threshold (no alarm condition), the contact is open if the wiring is NO or closed if the wiring is NC. If the condensate level is above the alarm threshold (alarm condition), the contact is closed if the wiring is NO or open if the wiring is NC. If proportional valves are installed in the air conditioning units, an additional safety device must be provided that can interrupt the chilled water production, in the event of power failure. j) Function test Pour a small quantity of water into the drain pan. Check that the pump starts, draws water away and stops when the water level falls. Add more water until the alarm operates. 39

40 k) Service Frequency: at the beginning of the season. Clean the detection unit and the filter. Disconnect the power supply before carrying out any work on the Aqualia installation including the pump. Remove the cover, the filter and the float, clean the detection unit and the float using a solution of water containing 5% bleach. Replace the float in its initial position (magnet faced upwards), refit the filter and reinstall the cover. Carry out an operating test on the pump and the alarm. When the air conditioner is installed in areas likely to cause or favour extensive dirtying of the condensate water, increase the maintenance frequency. m) Safety An alarm contact will prevent overflow (cutting off the refrigeration) An auto-resetting thermal cut-out: tripping temperature 70 C Earth the pump Safety transformer as per standard EN Housing made of ABS. l) Condensate drain pump features Maximum flow: 10 1/h Maximum discharge: 6 m head of water. Maximum suction: 2.5 m head of water. Power supply: 230 V ±10%/50 Hz/1 Ph. Power consumption: 18 VA. PUMP BLOCK SUPPORT BRACKET PUMP BLOCK FIXING SCREWS 6 mm Ø FLEXIBLE TUBES PUMP BLOCK SUPPORT BRACKET FIXING SCREWS ALUMINIUM DETECTOR BLOCK BRACKET PUMP BLOCK DOUBLE SIDED ADHESIVE TAPE DETECTOR BLOCK RUBBER TUBE PLASTIC DETECTOR BLOCK SUPPORT LABEL SHOWING THE ATTACHMENT PLAN FOR FIXING THE PUMP BLOCK SUPPORT BRACKET Fig. 1 40