42GM. Individual Air Treatment Module for Variable-Flow Systems. Installation, operation and maintenance instructions

42GM Individual Air Treatment Module for Variable-Flow Systems Installation, operation and maintenance instructions

CONTENTS 1 - INTRODUCTION...3 2 - FEATURES...5 2.1 - Physical and electrical data...5 2.2 - Operating limits...6 2.3 - Dimensional drawings - 42GM on front and rear supports...7 2.4 - Packaging...8 2.5 - Receiving a shipment - installation methods...8 3 - SAFETY CONSIDERATIONS...9 3.1 - General...9 3.2 - Precautions against electrocution...9 3.3 - General installation recommendations...9 3.4 - Conformity...9 4 - INSTALLATION... 10 4.1 - Installation of the front fastening supports, the rear suspension rail and the rectangular duct outlets... 10 4.2-42GM installation...11 4.3 - Removing a 42GM unit... 13 5 - FRESH AIR... 14 5.1 - Constant fresh air controller (optional)... 14 5.2 - Variable fresh air controller (option)...14 6 - FAN MOTOR ASSEMBLY... 15 6.1 - Description... 15 6.2 - Fan motor removal... 15 7 - WATER COIL... 16 7.1 - Description... 16 7.2 - Removing the coil... 16 7.3 - Water inlet/outlet connections...17 8 - FLEXIBLE WATER PIPES... 17 9 - VALVE MOTOR AND 2-WAY VALVE BODY... 18 9.1 - Motor of the on/off thermoelectric valve motor... 18 9.2 - Valve motor replacement procedure...18 9.3 - Replacing the valve body...18 10 - FILTER... 19 11 - ELECTRIC HEATER... 20 11.1 - General...20 11.2 - Description... 20 11.3 - Removing the electric heater...20 12 - PERFORMANCES... 21 12.1 - Electrical data... 21 12.2 - Air flow/available static pressure data... 22 13 - CONTROLLER... 23 13.1 - Carrier numeric controller... 23 13.2 - Carrier room thermostats... 23 The illustrations shown in this document are solely for information, and not contractually binding. The manufacturer reserves the right to make changes without previous notification. 2

1 - INTRODUCTION The 42GM Individual Air Treatment Module (ITM) is something more than a simple air conditioner which enables room air temperature to be controlled. It is a total, integrated comfort system in the building. The Carrier 42GM is a compact central station air handler to supply conditioned air at a rate of 125 l/s to rooms with floor areas of approximately 25 m 2. The main components of the unit are an air filter, a fresh air supply, equipped with an air flow controller (option), a chilled water cooling coil, a hot water heating coil or an electric resistance heater, a centrifugal fan. The unit is controlled by a Carrier numeric controller. The 42GM is connected, on site, through two flexible rectangular ducts (low thermal conductivity, low noise transmission supplied by others) to one or more high induction plenums fitted with Carrier linear diffusers in the false ceiling. Typically, these will be Carrier Moduboot 35BD/35SR units with each one serving an individual room or zone and providing both supply air and return air paths according to diffuser model. The 42GM has a Carrier numeric controller. Each room occupant then has his or her own Zone User Interface control module, on a wall (with a mounting base) or desk, with which to select the preferred comfort level: Room ambient temperature Select Occupied or Unoccupied mode at each 42GM to control energy usage Ventilation air (the rate of air replacement) Lighting on or off Blinds raised or lowered and their inclination In addition, connection to a central Building Management System allows units to be controlled individually to satisfy overriding criteria or to respond to local regulations. The 42GM is designed to be installed in false ceilings. Their high static pressure capability allows them to be used with long ducts. WARNING: Switch off the electrical power supply before doing any work on the unit. 3

42GM - Four main components The illustrations shown in this document are solely for information, and not contractually binding. Front fastening support Rear suspension rail 42GM Individual Air Treatment Module Duct outlets (connecting pieces) 4

2 - FEATURES 2.1 - Physical and electrical data 42GM ITM 2 pipes 4 pipes + electric heater Nominal air flow l/s (m 3 /h) 125 (450) 125 (450) Total cooling capacity* kw 3.33 2.87 Sensible heating capacity* kw 2.31 2.12 Heating capacity** kw - 1.5 Power supply 230 V- 1 ph - 50 Hz U % +/- 10 +/- 10 Operating weight (6-row coil) kg 30 30 Water coil 3/8 copper tubes, aluminium fins, test pressure 24 bar, operating pressure 16 bar Water coil volume l 1.42 1.22 + 0.2 PTC electric heater (PTC = positive temperature coefficient) Max. capacity at nominal air flow kw 1.88 - Current draw (± 10%) A 11 - Power input at zero flow W 100 - Safety thermostat with automatic reset - cut-out temperature (conforms with CE) C 70 - Fan Centrifugal fan, single wheel double inlet double inlet Nominal air flow l/s (m 3 /h) 125 (450) 125 (450) Static pressure at nominal air flow (without air purifier) Pa 210 210 Fan motor 230 V-1 ph-50 Hz, 2-pole open asynchronous, permanent capacitor, inherent overload protection, class B insulation, varnish class F, connected to a speed controller Protection index IP 44 44 Max. power input at 230 VAC W 185 185 Min. output from electronic speed controller (RMS) V 80 80 Nominal current A 0.85 0.85 Starting current A 3.64 3.64 Air filter Throwaway, 48 mm thick, efficiency F6 according to EN 779, EU6 according to EUROVENT 4/5), fire rating medium M1, metal frame Dimensions mm 265 x 255 265 x 255 Pressure drop, clean, at 125 l/s (450 m 3 /h) Pa 53 53 Air purifier (option) Number of UV-C lamps 1 1 Nominal current consumption A 0.09 0.09 Pressure drop at 125 l/s (450 m 3 /h) Pa 20 20 Fresh air connection External diameter mm 125 125 Minimum constant air flow ( -10 %, +20 %) l/s (m 3 /h) 8.3 (30) 8.3 (30) Minimum constant air flow ( -10 %, +20 %) l/s (m 3 /h) 44.4 (160) 44.4 (160) Min./max. variable air flow (optional motorised valve) l/s (m 3 /h) 0/55 (0/200) 0/55 (0/200) P (upstream/downstream) - controller at 8.3 l/s (30 m 3 /h) Pa 50/200 50/200 - controller at 44.4 l/s (160 m 3 /h) Pa 70/200 70/200 Min. available pressure in the upstream air duct (motorised valve) Pa 180 180 Water connections 42GM modules are designed and tested for 16 bar operating pressure. The total operating circuit of the 42GM is guaranteed for an operating pressure of 10 bar. Contact your local Carrier representative for advice when an application calls for an operating pressure of 10 bar. Notes: * Based upon water entering at 7 C, room air at 27 C dry bulb, 47% relative humidity, 5 K t and nominal air flow. Capacity takes account of the fan-motor assembly heat. ** Based upon water entering at 50 C, room air at 19 C, 10 K t and nominal air flow. Capacity takes account of the fan-motor assembly heat. 5

2.2 - Operating limits Cooling mode Supply air temperature 12 C when the unit is installed where the ambient temperature is 27 C dry bulb with 65% relative humidity. Heating mode Max. supply air temperature = 60 C. If an electric heater is used, the minimum unit operating flow rate is 16.6 l/s (60 m 3 /h). Operating environment: The 42GM has been designed for internal application in urban conditions having a non-corrosive, dust-free and non-marine environment. The concentrations of the following chemicals must not be exceeded in any event: SO 2 < 0.02 ppm H 2 S < 0.02 ppm NO, NO 2 < 1 ppm NH 3 < 6 ppm N 2 O < 0.25 ppm Recommended coil water quality At installation handover, and then periodically every year, it is advised to analyse the water for bacteria (detection of ferro-bacterias, H 2 S-producing and sulphate-reducing bacteria) and chemicals (in order to avoid problems due to corrosion and scaling). The water circuit must include all the necessary elements for the treatment of the water: filters, additives, intermediate exchangers, purges, drains, isolating valves, etc., according to the analysis results. The results must be in accordance with the values shown below: Total hardness in French degrees: 10 < TH < 15 Chloride [CL - ] < 10 mg/litre 2- Sulphate [SO 4 ] < 30 mg/litre Nitrate [NO 3- ] = 0 mg/litre Dissolved iron: < 0.5 mg/litre Dissolved oxygen: 4 < [O2] < 9 mg/litre Carbon dioxide [CO 2 ] < 30 mg/litre Resistivity: 2000 < Resistivity < 5000 Ω cm ph: 6.9 < ph < 8 6

2.3 - Dimensional drawings - 42GM on front and rear supports 2.3.1-42GM with front fastening support with constant fresh air volume, mm 300 225 40 Supply 25 85 180 Return Fresh air 315 32 85 88 404 315 240 150 Ø124 938 oblong 13x20 820 19 38 30 260 225 56 886 991 1081 2.3.2-42GM with front fastening support with variable fresh air volume, mm The illustrations shown in this document are solely for information, and not contractually binding. 300 225 Supply 40 25 85 180 Return Fresh air 32 85 404 315 180 247 240 150 Ø124 Minimum static pressure 180 Pa Carrier recommends the installation of a semi-rigid round duct of 180 mm (1.5 mm diameter) length 938 oblong 13x20 820 38 30 260 225 56 1398 886 991 1081 The illustrations shown in this document are solely for information, and not contractually binding. 7

2.4 - Packaging The 42GM units, the front fastening supports and the duct connection collars are shipped on wooden pallets and covered overall with protective plastic film wrapping, in quantities shown in the table. Units Pallet per Length Width Height Weight pallet (mm) (mm) (mm) (kg) 42GM size 1 12 1500 1000 1320 375 NOTE: If Export packaging is needed, please contact your local Carrier representative. A 2 m long rear suspension rail is supplied. This assembly allows suspension of six size 1 42GM units. The rails can be cut to the required length if necessary. The front fastening supports are supplied pre-assembled in a sub-assembly of five elements. Foam plates are glued to each support face; their function is to ensure the leak-tightness of the installed assembly (collars, front support, 42GM). They are generally supplied with the fresh air controllers installed (without motorized valve). NOTE: When the material is received, it is important to verify that these joint plates are not damaged. Also, please ensure that these joints are not damaged during installation of the supports. All screws required to assemble the collars on the front support are supplied loosely screwed into the collars. WARNING: When moving the 42GM units do not use water pipes, condensate drain pipes, flexible pipes, fresh air connections to lift them, nor the supply or return air openings which are protected by an adhesive plastic film (this film should be removed at the last moment when the module is attached to its support). If these instructions are not followed, serious damage could be caused (e.g. to the electric heater). Do not install a unit where flammable gases or products of an acidic or alkaline character may be present. The copper/ aluminium coil or plastic components inside the unit could suffer irreparable corrosion damage in their presence. The presence of electrical components creates hazards to those installing and servicing these units. Only properly qualified electricians are authorized to install, service and repair these units. Some routine maintenance such as filter replacement may be entrusted to non-skilled personnel. Before carrying out any work, all personnel must familiarize themselves with the contents of this manual and all informative tags and labels attached to the units. It is essential to adhere to all applicable safety regulations. Wear eye protectors, work gloves and non-flammable clothing when soldering or brazing. Always have a fire extinguisher of the appropriate type close at hand. WARNING: Disconnect the power supply to the unit and to any accessories before carrying out any work on a unit. WARNING: Failure to take proper account of the above advice and unauthorised modification of the electrical connections will render the Carrier warranty on the product null and void. NOTE: Immediately check for damage in transit when any shipment is received. To protect against damage and contamination, leave all packages fully wrapped until the units are about to be installed. For the same reasons leave the air inlets and outlets covered with the protective film until the air ducts are about to be connected. 2.5 - Receiving a shipment - installation methods When receiving a shipment, check the condition of the goods and report any damage in transit to the shipping company. Do not unpack the units until just before they are due to be installed, and make sure they are as close as possible to the installation site when unpacking them. Do not stack the units and do not place heavy articles of any sort on them. 8

3 - SAFETY CONSIDERATIONS 3.1 - 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 install, 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. Comply with all the safety rules and regulations currently in force. Wear eye protectors and work gloves. Take care when moving or positioning equipment. 3.2 - 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 15 100 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. 3.3 - General installation recommendations In general terms the following rules must be applied: - Units must be provided with over-voltage protection upstream (not supplied by Carrier) Unit without electric heater Unit with electric heater Upstream over-voltage protection T2A T16A - 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 a cable clamp. A hole is provided for this purpose in the plastic Carrier controller housing. 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 V a.c., 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. 3.4 - 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. IMPORTANT: The Carrier numeric controller, power module, or in general units fitted with controls loops must have an isolating device upstream (for example a double-pole circuit breaker). If necessary, an easily operated emergency stop device (such as a punch-button 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 15 100 and UK IEE Wiring Regulations. These devices are not supplied by Carrier. 9

4 - INSTALLATION 4.1 - Installation of the front fastening supports, the rear suspension rail and the rectangular duct outlets 4.1.1 - General The front fastening supports and the rear suspension rail are designed for the installation of the 42GM unit. This allows these units to be installed while building proceeds so that air ducts and the false ceiling can be installed much sooner than is usual. The operative section of the 42GM need not be installed until just before the tenants arrive. They can be ordered for delivery very late in the building cycle - a very important financial consideration where major installations are involved. Ducts connect the supports to the diffusers. These are rectangular over a length that should be as short as possible in order to minimise pressure losses (pressure losses in rectangular ducts are higher than pressure losses in circular ducts). They must then be changed to circular ducts with a 200 mm diameter, using an adaptor piece. The circular ducts are then connected to the diffusers. The pressure drops through the ducts must be compatible with the performance of the 42GM. The internal duct surfaces must be as smooth as possible. Avoid sharp bends. Check that there are no leaks and that they have not become fouled during installation. 4.1.2 - Installation of the front fastening support and the rear suspension rail The front suspension supports are supplied as pre-assembled sub-assemblies (5 off) and can be disconnected and reassembled as required (M8 screws). Once their installation site has been selected, use a complete assembly as a template to mark the positions of the fastening points. The supports must be fixed in a very rigid way to the concrete slab, suitable for the weight carried. They are designed for the installation of the 42GM units (the fixing devices to the concrete slab are not supplied by Carrier). IMPORTANT: When positioning the front fastening supports take care to avoid damaging or changing the joint plates on either side of the supports (these joints ensure leak-tightness of the system. After the front fastening supports have been installed, fix the rear suspension rail parallel to the front supports, following the centre point distances below. The rail must be fixed in a very rigid way to the concrete slab, suitable for the weight carried (the fixing devices to the concrete slab are not supplied by Carrier). VERY IMPORTANT: For correct operation of the 42GM unit the front fastening supports and the rear suspension rail must be level. Protect the ducts against the ingress of building debris which could be sucked into the unit possibly damaging the fan, electric heater and the thermostatic damper on the diffuser. As required by local sound emission codes install sound absorbing and damping materials. 300 225 25 40 85 180 315 32 85 88 404 315 240 150 Ø124 938 oblong 13x20 820 19 38 30 260 225 56 886 991 1081 The illustrations shown in this document are solely for information, and not contractually binding. 10

4.1.3 - Installation of the rectangular duct outlets Supply and return duct outlets (connecting pieces) must be attached to each front fastening support of the 42GM units. These are separate, and complete leak-tightness between the connecting pieces and the rectangular ducts is easily ensured before they are installed. Once the connecting pieces are installed on the ducts they only need to be fixed to the front fastening supports, using the two M5 screws supplied with the connecting pieces. For the assembly method see the diagram below. Duct outlets (connecting pieces) Screws M5 4.2-42GM installation 4.2.1 - General The 42GM is generally the most important system element to be installed when all else is done. There are 2 reasons for this: - Avoidance of damage to the units while heavy work is still in progress - Keeping work areas as free of clutter as possible. When the site is ready for the modules - the front fastening support is firmly fixed to the concrete slab, the ducts are connected to the front support, the rear suspension rail is firmly fixed to the concrete slab, the water manifolds, shut-off valves and air vents are in place on their connection spigots, the condensate drain piping is installed, electrical installation is complete - only a few minutes are needed to install the module, make the water and electrical connections and connect the condensate drain together with the non-return valve (see Fig. 4). Adequate filter access and manoeuvring space will have been provided (refer to the dimensional drawings). Front fastening support WARNING: Do not use the water pipes or the electrical cables as handles for manoeuvring the modules. They may suffer serious damage. A hydraulic lift and a folding ladder will facilitate the task of fixing the 42GM unit. Use a support block (e.g. made of wood or steel, dimensions 296 x 900 mm), with the height at the front 10 mm higher than at the back to allow installation of the 42GM (see Fig. 1). Fig. 1 Support block 11

4.2.2 - Installation To attach the 42GM unit to the front fastening support and rear suspension rail proceed as follows: - Position the clamping nuts supplied with the unit (quantity and positions depend on the number of units to be installed) on the rear suspension rail. - Place the 42GM unit on the support block and place the complete assembly on the hydraulic lift (see Fig. 1). - Raise the hydraulic lift (movement 1, see Fig. 2) so that the two hooks on the front of the 42GM unit are level with the two rectangular openings on the front fastening support, designed to engage with the hooks. - Then take the 42GM unit closer to the front fastening support and engage the two hooks in their position (movement 2, see Fig. 2). - Lower the hydraulic lift slightly (approx. 10 mm) so that the two hooks of the 42GM unit are engaged in their position on the front fastening support (movement 3, see Fig. 3). - Lock the assembly, using the clamping nut that slides into the rear suspension rail and has its seat in the slot on the fixing corner bracket, situated at the rear of the 42GM unit. Tighten the unit well (movement 4, see Fig. 3). Fig. 2 Concrete slab Front fastening support Rear suspension rail 2 2 hooks on the 42GM Support block 1 Clamping nut Fig. 3 4 3 The illustrations shown in this document are solely for information, and not contractually binding. 12

NOTE: Once the 42GM unit has been installed, ensure that it is level or slightly sloped towards the rear of the unit (to ensure that the condensate is drained correctly). - Connect the flexible water pipes. Each flexible pipe is equipped with a 1/2 gas screw connector. - Connect the condensate drain pipe, using clear 10 mm bore pipe and provide a fall of 10 mm/metre over the whole horizontal pipe run. Install a 50 mm (minimum) siphon to prevent gases and odours from flowing back into the ceiling void (see Fig. 4). NOTE: The condensate drain pipe has to be attached to the drain pan by a collar (not supplied by Carrier). When all modules are installed in this way open the shut-off valves on the manifolds, bleed all air from the circuits. Bleed valves are on the system manifolds (no purge on the unit) then pressurise the system. Now the electrical connections can be made. Do not switch the power on until the connection and earthing are complete. 4.3 - Removing a 42GM unit Disconnect the power supply before carrying out any work on a 42GM unit by switching off the power supply at the isolator provided for the purpose during installation (isolator not supplied by Carrier): - Disconnect the power supply cable and the earth wire fitted with a flat tag. Disconnect the power supply cable of the user interface. Disconnect the power supply cable for the BMS bus. Disconnect the connection cable for the window contact. Disconnect the connection cable for the motorised fresh air valve. - Disconnect the condensate drain pipe. - Close the water valves on the system supply manifolds. - Disconnect the flexible water pipes by unscrewing the 1/2 gas connectors. WARNING: Since the flexible water pipes do not have drain valves, provide: - either a receiver to allow the flexible pipes and part of the cooling coil to be drained (in this case do not drain the flexible riser pipes during the removal of the unit); - or male plugs to be screwed onto the flexible pipes. - Move the hydraulic lift and the support block under the 42GM unit. - Loosen the clamping nut on the rear suspension rail. - Raise the hydraulic lift slightly (approx. 10 mm) to disengage the two hooks at the front of the 42GM from their rectangular seat in the front fastening support. - Lower the hydraulic lift and set the unit down. Fig. 4 Slope 2% Non-return valve Siphon 50 mm Slope 2% Clear Ø 10 mm ID pipe (not supplied by Carrier) Ø 6 mm hole at the top Non-return valve Condensate drain pipe Joint Ø 16 mm hole in the horizontal pipe on the drain section 13

5 - FRESH AIR 5.1 - Constant fresh air controller (optional) Modification procedure: Disconnect the fresh air duct from the plastic spigot on the 42GM. Move or relocate the two plastic restricters. Reconnect the fresh air duct to the spigot. Accessory fresh air duct Flexible fresh air duct, diameter 125 mm, maximum length 500 mm, fire rating M1, fitted with a coupling sleeve at each end. The constant fresh air controller for the 42GM gives precise control of the rate at which fresh air ventilation air is introduced and the supply air refresh rate. Selection of the fresh air controller bearing in mind the occupancy of each room or zone is critical. Range of fresh air flow controllers available: - 8.3 l/s (30 m 3 /h): -10%; + 20% - 16.6 l/s (60 m 3 /h): -10%; + 20% 5.2 - Variable fresh air controller (option) The fresh air supply is located before the filter and the water coil. The collar which houses the flow controller is made of recyclable ABS and has a connection diameter of 125 mm. The 16.6 l/s or 60 m 3 /h fresh air controller may be modified on site by relocating or removing two plastic restricters in order to increase its constant fresh air flow capacity to a maximum of 44.4 l/s or 160 m 3 /h. A label on the 42GM front fastening support shows how to readjust the two plastic restricters. NOTE: To operate correctly, the 8.3 l/s or 30 m3/h constant fresh air flow controller requires a differential pressure in the range 50 Pa to 200 Pa. The 16.6 l/s or 60 m 3 /h constant fresh air controller requires a differential pressure in the range 70 Pa to 200 Pa. 16.6 l/s (60 m 3 /h) 20.8 l/s (75 m 3 /h) The 42GM can be equipped with a variable fresh air controller that permits control of the air introduction and renewal. The fresh air rate can be set at the Carrier controller. This fresh air controller is supplied by Carrier and can be installed directly on the front fastening support of the 42GM unit, which is designed to accommodate it. NOTE: Carrier recommends the installation of a straight semi-rigid circular duct (12.5 mm diameter) 180 mm long (1.5 x diameter) upstream of the controller. This must be as straight as possible to prevent any problems in the pipe (maximum pipe run without bends). 27.7 l/s (100 m 3 /h) 36.1 l/s (130 m 3 /h) 44.4 l/s (160 m 3 /h) The variable fresh air controller, supplied by Carrier, requires a static pressure that is higher than the 180 Pa minimum. 14

6 - FAN MOTOR ASSEMBLY 6.1 - Description The 42GM has a double inlet fan to give very high available static pressure. The fan motor is supplied at 230 V. Its speed is varied by a numeric controller card. 6.2 - Fan motor removal WARNING: Switch off the electrical power supply before doing any work on the unit. For the fan motor assembly to be removed, the 42GM itself must first be removed. The assembly is accessed through the removable unit side which must therefore be removed. Removal procedure: - Remove the 42GM unit as described in the chapter Removing a 42GM unit. - Lay the module on its non-removable side (fixed by rivets). - Uninstall the removable side, fixed by screws. - Disconnect the quick connect power supply cable for the fan motor. - Disconnect the water piping from the coil side (be careful not to lose the joints). - Unscrew the two screws (A) and remove the fan motor assembly. Re-installation procedure: - Follow the instructions above in reverse order, and refer to the unit installation procedure. NOTE: When re-installing the removable side of the unit, ensure that the coil is correctly positioned on the panel. Screws A The illustrations shown in this document are solely for information, and not contractually binding. 15

7 - WATER COIL 7.1 - Description Aluminium fins are mechanically bonded by expansion onto 3/8 copper tube. Male/female water inlet/outlet connections are 1/2 gas threaded nut. ATTENTION: The unit does not incorporate an air vent. This must be installed during the installation. Available coils: - for 2-pipe systems (for use with electric heater) - for 4-pipe systems NOTE: Each 42GM has a label showing the position of the water inlets and outlets on the coil. Ensure that the water system is constantly under controlled pressure to ensure the correct charging of the coil pipes. 7.2 - Removing the coil WARNING: Switch off the electrical power supply before doing any work on the unit. Removal procedure: - Remove the 42GM unit as described in the chapter Removing a 42GM unit. - Lay the module on its non-removable side (fixed by rivets). - Uninstall the removable side, fixed by screws. - Disconnect the water piping from the coil side (be careful not to lose the joints). - Unscrew the two screws (A), fixing the condensate pan (see diagram below). - Remove the coil by keeping the condensate pan slightly pulled out so that it disengages (see diagram below). - Insert the new coil, making sure that it is correctly positioned. Re-installation procedure: - Follow the instructions above in reverse order, and refer to the unit installation procedure. NOTE: When connecting the new coil to the flexible pipes: - be careful not to damage the coil manifolds by tightening them too much. Carrier recommends the use of a dynamometric key, set to 15 Nm; - install new leak-tight joints between coil, valves and flexible pipes. When re-installing the removable unit side ensure that this is correctly positioned in relation to the coil. WARNING: Bleed the circuit thoroughly when refilling the circuit with water. Screws A Pull the pan out slightly 16

7.3 - Water inlet/outlet connections 2-pipe version 38 mm 176 mm 130 mm Flexible pipes, 400 mm Threaded nuts G1/2" Condensate drain Ø 12 4-pipe version 176 mm 130 mm 40 mm 40 mm 8 - FLEXIBLE WATER PIPES Description Flexible pipes are used to make the water connections. Every branch of the system must therefore have an isolating valve. Insulation: cell foam rubber to M1 fire rating. Minimum bending radius: 75 mm. The flexible water pipes are designed to carry treated or untreated water (maximum 40% concentration of ethylene glycol or propylene glycol). Maximum hot water temperature 90 C. Operating pressure: maximum 10 bar. Connections: G1/2 threaded nut. Length: 400 mm (unit outlet). The illustrations shown in this document are solely for information, and not contractually binding. 17

9 - VALVE MOTOR AND 2-WAY VALVE BODY 9.1 - Motor of the on/off therm-electric valve motor NOTE: The motor of the thermoelectric valve is supplied in the normally closed position. This means that in order to fill the system with water, to ensure water system balancing and to purge the units, it is necessary to open the valves either via wall thermostats or via the BMS. 9.1.1 - Operation Linear movement is controlled by expansion and contraction of a wax element heated by an electrical resistor. 9.1.2 - Specifications Power supply Inrush current Holding current Power Maximum travel 230 V a.c. (± 10%) - 1 Ph-50 Hz) 0.7 A 0.013 A 3 W 8 mm Operating temperature 0 to 50 C Degree of protection IP43 if installed vertically IP40 if installed horizontally Opening time 4 min. Closing time Maximum 7 min. depending on valve motor heating-up time (ambient temperature 20 C) Connection cable 2 x 0.75 mm 2 Dimensions Permitted differential pressure Diameter 50 mm Height 68.5 mm 2.5 bar (2-way valve) 9.2 - Valve motor replacement procedure To remove the valve motor or valve body the unit must first be removed. Disconnect the power supply to the unit before carrying out any work on a unit. - Remove the 42GM unit as described in the chapter Removing a 42GM unit. - Lay the module on its non-removable side (fixed by rivets). - Uninstall the removable side, fixed by screws. - Unscrew the valve motor and disconnect the cable at the connector inside the unit after the filter (in air flow direction) for the cold-water valve or at the controller for the hot-water valve. - Remove the valve motor assembly with its cable. - Replace and re-install it in reverse order. - Re-install the 42GM unit, as described in the chapter 42GM installation. WARNING: Bleed all water from the circuit when it is refilled. 9.3 - Replacing the valve body Disconnect the power supply to the unit before carrying out any work on a unit. Replace the valve body, the unit must first be removed. - Remove the 42GM unit as described in the chapter Removing a 42GM unit. - Lay the module on its non-removable side (fixed by rivets). - Uninstall the removable side, fixed by screws. - Unscrew the valve motor. - Disconnect the valve body on the flexible pipe side and on the coil side, by loosening the screw connectors. Make sure that the coil manifold is not damaged. - Replace the valve body. NOTE: When connecting the new valve to the flexible pipes and coil: - be careful not to damage the coil manifolds by tightening them too much. Carrier recommends the use of a dynamometric key, set to 15 Nm; - install new leak-tight joints between coil, valves and flexible pipes. - make sure that the fluid flows in the direction of the marker arrow on the valve body (if it is installed the wrong way round the valve body will be damaged). - Re-tighten the valve motor screws. - Close the unit by re-attaching the removable side. - Re-install the 42GM unit, as described in the chapter 42GM installation. WARNING: Bleed all water from the circuit when it is refilled. 18

10 - FILTER The 42GM has, as standard, a high-efficiency F6 filter in accordance with standard EN 779 or EU 6 in accordance with Eurovent 4/5. Fire rating medium M1. The filter can be removed through a door in the underside of the unit. The ease with which the filter can be removed and replaced is an important benefit for service technicians. Air filters should be changed regularly (F). How often this is needed depends on the cleanliness of the working environment and the rate at which the filter becomes clogged. If clogged filters are not changed they can increase the pressure drop, trapped dust particles may be given off and entrained in the air supply, and the general performance of the 42GM may be degraded as the air flow reduces. F 19

11 - ELECTRIC HEATER 11.1 - General The 42GM can be equipped with an electric heater to provide heating. In this case it is equipped with an innovative and intelligent electric heating system. The electric heater generates air pressure drops, is mounted on a rotation axis and oscillates between two positions: - a vertical position - a horizontal position (corresponding to the cooling mode). This has the following advantages: - obtains a higher cooling capacity - achieves energy savings (fan-motor assembly power consumption lower for a given flow rate). 11.2 - Description These are high performance PTC electric resistance heaters which make use of two technologies: electric heating and its ability to control and limit its own surface temperature (a state of the art technology based upon the use of ceramics). The technology guarantees total self-regulation with absolute control of the power consumption. In addition each heater coil is fitted with a self-locking safety thermostat which cuts out at 70 C. The actual heating power depends upon the air flow and the entering air temperature. NOTE: A minimum air flow is required to prevent overheating and incorrect cut-out of the safety thermostat. This rate is 16.6 l/s (60 m 3 /h). Electric heater rotation is ensured by a thermo-electric all-ornothing actuator. This is supplied in parallel with the valve motor of the cold-water valve and regulated by the controller. The assembly is installed on an access plate that can be removed through the filter door (under the unit) - see diagram. The electric heater and the thermo-electric actuator can be removed via the filter access (without removing the unit). 11.3 - Removing the electric heater WARNING: Switch off the electrical power supply before doing any work on the unit. If there is a malfunction in the electric heater assembly, this must be removed. Proceed as follows: - Open the filter door. - Remove the filter. - Remove the CO 2 sensor from the unit (if this option is installed). - Unscrew the two screws A (see diagram). - Unclip the two cables supplying this assembly from their cable clips. - Carefully pull down the plate that supports the electric heater assembly and pull it out from the unit. The length of the cable permits intervention on this assembly while it is approximately 300 mm below the unit. This means you can: - visually ensure the correct mechanical operation of the assembly (correct electric heater rotation). - replace the PTC electric heater, ensuring that the cables are marked before removal. - replace the thermo-electric actuator. Replace the assembly by following the instructions in reverse order. After removing the filter, remove screws A Screws A The illustrations shown in this document are solely for information, and not contractually binding. 20

12 - PERFORMANCES 12.1 - Electrical data 42GM size 1 without electric heater U I P Fan speed Qv Qv Pressure P1 Pressure P2 (V) (A) (W) r/s (rpm) (m 3 /h) (l/s) Pa Pa 230 0.87 191 39.1 (2347) 505 140.2 135 110 230 0.85 185 40.1 (2406) 457 126.9 200 180 230 0.83 179 40.9 (2454) 408 113.3 262 246 230 0.82 176 41.5 (2488) 375 104.1 300 286 230 1.81 173 41.7 (2503) 348 96.6 327 315 230 0.79 168 42.4 (2543) 305 84.7 367 358 230 0.78 163 42.9 (2576) 268 74.4 398 391 200 0.82 162 35.0 (2102) 468 130.0 82 61 200 0.81 159 35.9 (2155) 443 123.0 124 105 200 0.79 156 37.1 (2225) 403 111.9 185 169 200 0.78 151 37.8 (2269) 371 103.0 225 212 200 0.76 147 38.8 (2326) 338 93.8 268 257 200 0.75 144 39.5 (2370) 307 85.2 300 291 200 0.74 140 40.3 (2415) 271 75.2 336 329 200 0.72 135 41.0 (2462) 233 64.7 372 367 170 0.75 128 30.1 (1804) 393 109.1 56 41 170 0.74 127 31.7 (1903) 360 100.0 112 99 170 0.73 124 32.8 (1966) 336 93.3 151 140 170 0.71 120 34.0 (2039) 311 86.3 192 183 170 0.70 117 35.4 (2123) 272 75.5 238 231 170 0.68 114 36.6 (2193) 240 66.6 277 271 170 0.66 110 38.2 (2294) 189 52.5 337 334 170 0.64 106 39.3 (2360) 150 41.6 373 371 140 0.65 92 25.1 (1504) 284 78.8 61 53 140 0.64 91 26.9 (1613) 257 71.3 105 99 140 0.63 89 28.7 (1722) 225 62.5 153 148 140 0.62 87 30.6 (1838) 193 53.6 194 190 140 0.61 85 32.0 (1918) 163 45.2 227 224 140 0.59 84 33.6 (2017) 131 36.3 265 263 140 0.57 80 35.5 (2130) 97 26.9 309 308 110 0.52 59 17.4 (1044) 214 59.4 9 5 110 0.52 59 19.0 (1137) 187 51.9 38 35 110 0.52 58 21.1 (1267) 153 42.5 76 74 110 0.52 58 22.6 (1357) 134 37.2 100 98 110 0.51 57 23.9 (1436) 111 30.8 126 125 110 0.51 56 25.4 (1524) 92 25.5 147 146 110 0.50 55 27.3 (1640) 63 17.5 183 183 80 0.39 32 12.3 (740) 140 38.8 2 0 80 0.38 31 14.5 (870) 95 26.3 34 33 80 0.38 31 15.4 (922) 71 19.7 47 47 80 0.38 31 16.9 (1013) 41 11.3 66 66 Legend: U : Fan motor power supply I : Current draw P : Power input to the fan motor, Carrier controller or speed controller Fan speed : Fan motor rotation speed in revolutions/second (revolutions/minute) Qv : Air flow Pressure P1 : Available static pressure (without air purifier) Pressure P2 : Available static pressure (with air purifier) 21

12.2 - Air flow/available static pressure data Available static pressure curve (Pa) as a function of air flow (m 3 /h or l/s) Available pressure, Pa 400 350 300 250 200 150 U = 230 V 100 U = 200 V 50 U = 140 V U = 170 V U = 110 V 0 U = 80 V 0 50 100 150 200 250 300 350 400 450 500 550 600 m3/h 0 14 28 42 56 69 83 97 111 125 139 153 167 l/s Air flow, Qv Legend: Without electric heater (with 6-row water coil) With electric heater (with 5-row water coil) U Fan motor power supply IMPORTANT: The curves were derived by smoothing, based on the information contained in the electrical data table. 22

13 - CONTROLLER 13.1 - Carrier numeric controller Each 42GM is fitted with a configurable and communicating numeric controller. The controller is directly fitted to each module. 13.2 - Carrier room thermostats Room thermostats are elegantly designed to be fully compatible with any style of interior decor. The main functions of the controller are: Controlling room temperature. Raising, lowering and adjusting the angle of Venetian blinds (optional). Brightening and dimming light sources (optional). Selecting comfort or unoccupied mode through a Zone User Interface or wall thermostat. Controlling ventilation (e.g. by selecting forced ventilation mode). NOTE: For further information, please refer to the selection manual, installation manual or start-up handbook for the Carrier numeric controller. The illustrations shown in this document are solely for information, and not contractually binding. 23

13.2.1 - Wall thermostat installation The thermostat is for use on indoor walls only. Mounting height: 1.5 m above floor level Locate the thermostat away from heat sources, avoid air rising from inlet cable conduits, and avoid draughts from doors, windows etc. IMPORTANT: Thermostats must be installed by qualified technicians who are fully familiar with all applicable safety standards and regulations. Do not connect equipment of any kind when the power is switched on. Carrier S.A.S. Demonstration Suite Whether you live in the tropics or in Greenland Whether you suffer from the heat, from the cold or from lack of air CARRIER has the solution and can show it to you in the demonstration suite simulation of the climate in your region simulation of the heating and cooling loads according to your needs measuring, storing and display of the air temperatures and the air distribution pattern taking into account your climatic and architectural constraints - even at climatic extremes optimisation of the physical location of the air terminals in your building walls or ceilings determination and control of the sound level in every room simulation of the control system of your terminals and their link to your BMS system and finally, simulation of how your interior will look, with a floor plan, lights and blinds to ensure true quality The programmes available Experience a real preview of your future installation Order No.: 14223-76, 07.2005. Supersedes order No.: 14223-76, 06.2003 Manufacturer reserves the right to change any product specifications without notice. Manufactured by: Carrier S.A., Montluel, France. Printed in the Netherlands on totally chlorine-free paper.