Carrier 42BJ Individual Comfort Module for Variable Air Volume Systems Instruction Manual

Carrier 42BJ Individual Comfort Module for Variable Air Volume Systems

PRECAUTIONS

Operating limits

Cooling mode
Minimum supply air temperature 12°C when the unit is installed where the ambient temperature is 27°C in dry bulb with 65% relative humidity.

Heating mode
Max. supply air temperature = 60°C to avoid damage of the discharge spigots. To avoid all risks of stratification, the Carrier recommends keeping the supply air temperature below 35°C.

Operating environment
The 42BJ ICM LEC has been designed for indoor 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

• SO2 < 0,02 ppm
• H2S < 0,02 ppm
• NO, NO2 < 1 ppm
• NH3 < 6 ppm
• N2O < 0,25 ppm

Do not install a unit where flammable gases or products of an acidic or alkaline character may be present. The copper/aluminium coil or components inside the unit could suffer irreparable corrosion damage in their presence.

Recommended coil water quality

At installation handover, and then periodically every year, it is advised to analyse the water for bacteria (detection of ferro-bacteria, H2S-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.

The results must be in accordance with the values shown below:

• Total hardness in mmol/l: 1 < mmol/l < 1,5
• Chloride [CL-] < 10 mg/litre
• Sulphate [SO4
• 2-] < 30 mg/litre
• Nitrate [NO3
• ] = 0 mg/litre
• Dissolved iron: < 0,5 mg/litre
• Dissolved oxygen: 4 < [O2] < 9 mg/litre
• Carbon dioxide [CO2] < 30 mg/litre
• Resistivity: 20 Ohm·m < Resistivity < 50 Ohm·m
• pH: 6,9 < pH < 8

Clearances required

Please refer to Fig. 1.

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 place heavy articles of any sort on them.

Supply voltage 230V ± 10% – 50 Hz

Check that the supply voltage and frequency correspond to the values of the unit to be installed.
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. Switch off the main electrical power supply to the unit and accessories (if installed) before doing any work on the unit.

General

Installing, commissioning and servicing of the various components (unit, control system, hot and cold water system, air distribution system) can be dangerous unless certain aspects of the installation, such as the presence of mains electricity and hot or cold 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.
Definition of the pictograms used:

• Electrical danger – Fig. 3
• Caution hand hazard – Fig. 4
• General danger – Fig. 5

Comply with all safety rules and regulations currently in force. Wear eye protectors and work gloves. Take care when moving or positioning equipment.

Protection against electrocution

Only personnel qualified to perform electrical and maintenance work may make electrical connections. In particular it is obligatory to disconnect all 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, commercial and light industrial areas. They also comply with the low-voltage directive.

General installation conditions

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. The installation must be equipped with a device to protect against earth faults. The disconnect device must simultaneously disconnect the two poles (phase and neutral), and have a distance of at least 3 mm between the contacts, in compliance with the installation instructions. The mains power cable must have 3 conductors (blue, brown, green/yellow) and its cross section and type must comply with the specifications set out by the applicable EN or IEC standard. Refer to the selection sheet or the name plate to determine the maximum input current. These devices are not supplied by Carrier.
In general terms the following rules must be applied.

Upstream over-voltage protection|
---|---
Unit without electric heater| T2A
Unit with electric heater| T16A

• Units must be provided with over-voltage protection upstream (not supplied by Carrier).
• The power disconnection 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.

Caution for the control of the 42BJ ICM LEC

IMPORTANT: It is not permitted to connect several 42BJ ICM LEC units to the same control device (wall thermostat, electronic NTC controller, HDB controller, etc.)

Regulations

Declaration of Conformity UE
This unit complies with the provisions of European Directives: 2006/42/EC (Machinery)
2014/30/EU (EMC)
2011/65/EU (RoHS)
Electronic Equipment Regulations 2012
2009/125/EC (Eco Design) & regulation 327/2011/UE REGULATION (EC) No 1907/2006 (REACH)

UK Declaration of Conformity This unit complies with the requirements of:
Supply of Machinery (Safety) Regulations 2008 Electromagnetic Compatibility Regulations 2016
The Restriction of the Use of Certain Hazardous Substances in Electrical and
Electronic Equipment Regulations 2012 The Ecodesign for Energy-Related Products and Energy Information Regulations
2019, and following amendments
UK REACH Regulations 2019

UK importer :
Toshiba Carrier UK Ltd, Porsham Close, Roborough, Plymouth, PL6 7DB

INSTALLATION OF THE UNIT

Installing the unit in the false ceiling

The positioning of the unit must not create an obstacle that may lead to an unequal distribution and/or return flow of the air. The ceiling must be sufficiently even to allow a simple installation without danger from the unit. The supporting structure must be able to carry the unit weight and prevent deformation, breaks or vibrations during operation.
INSTALLATION PRECAUTIONS: During the installation process, remove all debris and construction material from the ducts to prevent any damage to the unit.

Installation procedure

• Position the unit close to where it is to be installed in the ceiling void or under the floor. For installation in a false ceiling use a hydraulic lift and a folding ladder to make the task easier (Fig. 6).
• Underfloor installation: install the adjustable rubber feet to the unit. These feet are available as an accessory. Please contact your local Carrier contact.
• Check that the clearances around the unit are sufficient to allow easy maintenance. Please refer to the diagram that shows the service clearances.
• Mark the position of the threaded hangers on the ceiling. If several units need to be installed, it may be advisable to produce a drilling template (see Fig. 2).
• The method of fixing the threaded hangers (not supplied by Carrier) depends on the ceiling type (maximum diameter of the threaded hangers is 8 mm). Once the threaded hangers are fixed to the ceiling, tighten the first nuts.

WARNING: When moving the units, do not use water pipes, condensate drain pan, valves or flexible pipes to lift them.
Lift the unit and align it on the threaded hangers, insert the second nuts and tighten them slightly.
NOTE: At this point do not tighten the nuts fully and do not clamp the unit up to the ceiling (leave a space between the ceiling and the unit). The nuts will be adjusted finally, when the unit has been connected to the pipework and ducts and levelled.

Level the unit (Figs. 7 and 8)

Adjust the hanger nuts so that the unit is inclined 0.5% towards the condensate drain pan. In the other direction (air flow direction) the unit must be perfectly level (Fig. 8).
Condensate drain pipe (Fig. 9):

Use a flexible pipe with an inside diameter of 16 mm and provide a constant fall of 20 mm/m over the whole horizontal pipe run. Install a 50 mm (minimum) siphon to prevent gases and odours from flowing back into the ceiling void. If several units are connected to a common collector, a device must be installed (Fig. 10). Before operating the unit, ensure that the water flows into the internal condensate drain pan by pouring some water into it. If problems are detected, check the drain pipe slope and look for possible obstructions. In all cases the connection duct(s) at the unit outlet must be insulated to prevent any condensate formation on the walls.

NOTE: The pressure losses of these ducts must be compatible with the unit performance. The duct must be as smooth as possible. Avoid sharp bends. Check that there are no leaks or kinks, and that there is no dirt or installation debris inside the ducts. Debris within the ducts might damage the fan wheel and the damper in the air diffusers.
When installation is complete – i.e. when the 42BJ is attached to the ceiling, air ducts are complete, water manifolds are in position with stop valves ready on the connection stubs, and electrical installation is prepared – then connect the water pipes (Carrier recommends the use of flexible water pipes that can be supplied as an accessory). Each flexible pipe has a 1/2” gas screw connector, depending on the model. Ensure that a gasket (not supplied by Carrier) is installed between the screw connector and the stop valve.
When all units are installed, open the stop valves on the manifolds, bleed and then pressurize the circuits. To bleed the coils, remove the plastic plugs on the coil access door and then slightly undo the bleed screws with a screwdriver. Close the valve firmly when all air has escaped.
NOTE: Do not switch on the power until all connections are made and earthed.

Remocal procedure
Switch off the unit power supply at the isolator provided for the purpose during installation (isolator not supplied by Carrier).

• Disconnect the power supply and connection cables.
• Close the isolating valves on the manifolds.
• Disconnect the flexible water pipes by unscrewing the gas connectors.

WARNING: Since the flexible water pipes do not have drain valves, a receiver must be provided to allow the cooling coil to be drained.

•  Disconnect the supply and return air ducts.
• Disconnect the flexible condensate drain pipe. Drain the siphon into a suitable vessel.
• Support the unit lightly and release it by unscrewing the four nuts on the threaded hangers. Lower the unit carefully.

COMPONENTS

Fan motor assembly

Description
The ICM has a double inlet high static pressure fan motor assembly. The low energy consumption motor uses a 230 V ± 10%, 50 Hz single-phase power supply and runs at variable speed under the control of a Carrier numeric controller supplying 0-10 V control signal.

Fan motor assembly removal procedure
WARNING: Disconnect the power supply to the unit before carrying out any work on the unit. If the fan develops a fault the whole assembly must be removed and replaced.

• Remove the fan access panel (12a).
• Disconnect the fan motor assembly power supply cables equipped with quick connectors (power and control wiring).
• Disconnect the electric heater supply cable from the 42BJ. The cable has three wires terminating in flat spade connectors.
• The fan motor and its support are held in place by one screw (12b) and three lugs. Remove this screw and slide the assembly free of the lugs.
• Remove the fan from its support panel (4 screws – 12c).
• Replace the fan motor assembly and follow the procedure in reverse order.

WARNING: To reconnect the motor cables separate the power wiring cable from the control wiring cable and pull them apart as far as possible.

Water coil

Coil removal procedure
WARNING: Disconnect the power supply to the unit before carrying out any work on the unit.

• Close the isolating valves on the manifolds.
• Unscrew the union nuts to disconnect the flexible water pipes.
• Remove the valve actuators taking care to identify the cooling and heating valves.
• Disconnect the flexible condensate drain pipe which is held in place by a collar (the collar is not supplied by Carrier).
• Remove the two-way or three-way water flow control valve bodies. Depending how the 42BJ ICM LEC is configured, the three-way valve coupling may be fitted with a heating/cooling changeover switch, if so do not remove it.
• Remove the 4 torx screws (T20) and slide out the coil and drain pan assembly.
• Replacement is by the reversal of the procedure des-cribed above. Ensure that all gaskets are changed (new gaskets fitted) and that the inlet and outlet connections to the coil are made correctly using an appropriate sealing compound applied to the valve body.
• Bleed all air from the coil during refilling.

ATTENTION: It is advisable to tighten the valve body to the coils with caution (15 N·m is sufficient) to ensure they are not damaged.

Coil inlet/outlet positions (Fig. 15)

• Water inlets/outlets, sizes 1.9/2.9.
• Water inlets/outlets, size 4.9.

ATTENTION: Carefully observe the direction indicated by the arrow on the valves, based on the connection side and the valve type.

Duct connection spigots

These are manufactured from high density plastic with a VO fire rating. They are encased inside the unit. 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.

Optional air filter and filter access: air filter replacement

Air filters should be changed regularly. 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 ICM may be degraded as the air flow reduces.
NOTE: The condensate drain pan is located at the suction end of the fan, and could therefore overflow if the air filter became clogged. This is because the partial vacuum inside the unit could stop the condensate from draining normally.

Access from the side (Fig. 1c)
To access the filter, open the latch, open the hinged access door and remove the filter from its housing by releasing the two clips which hold it in place.
When replacing the filter, make sure that the sealing gasket is against the internal metal housing.

Access from above or below (Figs. 1a and 1b)
In these situations the filter is installed in a removable plug-in unit. To replace the filter assembly, disengage the two latches and withdraw the plug- in unit. Remove the old filter and insert a new one ensuring that the sealing gasket is against the internal metal housing.

NOTE: When installing an ICM in a ceiling void, check that no T-bars will obstruct access to the filter or prevent the plug-in unit from being withdrawn.

COMPONENTS

Constant-volume fresh air controller

Constant-volume fresh air controller
The 42BJ ICM can be fitted with a constant fresh air flow controller allowing the introduction of fresh air and the air change rate to be controlled.
The following range of fresh air controllers is available:

Option a: 8.3 l/s (30 m3/h) (-10%; +20%)
Option b: 16.6-44.4 l/s (60-160 m3/h) (-10%; +20%)
Options a and b: the diameter of the spigot housing the fresh air flow controller is 125 mm.
The 16.6 1/s (60 m3/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 44.4 1/s (160 m3/h). A label on the 42BJ ICM shows how to adjust the two plastic restrictors (Fig. 11 ).

Modification procedure

• Disconnect the fresh air duct from the spigot on the unit.
• Remove or reposition the two plastic restrictors, following the fresh air flow controller.
• Reconnect the fresh air duct to the spigot.

IMPORTANT: If the 42BJ ICM 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.
NOTE: To operate correctly, the 8.3 l/s (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 (60 m3/h) constant fresh air controller requires a differential pressure in the range 70 to 200 Pa.

Fresh air controller with variable air volume

The 42BJ ICM can be equipped with an optional variable fresh air flow controller from 0 to 55 l/s (0 to 200 m3/h).This is connected to the numeric Carrier controller and can regulate the fresh air intake in two ways:

• either using a fixed rate set by the installer that can be reconfigured as required
• or based on the CO2 level; in this case it is connected to a
• CO2 sensor via the Carrier numeric controller.

NOTE: With the variable fresh air flow controller the upstream pressure in the fresh air duct must be 180 Pa.

Optional water flow control valves

These valves are two-way or three-way type, with a body designed to withstand a 16 bar operating pressure.

Thermoelectric actuator (on/off)
The actuator is a 230 V a.c. on/off type.
NOTE: The thermoelectric actuator is supplied in the normally closed position for both the two- and the three-way valve (way A-AB closed for a three-way valve).
To enable the installation to be filled with water, the water circuits to be equalised and the units to be purged, the actuators must be connected to the power supply to open the valves via a command from the wall thermostats or from the BMS.

Actuator replacement procedure
The actuators on both the chilled water and the hot water valves may be replaced if either develops a fault.

• Disconnect the power supply to the unit before carrying out any work on a unit.
• Disconnect the actuator power supply cable equipped with a quick connector.
• Uncouple the faulty actuator. Refitting is by the reversal of the procedure described above.

WARNING: Ensure that the actuator is firmly screwed to the valve body (maximum torque 15 N·m).

Valve body replacement procedure

• Disconnect the power supply before carrying out any work on a unit.

• Close the isolating valves on the manifolds.

• Unscrew the union nuts to disconnect the flexible water pipes.

• Remove the valve actuators taking care to identify the cooling and heating valves.

• Remove the two-way or three-way water flow control valve bodies. Depending how the unit is configured, the three-way valve coupling may be fitted with a heating/cooling changeover switch, if so do not remove it.

• Fit the new valve body to the coil (fit new gaskets).

• Refit the valve actuators taking care to ensure that they are correctly fixed to the valve body.

• Reconnect the flexible water pipes by tightening the union nuts. Retighten all the water connections and ensure that all gaskets have been changed and correctly fitted (maximum torque 15 N·m).

• Open the isolating valves on the manifolds and purge all air
  from the system.

• Check that there are no leaks and reconnect the power to the unit.

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.

Replacing the electric heater (Fig. 13)
CAUTION: It is vital to disconnect the ICM from the general power supply before carrying out any work on the electric heater.
If the electric heater develops a fault, the assembly must be removed and replaced; the fan unit will have to be removed to make this possible.

• a) Refer to the fan removal procedure.
• b) Remove the support assembly and the electric heater by removing the two screws.
• c) Disconnect the electric heater cable (3 wires terminating in flat spade connectors).
• d) Release the heater mounting and remove the heater.
• e) Replace the defective heater.
• f) Use the above procedure in reverse to install the new heater and to reinstall the fan motor assembly.

WARNING

•  Do not touch the heater elements when the heater is switched on.
• Do not touch the fan wheel during the removal and re-assembly process.

COMPONENTS

Flexible pipe option
Ensure that the following minimum bending radius is observed:

• insulated pipes: 106 mm The flexible water pipes are designed to carry treated water (maximum 40% concentration of ethylene glycol or propylene glycol).
• Maximum operating temperature, heating: 90°C.
• Operating pressure: 16 bar

Carrier numeric controller
For further information, please refer to the selection manual, installation manual or start-up manual for the Carrier numeric controller.

Adjustable feet (accessories) for installation in a false floor void

Introduction
An ICM may be installed in a floor void. Adjustable feet with built-in vibration absorbers are available as accessories for installation on site. For further information please contact your local Carrier representative.

Procedure for fitting (see Figs. 14 and 15)

a) Install angle bracket 1 using the screws supplied. There are two possible height settings with different adjustment ranges:

• high setting: adjustment range 45 to 50 mm,
• low setting: adjustment range 30 to 35 mm.

b) Screw foot 2 in or out according to the height needed.

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