INSTALLATION, START-UP AND

Carrier
International SERVICE INSTRUCTIONS
42D
Sdn. Bhd.
Malaysia FAN COIL AIR CONDITIONERS

CONTENTS:
INSTALLATION 1
PHYSICAL DATA 2
POWER ON 3
START-UP 3
SERVICE 3-4
INSTALLATION
Step 1 - Unpack and Inspect Units
Remove shipping
R hi i wraps from
f allll units.
it Check
Ch k the
th shipment
hi t all applicable codes.
against shipping order. Check for concealed shipping
damage. If shipment is damaged or incomplete, file claim
with transportation company and advise Carrier immediately.
Step 2 - Protect Units from Damage
To maintain warranty, protect unit against adverse weather,
theft or vandalism at jobsite.
Step 3 - Prepare Jobsite for Unit Installation
To save time and reduce the possibility of costly errors, set
up a complete sample installation in a typical room at jobsite.
Check all critical dimensions such as pipe, wire and duct
connection requirements. Refer to job drawings and product
dimension drawings as required. Instruct all trades in their
part of the installation
Step 4 - Identify and Prepare Units
1. Be sure unit power requirements match available power
source. Refer to unit nameplate and wiring diagram.
2. Units are designed for chilled water or hot water (190°F
maximum) only. Unit may be equipped with optional
electric heater. Be sure that the required control
packages for the unit have been supplied.
3. Check all tags on unit to determine if shipping screws
are to be removed. Remove screws as directed.
Step 5 - Place Unit in Position
1. Be sure unit is level or pitched towards drain to ensure
proper drainage and operation. (see Fig. 1 and 2.) Pitch
of suspended unit can change after coil is filled; recheck
after filling coil.
Unit weight distribution is not uniform at mounting points.
Suspend unit at factory-provided holes (Fig. 2). If used,
select and adjust vibration isolators so that unit is
uniformly suspended and pitched.
2. Models, with bottom inlet, may be installed in
noncombustible return air spaces only.
3. Protect units from damage caused by jobsite debris. Do
not allow foreign material to fall in unit drain pan.
Prevent dust and debris from being deposited on motor
or fan wheels.
Fig. 1 – Drain Line Details, Typical
Step 6 - Make Piping Connections
DRAIN LINE - Install a trapped drain line in accordance with
codes Slope drain line away from unit.
unit Insulate
drain line to prevent sweating. Drain connections are shown
in Fig. 1 and 2.
WATER SUPPLY/RETURN CONNECTIONS - Maximum
allowable entering hot water temperature is 190°F. Install
piping in accordance with all applicable codes. See Table 1.
Position valves over the drain pan. Be sure valves are in
proper operating position and are easily accessible for
adjustment.
If valves cannot be installed over drain pan, insulate valves
to prevent sweating.
If coil and valve package connections are to be made with a
solder joint, care should be taken to ensure that no
components in the valve package are subjected to a
temperature high enough to damage seals or other
materials. Many 2- position electric control valves have a
manual operating lever. This lever should be in the OPEN
position during all soldering operations.
If coil connection is made with a union, the coil side of the
union must be prevented from twisting (i.e., it should be
“backed
backed up up”)) during tightening.
tightening Do NOT over-tighten!
over tighten!
Over-tightening distorts the union seal surface and destroys
the union.
Steam Connections - On units with steam-heating coils,
the maximum steam pressure applied to the unit should
never exceed 10 psig.
Test And Insulate - When Wh allll joints
j i t are completed,
l t d
perform hydrostatic test for leaks. Vent all coils at this time.
Check interior unit piping for signs of leakage from shipping
damage or mishandling. If leaks are found, notify a Carrier
representative before initiating any repair. Release trapped
air from system (see Step 9-6).
All water coils must be protected from freezing after
initial filling with water. Even if system is drained, unit
coils may still have enough water to cause damage
when exposed to temperatures below freezing
 42DF/DFD
42DF 42DE/DED
42DC/DCD
LEGEND:
1 - Coil
2 - Drain, 7/8” O.D.
3 - Hanger Mounting Holes diameter, 7/8”
4 - Junction Box (or power K.O.)
5 - Supply Air Duct Collar, 1”
Note: 6 - Coil Outlet
42DE & DF are supplied complete with the casing and 7 - Coil Inlet
the legend for internal parts are as per 42DC diagram. 8 - Access Panel

42DC/DCD 42DE/DED, DF/DFD Units with aquastats furnished and installed at the factory
Unit may be shipped with the aquastats mounted on a coil
Inlet Outlet Inlet Outlet
Size stubout. If so, remove the aquastat before installing a valve
(in. OD) (in. OD) (in. OD) (in. OD) package.
p g When re-installing
g the aquastats,
q , consult the
006 7/8 7/8 factory piping diagram in the submittals for proper location. If
008 7/8 7/8 the valve package is field supplied, the aquastat must be
installed in a location where it will sense the water
010 7/8 7/8
temperature regardless of the position of the control valve. A
012 7/8 7/8 bleed bypass may be required to ensure proper aquastat
7/8 7/8
014 1 1/8 1 1/8 operation.
016 1 1/8 1 1/8
All field wiring
g should be done in accordance with g governing
g
018 1 1/8 1 1/8 codes and ordinances. Any modification of unit wiring without
020 1 1/8 1 1/8 factory authorization will void all factory warranties and will
nullify any agency listings.

Following the hydrostatic test, insulate all piping, controls
and valves to unit to prevent sweating.
To ensure compliance with building codes, restore the
structure’s original fire resistance rating by sealing all holes
with material carrying the same fire rating as the structure.
Step 7 - Make Electrical Connections
See unit serial plate for required supply voltage, fan and
heater amperage, and required circuit ampacities. See unit
wiring diagram for unit wiring and field wiring.
The fan motor(s) should never be controlled by any wiring or
device other than the factory-supplied switch or thermostat/
switch combination unless factory authorization has been
obtained. Fan motor(s) may be wired for temporary use
during construction only if: (1) prior factory approval has
been obtained, and (2) wiring and operation are done in strict
accordance with the instructions issued by the factory.
Step 8 - Make Duct Connections
Install all ductwork to and from unit in accordance with all
applicable codes. Duct construction must allow unit to
operate without duct external static pressure limits as shown
on job submittals. Units designed to operate with ductwork
may be damaged if operated without the intended ductwork
attached. Units configured to bring in outside air should have
some method of low temperature protection to prevent coil
freeze-up.
Insulate all ductwork as required. Use flexible connections to
minimizee duct
duct-to-unit
to u t aalignment
g e t p problems
ob e s a and
d noise
o se
transmission where specified.
Install ductwork, accessory grills and plenums so that they
do not restrict access to filter. (See Fig. 2 and Table 2.)

2
Prevent dust and debris from setting in unit. If wall finish or START-UP
color is to be spray applied, cover all openings to prevent Start-up procedures vary depending upon the time of year
spray from entering unit. (summer or winter) and building characteristics (new building
or old building, occupied or unoccupied, etc.).
Table 2 - Filter Data (One-in. thick)
Start up in the cooling mode requires that proper care be
Start-up
Unit Size L x H (inch) given to avoid condensation problems. Condensation forms
Size 42DC/DCD 42DE/DED 42DF/DFD on surfaces that are colder than the dew point of the
surrounding air. If a unit is started and is fed low-temperature
006 14 x 21 14 x 13 ¾
chilled water in a hot, humid setting, condensation will form
008 14 x 26 14 x 19 ¾ on many parts of the unit. In order to avoid excessive
010 14 x 30 14 x 23 ¾ condensation, water of a higher temperature should be used
-approximately 65-70°F. Also, the building should be as
012 14 x 35 14 x 27 ¾ completely
p y enclosed as p possible and outside air supply
pp y fans
014 14 x 40 14 x 33 ¾ and bathroom and kitchen exhaust fans should be off.
016 14 x 45 14 x 37 ¾
As the building temperature drops, the chilled water
018 14 x 50 14 x 43 ¾ temperature can gradually be reduced until it reaches 50°F.
020 14 x 54 14 x 47 ¾ At this point, the outside air fans can be turned on. When the
chilled water temperature is reduced to its design point the
Note: Filter sizes for models 42DC/DCD and DF/DFD are exhaust fans can be turned on.
factory supplied cleanable filters.

Step 9 - Make Final Preparations

POWER OFF (open unit electrical disconnect).
SERVICE
Excessive Condensation on Fan Coil Unit Parts
Excessive condensation can be caused by running chilled
water through a fan coil unit with its fan off. Therefore, if fan
cycling control is used, a water flow control valve should be
Be sure electrical disconnect is open, locked and tagged installed to shut off the water when the fan stops.
when working on unit.
The following 2 practices will also help avoid condensation
1. Install thermostat and perform any other final wiring as problem:
applicable. 1. Continuous fan operation, with motorized chilled water
2. Clean dirt, dust and other construction debris from unit valve controlled by thermostat.
interior. Be sure to check fan wheel and housing. 2. Continuous fan operation, with thermostat control to
3. Rotate fan wheel by hand to be sure it is free and does switch fan from high to low speed (Instead of switching it
not rub housing. Check that nuts securing fan assembly off).
to fan deck are tight.
tight
To Clean Coil
POWER ON 1. Be sure electrical disconnect is open, locked and tagged
4. Turn on unit power. Check fan and motor operation. while working on unit.
5. Be sure drain line is clear and is properly and securely 2. Remove access panels, grilles or fan deck as required
positioned. Pour water into drain to check operation. and brush between coil fins with stiff wire brush. Follow
6. Vent all air from unit coil and related piping. If air vent is up by cleaning with vacuum cleaner. If coil is cleaned with
manual, release air from system by turning air vent air hose and nozzle, take care not to drive dirt and dust
screw 11/2 turns
t counterclockwise
t l k i with
ith screwdriver.
di i t other
into th components. t
When steady stream of water begins to escape, close 3. Install clean filter as described in Clean or Replace Air
valve. If air vent is automatic, trapped air will be vented Filters.
automatically. Vent releases air slowly, usually dripping
water into drain pan in the process. Check Drain -Lock open and tag unit electrical disconnect.
Check drain pan, drain line and trap at start of each cooling
Make sure all service valves are open and that season. A standard-type pipe cleaner for 7/8-in. ID pipe can
motorized control valves, if supplied, are set for be used to be sure pipe is clear of obstruction so that
automatic operation.
operation condensate is carried away. away Check drain line at filter
cleaning time during the cooling season. Be sure that debris
6. Check all control valves in the system for proper has not fallen into unit through supply air grille
operation in accordance with valve manufacturer’s
instructions. Remove Fan Assembly -Lock open and tag unit
7. Check that air filter of correct type and size is installed in electrical disconnect. For access to fan assembly, remove
unit filter rack. Also, see Service, Clean or Replace Air either side or front panel. If unit has an extra long fan motor
Filters. conduit lead, remove fan assembly from its tracks.
Otherwise disconnect motor leads at motor terminals.
Otherwise, terminals Then
Do not start-up or operate unit without filter. Be sure filter and
slide out fan assembly.
unit interior are clean
Fan Motor Bearings - Standard motors are permanently
lubricated and sealed. No lubrication is required unless
special motors have been provided or unusual operating
conditions exist.
3
Clean Fan -Lock open and tag unit electrical disconnect. WASHABLE FILTER - Replace filter with a good quality
Remove dirt and dust accumulation from fan wheel blades, filter of the same size shown in Table 2. Do not attempt to
fan housing and motor using a brush and vacuum cleaner. clean and reuse disposable filters.

Clean Electric Heater -Lock open and tag heater and unit
di
disconnects.
t Check
Ch k that
th t airflow
i fl th
through
h heater
h t elements
l t is
i PERMANENT FILTER (Fiber Type)
unobstructed. Clean heater elements with soft brush or 1. Tap on solid surface to dislodge heavy particles.
vacuum cleaner as necessary. 2. Wash in hot water. If needed, use mild solution of
commercial solvent such as sal soda or trisodium
Clean or Replace Air Filters -Lock open and tag unit phosphate.
electrical disconnect. At the start of each cooling season and 3. Set filter on end so that water drains out through slots in
after each month of operation (more or less depending on frame. Allow filter to dry thoroughly.
operating conditions) replace throwaway filter or clean 4. Recharge filter with Film-Cor or similar recharging oil.
permanent filter. Three ounces is sufficient for medium-size
medium size filter.
filter Oil may
be applied by insect spray gun. For easier spraying, the
To remove filter, remove unit front panel and slip filter oil can be warmed. If filter is dipped in recharging oil,
forward out of filter rack. remove it immediately and allow to drain through slots in
frame.
5. Replace filter in unit. Replace unit front panel. If another
type of filter is used, follow filter manufacturer’s
instruction.

Carrier
International
Sdn. Bhd.
Malaysia

Carrier International Sdn. Bhd. (3385-T)

Lot 4, Jalan P/6, 43650 Bandar Baru Bangi,
Selangor, Malaysia.
T l 603
Tel: 603-89258001
89258001
Fax: 603-89256589

42D Rev-2
04 2012
Manufacturer reserves the right to discontinue,
or change at any time, specifications or designs
without notice and without incurring obligations.