42BJ ULTRA - Sizes 1.6-2.6-4.7 Local Air Conditioning...

42BJ ULTRA - Sizes 1.6-2.6-4.7

Local AirConditioning Unit

Installation manual

Hot/chilled waterinlet/outlet

Thermophonic ducting

Supply/returnModuBoot

Fresh airinlet

ULTRA

The photo shown on the front cover is solely for information, and not contractually binding.

Contents

1 - INTRODUCTION .........................................................................................................................................................................4

2 - FEATURES ....................................................................................................................................................................................52.1 - Physical and electrical data ..........................................................................................................................................................62.2 - Dimensional drawings ..................................................................................................................................................................72.3 - ULTRA packaging......................................................................................................................................................................122.4 - Receiving a shipment - installation methods .............................................................................................................................12

3 - SAFETY CONSIDERATIONS AND REGULATIONS ..........................................................................................................133.1 - General........................................................................................................................................................................................133.2 - Precautions against electrocution ...............................................................................................................................................133.3 - Installation Recommendations ...................................................................................................................................................133.4 - Conformity..................................................................................................................................................................................13

4 - INSTALLING THE 42BJ ULTRA ............................................................................................................................................144.1 - Matching the ULTRA to the false ceiling ..................................................................................................................................144.2 - Safety precautions ......................................................................................................................................................................144.3 - Installation procedure .................................................................................................................................................................144.4 - Removing an ULTRA.................................................................................................................................................................15

5 - FRESH AIR..................................................................................................................................................................................165.1 - Constant flow fresh air controller ..............................................................................................................................................165.2 - Fresh air duct as optional accessory...........................................................................................................................................16

6 - FAN MOTOR...............................................................................................................................................................................176.1 - Description..................................................................................................................................................................................176.2 - Removing the fan assembly .......................................................................................................................................................176.3 - Replacing the capacitor ..............................................................................................................................................................17

7 - WATER COIL..............................................................................................................................................................................187.1 - Description..................................................................................................................................................................................187.2 - Removing the water coil ............................................................................................................................................................187.3 - Coil inlet/outlet positions ...........................................................................................................................................................19

8 - WATER FLOW CONTROL VALVES ......................................................................................................................................218.1 - Description..................................................................................................................................................................................218.2 - Replacing actuators ....................................................................................................................................................................218.3 - Electrical circuit diagrams for actuators ....................................................................................................................................218.4 - Replacing a valve body ..............................................................................................................................................................21

9 - FLEXIBLE WATER HOSES .....................................................................................................................................................22

10 - AIR FILTER AND ACCESS ....................................................................................................................................................2310.1 - Description................................................................................................................................................................................2310.2 - Replacing the air filter..............................................................................................................................................................23

11 - ELECTRIC HEATER...............................................................................................................................................................2411.1 - Electric resistance heater - size 1.6 ..........................................................................................................................................2411.2 - Shielded electric heater with spiral fins - sizes 2.6 and 4.7 .....................................................................................................2411.3 - Replacing the electric heater ....................................................................................................................................................2411.4 - Wiring diagram for a single stage of the electric heater ..........................................................................................................25

12 - CARRIER ELECTROMECHANICAL CONTROLLER ....................................................................................................2612.1 - Description................................................................................................................................................................................2612.2 - The various ULTRA configurations available..........................................................................................................................2612.3 - Technical specification for the heating/cooling changeover switch ........................................................................................2612.4 - Master/slave control .................................................................................................................................................................2812.5 - Wiring diagrams .......................................................................................................................................................................28

13 - ACCESSORIES .........................................................................................................................................................................3113.1 - Adjustable feet for installing an ULTRA in a false floor .........................................................................................................3113.2 - Condensate drain pump............................................................................................................................................................31

4

HOT/CHILLED WATERINLET/OUTLET

DISCHARGE/RETURNMODUBOOT

This simplifies maintenance, since these circuits are normallyinstalled in corridors and halls, and therefore never passthrough air conditioned spaces. Only the passive elements ofthe system, that is the 35BD diffusers, are within occupiedspaces.

Nowadays the noise level, or rather the lack of noise, is a deci-ding factor in the selection of an air conditioning system. Lownoise was a key objective in the design of the 42BJ ULTRA.In addition its high available static pressure allows the unit tobe installed well away from the air conditioned space.

Low noise, remoteness from the space which it serves alliedwith easy maintenance are key attributes influencing the selec-tion of an air conditioning system.

1 - INTRODUCTION

The compact 42BJ ULTRA is available in three sizes with achoice of three motor drives and is capable of air conditioningrooms ranging from 25 m2 to 50 m2 in area.

Its main components are a motorised, variable-speed centrifu-gal fan, a high-efficiency air filter, a fresh air supply fittedwith an air flow control unit, a chilled water cooling coil andeither a hot water heating coil or an electric heating unit.

Flexible, thermally insulated (isophonic) discharge and returnducts are installed on site, connecting the module to one ormore plenums in the false ceiling. These feed unobtrusivelinear ceiling diffusers (typically Carrier Moduboot35BD/35SR units) supplying the room or zone where airconditioning is required.

The complete system comprises one or more Carrier air orwater-cooled chillers connected to one or more air handlerssupplying fresh air to the 42BJ ULTRA. These may be instal-led in underfloor voids or above false ceilings, preferably incorridors, where they are connected to hot and chilled watercircuits as well as the fresh air supply.

5

2 - FEATURES

The modular design of the 42BJ ULTRA allows it to be usedefficiently to meet the heating, cooling and air conditioningrequirements of medium-sized rooms. With an overall depth ofonly 270 mm (except size 4.7, depth: 345 mm), these units areeasily installed in voids above suspended ceilings or belowfalse floors.

Their casings are built of 10/10 galvanised sheet steel linedwith 13 mm of fibre wool which in turn is protected by a layerof erosion-resistant neoprene.

The drive motor access door is coated with 13 mm of fibrewool and the air filter access panel is covered with 5 mm offoam.

NOTE:Operating limits: air discharge temperature 12°C when theunit is installed in an area with an ambient temperature of27°C dry bulb and a relative humidity of 70%.

6

2.1 - Physical and electrical data

42BJ ULTRA Size 1.6 Size 2.66 Size 4.7

Nominal air flow l/s (m3/h) 166 (600) 194 (700) 264 (950)

Total cooling capacity (water cooling coil)* kW 3.66 4.7 6.0

Heating capacity (water heating coil)** kW 1.9 2.6 3.8

Power supply 230 V - single phase - 50 Hz U% ± 10 ± 10 ± 10

Operating weight (6-row coil and control) kg 31 40 60

Water coil with:• 3/8” copper tubes• Aluminium fins• Purge valve• Water connection with

- inlet (screw connection) G 1/2” G 1/2” G 1/2”- outlet (screw connection) G 1/2” G 1/2” G 1/2”

• Test pressure kPa 2400 2400 2400• Operating pressure kPa 1600 1600 1600

5-row coil• Number of passes 2 3 3• Water content l 0.9 1.2 1.5

1-row coil• Number of passes 1 1 4• Water content l 0.2 0.29 0.45

Shielded electric heater with spiral fins:• Power supply 230 V - single phase - 50 Hz U% - ± 10 ± 10• Power available other than for fan (+5%/ -10%) W - 1600 1600• Trigger temperature for manually reset safety thermostat 98°C (0 °C/-16 °C) °C - 112 112• Minimum air flow passing over the heater l/s (m3/h) - 56 (200 56 (200)

Electric resistance heater:• Power supply 230 V - single phase - 50 Hz U% ± 10 - -• Power available other than for fan (+5%/ -10%) W 1000 - -• Trigger temperature for automatically reset safety thermostat °C 75 - -• Fusion temperature for safety thermostat °C 150• Current drawn A 4.35 - -• Minimum air flow passing over the heater l/s (m3/h) 64 (230) - -

Fan:• Forward-curved centrifugal fan, single wheel double inlet double inlet double inlet• Air flow at high speed l/s (m3/h) 166 (600) 194 (700) 264 (950)• Static pressure at high speed*** Pa 80 80 85

Motor:Supply 230 V - single phase - 50 Hz U% ± 10 ± 10 ± 10Asynchronous, inherent overload protection Nbr of 2 2 2Permanent capacitor, class B insulation, polesvarnish class F, protection IP 44.• Maximum power at high speed*** W 219 245 183• Nominal current at high speed*** A 0.96 1.07 0.80• Starting current at high speed A 3.0 4.4 3.3

Air filter:Throwaway, fire rating medium M1 G3 F5 F5• Dimensions mm 240 x 400 240 x 550 315 x 550• Pressure drop, clean, at nominal air flow Pa 30 35 40

Fresh air connection:• Outside connection diameter mm 125 125 125• Constant minimum air flow (-10%; +20 %) l/s (m3/h) 8.3 (30) 8.3 (30) 8.3 (30)• Constant maximum air flow (-10%; +20 %) l/s (m3/h) 44.4 (160) 44.4 (160) 44.4 (160)• ∆P (upstream/downstream):

- Controller at 8.3 l/s (30 m3/h) Pa 50 - 200 50 - 200 50 - 200- Controller at 44.4 l/s (160 m3/h) Pa 70 - 200 70 - 200 70 - 200

• Fire rating of fresh air controller: M1

ULTRA water connectionsULTRA modules are designed and tested for 16 bar operating pressure. The total operating circuit of the ULTRA is guaranteed for anoperating pressure of 10 bar.Contact your local Carrier representative for advice if an application requires an operating pressure of 16 bar.

* Based on water entering at 6°C, room air at 25°C dry bulb, 50% relative humidity and 5 K ∆t at nominal air flow.** Based on water entering at 50°C, room air at 19°C and 10 K ∆t at nominal air flow.*** For more precise information please refer to the electrical data tables

7

Size 2.6

2.2 - Dimensional drawings

2.2.1 - Clearances for maintenance, mm

Size 1.6

Removable drain pan and coil assembly

Fan motor access door

Filter access side door

Clearance for lowerfilter access panel


Electric heater



Clearance for lower filteraccess panel

8

2.2.1 - Clearances for maintenance, mm (continued)

Size 4.7

2202001100 300

600

750

120

Clearance for lowerfilter access panel




9

Sizes 2.6 and 4.7

Grommet

Grommet

2.2 - Dimensional drawings, continued

2.2.2 - Template for fixing threaded rods, mm

Size 1.6

10

Size 2.6

Ø 16 condensate outlet

Detail rep. 1

Grommet

2.2 - Dimensional drawings, continued

2.2.3 - Dimensions, mm

Size 1.6

Legend:1 Suspension lugs2 Coil hot/chilled water3 Electromechanical controller4 Air filter5 Hot/chilled water supply and return connections6 Fresh air connection7 Return air duct connection8 Supply air duct connection9 Water flow control valves10 Filter access door11 Fan motor access door12 Three-speed fan motor assembly13 Condensate drain pan14 Electric heater

Ø 16 condensate outlet

Detail rep. 1

Grommet


11

2.2.3 - Dimensions, mm (continued)

Size 4.7

25

650

600

220

8 7

1040

660

720

1 1000

10

5

Ø 8.5

Ø 249

Ø 1

24

611

125 110

2

4

12

9

155 600 42.5

345

157.

5

110 1100

84

207.

5

Ø 8.5

3 14

13

Grommet


12

Palletised

Size 1 10 1600 1100 1500 320

Size 2 10 1700 1350 1500 450

Size 3 10 1700 1350 1500 430

Size 4 6 1800 1350 1200 410

Units perpallet

Length(mm)

Width(mm)

Height(mm)

Weight(kg)

NOTE:When receiving a shipment of units, check at once that noneof the packages has been damaged. To maintain the protec-tion of the packaging as long as possible, do not open anypackage until just before a unit is to be installed.

2.3 - ULTRA packaging

Packaged on wooden pallets and protected by heat-shrunk orstretchable plastic film.

NOTE:If “Export” packaging is needed, please contact your localCarrier representative.

2.4 - Receiving a shipment - installation methods

When receiving a shipment, check the condition of the goodsand report any damage in transit to the shipping company. Donot unpack the units until just before they are due to be instal-led, and make sure they are as close as possible to the installa-tion site when unpacking them. Do not stack the units and donot place heavy articles of any sort on them.

WARNING:When moving the units do not use water pipe connections orcondensate drain stubs, valves or flexible pipes as handles.

The presence of electrical components creates hazards to thoseinstalling and servicing these units. Only properly qualifiedelectricians may be authorised to install, service and repairthese units. Some routine maintenance such as cleaning of thecoils and filter replacement may be entrusted to non-skilledpersonnel. Before carrying out any work, qualified techniciansmust familiarise themselves with the contents of this manualand all informative tags and labels attached to the units. It isessential to adhere to all applicable safety regulations. Weareye protectors, work gloves and non-flammable clothing whensoldering or brazing. Always have a fire extinguisher of theappropriate type close at hand.

WARNING:Disconnect the power supply to the unit and to any accesso-ries before carrying out any work on a unit.

Do not install a unit where flammable gases or products of anacidic or alkaline character may be present. The copper/alumi-nium coil or plastic components inside the unit could sufferirreparable corrosion damage in their presence.

WARNING:Failure to take proper account of the above advice andunauthorised modification of the electrical connections willrender the warranty on the product null and void.

FRESH AIR CONTROLLER

LATERAL FILTER ACCESS OPTIONFILTER TOP ACCESSOPTION

FILTER ACCESS OPTION FROM BELOW

DRAIN PAN AND COIL ASSEMBLY

FAN MOTOR ASSEMBLYFAN ACCESS

PANELS

13

3 - SAFETY CONSIDERATIONS

3.1 - General

Installing, commissioning and servicing of the various compo-nents which make up the different controls loops can be dan-gerous unless certain aspects of the installation, such as thepresence of mains electricity and hot or chilled water in the airconditioning equipment, are taken into account.

Only specially trained and qualified technicians and installerswho have been fully trained on the product concerned areauthorised to install, commission and service this equipment.

During servicing work, it is essential to apply all the recom-mendations and instructions given in service leaflets, on labelsor in the instructions delivered with the equipment, and tocomply with any other relevant instructions.

Definition of the pictograms used

Electrical Danger

Caution hand hazard

General Danger

UV-C light: do not look directly at this lightwithout protective glasses.

Comply with all the safety rules and regulations currently inforce.

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 recommendedby the IEC (International Electrotechnical Commission) in itsstandard IEC 364, corresponding to Europe HD 384, FranceNFC 15 100 and UK IEE Wiring Regulations, may haveaccess to electrical components. In particular it is obligatory todisconnect all electrical power supplies to the unit and itsaccessories before carrying out any work. Disconnect the mainpower supply with an isolating device (not supplied byCarrier).

IMPORTANT:The components, which make up the different controls loopsdescribed in this manual include electronic items. As such,they may generate or be harmed by electromagnetic interfe-rence unless they are installed and used in accordance withthese instructions. The components making up these controlssystems conform to the requirements of electromagnetic com-patibility in residential and industrial areas. They also com-ply with the low-voltage directive.

3.3 - General installation recommendations

IMPORTANT:In general units fitted with controls loops must have an isola-ting device upstream (for example a double-pole circuit brea-ker). If necessary, an easily operated emergency stop device(such as a punch-button switch) must cut off the power to allequipment. These safety devices shall be sized and installed inaccordance with IEC Recommendation 364, corresponding toEurope HD 384, France NFC 15 100 and UK IEE WiringRegulations. These devices are not supplied by Carrier.

In general terms the following rules must be applied:

- Units must be provided with over voltage protection up-stream (not supplied by Carrier)

Upstream over voltage protection

Unit without electric heater T2A

Unit with electric heater T10A

- Units must be protected by a differential type earth leakagecurrent device (not supplied by Carrier)

- The power disconnexion device must be clearly labelled toidentify which items of equipment are connected to it.

- The wiring of the components which make up the differentcontrol systems must be carried out in accordance with thelatest rules and regulations by professional installers.

- The power supply cable must be double insulated and fixedusing an appropriate cable clamp. The cable must be clampedon the outer insulation.

- The controls loop components must be installed in an environ-ment, which conforms to their index of protection (IP).

3.4 - Conformity

This equipment has been declared to be in conformity with themain requirements of the directive by virtue of using the follo-wing standards:- Electromagnetic compatibility: 89/336/EEC- Low-voltage directive: 73/23/EEC

14

4 - INSTALLING THE 42BJ ULTRA

4.1 - Matching the ULTRA to the false ceiling

Before beginning the installation process it is advisable tobecome familiar with the overall plan of the installation. Amounting template will assist in making a plan. Your localCarrier representative can provide one. All components of theinstallation must be coordinated on the plan: ULTRAs, 35BDModuboots, supply and return air ducts, and fitting the falseceiling.

4.2 - Safety precautions

During the installation process, remove all debris from theducts so that nothing is left behind that might damage the unit.

4.3 - Installation procedure

a) Set the ULTRA on the ground approximately above orbelow the spot where it is to be installed in the ceiling orfloor void.

• Ceiling void installation:

A hydraulic lift and a folding ladder will make the task easier.

• Floor void installation:

Install the adjustable rubber feet on the unit. These are avai-lable as optional accessories from your local Carrier represen-tative.

b) Confirm that the clearances around the unit are suffi-cient to allow proper and speedy maintenance. Refer toearlier pages specifying the clearances required.

c) Offer the template up to the ceiling and mark the posi-tion of the threaded hangers.

The method of fixing the threaded hangers (not supplied byCarrier) will depend upon the nature and condition of the cei-ling. If in doubt seek professional advice. The maximum dia-meter of the hangers is 8 mm.

WARNING:When moving a unit do not use the water pipe connections,condensate drain pan, valves, flexible pipes or electricalcables as handles.

Lift the unit and align it on the threaded hangers. Screw thenuts on loosely.

NOTE:At this point do not tighten the nuts fully and do not clamp theunit up to the ceiling. The nuts will be adjusted finally whenthe unit has been connected to the pipework and ducts andlevelled.

d) Level the unit

Adjust the hanger nuts so that the condensate drain pan is about5 mm below the opposite side of the unit. Check that the slopeis adequate by connecting a 2 metre length of 16 mm transpa-rent pipe to the drain stub. Empty some water into the drain panuntil the water level in the pipe is at the lower edge of the drainpan.

The water level in the opposite end of the pipe should be about5 mm below the base of the drain pan. Refer to the figureabove.

e) Condensate drain pipe

Use clear 16 mm bore plastic cold water pipe and provide afall of 20 mm/metre over the whole horizontal pipe run. Installa 50 mm (minimum) siphon to prevent gases and odours fromflowing back into the ceiling void.

NOTE:The condensate drain pipe has to be attached to the drainpan by a collar (not supplied by Carrier).

Fall:20 mm/m

Siphon:50 mm

15

4.4 - Removing an ULTRA

WARNING:Disconnect the power supply before carrying out any workon an ULTRA.

a) Switch off the power supply at the isolator provided for thepurpose during installation (isolator not supplied by Carrier).

b) Disconnect the power supply cables:

Remove the two hexagon head screws (8 mm AF) securing theABS protective cover.

Disconnect the quick connect power supply cable from thethermostat (7 or 8 wires) and withdraw the earth wire comple-te with its flat tag.

c) Close the isolating valves on the manifolds.

d) Disconnect the flexible water pipes by unscrewing the 1/2”gas connectors.

WARNING:Since the flexible water pipes do not have drain valves, areceiver must be provided to allow the cooling coil to be drained. The coil water capacity of the ULTRA T 2.6 is 1.2litres.

e) Disconnect the supply air and return air ducts and the freshair duct if fitted.

f) Disconnect the flexible condensate drain pipe. Drain thesiphon into a suitable vessel.

g) Support the unit and release it gently by unscrewing thefour nuts on the screwed hangers. Lower the unit carefully.

When several units are connected to a common collector, usethe piping scheme shown in the diagram below.

f) Install ceiling void air diffusers as shown in the plan forthe room that is to be air conditioned.

Connect the supply and return air duct to the correspondingcollars on both the diffuser plenum and the ULTRA. When theunit and the false ceiling have been installed, and before start-up, remove the protective film from the diffuser.

NOTE:ULTRAs are connected to the diffusers by ducts. The pressu-re drop in the ducts must be compatible with the capacity ofthe unit. The inner surfaces of the duct must be as smooth aspossible. Avoid sharp bends.

Check that there are no leaks or kinks, and that there is nodirt or installation debris inside the ducts. Debris within theducts might damage the fan scrolls and the temperature sen-sitive elements (calorstat) mounted in the air diffusers.

Check local noise level regulations and if necessary fit noisebaffles.

g) For ULTRAs with the fresh air inlet option, connect thefresh air supply duct.

h) When installation is complete - i.e. the ULTRA is instal-led in the false ceiling or floor void, air ducts are complete,water manifolds are in position with stop valves ready onthe connection stubs, and electrical installation is prepared- then connect the flexible water pipes (see “Flexible waterpipes” in a later section).

Every flexible pipe has a 1/2” gas screw connector.

Ensure that a gasket (not supplied by Carrier) is installed be-tween the screw connector and the stop valve.

i) When all units are installed, open the stop valves on themanifolds, bleed and then pressurise the circuits. To bleedthe coils, remove the plastic plugs on the coil access doorand then slightly undo the bleed screws with a screwdriver.Close the valve firmly when all air has escaped.

j) Make the electrical connections.

Do not switch on the power until all connections are made andsecured and all protective covers are in place. The installationcan then be started.

Fall20 mm/m

Siphon50 mm

Fall20 mm/m

ICM

ICM

16

5 - FRESH AIR

5.1 - Constant flow fresh air controller

The 42BJ ULTRA can be fitted with a constant fresh air flowcontroller allowing the number of air changes to be controlled.It is vital to choose the correct constant fresh air flow control-ler for the use to which the room or zone concerned will beput.

The following range of controllers is available:- 30 m3/h or 8.3 l/s (-10%; + 20%)- 60 m3/h or 16.6 l/s (-10%; + 20%)

The fresh air supply inlet is located upstream of the water coil.The 125 mm spigot which houses the flow controller is madeof ABS.

The 60 m3/h or 16.6 l/s fresh air controller may be modified onsite by relocating or removing two plastic restricters in orderto increase its constant fresh air flow capacity to a maximumof 160 m3/h or 44.4 l/s.

A label on the 42BJ shows how to readjust the two plastic res-tricters.

Modification procedure:

• Disconnect the fresh air duct from the plastic spigot on theULTRA.

• Remove the fresh air controller from inside the spigot.• Move or relocate the two plastic restricters.• Replace the fresh air controller in the spigot.• Reconnect the fresh air duct to the spigot.

NOTE:Two types of plastic spigot may be fitted to the ULTRA,depending on the capacity of the fresh air controller chosen.One spigot can accept only the 8.3 l/s or 30 m3/h controller.The other one can accept only the field modifiable 16.6 l/s or60 m3/h controller. This means there is no possibility ofmixing up the two types of controller during installation orservicing.

If the ULTRA is fitted with a return air temperature sensor,the constant fresh air flow rate must not exceed 50% of theair flow rate delivered by the unit at minimum speed.

NOTE:To operate correctly, the 8.3 l/s or 30 m3/h constant fresh airflow controller requires a differential pressure in the range50 Pa to 200 Pa. The 16.6 l/s or 60 m3/h constant fresh aircontroller requires a differential pressure in the range 70 Pato 200 Pa.

5.2 - Fresh air duct as optional accessory

Flexible fresh air duct, diameter 125 mm, maximum length500 mm, fitted with two coupling sleeves integral with theduct (the duct fire rating is M1).

FRESH AIR CONTROLLER

16.7 l/s (60 m3/h)

27.8 l/s (100 m3/h)

20.8 l/s (75 m3/h)

36.1 l/s (130 m3/h) 44.4 l/s (160 m3/h)

17

6 - FAN MOTOR

6.1 - Description

The basic ULTRA module consists of a three-speed centrifugalfan motor, variable-speed, centrifugal fan with single wheel,forward-curved blade and single or double inlet.

Low noise was a key objective in the design of the fan motor.In addition its high available static pressure allows the ULTRAto be installed well away from the air conditioned space.

Its power supply is single-phase, 230 V a.c. ± 10%, 50 Hz.

NOTE:In order to simplify maintenance, the fan motor is held inposition by three lugs and one screw. Electrical connectionsuse a quick connector to prevent wiring errors and signifi-cantly reduce maintenance time.

6.2 - Removing the fan assembly

WARNING:Disconnect the power supply to the ULTRA before carryingout any work on the unit.

If the fan develops a fault the whole assembly must be remo-ved and replaced.

a) Unscrew the 6 hexagon head screws (8 mm AF) securingthe fan access panel. Remove the panel.

b) Disconnect the quick connect power supply cable for thefan motor.

c) The fan assembly is held in place by one hexagon headscrew (8 mm AF) and three lugs. Remove this screw andslide the assembly free of the lugs.

d) Replace the fan motor assembly and follow the procedu-re in reverse order to complete the installation.

6.3 - Replacing the capacitor

a) Disconnect the power supply to the ULTRA before car-rying out any work on the unit.

b) Unscrew the 6 hexagon head screws (8 mm AF) securingthe fan access panel. Remove the panel.

c) Unscrew the capacitor securing collar(s). Each spigot isheld in place by a hexagon head screw (8 mm AF).

d) Disconnect the capacitor either by the flat lugs at theback of the capacitor, or at the quick connector. This canbe done by using a screwdriver to press down the tongueon the appropriate terminal.

e) Reversing the above procedure, replace, secure andconnect the new capacitor.

ULTRA size 1.6

ULTRA size 2.6

8 µF 400 Vcapacitor


7.5 µF 400 Vcapacitor

Access panel fixing screws

Fan motor assembly

Access panel

Fixing screw

Note: depending on the fan motor model, please check the fan capacitorvalue before replacing the capacitor

Note: depending on the fan motor model, please check the fan capacitorvalue before replacing the capacitor

18

ULTRA size 4.7

ULTRA size 1.6. Detail of connection for 8 µF capacitor

Capa 6 µF 400V

Capa 4 µF 400V

L.S.

COM

MO

NEA

RTH

M.S

.T.

S.

RED

BLUE

GRE

YBL

ACK

GREE

N/YE

LLOW

7 - WATER COIL

7.1 - Description

The water coil has aluminium fins which are expansion-bon-ded to a 3/8” diameter copper tube.

Water inlet and outlet connections are threaded 1/2” gas. Airpurge valves are standard. The coil is integral with the drainpan and coil access door to simplify removal for service.

Coils available are: 5 rows for two-pipe systems with change-over or for use with electric heater: 6 rows with 5 rows coolingand 1 row heating.

NOTE:Each ULTRA has a label showing the position of the waterinlets and outlets on the coil.

Recommended coil water quality

At installation handover, and then periodically every year, it isadvised to analyse the water for bacteria (detection of ferro-bacterias, H2S producing and sulphate reducing bacteria) andchemicals (in order to avoid problems due to corrosion andscaling).

The water circuit must include all the necessary elements forthe treatment of the water: filters, additives, intermediateexchangers, purges, drains, isolating valves, etc., according tothe analysis results.

The results must be in accordance with the values shownbelow:

• Total hardness in French degrees:10 < TH < 15• Chloride [CL-] < 10 mg/l• Sulphate [SO4

2-] < 30 mg/l• Nitrate [NO3

-] = 0 mg/l• Dissolved iron < 0.5 mg/l• Dissolved oxygen 4 < [O2] < 9 mg/l• Carbon dioxide [CO2] < 30 mg/l• Resistivity 2000<Resistivity<5000 Ωcm• pH 6.9 < pH < 8

7.2 - Removing the water coil

WARNING:Disconnect the power supply to the ULTRA before carryingout any work on the unit.

a) Close the isolating valves on the manifolds.

b) Unscrew the 1/2” gas connections to disconnect theflexible water pipes.

c) Remove the two-port or three-port water flow controlvalve bodies. Depending how the ULTRA is configured, thecoupling on a three-port valve may be fitted with a heat-ing/cooling changeover switch. If so, do not remove it.

d) Disconnect the flexible condensate drain pipe which isheld in place by a collar (the collar is not supplied byCarrier).

e) Remove the 4 hexagon head screws (8 mm AF) and slideout the coil and drain pan assembly.

f) Reverse the removal procedure described above to installthe replacement coil and drain pan assembly. Ensure thatall joints are made correctly and are leaktight.

WARNING:Bleed all air from the coil when it is refilled.



19

Three-port valves

HOT WATEROUT

1/2” GAS CONNECTION NUT

FORGED BRASS NUT 12 MM HT. (1/2") GASCONNECTION WITH TURNED-UP FLANGE (15/21)EXT. DIAMETER 18 MM.

DETAIL OF COIL CONNECTOR DETAIL OF VALVE CONNECTOR

DETAIL OF VALVE CONNECTORDETAIL OF COUPLING CONNECTOR

HOT WATERIN

CHILLED WATERIN

CHILLED WATEROUT

HOT WATEROUT

HOT WATERIN

CHILLED WATERIN

CHILLED WATEROUT

7.3 - Coil inlet/outlet positions (dimensions in mm)

7.3.1 - ULTRA sizes 1.6 and 2.6

Two-port valves

20

Ø16

Ø8

822

68.5

225

51.5

75 172.5

G1/

2"

Ø12

Ø12

8

G1/

2"

Ø12

8

AB A

B

68.5

225

164

51.5 75

AB A

B

172.5

Three-port valves

HOT WATEROUT

1/2” GAS CONNECTION NUT

FORGED BRASS NUT 12 MM HT. (1/2") GASCONNECTION WITH TURNED-UP FLANGE (15/21)EXT. DIAMETER 18 MM.

DETAIL OF COIL CONNECTOR

DETAIL OF VALVE CONNECTOR

DETAIL OF VALVE CONNECTOR

DETAIL OF COUPLING CONNECTOR

HOTWATER IN

CHILLEDWATER IN

CHILLEDWATER OUT

HOT WATEROUT

HOT WATER IN

CHILLEDWATER IN

CHILLEDWATER OUT

7.3 - Coil inlet/outlet positions, continued (dimensions in mm)

7.3.2 - ULTRA size 4.7

Two-port valves

21

8 - WATER FLOW CONTROL VALVES

These valves are two-port or three-port type, with a body desi-gned to withstand a 16 bar operating pressure.

8.1 - Electrothermal actuator (on/off)

This on/off type actuator is used with a Carrier room thermo-stat (electromechanical controller).

NOTE:The electrothermal actuator is delivered in the normally clo-sed position regardless of the two-port or three-port valvebody used (port A-AB closed in the case of a three-portvalve).

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 commandfrom the wall thermostats.

8.2 - Replacing actuators

The actuators on both the chilled water and the hot watervalves may be replaced if either develops a fault.

a) Disconnect the power supply to the unit before carryingout any work on a unit.

b) Disconnect the actuator power supply cable.Remove the plastic protection cover (held in place with twohexagon head (8 mm AF) screws). Disconnect the quickconnect power supply cable on the actuator. This can be doneby using a screwdriver to press down on the spring tongue andpulling out the wire from the appropriate terminal.

c) Uncouple the faulty actuator. Reverse the removal proce-dure described above when installing the replacementmotor.

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

8.3 - Electrical circuit diagrams for actuators

8.4 - Replacing a valve body

a) Disconnect the power supply to the unit before carryingout any work on a unit.

b) Close the isolating valves on the manifolds.

c) Uncouple the actuator from the valve body.

d) Disconnect the 1/2” gas connection nut on the flexiblewater pipe from the valve to be replaced.

e) Unscrew and remove the valve body to be replaced (1/2”gas connection).

f) Install a new valve body on the coil.

g) Reconnect the flexible water pipe.

h) Reinstall the actuator ensuring that it is securely screwed to the valve body.

i) Tighten all water pipes ensuring that all seals are cor-rectly installed (torque 15 N/m).

j) Open the isolating valves on the manifolds and bleed allair from the system.

k) Check that there are no leaks and restart the ULTRA.

WARNING:When replacing a valve always ensure that the direction offlow through the valve is as shown by the arrow on the valvebody.

If the direction of flow is wrong, the valve will deterioraterapidly.

ACTUATOR FORHEATING VALVE

BROWN BLUE

ACTUATOR FORCOOLING VALVE

BLUEBROWN

BROWNRED

BLACK


CHANGEOVER

FM

FM

22

8.4.1 - Two-port valve body 8.4.2 - Three-port valve body

DIRECTION ARROWTO COIL

Two-port valves

Three-port valves

9 - FLEXIBLE WATER PIPES

• Materials- Pipes: MEPD-based elastomer (modified ethylene-propy-

lene-diene)- Braid: 304L stainless steel- Insulation: cell foam rubber to M1 fire rating (chilled

water pipes only, 9 mm thickness).• Characteristics

- Minimum bending radius: 35 mm non-insulated, 75 mminsulated

• The flexible water pipes are designed to carry treated oruntreated water (maximum 40% concentration of ethyleneglycol or propylene glycol).

• Maximum hot water temperature 90°C• Operating pressure: 16 bars• Test pressure: 24 bars• Connections: 1/2” BSP threaded nut

CONNECTOR NUT- THREAD DEPTH 9.5 MM- INTERNAL THREAD 1/2” TO STANDARD NFE 03-005- PROVIDE LEAKTIGHT SEAL (NOT SUPPLIED BY CARRIER)

CONNECTOR NUT- THREAD DEPTH 9.5 MM- INTERNAL THREAD 1/2” TO STANDARD NFE 03-005- PROVIDE LEAKTIGHT SEAL (NOT SUPPLIED BY CARRIER)

23

10 - AIR FILTER AND ACCESS

10.1 - Description

The 42BJ ULTRA is fitted with a high efficiency filter.

Fire rating medium M1, metal frame

Three filter access options are provided on the 42BJ:• From above for units in false floor voids• From below for units in false ceiling voids• From the side for every installations

10.2 - Replacing the air filter

Air filters should be changed regularly. How often this is nee-ded depends on the cleanliness of the working environmentand the rate at which the filter becomes clogged.

If clogged filters are not changed they can increase the pressu-re drop, trapped dust particles may be given off and entrainedin the air supply, and the general performance of the ULTRAmay be degraded as the air flow reduces.

NOTE:The condensate drain pan is located at the suction end of thefan, and could therefore overflow if the air filter becameclogged. This is because the partial vacuum inside the unitcould stop the condensate from draining normally.

10.2.1 - Access from the side

To access the filter, open the latch, open the hinged accessdoor and remove the filter from its housing by releasing thetwo clips which hold it in place.

When replacing the filter, make sure that the sealing gasket isagainst the internal metal housing.

10.2.2 - Access from the above or below

In these situations the filter is installed in a removable plug-inunit. To replace the filter assembly, disengage the two latchesand withdraw the plug-in unit. Remove the old filter and inserta new one ensuring that the sealing gasket is against the inter-nal metal housing.

NOTE:When installing an ULTRA in a ceiling void, check that noT-beams will obstruct access to the filter or prevent the plug-in unit from being withdrawn.

DIRECTION OF AIR FLOW

FOAM GASKET

24

11 - ELECTRIC HEATER

11.1 - Electric resistance heater type - size 1.6• Specification: 230 V (±10%) - 1 ph - 50 Hz

• Capacity per heater: size 1.6 - 1000 W +5%/-10%)

• The heater is equipped with two safety devices:

a) An automatically controlled integrated safety thermostatwith a trigger temperature of 75°C.

When the trigger temperature is reached, a resistance hea-ter is automatically energised and prevents automatic reset-ting, if the system is energised, but has insufficient airflow. Reset is achieved by suppressing the supply voltageof the electric heater. The safety thermostat protects theunit from overheating, generally the result of electricitypassing through the heater when there is insufficient airflow.

b) A thermal fuse tripping at 150°C.

NOTE: The minimum discharge air flow of 64 l/s (230 m3/h)is required to avoid damage to the electric heaters.

CAUTION: It is vital to disconnect the 42BJ from the gene-ral power supply before working on the electric heater.

11.2 - Shielded electric heater with spiral fins - sizes2.6 and 4.7

This is a shielded electric heater with spiral fins. It has twostages, each of 800 W (+5%; -10%) wired in parallel. Theelectrical resistors are connected within an IP407 galvanisedsheet steel casing which is fitted with a packing gland to admitthe power supply cable.

The heater unit is fitted with a manually reset safety thermo-stat. This normally closed contact is triggered by a rise in tem-perature to 112°C (+0; -16).

The safety thermostat protects the unit from overheating, gene-rally the result of electricity passing through the heater whenthere is insufficient air flow. The thermostat can be resetwithout dismantling the unit. Simply remove the protectivecover from the terminal box (casing) on the heater and pressthe small plastic rod located in the middle of the thermostat.However, if the safety thermostat is triggered, it is essential tofind and rectify the cause before resetting.

11.3 - Replacing the electric heater - sizes 2.6 and 4.7

If the electric heater develops a fault, the assembly must beremoved and replaced.

CAUTION:It is vital to disconnect the ULTRA from the main power sup-ply before carrying out any work on the electric heater.

The heating resistors and casing form a single plug-in unit tosimplify dismantling for maintenance purposes.

a) Remove the protective cover from the terminal box byundoing the 2 hexagon head 8 mm AF screws which hold it inplace.

b) Disconnect the power supply cable from the electric heater.This consists of three wires ending in eyelet lugs on the neu-tral and live conductors and a flat lug on the earth conductor.

SAFETY THERMOSTATRESET SWITCH

ELECTRIC HEATER

25

c) Remove the electric heater by taking out the two screwsholding the protective casing in place (hexagon head 8 mmAF).

d) Replace the defective heater with a new one.

e) Reverse the above procedure to install the new electric hea-ter.

11.4 - Wiring diagram for a single stage of the elec-tric heater

The electric heater can be rewired on site to use a single 800W resistor. For this, remove the two copper connection strips.A label attached to the 42BJ shows how the two heating resis-tors should be rewired.

11.4.1 - Wiring diagram for one stage of an electric heaterfor a size 1.6 ULTRA



CAUTION:It is vital to disconnect the ULTRA from the main power sup-ply before carrying out any work on the electric heater.

SIZE 1 ELECTRIC HEATER POSITION

ELECTRIC HEATER

REMOVE COPPER CONNECTION STRIPS

BRIDGE

Green/Yellow

Brown

Blue

CABLE-FREETERMINALS

SIZES 2 & 3 ELECTRIC HEATER POSITION

ELECTRIC HEATER

REMOVECOPPERCONNECTIONSTRIPS

BRIDGE

Green/YellowBlue

CABLE-FREE TERMINALS

Brown

GREEN/YELLOW

BROWN

BLUE

BRIDGE CABLE-FREE TERMINALS

SIZE 4 ELECTRIC HEATER POSITION

ELECTRIC HEATER

BLUE WIRE

BROWNWIRE BRIDGE

GREEN/YELLOWWIRE

CABLE-FREE TERMINALS

1. Remove the 2 copper connection strips2. Wire the resistor as described

26

12 - CARRIER ELECTROMECHANICAL CONTROLLER

12.1 - Description

The ULTRA may be fitted with an electromechanical control-ler developed and tested by Carrier in our research and deve-lopment laboratories.

If this option is taken, each ULTRA then has a water flowcontrol valve or valves of the “on/off” type, flexible waterpipes to simplify the connection of units to the primary hotand/or chilled water circuits, and in appropriate cases a powerrelay for controlling the electric heater.

This option also includes a male-female quick connect termi-nal block for connecting the various cables that come from thethree speed fan motor, the valve actuators, the electric heaterpower relay and, if appropriate, from the heating/coolingchangeover configuration switch for ULTRAs fitted with asingle “hot or cold” coil.

The male-female quick connect terminal block and the electricheater power relay are mounted on DIN rail and protected byan ABS cover.

The DIN rail is made large enough to accept a bipolar discon-necting switch and integral fuse holder (please contact yourCarrier representative).

The quick connect terminal block and flexible water pipes willbe appreciated when servicing work is being carried out, sincethey enable service times to be significantly reduced.Replacing or moving a unit becomes a simple matter.

A wall-mounted room thermostat can be supplied with theULTRA as an accessory. This thermostat will be connecteddirectly to the female side of the quick connect terminal block(see section describing room thermostats).

12.2 - The various ULTRA configurations available

Each ULTRA can be fitted with one or two on/off valves, twoor three ports and flexible water pipes, depending how the hea-ter is configured.

a) The ULTRA is fitted with a 5-row cooling coil (2 pipes).

Operates in cooling mode only.

This option includes a 2-port on/off valve and two insulatedflexible water pipes.

b) The ULTRA is fitted with a 5-row cooling or heating coil(2 pipes with changeover).

Operates in cooling or heating mode. This application is of theheat pump type.

This option includes a 3-port on/off valve, a heating/coolingchangeover switch and two insulated flexible water pipes.

c) The ULTRA is fitted with a 5 row cooling coil and 1 rowheating coil (4 pipes).

Operates in cooling and heating mode in sequence.

This option includes 2 valves, 2 on/off ports and 4 flexiblewater pipes, 2 of which are insulated and 2 uninsulated.

d) The ULTRA is fitted with a 5 row cooling coil and anelectric heater (2 pipes and 2 wires).

Operates in cooling mode or heating mode with electric heaterin sequence.

This option includes a 2-port on/off valve, 2 insulated flexiblewater pipes and 1 power relay for controlling the electric hea-ter.

12.3 - Technical specification for the heating/coolingchangeover switch

The heating/cooling changeover switch is designed to be in-stalled straight onto the couplings of the 3-port valves on theULTRA. It detects temperature changes in the fluid circulatingin the primary water circuit. A changeover switch operatesaccording to the water temperature in accordance with the dia-gram below.

WIRE LENGTH:1000 mm

27

When a heating/cooling changeover switch is connected be-tween the room thermostat and the water flow control valve,the changeover between heating and cooling modes takesplace automatically in accordance with the following diagram.

BLUEBROWN

BROWNRED

BLACK


CHANGEOVER

∆: Differential: 11,1 K ± 3,3CM: Cooling modeHM: Heating modeθ: Water temperature in °C

FM

28

12.4 - Master/slave control

It is possible to link a maximum of two ULTRAs to one Carrier thermostat without the need for additional relays. Electrothermalon/off valves rated at 230 V a.c. are used. When electric heaters are used with a cooling coil, it is essential for the electric heaterto have a power relay.

Alimentation : 230V, 50Hz, 1 ph3G1,5mm2

Protection : T 2A

N L

5 x 0.75mm2

7 x 0.75mm2

Vitesse 2

Vitesse 3 (GV)

L : alimentation thermostat (230V a.c.)

N : alimentation thermostat (230V a.c.)

Vitesse 1 (PV)

Ouverture vanne chaude

Ouverture vanne froide


Protection : T 2A

N L

4 tubes

5 x 0.75mm2


Protection : T 16A

N L

7 x 0.75mm2

Commande batterie électrique

Vitesse 2

Vitesse 3 (GV)



Vitesse 1 (PV)



Protection : T 16A

N L

2 tubes - 2 fils

12.5 - Master/slave control: two-pipe + electric heater configuration

Coolingvalve

Heatingvalve

Fan

Supply:230 V, 50 Hz, 1 phase

3G1, 5 mm2

Protection: T2A


3G2, 5 mm2

Protection: T16A

Speed 1 (LS)Speed 2Speed 3 (HS)

Cooling valve controlHeating valve control

L: Thermostat supply (230 V a.c.)

N: Thermostat supply (230 V a.c.)

Fan


3G1, 5 mm2

Protection: T2A

Fan

Fan

Coolingvalve


3G2, 5 mm2

Protection: T16A

Speed 1 (LS)Speed 2Speed 3 (HS)

Cooling valve control

Electric heater control



Coolingvalve

Four-pipe configuration

Two pipes, two wires

SLA

VE

MA

ST

ER

SLA

VE

MA

ST

ER

29

12.5 - Wiring diagrams

The ULTRA unit can be supplied without a control system,that is, without valves or flexible water pipes, but with fancable bundle and electric heater ready to connect (dependingon the configuration).

If this option is chosen, the ULTRA is supplied without a ter-minal strip, power relay or plastic protective cover.

This option is specially provided for installers who wish to fitthe control system to the ULTRA themselves.

12.5.1 - Wiring diagrams with cable bundles ready toconnect

Fan wiring

Electric heater wiring

HIGHSPEED

SECTION 5 x 1 mm2

BLU

E

RE

D

GR

EY

BLA

CK

GR

EE

N/Y

ELL

OW

FAN

MEDIUMSPEED

LOWSPEED

NEUTRAL

BROWN

BLUE

GR

EE

N/Y

ELL

OW

SECTION 3 x 1.5 mm2

230 V a.c./50Hz

230 V a.c.50Hz

30

Alimentation : 230V, 50Hz, 1 phase3G1,5mm2

Protection : T 2A

N L

LIAISON: 6 x 0.75mm2

Vitesse 1 (PV)




Vitesse 3 (GV)

Vitesse 2

Configuration 2 tubes

Configuration 2 tubes avec inverseur chaud / froid


Protection : T 2A

L

L : alimentation thermostat (230V a.c.)N : alimentation thermostat (230V a.c.)

Commande vanne chaude

Vitesse 2

Vitesse 3 (GV)

7 x 0.75mm2

Commande vanne froide

Vitesse 1 (PV)

N


12.5.4 - Five row coil, cooling

12.5.3 - Five-row coil with heating/cooling changeover switch

Power supply 230 V, 50 Hz, 1 phase(3 x 1.5 mm2)Protection: T2A

Cables: 6 x 0.75 mm2

Coolingvalve

Power supply 230 V, 50 Hz, 1 phase (3 x 1.5 mm2)Protection: T2A

FanCables: 7 x 0.75 mm2

Fan

Speed 1 (LS)

Speed 2

Speed 3 (HS)



Speed 1 (LS)

Speed 2

Speed 3 (HS)


Heating valve control



Change-over

Cooling valve open

Two-pipe configuration

Two-pipe configuration with heating/cooling/ changeover switch

31

12.5.4 - Six-row coil, five rows cooling, one row heating

12.5.5 - Five-row cooling coil and electric heater (2 x 800 W)

7 x 0.75mm2


Protection : T 2A

N L



Ouverture vanne chaude

Vitesse 2

Vitesse 3 (GV)


Vitesse 1 (PV)

Configuration 4 tubesLIAISON: 7 x 0.75mm2

LN


Protection : T 16A

6 x 0.75mm2

Vitesse 3 (GV)




Vitesse 1 (PV)

Vitesse 2

Configuration 2 tubes et batterie électrique

Commande chauffage électrique


Power supply 230 V,50 Hz, 1 phase 3G 2.5 mm2

Protection: T16A

Power supply 230 V,50 Hz, 1 phase 3G 1.5 mm2

Protection: T2A


Coolingvalve

Fan

Speed 1 (LS)

Speed 2

Speed 3 (HS)



Heatingvalve


Coolingvalve

Fan

Speed 1 (LS)

Speed 2

Speed 3 (HS)




Heating valve control

Cooling valve open

Electric heater control

Four-pipe configuration

Two-pipe configuration + electric heater

32

13 - ACCESSORIES

13.1 - Adjustable feet for installing an ULTRA in afalse floor

13.1.1 - Introduction

An ULTRA may be installed in a false floor. Adjustable feetwith built-in vibration absorbers are available as optionalextras for installation on site. For further information pleasecontact your local Carrier representative.

13.1.2 - Procedure for fitting

1. Install angle bracket 1 using the screws supplied.There are two possible height settings with different adjust-ment ranges:- high setting: adjustment range 15 to 27 mm,- low setting: adjustment range 33 to 45 mm.

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

13.2 - Condensate drain pump

13.2.1 - Introduction

An ULTRA can be fitted with a condensate drain pump, prefe-rably before but if necessary after the unit has been installed ina false floor or ceiling.

13.2.2 - Procedure for fitting

1) Compare the contents of the parts kit with those shownin Fig. 1 on page 34.

2) Install the detector block support bracket.

• Install the aluminium detector block bracket on the conden-sate drain pan as shown in Fig. 2-A (page 34).

NOTE:The detector support bracket must be installed horizontallyas shown in Fig. 2 (maximum angle 15°) on page 34.

3) Install the detector block

• Use the rubber tube supplied to connect the detector to thecondensate drain (Fig. 2-B).

• Connect the 6 mm bore flexible tube to the outlet stub on thedetector.

• Connect the small 6 mm bore flexible tube to the vent outletof the detector block.

• Attach the detector block support to the aluminium bracketwith the double-sided adhesive tape supplied (Fig. 2, page34), and then, clip the detector block to the plastic bracket.

NOTE:The detector must be installed horizontally.The rubber tube must be attached to the outlet stub on thecondensate drain pan by a collar (not supplied by Carrier).

4) Install the pump support bracket

• The pump support bracket must be attached to the ULTRAby the two self-tapping screws provided. A self-adhesivelabel showing the attachment plan is designed to help in thefitting process (Fig. 3, page 35).

5) Install the pump

• The pump can be installed anywhere and can be up to 2.5metres above the unit.

• Using the 2 screws supplied, fix the pump to the metal sup-port bracket previously fixed to the ULTRA.

NOTE:There must be a space left around the pump unit so that it isprovided with cooling when operating for long periods oftime.

The pump unit must not be immersed or placed outside ofthe premises or in damp place.

FIXING HOLES FOR ADJUSTABLE FEET

HIGH POSITION LOW POSITION

33

6) Connect the detector to the pump

• Connect the telephone type RJ11 connector to the pump.• Connect the 6 mm bore flexible tube to the ribbed outlet on

the pump as shown in Fig. 4 on page 35.• The arrow on the pump body shows the direction of water

flow.

7) Connect the pump

• Connect the 6 mm bore flexible tube between the ribbed out-let on the pump and the common condensate drain.

8) Mains connection

• Connect the power supply of the ULTRA to the mains supply(as shown in fig. 4) by means of:

- an interconnexion cable (HO VVF) with 0.75 mm2 lengths,provided with an electric protection and isolating device(not supplied) conformed to the IEC 345 standard on phaseand neutral

- a fusible on phase of 630 mA.

WARNING:Before power supply, make sure that the cover of the pumpunit is properly closed.

WARNING:If proportional valves are installed in the air conditioningunits, an additional safety device must be provided that caninterrupt the chilled water production, in case there is apower cut.

9) Connect the alarm

The condensate level detector consists of a float which candetect three different levels:• Pump on level: 17 mm ± 2 mm of condensate. When thislevel is exceeded the pump will start automatically.• Pump off level: 11 mm ± 2 mm of condensate. When thepump has been operating, it will shut off when the level fallsbelow this threshold.

Alarm level: 21 mm ± 2 mm of condensate. This situationgenerates an alarm from which recovery is by means of a dry-reed output. If the alarm threshold is reached or exceeded, thecondensate drain pump keeps running.

The alarm condition applies if the condensate level is abovethe alarm threshold.

The alarm condition no longer applies when the level is belowthe alarm threshold.

The device includes a potential-free changeover switch with acapacitance 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 alarmcondition) → the contact is open if the wiring is NO or closedif the wiring is NC.

If the condensate level is above the alarm threshold (alarmcondition) → the contact is closed if the wiring is NO or openif the wiring is NF.

10) Function test

Tip a small quantity of water into the drain pan. Check that thepump starts, draws water away and stops when the water levelfalls. Add more water until the alarm operates.

11) Service

Periodicity: at the beginning of the season.

Clean the detection unit and the filter. Disconnect from mainssupply before opening.

Remove the lid, remove the filter, remove the float, clean thedetection unit and the float using a solution of water contai-ning 5% bleach. Replace the float in its initial position(magnet faced upwards), reinstall the filter, reinstall the lid andscrew it down (maximum torque load 0.7 Nm). Carry out anoperating test on the pump and the alarm. When the air condi-tioner is installed in areas liable to cause of favor extensivedirtying of the condensate water, maintain more frequently.

12) Features of the condensate drain pump

Maximum flow: 0,0027 l/s (10 l/h)Maximum lift: 60 kPaMaximum suction: 25 kPaPower supply: 230 V ± 10%/ 50 Hz/single phasePower consumption: 18 VA

13) Safety

• The alarm contact will prevent overflow (cutting off the refri-geration)

• An auto-resetting thermal circuit breaker cut-off temperature70°C

• Grounding of pump• Safety transformer as per standard EN 60 742• Housing of ABS VO.

34

RUBBER TUBE

DOUBLE SIDE ADHESIVE TAPE

PUMP BLOCK

DETECTOR BLOCK

PUMP BLOCK SUPPORTBRACKET

DETECTOR BLOCK SUPPORT

LABEL SHOWING THE ATTACHMENT PLAN FORFIXING THE PUMP BLOCK SUPPORT BRACKET

ALUMINIUM DETECTOR BLOCK BRACKET

FLEXIBLE TUBES

2-A

2-B

Pump kit (Fig. 1)

PUMP BLOCK SUPPORT BRACKETFIXING SCREWS

Installing the detector on the drain pan (Fig. 2)

35

FIXING SCREW

PUMP SUPPORT BRACKET

PHASE

NEUTRAL

EARTH

DON’T PINCH THE TUBE

NORMALLY CLOSED

PUMP OUTLET

ELECTRICAL CONNECTION

NORMALLY OPEN

COMMON

LABEL SHOWING THE ATTACHMENT PLAN

Pump connections (Fig. 3)

Pump block installation (Fig. 4)

RJ11 CONNECTION(THELEPHONE TYPE)

PUMP INLET

CONDANSATE DRAINFLEXIBLE TUBE Ø 6

SMALLFLEXIBLE TUBE

DON’T PINCH THE TUBE

Manufacturer: Carrier s.a., Montluel, France.Printed in Holland.

Order No.: 14252-76, 06.2005 - Supersedes order No.: 14211-76, 07.2002.Manufacturer reserves the right to change any product specification without notice.

Carrier S.A.S. Demonstration SuiteWhether you live in the tropics or in Greenland

Whether you suffer from the heat, from the cold or from lack of airCARRIER has the solution and can show it to you in the demonstration suite

The programmes available

simulation of the climate in your region

simulation of the heating and cooling loads according toyour needs

measuring, storing and display of the air temperaturesand the air distribution pattern taking into account your cli-matic and architectural constraints - even at climaticextremes

optimisation of the physical location of the air terminals inyour building walls or ceilings

determination and control of the sound level in everyroom

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

Experience a real preview of your future installation

Date post:	03-Apr-2020
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