42EL Ducted Fan Coil Unit - Acare · 2.1 - Physical and electrical data ... 14 3.1 - General ... The Carrier 42EL Aqualia compact fan coil unit is available in

Installation Manual

42EL

Ducted Fan Coil Unit

SupplyModuboot

The photograph on the front cover is for illustrativepurposes only and is not part of any offer for sale orcontract. The manufacturer reserves the right to change thedesign at any moment without prior warning.

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

2 - FEATURES ........................................................................42.1 - Physical and electrical data ...............................................52.2 - Dimensional drawings.......................................................62.3 - Aqualia packaging...........................................................132.4 - Receiving a shipment - installation method ...................13

3 - SAFETY CONSIDERATIONS.......................................143.1 - General ............................................................................143.2 - Precautions against electrocution ...................................143.3 - Installation recommendations .........................................143.4 - Conformity ......................................................................14

4 - INSTALLING THE AQUALIA .....................................154.1 - Co-ordinating the unit with the false ceiling ..................154.2 - Installation precautions ..................................................154.3 - Installation procedure .....................................................154.4 - Removal procedure .........................................................16

5 - FRESH AIR .....................................................................185.1 - Fresh air controller ......................................................... 185.2 - Fresh air duct accessory item ..........................................18

6 - FAN MOTOR ASSEMBLY ............................................196.1 - Description .....................................................................196.2 - Fan assembly removal procedure....................................196.3 - Capacitor replacement procedure....................................20

7 - ELECTRIC HEATER .....................................................217.1 - Description .....................................................................217.2 - Electric heater replacement procedure ............................21

8 - DUCT CONNECTION SPIGOTS..................................22

9 - WATER COIL .................................................................229.1 - Description .....................................................................229.2 - Coil removal procedure ..................................................229.3 - Coil inlet/outlet positions ...............................................23

10 - WATER FLOW CONTROL VALVES ........................2510.1 - Electrothermal actuator (on/off) ...................................2510.2 - Actuator replacement procedure ...................................2510.3 - Actuator electrical connections .....................................2510.4 - Valve body replacement procedure ...............................2610.5 - Technical specification for the heating/cooling

changeover switch .........................................................28

11 - FLEXIBLE WATER PIPES .........................................2911.1 - Two-way valves ............................................................2911.2 - Three-way valves .........................................................30

12 - AIR FILTER AND ACCESS .......................................3112.1 - Description ...................................................................3112.2 - Air filter replacement ....................................................31

13 - CONTROLS ...................................................................3213.1 - MAESTRO numeric controller ....................................3213.2 - Carrier electronic thermostat ........................................3213.3 - Carrier EXCEL 10 controller .......................................34

14 - ACCESSORIES .............................................................3914.1 - Condensate drain pump ................................................3914.2 - Adjustable feet for installing Aqualia units

in false floor voids.........................................................42

15 - AQUALIA PERFORMANCE DATA...........................4315.1 - Electrical data................................................................4315.2 - Air flow data ................................................................44

Contents

44

1 - INTRODUCTION

The Carrier 42EL Aqualia compact fan coil unit is available intwo sizes and with two motor drive combinations and iscapable of air conditioning rooms from 25 to 50 m2 in area.

The main components of each unit comprise a centrifugal fan,a fresh air inlet with an air flow regulator (option), a chilledwater cooling coil and either a hot water heating coil or anelectric heater.

Connections between the unit and one or more linear bootdiffusers (35BD/SR Moduboot range), installed in the falseceiling above the area to be air conditioned are made on siteusing thermally and acoustically insulated flexible ducting.

The complete system comprises one or more Carrier air or water-cooled chillers and one or more air handling units to supply freshair to the 42EL Aqualia units. These may be installed in falseceiling or under floor voids (for size 1 only) where they can beconnected to the fresh air supply and the hot and chilled-watercircuits.

With a low height of less than 230 mm (for size 1 only), the 42ELAqualia can be installed in most areas. Its design allows for easymaintenance.

Different duct connection spigot arrangements allow mostsite requirements to be accommodated. The supply andreturn air plenum connection spigots are sized for theconnection of Ø 200 or 250 mm (depending on sizes)supply/return air ducts and the Ø 125 or 160 mm fresh airsupply duct.

The position and number of supply/return plenum connectionspigots are configured to allow for the connection of 2 or 3ducts for size 1, 3 or 5 ducts for size 2, for the supply as well asfor the return, as shown below. An open (non ducted) return airinlet may be provided instead of a return plenum.

NOTE:It is strongly recommended to select more than 3 ducts ateach adapter, for sizes 1.2 or 5.2.

Noise or more precisely the absence of noise is a decidingfactor in the selection of an air conditioning system.

The Aqualia has been designed to be particularly quiet.

Low noise levels and easy maintenance are key factorsinfluencing the selection of an air conditioning system.

2 - FEATURES

The modular design of the Carrier Aqualia allows it to meet thedifferent heating or air conditioning requirements of medium-sized spaces. With an overall depth of only 230 mm (for size 1only) including fixings, these units are easily installed insuspended false ceilings or false floor voids.

The Aqualia casing is manufactured from 1.2 mm galvanisedsheet steel lined internally with a 6 mm layer of melaminewhich is itself protected by an aluminium film in order toguarantee the thermal and acoustical insulation of the unit.

Several Aqualia versions are available to meet different siterequirements:

Aqualia size 1

• unit with ducted return air. Filter removal is either from belowfor ceiling void installations or from above for floor voidinstallations.

• unit with open (non ducted) return air inlet. Filter removal isfrom the rear of the unit

Aqualia size 2

• Filter removal is from the unit side, independent of theconfiguration: with ducted return air or with open return airinlet.

NOTE:Operating limits:

Cooling Mode: Supply air temperature 12°C, when the unitis installed in an ambient temperature of 27°C dry bulb and65% relative humidity.

Heating Mode: Maximum supply air temperature 60°C.

The 42EL is designed for internal application in non corrosive,dust free and non marine urban environments. Theconcentrations of the following gases must not be exceeded:

SO2 < 0.02 ppmH2S < 0.02 ppmNO, NO2 < 1.0 ppmNH3 < 6.0 ppmN2O < 0.25 ppm

55

2.1 - Physical and electrical data

Legend:(1) At nominal air flow(2) Refer to performance data tables* Based on an entering water temperature of 7°C, entering air at

27°C dry bulb and 47% relative humidity, and a water temperaturedifference of 5 K at nominal air flow (EUROVENT conditions).

** Based on an entering water temperature of 50°C, entering air at20°C and a water temperature difference of 10 K at nominal airflow (EUROVENT conditions).

42EL Aqualia Size 1.1 or 5.1 Size 1.2 or 5.2 Size 2.3 Size 2.4Nominal air flow l/s (m3/h) 204 (735) 254 (915) 442 (1590) 526 (1895)Total cooling capacity - chilled water coil (1) kW* 4.3 5.1 10.2 11.6Sensible capacity - chilled water coil (1) kW* 3.3 4.0 7.8 9.0Heating capacity - hot water coil (1) kW** 4.4 5.3 11.6 13.4Power supply 230 V - 1 ph - 50 Hz U% ± 10 ± 10 ± 10 ± 10Operating weight (4-row water coil) kg 52 53 85 85

Water coil3/8 in. Ø copper tubesAluminium fins, purge valve, female connection• Test pressure kPa 2400 2400 2400 2400• Operating pressure kPa 1600 1600 1600 1600

2-row coil• Connection 1/2” nut (gas) 3/4” nut (gas)• Water content l 1.7 1.7 3.5 3.5

Monobloc 4-row coil• Cooling connection: 1/2” nut (gas) 3/4” nut (gas)• Heating connection: 1/2” nut (gas)• Water content- cooling l 1.7 1.7 3.5 3.5- heating l 0.6 0.6 1 1

Electric heater-resistance wire type• Power supply: 230 V - 1 ph - 50 Hz U% ± 10 ± 10 ± 10 ± 10• Heating capacity - excluding fan heat (+5%; -10%) W 1000 1500 2000 2000• Self-resetting safety thermostat cut out temperature °C 75 75 75 75• Over temperature thermofuse link, fusing temperature °C 150 150 150 150• Current absorbed A 4.35 6.52 8.7 8.7• Minimum heater air flow required l/s (m3/h) 64 (230) 122 (440) 97 (350) 97 (350)

Fan• Forward curved centrifugal fan

number of centrifugal wheels 2 3 2 2• Nominal air flow l/s (m3/h) 204 (735) 254 (915) 442 (1590) 526 (1895)• Static pressure available at nominal air flow (2)

(unit without supply and return air octopus) Pa 50 50 65 65

MotorSupply voltage: 230 V - 1ph - 50 Hz, 2-pole asynchronous,internal overload protection, permanent capacitor,class B winding insulation, varnish class F.• Maximum absorbed power at 230 V (2) W 105 158 290 350• Nominal current (2) A 0.5 0.75 1.26 1.52• Starting current A 0.86 1.97 1.97 2.85

Air filterThrowaway, fire rating medium: M1 (French standard)• Dimensions mm 218 x 984 218 x 984 310 x 1100 310 x 1100• Filter efficiency: 65% (gravimetric)

Fresh air connectionOutside diameter mm 125 125 125/159 125/159Constant minimum air flow (-10%; + 20%) l/s (m3/h) 8.3 (30) 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)/69.4 (250) 44.4 (160)/69.4 (250)∆P (upstream/downstream):- Controller 8.3 l/s (30 m3/h) Pa 50-200 50-200 50-200 50-200- Controller 44.4 l/s (160 m3/h) or 69.4 l/s (250 m3/h) Pa 70-200 70-200 70-200 70-200

Aqualia water connectionsThe water circuit in the Aqualia units is guaranteed for an operating pressure of 1000 kPa, although the Aqualia units components are individuallydesigned and tested for a pressure of 1600 kPa.For applications requiring an operating pressure of more than 1000 kPa, please contact your local Carrier representative.

66

2.2 - Dimensional drawings

2.2.1 - Maintenance access space required, mm

Sizes 1.1 or 5.1 and 1.2 and 5.2

- Ducted return air- Non-ducted return air

77

2.2.1 - Maintenance access space required, mm (continued)

Sizes 2.3 and 2.4

- Non-ducted return air- Ducted return air

88

Filter access sizes 1.1 or 5.1 and 1.2 and 5.2

Ducted return air

Non-ducted return air

9

Filter access sizes 2.3 and 2.4

10

2.2.2 - Overall dimensions, mm

Sizes 1.1 or 5.1 and 1.2 and 5.2

- Non-ducted return air- Ducted return air

11

2.2.2 - Overall dimensions, mm (continued)

Sizes 2.3 and 2.4

Non-ducted return air

12

Return Octopus

1313

2.3 - Aqualia packaging

Aqualia units are packed on wooden pallets, separated byspacers and protected by heat-shrunk or stretchable plastic film.

NOTE:For “Export” packing please contact your local Carrierrepresentative.

Pallet weight and dimensions

N° of units Length Width Height Weightper pallet (mm) (mm) (mm) (kg)

Sizes 1.1 or 5.1and 1.2 or 5.2 7 1600 1100 1810 400

Sizes 2.3 or 2.4 4 1700 1500 1700 375

NOTE:Check the packaging for damage upon receipt of theequipment. Unpacking of the equipment should be left untiljust before final installation to avoid any damage ordeterioration to the units on site.

2.4 - Receiving a shipment - installation methods

Check the condition of the equipment upon receipt, anydamage due to transport should be notified in writing to thetransporter. Unpacking of the equipment should be left untiljust before final installation and should be as close to theinstallation as possible. Avoid placing any heavy objects on thepacking.

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

The presence of electrical components creates hazards to thoseinstalling and servicing these units. Only properly qualifiedelectricians may be authorised to instal, service and repair theseunits. Some routine maintenance such as cleaning of the coilsand filter replacement may be entrusted to non-skilledpersonnel. Before carrying out any work, all personnel,including qualified technicians, must familiarise themselveswith the contents of this manual and all name plates and labelsattached to the units. It is essential to adhere to all applicablelocal safety regulations. Wear eye protectors, safety gloves andnon-flammable clothing when soldering or brazing. Alwayshave a fire extinguisher of the appropriate type close at hand.

NOTE:Disconnect the power supply to the unit and to anyaccessories before carrying out any work on a unit.

Do not instal units in environments where flammable gases orproducts of an acidic or alkaline nature may be present. Thecopper/aluminium coil or plastic components inside the unitcould suffer irreparable 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.

1414

3 - SAFETY CONSIDERATIONS

3.1 - General

Installing, commissioning and servicing of the variouscomponents which make up the different control loops can bedangerous 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 instal, commission and service this equipment.

During servicing work, it is essential to apply allrecommendations and instructions given in service leaflets, onlabels or in the instructions delivered with the equipment, andto comply with any other relevant instructions.

Definition of the pictograms used

Electrical Danger

Caution hand hazard

General Danger

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 have accessto 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 control loopsdescribed in this manual include electronic items. As such,they may generate or be harmed by electromagneticinterference unless they are installed and used in accordancewith these instructions. The components making up thesecontrol systems conform to the requirements ofelectromagnetic compatibility in residential and industrialareas. They also comply with the low-voltage directive.

3.3 - General installation recommendations

IMPORTANT:The controllers must have an isolating device upstream (forexample a double-pole circuit breaker). If necessary, aneasily operated emergency stop device (such as a punch-button switch) must cut off the power to all equipment. Thesesafety devices shall be sized and installed in accordance withIEC Recommendation 364, corresponding to Europe HD 384,France NFC 15 100 and UK IEE Wiring Regulations. Thesedevices are not supplied by Carrier.

In general terms the following rules must be applied:

- Units must be provided with overvoltage protection upstream(not supplied by Carrier)

Upstream overvoltage protection

Unit without electric heater T2A

Standard unit size 1 with electric heater T10A

Standard unit size 2 with electric heater T16A

- 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 and the communication buses must be carriedout in accordance with the latest rules and regulations byprofessional installers.

- The power supply cable must be doubly insulated and fixedusing an appropriate cable clamp or the cable clamp suppliedwith the MAESTRO controller. The cable must be clampedon the outer insulation.

- The control loop components must be installed in anenvironment, 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 keptphysically 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 incommon with the 230 VAC, 30 A cable)

• Do not pass low-voltage wires through loops in the powercables

• Do not connect heavy inductive loads to the sameelectrical supply (circuit breaker) used by the controllers,power modules or speed controllers.

• Use the screened cable type recommended by Carrier andmake sure all cables are connected to the controllers andpower modules.

3.4 - Conformity

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

1515

4 - INSTALLING THE AQUALIA

4.1 - Installing the unit in the false ceiling

Before beginning the installation process it is advisable tobecome familiar with the overall installation drawing. Amounting template, available your local Carrier representative,will assist in planning the installation. Co-ordinate theinstallation of the Aqualia units and the 35BD/35SRModuboots or other types of diffusers with the supply andreturn air ducts and the fitting of the false ceiling.

4.2 - Installation precautions

During the installation process, remove all debris andconstruction material from the ducts to prevent any damage tothe unit.

4.3 - Installation procedure

a) Position the Aqualia on the floor close to where it is to beinstalled in the ceiling or floor void.

• Floor void installation for units sizes 5.1 or 5.2

Remove the unit packing.

The adjustable rubber mounting feet are factory-installed.

• Ceiling void installation:

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

b) Check that the clearances around the unit are sufficient toallow for easy maintenance.

c) Offer the template up to the ceiling and mark the position ofthe threaded hangers.

The method of fixing the threaded hangers, not supplied byCarrier, depends upon the ceiling type. The maximum diameterof 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 to support the unit, but do not tighten.

NOTE:At this point do not tighten the nuts fully and do not clampthe unit up to the ceiling slab. The nuts will be finallyadjusted after the pipework or flexible connections have beenmade and the unit has been levelled.

d) Levelling the unit

Adjust the unit so that the condensate drain pan is about 5 mmbelow the opposite side of the unit. To check that the slope isadequate connect a 2 m length of 16 mm transparent tubing tothe drain stub. Empty some water into the drain pan until thewater level in the pipe is at the bottom of the auxiliary drainpan, point B.

The water level in the opposite end of the pipe, position A,should be about 5 mm below the bottom of the drain pan.

e) Condensate drain pipe

Use 16 mm internal diameter clear plastic cold water pipearranged to provide a uniform fall of 2 cm/m over thehorizontal pipe run. Instal a 50 mm (minimum) siphon toprevent waste water gases and odours from being drawn intothe ceiling void.

NOTE:The condensate drain pipe is secured to the drain pan by acollar (not supplied by Carrier).

31 to

43

1616

When several units are connected to a common condensatecollector, use the piping arrangement shown in the followingdiagram.

f) Instal the diffusers as shown on the false ceiling layoutdrawing.

Connect the supply and return air ducts to the correspondingspigot connections on diffuser and Aqualia plenums. When theunit and the false ceiling have been installed, and before start-up, remove the protective film from the diffuser.

NOTE:Aqualia units are connected to the diffusers by ducts. Thepressure drops in the ducts must be compatible with thecapacity of the unit. The inner surfaces of the duct must be assmooth as possible. Avoid sharp bends.

Check that there are no air leaks or kinks in the ducts.

Ensure that there is no dirt or construction material inside theducts that could be harmful to the mechanical components of thesystem such as the fan wheel and the diffuser damper actuators.

Check the noise level requirements and if necessary, add soundattenuators.

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

h) When installation is complete - i.e. the Aqualia is installedin the false ceiling or floor void, the air ducts are connected,the water manifolds are in position with isolating valvesfitted to the connection stubs, and the electrical installationis ready - connect the flexible water pipes (refer to “Flexiblewater pipes”).

Each flexible pipe has a 1/2” or 3/4” BSP union nut, followingthe unit size

Do not forget to fit a sealing washer (not supplied by Carrier)between the flexible pipe connector and the isolating valve.

i) When all units are installed, open the isolating valves on themanifolds, bleed and then pressurise the circuits. To bleedthe coils slightly undo the bleed screws.

j) Make the electrical connections.

Do not switch on the power until all power and earthconnections have been made.

The installation can now be started.

4.4 - Aqualia unit removal procedure

WARNING:Disconnect the power supply before carrying out any work onan Aqualia unit.

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.

• Maestro Zone and Excel 10 controller

Regarding the Excel 10 controller, remove the ABS protectivecover secured by two hexagon head screws (8 mm AF).

Disconnect the power supply cable and the earth wire fitted witha flat connector. Disconnect the quick connect coupler from theZone User Interface for the Maestro controller, from the wall-mounted thermostat for the Excel 10 controller. Whereappropriate disconnect the quick connect cable for the BMS bus.

Disconnect the quick connect coupler for the window contact.

• Carrier electronic wall-mounted thermostat

Remove the ABS protective cover secured by two hexagonhead screws (8 mm AF).

Disconnect the power supply quick connect coupler andwithdraw the earth wire complete with a flat connector.

c) Close the isolating valves on the manifolds.

d) Disconnect the flexible water pipes by unscrewing the unionnuts.

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

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

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

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

2% slope

5cm

sip

hon

1717

5cm siphon

2% s

lope

2% s

lope

1818

5 - FRESH AIR

5.1 - Fresh air flow controller

The Aqualia can be fitted with a constant fresh air flowcontroller allowing the introduction of fresh air and the airchange rate to be controlled. It is essential that the selection ofthe regulator takes into account the intended usage of the room.

The following range of fresh air controllers is available:

Option a: 8.3 l/s or 30 m3/h (-10%; + 20%) (size 1)Option b: 16.6 l/s or 60 m3/h (-10%; + 20%) (sizes 1 and 2)Option c: 69.4 l/s or 250 m3/h (-10%; + 20%) (size 2)

The fresh air supply is located upstream of the water coil.

Options a and b: the 125 mm spigot housing the fresh air flowcontroller is made of ABS plastic.

The 16.6 1/s (60 m3/h) fresh air controller may be modified onsite by relocating or removing two plastic restrictors in orderto increase the maximum constant fresh air flow capacity to44.4 1/s (160 m3/h).

A label on the 42EL shows how to adjust the two plastic restrictors.

Modification procedure

• Disconnect the fresh air duct from the spigot on the Aqualia.• Remove or reposition the two plastic restrictors, following the

fresh air flow controller.• Reconnect the fresh air duct to the spigot.

Option c: the 159 mm spigot housing the fresh-air flowcontroller is made of metal.

NOTE:Two types of plastic spigot and one type of metallic spigotmay be fitted to the Aqualia, depending on the capacity of thefresh air controller chosen. One plastic spigot can acceptonly the 8.3 l/s (30 m3/h) controller. The other one can acceptonly the field modifiable 16.6 l/s (60 m3/h) controller. Thismeans there is no possibility of mixing up the two types ofcontroller during installation or servicing.

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

NOTE:To operate correctly, the 8.3 l/s (30 m3/h) constant fresh airflow controller requires a differential pressure in the range50 Pa to 200 Pa. The 16.6 l/s (60 m3/h) constant fresh aircontroller requires a differential pressure in the range 70 to200 Pa.

5.2 - Fresh air duct accessory

Flexible fresh air duct, diameter 125 mm, maximum length0.5 m, supplied with fixing collars at each end (fresh air ductfire rating: M1, French standard).

1919

6 - FAN MOTOR ASSEMBLY

6.1 - Description

6.1.1 - Aqualia size 1

Aqualia size 1 has multi-speed fan-motor assemblies, withdouble-inlet forward-curved fans for unit size 1.1 or 5.1(735 m3/h or 204 l/s with 50 Pa available pressure) or triple-inlet forward-curved fans for unit size 1.2 or 5.2 (915 m3/h or254 l/s with 50 Pa available pressure).

Motor supply voltage is single-phase 230 V ± 10%, 50 Hz

An auto transformer provides the fan motor with 6 possiblespeeds, which allows the installer a large flexibility in settingthe air flows. A selection of three of the six available speedscan be made taking into account the local electromechanicaland electronic regulations in force. This adaptability is muchappreciated by installers.

Minimum speed: terminal 6Maximum speed: terminal 1

• As standard, 42EL units size 1 are prewired to the factorysettings, for speeds 1, 3 and 5.

• For other fan motor speed wiring combinations refer to theunit codification.

6.1.2 - Aqualia size 2

Aqualia size 2 has multi-speed fan-motor assemblies, withdouble-inlet forward-curved fans.

• Size 2.3: 1590 m3/h or 442 l/s with 65 Pa available pressure• Size 2.4: 1895 m3/h or 526 l/s with 65 Pa available pressure

The fan motor has four speeds, provided by a multi-windingelectric motor. Three of four speeds must be selected to allowconnection of the fan motor in accordance with the applicableelectromechanical or electronic regulations (for fan coils).

Minimum speed: terminal 4Maximum speed: terminal 1

• As standard, 42EL units size 2 are prewired to the factorysettings, for speeds 1, 2 and 3.

• For other fan motor speed wiring combinations refer to theunit codification.

NOTE:In order to simplify maintenance, the fan motor assembly isfixed by 6 or 8 lugs (depending on the unit size) and a singlescrew. Electrical connections are made using quickconnectors, preventing wiring errors and considerablyreducing service and maintenance time.

6.2 - Fan assembly removal procedure

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

Identify and note the fan speeds wired to the autotransformerterminal block or to the multi-winding electric motor.

If the fan develops a fault the whole assembly must beremoved and replaced.

a) Remove the filter

b) Unscrew the fan access panel. Remove the panel.

c) Disconnect the power supply cable, fitted with a quickconnector, to the fan motor assembly.

d) The fan assembly is held in place by one torx screw (T20)and several lugs. Remove this screw and slide the assemblyfree of the lugs.

e) Remove the fan motor assembly.

NOTE:Be careful not to touch the fan blades during the removalprocess to avoid unbalancing the fans.

f) For units with the electric heater option, disconnect thepower supply cable to the heater. Withdraw the cable throughthe cable gland.

g) Unscrew the electric heater.

h) Replacement of the fan motor assembly is by the reversal ofthe above procedure.

2020

WARNING:The electrical connections to the fan motor must be made inaccordance with the labels on the connector block.

Red wire: low speedGrey wire: medium speedBlack wire: high speedEarth connection: connect the yellow/green wire

6.3 - Capacitor replacement procedure

a) Disconnect the power supply to the Aqualia beforecarrying any work on the unit.

b) Remove the filter

c) Remove the fan motor assembly access panel

d) Unscrew the HM8 capacitor fixing screw. This is located onthe fan motor assembly chassis

e) Disconnect the capacitor by withdrawing the flat spadeconnectors from the back of the capacitor

f) Replacement of the capacitor assembly is by the reversal ofthe above procedure.

2121

7 - ELECTRIC HEATER

7.1- Description

Electric heater-resistance wire type

• Supply voltage: 230 V (± 10%) - 1 ph - 50 Hz• Capacity per coil:

- Size 1: 500 W (+ 5%; - 10%)- Size 2: 1000 W (+ 5%; - 10%)

• Number of coils per unit:- Size 1.1 or 5.1: 2- Size 1.2 or 5.2: 3- Size 2.3 or 2.4: 2

• Maximum unit heating capacity size 1.1 or 5.1: 1000 W• Maximum unit heating capacity size 1.2 or 5.1: 1500 W• Maximum unit heating capacity size 2.3 or 2.4: 2000 W

• Each heater is protected with double temperature protection:

a) Safety thermostat - resettable type. Trip temperature 75°C.When the trip temperature is reached a thermostat heater isenergised that prevents auto resetting of the thermostat aslong as the power is switched on and there is no air flow.Resetting of the thermostat is achieved by switching off thepower supply to the heater. The safety thermostat protectsthe unit against overheating due to the operation of theelectric heater with no or low air flow.

b) Thermofuse link - fusing temperature 150°C.

NOTE:Minimum air flow must be maintained to avoid damaging theelectric heaters:• Unit size 1.1 or 5.1: minimum air flow 64 l/s (230 m3/h) • Unit size 1.2 or 5.2: minimum air flow 122 l/s (440 m3/h) • Unit size 2.3 or 2.4: minimum air flow 97 l/s (350 m3/h)

WARNING:Disconnect the power supply before carrying out any work onthe unit.

Screw Screw

7.2 - Electric heater replacement procedure

WARNING:Disconnect the power supply before carrying out any work onthe unit

If the electric heater develops a fault, it must be replaced; thisrequires the removal of the fan motor assembly.

CAUTION:Do not touch the live metal heater elements when the electricheater is connected to the power supply.

a) Remove the filter

b) Remove the fan motor assembly access panel

c) Identify and note the fan speeds wired to the autotransformerterminal block or to the multi-winding electric motor.Disconnect the power supply cable, fitted with a quickconnector, to the fan motor assembly

d) The fan assembly is held in place by one torx screw (T20)and several lugs. Remove this screw and slide the assemblyfree of the lugs

e) Remove the fan motor assembly

NOTE:Be careful not to touch the fan blades during the removalprocess to avoid unbalancing the fans.

g) Unscrew the electric heater

h) Replacement of the fan motor assembly is by the reversal ofthe above procedure.

2222

8 - DUCT CONNECTION SPIGOTS

These are manufactured from high density plastic with a VOfire rating, more or less equivalent to class M1 (Frenchstandard).

The ducts should be fixed to these spigots using circular collarsor adhesive. Screws and rivets should not be used.

WARNING:In order to guarantee good air tightness, the duct shouldoverlap the whole of the spigot.

- Make sure that the maximum supply air temperature does notexceed 60°C.

- Do not lift or support the unit using the spigots, place loadson the spigots or damage the spigots during installation oroperation.

9 - WATER COIL

9.1 - Description

The water coil has aluminium fins mechanically bonded byexpansion onto copper tubes.

Water inlet and outlet connections are 1/2” or 3/4” BSP unionnuts (female) for the size 2 cooling coil. Air purge valves arestandard. The coil is integral with the drain pan and coil accessdoor to ease of removal during service and maintenance.

Coils available are:

• 2 rows for two-pipe changeover systems or for use withelectric heater.

• 4-row systems.

9.2 - Coil removal procedure

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

a) Close the isolating valves on the manifolds.

b) Unscrew the union nuts to disconnect the flexible waterpipes.

c) Remove the valve actuators taking care to identify thecooling and heating valves.

d) Disconnect the flexible condensate drain pipe which is heldin place by a collar (the collar is not supplied by Carrier).

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

f) Remove the two-way or three-way water flow control valvebodies. Depending how the Aqualia is configured, the three-way valve coupling may be fitted with a heating/coolingchangeover switch, if so do not remove it.

g) Replacement is by the reversal of the procedure describedabove. Ensure that all gaskets are fitted and that the inlet andoutlet connections to the coil are made correctly using anappropriate sealing compound applied to the valve body.

WARNING:Bleed all air from the coil during refilling.

2323

9.3 - Coil inlet/outlet positions

9.3.1 - Aqualia size 1

24

9.3.2 - Aqualia size 2

3-way cooling valve 2-way cooling valve

2-way heating valve3-way heating valve

Cooling wateroutlet

Heating wateroutlet

Heating wateroutlet

Heating waterinlet

Heating waterinlet

Cooling wateroutlet

Cooling waterinlet

Cooling waterinlet

25

10 - WATER FLOW CONTROL VALVES

Top of the range Aqualia units will be fitted with a CarrierMaestro Zone Controller, an electronic thermostat or Excel 10communicating controller to control the water flow controlvalve or valves. These valves are two-way or three-way type,with a body designed to withstand a 16 bar operating pressure.

10.1 - Electrothermal actuator (On/Off)

This on/off type actuator is used with a Carrier electronicthermostat (wall-mounted) and the Maestro Zone Controller.

NOTE:The electrothermal actuator is delivered in the normallyclosed position regardless of the two-way or three-way valvebody used (way A-AB closed in the case of a three-way valve).

Therefore to enable the installation to be filled with water, thewater circuits to be equalised and the units to be purged, thevalves will have to be opened by sending a command eitherfrom the wall thermostats or from the BMS.

10.2 - Actuator replacement procedure

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 carrying outany work on a unit.

b) Disconnect the actuator power supply cable.

• 230 V On/Off type actuator used with a Maestro ZoneController

Disconnect the actuator power supply cable fitted with a quickconnector.

• 230 V On/Off actuator used with an electronic thermostat

Remove the plastic protection cap held in place with twohexagon head (8 mm AF) screws. Disconnect the actuatorpower supply cable connected to the quick connector. This canbe done by pressing down the spring tongue using ascrewdriver and pulling out the wire from the appropriateterminal.

• 24 V On/Off actuator used with Carrier Excel 10 controller

Remove the plastic protection cap held in place with twohexagon head (8 mm AF) screws.

Disconnect the actuator power supply cable fitted with a quickconnector.

c) Uncouple the faulty actuator. Refitting is by the reversal ofthe procedure described above.

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

10.3 - Actuator electrical connections

10.3.1 - Maestro Controls

NOTE:For further information, please refer to the selection manualand the Carrier Maestro Zone Controller installation,operation and maintenance instructions.

10.3.2 - Carrier electronic thermostat

10.3.3 - Carrier Excel 10 controls

CABLE LENGTH 1 m

CARRIER ELECTRONIC THERMOSTAT

CARRIER MAESTRO CONTROLLER

26

10.4 - Valve body replacement procedure

a) Disconnect the power supply before carrying out any workon a unit.

b) Close the isolating valves on the manifolds.

c) Unscrew the union nuts to disconnect the flexible water pipes.

d) Remove the valve actuators taking care to identify thecooling and heating valves.

e) Disconnect the flexible condensate drain pipe which is heldin place by a collar (the collar is not supplied by Carrier).

f) Remove the 4 hexagon head screws (8 mm AF) and slide outthe coil and drain pan assembly.

g) Remove the two-way or three-way water flow control valvebodies. Depending how the Aqualia is configured, the three-way valve coupling may be fitted with a heating/coolingchangeover switch, if so do not remove it.

h) Fit the new valve body to the coil. Ensure that theconnections to the coil are made correctly.

i) Refit the coil and condensate assembly.

j) Reconnect the flexible condensate drain pipe which is held inplace by a collar (the collar is not supplied by Carrier).

k) Refit the valve actuators taking care to ensure that they arecorrectly fixed to the valve body.

l) Reconnect the flexible water pipes by tightening the unionnuts. Retighten all the water connections and ensure that allseals are correctly installed (maximum torque 15 N/m).

m) Open the isolating valves on the manifolds and purge all airfrom the system.

n) Check that there are no leaks and reconnect the power to theAqualia.

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 body willdeteriorate rapidly.

Two-way valve (Aqualia size 1) Three-way valve (Aqualia size 1)

WATER OUTLET

WATEROUTLET

WATER INLET WATER INLET

3-way cooling valve 2-way cooling valve

2-way heating valve3-way heating valve

Cooling wateroutlet

Heating wateroutlet

Heating wateroutlet

Heating waterinlet

Heating waterinlet

Cooling wateroutlet

Cooling waterinlet

Cooling waterinlet

Aqualia size 2

27

2-way valve body

3-way valve body

2828

10.5 - Technical specification for the heating/coolingchangeover switch

The heating/cooling changeover switch is designed to beinstalled straight onto the couplings of the 3-port valves on theCarrier electronic thermostat. It detects temperature changes inthe fluid circulating in the primary water circuit. A changeoverswitch operates according to the water temperature inaccordance with the diagram below.

When a heating/cooling changeover switch is connectedbetween the room thermostat and the water flow control valve,the changeover between heating and cooling modes takes placeautomatically in accordance with the following diagram.

2929

11 - FLEXIBLE WATER PIPES

Size 1 coil Size 2 coil

11.1 - Aqualia size 1

11.1.1 - Two-way valve

Materials

• Pipes: MEPD-based elastomer (modified ethylene-propylene-diene)

• Braid: 304L stainless steel• Insulation: cellular foam rubber with M1 (French standard)

fire rating (9 mm thick, chilled water pipes only).

Characteristics

• Minimum bending radius: non-insulated 35 mm, insulated75 mm

• The flexible water pipes are designed for treated or untreatedwater (maximum 40% ethylene glycol or propylene glycol).

• Maximum hot water temperature 90°C• Maximum operating pressure: 16 bar• Test pressure: 24 bar• Connections: 1/2” or 3/4” BSP union nuts (female)• Length: 1 m for flexible pipes connected to the water coil and

930 mm for pipes connected to water valves.

30

11.1 - Aqualia size 1, continued

11.1.2 - Three-way valve

11.2 - Aqualia size 2

3-way cooling valve 2-way cooling valve

2-way heating valve

3-way heating valve

Cooling wateroutlet

Heating wateroutlet

Heating wateroutlet

Heating waterinlet

Heating waterinlet

Cooling wateroutlet

Cooling waterinlet

Cooling waterinlet

31

12 - AIR FILTER AND ACCESS

12.1 - Description

The Carrier Aqualia is fitted with a 65% gravimetric filter (G2).

Medium fire rating M1 (French standard), metal wire frame

Different filter access options are available to suit different siterequirements:

Aqualia size 1

• Unit with ducted return air:- Filter removal is from above for floor void installations.- Filter removal is from below for ceiling void installations.

• Unit with open (non ducted) return air inlet:- Filter removal is from the rear of the unit

Aqualia size 2

• Unit with ducted or non ducted return air: filter removablefrom the side. This filter is hinged at the centre to facilitateremoval.

12.2 - Air filter replacement

Air filters should be changed regularly. Filter life depends onthe rate at which the filter becomes clogged, which dependsupon the cleanliness of the working environment.

If clogged filters are not changed they can increase the airpressure drop, trapped dust particles may be given off andentrained in the air supply, and the general performance of theAqualia may be degraded (as the air flow reduces).

NOTE:When installing an Aqualia in a ceiling void, check that no T-bars will obstruct filter access and removal.

32

13 - CONTROLS

13.1 - numeric controller

At the top of the range, each Aqualia is fitted with a Maestroprogrammable numeric controller to control each of the unitsinstalled in each air conditioned zone.

The main functions of the controller are:• Controlling room temperature• Raising, lowering and adjusting the angle of the blinds

(optional)• Switching the lights on and off (optional)• Selecting occupied or unoccupied mode through a Zone User

Interface

NOTE:For further information, please refer to the selection manualand the Carrier Maestro Zone Controller installation manualoperation and maintenance instructions.

13.2 - Carrier electronic thermostat

13.2.1 - Description

The Aqualia may be provided with a 3-speed Carrier electronicwall thermostat.

With this option each Aqualia can be equipped with an “on/off”type water control valve and flexible water pipes to simplifythe connection of units to the primary hot and/or chilled water.

This electronic thermostat option also includes a male-femalequick connect terminal block for connecting the different wiresfrom the fan motor, valve actuators, the electric heater and theheating/cooling changeover switch for Aqualia units equippedwith a single “heating or cooling” coil.

The male-female quick connect terminal block is DIN railmounted and protected by a recyclable plastic cover.

The DIN rail is large enough to accept a two pole-disconnecting switch with integral fuse holder (not supplied byCarrier).

The quick connect terminal block and flexible water pipes willbe appreciated during maintenance and servicing operations,since they enable significant time savings to be made. Thereplacing or moving of a unit is greatly simplified.

13.2.2 - Location of the wall-mounted thermostat

• The thermostat is for indoor wall mounting only

• Mounting height: 1.5 m above floor level

• Locate the thermostat away from heat sources, avoid airconvection from cables and avoid drafts (doors, windows, etc).

SUPPLY AIRMODUBOOT

33

34

13.3 - Carrier Excel 10 controller

13.3.1 - Introduction

At the top of the range, 42EL Aqualia units can be suppliedwith Carrier Excel 10 numeric programmable controller tocontrol the units located in each zone.

The Carrier Excel 10 numeric controller can operate as stand-alone or be networked to a standard Echelon LonWorks®

communications bus. This controller can control a hot watercoil and/or an electric heater (directly without a relay) and achilled water cooling coil.

The power supply to the Carrier Excel 10 numeric controller is230 VAC (±10%) avoiding the need for a transformer.

Each Aqualia can be supplied with on/off water flow controlvalves and flexible water pipes to simplify the connections tothe hot and chilled water supplies.

13.3.2 - Features

• LonMark® HVAC profile N° 8020• Stand-alone operation or with a high speed 78 kbits/s

Echelon® bus (E-bus) network.• Uses Echelon LonTalk® protocol• Direct connections to the electrothermal valve actuators• Direct connections to the fan speed switch (230 VAC)• Direct connections to the electric heater (230 VAC)• Factory configured default settings• Interlocks and timers to protect equipment• Controller supply 230 VAC (±10%)

13.3.3 - Description

Excel 10 controllers are LonMark® compliant fan coilcontrollers from the Excel 10 product range. They are used forcontrolling 2 or 4 -pipe fan coil units, with optional electricheater, and can control 3 fan speeds. The controllers aresupplied with factory configured default settings and are fullyoperational once installed. The controller can be configuredwith job-specific settings using standard Echelon configurationtools. A variety of wall modules may be interfaced with thecontroller to provide some or all of the following features: setpoint adjustment, fan speed adjustment and occupancy overridebutton. All the wall modules include a space temperaturesensor. A remote return air sensor can also be used.

Output Options

Heating Floating, electrothermal, PWM, On/Off, multi-stageelectric heater

Cooling Floating, electrothermal, PWM, On/Off

Fan On/Off, 2 or 3 speed

Electric heater On/Off

Table 2 - Control outputs

NOTE:By default the valve actuators are of the electrothermal type.If proportional actuators (3 way, 24 VAC, floating) arerequired, please contact your local Carrier representative.

13.3.3.1 - Control sequence

The heating and cooling sequences can be selected to be activeor inactive giving a total of 8 different control sequences (eachwith or without fan control):- heating only- cooling only- heating/cooling changeover- sequential heating and cooling- the above options with electric reheat.

Control sequence

13.3.3.2 - Operating modes

The controller provides the following operating modes:

Occupied mode

This is the normal operating mode for a room or occupiedzone. The controller can be put into this mode from a networkcommand, or by the mode override button located on the wallmodule. In occupied mode the fan speed is controlled by thefan speed switch setting on the thermostat or the controlalgorithm speed setting if the fan speed switch is set to “auto”.The fan can be configured to remain on or turn off in theneutral zone.

Standby mode

The standby mode saves energy by reducing the demand forheating or cooling when the space is temporarily unoccupied.In this mode the fan is switched off in the neutral zone.

35

Night/Unoccupied mode

This mode is used when the space is unoccupied for longerperiods, for example at night, during the weekend or holidays.

Window open

If the controller is configured for window open detection, thecontroller will automatically disable the heating and coolingcontrol until the window is shut. Frost protection remainsactive.

Frost protection

If the temperature drops below 8°C, the controller enables theheating mode as protection against freezing.

Smoke control

The fan can be turned on or off by network command forsmoke control.

Heating/Cooling changeover

The controller can be used to control an Aqualia 2-pipe systemunit using a changeover input.

Typical application

13.3.3.3 - Wall mounted controller wiring/layout diagram

CARRIER EXCEL 10CONTROLLER

WALL MOUNTEDTEMPERATURE

SENSOR

WINDOWCONTACT

E-BUSE-BUS

NOTE:This wire is not provided for electrothermal type actuators.

36

13.3.4 - Specification

Input/Outputs

Inputs Function Characteristic

On/Off Window/occupied/ Closed if ≤ 400 ΩChangeover/ Open if ≥ 10 kΩair flow

Analogue/ Fan speed/ ResistorOn/Off1 override Network

Analogue Temperature sensor 20 kΩ NTC

Analogue1 Setpoint adjustment 10 kΩ

Outputs Function Characteristic

On/Off1 Override LED 0/5 VAC

Triac (2 pairs)2 Heating and cooling 24 VAC, 250 mA max continuous, 650 mA maxsurge (≤ 30 s)

Relay Fan command 20 to 253 VAC, 3 A max

Power Electric heater 20 to 300 VACrelay (resistive load) 10 A max

Table 3 - Inputs/Outputs characteristics

Legend:1 Wall module connection only2 See table 2 for the types of output

Supply

230 VAC ±10%, 50 Hz

Power consumption

30 VA max

Hardware design

Processor: Neuron 3150 running at 5 MHz, with 2 Ko RAMand 0.5 Ko of EEPROM on chip.

External memory: EPROM, 62 Ko x 8.

Transformer (circuit board mounted): 16 VA with thermal fuse.

Temperature sensing range

0 to 40°C

Environmental Ratings

Operating temperature: 0 to 50°C

Shipping/storage temperature: - 40 to 70°C

Relative humidity: 5% to 95% without condensation

Dimensions

101 x 257 x 60 mm

CUT-OUT FOR EUROPEAN APPLICATION

STA

ND

AR

D F

IXIN

G2

x 4

mm

Ø S

CR

EW

S

37

Mounting

The Excel 10 controller is DIN rail mounted

Conformity

CEEN5008-1EN5008-2Meets the requirements of FCC chap 15, class B

Accessory items

Excel 10 wall-mounted thermostatExcel 10 terminal module FTT/LPT 209541BReturn air sensor.

Communication

The Excel 10 controller uses a transformer coupled E-bus portto communicate at 78 kbits/s, the controllers use free topologytransceivers (FTT).

This interface assures galvanic insulation and stronglyattenuates common mode transients.

The E-bus is insensitive to polarity, which eliminatesconnection errors during installation.

The recommended wire size to be used for the E-bus is level IV22 AWG (0.34 mm2) non-shielded, twisted pair, solid core wire(Belden reference H2201504 or 9D220150).

An FTT network can be in bus, star or loop or any combinationof these topologies.

LonMark® operating protocol

Excel 10 controllers support the LonMark® N° 8020 functionalprofile version 2.0 (see diagram on page 38).

38

NOTE:The variables not used are shown in grey

LonMark® operating protocol

39

14 - ACCESSORIES

14.1 - Condensate drain pump

14.1.1 - Introduction

Aqualia units can be fitted with condensate drain pumps,preferably before but if necessary after the unit has beeninstalled in the false floor or ceiling.

14.1.2 - Procedure for installation

a) Check the contents of the parts kit with those shown inFig. 1.

b) Installation of the detector block support bracket.

Instal the aluminium detector block bracket on the condensatedrain pan as shown in Fig. 2-A.

NOTE:The detector support bracket must be installed horizontally asshown in Fig. 2 (maximum angle 15°).

c) Installation of the pump support bracket

Bend the support bracket into a right angle to suit the chosenlocation of the pump.

d) Installation of the detector block

• Connect the detector to the condensate drain using the rubbertube supplied (Fig. 2-B).

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

• Connect the short 6 mm bore flexible tube to the detectorvent.

• Attach the detector block support to the aluminium bracketwith the double-sided adhesive pad supplied (Fig. 2-C), andthen clip the detector block to the plastic bracket.

NOTE:The detector must be installed horizontally.

The rubber tube must be secured to the outlet stub on thecondensate drain pan by a collar (not supplied by Carrier).

e) Installation of the pump

• The pump can be installed anywhere and can if necessary belocated up to 2.5 m above the unit.

• Using the 2 screws supplied, fix the pump to the metalsupport bracket previously fitted to the Aqualia.

• A clearance space must be left around the pump in order toprovide for cooling during long operating periods. Do notinsulate the pump block.

• The pump unit must not be immersed or placed outside thebuilding or in damp place.

f) Connection between the detector and the pump

• Connect the RJ 11 (telephone type) connector to the pump.• Connect the 6 mm bore flexible tube to the ribbed outlet on

the pump as shown in Fig. 4.• Respect the direction of water flow as shown by the arrow on

the pump body.

g) Connection of the pump

Connect the 6 mm bore flexible tube between the ribbed outleton the pump and the condensate drain.

h) Electrical connection

Connect to the power supply of the Aqualia or to the mainssupply using:

• an interconnexion cable (HO VVF) with 0.75 mm2 cores

• an electrical protection and isolating device (not supplied),conforming to IEC 345 standard, on the line (phase) andneutral

• a 630 mA fuse on the line (phase).

i) Connection of the alarm

The condensate level detector consists of a float, which candetect three different condensate levels:• Pump on level: 17 mm ±2 mm of condensate. When this level

is exceeded the pump will start automatically.• Pump off level: 11 mm ±2 mm of condensate. When the

pump has been operating, it will switch off when the levelfalls below this threshold.

• Alarm level: 21 mm ±2 mm of condensate. When this level isreached a volt free contact operates which can be connectedto an external alarm. If the alarm threshold is reached orexceeded, the condensate drain pump keeps running.

The alarm condition applies if the condensate level is above thealarm threshold.

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

The device includes a volt-free changeover switch with acapacity 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 closed ifthe wiring is NC.

If the condensate level is above the alarm threshold (alarmcondition), the contact is closed if the wiring is NO or open ifthe wiring is NC.

NOTE:If proportional valves are installed in the air conditioningunits, an additional safety device must be provided that caninterrupt the chilled water production, in the event of powerfailure.

j) Function test

Pour a small quantity of water into the drain pan. Check thatthe pump starts, draws water away and stops when the waterlevel falls. Add more water until the alarm operates.

40

k) Service

Frequency: at the beginning of the season.

Clean the detection unit and the filter. Disconnect the powersupply before carrying out any work on the Aqualia installationincluding the pump.

Remove the cover, the filter and the float, clean the detectionunit and the float using a solution of water containing 5%bleach. Replace the float in its initial position (magnet facedupwards), refit the filter and reinstall the cover. Carry out anoperating test on the pump and the alarm. When the airconditioner is installed in areas likely to cause or favourextensive dirtying of the condensate water, increase themaintenance frequency.

l) Condensate drain pump features

• Maximum flow: 10 1/h• Maximum discharge: 6 m head of water.• Maximum suction: 2.5 m head of water.• Power supply: 230 V ±10%/50 Hz/1 Ph.• Power consumption: 18 VA.

m) Safety

• An alarm contact will prevent overflow (cutting off therefrigeration)

• An auto-resetting thermal cut-out: tripping temperature 70°C• Earth the pump• Safety transformer as per standard EN 60 742• Housing made of ABS.

Fig. 1

PUMP BLOCKSUPPORT BRACKET

PUMP BLOCK

RUBBER TUBE

DETECTOR BLOCK

PLASTIC DETECTOR BLOCK SUPPORT

DOUBLE SIDED ADHESIVE TAPE

LABEL SHOWING THE ATTACHMENT PLAN FORFIXING THE PUMP BLOCK SUPPORT BRACKET

ALUMINIUM DETECTOR BLOCK BRACKET

PUMP BLOCKFIXING SCREWS

PUMP BLOCK SUPPORTBRACKET FIXING SCREWS

6 mm Ø FLEXIBLE TUBES

41

DETECTOR BLOCK POSITION

ADHESIVE TAPE

DETECTOR BLOCK SUPPORT BRACKET

PUMP BLOCK SUPPORT FIXING SCREW

PUMP BLOCK FIXING SCREW

PUMP BLOCK SUPPORT BRACKET

HOLE DRILLING TEMPLATE

42

NOTE:If proportional valves are installed in the air conditioning units, an additional safety device must be provided that can interruptthe chilled water production, in the event of power failure.

14.2 - Adjustable feet for installation of Aqualia sizes 5.1 and 5.2, in false floor voids

14.2.1 - Introduction

Adjustable anti-vibration mounting feet are available as factory fitted accessory items for Aqualia units installed in false floorvoids. These feet are fitted to the inside of the support brackets to prevent damage during transport and must be refitted to thecorrect position before installation - see diagram below.

14.2.2 - Fitting procedure

1. Reposition the feet in the correct location2. Adjust the feet to the required height: adjustment 31 to 43 mm.

Fig. 4

Line(phase)Neutral

Earth

Normally openCommonNormally closed

Pump outlet

Pump outlet

Pump inlet

Pump inlet

RJ11 CONNECTION(telephone type)

Small venttube

Do not pinch the tube

Do not pinch the tube

Direction of condensateevacuation

31 to

43

mm

43

15 - AQUALIA PERFORMANCE DATA

15.1 - Electrical data

15.1.1 - Aqualia sizes 1.1 and 5.1

15.1.2 - Aqualia sizes 1.2 and 5.2

Vn I P RPM Qv Qv Press.(A) (W) (tr/mn) (m3/h) (l/s) (Pa)

V1 0.51 109 1330 800 222 420.50 105 1350 718 199 520.48 101 1370 642 178 590.47 98 1380 528 147 680.46 95 1395 443 123 740.45 91 1410 370 103 780.44 89 1420 294 82 830.44 86 1430 201 56 88

V2 0.34 75 1180 622 173 390.31 71 1225 560 156 480.31 69 1260 522 145 530.29 65 1295 444 123 610.27 61 1330 363 101 680.26 58 1355 270 75 750.25 54 1385 190 53 800.24 53 1395 113 31 84

V3 0.30 67 875 567 158 120.28 63 1005 512 142 280.27 60 1065 480 133 350.25 57 1160 416 116 470.23 53 1220 357 99 560.23 51 1255 320 89 610.21 49 1290 255 71 680.19 44 1355 161 45 780.19 42 1375 87 24 83

Vn I P RPM Qv Qv Press.(A) (W) (tr/mn) (m3/h) (l/s) (Pa)

V4 0.26 57 720 468 130 60.24 53 940 414 115 260.23 52 1015 379 105 350.22 50 1110 318 88 470.20 46 1200 251 70 570.19 43 1255 188 52 660.17 40 1310 133 37 720.16 37 1345 59 16 79

V5 0.21 46 660 360 100 90.20 45 785 338 94 180.19 44 875 309 86 250.18 41 1060 225 63 450.17 38 1160 177 49 570.15 35 1255 100 28 700.14 33 1295 63 18 76

V6 0.17 39 660 260 72 120.17 38 705 250 69 150.16 37 880 195 54 300.15 34 1070 134 37 490.14 30 1220 61 17 68

Vn I P RPM Qv Qv Press.(A) (W) (tr/mn) (m3/h) (l/s) (Pa)

V1 0.78 163 1407 1027 285 370.75 158 1413 950 264 460.74 152 1420 854 237 570.73 151 1425 830 231 590.72 149 1428 751 209 650.71 146 1431 699 194 690.70 145 1434 651 181 710.69 143 1437 597 166 740.68 140 1440 548 152 77

V2 0.57 132 1272 1002 278 250.55 127 1293 930 258 360.54 124 1308 907 252 390.52 120 1325 857 238 440.51 117 1338 804 223 490.49 113 1350 751 209 550.48 110 1361 701 195 600.47 107 1370 658 183 640.45 104 1378 598 166 690.43 98 1392 499 139 75

V3 0.56 127 934 806 224 70.51 117 1100 754 209 270.48 110 1174 707 196 380.46 104 1224 664 184 450.43 99 1265 607 169 550.42 95 1294 562 156 600.40 91 1319 514 143 650.38 87 1348 447 124 710.37 85 1359 405 113 74

Vn I P RPM Qv Qv Press.(A) (W) (tr/mn) (m3/h) (l/s) (Pa)

V4 0.52 118 890 684 190 110.48 110 1067 660 183 300.46 104 1134 630 175 390.43 97 1214 578 161 500.40 92 1262 522 145 580.38 88 1293 468 130 650.36 82 1330 390 108 730.33 76 1365 290 81 80

V5 0.51 117 693 623 173 00.49 112 902 616 171 160.47 107 992 605 168 260.44 101 1083 571 159 400.41 95 1172 535 149 510.39 90 1228 491 136 570.37 84 1279 423 118 660.34 78 1324 341 95 740.31 71 1365 234 65 81

V6 0.50 113 656 557 155 10.47 108 870 535 149 180.44 101 1021 523 145 340.42 96 1114 508 141 420.39 90 1181 472 131 500.37 85 1237 430 119 590.35 79 1290 364 101 680.32 73 1325 294 82 750.30 69 1357 228 63 800.30 66 1369 144 40 85

Legend:I : Current drawn by the fan motorP : Power input to the fan motorRPM : Fan motor speedQv : Air flow ratePress. : Available static pressure

NOTE:Voltage supply: 230 V ± 10%

44

15.1 - Electrical data, continued

15.1.3 - Aqualia size 2.3 15.1.4 - Aqualia size 2.4

Vn I P RPM Qv Qv Press.(A) (W) (tr/mn) (m3/h) (l/s) (Pa)

V1 1.45 334 919 1810 503 11.28 294 1111 1588 441 651.25 288 1155 1520 422 781.22 281 1167 1481 411 841.19 274 1189 1429 397 911.17 269 1207 1383 384 981.15 265 1223 1347 374 1021.12 258 1239 1281 356 1101.10 253 1260 1223 340 1141.06 244 1282 1137 316 119

* * * * * *

V2 1.12 252 784 1484 412 31.04 234 942 1330 369 431.02 230 980 1290 358 531.00 225 1026 1246 346 640.97 219 1064 1192 331 730.94 212 1108 1118 311 860.91 205 1150 1060 294 950.87 196 1181 985 274 1060.84 189 1225 910 253 1130.80 180 1254 798 222 121

V3 0.91 205 732 1282 356 00.87 196 868 1146 318 330.84 189 914 1094 304 460.83 187 959 1043 290 560.80 180 1000 989 275 650.78 176 1040 930 258 750.76 171 1100 857 238 840.74 167 1131 808 224 910.70 158 1164 725 201 1030.66 149 1218 584 162 118

V4 0.72 159 692 1042 289 30.71 157 802 963 268 220.70 155 857 904 251 350.69 152 889 866 241 410.67 150 930 815 226 500.65 145 964 760 211 600.62 138 1007 698 194 720.59 132 1055 615 171 880.56 125 1086 543 151 1000.53 118 1129 446 124 114

Vn I P RPM Qv Qv Press.(A) (W) (tr/mn) (m3/h) (l/s) (Pa)

V1 1.88 419 1061 2217 616 41.73 386 1155 2004 557 451.70 379 1177 1941 539 571.67 373 1190 1905 529 631.62 361 1215 1829 508 761.59 355 1238 1750 486 871.57 350 1250 1725 479 901.55 346 1260 1660 461 961.51 337 1280 1580 439 1031.46 326 1300 1485 413 1111.44 321 1311 1399 389 118

V2 1.80 410 995 2038 566 31.58 360 1128 1823 506 541.54 351 1156 1766 491 651.49 339 1186 1693 470 761.46 332 1206 1626 452 841.41 321 1 1541 428 921.37 312 1254 1465 407 991.34 305 1270 1374 382 1071.29 291 1290 1268 352 1151.28 289 1302 1224 340 118

V3 1.66 378 890 1750 486 61.58 360 968 1708 474 231.50 342 1026 1641 456 421.43 326 1075 1558 433 591.37 312 1124 1496 416 701.31 298 1165 1419 394 831.27 286 1198 1363 379 901.22 275 1215 1264 351 1011.17 264 1260 1165 324 1111.12 252 1288 1059 294 121

V4 1.47 338 774 1483 412 11.37 315 924 1399 389 371.30 299 991 1330 369 551.25 288 1036 1284 357 651.20 276 1121 1198 333 801.14 262 1164 1119 311 941.10 253 1200 1055 293 1031.04 239 1231 981 273 1131.01 232 1263 899 250 120

Legend:I : Current drawn by the fan motorP : Power input to the fan motorRPM : Fan motor speedQv : Air flow ratePress. : Available static pressure

NOTE:Voltage supply: 230 V ± 10%

45

15.2 - Air flow data

15.2.1 - Static pressure available (Pa) against air flow (m3/h)

Aqualia sizes 1.1 and 5.1

IMPORTANT:The curves were derived by smoothing, based on theinformation shown in the electrical data table.

NOTE:The data is for units without supply and return plenums. Seetable 15.2.2 for the plenum pressure drops.

Aqualia sizes 1.2 and 5.2

46

15.2 - Air flow data, continued

15.2.1 - Static pressure available (Pa) against air flow (m3/h)

Aqualia size 2.3

IMPORTANT:The curves were derived by smoothing, based on theinformation shown in the electrical data table.

NOTE:The data is for units without supply and return plenums. Seetable 15.2.2 for the plenum pressure drops.

Aqualia size 2.4

47

15.2.2 - Air pressure drops for octopus plenum boxes as a function of the number of spigots (200 mm Ø) ??

Size 1 (spigots Ø 200 mm)

Size 2 (spigots Ø 250 mm)

Air flow (m3/h) 100 200 300 400 450 500 550 600 650 700 750 800 850 900 950

Air flow (l/s) 27.78 55.6 83.3 111.1 125 138.9 152.8 166.7 180.6 194.4 208.3 222.2 236.1 250 263.89

2 spigots SUP 0.3 1.0 2.3 4.0 5.1 6.3 7.6 9.0 10.6 12.3 14.1 16.1 18.1 20.3 22.6RET 0.4 1.8 4.0 7.2 9.1 11.2 13.6 16.1 18.9 22.0 25.2 28.7 32.4 36.3 40.5

3 spigots SUP 0.1 0.4 0.9 1.6 2.0 2.5 3.1 3.6 4.3 4.9 5.7 6.5 7.3 8.2 9.1RET 0.2 0.8 1.8 3.1 4.0 4.9 6.0 7.1 8.3 9.6 11.1 12.6 14.2 15.9 17.8

4 spigots SUP 0.1 0.2 0.5 0.9 1.1 1.4 1.6 1.9 2.3 2.7 3.0 3.5 3.9 4.4 4.9RET 0.1 0.4 0.8 1.4 1.8 2.3 2.7 3.2 3.8 4.4 5.1 5.8 6.5 7.3 8.1

5 spigots SUP 0.0 0.2 0.4 0.7 0.8 1.0 1.3 1.5 1.8 2.0 2.3 2.7 3.0 3.4 3.8RET 0.1 0.3 0.6 1.1 1.4 1.7 2.1 2.5 2.9 3.4 3.9 4.4 5.0 5.6 6.3

Air flow (m3/h) 200 400 600 800 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

Air flow (l/s) 55.6 111.1 166.7 222.2 277.8 305.6 333.3 361.1 388.9 416.7 444.4 472.2 500.0 527.8 555.6

3 spigots SUP 0.0 0.1 0.3 0.5 0.8 0.9 1.1 1.3 1.5 1.7 2.0 2.2 2.5 2.8 3.1RET 0.2 0.8 1.9 3.3 5.2 6.3 7.4 8.7 10.1 11.6 13.2 14.9 16.7 18.7 20.7

4 spigots SUP 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0RET 0.1 0.6 1.3 2.4 3.7 4.5 5.4 6.3 7.3 8.4 9.5 10.7 12.0 13.4 14.9

5 spigots SUP 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0RET 0.1 0.4 1.0 1.8 2.8 3.4 4.0 4.7 5.4 6.2 7.1 8.0 9.0 10.0 11.1

Legend:SUP: supplyRET: return

Order No.: 14232-79, December 2000 - Supersedes order No.: 14232-79, July 1999Manufacturer reserves the right to change any product specification without notice.

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