Carrier 42EL Aqualia Manual

Installation, operation and maintenance
instructions
Terminal Controller
for 42ELAqualia and 42BJ
Ultra units
50 Hz

2
The cover graphic is for illustrative purposes only and is not part of any offer for sale or contract.

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Contents
1 - INTRODUCTION ........................................................................................................................................................................ 4
1.1 - Global architecture of the Aquasmart system ........................................................................................................................ 4
2 - AFETY CON IDERATION ................................................................................................................................................... 4
2.1 - General .................................................................................................................................................................................. 4
2.2 - Precautions against electrocution .......................................................................................................................................... 4
2.3 - General installation recommendations .................................................................................................................................. 4
3 - PRODUCT OVERVIEW............................................................................................................................................................. 5
3.1 - Power su ly characteristics ................................................................................................................................................. 5
3.2 - Technical characteristics of the communication system........................................................................................................ 5
3.3 - Controller in uts and out uts
4 - CONFIGURATION ..................................................................................................................................................................... 6
4.1 - Unit ty e ................................................................................................................................................................................ 6
4.2 - Addressing ............................................................................................................................................................................. 6
4.3 - Configuration of the Terminal Controller (Tc) with the System Manager (Sm). .................................................................. 6
4.4 - Configuration of the Terminal Controller (Tc) with the Carrier Room Controller (CRC). ................................................... 6
5 - Y TEM MODE ........................................................................................................................................................................ 7
5.1 - Cool and heat control set oint ............................................................................................................................................... 7
5.2 - Unoccu ied mode (room unoccu ied time schedules). ......................................................................................................... 7
5.3 - Frost rotection mode ............................................................................................................................................................ 7
5.4 - Occu ied mode (room occu ied time schedules).. ................................................................................................................ 7
6 - CONTROL MODE .................................................................................................................................................................... 8
6.1 - Control modes with the changeover o tion for 2- i e systems ............................................................................................ 8
6.2 - Summary cooling and heating mode tables in Occu ied mode ............................................................................................ 9
7 - MAIN Y TEM AFETY AND INTERLOCK DEVICE ................................................................................................... 10
7.1 - Window contact o eration ................................................................................................................................................... 10
7.2 - Cold draught rotection ....................................................................................................................................................... 10
7.3 - Loadshedding ...................................................................................................................................................................... 10
8 - CONNECTION ........................................................................................................................................................................ 11
8.1 - Two- i e and two-wire configuration ................................................................................................................................. 11
8.2 - Two- i e or four- i e configuration ................................................................................................................................... 11
9 - TROUBLE HOOTING ............................................................................................................................................................ 12

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1 - INTRODUCTION
Before using this document it is important to read the complete
42ELAqualia, 42BJ Ultra, System Manager (Sm) and Carrier
Room Controller (CRC) User Manuals.
Before beginning, verify that the water temperature sensor is
correctly installed:
- on a 2- i e system, u stream of the three-way valve
( i ing side)
- on a 4- i e system, u stream of the three-way heating
valve ( i ing side)
1.1 - Global architecture of the Aquasmart system
A basicAquasmart system includes a liquid chiller and/or a
boiler or a heat pump connected to terminal units, such as the
Aqualia or the Ultra, via a controller: the System Manager.
Each Aqualia or Ultra unit includes a Terminal Controller
connected to the System Manager and a CRC (accessory).A
CRC can be connected to one or several Terminal Controllers
(6 maximum).
2- SAFETY CONSIDERATIONS
2.1 - General
The Aquasmart Terminal Controller used on the Aqualia and
Ultra units is designed to be used indoors in residential or
industrial a lications.
Installation, commissioning and servicing of the various
com onents of the control system can be dangerous unless
certain as ects of the installation, such as the resence of mains
electricity and hot or chilled water in the air conditioning
equi ment, are taken into account.
Only s ecially trained and qualified technicians and installers
who have been fully trained on the roduct concerned are
authorised to install, commission and service this equi ment.
During servicing work, it is essential to a ly all recommenda-
tions and instructions given in service leaflets, on labels or in
the instructions delivered with the equi ment, and to com ly
with any other relevant instructions.
Definition of the pictograms used
Electrical danger
Caution hand hazard
General danger
 Com ly with all safety rules and regulations currently in
force.
 Wear eye rotectors and work gloves.
 Take care when moving or ositioning equi ment.
2.2 - Precautions against electrocution
Only electricians who are qualified to the level recommended
in standard IEC 60364 may have access to electrical com o-
nents. In articular it is obligatory to disconnect all electrical
ower su lies to the unit and its accessories before carrying
out any work.
IMPORTANT: The components that make up the various
control systems described in this manual include electronic
components. These may generate or be damaged by electro-
magnetic interference unless they are installed and used in
accordance with these instructions. The components making
up these controls systems conform to the requirements for
electromagnetic compatibility in residential and industrial
areas. They also comply with the low-voltage directive.
IMPORTANT: This equipment has been declared to be in
conformity with the following standards:
- Electromagnetic compatibility: 89/336/EEC
- Low-voltage directive: 73/23/EEC.
2.3 - General installation recommendations
IMPORTANT: The Aquasmart Terminal Controller, or in
general, units equipped with controls loops, must have an
isolating device upstream (for example a two-pole circuit
breaker). If necessary, an easily accessible emergency stop
device (such as a punch-button switch) must cut off the power
to all equipment. These safety devices shall be sized and
installed in accordance with recommendation IEC 60364.
These devices are not supplied by Carrier.
IMPORTANT: When handling the board always wear
antistatic gloves to prevent destructive voltages from
damaging the electronic components.

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3 - PRODUCT OVERVIEW
The Terminal Controller consists of:
- an electronic board (named HY-NEC)
- a communication board (named HY-NEC PRIME)
- a Carrier Room Controller (accessory)
- a transformer (not su lied by Carrier)
3.1 - Power supply characteristics
The Terminal Controller must be su lied with 230 V a.c.
(±10%), 50 Hz.
The recommended cable is Ground - Neutral - Line.
3.2 - Technical characteristics of the communication
systems
 Local bus RS 485 (not su lied by Carrier)
 Two multi le double-insulation cables (3 x 0,5 and 2 x 0,5
mm). Recommended ty e: H03VV-F.
 One Carrier Room Controller (CRC) for 6 Terminal
Controllers maximum
 Secondary bus RS 485 (not su lied by Carrier); 2 airs
shielded. This bus can connect u to 128 Terminal
Controllers (Tc) and the System Manager. The
communication cable shielding is connected to the earth
of a Terminal Controller.
 The Tc can also o erate autonomously.
3.3 - Controller inputs and outputs
3.3.1 - Inputs description
 Air tem erature sensor
 Water tem erature sensor
 Electric heater ower su ly
 CRC
 Window contact
 Communication bus
 Condensate level
3.3.2 - Outputs description
 Indoor fan motor
 Heat/cool water valve
 Hot water valve
 Condensate um
 Electric heater
 System Manager
In general terms the following rules must be applied:
 Units must be rovided with over-voltage rotection
u stream (not su lied by Carrier)
 Units must be equi ed with differential ty e earth
leakage current rotection (not su lied by Carrier).
U stream over-voltage rotection:
- Unit without electric heater = T 2 A
- Unit with electric heaters = T 16 A
 The ower disconnection device must be clearly labelled
to identify which items of equi ment are connected to it.
 The wiring of the com onents that make u the various
control systems and of the communication buses must be
carried out in accordance with the latest rules and
regulations by rofessional installers.
 The ower su ly cable must have double insulation and
be fixed using an a ro riate cable clam . The cable
clam must be on the outer insulation.
 The control loo com onents must be installed in an
environment, which conforms to the rotection index (IP).
The maximum level of ollution is normal ollution (level
2) and installation category 11.
 The low-voltage wiring (communication bus) must be
ke t hysically se arate from the ower su ly wiring.
 To avoid interference with the communication links:
- keep low-voltage wiring away from power cables and
avoid using the same cable run (300 mm maximum,
common with the 230 V a.c., 30 A cable)
- Do not pass low-voltage cables through loops in the
power cables
- Do not connect heavy inductive loads to the same
power supply (circuit breaker) that is used by the
controllers.
IMPORTANT: Normal shipping and storage conditions are
between -40 and 85°C.
The humidity range is 0% to 95% relative humidity, non-
condensing for storage.
IMPORTANT: Normal ambient operating temperature is
between 0 and 32°C.
Normal control box operating temperature is between 0 and
50°C, with 10% to 95% relative humidity, non-condensing
humidity.

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General description of the Aquasmart system
A
B
4.4 - Configuration of the Terminal Controller (Tc)
with the Carrier Room Controller (CRC)
Please refer to the Installation Manual for the CRC.
Legend
1 Primary bus (not supplied by Carrier)
2 Secondary bus (not supplied by Carrier)
3 Local bus (not supplied by Carrier)
4 Terminal Controller
A Other terminal units
B Aqualia or Ultra
Outside temperature
4.3 - Configuration of the Terminal Controller (Tc) with
the System Manager (Sm)
Please refer to the Installation Manual for the System Manager.
4 - CONFIGURATION
4.1 - Unit type
1 - High-Wall 6/12
2 - High-Wall 18/24
3 - Cassette
4 - 42Y vertival (default)
5 - 42JW, 42 L Aqualia, 42Y horizontal, 42BJ Ultra
Water control (opposite to air control only) is the only possibility
with the Aqualia or Ultra. The available configurations are:
- 4 pipe
- 2 pipe changeover without electric heater
- 2 pipe changeover with electric heater
4.2 - Addressing
ach Tc has a unique serial number in its microprocessor (1 to
999.999). This serial number is visible on the Tc control box
(two self-adhesive stickers). One sticker must remain on the
control box. The other sticker must be removed and put on a
special sheet. Please refer to the System Manager installation
manual for the addressing process and for additional details.

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The system may switch back to non-communicating status if
no System Manager message has been received for 5 minutes.
Unoccupied mode for communicating systems
The system will operate same as in Occupied mode using the
unoccupied deadband configured at the System Manager, with
the algorithms described in the following illustration.
5.3 - Frost protection mode
This mode is entered directly by System Manager or by the
window contact. It allows the system to operate in a low-
energy state while protecting the zone air against frost.
When the room air temperature is lower than 7°C:
- the control mode is Heat Demand
- the fan speed is Maximum
5.4 - Occupied mode (room occupied time schedules)
The Occupied deadband is controlled by the System Manager
and actually represents 1/2 of the full deadband. It refers to the
difference in temperature used by the system (room tempera-
ture compared with setpoint temperature) in Occupied mode.
This permits determining the heat or cool control setpoints.
The default value for the unoccupied deadband is 1°C.
This function is enabled when the user operating mode
parameter is set to Occupied. Based on system parameters, a
Heat/Cool and a Demand/Satisfied operating mode are
determined.
Normal Occupied mode
See also diagram below.
Diagram of automatic changeover (default value)
Legend
1 Deadband
HCS Setpoint, heating mode*
CCS Setpoint, cooling mode*
Setpoint User setpoint
Heating mode operation (hot water or electric heater)
Cooling mode operation (cold water)
* HCS (heat control setpoint) =
User setpoint - 1/2 of the full deadband - 0,5°C
* CCS (cool control setpont) =
User setpoint + 1/2 of the full deadband + 0,5°C
Note:
After changeover from cooling to heating mode there is a 10 minute time delay
between the heating mode and the cooling mode demand.
1
HCS HCS + 1˚C Setpoint CCS - 1˚C CCS
ON
OF
F
ON
OFF
5 - SYSTEM MODES
5.1 - Cool and heat control setpoint
In cooling mode, the demand on the system is based on the
difference between the room temperature and the cool control
setpoint.
In heating mode, the demand on the system is based on the heat
control setpoint minus the room temperature.
Heat control setpoint = user setpoint - 1/2 deadband - 0,5°C
Cool control setpoint = user setpoint + 1/2 deadband + 0,5°C
The control setpoints (heat and cool) must be within the
following range:
Minimum temperature 10°C
Maximum temperature 35°C
5.2 - Unoccupied mode (room unoccupied time
schedules)
The Unoccupied deadband is controlled by the System
Manager and actually represents 1/2 of the full deadband. It
refers to the difference in temperature used by the system
(room temperature compared with setpoint temperature) in
Unoccupied mode. This permits determining the heat or cool
control setpoints. The default value for the unoccupied
deadband is 3°C.
OFF mode for non-communicating systems
Setting the system to the OFF mode with the CRC leads to the
changeover of the Tc to Unoccupied mode. The system is
considered as non-communicating when it is energised, and
will switch to communicating when a message is received from
the System Manager.

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ON OFF ON OFF
15 20 30 35 ˚C
6 - CONTROL MODES
6.1 - Control modes with changeover option for 2-
pipe systems
The changeover algorithm, shown in the diagram below,
establishes hot or cold water temperature limits in two-pipe
systems.
Between 20°C and 30°C water temperature the unit will run in
Heat Satisfied or Cool Satisfied mode, except units with
electric heat that may be in Heat Demand mode. The fan shall
operate in accordance with the selected mode.
Legend
°C Water temperature
Cooling mode
Heating mode

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Water temperature
Temperature below 15°C* Temperature from15 to 35°C Temperature above 35°C**
Air °C Valve Fan Valve Fan Valve Fan
ON
ON
ON
ON
ON
ON
Two-pipe changeover plus two wires configuration
Water temperature
Temperature below 15°C* Temperature from15 to 35°C Temperature from 35 to 43°C** Temperature above 43°C
Air °C Valve Heater Fan Valve Heater Fan Valve Heater Fan Valve Heater Fan
ON
ON
ON
ON ON ON ON ON
ON ON ON ON ON
ON ON ON ON ON
Four-pipe configuration
Water temperature - hot water circuit
Temperature below 35°C* Temperature above 35°C
Air °C Heating valve Cooling valve Fan Heating valve Cooling valve Fan
ON ON
ON ON
ON ON
ON ON
ON ON
ON ON
6.2 - Summary cooling and heating mode tables in Occupied mode
Two-pipe changeover configuration
Air temperature decrease
Air temperature increase
Note:
If the CRC temperature sensor is selected in the Heating Satsfied mode, the fan
operates to protect against cold draughts (see chapter “Cold draught protection”).
Legend
Heater Electric heater
* Cooling demand
The valve opens if the water temperature falls below 15°C. The valve
closes if the water temperature rises above 20°C.
** Heating demand
The valve opens if the water temperature rises above 35°C. The valve
closes if the water temperature falls below 30°C.
Setpoint
Minimum fan speed
Medium fan speed
Maximum fan speed

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7 - MAIN SYSTEM SAFETY AND INTERLOCK
DEVICES
7.1 - Window contact operation
If the window contact indicates Window Open for more than
one minute, the unit is switched to Frost Protect mode. The
unit returns to normal operation when the window contact
indicates Window Closed.
The window contact can be configured in NO (normally open)
or NC (normally closed) mode from the CRC or System
Manager.
7.2 - Cold draught protection
This mode is not available, when the electric heater is
energised, or when the CRC temperature sensor is not selected.
Heat Demand Mode:
- If the water temperature is below 30°C, the fan turns off.
- The fan restarts when the water temperature is above 35°C
and runs at the speed selected by the user.
Heat Satisfied Mode:
- If the user fan setting is auto, the fan is de-energised.
- Otherwise the fan runs at minimum speed.
7.3 - Loadshedding
When the loadshed mode is active (Sm configuration), the
electric heaters remain de-energised. Default control is not
active.

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WIRING: CRC and window contact at the terminal inside the
control box.
Connectors supplied in the control box
- 230V + earth supply: Phoenix contact reference 18 04 91
7 + 18 37 32 4
- Secondary network: Wago 231-103/026-000 + 232-603
Legend
1 Return air temperature sensor (J4 AIR)
2 Water temperature sensor (J5 COIL)
3 Three-speed fan
4A Three-way changeover valve
5A Electric heater
4B Three-way cooling or changeover valve
5B Three-way heating valve
6 CRC
7 Window contact, presence detector
8 Secondary bus (not supplied by Carrier)
9 Fuse 3.15 A - 250 V - 5 x 20 mm
Fan cables Terminals
Red V1
Grey V2
Black V3
Blue N
Green/yellow Earth
8.2 - Two-pipe or four-pipe configuration
8 - CONNECTIONS
8.1 - Two-pipe + two-wire configuration
CAUTION: Only open the cover, after the system has been
de-energised.
230V - 16A - 50hz
+
0 V
-
J3
J10
1
2
3
5A
6
7
8
9
4A
+
0V
-1
2
3
230V - 16A - 50hz
J3
J10
4B
7
8
9
6
5B

Order No: 13414-76, 10.2003 - Supersedes order No: 13414-76, 06.2001 Manufacturer: Carrier s.a., Montluel, France.
Manufacturer reserves the right to change any product specifications without notice. Printed in the Netherlands on chlorine-free paper.
9 - TROUBLESHOOTING
The list below shows the main problems encountered, as well as the main remedies.
SYMPTOMS
The Aqualia or Ultra does not start
Cooling or heating is insufficient
IMPORTANT: If the problem persists after the checks above
have been carried out, please contact your local Carrier
representative.
REMEDIES
Check that the power supply is correctly installed.
Is the board LED flashing?
Ensure that the power supply conforms to the requirements
Has a fuse blown?
Change the fuse.
Has there been a power-cut?
Restart after the power has been restored.
Is the filter dirty?
Clean the air filter.
Is the setpoint correctly controlled?
Verify, and if necessary, change.
Is the controller in Frost-Protect mode?
Check if a window is open, and close it, if necessary.
Incorrect controller configuration?
Check the NO or NC configuration of the window contact.
Is the water temperature sensor or the ambient temperature sensor or the return air temperature sensor defective?
Change it.
Does anything obstruct the unit air inlet or outlet?
Remove the obstruction.
Do the water valves open correctly?
Is the changeover mode status incompatible?
See paragraph “Summary cooling and heating mode tables in occupied mode”.
Is the local, primary or secondary communication bus disconnected or defective?
Verify and reconnect the bus.
Verify the operation of the CRC: Is it On/Off?
Is automatic or manual speed selected?
Verify the System Manager time schedule program.