Installation and Start-Up Instructions
Contents
1. Only use return air opening provided All return air must pass through the coil See Fig 4 B Modular Units The FK4C fan coil in size 006 is a 2 piece modular unit Modular construction allows installer to disassemble unit into 2 components coil box and blower box for ease of installation See Fig 5 To disassemble unit remove rear corner brackets by removing 2 screws which secure brackets See Fig 5 Remove either 2 screws in each front corner of coil box or 2 screws in blower box Do not remove all 4 screws in each corner See Fig 5 Sections may now be separated by lifting top section from lower section To reassemble reverse above procedure Be certain to reinstall all fasteners when reassembling C Horizontal Installations Be sure installation complies with all applicable building codes that may require installation of a secondary condensate pan 1 Arrange support for unit by setting it in or above secondary condensate pan 2 When suspending unit from ceiling dimples in casing indicate proper location of screws for mounting metal support straps See Fig 6 N CAUTION For optimum condensate drainage performance in horizontal installations unit should be leveled along its lingth or raised 1 4 in at the air inlet The unit should also be pitched forward 1 4 in to 1 2 in toward the front condensate drains D Horizontal Right Conversion of Units with Slope Coils To convert units for horizontal right inst2. 900 9I ST 97 nii om 8 LC 9Uyeroc om OV GAddIHS SV NOILVOl lddV 109 v 109 v MOTAN 1431 ZIHOH ad SLS Her e 3 Ir 4 H adAL adAL I a i ZEIL T iss pele hy x SA0V1d 2 gt KEEN z A P dAL o t k Wi ER TE E Par S o gt G G mud PE a A o kr Med AHVMWIHd E 4l Sat ONILLIS WG Nivud lei VIO3dS TIVLSNI AYYNIHd NIVHQ AHVGNOO3S Menu AHVONOO3S x Sdov d 2 dAL NES a P aanadns 01914 dezau d D 38 OL 3HVMQHVH ONIONVH TWLNOZIHOH Vid 9E1 0 ENS F G3alAOHd S310H WOLLOG L3NISVO NI LJNIGVO JO XOV8 ONY m Nd dOL NI d3dlAOHd STi SNOLLVOOT1 INNON TWLNOZIHOH S MOHN GAddIHS SV NOlLVOIddv 1109 3d07S 7100 3407S MO14dN 145 ZIHOH 2 m t 3 Du Je d D adAL 8 adAL Z gt Pu i MTS i e Oy iq E p pal gt ASTM Z Kan Et ps z bs eo Sit dL N L TIO sst I l Hez 2 G alt gt o Oo o gt Lo s h oo e S kr 1 NIVHG AHY NOO3S NIVHG AHVWIHd E a adAL ee Nivaa Ble L AHVONOO3S Meng AYYNIHd x SAOV1d 2 G dAL BIST S3OVd v F 1 dAL ole kt MO UI INSTALLATION PROCEDURE 1 CHECK EQUIPMENT Unpack unit and move to final location Remove carton taking care not to damage unit Inspect equipment f
3. Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs is available using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service Training A94328 1995 CAC BDP P O Box 70 Indianapolis IN 46206 imfk4co1 18 Book Tab 1 3d 4 2e Catalog No 92 33FK 4C1
4. PROCEDURE 6 CONNECT REFRIGERANT TUBING See Dimensional Drawing for tube connection sizes type and locations Use accessory tubing package or field supplied tubing of refrigerant grade Insulate entire suction tube if field supplied tubing is used Tubing package has an insulated suction tube Do not use damaged dirty or contaminated tubing because it may plug refrigerant flow control device When tubing package is used and sweat connections are made within 60 sec coil and tubing system does not require evacuation Always evacuate if field supplied tubing is used N CAUTION A brazing shield MUST be used when tubing sets are being brazed to the unit connections to prevent damage to the unit surface N CAUTION To prevent damage to thermostatic expansion valve remove sensor bulb from vapor tube while brazing or soldering vapor connections Units have sweat suction and liquid tube connections Make suction tube connection first Cut tubing to correct length 2 Insert tube into sweat connection on unit until it bottoms 3 Solder with low temperature 430 F silver alloy solder N CAUTION Wrap a wet cloth around rear of fitting to prevent damage to factory made joints 4 Evacuate coil and tubing system if connections are not made within 60 sec or tubing package is not used PROCEDURE 7 CONDENSATE DRAIN Units are equipped with primary and secondary 3 4 in FPT drain connections Use a 3 4 in glue joint with fittings provid
5. CIRCUIT FUSING AND REFERENCE The low voltage circuit is fused by a board mounted 5 amp automotive fuse placed in series with the transformer SEC2 and the R circuit The C circuit of the transformer is referenced to chassis ground through a printed circuit run at SEC1 connected to metal standoff marked with ground symbol PROCEDURE 10 ACCESSORY INSTALLATION A Accessory Electric Heaters Electric heaters may be installed with the FK4C Fan Coil per the instructions supplied with the electric heater package NOTE It is not necessary to cover the opening for accessory heaters The unit will perform properly without this opening covered dpa N ec s A EASY SELECT 163 a pee S Ow A SR Ter DAE er ES hw aaa Ed in Po JAL e Ton fere FK4C 230 VAC OR m REO AUX1 AUX2 115 VAC BRANCH CKT FI tv C G GND HOT NEUT A A A A Q Q z MI rs J I SW G a S lt DOR Ga ae uote EAC PLUG T O ive A L E a L 4 MM fat eral ere eel aat iu B gt A VAC BEI AV a 24 VAC RELAY l HO Ss BLK T COM A95277 E si Fig 19 PCB Mounted with Wiring and Accessory Air A95318 Cleaner Relay Fig 20 EAC Relay Wiring Schematic B Electronic Air Cleaner Connections Because the ICM2 blower motor used in the FK4C fan coil i
6. O rd RY HEATER MOTOR S Bei MOLEX 12 PIN CONNECTOR A95275 Fig 17 Detail of FK4C Printed Circuit Board C SYSTEM TYPE Select system type installed AC or HP The type of system must be selected 1 AC Air conditioner 2 HP COMFORT Provides approximately 315 CFM ton for higher normal heating air delivery temperature Provides approximately 350 CFM ton cooling airflow for good humidity removal 3 HP EFF Provides same airflow for heating and cooling modes approximately 350 cfm ton The factory setting is AC See Fig 17 C as indicated D AC HP CFM ADJUST Select Medium Low or High airflow To provide airflow at the rates described above the AC HP ADJUST select is factory set to the nominal nom tap The adjust selections HI LO will regulate airflow supplied for all operational modes except non heat pump heating modes 15 and 10 respectively The adjust selection options are provided to adjust airflow supplied to meet individual installation needs for such things as noise comfort and humidity removal See Fig 17 D as indicated E ON OFF DELAY Select desired time delay profile Four motor operation delay profiles are provided to customize and enhance system operation See Fig 17 E as indicated The selection options are 1 The standard 90 sec off delay Factory setting 2 No delay option used for servicing unit or when a thermostat is utilized to perform delay functions 3 A 30
7. UPFLOW DOWNFLOW SECONDARY DRAIN 2 1 2 Eessen FIELD SUPPLIED RETURN PLENUM UPFLOW DOWNFLOW PRIMARY DRAIN Fig 4 Slope Coil Unit in Upflow Application 5 A93096 2 SCREWS REAR CORNER BRACKET 2 SCREWS COIL BOX A90168 Fig 5 Modular Unit Assembly PROCEDURE 3 AIR DUCTS Connect the supply air duct over outside of 3 4 in flange provided on supply air opening Secure duct to flange with proper fasteners for type of duct used and tape duct to unit joint Duct connection flanges are provided on unit air discharge connection When using FK4C units with 20 24 and 30 kw electric heaters maintain a 1 in clearance from combustible materials to discharge plenum and ductwork for a distance of 36 in from unit Use an accessory downflow base to maintain proper clearance on downflow installations Use flexible connectors between ductwork and unit to prevent transmission of vibration When electric heater is installed use heat resistant material for flexible connector between ductwork and unit at discharge connection Ductwork passing through unconditioned space must be insulated and covered with vapor barrier A Ductwork Acoustical Treatment Metal duct systems that do not have a 90 elbow and 10 ft of main duct to first branch takeoff may require internal acoustical insulation lining As an alternative fibrous ductwork may be used if constructed and installed in accordance with the latest
8. any local codes or ordinances that may apply Use copper wire only The unit must have a separate branch electric circuit with a field supplied disconnect switch located within sight from and readily accessible from the unit E S A COIL IN HORIZONTAL LEFT FIELD SUPPLIED HANGING STRAPS 24 IN FRONT SERVICE GLEARANGE FULL FACE e OF UNIT LOW VOLT m ENTRY OPTIONS he W lt OPTIONAL RETURN o AIR FLANGE KIT KO Lon D o i W 13 4 cla s Se FILTER ACCESS LEARANCE CONDENSATE SECONDARY POWER DRAIN SNE ENTRY OPTIONS A90167 Fig 6 Slope Coil in Horizontal Left Application COIL MOUNTING BLOWER SES ASSEMBLY COIL SUPPORT RAIL COIL SUPPORT RAIL SECONDARY REFRIGERANT CONDENSATE CONNECTIONS PRIMARY CONDENSATE DRAIN A90174 Fig 7 Slope Coil in Horizontal Right Application Ip AIR SEAL ASSEMBLY REFRIGERANT CONNECTIONS A SS C 2 CZ COIL BRACKET DRAIN PAN SUPPORT 8 BRACKET e CL Z HORIZONTAL RIGHT a APPLICATION B C D BG ane EECH B 22 a a IG FACTORY SHIPPED COIL G HORIZONTAL SUPPORT COIL e LEFT APPLICATION RAIL BRACKET SES METAL HORIZONTAL SECONDARY PRIMARY B S DRAIN PAN CONDENSATE CONDENSATE C DRAIN DRAIN A91119 Fig 8 A Coil in Horizontal Right Application Thermostat FK4C Outdoor Subbase Terminal Terminal Block Board Thermostat FK4C Outdoor Subbase f l Terminal Ter
9. edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with National Fire Protection Association as tested by UL Standard 181 for Class 1 air ducts PROCEDURE 4 ELECTRICAL CONNECTIONS A Line Voltage Connections Units with 15 20 24 and 30 kw heaters are factory wired for dual circuit operation When single circuit operation is required install factory authorized adapter kit for fused models only Check all factory wiring per unit wiring diagram and inspect factory wiring connections to be sure none were loosened in transit or installation N WARNING Before installing or servicing system always turn off all power to system There may be more than 1 disconnect switch Turn off accessory heater power if applicable Electrical shock can cause personal injury or death Z CAUTION If a disconnect switch is to be mounted on the unit select a location where drill or fastener will not contact electrical or refrigerant components Electrical shock can cause personal injury or death NOTE Before proceeding with electrical connections make certain that supply voltage frequency and phase are as specified on unit rating plate Be sure that electrical service provided by the utility is sufficient to handle the additional load imposed by this equipment See unit wiring label for proper field high and low voltage wiring Make all electrical connections in accordance with NEC and
10. ANNOO S IIVL3d 109 AM HLIM NMOHS MAIA LNOYS SNIN3dO NMOHS SNOILVOO1 NOLLO3NNOO me z ER t SIJNOO Nd SS322V gl ne N 9t 0z lr d S1IVL30 1109 3dO1S ANYd S 399V HALT o o p Lr og T EIC AS I H EE a i HR gy L Oo ue v l y PU Ab o Wn 4 901 Sun i el d yvindow i S O l j NOLLOANNOO LES if NI NOLLONS CUAL K T e t R T3Nvd ONILLIS EIL Jl te toz I Riaz 1 f we ie NOILOANNOO 3NH AINON pA o ol ee HI if r3 i FEL MED 9 Lo bei n OI Y TaNvd 13NI8VO 3O3ld NOLLSSNINGS OML V 3AVH NOILO3NNOO 3NH anon SSd90V 1109 TIM SLNN v IXR 9Nn anon o E uvindow 3dis ALISOddO ONIHIM NOILO3NNOO LON H3MOd 299 LOA HOIH HOH aN NOLLOnS S O VIC OZ Ee t Bi TANVd SS320V ALWNYALTV AINO SUND 1109 3dO1S YALVSH 21910919 9 K ONIN3dO Nuni3H JAIS 1HOlH 1OH1NOO H3MO18 L A i Q31H3ANOO 01914 1VNOlLdO NOIVOOS o L G3diAoHd SONLLLIJ VIA uivaua Uc t H ANIOP 3N19 OAd SIWWAS Pie S1109 V ZIHOH HO LOANNOOSIC ie Vio 7 T ao EN snz MOTSNMOG MO14dN Ld He SNOLLOANNOO Med 3LYSNIANOO 9 eus Ie 4 4 ONIGIM IOHINOS 1V3MS Q l Bis ainon g S 2 SOVIHOR MOT Od 1V3MS 8 900 S00 E00 ONIHIM HIMOA 3OVLTOA HOIH HOS Bl Ab EISE SS 5 PE EUR i wg 07 9 Siet 8 2 O vid 8 2 1V3MS 01 bie 200 gt 100 NOILONS e D Sie le aus 4 SUN S3ZIS NOILO3NNOO LINN Beh re man dOL d i GATIVLSNI 38 LSAW NYd 31VSN3QNOO AHVONOO3S
11. CIRCUITS R TO Y Y2 AND R TO O The fan coil delivers single speed cooling airflow THERMOSTAT CLOSES CIRCUIT R TO Y1 R TO Y2 AND R TO O The fan coil delivers 2 speed high cooling airflow C Cooling Mode Two speed low THERMOSTAT CLOSES CIRCUITS R TO Y1 ANDR TOO The fan coil delivers 2 speed low cooling airflow D Electric Heat Heating Mode THERMOSTAT CLOSES CIRCUIT R TO W W1 OR W2 The fan coil delivers the selected electric heat airflow 10 E Heat Pump Heating Mode Single speed or 2 Speed High THERMOSTAT CLOSES CIRCUIT R TO Y Y2 The fan coil delivers single speed heat pump heating airflow THERMOSTAT CLOSES CIRCUIT R TO Y1 AND R TO Y Y2 The fan coil delivers 2 speed high heat pump heating airflow F Heat Pump Heating Mode 2 speed low THERMOSTAT CLOSES CIRCUIT R TO Y1 The fan coil delivers 2 speed heat pump heating low airflow G Heat Pump Heating with Auxiliary Electric Heat THERMOSTAT CLOSES CIRCUITS R TO Y Y2 AND OR R TO Y1 WITH R TO W W1 OR W2 AND R TO O IN THE CASE OF DEFROST In the event that electric heating is called for by the thermostat while the heat pump is also operating in either heating or defrost modes the motor will modify its airflow output if necessary to provide an airflow which is defined as safe for the operation of the electric heater during heat pump operation That airflow is the greater of the heat pump heating airflow and the greater of the electric heater only airflow
12. Installation and Start Up Instructions Direct Expansion Fan Coil 001 006 A92500 Fig 1 Model FK4C NOTE Read entire instruction manual before starting installation INTRODUCTION Model FK4C Fan Coil Units are designed for flexibility and can be used for upflow horizontal or downflow applications These units are available for application in systems of 18 000 through 60 000 Btuh nominal cooling capacities See Fig 2 and 3 Factory authorized field installed electric heater packages are available in 5 through 30 kw See product data for available accessory kits Z WARNING Before installing or servicing fan coil always turn off all power to unit There may be more than 1 disconnect switch Turn off accessory heater power if applicable Electrical shock can cause personal injury or death SAFETY CONSIDERATIONS Improper installation adjustment alteration service maintenance or use can cause explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for brazing operations Have fire extinguishe
13. OTT 01914 v 3OVdS ONIATYONHI3O Q3HSINId H3AO GATIVLSNI N3HM E SIVIHILYN 318 LSngWOO OL 3oNvuv31o Lona 3OuVHOSIQ WOH 3ONVHV3TO DL JO WEINI Y ONIHIM OHINOO NIVLNIVIN LSAW SH31V3H W 09 ANY YZ OZ HLIM SLINN 2 SEENEN uod BOIAH3S HOI INOY4 WOHS LS MOTI I le SILON Buimeig jeuoisuawig e_ Du DHOTHM ONLLViddO LLES6Y G31H3ANOO 071914 NOILYONddY SE 1100 v 1HOlH ZIHOH MO HNMOG 3 dAL d adAL v7 R pe Bier deM v S3ovid 2 KA TEL dAL dAL dei SO pet ne pud ul rz z z vea SEEKS NIV 5 g AHVONOO3S L 3 NIVHd Q9 J lo o P AL L Dni V dAl C V ott ff NIVHG AHVMWIHd i e ONILLIJ Wed d TVIO3dS TIVLSNI d NIVHQ AHVONOO3S ol Jh N r lt H bP d ies eb sissovid o Hi gAL My hes t MOTSHIV Q31H3ANOO 071914 NOILYONddY 1109 3407s 109 3dO1 1H5lH ZIHOH MO14NMOQ adAL H adAL Am rm PU S3ovid v x S4OV1d 2 n Sc Ig Je K SC dAL L aly d Ki G E pe lt S L T CR o l E T4 O el e 1 2m NIVHd 4 AHVIAIHd Ed Mu 9 s ye NE A tH k N AUWANOOAS ly dAl C E NIVHGQ AHVONOO3S A NINO AYYNIHd b N k Te 64 o n 2 H k quee t x SAOV1d 2 Lr ET 1 kz t MO13HIV are 8 C C oysrce
14. a standard humidistat See Fig 17 These terminals are energized with 24vac whenever G thermostat signal is present See Fig 21 Alternately the 24vac signal may be sourced from the W and C terminal block connections D De Humidify Mode Humidistat Connection Latent capacities for systems using the FK4C fan coil are better than average systems If increased latent capacity is an application requirement the field wiring terminal block provides connection terminals for use of a standard humidistat The FK4C fan coil will detect the humidistat contacts opening on increasing humidity and reduce its airflow to approximately 8096 of nominal cooling mode airflow This reduction will increase the system latent capacity until the humidity falls to a level which causes the humidistat to close its contacts When the contacts close the airflow will return to 100 of the selected cooling airflow To activate this mode remove Jumper J1 and wire in a standard humidistat See Fig 22 CARE AND MAINTENANCE For continuing high performance and to minimize possible equipment failure it is essential that periodic maintenance be performed on this equipment Consult your local dealer as to the proper frequency of maintenance and the availability of a maintenance contract E EASY SELECT BOARD TERMINAL BLOCK HUMIDISTAT J1 E HUM 1 C vac TO HUMIDIFIER Ul x eU HUM 2 REMOVE m G JUMPER HUMIDIFIER WIRING A95317 A95316 F
15. allations 1 Remove blower and coil access panels and fitting panel See Fig 7 2 Remove screw securing coil assembly to right side casing flange 3 Remove coil assembly 4 Lay fan coil on its right side and reinstall coil assembly with condensate pan down See Fig 7 5 Attach coil to casing flange using previously removed coil mounting screw 6 Reinstall access panels and fitting panel aligning holes with tubing connections and condensate pan connections Make sure liquid and suction tube grommets are in place to prevent air leaks and cabinet sweating Install grommets after brazing E Horizontal Right Conversion of Units With A Coil To convert units for horizontal right installations 1 Remove blower and coil access panels See Fig 8 Remove fitting door clip to plastic condensate pan and remove fitting door Remove snap in shipping clip securing A coil in unit Remove coil assembly Remove metal horizontal drain pan from coil assembly Remove horizontal drain pan support bracket from coil support rail and reinstall coil support rail on the opposite side YA tA A WO N Remove condensate drain plugs from 1 side of horizontal drain pan and install in drain connection openings on opposite side A 8 Convert air seal assembly for horizontal right See Fig 8 inset 9 10 11 a Remove air seal assembly from coil by removing 4 screws b Remove air splitter B from coil seal assembly by removing 3 sc
16. and 10 C Intelligent Heat Staging Option Intelligent staging of the electric heat package is possible when the FK4C is installed as a part of a single speed heat pump system using a corporate 2 speed programmable thermostat and any one of the electric heat packages 9kw 15kw 24kw or 30kw To activate intelligent staging the intelligent staging switch in thermostat must be set and W1 W2 jumper J2 must be removed Complete system low voltage wiring as shown in Fig 11 Do not use outdoor thermostats when using intelligent heat staging NOTE Where local codes require thermostat wiring be routed through conduit or raceways splices can be made inside the fan coil unit All wiring must be NEC Class 1 and must be separated from incoming power leads A factory authorized disconnect kit is available for installation of 0 through 10 kw applications When electric heat packages with circuit breakers are installed the circuit breaker can be used as a disconnect NOTE Transformer is factory wired for 230v operation For 208v applications disconnect black wires from 230v terminal on the transformer and connect them to the 208v terminal See Fig 12 The secondary circuit of the transformer is protected by a 5 amp fuse mounted on the printed circuit board ere SECONDARY A PRIMARY A94067 Fig 12 Transformer Connections D Ground Connections Use UL listed conduit and conduit connector to connect supply wire s to unit and obtai
17. e informed that when condensate flows from the secondary drain or external condensate pane the unit requires servicing else water damage will occur Install traps in the condensate lines as close to the coil as possible See Fig 16 Make sure that the outlet of each trap is below its connection to the condensate pan to prevent condensate from overflowing the drain pan Prime all traps test for leaks and insulate traps if located above a living are Condensate drain lines should be pitched downward at a minimum of 1 in for every 10 ft of length Consult local codes for additional restrictions or precautions DO NOT USE SHALLOW RUNNING TRAPS 2 A95320 Fig 14 Insufficient Condensate Trap A95321 Fig 13 Recommended Condensate Trap os R l S SECONDARY Va PRIMARY TRAP REQUIRED 0 FILTER 2 1 4 IN MIN ACCESS SECONDARY FITTING PRIMARY FITTING PANEL WITH BUILT IN DAM cr A90347 A90173 Fig 15 Primary and Secondary Fittings Fig 16 Condensate Trap and Unit Z CAUTION Never operate unit without a filter or with filter access door removed Damage to blower motor or coil can result Factory authorized filters must be used when locating the filter inside the unit See Table 2 For those applications where access to an internal filter is impractical a field supplied filter must be installed in the return duct system PROCEDURE 8 UNIT START UP Refer to outdoor unit Installation Instructions for system sta
18. ed for units with A coils in horizontal applications It is recommended that PVC fittings be used on the plastic condensate pan Do not over tighten Finger tighten plus 1 1 2 turns N CAUTION To prevent property damage and achieve optimum drainage performance BOTH primary and secondary drain lines should be installed and include properly sized condensate traps See Fig 13 Shallow running taps are inadequate and DO NOT allow proper condensate drainage See Fig 14 For horizontal installations of units with A coils use plastic fittings provided See Fig 15 Make sure that the correct plastic fitting is installed in the correct location on the horizontal drain pan Use pipe dope NOTE When connection condensate drain lines avoid blocking filter access panel Prime both primary and secondary condensate traps after connecting to drain pan NOTE If unit is located in or above a living space where damage may result from condensate overflow a field supplied external condensate pan should be installed underneath the entire unit and a secondary condensate line with appropriate trap should be run from the unit into the pan Any condensate in this external condensate pan should be drained to a noticeable place As an alternative to using an external condensate pan some localities may allow the running of a separate 3 4 in condensate line with appropriate trap to a place where the condensate will be noticeable The owner of the structure must b
19. ig 21 Humidifier Wiring Fig 22 Humidistat Wiring for De Humidify Mode The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools If you do not possess these contact your dealer for maintenance The only consumer service recommended or required is filter maintenance A WARNING Disconnect all power to the unit before servicing the field wires or removing the control package The disconnect when used on the access panel does not disconnect power to the line side of the disconnect but does allow safe service to all other parts of the unit If the unit does not have a disconnect disregard the foregoing Instead make sure that a disconnecting means is within sight from and is readily accessible from the unit Disconnect all electrical power to the unit before performing any maintenance or service on it A failure to follow this warning can cause electrical shock fire personal injury or death The minimum maintenance requirements for this equipment are as follows 1 Inspect and clean or replace air filter each month or as required 2 Inspect cooling coil drain pan and condensate drain each cooling season for cleanliness Clean as necessary An inspection port is provided on all A coil delta plates Remove plastic plug to inspect 3 Inspect blower motor and wheel for cleanliness each heating and cooling season Clean as necessary 4 Inspect electrical connections for tightness and contr
20. learance is available to clean 8 Remove blower wheel from housing by removing cutoff plate from blower housing outlet Note wheel orientation and cutoff location for reassembly The blower motor and wheel may be cleaned by using a vacuum with a soft brush attachment 9 Remove grease with a mild solvent such as hot water and detergent Be careful not to disturb balance weights clips on blower wheel vanes Also do not drop or bend wheel as balance will be affected To reassemble blower after cleaning 1 Place blower wheel back into housing Be sure to position correctly for proper location Reassemble cutoff plate to housing using identified holes from disassembly procedure 2 3 Position motor and mount in same position as before when blower housing was in unit 4 Secure motor mount to housing using removed bolts Make sure mount or motor is grounded to blower housing 5 Locate blower wheel setscrew over flat on motor shaft Rotate wheel in housing It should not rub housing and should be centered in inlet opening If not centered loosen setscrew and align as necessary ON Attach green wire to blower housing with screw 7 Slide blower assembly on to blower deck Once blower is within the unit envelope make sure to force blower assembly toward control box while sliding assembly into unit to ensure that blower assembly engages deck properly 8 Fasten blower assembly to deck with screws previously removed 9 Reconnect mot
21. minal Block Board N e Z z z N eo 8 a E E es esi ET A95313 Fig 9 Single Speed Heat Pump Wiring 9 Le D m EH gt D lt N N i2 SIS Sl fel e EST 9 A95314 Fig 10 Two Speed Heat Pump Wiring THERMOSTAT EASY SELECT OUTDOOR UNIT TERMINAL BOARD TERMINAL TERMINAL BLOCK BLOCK BLOCK ELENE 5 e NS ZI Z EASY SELECT BOARD JUMPER J2 A95315 Fig 11 Single Speed Heat Pump Wiring with Intelligent Heat Staging B 24 V Control System Connections to Unit Printed Circuit Board PCB Refer to unit wiring instructions for recommended wiring procedures Use No 18 AWG color coded insulated 35C minimum wires to make low voltage connections between thermostat and unit If thermostat is located more than 100 ft from unit as measured along the low voltage wires use No 16 AWG color coded insulated 35 C minimum wires PCB is circuited for single stage heater operation When additional heater staging is desired using 2 stage or outdoor thermostats see applicable outdoor unit instructions Remove Jumper J2 on PCB 1 The 5 8 and 10 kw heaters are single stage only 2 The 15 and 20 kw heaters are adaptable for 2 stage operation 3 The 24 and 30 kw heaters are adaptable for up to 3 stage operation Connect low voltage leads to thermostat and outdoor unit See Fig 9
22. n proper grounding Grounding may also be accomplished by using grounding lug provided in control box Use of dual or multiple supply circuits will require grounding of each circuit to ground lugs provided on unit and heaters A WARNING The cabinet must have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 and local codes to minimize personal injury if an electrical fault should occur The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes Failure to follow this warning could result in an electrical shock fire or death PROCEDURE 5 FK4C FAN COIL SEQUENCE OF OPERATION The FK4C will supply airflow in a range which is more than twice the range of a standard fan coil It is designed for nominal cooling capacities at a 50 F evaporator temperature and to provide the required airflow which enables it to match with 4 air conditioner or heat pump system sizes The following table outlines the CFM range for the different FK4C fan coil sizes Table 1 CFM Range for FK4C Units FAN COIL SIZE SYSTEM SIZES CFM RANGE FK4CNF001 018 024 030 036 450 1275 FK4CNF002 018 024 030 036 450 1275 FK4CNB005 030 036 042 048 550 1700 FK4CNB006 036 042 048 060 550 2150 A Continuous Fan FK4CNF003 024 030 036 042 525 1475 THERMOSTAT CLOSES CIRCUIT R TO G The blower runs at continuous fan airflow B Cooling Mode Single speed or 2 speed high THERMOSTAT CLOSES
23. of the heat pump heating airflow and the electric heater airflow to ensure safe heater operation The factory selection is the largest heater range approved See Fig 17 A as indicated B AC HP SIZE Select system size installed The factory setting for air conditioner or heat pump size is the largest unit meant for application with the model of fan coil purchased The installer needs to select the air conditioner or heat pump size to ensure that airflow delivered falls within proper range for the size unit installed This applies to all operational modes with the exception of electric heat modes See Fig 17 B as indicated Table 2 Filter Kits PART NUMBER SIZE USED WITH FILTER KIT 12 KFAFK0212MED 001 002 PACK KFAFK0312LRG 003 005 KFAFK0412XXL 006 LOW VOLTAGE TERMINAL BLOCK PRINTED CIRCUIT BOARD N SEC1 SEC2 i Ca les i fey Du EASY SELECT AUX HEAT KW CFM R aA 2 WI X ZS J2 SE W vio H ji lil d Less 1 e AC HP SIZE W gt UJ 036 030 024 018 a s al ala SYSTEM TYPE AC HP COMFORT HP EFF C m 8 AC HP CFM ADJUST G NOM LO HI H aliclelele 8 8 8 ON OFF DELAY i m d amp 3 c 8 3 AUXI HUM1 EL 7 7 m mM de SI ONTINUOUS FAN D LO MED HI EL A 6 AUX2 HUM2 CEBD430226 01B CESS430226 01B z fJ oS OS 900000000000 AVAC
24. ols for proper operation each heating and cooling season Service as necessary Z WARNING As with any mechanical equipment personal injury can result from sharp metal edges etc therefore care should be taken when removing parts PROCEDURE 1 FILTER ASSEMBLY To clean or replace air filter slide plastic connectors toward center of unit and remove filter access door Push filter up and back into unit then slide filter out Clean filter by using cold water and allow filter to dry No oiling or coating of filter is required New filters are available from your local distributor Place filter in slot with cross mesh binding up or facing the cooling coil and replace filter access door A WARNING Because of possible damage to the equipment or personal injury the maintenance items below should be performed by a trained service person Consumer service in these areas is not recommended PROCEDURE 2 COOLING COIL DRAIN PAN AND CONDENSATE DRAIN The cooling coil is easily cleaned when it is dry therefore inspect the coil and clean if necessary before each cooling season To check or clean the cooling coil remove the coil access panel If the coil is coated with dirt or lint vacuum it with a soft brush attachment Be careful not to bend coil fins If coil is coated with oil or grease clean it with a mild detergent and water solution Rinse coil with clear water Be careful not to splash water on the insulation Inspect drain pan and conden
25. or damage prior to installation File claim with shipping company if shipment is damaged or incomplete Locate unit rating plate which contains proper installation information Check rating plate to be sure unit matches job specifications PROCEDURE 2 MOUNT FAN COIL Unit can stand or lie on floor or hang from ceiling or wall Allow space for wiring piping and servicing unit IMPORTANT When unit is installed over a finished ceiling and or living area building codes CABO M 1701 2 UMC 1205 SBCCI 603 4 may require a field supplied secondary condensate pan to be installed under the entire unit Some localities may allow as an alterative the running of a separate secondary condensate line Consult local codes for additional restrictions or precautions When installing any fan coil over a finished ceiling and or living area installation of a secondary drain pan under entire unit to avoid damage to ceiling is recommended The FK4C Fan Coils can be installed for upflow and horizontal left applications as factory shipped Units can be installed for horizontal right applications with field modifications Units may be converted for downflow applications using factory authorized accessory kit NOTE To ensure proper drainage for horizontal installations unit must be installed so it is within 1 8 in level of the length and width of unit A Upflow Installation If return air is to be ducted install duct flush with floor Set unit on floor over opening
26. or power and control connectors at motor 10 Reconnect electrical power to unit and test blower for proper rotation PROCEDURE 4 ELECTRICAL CONTROLS AND WIRING A WARNING Before installing or servicing system always turn off all power to system Turn off accessory heater power if applicable Electrical shock can cause personal injury or death With ALL power disconnected inspect all electrical connections for tightness Tighten all screws on electrical connections If any discolored or burned connections are noticed disassemble the connection clean all parts and stripped wire and reassemble properly and securely Electrical controls are difficult to check without proper instrumentation therefore reconnect electrical power to unit and observe unit through 1 complete operating cycle If there are any discrepancies in the operating cycle contact your dealer and request service PROCEDURE 5 REFRIGERANT CIRCUIT The refrigerant circuit is difficult to check for leaks without proper equipment Therefore if low cooling performance is suspected contact your local dealer for service PROCEDURE 6 OWNER USER INSTRUCTION Using the Owners User Manual furnished in outdoor unit explain system operation with particular emphasis on indoor fan coil operation sounds SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual including Unit Familiarization
27. r available Read these instructions thoroughly and follow all warnings or cautions attached to the unit Consult local building codes and National Electrical Code NEC for special requirements Recognize safety information This is the safety alert symbol N When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the signal word DANGER WARNING or CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage Form IM FK4C 01 Cancels IM FK4B 02 Printed in U S A 8 95 Catalog No 92 33FK 4C1 Ure oer oucer oer Ses La Buimeig jeuoisuswig z DI KISS e omvmze SE v E CC 9U TI vC 91 66 ISS v 1 6l 8 1 1c OU L S Hiel 8 T 1c 91 L 6 oue ves 8 S LI SES u A Se ae ee o5 a OLES6V Div LIINI MAIA ACIS LHOW SNOlLVOl lddv MOT4JNMOG S109 V ON SNOLLVOllddV LHOIY ZIHOH HO MOTANMOG S7109 3dO 1S HO4d SNOlLVOllddV 14331 ZIHOH HO MOO HOd u AL ad o j s pj wv J SNOILVOl1ddV ZIHOH HO MO1sdN HOJ SNOILVOOT1 NOILO
28. rews c Remove filler plate A and install air splitter B in place of filler plate d Install filler plate A as shown in horizontal right application See Fig 8 inset e Remove condensate troughs C and install on opposite tube sheets See Fig 8 insets f Install hose onto plastic spout Install horizontal pan on right side of coil assembly with plugged condensate openings to rear of assembly Slide coil assembly into casing Be sure clips on each corner engage coil support rails See Fig 8 Remove condensate drain knockouts from right side of coil access panel 12 Reinstall access panels and fitting door aligning holes with tubing connections and condensate pan connections Make sure liquid and suction tube grommets are in place to prevent air leaks and cabinet sweating F Downflow Installations To convert units for downflow applications refer to Installation Instructions supplied with kit for proper installation For FK4C unit sizes 001 and 002 use kit KFADCO2OISLP For FK4C unit sizes 003 005 and 006 use kit KFADC0301ACL Use fireproof resilient gasket 1 8 to 1 4 in thick between duct unit and floor FIELD SUPPLIED SUPPLY DUCT POWER ENTRY OPTIONS LOW VOLT ENTRY OPTIONS 24 FRONT SERVICE CLEARANCE SLOPE COIL SIDE RETURN UPFLOW DOWNFLOW SECONDARY DRAIN DOWNFLOW PRIMARY DRAIN FIELD MODIFIED A SIDE RETURN LOCATION FOR SLOPE COIL UNITS ONLY
29. rt up instructions and refrigerant charging method details PROCEDURE 9 EASY SELECT CONFIGURATION TAPS The EASY SELECT taps are used by the installer to configure a system The ICM2 uses the selected taps to modify its operation to a pre programmed table of airflows Airflows are based on system size or mode of operation and those airflows are modified in response to other inputs such as the need for de humidification See Fig 17 and 18 The FK4C Fan Coil must be configured to operate properly with system components with which it is installed To successfully configure a basic system see information printed on circuit board label located next to select pins move the 6 select wires to the pins which match the components used A AUX HEAT KW CFM Select heater range for size of electric heater installed The installer must select the auxiliary heat airflow approved for application with the kw size heater installed If no heater is installed this step can be skipped Each select pin is marked with a range of heaters for which the airflow also marked is approved The heater installed must fall within the range selected for safe and continuous operation It is appropriate to mention that the airflow marked is that airflow which will be supplied in emergency heat mode and heating mode on air conditioners when electric heat is the primary heating source In heat pump heating mode when the electric heaters are energized the ICM2 will run the higher
30. s controlled by low voltage signals a switched 230vac electronic air cleaner power signal is not available This signal is replaced by a 24vac signal which is provided at PCB terminals AUX1 and AUX 2 See Fig 17 and 18 This signal is present whenever the G thermostat signal is present heat pump heating cooling and continuous blower modes When the FK4C fan coil is installed with an electronic air cleaner use EAC relay kit KFAIRO201ACR or a field supplied 24vac relay The EAC relay kit consist of a 24vac relay which mounts directly on the PCB bracket inside the fan coil using factory punched screw holes 2 mounting screws two pre terminated wires for connection of the relay coil to the AUX1 and AUX2 terminals 2 16 AWG stripped leads for connection of the relay contacts for control of power to the EAC wire nuts and wiring instructions See Fig 19 If the EAC relay is field supplied use field supplied wiring terminations and wire per the EAC wiring schematic See Fig 20 NOTE If the FK4C is installed with an air conditioner and the electric heat is the primary heating device a thermostat which turns on the G output with a call for heat is required for air cleaning or humidification during heating mode A Corporate thermostat with the fan on with W option set to on is recommended C Humidifier Humidistat Connections Terminals HUM1 and HUM2 are provided for direct connection to the low voltage control of a humidifier through
31. sate drain at the same time the cooling coil is checked Clean drain pan and condensate drain by removing any foreign matter from the pan Flush pan and drain tube with clear water If drain tube is restricted it can generally be cleared by high pressure water Cut plastic line and work outside the condensate pan and away from coil to clear drain tube N CAUTION Do not use caustic household drain cleaners in the condensate pan or near the coil Drain cleaners can quickly destroy coils Electrical shock can cause personal injury or death PROCEDURE 3 BLOWER MOTOR AND WHEEL Clean blower motor and wheel when cooling coil is cleaned N CAUTION Disconnect electrical power before removing any access panels 16 To clean blower motor or blower wheel Remove blower access panel Remove motor power and control connectors from motor Note lead location for ease of reassembly 1 2 3 Remove 2 outside screws holding blower motor assembly against blower deck flange and slide assembly out of cabinet 4 Remove screw with green wire from blower housing 5 Mark blower wheel motor and motor support in relation to blower housing before disassembly to ensure proper reassembly Note position of blades on wheel ON Loosen setscrew holding blower wheel onto motor shaft 7 Remove 3 bolts holding motor mount to blower housing and slide motor and mount out of housing Further disassembly should not be necessary as adequate c
32. sec on delay with no airflow 90 sec off delay at 100 airflow profile is used when it is desirable to allow system coils time to heat up cool down in conjunction with the airflow This profile will minimize cold blow in heat pump operation and could enhance system efficiency 4 ENH enhanced selection provides a 30 sec on delay with no airflow 180 sec off delay at half airflow add comfort and efficiency results H SN nd SECH ae fF 3 ea n JI p EASY RUN ea AUX HEAT KWICFM R 0 20 0 10 ei Mo TS Qe J2 Lea W AC HP SIZE E W 030 024 018 FAS j als i Eed SYSTEM TYPE L UT HP EFF eS YY C HP CFM ADJUST YE LO HI e G ala WHT L DIE FAN LOW MED YEL 2 01B CESS430226 01B gt c 2 x c Q Q D 8 ON OFF DELAY i of gt C x M x c z N HEATER MOT WL S NV gy gt J 12 PIN MATE N LOCK ELECTRIC HEAT CONNECTOR SCH Fig 18 PCB Wiring Arrangement A95276 F CONTINUOUS FAN Select desired fan speed when thermostat is set on continuous fan 1 LO speed factory setting 50 cooling mode airflow 2 MED speed move connector to MED 65 cooling mode airflow 3 HI speed move connector of HI 100 cooling mode airflow See Fig 17 F as indicated G LOW VOLTAGE
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