Installation Instructions
Contents
1. 4 MAX A02003 Fig 7 A Coil V4 Y cA COIL FACTORY SHIPPED HORIZONTAL LEFT 0 gt BRACKET APPLICATION CS Z COIL SESS ZZ SUPPORT SS S3 RAIL B 8 C 2 DRAIN PAN SUPPORT M BRACKET 5 e QNSE we 4 COIL SASL BRACKET BAS WA NER HORIZONTAL DRAIN PAN PRIMARY DRAIN AIR SEAL HORIZONTAL LEFT ASSEMBLY SECONDARY DRAIN HORIZONTAL LEFT REFRIGERANT CONNECTIONS 00072 Fig 8 A Coil in Horizontal Left Application Factory Ready 6 User Interface Fan Coil Outdoor Air Thermistor if used Humidifier A03077 Fig 9 FE4A Fan Coil Wiring with Single Speed AC HP Check all factory wiring per unit wiring diagram and inspect factory wiring connections to be sure none were loosened in transit or installation A 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 N 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 A WARNING Field wires on the line side of the disconnect remain live even when the pull out is removed Service and maintenance to incoming wiring can not be performed until the main disconnect switch remote to the unit2. 4 Check motor and motor control module following the instructions in Section C ECM Motor Troubleshooting STATUS CODE 26 INVALID HEATER SIZE On initial power up fan coil control will write into memory electric heater size as read from heater if heater is provided with Identifier Resistor IDR Heater size must be valid for combination of indoor and outdoor components installed Fan coil control will read IDR value connected to pins 5 and 8 of heater harness connector If no resistor is found system User Interface will prompt installer to verify that no heater is installed Verifying that this is correct will establish that fan coil is operating without an electric heater accessory Upon choosing negative option installer will be prompted to select heater size installed from a list of valid heater sizes for fan coil and outdoor unit size installed If heater ID resistor value read is invalid Status Code 26 will be displayed on STATUS LED If heater installed is equipped with a resistor connected to pins 5 and 8 of heater harness connector and status code 26 is displayed on STATUS LED 1 Check wiring harness connections to be sure connections are secure 2 If symptoms persist disconnect wiring harness at fan coil control heater header and check for a resistance value greater than 5000 ohms 3 Check for proper wiring of resistor assembly 4 Make sure heater size installed is an approved size for outdoor unit and fan coil sizes installed
3. NOTE Fan coil control will not operate electric heater until this Status Code is resolved If the heater size is set through the User Interface the heater will be operated as a single stage heater If staging is desired the IDR value must be read in by the fan coil control STATUS CODE 36 HEATER OUTPUT NOT SENSED WHEN ENERGIZED Fan coil control is provided with circuitry to detect presence of a 24 vac signal on Electric Heater stage 1 and stage 2 outputs If fan coil control energizes either heater stage and does not detect the 24 vac signal on output Status Code 36 will be displayed on the STATUS LED Fan coil control will continue to energize heater output s and adjust blower operation to a safe airflow level for energized electric heat stage s To find the fault 1 Check for 24 vac on heater stage outputs Fan coil control or sensing circuit may be bad NOTE It may be useful as an electric heater troubleshooting procedure to disconnect the system communications to force Status Code 16 enabling of emergency heat mode It is difficult to know which heater output is energized or not energized in normal operation When fan coil is operated in emergency heat mode using electric heaters both outputs are energized and de engergized together Terminal strip inputs to control can then be connected R to W to turn on both electric heat outputs Heater output sensing circuits can then be checked to resolve Status Code 36 or 37 problems 3 STAT
4. Wrap all filter driers and service valves with wet cloth when brazing A liquid line filter drier is required on every unit Do not use an R 22 TXV If indoor unit is equipped with an R 22 TXV it must be changed to a Puron TXV Never open system to atmosphere while it is under a vacuum When system must be opened for service break vacuum with dry nitrogen and replace filter driers Do not vent Puron into the atmosphere Do not use capillary tube indoor coils Observe all warnings cautions and bold text 2003 CAC BDP 7310 W Morris St Indianapolis IN 46231 imfe4a01 16 Book Tab 1 4 3d 2e Catalog No 63FE 4A0
5. The conversion of the fan coil to downflow requires special procedures for the condensate drains on both A coil and Slope units The vertical drains have an overflow hole between the primary and secondary drain holes This hole is plugged for all applications except downflow but must be used for downflow During the conversion process remove the plastic cap covering the vertical drains only and discard Remove the plug from the overflow hole and discard At completion of the downflow installation caulk around the vertical pan fitting to door joint to retain the low air leak performance of the unit Failure to follow this caution will result in minor property damage To connect drains the cap openings must be removed Use a knife to start opening near tab and using pliers pull tab to remove disk Clean edge of opening if necessary and install the condensate line Finally caulk around lines where they exit fitting to retain low leak rating of the unit Units are equipped with primary and secondary 3 4 in FPT drain connections For proper condensate line installation see Fig 2 4 5 6 and 8 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 12 and 14 Factory approved condensate traps are available Be sure to install plastic push in plugs in unused condensate drain fittings It is recommended that PVC fittings be used on
6. is turned off Failure to do so will result in electrical shock causing 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 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 B 24 V Control System Connections to Unit Printed Circuit Board PCB Use No 18 AWG color coded insulated 35 C minimum wires to make low voltage connections between User Interface and unit If User Interface 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 or in accordance with local codes Connect low voltage leads to user interface and outdoor unit See fig 9 or 10 NOTE Where local codes require user interface wiring be routed through conduit or raceways splices can be made inside 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 installati
7. coil control will not operate electric heaters while a fault condition exists The fan coil control communicates with the motor at least once every 5 seconds even when the motor is idle If during operation the fan coil control does not communicate with the motor for more than 25 seconds the motor will shut itself down and wait for communications to be reestablished D Using Motor LED in Troubleshooting The MOTOR LED is connected to the blower motor communication line and works with the fan coil control microprocessor and the STATUS LED to provide fan coil operation and troubleshooting information When the motor is commanded to operate the MOTOR LED will be turned on and will flash each time instructions are sent to the motor When the motor is commanded to stop the MOTOR LED will be turned off If the MOTOR LED is lit flashing and the motor is running or if the MOTOR LED is off and the motor is stopped operation is normal and no motor fault exists If the MOTOR LED is lit flashing and the motor does not run or if the MOTOR LED is off and the motor is running check the STATUS LED for the Status Code Refer to the troubleshooting instructions for the indicated Status Code in Section E Fan Coil Troubleshooting E Fan Coil Troubleshooting Fan coil faults indicated by flashing codes on the amber system STATUS LED can be resolved using troubleshooting information provided below Codes are listed in order of their priority highest to lowest
8. plastic condensate pan Do not over tighten Finger tighten plus 1 1 2 turns Use pipe dope Z CAUTION Shallow running traps are inadequate and DO NOT allow proper condensate drainage See Fig 13 Failure to follow this caution will result in minor property damage NOTE When connecting condensate drain lines avoid blocking filter access panel Prime both primary and secondary condensate traps after connecting to drain pan Q A03002 Fig 12 Recommended Condensate Trap DO NOT USE SHALLOW RUNNING TRAPS A03013 Fig 13 Insufficient Condensate Trap FILTER ACCESS PANEL SECONDARY DRAIN WITH APPROPRIATE TRAP REQUIRED USE FACTORY KIT OR a FIELD SUPPLIED TRAP PRIMARY TRAP REQUIRE USE FACTORY KIT OR FIELD SUPPLIED TRAP OF SUFFICIENT DEPTH STANDARD P TRAPS ARE NOT SUFFICIENT SEE FIGURE OF RECOMMENDED CONDENSATE TRAP A03003 Fig 14 Condensate Trap and Unit 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 entire unit and a secondary condensate line with appropriate trap should be run from 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 use of a separate 3 4 in condensate line with appropriate trap to a place where condensate will be noti
9. the User Interface is powered and connections are made A to A B to B etc and wiring is not shorted Mis wiring or shorting of the ABCD communications wiring will not allow successful communications Correcting wiring faults will clear the code and reestablish communications Shorting or mis wiring the low voltage system wiring will not cause damage to fan coil control or to User Interface but may cause the low voltage fuse to open STATUS CODE 46 BROWNOUT CONDITION If the secondary voltage of the transformer falls below 15 vac for a period exceeding 4 seconds Status Code 46 will be displayed on STATUS LED If system includes a non communicating outdoor air conditioner or heat pump the User Interface will command the fan coil to turn off Y output controlling compressor When secondary voltage rises above 17 vac for more than 4 seconds the brownout condition is cleared and normal system operation will resume subject to any minimum compressor off delay function which may be in effect Brownout does not affect blower or electric heater operation STATUS CODE 53 OUTDOOR AIR TEMPERATURE SENSOR FAULT If an OAT sensor is found at power up input is constantly checked to be within a valid temperature range If sensor is found to be open or shorted at any time after initial validation Status Code 53 will be displayed at amber STATUS LED Check for faults in wiring connecting sensor to OAT terminals Using an Ohmmeter check resistance of thermistor
10. transformer SECI and R circuit The C circuit of transformer circuit is referenced to chassis ground through a printed circuit run at SEC2 and metal PC board mounting eyelets Check to be sure PC Board is mounted securely using both factory installed screws PROCEDURE 8 ACCESSORY INSTALLATION A Accessory Electric Heaters Electric heaters may be installed with FE4A Fan Coil per instructions supplied with electric heater package See unit rating plate for factory approved electric heater kits NOTE Units installed without electric heat should have a field supplied sheet metal block off plate installed over heater opening This reduces air leakage and formation of exterior condensation B Outdoor Air Thermistor OAT A 2 screw terminal strip is provided for connection of an outdoor temperature thermistor This strip is marked OAT The installation of an outdoor temperature sensor using the fan coil OAT terminals is optional If the outdoor unit is not equipped for communications fan coil OAT input can be used to supply outdoor temperature data for system level functions and for temperature display on User Interface Outdoor units with a communicating control are shipped with a factory installed OAT This factory installed OAT is used for all outdoor unit specific and system level functions requiring outdoor temperature if an OAT is not added to fan coil If an OAT is added in the fan coil the fan coil connected OAT will be used for system le
11. will energize the HUM output to turn humidifier on and de energize HUM output to turn humidifier off Wire HUM and C terminals directly to humidifier as shown in Fig 9 or 10 PROCEDURE 9 START UP AND TROUBLESHOOTING NOTE Always check high and low voltage supply to the fan coil components Check the integrity of the plug receptacle connections and fan coil wiring harness prior to assuming a component failure A LED Description LEDs built into fan coil control provide installer or service person information concerning operation and or fault condition of the fan coil control and ECM motor This information is also available at system User Interface in text with basic troubleshooting instructions Careful use of information displayed will reduce the need for extensive manual troubleshooting The amber LED located at bottom center of control adjacent to motor harness plug is Motor Status LED and it is labeled MOTOR A second amber LED located in upper right center of control adjacent to System Communications connector A B C D is the System Status LED and it is labeled STATUS The green LED labeled COMM is also located adjacent to System Communications connector below STATUS LED and is used as an indicator of system communications status Status Codes will be displayed on the STATUS LED using the following protocol 10 00V38 xH 000000 Iss 1 OAT HUMCWOYR S3lV3H llunnnn Jo
12. In UPFLOW DOWNFLOW SECONDARY DRAIN T l Nd UPFLOW DOWNFLOW i PRIMARY DRAIN E M FIELD MODIFIED A SIDE RETURN LOCATION FOR 2 1 2 SLOPE COIL UNITS ONLY UPFLOW DOWNFLOW SECONDARY DRAIN UPFLOW DOWNFLOW FIELD SUPPLIED PRIMARY DRAIN RETURN PLENUM A00091 Fig 2 Slope Coil Unit in Upflow Application These units are designed to meet low air leak requirements currently in effect Because of this units need special attention in the condensate pan and drain connection area and when brazing tubing These units are available for application in systems of 18 000 through 60 000 Btuh nominal cooling capacities Factory authorized field installed electric heater packages are available in 5 through 30 kw See Product Data for available accessory kits INSTALLATION PROCEDURE 1 CHECK EQUIPMENT Unpack unit and move to final location Remove carton taking care not to damage unit Inspect equipment for 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 proper trapping and servicing unit IMPORTANT When unit is installed over a finished ceiling and or living area building codes may require a field supplied secondary condensate p
13. Installation Instructions Communicating Fan Coil for Puron Refrigerant 002 003 005 006 NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue TABLE OF CONTENTS SAFETY CONSIDERATIONS 35 Su aa sq Shu aan ea ee dee eer REHAB ee era aS 1 INTRODUCTION ves rte tp e ad Rete Ot o Ead oped op ge ly ane ele ple te ove ie ue Edited 1 INSTALLA TION Serora Eka sia ete Pele NS hi E a IR SSS 2 fe eo ESE as dade ber eg eye ENS 2 Check Equipment ninn un sS San isa ua is terr te e e P Tee i I p UR Ie ERES 2 Mount Fan Goll n ner ron m eter eu see ted son ON Eee De ike did a d dii er LE 2 END 5 Electrical Connections e rp ERE GR RR PREIS 5 Refrigerant Tubing Connection and EvVacuati h u L u a un Bn t uD a hu s NSA a n a suq u aspa asqa 7 Condensate DIA grece ete e ecdesiae eoe cae eee ep c a Ed dy e boe e ien ded pes 8 Unit Start Up 10 Accessory Installati On Vos state eene nee or oen ics tecta canes aed tee Kiera sete ee on Mica eth seat Ceuta reed umasa m AR m n uywaqa 10 Start Up and Troubleshootmig s 250 te e e ne e 10 FFAA Fan Coil Sequence of Operatiori 2 2 sa UO HERE e Ra eR Ee REPRE RU ntt ee iei pr ded 14 CARE AND MAINTENAN DE eiii eee tinet e eo rigen egeo staves OV Aot DEus DO ere be Neve once oet ede ege at te EO De Ove v dec esee eee ge 14 PURON QUICK REFERENCE GUIDE 5 5 a u tuh AM RR RA d ee e eee t
14. Though multiple faults can exist at any time only the highest priority code will be displayed on STATUS LED Clearing the indicated fault when multiple faults exist will cause the next highest priority Status Code to be flashed All existing faults as well as a fault history can be viewed at User Interface STATUS CODE 45 CONTROL BOARD TEST FAULT Fan coil control has failed internal start up tests and must be replaced No other service procedure will correct STATUS CODE 37 HEATER OUTPUT SENSED ON WHEN NOT ENERGIZED Fan coil control is provided with circuitry to detect presence of a 24 vac signal on Electric Heater stage 1 and stage 2 outputs If fan coil control detects a 24 vac signal on either heater stage output and it is not supplying signal Status Code 37 will be displayed on STATUS LED Fan coil control will turn off output and command blower motor to supply an airflow determined to be safe for current operation mode with electric heaters energized To find the fault 1 Stop all system operations at User Interface and check heater stage 24 vac outputs 2 Disconnect electric heater at plug receptacle 2 and check heater wiring for faults See Status Code 36 for more information STATUS CODE 44 MOTOR COMMUNICATION FAULT The MOTOR LED is connected to the blower motor communication line and works with the fan coil control microprocessor and STATUS LED to provide fan coil operation and troubleshooting information When motor is co
15. US CODE 41 BLOWER MOTOR FAULT If MOTOR LED is lit and flashing and motor does not run 1 Check STATUS LED If STATUS LED is indicating Status Code 41 motor control has detected that the motor will not come up to speed within 30 seconds of being commanded to run or that the motor has been slowed to below 250 rpm for more than 10 seconds after coming up to speed Motor wiring harness and fan coil control are operating properly do not replace 2 Check to be sure that the blower wheel is not rubbing the housing 3 Check motor to be sure that the motor shaft is not seized motor control module must be removed and electronics disconnected from windings to perform this check properly 4 Check motor windings section following instructions in Section C ECM Motor Troubleshooting If all these checks are normal the motor control module may need replacement STATUS CODE 16 SYSTEM COMMUNICATION FAULT If at any time system communications are not successful for a period exceeding 2 minutes the fan coil control will only allow emergency heating or cooling operation using a common thermostat a non communicating outdoor unit and the R C Y O W outdoor unit terminal strip connections and will display Status code 16 on the amber STATUS LED see section E Emergency Heating and Cooling Modes No further fan coil troubleshooting information will be available at the User Interface until communications are reestablished Check system wiring to be sure
16. an to be installed under the entire unit Some localities may allow the alterative of running 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 FE4A Fan Coils can be installed for upflow and horizontal left applications as factory shipped See Fig 2 4 and 8 Units can be installed for horizontal right applications with field modifications Units may be converted for downflow applications using factory authorized accessory kits 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 Only use return air opening provided All return air must pass through the coil See Fig 2 B Modular Units The FE4A 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 To disassemble unit remove rear corner brackets by removing 2 screws which secure brackets Remove either 2 screws in each front corner of coil box or 2 screws in blower box See Fig 3 Do not remove all 4 screws in each corner Sections may now
17. 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 4 ER 2 SCREWS REAR CORNER BRACKET 2 SCREWS COIL BOX A95293 Fig 3 Modular Unit Assembly PRIMARY FIELD otras DRAIN SUPPLIED HANGING STRAPS 002 005 21 IN 006 24 IN FRONT SERVICE CLEARANCE FULL FACE OF UNIT LOW VOLT ENTRY OPTIONS 1 3 4 IN t FILTER ACCESS A CLEARANCE o PRIMARY D gt DRAIN SECONDARY POWER DRAN ENTRY OPTIONS A00096 Fig 4 Slope Coil in Horizontal Left Application Factory Ready D Horizontal Right Conversion of Units with Slope Coils NOTE Gasket kit number KFAHDOIOISLP is required for horizontal slope coil conversion to maintain low air leak low sweat performance 1 Remove blower and coil access panels and fitting panel See Fig 5 Remove screw securing coil assembly to right side casing flange Remove coil assembly 2 3 4 Lay fan coil on its right side and reinstall coil assembly with condensate pa
18. ceable The owner of the structure must be informed that when condensate flows from the secondary drain or external condensate pan the unit requires servicing or water damage will occur Install traps in condensate lines as close to the coil as possible See Fig 14 Make sure that the outlet of each trap is below its connection to the condensate pan to prevent condensate from overflowing drain pan Prime all traps test for leaks and insulate traps if located above a living area 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 agn Table 1 Filter Kits PART NUMBER SIZE USED WITH FILTER KIT KFAFK0212MED 002 12 PACK KFAFK0312LRG 003 005 KFAFK0412XXL 006 N CAUTION Never operate unit without a filter or with filter access door removed Damage to blower motor or coil can result IMPORTANT Factory authorized filters must be used when locating the filter inside the unit See Table 1 For those applications where access to an internal filter is impractical a field supplied filter must be installed in return duct system PROCEDURE 7 UNIT START UP Refer to outdoor unit Installation Instructions for system start up instructions and refrigerant charging method details A Low Voltage Circuit Fusing and Reference The low voltage circuit is fused by a board mounted 5 amp automotive fuse placed in series with
19. e 16 SAFETY CONSIDERATIONS N CAUTION 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 kits or accessories when installing Follow all safety codes Wear safety glasses and work gloves Use quenching cloth for brazing operations Have fire extinguisher 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 When you see this symbol on the unit and in instructions manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING CAUTION and NOTE 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 personalinjury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight sugges
20. eaters PROCEDURE 5 REFRIGERANT TUBING CONNECTION AND EVACUATION 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 seconds coil and tubing system does not require evacuation Always evacuate coil and field supplied tubing to 500 microns before opening outdoor unit service valves a User Interface Fan Coil Communicating AC HP Humidifier A03076 A94067 Fig 11 Transformer Connections 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 and condensate pan fitting caps Units have sweat suction and liquid tube connections Make suction tube connection first 1 Cut tubing to correct length 2 Insert tube into sweat connection on unit until it bottoms 3 Braze connection using silver bearing or non silver bearing brazing materials Do not use solder materials which melt below 800 F Consult local code requirements Z CAUTION Wrap a wet cloth around rear of fitting to prevent damage to TXV and factory made joints 4 Evacuate coil and tubing system to 500 microns using deep vacuum method PROCEDURE 6 CONDENSATE DRAIN Z CAUTION
21. ed in LED information aids and follow troubleshooting steps described below before replacing motor control module or entire motor Motor control module is available as a replacement part VERIFY MOTOR WINDING SECTION N CAUTION After disconnecting power from the ECM motor wait at least 5 minutes before removing the control section Internal capacitors require time to discharge Minor injury from electrical shock may result from early contact with live metal parts Before proceeding to replace a motor control module 1 Check motor winding section to be sure it is functional 2 Remove motor control module section and unplug winding plug Motor shaft should turn freely resistance between any two motor leads should be similar and resistance between any motor lead and unpainted motor end should exceed 100 000 ohms 3 Failing any of these tests entire ECM motor must be replaced 4 Passing all of the tests motor control module alone can be replaced MOTOR TURNS SLOWLY 1 Low static pressure loading of blower while access panel is removed will cause blower to run slowly Particularly at low airflow requests This is normal do not assume a fault exists 2 Recheck airflow and system static pressure using User Interface service screens with access panel in place NOTE Blower motor faults will not cause a lockout of blower operation Fan coil control will attempt to run the blower motor as long as User Interface maintains a demand for airflow Fan
22. for a short or open condition If thermistor is shorted or open replace it to return the system to normal operation If fault is in the wiring connections correcting the fault will clear the code and return the system to normal operation NOTE If fault condition is an open thermistor or a wiring problem that appears to be an open thermistor and the power to the fan coil control is cycled off the fault code will be cleared on the next power up but the fault will remain and system operation will not be as expected This is because on power up the fan coil control cannot discern the difference between an open sensor or if a sensor is not installed F Emergency Heating and Cooling Modes Fan coil control can provide emergency heating or cooling using a common heat cool thermostat in the event that there are no system communications fault is in User Interface and no replacement is immediately available To activate these modes the thermostat and outdoor unit must be wired as a common heating cooling system to fan coil control RYWC terminals Fan coil control must be powered and displaying Status Code 16 System Communication Fault NOTE These emergency modes do not provide the level of comfort and efficiency expected by the consumer and should only be activated when User Interface cannot be replaced immediately PROCEDURE 10 FE4A FAN COIL SEQUENCE OF OPERATION The FEAA fan coil is designed for installation with a communicating User Interface Thi
23. iodic maintenance be performed on this equipment The only required maintenance that may be performed by the consumer is filter maintenance N WARNING Disconnect all power to unit before servicing field wires or removing control package The disconnect when used on access panel does not disconnect power to the line side of disconnect but does allow safe service to all other parts of unit If 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 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 14 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 controls for proper operation each heating and cooling season Service as necessary Consult Fan Coil Service Manual available from equipment distributor for maintenance procedures A WARNING As with an
24. mmanded to operate the MOTOR LED will be turned on and will flash each time instructions are sent to the motor When the motor is commanded to stop the MOTOR LED will be turned off The MOTOR LED will not flash to indicate communications when it is turned off Fan coil control is constantly communicating with the motor even when the motor and MOTOR LED are off If motor does not acknowledge receipt of communications the control will display Status Code 44 on STATUS LED and continue to try to communicate with the motor If motor acknowledges communication status code will be cleared If MOTOR LED is lit and flashing and motor does not run 1 Check the STATUS LED If STATUS LED is indicating a Status 44 code check the motor wiring harness for proper connection to control and motor receptacles 2 Check motor wiring harness to be sure all wiring complies with wiring diagram description makes a complete circuit from connector to connector and is not shorted 3 Check 12 Vdc low voltage supply to motor at pins 1 and 2 of motor header connection to fan coil control If all checks are normal fan coil control is good and control module on motor may need replacement Check motor and Motor Control Module following the instructions in Section C ECM Motor Troubleshooting Shorted or mis wiring of the low voltage motor harness wiring will not cause damage to fan coil control or to motor control module If the MOTOR LED is off STATUS LED is i
25. n down 5 Attach coil to casing flange using previously removed coil mounting screw 6 Make sure pan cap in fitting door is properly seated on fitting door to retain low air leak rating of the unit pac oe COIL MOUNTING BLOWER CREW ASSEMBLY COIL SUPPORT RAIL SLOPE COIL SKI DRAINPAN PRIMARY DRAIN REFRIGERANT CONNECTIONS SECONDARY DRAIN Fig 5 Slope Coil in Horizontal Right Application 7 Add gaskets included in kit per kit instructions 8 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 metal clip securing fitting panel to condensate pan Remove fitting panel SON Q UN Remove blower and coil access panels See Fig 6 Remove 2 snap in clips securing A coil in unit Slide coil and pan assembly out of unit Convert air seal assembly for horizontal right a Remove air seal assembly from coil by removing 4 screws Remove air splitter B from coil seal assembly by removing 3 screws See Fig 6 inset Remove filler plate A and install air splitter B in place of filler plate Install filler plate A as shown in horizontal right application Remove condensa
26. ndicating a Status Code 44 and motor is running 1 Disconnect the motor harness at the fan coil control If motor continues to run fan coil control is good and control module on motor may need replacement STATUS CODE 25 INVALID MOTOR MODEL SELECTION On initial start up fan coil control shall poll motor for its size data and check fan coil size data stored in fan coil control memory 1 If motor size is incorrect for fan coil size or fan coil size data is invalid Status Code 25 will be displayed on STATUS LED 2 If model size data is missing as is the case when a replacement fan coil control is installed system User Interface will prompt installer to enter correct model size from a list of valid sizes 3 If motor size is incorrect for model size motor must be replaced with proper size motor Fan coil control will not respond to operation requests until this fault condition is resolved STATUS CODE 27 INVALID OUTDOOR UNIT SIZE On initial power up fan coil control will write into memory outdoor unit size as provided by User Interface in a fully communicating system 1 If outdoor unit size is invalid Status Code 27 will be displayed on STATUS LED 2 User Interface will prompt the installer to choose size from a list of valid sizes for application with fan coil 3 Check communications wiring to be sure User Interface has established communications with outdoor unit or select proper size from valid size list provided at User Interface
27. o n n o s A Fig 15 Detail of FE4A Printed Circuit Board A03169 Table 2 FE4A Fan Coil Airflow Delivery Chart CFM Electric Heating Modes OUTDOOR UNIT CAPACITY BTUH EMERGENCY 18 000 650 24 000 675 30 000 850 1050 36 000 1000 1125 EMERGENCY 850 1100 24 000 30 000 1100 1150 36 000 1150 1275 42 000 1300 1400 EMERGENCY 1100 1600 30 000 1150 36 000 1275 42 000 1400 48 000 1500 1600 EMERGENCY 1050 1050 36 000 1150 1350 42 000 1150 1350 48 000 1325 1400 60 000 1650 1650 ELECTRIC HEATER KW RANGE The number of short flashes indicates first digit of code The number of long flashes indicates second digit of code A short flash is 0 25 seconds on A long flash is 1 second on The time between flashes is 0 25 seconds The time between last short flash and first long flash is 1 second Qv p gt 5 The LED will be off for 2 5 seconds before repeating code B Fan Coil Control Start Up and System Communications Troubleshooting On power up green COMM LED will be turned off until successful system communications are established this should happen within 10 seconds Once communications with User Interface are successful COMM LED will be lit and held on At the same time amber STATUS LED will be lit and held continuously on until a request for operating mode is received The STATUS LED will be on any time fan coil is in idle mode If at any time communications are not succe
28. on of 0 through 10 kw applications When electric heat packages with circuit breakers are installed the circuit breaker can be used as a disconnect Transformer is factory wired for 230 v operation For 208 v applications disconnect black wire from 230 v terminal on transformer and connect it to 208 v terminal See Fig 11 The secondary circuit of transformer is protected by a 5 amp fuse mounted on printed circuit board NOTE Mis wiring or shorting any of the low voltage connections may cause the low voltage fuse to open but will not damage the User Interface or fan coil control Simply rewire and replace fuse to correct fault C Ground Connections N 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 See Ground Conduit Note below Failure to follow this warning could result in an electrical shock fire or death NOTE Use UL listed conduit and conduit connector to connect supply wire s to unit and obtain proper grounding If conduit connection uses reducing washers a separate ground wire must be used 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 h
29. s fan coil will not respond to commands provided by a common thermostat except under certain emergency situations described in Procedure 9 Start Up and Troubleshooting The User Interface uses temperature humidity and other data supplied from indoor and outdoor system components to control heating or cooling system for optimum comfort The fan coil will be commanded by User Interface to supply airflow and in the case of a non communicating outdoor unit Air Conditioner or Heat Pump control The fan coil will operate blower at requested airflow for most modes The nominal requested airflow will be 350 cfm per ton of nominal cooling capacity as defined by outdoor unit size Actual airflow request will be adjusted from nominal using indoor and outdoor temperature and indoor humidity data to optimize the system operation for occupant comfort and system efficiency Refer to User Interface literature for further system control details Airflow during electric heater operation must be greater than a minimum level for safe operation If User Interface instructs fan coil to turn on electric heat and the requested airflow is less than the minimum value required for safe operation of installed heater the fan coil control will override requested value with the value shown in Table 2 FE4A Fan Coil Airflow Delivery Chart Electric Heating Modes CARE AND MAINTENANCE For continuing high performance and to minimize possible equipment failure it is essential that per
30. ssful for a period exceeding 2 minutes fan coil control will only allow emergency heating or cooling operation using a common thermostat a non communicating outdoor unit and the R C Y O W outdoor unit terminal strip connections and will display Status Code 16 System Communication Fault on amber STATUS LED No further fan coil troubleshooting information will be available at User Interface until communications are re established If COMM LED does not light within proper time period and status code is not displayed 1 Check system transformer high and low voltage to be sure the system is powered 2 Check fuse on fan coil control to be sure it is not blown If fuse is open check system wiring before replacing it to be sure a short does not cause a failure of replacement fuse If COMM LED does not light within proper time period and status code is displayed 1 Check system wiring to be sure User Interface is powered and connections are made A to A B to B etc and wiring is not shorted Mis wiring or shorting of the ABCD communications wiring will not allow successful communications NOTE Shorting or mis wiring low voltage system wiring will not cause damage to fan coil control or User Interface but may cause low voltage fuse to open C ECM Motor Troubleshooting The ECM motor used in this product consists of two parts the control module and the motor winding section Do not assume motor or module is defective if it will not start Use the design
31. t 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 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 edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with National Fire Protection Association Standards 90A or B as tested by UL Standard 181 for Class 1 air ducts PROCEDURE 4 ELECTRICAL CONNECTIONS A Line Voltage Connections If unit contains an electric heater remove and discard power plug from fan coil and connect male plug from heater to female plug from unit wiring harness See Electric Heater Installation Instructions For units without electric heat 1 Connect 208 230v power leads from field disconnect to yellow and black striped leads 2 Connect ground wire to unit ground lug oe SECURE FAN COIL TO STRUCTURE UNIT AWAY FROM WALL PIPE STRAP TYPICAL BOTH SIDES s OR UNIT AGAINST WALL 1 8 IN THICK ANGLE MOUNTING BRACKET TYPICAL BOTH SIDES DOWN FLOW lt BASE KIT KFACB wv SECURE UNIT TO FLOOR ANGLE BRACKET OR PIPE STRAP
32. te troughs C and install on opposite tube sheets Install hose onto plastic spout 7 Install horizontal pan on right side of coil assembly 8 Slide coil assembly into casing Be sure coil bracket on each corner of vertical pan engages coil support rails A03001 Remove horizontal drain pan support bracket from coil support rail on left side of unit and reinstall on coil support rail on right side of unit 9 Reinstall 2 snap in clips to correctly position and secure coil assembly in unit Be sure clip with large offset is used on right side of unit 10 11 12 13 14 to secure horizontal pan Remove two oval fitting caps from left side of the coil access panel and fitting panel Remove insulation knockouts on right side of coil access panel Remove 2 oval coil access panel plugs and reinstall into holes on left side of coil access panel and fitting panel Make sure liquid and suction tube grommets are in place to prevent air leaks and cabinet sweating F Downflow Installations Install condensate pan fitting caps from Step 10 in right side of coil door making sure that cap snaps and seats cleanly on back side of the coil door Make sure no insulation interferes with seating of cap Reinstall access and fitting panels aligning holes with tubing connections and condensate pan connections Be sure to reinstall metal clip between fitting panel and vertical condensate pan A CAUTION The conversion of the fan coil to do
33. tions which will result in enhanced installation reliability or operation N WARNING Before installing or servicing unit 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 INTRODUCTION Model FE4A Fan Coil is designed to be installed with a communicating user interface The FE4A fan coil will provide airflow at a rate commanded by the User Interface The nominal airflow ton rate is 350 CFM ton The User Interface will modify the commanded airflow under certain operating modes Refer to the User Interface literature for further system control details This fan coil will not respond to commands from a common thermostat except under certain emergency situations explained in this document The instructions contained herein provide guidance to successfully install this fan coil Model FEAA Fan Coil units are designed for flexibility and can be used for upflow horizontal or downflow kits required for manufactured and mobile home applications These units are designed specifically for Puron R 410A refrigerant and must be used only with Puron air conditioners and heat pumps as shipped Form IM FE4A 01 Cancels NEW Printed in U S A 10 03 Catalog No 63FE 4A0 POWER ENTRY FIELD SUPPLIED OPTIONS ih SUPPLY DUCT LOW VOLT ENTRY OPTIONS 002 005 21 IN Y 006 24 IN FRONT SERVICE lo CLEARANCE a UNIT A 003 19
34. to maintain low air leak low sweat performance G Manufactured and Mobile Home Housing Applications Fan coil unit must be secured to the structure using field supplied hardware 2 Allow a minimum of 24 clearance from access panels 3 Recommended method of securing for typical applications a If fan coil is away from wall attach pipe strap to top of fan coil using No 10 self tapping screws Angle strap down and away from back of fan coil remove all slack and fasten to wall stud of structure using 5 16 in lag screws Typical both sides of fan coil b If fan coil is against wall secure fan coil to wall stud using 1 8 in thick right angle brackets Attach brackets to fan coil using No 10 self tapping screws and to wall stud using 5 16 in lag screws See Fig 7 PROCEDURE 3 AIR DUCTS Connect 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 seal duct to unit joint Duct connection flanges are provided on unit air discharge connection When using FE4A 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 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 hea
35. vel functions and the factory supplied outdoor unit OAT will be used for outdoor unit control functions Using two wires of field supplied thermostat wire cable wire one lead of thermistor to one screw terminal and the other lead to remaining screw terminal there is no polarity to be observed It is strongly recommended that two wires be used to connect the thermistor to eliminate noise interference in temperature reading If there are not two spare wires available in cable one wire may be used to connect thermistor to OAT screw terminal 1 and the other lead of the thermistor can be wired to 24 vac COM C wire OAT screw terminal 1 is terminal located closest to the ABCD system communications and is marked with a small number 1 next to the terminal strip NOTE Mis wiring OAT inputs will not cause damage to either fan coil control or thermistor If the thermistor is wired incorrectly no reading will appear at User Interface Re wire thermistor correctly for normal operation C Electronic Air Cleaner Connections When using an electronic air cleaner with FE4A Fan Coil use Airflow Sensor Part No KEAACOI01AAA The airflow sensor turns on electronic air cleaner when fan coil blower is operating D Humidifier Connections The Fan Coil Control Terminal marked HUM is provided for low voltage 24 vac control of a humidifier No humidistat is required as User Interface monitors indoor humidity When commanded to operate humidifier the fan coil control
36. wnflow requires special procedures for the condensate drains on both A coil and Slope units The vertical drains have an overflow hole between the primary and secondary drain holes This hole is plugged for all applications except downflow but must be used for downflow During conversion process remove plastic cap covering vertical drains only and discard Remove plug from overflow hole and discard At completion of downflow installation caulk around vertical pan fitting to door joint to retain low air leak performance of the unit Failure to follow this caution will result in minor property damage REFRIGERANT CONNECTIONS AIR SEAL ASSEMBLY x HORIZONTAL RIGHT APPLICATION COIL P SUPPORT RAIL COIL BRACKET DRAIN PAN SUPPORT SW BRACKET N COIL SUPPORT SNI RAIL b 4 Scie BRACKET HORIZONTAL DRAIN PAN PRIMARY DRAIN HORIZONTAL RIGHT SECONDARY DRAIN HORIZONTAL RIGHT A00071 Fig 6 A Coil in Horizontal Right Application NOTE To convert units for downflow applications refer to Installation Instructions supplied with kit for proper installation For unit size 003 use kit Part No KFADCO2OISLP For unit sizes 002 005 and 006 use kit Part No KFADCO0401ACL Use fireproof resilient gasket 1 8 to 1 4 in thick between duct unit and floor NOTE Gasket kit number KFAHDOIOISLP is also required for all downflow applications
37. y mechanical equipment personal injury can result from sharp metal edges etc therefore care should be taken when removing parts Using the Owner s User Manual furnished in outdoor unit the installing technician should explain system operation to the consumer with particular emphasis on indoor fan coil operation sounds and filter maintenance 5 PURON QUICK REFERENCE GUIDE FOR INSTALLERS AND TECHNICIANS Puron refrigerant operates at 50 70 percent higher pressures than R 22 Be sure that servicing equipment and replacement components are designed to operate with Puron Puron refrigerant cylinders are rose colored Recovery cylinder service pressure rating must be 400 psig DOT 4BA400 or DOT BW400 Puron systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose Manifold sets should be 750 psig high side and 200 psig low side with 520 psig low side retard Use hoses with 750 psig service pressure rating Leak detectors should be designed to detect HFC refrigerant Puron as other HFC s is only compatible with POE oils Vacuum pumps will not remove moisture from oil Do not use liquid line filter driers with rated working pressures less than 600 psig Do not install a suction line filter drier in liquid line POE oils absorb moisture rapidly Do not expose oil to atmosphere POE oils may cause damage to certain plastics and roofing materials
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