Service manual

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TABLE OF CONTENTS

Page

SAFETY CONSIDERATIONS...................................................2

INTRODUCTION ........................................................................2

UNIT IDENTIFICATION...........................................................2

PRODUCT OFFERING..............................................................4

FAN MOTOR SPEED TAPS .....................................................4

FA4A, FB4A, FC4B, FF1D, FH4A, AND FX4A

CIRCUIT BOARD FUNCTION AND TROUBLESHOOTING

— CES013003-00 and -01 PCB...............................................2-7

• Printed Circuit Board Component Layout and Description.......2

• Unit Functions ............................................................................2

• Troubleshooting PCB ..................................................................5

CIRCUIT BOARD FUNCTION AND TROUBLESHOOTING

— HK61GA001 and HK61GA003 PCB .........................8-19

• Printed Circuit Board Component Layout and Description.......8

• PCB Component Functions.........................................................9

• Troubleshooting PCB ................................................................11

ELECTRIC HEATER FUNCTION

AND TROUBLESHOOTING..............................................19

• Description of Electric Heater Components.............................19

• Troubleshooting KFA, KFB, KFC, and KFD Series

Electric Heaters.......................................................................20

FAN COIL DESCRIPTION

AND TROUBLESHOOTING — FK4B .......................20-27

• Integrated Controls and Motor (ICM2) ....................................20

• PCB Layout and Description ....................................................20

• Sequence of Operation ..............................................................21

• Easy Select Configuration Taps................................................22

• Troubleshooting PCB ................................................................24

• Troubleshooting ICM2 ..............................................................26

• Condensed Version of Troubleshooting FK4B Motor

and Controls ...............................................................................26

• Accessories ................................................................................27

FAN COIL DESCRIPTION

AND TROUBLESHOOTING — FK4C, FV4A...........28-34

• Integrated Controls and Motor (ICM2) ....................................28

• PCB Layout and Description ....................................................28

• Sequence of Operation ..............................................................28

• Easy Select Configuration Taps................................................30

• Troubleshooting PCB ................................................................32

• Troubleshooting ICM2 ..............................................................34

• Condensed Version of Troubleshooting

FK4C, FV4A Motor and Controls .........................................34

• Accessories ................................................................................34

THERMOSTATIC EXPANSION VALVES (TXV) ..............35

• Problems Affecting TXV ..........................................................36

PISTON BODY CLEANING OR REPLACEMENT............36

LIQUID TUBE STRAINER .....................................................36

FA, FB, FC, FK COIL/CONDENSATE PAN

REMOVAL AND REPLACEMENT..................................36

• A-Coil Units ..............................................................................36

• Slope Coil Units ........................................................................37

FX, FV COIL/CONDENSATE PAN REMOVAL

AND REPLACEMENT........................................................38

CARE AND MAINTENANCE.................................................39

• Filter Assembly .........................................................................39

• Cooling Coil, Drain Pan, and Condensate Drain.....................39

• Blower Motor and Wheel .........................................................39

FF1A/FF1B/FF1C SERVICE AND

TROUBLESHOOTING ..................................................40-42

• Fan Motor ..................................................................................40

• Electric Heater Service..............................................................40

• Cleaning or Replacing Refrigerant Flow-Control Device .......40

• Liquid Tube Strainer .................................................................40

• Sequence of Operation ..............................................................40

• Care and Maintenance...............................................................40

FD3A SERVICE AND TROUBLESHOOTING...............44-45

• Fan Motor ..................................................................................44

• Electric Heater Service..............................................................44

• Cleaning or Replacing Refrigerant Flow-Control Device .......44

• Liquid Tube Strainer .................................................................44

• Care and Maintenance...............................................................45

FG3A SERVICE AND TROUBLESHOOTING...............45-46

• Service .......................................................................................45

• Maintenance...............................................................................46

FA4A, FB4A, FC4B, FX4A SMART HEAT CIRCUIT

BOARD FUNCTION AND TROUBLESHOOTING..46-50

• PCB Component Layout, Description, and Function...............46

• Unit Functions ...........................................................................46

• Smart Heat Operation................................................................47

• Electrical Operating Sequences and Troubleshooting..............48

PURON® (R-410A) QUICK REFERENCE GUIDE.............50

Fig. 1—Typical Fan Coil

A98023

Service Manual

RESIDENTIAL FAN COIL UNITS

Cancels: SM03-4 SM03-5

6-99

—1—

Summary of content (52 pages)

PAGE 1
Service Manual RESIDENTIAL FAN COIL UNITS Cancels: SM03-4 SM03-5 6-99 TABLE OF CONTENTS Page SAFETY CONSIDERATIONS...................................................2 INTRODUCTION ........................................................................2 UNIT IDENTIFICATION...........................................................2 PRODUCT OFFERING ..............................................................4 FAN MOTOR SPEED TAPS .....................................................
PAGE 2
This symbol → indicates a change since the last issue. 2. A 5-amp fuse is used to protect the low-voltage transformer secondary. 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.
PAGE 3
—3— 789 5th Position—Fan Coil A - 115-1-60 N - 208/230-1-60 S - 230-1-50 Variations A - Common Unit A - Original Variations 15 16 A - Standard Unit Minor Series 14 Heating Size (KW) 13 A98114 10th, 11th, 12th Positions—Fan Coil 005 010 Etc. 018 (11⁄ 2 Ton) 024 (2 Ton) 001 (Multi Tons) 002 (Multi Tons) Etc. Cooling Size 10 11 12 Fig.
PAGE 4
TABLE 1—PRODUCT OFFERING MODEL FA4ANF FB4ANB FB4ANF UNIT SIZE 018-060 042-070 018-060 FB4ASB 042-060 FB4ASF 018-060 FC4BNB FC4BNF FD3ANA FF1A/FF1B/FF1C/FF1D FG3ANA FH4ANB FH4ANF FK4CNB FK4CNF FX4ANF FX4ANB FV4ANF FV4ANB 042-070 024-060 018-030 018-030 024, 036, 048, 060 003, 004 001-004 006 001-005 030-048 060 002, 003, 005 006 DESCRIPTION Multipoise Multipoise Multipoise Multipoise 50 Hz Multipoise 50 Hz Multipoise Multipoise Horizontal Vertical Horizontal/Small Commercial Multipoise Multipoise Mul
PAGE 5
CAUTION: SCHEMATIC DIAGRAM NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND SEE RATING PLATE FOR VOLTS & HERTZ ATTENTION: FIELD POWER WIRING NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE COOLING CONTROLS ELECTRIC HEAT DISC GND SYSTEM TRANSFORMER: 40.0VA FAN COIL/HEATER: 8.4VA REMAINING VA AVAILABLE: 31.
PAGE 6
C9725 L145-55F 312753 T-O-D 60TX11 HH19ZA945 C9725 L145-55F 312753 T-O-D 60TX11 HH19ZA945 WARNING ELECTRIC SHOCK HAZARD DISCONNECT REMOTE POWER SUPPLY BEFORE OPENING PANEL. NC NO SPT PULL TO OPEN 5 FAN RELAY 322861-101 REV. A WARNING C9701 L145-55F 312753 T-O-D 60TX11 HH19ZA945 C9701 L145-55F 312753 T-O-D 60TX11 HH19ZA945 FF1D CONTROL BOX ELECTRIC SHOCK HAZARD DISCONNECT REMOTE POWER SUPPLY BEFORE OPENING PANEL. PULL TO OPEN 322861-101 REV. A FF1A/FF1B/FF1C CONTROL BOX A98184 Fig.
PAGE 7
CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND BLOWER MOTOR ROTATION ATTENTION: LEGEND 30KW 1PH SCHEMATIC DIAGRAM CAP COM F FM DISCONNECT PER NEC FIELD POWER WIRING HVTB GND SEE RATING PLATE FOR VOLTS & HERTZ SEE NOTE #1 LS6 HTR6 BLK BLK 11 SEQ 3 BLK YEL LS5 HTR5 BLK 9 10 YEL FU5 YEL LS4 YEL CB/FU3 HTR4 BLK YEL LS3 HTR3 BLK YEL 8 CB/FU2 BLK 1 BRN 5. 6. 7. 8. 9. 10. 11. 12. 13.
PAGE 8
CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND BLOWER MOTOR ROTATION ATTENTION: NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE SCHEMATIC DIAGRAM COMPONENT ARRANGEMENT DISCONNECT PER NEC SEE RATING PLATE FOR VOLTS & HERTZ SEE NOTE #1 HTR3 HTR1 L3 FU1 FU3 CB1 CB2 GND LS4 HTR4 BLK LS3 HTR3 BLK YEL YEL YEL CB2 INTERNAL PROTECTION MAY BE EITHER FUSES OR CIRCUIT BREAKERS YEL LS2 HTR2 BLK LS1 HTR1 YEL
PAGE 9
HK61GA001 LOW VOLTAGE TERMINAL BOARD W2-3 2ND STAGE W2-E ELECTRIC HEAT BREAKOFF TABS FOR STAGING 3RD STAGE FAN TDB NOT USED 2FC-1 HK61GA001A INTERLOCK DIODES FUSE (LOW VOLTAGE) 5 AMP FUSE MAX C PLUG 3 2 1 6 5 4 9 8 7 AUX1 24VDC AUX2 12 11 10 TRANSFORMER CONNECTIONS F4 FAN RELAY TRANSFORMER AC LINE T1 T2 COMMON DUMMY CONNECTIONS FOR VARIOUS ACCESSORIES DUMMY T3 F3 FAN CONNECTIONS F2 L2 EAC2 DUMMY L1 EAC1 COMMON 240 VAC 240 VAC FAN F1 ELECTRONIC AIR CLEANER CONNECTIO
PAGE 10
HK61GA003 LOW VOLTAGE TERMINAL BOARD 2FD-1 Y W3 W2-3 2ND STAGE L ELECTRIC HEAT BREAKOFF TABS FOR STAGING FAN INTERLOCK DIODES AND FAN TIME DELAY OFF CIRCUIT W2-E W2 O 3RD STAGE E Y G FUSE (LOW VOLTAGE) R 5 AMP FUSE MAX C PLUG 12 9 6 3 11 8 5 2 10 7 4 1 R HK61GA003 AUX1 24VDC AUX2 FAN RELAY CONNECTIONS FOR VARIOUS ACCESSORIES F4 DUMMY F3 FAN CONNECTIONS TRANSFORMER CONNECTIONS T1 T2 COMMON DUMMY T3 TRANSFORMER AC LINE F2 L2 EAC2 DUMMY L1 EAC1 COMMON 240 VAC
PAGE 11
6. W2 is used to turn on the first stage of electric heat which is interlocked with the fan through the normally closed fan relay. Unless the tabs are broken off, all stages of electric heat will turn on when W2 receives a signal from the thermostat. 7. W3 is used to turn on the second stage of electric heat. Note the W2 and W3 tab must be broken off for individual staging to take place. Energizing W3 will always turn on the first stage through the diodes even if the tabs are broken off. 8.
PAGE 12
YEL FU5 FU3 FU1 LS 6 HTR6 12 YEL LS 5 HTR5 YEL LS 4 HTR4 YEL LS 5 HTR5 YEL LS 2 HTR2 YEL BLK BLK BLK 11 10 9 8 7 BLK BLK BLK BLK BLK FU4 SEQ 2 6 5 4 3 BLK BLK LS 1 HTR1 FU6 SEQ 3 BLK LOW VOLTAGE TERMINAL BOARD FU2 SEQ 1 2 BLK 1 YEL BLU BLK W2-3 W3 L W2-E W2 O TO INDOOR THERMOSTAT E FAN TDB Y 2FC-1 G CONNECT E TO E C TO C ETC.
PAGE 13
L W2 O E Y G R C W3 D-1 2S C BLK AU VACX2 AUX 2 F4 AUX 1 TRA NSF ORM AC E LINE R NO TO HIGHER FAN SPEED AUX 1 FR CB W2 O NC E Y G R C ORG AUX 2 CB F3 F2 F1 A97028 2-05868-2A L2 208/240 VAC TWO SPEED FAN RELAY WIRING BLK F4 FAN COMMON UNUSED LEAD 24 VDC AUX 1 LOW MTR SPD HI MTR SPD LOW VOLTAGE BOARD W3 NO L COM RED MARKED TERMINAL UNMARKED TERMINAL FIELD CTRL WIRING FACTORY POWER WIRING FIELD POWER WIRING FAN RELAY CIRCUIT BOARD FR Fig.
PAGE 14
W3 L W2 O E Y D-1 2S G R C AUX 1 NC TO LOWER FAN SPEED C BLK AUX 2 YEL FAN MOTOR COMMON LEAD MY DUM MON AUX VAC 2 AUX 1 TR A N S FOR AC ME LINE R T1 T2 T3 F4 F3 L2 EAC 2 F FAN 2 F1 FR CB HST HST C NO ORG E Y G R C MARKED TERMINAL UNMARKED TERMINAL FIELD CTRL WIRING FACTORY POWER WIRING FIELD POWER WIRING FAN RELAY CIRCUIT BOARD HUMIDISTAT AUX 2 CB F3 F2 A97029 F1 2-05868-1A L2 208/240 VAC LATENT CAPACITY CONTROL WIRING BLK F4 FAN COMMON UNUSED LEAD 24 VDC AU
PAGE 15
VIO W3 L W2 O E Y G R C G C H K61 G A00 C 1 C-1 2F BRN YEL T3 MY F4 AUX 1 AUX 2 TRA NSF ORM AC E LINE R T1 T2 FAN MOTOR COMMON LEAD YEL MON L1 E FR CB TDR W2 O E Y G R C BRN NC 2 LOW VOLTAGE BOARD W3 L TDR VIO NO 3 COM 1 MARKED TERMINAL UNMARKED TERMINAL FIELD CTRL WIRING FACTORY POWER WIRING FIELD POWER WIRING FAN RELAY CIRCUIT BOARD TIME DELAY RELAY Fig.
PAGE 16
LOW-VOLTAGE COIL TERMINALS VIO W3 L W2 O E BLU G R C G ORG RED AUX 2 BLK YEL FAN MOTOR COMMON LEAD FR CB HST TDR HST C NO ORG L W2 NO O NC E Y TDR VIO G NC 2 C BRN NO R COM 1 3 MARKED TERMINAL UNMARKED TERMINAL FIELD CTRL WIRING FACTORY POWER WIRING FIELD POWER WIRING FAN RELAY CIRCUIT BOARD HUMIDSTAT TIME DELAY RELAY AUX 2 A97031 CB F3 F2 F1 YEL L2 208/240 VAC 2-05868-4A TIME DELAY RELAY TWO SPEED FAN RELAY (LATENT CAPACITY) BLK F4 FAN COMMON UNUSED LEAD
PAGE 17
FU1 FU3 YEL LS 4 HTR4 YEL LS 3 HTR3 YEL LS 2 HTR2 YEL LS 1 HTR1 FU4 BLK 8 YEL BLK BLK SEQ 2 6 5 4 3 BLK BLK BLK FU2 BLK 7 BLK SEQ 1 2 BLK 1 YEL BLU BLK TERM BOARD W3 C W2 O 5 AMP FUSE MAX W2 C Y L Y O C VIO G R L G SEQ1 2 1 6 5 4 9 8 7 12 11 10 R RED 3 INDOOR THERMOSTAT E E ORG SEQ2 BRN YEL RELAY BLK 240 VDC AUX1 AUX2 BLU PLUG F4 AC LINE T1 COMMON T2 L2 EAC2 L1 EAC1 240 VAC 240 VAC DUMMY F3 DUMMY F2 FAN T3 DUMMY F1 COMMON
PAGE 18
A. If the fan will not turn on from the thermostat: 2. Check sequencer number 1 and the plug wiring. The yellow wire should be connected to pin number 9 of the plug and the limit switch. The black wire should be connected to pin number 7 of the plug and to sequencer number 1. 3. Check incoming high-voltage power leads. If these are not receiving power, the system cannot function. IF THERE IS NO HIGH VOLTAGE TO THE PCB: 1. Check the plug/receptacle connection; this brings power to the PCB.
PAGE 19
W2-3 W2-E FAN TDB BLOWN DIODE (b) 2FC-1 BLOWN DIODE (a) C 5 AMP FUSE MAX HK61GA001A 3 2 1 6 5 4 9 8 7 BLOWN DIODE (c) AUX1 24VDC AUX2 12 11 10 F4 RELAY TRANSFORMER AC LINE T1 T2 COMMON DUMMY DUMMY T3 F3 F2 L2 EAC2 DUMMY L1 EAC1 COMMON 240 VAC 240 VAC FAN F1 A97033 Fig.
PAGE 20
E. In simplistic terms, the sequencers which we use are nothing more than normally-open limit switches which sit on top of a small resistive heater. When voltage is applied to this heater, a positive temperature coefficient resistor (PTC), heat is supplied to a bimetallic disc which "snaps through" and closes switch. The time required for PTC to heat to a sufficient point controls ON timing of device. The time required for disc to cool down when power is removed controls OFF time of device.
PAGE 21
DO NOT REMOVE OPTIONAL SAFETY GROUND 1 2 3 4 5 POWER CONNECTOR 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 CONTROL CONNECTOR OPTIONAL SAFETY GROUND DRAIN HOLE A94079 Fig. 15—FK4B, FK4C and FV4A ICM2 Motor D. Electric Heat Heating Mode Thermostat closes circuit R to W2, W3, or E. Fuse Data: 5-amp automotive-type ATC/ATO (tan) 32v 200 percent current opening time of 5 sec maximum The terminal block positions W2, W3, and E are tied together by jumpers JW1 and JW2.
PAGE 22
LOW VOLTAGE TERMINAL BLOCK EASY SELECT AUX HEAT 5 AMP MAX RANGE KW 0-30 0-20 0-10 0-5 CFM 1200 1000 800 600 ST1 L 5 VIO AC/HP 042 R SIZE 036 030 024 BLU D10 O TYPE AC HP-COMFORT HP-EFF CFM ADJUST MED HI ORN LO Y/Y2 R1 BLK DELAY AC/HP TIME ON 0 30 0 OFF 90 90 0 Y1 CESS430023–01 AC/HP ENH G E JW2 D11 RED CEBD430023–01 GRY MOLEX 7-PIN CONNECTOR (1) PRINTED CIRCUIT BOARD C FS1 R3 MOTOR W2-E JUMPER 3RD STAGE W2 W3 W2-W3 JUMPER 2ND STAGE JW1 GROUN
PAGE 23
ST1 HIGH VOLTAGE 8 E JW2 D1 ST1 3 5 6 7 8 9 10 11 12 4 JW1 D2 ST1 JW4 10 W3 M1 JW3 9 W2 P1 2 1 T1 T2 M2 D2 T3 R3 SEC1 1K 2W D7 D8 ST1 3 C AUX1 D9 SEC2 HUM1 D4 PS1 AUX2 D5 HUM2 D6 ST1 2 R P2 ST1 7 G R2 1K 2W ST1 5 Y/Y2 W/W1 G C1 C2 R Y/Y2 Y1 D10 5 – 30 1200 5 – 20 1000 RED D11 QC19 R1 1K 2W ST1 4 Y1 ST1 1 L ST1 O 3 AUX.
PAGE 24
TABLE 3—MALE/FEMALE QUICK-CONNECT TERMINALS (FK4B) SIZE FEMALE SIZE MALE M2 T3 T2 DESCRIPTION Motor line voltage connection (230 vac 60 Hz) Transformer line voltage connection (230 vac 60 Hz) Transformer tap storage terminal for 208-vac lead Secondary connection from transformer (24 vac) This connection is common to chassis ground through eyelet marked GROUND SCREW REQUIRED.
PAGE 25
CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND BLOWER MOTOR ROTATION ATTENTION: NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE SCHEMATIC DIAGRAM 30KW 1PH SCHEMATIC DIAGRAM DISCONNECT PER NEC FIELD POWER WIRING DISCONNECT PER NEC FIELD POWER WIRING HVTB GND SEE RATING PLATE FOR VOLTS & HERTZ (SEE NOTE 1) GND L1 BLK L2 SEE RATING PLATE FOR VOLTS & HERTZ (SEE NOTE 1) YEL YEL FU6 YEL LS6 HTR6 BLK YEL LS5
PAGE 26
3. Check power leads L1 and L2. If these are not receiving power, system cannot function. 1. Check transformer and thermostat wiring. (See Fig. 16 and 18.) Be sure transformer is not shorting out because thermostat wires are miswired. IF PCB HAS HIGH VOLTAGE APPLIED TO IT: 2. Check wiring of sequencers. (See Fig. 16 and 18.) Be sure low-voltage and high-voltage wiring are connected to proper sequencers. 1. Check low-voltage transformer leads (red and brown). Be sure they are wired to correct locations.
PAGE 27
TABLE 6—FK4B MOTOR CONTROL TEST VALUES (WITH 16-PIN CONNECTOR AT MOTOR UNPLUGGED) SCREW TERMINALS HAVING 24 VAC OPERATING MODE Electric 1-Speed A/C 2-Speed A/C, Low Speed 2-Speed A/C, High Speed 1-Speed HP 1-Speed HP 2-Speed HP, Low Speed 2-Speed HP, Low Speed 2-Speed HP, High Speed 2-Speed HP, High Speed Continuous Fan Heating Cooling Cooling Cooling Cooling Heating Cooling Heating Cooling Heating R R R R R R R R R R R W2 Y/Y2 Y1 Y/Y2 Y/Y2 Y/Y2 Y1 Y1 Y/Y2 Y/Y2 G W3* G G G G G G G Y1 Y1 E* O O G G O
PAGE 28
24 VAC RELAY NO BLK WHT IX. INTEGRATED CONTROLS AND MOTOR (ICM2) An ICM2 is fed high voltage AC power through the 5-pin connector. (See Fig. 23.) The AC power is then rectified to DC by a diode module. After rectification, DC signal is electronically communicated and fed in sequential order to 3 stator windings. The frequency of these commutation pulses determines motor speed. The rotor is permanently magnetized. An ICM2 is powered with high voltage at all times.
PAGE 29
OPTIONAL SAFETY GROUND DRAIN HOLE 1 2 3 4 5 POWER CONNECTOR 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 DRAIN HOLE CONTROL CONNECTOR OPTIONAL SAFETY GROUND CONTROL POWER ENDSHIELD DRAIN HOLE A98201 Fig. 23—FK4C and FV4A ICM2.3 Motor circuit from R to G. The ICM adjusts airflow down to a lower CFM for maximum dehumidification for a period of 10 minutes. If this call continues, outdoor section and ICM shut off for 10 minutes.
PAGE 30
STI ® 5 AMP. MAX. SEC2 YYWWX J1 ® SEC1 DH EASY SELECT 5 R F1 AUX/HEAT KW/CFM 0-30 0-20 0-10 0-5 1075 875 725 625 W1 J2 VIO 036 AC/HP SIZE 030 024 W2 018 Y1 SYSTEM TYPE HP-COMFORT HP-EFF Y/Y2 LO HI D3 BLK R2 NOM G D1 AC/HP CFM ADJUST D5 R1 ORN O ON/OFF DELAY 30 90 0 0 ENH C D2 0 90 WHT CONTINUOUS FAN LO MED HI YEL YEL AUX1 HUM1 AUX2 HUM2 24VAC PL1 CES0130035-00 AC D4 BLU 1 GRY HEATER/MOTOR A96430 Fig. 24—Easy Select Board K.
PAGE 31
SYSTEM DIAGRAM HEATER/MOTOR SEC1 SEC2 1/4" 1/4" 12 11 10 9 8 7 6 5 4 3 2 1 5 AMP AUX1 1/4" HUM1 1/4" DH J1 R W1 AUX2 1/4" HUM2 1/4" GRY 1/4" J2 W2 Y1 Y/Y2 DIODE LOGIC G O C AUX HEAT KW/CFM AC/HP SIZE SYSTEM AC/HP CFM TYPE ADJUST ON/OFF DELAY CONTINUOUS FAN A96431 Fig.
PAGE 32
TABLE 8—CONNECTIONS AND CONNECTOR (FK4C) TYPE CONNECTION Heater Connection TYPE CONNECTOR PIN NO. 12-Pin Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 3. HP-EFF—provides same airflow for heating and cooling modes (approximately 350 CFM/ton). The factory setting is AC. (See Fig. 24.
PAGE 33
CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND BLOWER MOTOR ROTATION ATTENTION: NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE LEGEND 20KW 1PH SCHEMATIC DIAGRAM HTR4 BLK RELAY 3 4 2 LS3 HTR3 BLK RELAY 2 8 6 RELAY 2 4 2 RELAY 1 2 4 LS4 YEL YEL CB2 INTERNAL PROTECTION MAY BE EITHER FUSES OR CIRCUIT BREAKERS YEL YEL LS2 HTR2 BLK LS1 HTR1 BLK YEL L2 L4 L2 CB1 FU GND HVTB HTR REC BLK FIELD POWER WIRING
PAGE 34
→ TABLE 9—FK4C MOTOR CONTROL TEST VALUES (WITH 16-PIN CONNECTOR AT MOTOR UNPLUGGED) SCREW TERMINALS HAVING 24 VAC OPERATING MODE Electric 1-Speed A/C 2-Speed A/C, Low Speed 2-Speed A/C, High Speed 1-Speed HP 1-Speed HP 2-Speed HP, Low Speed 2-Speed HP, Low Speed 2-Speed HP, High Speed 2-Speed HP, High Speed Continuous Fan Continuous Fan Continuous Fan Heating Cooling Cooling Cooling Cooling Heating Cooling Heating Cooling Heating Low Medium High R R R R R R R R R R R R R W1 Y/Y2 Y1 Y/Y2 Y/Y2 Y/Y2 Y1 Y1
PAGE 35
- Check for 24v between pin-1 and pin-12 on the 16-pin plug. (See Fig. 27.) If no voltage is present, replace wiring harness. If voltage is present, jumper screw terminal R-Y/Y2 on circuit board and check for 24v between pin-1 and pin-14 on 16-pin plug. (See Fig. 27.) If voltage is present, check harness connections G, Y1, W1, W2. - If 24v is not present, the harness is bad. Replace harness. percent of nominal cooling mode airflow.
PAGE 36
I. A. PROBLEMS AFFECTING TXV 8. Reconnect refrigerant tube to piston body. 9. Pressurize tubing and coil, then leak check. Low Suction Pressure 10. Evacuate tubing and coil as necessary. 1. Restriction in TXV 2. Low refrigerant charge CAUTION: Use a backup wrench and do not over tighten, as deformation of the piston body will occur, causing the piston to lodge in a partially open or closed position. 3. Low indoor load 4. Low evaporator airflow B. High Suction Pressure 1.
PAGE 37
e. Turn off electrical supply to outdoor unit. a. Attach manifold/gage set to service valves. f. Front seat vapor service valve. b. Front seat (close) liquid tube service valve. g. Recover any remaining refrigerant. c. Start unit in cooling mode. NOTE: All outdoor unit coils will hold only factory-supplied amount of refrigerant.
PAGE 38
13. Install new coil into condensate pan using 2 original screws and 2 support columns. NOTE: Correct coil position in condensate pan is essential to reliable operation. 12. Place coil assembly in plastic condensate pan and secure using 4 screws through delta plate. (See Fig. 31.) 14. Install new coil/pan assembly into unit. Secure with 2 screws previously removed from unit casing. 14. Horizontal Applications only—Place horizontal condensate pan into position on coil/pan assembly.
PAGE 39
10. Remove remaining 2 screws securing coil to condensate pan. water and mild detergent. Rinse 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 cooling coil and replace filter access panel. 11. Remove coil from condensate pan. 12. Remove coil top seal. (See Fig. 32.) II. COOLING COIL, DRAIN PAN, AND CONDENSATE DRAIN 13.
PAGE 40
NOTE: Transformer is fused. Do not short circuit. 2. Reassemble cutoff plate to housing using identified holes from disassembly procedure. D. 3. Position motor and mount in same position as when blower housing was in unit. Secure motor mount on housing, using removed bolts. Make sure mount or motor is grounded to blower housing. III. CLEANING OR REPLACING REFRIGERANT FLOWCONTROL DEVICE Refer to Fig. 30 and instructions given in Piston Body Cleaning or Replacement section above. 4.
PAGE 41
SCHEMATIC DIAGRAM FOR 2, 3, & 5 KW HEATERS BLK SEE RATING PLATE FOR VOLTS & HZ IFR (TDR OPTIONAL) 3 1 BLK BLK COMPONENT ARRANGEMENT MOTOR CAP BRN TRANS LS1 DISCONNECT 2 4 RED L1 BLK 4 3 BLK HTR RED HTR2 2 TRANS A 1 WHEN EQUIPPED BRN P2 BLK BRN C 2 4 VIO MOTOR SPEED SELECTION HI = BLACK LOW = RED 2 BLK 4 W ORN G BRN C 3 FR BRN TRANS A BRN P2 IFR/TD CHASSIS GROUND BRN 5 SEQ 6 B T RED ORN R G UNMARKED TERMINAL YEL BLK BRN C BRN CHASSIS VIO GROUND W OPTION
PAGE 42
BLOWER WHEEL INLET RING 11⁄8″ GROMMET MOTOR A86006 Fig. 34—FF1A/FF1B/FF1C Motor, Inlet Ring, and Blower Wheel Assembly WARNING: As with any mechanical equipment, personal injury can result from sharp metal edges. Be careful when removing parts. CAUTION: Do not use caustic household drain cleaners in condensate pan or near coil. Drain cleaners can quickly destroy coils. C. Blower Motor and Wheel Clean blower motor and wheel when cooling coil is cleaned.
PAGE 43
SEE NOTE #4 L2 SCHEMATIC DIAGRAM YEL 1 1 T YEL FIELD POWER SUPPLY B 2 2 SEQ 1 BLK BLK SEQ 3 3 4 BLK BLK TB 2 SEQ BLK FR 3 L1 (OPTIONAL) FL-2 1 BLK 1 TB FCQT VIO HTR-1 (OPTIONAL) FL-1 2 LS-2 YEL SEQ TB 2 HTR-2 LS-1 LS-2 YEL YEL LS-1 YEL BLK 1 TB NOTE #2 BLK RED LO IFM 2 FR SEQ 3 TRANS BLK RED FC BLK 1 3 BRN QT HI NOTE #1 LS-2 VIO BLK TRANS YEL BLU FR 3 I N D O O R T H E R M O S T A T RED BLK TRANS R RED W2 VIO BRN BRN 24V BRN SEQ VIO 6 5 BRN BRN BRN BR
PAGE 44
III. CLEANING OR REPLACING REFRIGERANT FLOW-CONTROL DEVICE 3. Slide blower wheel onto motor shaft with setscrew upward and aligned with shaft flat portion. Vertically position wheel along shaft to position marked during disassembly. NOTE: If previous shaft was not marked or if replacing previous motor, set blower wheel position by sliding blower wheel along motor shaft to 1-1/8 in. above rubber grommets. (See Fig. 34.) 1. Pump down outdoor unit. Close service valves at outdoor unit.
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3. Remove sheet metal screw holding bracket clip in place. Screw is located between coil and refrigerant flow-control device. Blower motor and wheel may be cleaned using a vacuum with a soft brush attachment. Remove grease with a mild solvent such as hot water and detergent. Be careful not to disturb balance weights (clips) on blower wheel vanes. Do not drop or bend wheel as balance will be affected. FG3A SERVICE AND TROUBLESHOOTING I. SERVICE 4. Pull bracket clip out. 5.
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II. MAINTENANCE f. W2D terminal provides input from outdoor unit (heat pump) signaling control board that heat pump is in defrost. WARNING: Disconnect electrical power to all circuits before servicing unit. Failure to do so may result in personal injury from electrical shock or moving parts. g. W2T terminal provides input from thermostat signaling for supplemental or emergency heat. h. W3 terminal provides input from outdoor thermostat. W3 and W2T are factory connected by JW1.
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CEPL130121-01 MOV1 FS1 C4 C15 Z4 C11 R17 LED1 R2 W2D W 2T Z3 R5 R40 R18 R11 U2 O R16 R19 R10 C9 C8 JW6 G R12 R20 C12 C10 R13 U1 W3 C7 R15 JW4 JW5 R14 R26 R29 E CLIP JUMPER FOR HIGH SPEED FAN ONLY C B Q2 B C E D2 E D1 B C D4 Q1 8 7 Q3 K2 6 DUMMY T2 9 240 VAC F1 T3 COMMON ® HSCI FAN DUMMY JW2 (HIGH FAN ONLY WHEN CUT) AUX+ P1 5 4 3 LR40061 2 ® Yo AUX– 1 R27 JW8 R4 D3 1 JW1 (CUT WHEN OUTDOOR THERMOSTAT IS USED) JW1 Z2 R41 K1 R36 R37 R22 R28 R25
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D. Troubleshooting Printed-Circuit Board (Diagnostic LED) • Are line voltage fuses FU1 and FU2 good? If 208/230v is available across terminals F1 and HI and fan does not operate, check the following: The PCB of Smart Heat option heater package contains a microprocessor which controls fan operation, fan speed, outdoor unit, and heater elements. For troubleshooting, a service LED indicates condition of PCB. See Table 11 for LED flash codes.
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TABLE 12—TROUBLESHOOTING VOLTAGE READINGS AND TEST POINTS INPUT VOLTAGES LOCATION L1 and L2 L3 and L4 9-pin connector 7 and 9 T1 and T3 SEC1 and SEC2 R and C G and C Y and C NORMAL READING 208/230 vac 208/230 vac PURPOSE Main power supply input to fan coil Power to electric heaters 208/230 vac Power to smart control 208/230 vac 24 vac 24 vac 24 vac 24 vac Power to transformer Power from transformer secondary Power from transformer secondary Call for continuous fan signal from room thermostat Call for
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Eventually, the total number of heaters is cycled on. In emergency heat mode, LED indicator signals 7 flashes. • The amount of emergency heat available depends on whether jumper JW1 is cut and the number of heating elements. Table 13 illustrates results under various conditions. The heaters cycle on two elements initially and an additional element every 5 minutes until maximum level is reached. • • TABLE 13—EFFECT OF JW1 ON EMERGENCY HEAT JW1 cut* 4 elements 50% • 3 elements 66.
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CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND BLOWER MOTOR ROTATION ATTENTION: NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE SCHEMATIC DIAGRAM HTR3 BLK 4 HTR2 LS2 YEL BLK FU1 FU4 SEQ 1 3 4 BLK HTR4 10 BLK SEQ 2 8 7 SYSTEM TRANSFORMER: 40.0VA FAN COIL/HEATER: 26.3VA REMAINING VA AVAILABLE: 13.
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SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • 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.