Installation Instruction

Transcription

1 I eplacement Kit For FK4A ancels: New IIK FK4A Installation Instruction NT: ead the entire instruction manual before starting the installation. INTDUTI Kit is required when replacing I motors with the I motors in the FK4A Fan oils. The contents of the kit are listed in Table 1. The proper I motor to insert into related FK4A Fan oils is indicated in Table 2. Table 1-Kit ontents PAT N. DSIPTI QUANTITY S137 Printed-ircuit Board Label FK4B Label FK4B Label FK4B Label FK4B Label FK4B Label FK4B Wiring Label Power Harness ontrol Harness Bracket 1 AL76AZ128 S 6B X 3/4 SL HX HD 2 DSIPTI AND USA When removing an I motor, the contents of Kit must be used in the installation of an I motor. nly 1 of the 6 labels provided in the kit should be applied to the printed-circuit board S137. The application of the label is illustrated in Fig. 1. The selection of the proper label is indicated in Tabel 3. Table 2 I Motors Installed Into FK4A Fan oils DS DIN N. FK4ANF2 FK4ANF3 FK4ANF4 FK4ANF5 FK4ANF6 I PAT N. HD44A118 HD44A118 HD44A119 HD44A119 HD52A118 Before installation or servicing system, always turn off main power to system. There may be more than 1 disconnect switch. Turn off accessory heater power if applicable. lectrical shock can cause personal injury or death. SAFTY SIDATIS 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. onsult 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. efer 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 extinguisher available. ead these instructions thoroughly and follow all warning or cautions attached to the unit. onsult local building codes and National lectrical ode (N) for special requirements. ecognize safety information. This is the safety-alert symbol. 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 DAN, WANIN, or AU- TI. These words are used with the safety-alert symbol. DAN- identifies the most serious hazards which will result in severe personal injury or death. WANIN signifies hazards that could result in personal injury or death. AUTI is used to identify unsafe practices which would result in minor personal injury or product and property damage. Step 1 heck quipment INSTALLATI ompare the contents of the kit with Table 1. (See Fig. 1.) Step 2 emove Blower Panel to Access Motor and Printed-ircuit Board emove blower access panel. ut and discard wire ties from motor control wiring in heater compartment and at blower mounting legs. ompletely disconnect printed-circuit board wiring and motor. (See Fig. 2.) emove circuit board, bracket, and motor wiring harnesses. Step 3 emove and eplace I Motor with I eplacement Motor To remove I motor: 1. emove 2 outside screws holding blower motor assembly against the blower-deck flange and slide assembly out of cabinet. 2. Loosen setscrew holding blower wheel onto motor shaft. 3. emove 3 bolts holding motor mount to blower housing and slide motor and mount out of housing. 4. emove motor mounting band and legs. To install the I motor: IMPTANT: The I motor must be mounted with connectors facing out of the cabinet. (See Fig. 2.) Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 P 11 atalog No FK-4A3 Printed in U.S.A. Form FK4A-1SI Pg eplaces: New Tab 3c 2c

2 Y UND SW QUI A/HP SIZ A 24 TYP HP-MFT A/HP ADJUST L A/HP TIM S2 MD 24 S1 HP-FF HI DLAY NH HAT S 24VD AUX1 HU HU V / FK4B4 A/HP SIZ Y UND SW QUI ASY SLT A/HP A TYP A/HP ADJUST A/HP TIM 3 9 S2 9 SIZ HP-MFT DLAY S1 HP-FF NH 3 MAX 1 1 SS BD VD AUX1 HU S L HU ASY SLT SS BD S137 L IM WITH NTS IN PP INTATI HAT 2 24 S137 Fig. 1 Printed-ircuit Board with Label verlay NT: Do not cover vent holes in motor shell with the motor mounting band. Do not install motor mounting band over control section of I. 1. Assemble motor mounting bands and legs to motor 2. Secure motor mount to housing using 3 bolts removed. Make sure mount or motor is grounded to blower housing. 3. Locate blower wheel setscrew over flat on motor shaft and tighten. otate wheel in housing. Blower wheel should not rub housing and should be centered in inlet opening. If not, loosen setscrew, realign blower wheel, tighten setscrew on shaft, and check rotation again. 4. Slide blower assembly on to blower deck. nce blower is within the unit envelope make sure to force blower assembly toward control box while sliding assembly into cabinet to ensure that blower assembly engages deck properly. 5. Fasten blower assembly to deck with 2 screws previously removed. 6. Apply wiring label on blower housing completely over old wiring label. Step 4 emove Fan oil ontrol Board HK61A2 1. emove screws securing control board mounting bracket to wrapper and top panel. 2. Tilt control board and slide tabs out of blower deck slots. Step 5 Install Printed-ircuit Board S137 To mount the printed-circuit board to the bracket: A Apply proper printed-circuit board label for fan coil size. (See Table 3.) 2. Slide the 2 right side tabs on the printed-circuit board into the slots on the right side of the bracket. 3. Slide the top tab up into the top slot until the screw holes in bracket line up with printed-circuit board standoffs. 4. Secure printed-circuit board to bracket at bottom most hole with No.6 x 3/4-in. screw provided. 5. Install board and bracket assembly by aligning tab on bracket with rear slot in the blower deck. 2 Fig. 2 Blower Motor and Printed-ircuit Board 6. Insert tab into slot and tilt assembly back into the control compartment until screw hole at top bracket aligns with the screw hole in top panel. 7. Secure with No.1 x 3/8-in. screw. Table 3 Printed-ircuit Board Labels UNIT LABL PAT N. ASY SLT N. FK4B FK4B FK4B FK4B FK4B Step 6 Make Transformer onnections To connect transformer wiring to printed-circuit board: 1. onnect brown secondary lead to S1. 2. onnect red secondary lead to S2. 3. onnect red primary lead to. 4. onnect blue primary lead to (23-v system, for 28-v system). 5. onnect black primary lead to (23-v system, for 28-v system). Step 7 Make ontrol or er onnection onnect cooling control or heater control harness to the printedcircuit board receptacle. Step 8 Install Motor Harnesses To install motor power harness: 1. Make connection at motor power receptacle. 2. oute power harness through the wiring hole in blower deck and make the following connections: a. Black power lead to. b. Yellow power lead to. A9336 c. Make ground connection by securing ground ring terminal to ground using second No. 6 x 3/4-in. screw and fastening to bracket at the remaining printed-circuit board standoff.

3 ASY SLT Y UND SW QUI A/HP SIZ Fig V onnection to Transformer TYP A/HP ADJUST L MD HI A/HP A 9 S TIM HP-MFT DLAY S1 HAT 6 HP-FF NH SS BD VD AUX1 HU 2 S S137 HU BWN BLAK A9313 WI TI ASY SLT Fig. 4 Printed-ircuit Board and Wiring Arrangement Y UND SW QUI A/HP SIZ A TYP A/HP ADJUST L MD HI A/HP 9 S HP-MFT TIM DLAY S1 HAT -5 6 HP-FF NH SS BD S 24VD AUX1 HU HU S137 L A9321 Failure to connect the ground as instructed will result in erratic or no blower operation. To install motor control harness: 1. onnect motor control harness at the motor control receptacle. 2. oute the harness between the blower deck and the blower access panel (control harness will not fit through the blower deck wiring hole). 3. Make the following control wire connections: a. onnect 7 pin connector to header on printed-circuit board. NT: The remaining wire connections can be made by matching the wire colors with the wire color labeled at the printed-circuit board connections (See Fig. 4.) b. ed lead to red printed-circuit board connection. c. ray lead to A/HP DLAY selection choose desired delay profile. d. Black lead to A/HP ADJUST choose medium, high, or low setting. e. range lead to TYP choose appropriate system type. f. Blue lead to A/HP SIZ choose correct system size. g. Violet lead to choose safe heater operation airflow if system includes electric heat. NT: See Sequence of peration and asy Select onfiguration Taps sections for information on system adjustments and operating characteristics. Step 9 Make System Thermostat onnections Make thermostat connections to indoor unit, outdoor unit, and thermostat system per wiring diagram. (See Fig. 5 and 6.) Step 1 Sequence of peration The fan coil will supply airflow in a range that is more than twice the range of a standard fan coil. It is designed for nominal cooling capacities at a 5 F evaporator temperature and to provide the 3 required airflow which enables it to match with 4 A/HP system sizes. Table 4 outlines the range for the different fan coil sizes. Table 4 Minimum for lectric er Application FAN IL UNIT SIZ 2, 3 4, 5 6 HAT PUMP UNIT SIZ MINIMUM F LTI HAT er Size Kw 5 8, 9, , 2 24, 3 er nly er nly er nly er nly Air onditioner with electric heater application. Airflows are minimum acceptable airflows. Actual airflow delivered will be per airflow charts for lectric ing Modes. TINUUS FAN Thermostat closes circuit to The blower will run at continuous fan. LIN MD Single speed or 2-speed high Thermostat closes circuits to and to The fan coil will deliver cooling. LIN MD 2-speed low

4 Thermostat Subbase Indoor Terminal Block utdoor Terminal Board Thermostat Subbase Indoor Terminal Block utdoor Terminal Board W 3 W 3 W 3 W 3 W 2 W 2 W 2 W 2 W 2 W 2 L L L L L L Y2 Y2 Y Y TYPIAL SINL - SPD HAT PUMP WIIN Fig. 5 Single-Speed Wiring A9312 TYPIAL TW - SPD HAT PUMP WIIN Fig. 6 Two-Speed Wiring A93177 Thermostat closes circuits to and to The fan coil will deliver 2-speed low cooling. Thermostat closes circuits to, to Y, and to The fan coil will deliver 2-speed high cooling. LTI HAT HATIN MD Thermostat closes circuit to,, or The fan coil will deliver the selected electric heat. HAT PUMP HATIN MD Single speed Thermostat closes circuit to The fan coil will deliver heat pump heating. HAT PUMP HATIN MD 2-speed Thermostat closes circuit to The fan coil will deliver 2-speed heat pump heating low. Thermostat closes circuit to and to The fan coil will deliver 2-speed heat pump heating high. HAT PUMP HATIN WITH AUXILIAY LTI HAT Thermostat closes circuits to and/or to with to, or (and to in the case of defrost) In the event that electric heating is called for by the thermostat while the heat pump is operating in either heating or defrost, the motor will modify its airflow output, if necessary, to provide an 4 airflow which is defined as safe for the operation of the electric heater with heat pump operating. The motor will always run the higher of the heat pump efficiencies or electric heat. Step 11 ASY SLT onfiguration Taps The ASY SLT taps are used by the installer to configure a system. The I motor 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 dehumidification. (See Fig. 7.) The fan coil must be configured to operate properly with the system components with which it is installed. To successfully configure a basic system move the 5 select wires to the pins which match the components used. See the information printed on the printed-circuit board located next to the select pins. Select heater range for size of electric heater installed. The installer must select the auxiliary heat airflow approved for application of the kw size heater installed. If no heater is installed, this step can be skipped. ach 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. The airflow marked is that airflow which will be supplied in the emergency heat mode and the heating mode on air conditioners when electric heat is the primary heating source. In heat pump heating mode any time the electric heaters are energized, the I will run the higher of the heat pump efficiency

5 UND SW QUI A9399 Fig. 7 Detail of asy Select Printed-ircuit Board airflow and the electric heater airflow to ensure safe heater operation. The factory selection is the largest heater range approved. (See Fig. 7, A.) A/HP SIZ Select system size installed The factory setting for A/HP Size is the largest unit meant for application with the model of fan coil purchased. The installer needs to select the air conditioner size to ensure that the airflow delivered falls within the proper range for the size unit installed in all operational modes. (See Fig. 7, B.) TYP Select system type installed A or HP. The Type system must be selected. The indication A is for air conditioner which is the factory setting. The HP-MFT provides the same airflow as the air conditioner selection, approximately 375 /ton. The HP-FF provides the most efficient airflow for heating and cooling modes, approximately 41 - /ton heating and 375 /ton cooling. (See Fig. 7,.) A/HP ADJUST Select medium, low, or high airflow. To provide airflow at the rates described above, the A/HP ADJUST select must be moved to the MD position. The factory selection is L. The adjust selections HI/L will regulate the airflow supplied for all operational modes, except non-heat pump heating modes, +1% and -1% respectively. The adjust selection options are provided to adjust the airflow supplied to meet individual installation needs for such things as noise, comfort, and humidity removal. (See Fig. 7, D.) A/HP TIM DLAY Select desired time delay profile. Four motor operation delay profiles are provided to customize and enhance system operation. (See Fig. 7,.) The selection options are: A B D MLX 7-PIN NT (1) 3/16 MAL FAST AMP-TYP (21)PLS Y ASY SLT A/HP SIZ The standard 9 sec off delay (factory setting). 12 A TYP A/HP ADJUST A/HP TIM 3 9 S HP-MFT DLAY S1 HAT S No delay option is used for servicing unit or when a thermostat is utilized to perform delay functions. 3. A 3 sec on/9 sec off delay profile, used when it is desirable to allow the system coils time to heat up/cool down prior to airflow. This profile will minimize cold blow in heat pump operation and could enhance system efficiency. 4. NH, enhanced selection, provides a 3 sec on/18 sec off delay at half airflow for added comfort and efficiency. 6 HP-FF NH SS BD VD AUX1 HU 2 S L HU LW VLTA TMINAL BLK (1) PINTD IUIT BAD - JUMP 3D STA - JUMP 2ND STA F 1/4 MAL FAST AMP-TYP (9)PLS AMP 12-PIN MAT-N-LK NT (1) 5 LW-VLTA IUIT FUSIN AND FN The low-voltage circuit is fused by a board-mounted 5-amp automotive fuse placed in series with the transformer S2 and the circuit. The circuit of the transformer is referenced to chassis ground through a printed circuit run at S1 connected to the metal standoff marked UND SW QUI. Step 12 Accessory Installation ASSY LTI HATS lectric heaters may be installed with the fan coil per instructions supplied with the electric heater packages. Before attempting to plug the heater into the asy Select interface board, the cooling control plug and stripped leads must be removed and discarded. To do this: 1. Disassemble the motor control plug connection and select leads from the printed-circuit board. 2. ut the wire tie from the transformer leads and the stripped leads. 3. Unplug the cooling control plug from the printed-circuit board, and discard the cooling control plug. 4. Plug the heater control plug into the printed-circuit board receptacle. 5. eplace the motor control plug and selection wires. Wire color printed on the printed-circuit board can be used as a guide in locating the proper connections for the selection wires. IMPTANT: Pull the heater control harness wires down and away from the fan coil door as far as possible, then wire tie to transformer leads using a field-supplied wire tie. Make sure that the motor control harness sleeve is positioned directly over the heater control harness plug. (See Fig. 4.) LTI AI LAN (A) NTIS The I blower motor used in the fan coil is controlled by low-voltage signals, therefore, the familiar 23-vac electronic air cleaner control/power signal, A1 and A2, is not available. The signal is replaced by a 24-vdc signal which is provided at circuit board terminals AUX1 and. (See Fig. 7, F.) The signal is present when either or W is present and is active in all heating and cooling modes. If 24-vdc relays are not readily available to the installer kit KFAI11A contains a 24-vdc relay which mounts directly inside the A cabinet. User supplied 11vac is switched by this relay to power the A when or W are present. This is the preferred connection because it allows low-voltage wiring to be run between the fan coil and the A and eliminates the problems of controlling a 11vac A from the 23-v power supplied by the fan coil. In heat pump applications, the signal is present in both cooling and heating modes, permitting the A to be controlled from the signal only. For this application, a user supplied 24-vac relay can be driven by the terminal, eliminating the need for the relay kit. The selection and mounting of this ac relay is the responsibility of the installer. The following instructions apply to the installation of dc relay kit Part No. KFAI11A. 1. emove the A door and the filter elements. 2. emove 2 screws to the left of the white power plug, and lift off the wiring box cover. 3. Attach relay from kit to the cover using appropriate sheet metal screws. If there are no mounting holes in the cover, locate the relay, mark the 2 hole locations, and drill 2 mounting holes to accommodate 2 sheet metal screws. (See Fig. 8.)

6 4. efer to the schematic to verify the following electrical connections. (See Fig. 9.) a. onnect the AUX1 and terminals on the fan coil ASY SLT board to the 2 relay coil terminals. (See Fig. 7, F.) Polarity is not important. Local codes may require separate routing from the 11-vac power to be connected next as these are low-voltage leads. This can be done by drilling a separate 3/8-in. hole for these leads to the left of the existing A wiring hole. oute the 2 wires through the hole and the provided strain relief. Use 3/16-in. quick connects provided to connect to the relay coil terminals. Use standard 1/4-in. quick connects at the ASY SLT board, routing the 2 wires through the thermostat wire knockout. b. From an available 11-vac branch circuit, connect the incoming black (hot) wire to 1 side of the relay normally open (N/) contact and the black A wire to the other side of the N/ contact using 1/4-in. quick connects. onnect the incoming white (neutral) wire directly to the white A wire. Then connect the incoming green ground wire to the A ground wire. oom for wire nuts within the wiring box is provided. 5. arefully fold the wiring and wire nuts into the wiring box and replace the box cover with the 2 screws. HUMIDIFI/HUMIDISTAT NTIS Terminals HU and HU are provided for direct connection to the low-voltage control of a humidifier through a standard humidistat. (See Fig. 7,.) These terminals are energized with 24vdc whenever the or W thermostat signals are present. (See Fig. 1.) Latent capacities for systems using the fan coil are better than average systems. If increased latent capacity is an application requirement, the FK4B can be wired to provide this requirement by adjusting its airflow in response to a standard humidistat input. Fig. 11 illustrates the wiring connections to activate dehumidify mode. onsult product airflow data for cooling and dehumidifying mode. Fig. 8 Mounting KFAI11A elaykit FK4B AUX1 MUNT FLUSH WITH THS TW DS 11 BANH KT ND HT NUT N WHT A PLU A VD LAY Fig. 9 elay Kit Wiring Schematic A

7 HUM 1 HUM 2 24-VD Table 5 FK4A2 lectric er Kw ange UTD UNIT APAITY BTUH Lo Med Hi Lo Med Hi Lo Med Hi L Med HI er nly * * * * * * * * * * * * *See note at bottom of Table 8. Table 6 FK4A3 lectric er Kw ange UTD UNIT APAITY BTUH Lo Med Hi Lo Med Hi Lo Med Hi Lo Med Hi er nly * * * * * * * * * * * * *See note at bottom of Table 8. Table 7 FK4A4, 5 lectric er Kw ange UTD UNIT APAITY BTUH Lo Med Hi Lo Med Hi Lo Med Hi Lo Med Hi er nly * * * * * * * * * *See note at bottom of Table 8. HUMIDISTAT HUMIDIFI WIIN Fig. 1 Humidifier Wiring T HUMIDIFI A93214 WI FM I Table 8 FK4A6 lectric er Kw ange HUMIDISTAT T PB TMINAL MAKD '' HUMIDISTAT WIIN F D-HUMIDIFY MD Fig. 11 Humidstat Wiring for Dehumidity Mode UTD UNIT APAITY BTUH Lo Med Hi Lo Med Hi Lo Med Hi Lo Med Hi er nly * * * * * * * * * *Lo, Med, and Hi refer to the A/HP ADJUST jumper selection. er only airflows are not adjustable by the A/HP ADJUST SLT jumper. Airflows shown are independent of external static pressure up to.5-in. wc. *Airflow not recommended for heater/system size. A

8 UNIT SIZ 2 3 4, 5 6 UTD UNIT APAITY See note at bottom of Table 1. UNIT SIZ 2 3 4, 5 6 Table 9 FK4A Airflow Delivery in Mode Single-Speed Application Nominal Dehumidity PATIN MD LIN 2-Speed Application High Speed Low Speed Nominal Dehumidity Nominal Dehumidity FAN LY UTD UNIT APAITY Table 1 FK4A Airflow Delivery in ing Mode PATIN MD HAT PUMP LY HATIN 2-Speed Application Single-Speed Application High Speed Low Speed omfort fficiency omfort fficiency omfort fficiency NT: Airflows are the result of A/HP ADJUST select jumper set on MD. an adjust airflow +1 percent (Hi) or -1 percent (Lo). Dry coil at 23v and 1 kw heater and filter installed. Airflow is independent of external static pressure within +/- 5 percent of values up to.7-in. wc. Airflows shown are at standard air conditions. opyright 1993 arrier orporation 1478o Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 P 11 atalog No FK-4A3 Printed in U.S.A. Form FK4A-1SI Pg eplaces: New Tab 3c 2c