Installation Instructions P/N

Transcription

1 IM2 eplacement Kit For FK4A ancels: IIK FK4A-2-2 IIK FK4A Installation Instructions P/N NTE: ead the entire instruction manual before starting the installation. SAFETY NSIDEATINS 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 Electrical ode (NE) for special requirements. ecognize 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 DANE, WANIN, AUTIN, and NTE. These words are used with the safety-alert symbol. DANE identifies the most serious hazards which will result in severe personal injury or death. WANIN signifies hazards which could result in personal injury or death. AUTIN is used to identify unsafe practices which would result in minor personal injury or product and property damage. NTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation. INTDUTIN Kit is required when replacing IM1 motors with the IM2 motors in the FK4A Fan oils. The contents of the kit are listed in Table 1. The proper IM2 motor to insert into related FK4A Fan oils is indicated in Table 2, and must be ordered separately (not included with this kit). Table 1-Kit ontents PAT N. DESIPTIN QUANTITY HK61EA5 Printed-ircuit oard Label (1, 2) Label (3) Label (5) Label (6) Wiring Label Harness racket 1 AL79AZ128 S 6 X 3/4 SL HX HD 2 HT1N236 Transformer 1 DESIPTIN AND USAE When removing an IM1 motor, the contents of Kit must be used in the installation of an IM2 motor. nly 1 of the 4 labels provided in the kit should be applied to the printed-circuit board HK61EA5. The application of the label is illustrated in Fig. 1. The selection of the proper label is indicated in Table 3. Table 2 FK4A eplacement Motor List PDUT N. FK4ANF2 FK4ANF3 FK4ANF4 FK4AN5 FK4AN6 IM2 MT PAT N. HD44AE131 HD44AE131 HD44AE132 HD44AE133 HD46AE244 efore 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. Electrical shock can cause personal injury or death. INSTALLATIN Step 1 heck Equipment ompare the contents of the kit with Table 1. Step 2 emove lower Panel to Access Motor and Printed-ircuit oard, emove ontrol Wiring 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, transformer, and motor. Step 3 emove and eplace IM1 Motor with IM2 eplacement Motor To remove IM1 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. 5. emove blower from motor shaft. To install the IM2 motor: IMPTANT: The IM2 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. ook 1 4 P 11 atalog No. 63FK-4A2 Printed in U.S.A. Form FK4A-3SI Pg eplaces: FK4A-2SI Tab 3c 2c

2 VI LU N WHT YEL L SE SE2 A/HP SIZE SYSTEM TYPE A HP-MFT HP-EFF NM 9 AUX HEAT KW/FM A/HP FM ADJUST L N/FF DELAY 3 9 ED ESS HI ENH NTINUUS FAN MED HI YEL TM HEATE/MT J1 J2 AUX1 HUM1 AUX2 HUM2 24VA Y KW FM VI EASY SELET TM 1 2 AUX HEAT KW/FM A/HP SIZE SE1 SE2 J1 EASY SELET KW FM VI EASY SELET TM AUX HEAT KW/FM J2 LU N A/HP SIZE SYSTEM TYPE A HP-MFT HP-EFF NM A/HP FM ADJUST L N/FF DELAY HI IM MT WITH NNETS IN PPE IENTATIN ENH WHT L NTINUUS FAN MED HI YEL AUX1 HUM1 YEL ED ESS HEATE/MT AUX2 HUM2 24VA Y A9838 Fig. 2 lower Motor and Printed-ircuit oard A9812 Fig. 1 Printed-ircuit oard with Label verlay NTE: Do not cover vent holes in motor shell with the motor mounting band. Do not install motor mounting band over control section of IM2. 1. Assemble motor mounting bands and legs to motor. 2. Secure motor mount to housing using 3 bolts removed. 3. Locate blower wheel setscrew over flat on motor shaft and tighten. otate wheel in housing. lower 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 to completely cover old wiring label. Step 4 emove Fan oil ontrol oard 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 emove and eplace Transformer 1. emove mounting screw and slide out transformer. 2. Install transformer HT1N236 with high voltage terminals facing out of cabinet and secure with screw removed above. Step 6 Install Printed-ircuit oard ES1335 To mount the printed-circuit board to the bracket: 1. Apply proper printed-circuit board label for fan coil size. (See Table 3 and Fig. 1.) 2. Slide the top tab up into the top slot until the screw holes in bracket line up with printed-circuit board standoffs. 3. Secure printed-circuit board to bracket with 2 No. 6 X 3/4-in. screws provided. 4. Install board and bracket assembly by aligning tab on bracket with rear slot in the blower deck 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. 6. Secure with No. 1 X 3/8-in. screw previously removed. Table 3 Printed-ircuit oard Labels LAEL PAT N. EASY SELET N. FK4A , 2 FK4A , 2 FK4A FK4A FK4A Step 7 Make Harness Wiring onnections to Transformer, P oard, and Motor 1. onnect red transformer secondary lead to SE2 terminal on P board. 2. onnect brown transformer secondary lead to SE1 terminal on P board. 3. onnect yellow high voltage wires in harness to M terminal on transformer. 4. onnect black high voltage wires in harness to 23v terminal (28v terminal on 28v systems) on transformer. NTE: The remaining P board connections can be made by matching wire colors with the wire color labeled at the printedcircuit board connections. 5. Make the following wire connections: a. Install 12-pin heater/motor control plug on harness onto the P board heater/motor header. b. ray lead to Y printed-circuit board connection. c. White lead to N/FF DELAY selection choose desired delay profile. d. lack lead to A/HP FM ADJUST choose NM, HI, or L setting. e. range lead to TYPE choose appropriate system type. f. lue lead to A/HP SIZE choose correct system size. g. Violet lead to AUX HEAT ANE choose safe heater operation airflow if system includes electric heat. 6. Note proper plug orientation, then install 16-pin motor control plug into motor control wiring receptacle.

3 IND NTL HEAT STAE 2 / N/A / HEAT STAE 1 W/ L STAE 1 FAN IL 1-SPEED AI NDITINE EMVE J2 JUMPE F HEAT STAIN Y size system installed for safe and continuous operation. Note that airflow marked is the airflow which will be supplied in emergency heat mode and heating mode on air conditioners when electric heat is the primary heating source. In heat pump heating mode when electric heaters are energized, the IM2 will run the higher of heat pump heating airflow and electric heater airflow to ensure safe heater operation. The factory selection is the largest heater range approved. (See Fig. 7-A, as indicated.) FAN IND NTL FAN IL 2-SPEED AI NDITINE 24 VA HT 24 VA MM UM EMVE J1 JUMPE F MDES HEAT STAE 2 HEAT STAE 1 L STAE 1 L STAE 2 / W/ / EMVE J2 JUMPE F HEAT STAIN Y2 HUMIDIFY N/A UTD SENS NNETIN HUM S1 S2 HUMIDIFIE (24 VA) UTD SENS FAN 24 VA HT UM EMVE J1 JUMPE F MDES A98116 Fig. 3 Fan oil with 1-Speed Air onditioner 7. Note proper plug orientation, then install 5-pin motor power plug into motor power wiring receptacle. Step 8 Make ooling ontrol or er onnection onnect cooling control or heater control plug into control wiring harness 12-pin receptacle. Step 9 Make Motor round onnection 1. Using the N ground lead from the motor power connector, make the motor ground connection by securing the ring connector to motor housing using No. 1 sheet metal screw. 2. Secure harness wiring to motor mounting leg using fieldsupplied wire tie. Step 1 Make System Thermostat onnections Make thermostat connections to indoor unit, outdoor unit, and thermostat system per wiring diagram. (See Fig. 3, 4, 5, and 6.) Step 11 Easy Select onfiguration Taps EASY SELET taps are used by the installer to configure a system. IM2 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 de-humidification. The FK4A Fan oil must be configured to operate properly with system components with which it is installed. To successfully configure a basic system (see information printed on circuit board label located next to select pins), move the 6 select wires to the pins which match the components used. AUX HEAT KW/FM SELET HEATE ANE F SIZE F ELETI HEATE INSTALLED Installer must select the auxiliary heat airflow approved for application with kw size heater installed. If no heater is installed, this step can be skipped. Each select pin is marked with a range of heaters for which airflow, also marked, is approved. For increased comfort select the narrowest kw range matching the heater size, for example, -1 for a 1-kw heater. This airflow must be greater than the minimum FM for electric heater application with the 24 VA MM HUMIDIFY N/A UTD SENS NNETIN HUM S1 S2 A98117 Fig. 4 Fan oil with 2-Speed Air onditioner A/HP SIZE SELET SYSTEM SIZE INSTALLED The factory setting for air conditioner or heat pump size is the largest unit meant for application with the model of fan coil purchased. Installer needs to select air conditioner or heat pump size to ensure that airflow delivered falls within proper range for the size unit installed. This applies to all operational modes with the exception of electric heat modes. (See Fig. 7-, as indicated.) SYSTEM TYPE SELET SYSTEM TYPE INSTALLED A HP The type of system must be selected: 1. A Air conditioner 2. HP-MFT Provides approximately 315 FM per ton for higher normal heating air delivery temperature. Provides approximately 35 FM per ton cooling airflow for good humidity removal. 3. HP-EFF Provides same airflow for heating and cooling modes; approximately 35 FM per ton. The factory setting is A. (See Fig. 7-, as indicated.) A/HP FM ADJUST SELET MEDIUM, LW, HIH AIFLW To provide airflow at rates described above, the A/HP ADJUST select is factory set to the nominal (NM) tap. The adjust selections HI/L will regulate airflow supplied for all operational modes, except non-heat pump heating modes, +15 percent and -1 percent respectively. The adjust selection options are provided to adjust airflow supplied to meet individual installation needs for such things as noise, comfort, and humidity removal. (See Fig. 7-D, as indicated.) HUMIDIFIE (24 VA) UTD SENS 3

4 IND NTL FAN IL 1-SPEED HEAT PUMP IND NTL FAN IL 2-SPEED HEAT PUMP VS LIN HEAT STAE 3 / / EMVE J2 JUMPE F HEAT STAIN VS LIN HEAT/L STAE 1 / / HEAT STAE 2 HEAT/L STAE 1 W/ Y HEAT STAE 3 HEAT/L STAE 2 W/ EMVE J2 JUMPE F HEAT STAIN FAN FAN Y2 24 VA HT UM EMVE J1 JUMPE F MDES 24 VA HT UM EMVE J1 F MDES W3 24 VA MM 24 VA MM HUMIDIFY VS HEATIN UTD SENS NNETIN HUM S1 S2 HUMIDIFIE (24 VA) UTD SENS HUMIDIFY VS HEATIN UTD SENS NNETIN HUM S1 S2 HUMIDIFIE (24 VA) UTD SENS Fig. 5 Fan oil with ne-speed A98118 N/FF DELAY SELET DESIED TIME DELAY P- FILE Four motor operation delay profiles are provided to customize and enhance system operation. (See Fig. 7-E, as indicated) Selection options are: 1. The standard 9 sec off delay (Factory setting) at 1 percent airflow. 2. No delay option used for servicing unit or when a thermostat is utilized to perform delay functions. 3. A 3 sec on delay with no airflow/9 sec off delay at 1 percent airflow profile is used when it is desirable to allow system coils time to heat-up/cool-down in conjunction with the airflow. 4. ENH, enhanced selection, provides a 3 sec on delay with no airflow, plus 15 sec at 7 percent airflow/no off delay for added comfort. (This profile will minimize cold blow in heat pump operation and could enhance system efficiency.) NTINUUS FAN SELET DESIED FAN SPEED WHEN THEMSTAT IS SET N NTINUUS FAN 1. L speed factory setting, 5 percent cooling mode airflow 2. MED speed move connector to MED, 65 percent cooling mode airflow. 3. HI speed move connector to HI, 1 percent cooling mode airflow. (See Fig. 7-F, as indicated.) LW-VLTAE IUIT FUSIN AND EFEENE The low-voltage circuit is fused by a board-mounted 5-amp automotive fuse placed in series with the transformer SE2 and the circuit. The circuit of the transformer is referenced to chassis ground through a printed circuit run at SE1 connected to metal standoff marked with ground symbol. ASI FAN IL NFIUATIN The following is the basic configuration of the fan coil. 4 A D E F Fig. 6 Fan oil with 2-Speed LW VLTAE TEMINAL PINTED IUIT AD KW FM VI LU N WHT YEL SE1 EASY SELET L SE2 A/HP SIZE SYSTEM TYPE A HP-MFT HP-EFF NM 9 AUX HEAT KW/FM A/HP FM ADJUST L N/FF DELAY 3 9 ED ESS HEATE/MT A98119 A95275 Fig. 7 Detail of Easy Select Printed-ircuit oard 1. AUX HEAT KW/FM Select the heater range for the size electric heater installed. 2. A/HP SIZE Select system size installed. 3. SYSTEM TYPE Select system type HP-EFF. 4. A/HP FM ADJUST Select NM. 5. N/FF DELAY Select /9 profile. HI ENH NTINUUS FAN MED HI YEL TM J1 J2 AUX1 HUM1 AUX2 HUM2 24VA Y MLEX 12-PIN NNET D H W 1 W 2 Y 1 Y/Y 2

5 6. NTINUUS FAN Select desired fan speed when thermostat is set to continuous fan. Step 12 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 required airflow which enables it to match with 4 A/HP system sizes. Table 4 outlines the FM range for the different fan coil sizes. FK4A SIZE Table 4 Minimum FM for Electric er Application HEAT PUMP SIZE MINIMUM FM F ELETI HEAT er Size KW 5 8, 9, , 2 24, 3 er nly , er nly er nly er nly er nly Air onditioner with electric heater application. Airflows are minimum acceptable airflows as UL listed. Actual airflow delivered will be per airflow charts for Electric ing Modes. NTINUUS FAN 1. Thermostat closes circuit to The blower runs at continuous fan airflow. LIN MDE 1. Thermostat closes circuits to, to, and to The fan coil delivers single speed cooling airflow. 2. Thermostat closes circuits to, to, to Y2, andto The fan coil delivers 2-speed high cooling airflow. LIN MDE 2-SPEED LW 1. Thermostat closes circuits to, to, an d to The fan coil delivers 2-speed low cooling airflow. LIN MDE DEHUMIDIFIATIN 1. Thermostat closes circuits to, to, and to, (or to for 2-speed low), and humidistat opens to The fan coil delivers airflow which is approximately 8 percent of the nominal cooling airflow to increase the latent capacity of the system. ELETI HEAT HEATIN MDE 1. Thermostat closes circuit to W/, or The fan coil delivers the selected electric heat airflow. 5 HEAT PUMP HEATIN MDE SINLE SPEED 1-SPEED HIH 1. Thermostat closes circuits to and to The fan coil delivers single speed heat pump heating airflow. 2. Thermostat closes circuits to, to, and to The fan coil delivers 2-speed high heat pump heating airflow. HEAT PUMP HEATIN MDE 2-SPEED LW 1. Thermostat closes circuits to and to The fan coil delivers 2-speed heat pump heating low airflow. HEAT PUMP HEATIN WITH AUXILIAY ELETI HEAT 1. Thermostat closes circuits to, to and/or to with to W/ 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 also operating in either heating or defrost modes, the motor will modify its airflow output, if necessary, to provide an airflow which is defined as safe for the operation of the electric heater during heat pump operation. That airflow is the greater of the heat pump heating airflow and the electric heater only airflow. AUX1 () ED FK4 AUX2 () ED 24 VA ELAY N M 23 VA 115 VA ANH KT ND HT NEUT N Fig. 8 EA elay Wiring Schematic A95318 Step 13 Accessory Installation AESSY ELETI HEATES Electric heaters may be installed with the FK4A Fan oil per instructions supplied with the electric heater package. ELETNI AI LEANE NNETINS ecause the IM2 blower motor used in the FK4A Fan oil is controlled by low-voltage signals, a switched 23-vac electronic air cleaner power signal is not available. This signal is replaced by a 24-vac signal which is provided at P terminals AUX1 and AUX 2 (See Fig. 8.) This signal is present whenever the thermostat signal is present (heat pump heating, cooling and continuous blower modes). When the FK4A Fan oil is installed with an electronic air cleaner, use EA relay kit Part No. KFAI21A or a field supplied 24-vac relay. The EA relay kit consist of a 24-vac relay which mounts directly on the P bracket inside the fan coil using factory punched screw holes, 2 mounting screws, 2 pre-terminated wires for connection of relay coil to AUX1 and AUX2 terminals, 2 No. 16 AW stripped leads for connection of relay contacts for control of power to the EA, wire nuts, and wiring instructions. (See Fig. 8.) WHT EA PLU

6 If EA relay is field supplied, use field supplied wiring, terminations and wire per the EA wiring schematic. (See Fig. 8.) NTE: If the FK4A is installed with an air conditioner and electric heat is the primary heating device, a thermostat which turns on the output with a call for heat is required for air cleaning or humidification during heating mode. A corporate thermostat set to fan on with W option is recommended. HUMIDIFIE/HUMIDISTAT NNETINS Terminals HUM1 and HUM2 are provided for direct connection to the low-voltage control of a humidifier through a standard humidistat. These terminals are energized with 24vac when thermostat signal is present. (See Fig. 9.) Alternately, the 24-vac signal may be sourced from the W and terminal block connections. HUMIDISTAT APAILITY WITH STANDAD HUMIDISTAT NNETIN Latent capacities for systems using the FK4A Fan oil are better than average systems. If increased latent capacity is an application requirement, the field wiring terminal block provides connection terminals for use of standard humidistat. The FK4A Fan oil will detect humidistat contacts opening on increasing humidity and reduce its airflow to approximately 8 percent of nominal cooling mode airflow. This reduction will increase system latent capacity until humidity falls to a level which causes humidistat to close its contacts. When contacts. close, airflow will return to 1 percent of selected cooling airflow. To activate this mode, remove Jumper J1 and wire in a standard humidistat. (See Fig. 1.) EASY SELET AD TEMINAL HUM 1 () HUM 2 () 24-VA HUMIDIFIE WIIN T HUMIDIFIE A95317 EMVE JUMPE J1 D H HUMIDISTAT Fig. 9 Humidifier Wiring A95316 Fig. 1 Humidistat Wiring for De-Humidify Mode Table 5 Airflow Delivery hart Electric ing Modes FK4A MDEL SIZE 2, 3 4 UTD ELETI HEATE KW ANE APAITY TUH L NM HI L NM HI L NM HI L NM HI 18, * * * * * * 24, * * * * 3, * , , * * * * * * 3, * * * 36, , FK4A MDEL SIZE 5 6 UTD ELETI HEATE KW ANE APAITY TUH L NM HI L NM HI L NM HI L NM HI 3, * * * * * * 36, * * * 42, , , * * * * * * 42, * * * 48, , NTE: L, NM, and HI refer to the A/HP FM ADJUST selection. * er/system combination not recommended with resulting airflows. 6

7 FK4A MDEL SIZE UTD APAITY Table 6 Airflow Delivery in ooling Mode PEATIN MDE LIN 2-Speed Application Single-Speed Application High Speed Low Speed Nominal A/ ooling A/ ooling Dehumidity Nominal A/ ooling A/ ooling Dehumidity Nominal A/ ooling A/ ooling Dehumidity FAN NLY L/MED/HI / 35 / 525 2, / 44 / / 55 / / 66 / / 44 / / 55 / / 66 / / 77 / / 55 / / 66 / / 77 / / 88 / / 66 / / 77 / / 88 / / 11 / 175 NTE:The above airflows are the result of A/HP FM ADJUST select jumper set on NM. Airflow can be adjusted +15 percent or -1 percent by selecting HI or L respectively. Dry coil at 23v with 1-kw heater and filter installed. Airflows shown are at standard air conditions. (.75 lb/ft 3 at in.-hg) FK4A MDEL SIZE UTD APAITY Table 7 Airflow Delivery in ing Mode PEATIN MDE HEAT PUMP NLY HEATIN 2-Speed Application Single-Speed Application High Speed Low Speed omfort Efficiency omfort Efficiency omfort Efficiency FAN NLY L/MED/HI / 35 / 525 2, / 395 / / 52 / / 595 / / 415/ / 52 / / 595 / / 695 / / 52 / / 595 / / 695 / / 795 / / 595 / / 695 / / 795 / / 99 / 1575 NTE:The above airflows are the result of A/HP FM ADJUST select jumper set on NM. Airflow can be adjusted +15 percent or -1 percent by selecting HI or L respectively. Dry coil at 23v with 1-kw heater and filter installed. Airflows shown are at standard air conditions (.75 lb/ft 3 at in.-hg). 7

8 opyright 21 arrier orporation fk4a3si Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. ook 1 4 P 11 atalog No. 63FK-4A2 Printed in U.S.A. Form FK4A-3SI Pg eplaces: FK4A-2SI Tab