Installation Instructions Electric Heater Packages KFAEH -CIRCUIT GROUND LUG TERMINAL BLOCK MULTI-CIRCUIT GROUND LUG COOLING CONTROL PLATE ADAPTER PLATE (MUST BE REMOVED WHEN INSTALLING LARGE HEATER) BLOCK (24- AND 0-KW) CLIP LATCH COVER (OMITTED ON -KW) Fig. Installation of -, 24-, and 0-kw Model Heaters A9054 NOTE: Read the entire instruction manual before starting the installation. SAFETY CONSIDERATIONS Installing and servicing heating and air conditioning equipment can be hazardous due to system pressures and electrical components. Only trained personnel should install or service heating and air conditioning equipment. Untrained personnel can perform basic maintenance functions such as cleaning coils, or cleaning and replacing filters. All other operations should be performed by trained service personnel. When working on air conditioning equipment, observe precautions in the literature, on tags, and on labels attached to the unit. Form: AG-FAEH-0 Cancels: AG-FB4A-04 Printed in U.S.A. -94 Catalog No. 92-FA-EH
INSERT BOX TAB HERE -CIRCUIT GROUND LUG COVER PLATE OR KNOCKOUT BOX TAB DIMPLE BOX DUAL-CIRCUIT GROUND LUG HEATER/CUTOUT COVER COVER WIRE TIE (REMOVE ON LARGE FAN COILS) Fig. 2Installation of Fused Model Heater A905 GROUND LUG CIRCUIT GROUND LINE SIDE CONNECTION BLOWER SHELF FAN COIL COVER PLATE WIRE ROUTING LOAD SIDE MOUNTING BRACKET WIRES TO HEATER WIRE TIE (REMOVE ON LARGER UNITS) Fig. Installation of Circuit Breaker Model Heater A905 2
INSULATION # SCREWS SLIDE BEZEL FLANGES UNDER INSULATION BACK OF PANEL Fig. 4Installation of Bezel for Circuit Breaker Model Heater A902 Follow all safety codes. Wear safety glasses and work gloves. Have a fire extinguisher available. WARNING: Before beginning any installation or modification, be sure the main electrical disconnect switch is in the OFF position. TAG THE DISCONNECT SWITCH WITH A SUITABLE WARNING LABEL. Electrical shock can cause personal injury or death. INTRODUCTION This instruction describes the installation of KFAEH accessory heaters in 2 fan coil designs and in the FK4 Fan Coils. The first design found in products manufactured before April 994 (week 494), has a large Texas Instruments printed-circuit board (PCB) with low-voltage terminal board with fan connections on the terminal board. The second design, manufactured after March 994 (week 94), has a small PCB, pigtails, and a wire harness. NOTE: The manufacturing date is approximated. Examine each product and compare to the description above to determine which design is being modified. PROCEDURE INSTALL ELECTRIC HEATER ASSEMBLY INSTALLATION NOTE: Ensure heater coils are not deformed or damaged during heater installation.. Make sure power to unit is off. 2. Remove blower access panel of fan coil unit. CAUTION: Before installation of heater, the black and yellow pigtail leads must be removed from the fan coil PCB or wire harness to prevent possible damage to the product. Electrical power will be provided to the board through the heater circuit plug.. Disconnect 2 power wires (black and yellow pigtail leads) from PCB or wire harness and discard. Wires may be part of a plug assembly or attached to terminals L and L2. Remove cooling control plate from fan coil. For -, 24-, and 0-kw heaters, remove adapter plate. (See Fig..) 4. Insert heater assembly into front of fan coil so that element rods engage holes in heat shield. 5. Attach heater control plate to fan coil using 2 screws. For -, 24-, and 0-kw heater models, attach front of heater to fan deck using third screw. (See Fig..) PROCEDURE 2ATTACH BOX OR CIRCUIT BREAKER BOX. For 5- and 20-kw fused models: After installing heater assembly, attach fuse assembly to side of fan coil unit by inserting fuse box tab between insulation and to left side of unit and fan deck. Mount front of assembly to side flange with 2 screws provided. On fan coil units size 042 and larger, remove wire tie that shortens wire length between heater and fuses. Fuse cover is closed by engaging dimples in fuse box. (See Fig. 2.) 2. For 24- and 0-kw fused models: Fuse assembly is mounted on heater. Be sure fuse cover is closed by engaging clip latch on unit top panel. (See Fig..)
ELECTRIC HEATER PART NO. KFAEH00N0 KFAEH20C0 KFAEH020N05 KFAEH0C05 KFAEH00N0 KFAEH40C0 KFAEH040N0 KFAEH50C0 KFAEH050F5 KFAEH0C5 KFAEH0S5 KFAEH00F20 KFAEH70C20 KFAEH90S20 KFAEH09 KFAEH005 KFAEH090 KFAEH00F24 KFAEH0F0 KFAEH200S24 KFAEH20S0 Field convertible to phase. DESCRIPTION kw, Non-fused kw, Circuit Breaker 5 kw, Non-fused 5 kw, Circuit Breaker kw, Non-fused kw, Circuit Breaker 0 kw, Non-fused 0 kw, Circuit Breaker 5 kw, Fused 5 kw, Circuit Breaker 5 kw, Fused (CSA) 20 kw, Fused 20 kw, Circuit Breaker 20 kw, Fused (CSA) 9 kw, Non-fused 5 kw, Non-fused kw, Non-fused 24 kw, Fused 0 kw, Fused 24 kw, Fused (CSA) 0 kw, Fused (CSA) Table Accessory Heater Usage MODEL FA, FB Phase MODEL FC MODEL FH MODEL FK 0, 024 024 00 A002 0-0 0-0 00, 002 0-070 024-070 00-004 0-070 024-070 00-004 024-070 024-070 00-004 00-070 00-070 002-004 Phase Only 0-070 042-070 Phase, Factory Shipped 0-070 042-070 002-004 00, 004 04-070 04-070 00, 004 A002, A00 B00, B00 A002-00 B00-00 A002-00 B00-00 A002-00 B00-00 A002-00 B00-00 A002-00, B00-00 A002-00, B00-00 A002-00, B00-00 A005, A00 B00 Table 2FK4A Minimum CFM for Electric Heater Application FK FAN COIL HEATER KW 5 9 0 5 20 24 0 002 00 00 970 970 970 040 004 225 225 225 225 005 400 400 400 400 400 400 00 750 750 750 750 750 750 Refer to unit Installation Instructions to select motor speed. CAUTION: injury or death. Ensure fuse box is closed before power is turned to ON position. Electrical shock may cause personal. For - through 20-kw circuit breaker models: After installing heater assembly, attach circuit breaker assembly to unit with screws provided. (See Fig..) On fan coil units size 042 and larger, remove wire tie that shortens wire length between heater and circuit breaker assembly to allow mounting of circuit breaker assembly. (See Fig..) Circuit breaker models require a bezel be installed in unit door to provide safe access to circuit breakers. Bezel mounts on outside of door with 2 No. screws provided. (See Fig. 4.) PROCEDURE MAKE ELECTRICAL CONNECTIONS Refer to unit instructions for recommended wiring procedures. Install wiring in accordance with all applicable local and national codes. (See Table.) Connect heater wiring harness plug to receptacle on PCB or wire harness. A positive connection must be made between plug and receptacle. Plug will interlock with receptacle when properly seated. Harness contains both 24-v control and high-voltage wiring. NOTE: s with or without electric heaters require a minimum CFM. Refer to unit wiring label to ensure the fan speed selected with electric heaters is equal to or greater than the minimum fan speed indicated. The minimum CFM for cooling is determined by the outdoor unit requirements. Use the higher of the 2 for year-round operation. A. Wire 24-v Control Systems. Connections to unit Use No. AWG color-coded, insulated (5 C minimum) wire to make the low-voltage connections between the thermostat, fan coil unit, and outdoor unit. If the thermostat is located more than 00 ft from the unit (as measured along the low-voltage wire), use No. AWG color-coded, insulated (5 C minimum) wire. All wiring must be separated from line voltage power leads. Refer to outdoor unit wiring instructions for additional wiring procedure recommendations. 2. Transformer 4
ELECTRIC HEATER ELECTRICAL DATA BRANCH CIRCUIT HEATER PART NO. KFAEH00N0 KFAEH20C0 KFAEH020N05 KFAEH0C05 KFAEH00N0 KFAEH40N0 KFAEH09 KFAEH040N0 KFAEH50C0 KFAEH050F5 KFAEH0S5 KFAEH0C5 KFAEH005 KFAEH090 KFAEH00F20 KFAEH90S20 KFAEH70C20 KFAEH00F24 KFAEH200S24 KFAEH0F0 KFAEH20S0 KW 240V 20V 2. 2. 5. 5..0.0 9. 0 7.5 0 7.5 5. 5. 5. 5..5 20 5.0 20 5.0 20 5.0 24.0 24.0 24.0 24.0 0 22.5 0 22.5 0 22.5 0 22.5 PHASE INTERNAL CIRCUIT PROTECTION CIRCUIT 0.9/2.0 0.9/2.0./20.0./20.0 2.9/2.0 2.9/2.0./20..2/40.0.2/40.0 54.2/59.9 54.2/59.9./4. 7./4.5 72./79.9 72./79.9 50./55.4.7/95.9 50./55.4.7/95.9 2./9.2 09.0/ 20.0 2./9.2 09.0/ 20.0 HEATER AMPS 20/20V L, L2 L, L4.2/40.0.2/40.0.2/40.0.2/40.0.2/40.0.2/40.0./20.0./20.0./20.0.2/40.0.2/40.0.2/40.0 CIRCUIT L, L2 L, L4.2/7.5.2/7.5 2.7/29.0 2.7/29.0 4.0/4.9 4.0/4.9 0.4/2.9 52.2/5.9 52.2/5.9 74.7/. 74.7/. 4.0/50.2 5.9/5. 97./0. 97./0. 9.5/7.2 /27.0 9.5/7.2 /27.0 5.2/9.4 4/ 57.0 5.2/9.4 4/ 57.0 MIN AMPACITY 20/20V 52.2/5.9 52.2/5.9 52.2/5.9 52.2/5.9 52.2/5.9 52.2/5.9 22.7/25.0 22.7/25.0 22.7/25.0 45./50.0 45./50.0 45./50.0 MIN WIRE (AWG) 20/20V CIRCUIT L, L2 L, L4 2 2 0 0 4 / /2 /2 4 4 0/00 40/00 4 0 0 0 MIN GND WIRE 20/20V CIRCUIT L, L2 L, L4 2 2 0 0 0 0 0 0 0 0 0 0/0 0/0 0/0 0/0 0/0 0/0 0/0 0/0 0/0 0/0 0/0 0/0 /CKT BKR AMPS 20/20V CIRCUIT L, L2 L, L4 20 20 25/0 25/0 45/50 45/50 5/5 0/0 0/0 0/90 0/90 50/50 0/0 00/0 00/0 70/0 25/50 70/0 25/50 90/00 50/75 90/00 50/75 0/0 0/0 0/0 0/0 0/0 0/0 25/25 25/25 25/25 50/50 50/50 50/50 MAX WIRE LENGTH 20/20V (FT) CIRCUIT L, L2 L, L4 /5 /5 /2 /2 /2 /2 0/ 7/79 7/79 /7 /7 7/2 94/95 4/0 4/0 /7 2/ /7 2/ 20/2 4/45 20/2 4/45 7/79 7/79 7/79 7/79 7/79 7/79 7/79 7/79 7/79 5/5 5/5 5/5 FIELD MULTIPOINT WIRING OF 24- AND 0-KW PHASE HEATER PART NO. KFAEH00F24 KFAEH200S24 KW HEATER AMPS 20/20V MIN AMPACITY 20/20V MIN WIRE (AWG) 20/20V /CKT BKR AMPS 20/20V MAX WIRE LENGTH 20/20V (FT) 240V 20V PHASE L/L2 L/L4 L5/L L/L2 L/L4 L5/L L/L2 L/L4 L5/L L/L2 L/L4 L5/L L/L2 L/L4 L5/L 24 2.9/2.0 2.9/2.0 2.9/2.0 4.0/4.9./40.0./40.0 MIN GND WIRE 20/20V 0 45/50 40/45 40/45 /2 7/7 7/7 KFAEH0F0 KFAEH20S0 0 22.5.2/40.0.2/40.0.2/40.0 52.2/5.9 45./50.0 45./50.0 0 0/0 50/0 50/0 7/79 5/5 5/5 Circuit Breaker Includes blower motor amps of largest fan coil used with heater. CSA fused with single-point wiring adaptor. Copper wire must be used. If other than uncoated (non-plated), 75 C ambient, copper wire (solid wire for 0 AWG and smaller, stranded wire for larger than 0 AWG) is used, consult applicable tables of the National Electric Code (ANSI/NFPA 70). Length shown is as measured way along wire path between unit and service panel for a voltage drop not to exceed 2%. The 24- and 0-kw heaters are convertible to -phase, single or multiple supply circuit. NOTE: Single circuit application of F5 and F20 heaters requires single-point wiring kit accessory. Table Electric Heater Data A 5
SECONDARY PRIMARY RED C BRN R BLU RED BLK DC AUX AUX2 F4 F T T2 T L2 EAC2 L EAC F2 F Fig. 5Connection of Transformer Before April 994 A954 SECONDARY BRN RED C 2 0 2 0 YEL BLK PRIMARY Transformer is factory wired for 20-v operation. For 20-v applications (manufactured before week 494), connect transformer red primary lead to T2 and connect blue primary lead to T. (See Fig. 5.) To convert to 20v on products manufactured after week 94, disconnect the black wire on the transformer 20-v terminal and reconnect it to the 20-v terminal. (See Fig..) The secondary circuit of the transformer is protected by a 5-amp fuse mounted on the PCB in both designs. CAUTION: If W2, W, and E are individually connected on any sequencer heater (24, 0, kw), as with outdoor thermostats or any other situation, an emergency heat relay must be used. This relay is in kit KHAOT020SEC and is normally used with kit KHAOT00FST for 2 outdoor thermostat systems.. Heater staging Fig. Connection of Transformer After March 994 Both designs are shipped circuited for single-stage operation. On products manufactured before week 494, staging or outdoor thermostats require breaking tabs off the PCB as needed and the installation of an accessory outdoor thermostat kit. (See Fig. 7.) On products manufactured after week 94, use outdoor thermostat kit KHAOT020SECT for 2-stage operation, and use both kit KHAOT020SEC and KHAOT00FST for -stage operation. When 2-stages are desired, cut W at the W2 wire nut, strip and reconnect per the thermostat kit instruction. (See Fig..) a. The -, 5-, - and 0-kw heaters are single stage only. b. The 9-, 5-, and 20-kw heaters are adaptable for 2-stage operation. c. The -, -24, and 0-kw heaters are adaptable for up to -stage operation. A9407
L R C G Y E O W2 W PRINTED CIRCUIT BOARD W2-W JUMPER 2ND STAGE W2-E JUMPER RD STAGE 5-AMP 24-VOLT Fig. 7Jumper Tabs on Printed-Circuit Board A952 B. Power Connections NOTE: Heater supply circuit wire size and overcurrent protection must comply with National Electrical Code (NEC) and UL branch circuit requirements. (See Table.) Wires and overcurrent protection, integral to the heater, are not required to meet branch circuit requirements. Internal circuit protection of 0 amps (maximum) is acceptable.. Unprotected heaters: a. The - through 0-kw single phase and 9-, 5-, and -kw -phase heaters can be wired for single-supply circuit only. Supply circuit connects to heater pigtail leads (terminal block on -kw heaters). b. The - through 0-kw single-phase heaters can use a separate field-installed, factory-authorized disconnect kit which installs in fan coil. 2. Circuit breaker heaters: a. The - through 0-kw heaters can be wired for single-supply circuit only. b. The 5- and 20-kw heaters can be wired for dual-supply circuits only.. Fused heaters: a. The 5- and 20-kw heaters can be wired for single- or dual-supply circuits. Single-supply circuit wiring requires a factory-authorized, single-point adapter kit. Canadian models are factory shipped with single-point adapter kit for single-supply circuits. b. The 24- and 0-kw heaters can be wired for single- or multiple-supply circuits. Heaters are factory wired for single circuit phase. To convert heaters to single circuit single phase, disconnect yellow lead from L and connect to L. Disconnect black lead from L and connect to L2. To convert heaters to multiple-supply circuit single phase, remove and discard leads between single-circuit terminal block and fuse block. Remove and discard single-circuit terminal block. Attach L through L power leads as indicated on label next to fuse block. C. Ground Connections WARNING: According to NEC, ANSI/NFPA 70, and local codes, the cabinet must have a uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes. Failure to follow this warning could result in an electric shock, fire, or death.. For unprotected or single-circuit heaters, equipment ground connection is provided on fan coil unit. (See Fig. or 2.) 2. For 5- and 20-kw circuit breaker heaters, an additional ground lug is provided on circuit breaker mounting bracket for dual-circuit grounding. (See Fig..). For 5- and 20-kw fused heaters, an additional ground lug is provided on fuse mounting bracket for dual-circuit grounding. (See Fig. 2.) 4. For 24- and 0-kw fused heaters, 2 additional ground lugs are provided for single-phase, multicircuit wiring. (See Fig..) D. Select Fan Speeds. On products manufactured before week 4 of 994, the factory-selected speed tap is connected to terminal F4. Unused fan speed taps are connected to terminals F2 and F. (See Table 4.) Select desired speed and attach to terminal F4. Attach unused speed tap to terminals F2 and F. 2. On products manufactured after week of 994, speed tap selection is done at the fan relay. To change motor speeds, disconnect the fan lead on the relay and replace with the motor speed tap desired. Save the insulating cap and replace on the motor lead that was removed from the relay. Refer to fan coil Installation Instructions for further clarification of speed tap selections. (See Fig..) 7
PCB FAN RELAY SPADE INSULATING CAP (2) MOTOR SPEED TAP LEADS 2 OR SPEED TAP TERMINAL COMMON YELLOW WRAPPER FAN DECK Fig. Motor Speed Tap and Fan Relay A940 PROCEDURE 4ATTACH WIRING DIAGRAM AND RATING LABEL Two wiring diagrams are included to cover both fan coil control designs. Select the proper label for the control design in the fan coil and attach it to the blower housing over the existing wiring label. On model FA, FB, FC, and FH units only, completely covering old wiring diagram label. Do not cover wiring label on model FK. Instead attach new heater rating label over existing electrical information rating label located on front access door of fan coil unit. (See Fig. 9.) PROCEDURE 5VERIFY INSTALLATION After completion of heater installation, check wiring to ensure proper connections and routings have been made. Ensure all electrical covers are in place and proper labels have been applied. Reinstall blower access door before turning unit power on.
UNIT RATING LABEL ON DOOR HEATER LABEL FROM KIT Fig. 9Heater Rating Label Location A90 Table 4Color Code for Motor Lead Wires FA, FB, FC, FH s MOTOR SPEED TAP Common High Medium Low WIRE COLOR Yellow Black Blue (Factory selected) Red or Blue 9
FAN UNIT 00, 002 OUTDOOR UNIT CAPACITY BTUH,000 24,000 0,000,000 Table 5FK4B Airflow Delivery ELECTRIC HEATER KW RANGE 0-5 0-0 0-5 0-20 LO MED HI LO MED HI LO MED HI LO MED HI 70 70 775 970 70 70 70 0 00 00 70 70 90 40 0 0 970 70 0 0 00 00 0 90 40 90 90 970 70 90 90 00 00 90 90 90 40 70 70 70 70 70 00 70 90 40 Fan Size 004 Outdoor Capacity Btuh,000 24,000 0,000,000 Electric Heater kw Range 0-5 0-5 0-5 0-20 LO MED HI LO MED HI LO MED HI LO MED HI 25 25 90 00 25 25 775 990 200 25 25 50 090 20 725 725 90 00 725 775 990 200 725 50 090 20 90 00 990 200 090 20 075 075 00 075 075 200 075 090 20 Fan Size 00 005 Outdoor Capacity Btuh 24,000 0,000,000 42,000 24,000 0,000,000 42,000 Electric Heater kw Range 0-5 0-0 0-0 0-20 LO MED HI LO MED HI LO MED HI LO MED HI 75 225 75 775 950 25 295 790 975 5 55 75 55 250 440 70 070 20 490 75 940 55 75 55 225 950 25 295 975 5 55 250 440 070 20 490 75 55 225 25 25 25 295 55 25 25 250 440 070 20 490 25 55 75 55 225 225 225 0 0 0 225 225 55 0 0 440 225 20 490 0 75 55 Fan Size 00 Outdoor Capacity Btuh,000 42,000 4,000 0,000 Electric Heater kw Range 0-0 0-20 0-20 0-0 LO MED HI LO MED HI LO MED HI LO MED HI 00 25 45 755 225 40 0 950 50 575 795 245 50 50 50 45 755 50 50 40 0 950 50 50 575 795 245 525 525 525 755 Airflow not recommended for heater/system size. NOTES: LO, MED, and HI refer to AC/HP CFM ADJUST jumper selection. HEATER ONLY airflows are not adjustable by the AC/HP CFM ADJUST SELECT jumper. Airflows shown are independent of external static pressure up to 0.5-in. wc and are at standard air conditions. FAN COIL 00, 002, 004 00, 005 00 525 525 0 950 Table FK4B Minimum CFM for Electric Heater Application HEAT PUMP UNIT 0 024 00 0 024 00 0 042 0 042 04 00 HEATER KW 525 575 795 245 750 750 755 750 750 950 5, 9, 0 5, 20 24,0 25 25 5 075 75 25 775 5 075 225 00 25 45 750 725 5 075 225 225 225 50 50 45 750 075 075 225 225 225 50 50 45 750 NOTES: Air conditioner with electric heater application. These airflows are minimum acceptable airflows as UL listed. Actual airflow delivered will be per the airflow delivery chart for Electric Heating Modes. 750 750 750 750 795 245 994 RESCO P.O. Box 7, Indianapolis, IN 420 4400r 0 Book/Tab /c, 4/2c Catalog No. 92-FA-EH