SERVICE MANUAL - Refripartes
SERVICE MANUALRESIDENTIAL FAN COIL UNITSFA4, FB4,FD3, FE4,FG3, FH4,FV4, FX4,FC4,FF1,FK4,40FKTABLE OF CONTENTSPageSAFETY CONSIDERATIONS.2INTRODUCTION.2UNIT IDENTIFICATION.2FAN COIL DESCRIPTION & TROUBLESHOOTING .2 - 25FK4B.2 - 11FV4A/FV4B/FK4C/FK4D/40FK .11 - 20FE4A.20 - 25CARE & MAINTENANCE .25 - 28FF1A/FF1V/FF1C SERVICE & TROUBLESHOOTING .28 - 32FD3A SERVICE & TROUBLESHOOTING .32 - 35FG3A SERVICE & TROUBLESHOOTING .35 - 36CIRCUIT BOARD FUNCTION & TROUBLESHOOTING .36 - 56FA4, FB4, FC4, FX4 Smart Heat Circuit Board (PCB).36 - 42FA4, FB4, FC4, FF1, FH4, FX4, CES013003-00 and 01 (HK61EA002) PCB.42 - 45HK61GA001 and 003 PCB.45 - 56ELECTRIC HEATER FUNCTION AND TROUBLESHOOTING.56 - 58THERMOSTATIC EXPANSION VALVES (TXV).58 - 59COIL AND CONDENSATE PAN REMOVAL & REPLACEMENT .59 - 63FOR FV/FA/FB/FC/FK FAN COILS .59 - 61FOR FX4 AND FV4 FAN COILS.61 - 63PURON QUICK REFERENCE GUIDE .64A98023Fig. 1—Typical Fan CoilForm:F-6SMCancels:F-5SM / SM03-5Printed in U.S.A.02-05Catalog No.03FA-4A6
This symbol indicates a change since the last issue.SAFETY CONSIDERATIONSImproper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which maycause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance.The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual installationinstructions packaged with the kits or accessories for detailed information.Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Readthese instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and National Electrical Code(NEC) for special installation requirements.It is important to recognize safety information. This is the safety-alert symbol . When you see this symbol on the unit or in instructions andmanuals, be alert to the potential for personal injury.Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies themost serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury ordeath. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage.WARNING: UNIT OPERATION AND SAFETY HAZARDFailure to follow this caution could result in personal injury or possible equipment damage.Puron (R-410A) systems operate at higher pressures than R-22 systems. Do not use R-22 service equipment or components onR-410A equipment. Ensure service equipment is rated for R-410A.INTRODUCTIONThe "F" series fan coil units are designed for flexibility in a variety of applications, meeting upflow, horizontal, or downflow requirements. Unitsare available in 1-1/2 through 5 ton nominal cooling capacities. Factory-authorized, field-installed electric heater packages are available in 3through 30 kilowatts.WARNING: ELECTRICAL SHOCK HAZARDFailure to follow this warning could result in personal injury or possible equipment damage.Before installing or servicing fan coil, always turn off all power to unit. There may be more than 1 disconnect switch. Turn off accessoryheater power if applicable.UNIT IDENTIFICATIONThe 16 position numbering chart allows identification of all available fan coil units. (See Fig. 2.)FAN COIL DESCRIPTIONAND TROUBLESHOOTINGFK4BThe FK4B has an integrated control and motor (ECM/ECM/ICM) and special circuit board.Setting up desired airflow on the FK4B is obtained by the selections made on Easy Select circuit board. The motor delivers requested airflowas defined by signals received from Easy Select Board and its internal programming. The major difference is that the FK4B motor reacts to changesin system static pressures to maintain constant airflow.Unlike conventional fan coils where static pressure affects airflow, the FK4B is a constant airflow unit. The blower delivers requested airflow upto about 0.7 in. of static pressure. The motor is pre-programmed and contains airflows for all modes of operation. Blower characteristics (airflow,torque, and speed-vs-static pressure) are known from laboratory testing. If any 3 characteristics are known, the fourth is defined.Requested airflow is known because of Easy Select board configuration and thermostat signals. Torque is known because it is directly related toarmature current which is measured by motor control. Speed is measured from its generated back EMF. This information is entered into anexpression which calculates torque from speed and airflow numbers. If calculation does not match stored blower characteristics, torque is adjustedevery 0.8 seconds until agreement is reached. The unit does not directly measure static pressure, but does react to a change in static to maintainconstant airflow.PROCEDURE 1—INTEGRATED CONTROLS AND MOTOR - FK4BThe motor is similar to the ECM/ICM1 used in FK4A series units, but cannot be used as a replacement without some modification to FK4A unit.The electronics of motor are built into rear of motor, deriving the name ECM/ICM. (See Fig. 3.)An ECM/ECM/ICM is first fed high voltage AC power through the 5-pin connector. 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 communicationpulses determines motor speed. The rotor is permanently magnetized.An ECM/ICM is powered with high voltage at all times. The motor will not run with high voltage alone. Low voltage must be applied to controlplug to run motor.PROCEDURE 2—PCB LAYOUT AND DESCRIPTION - FK4BNOTE: Layout of actual PCB is depicted in Fig. 4 and 5.The control is a single PCB which interfaces a variable-speed motor with other system components.Power for system is supplied from a 230-vac, 60-Hz line. Class 2 voltage (24 vac nom), used for thermostat connections, is derived from atransformer located in close proximity to control. The primary and secondary of transformer are connected to control board. The 24-vac secondarycircuit includes a socket, soldered into circuit at SEC2, to receive a 5-amp automotive-type fuse.—2—
—3—47895th Position—Fan CoilA - 115-1-60N - 208/230-1-60S - 230-1-50Electrical6th Position—Fan CoilA - StandardB - ModularF - Single PieceCoil Type6VariationsA - Common UnitA - OriginalVariations15 16A - Standard UnitMinor Series14Heating Size (KW)13A9811410th, 11th, 12th Positions—Fan Coil005010Etc.018 (11 2 Ton)024 (2 Ton)001 (Multi Tons)002 (Multi Tons)Etc.Cooling Size10 11 12Fig. 2—Fan Coil 16-Position Numbering SystemA - OriginalB - Second Series52nd Position—Fan CoilA - RNCB - StandardC - DeluxeD - Furred in, CasedE - Furred in, UncasedF - Through the WallG - CommercialH - Standard Electric FurnaceJ - Standard Hot WaterK - ICM Motor, High EfficiencyV - ICM Motor, Puron R-410AX - Standard, Puron R-410A1 - Upflow2 - Downflow3 - Horizontal4 - Multipoise5 - Upflow/DownflowAirflow3Major Series2Unit SpecificsF - Fan CoilType of Unit1
DO NOT REMOVEOPTIONAL SAFETY GROUND12345POWER CONNECTOR9 10 11 12 13 14 15 161 2 3 4 5 6 7 8CONTROL CONNECTOROPTIONALSAFETYGROUNDDRAINHOLEA94079Fig. 3—FK4B, FK4C and FV4A motor MotorLOW VOLTAGETERMINAL BLOCKEASY SELECTAUXHEAT5 -EFFCFMADJUSTMEDHIORNLOY/Y2R1BLKDELAYAC/HP 1REDCEBD430023–01GRYMOLEX 7-PINCONNECTOR (1)PRINTEDCIRCUITBOARDCFS1R3MOTORW2-E JUMPER3RD STAGEW2W3W2-W3 JUMPER2ND UX1JW4D3HUM2AUX224VAC3 16-IN.MALEFASTONAMP–TYP(21) PLCSXFORMMOTOR1 MP–TYP(9) PLCSP1D8 D7 D5D6T3D1CES0130007–00AMP 12-PIN MATE-N-LOCKCONNECTOR (1)A94076Fig. 4—Easy Select Board (FK4B)Connection to heater panel is made through 12-circuit connector P1. Connections to thermostat are made at screw terminals. Line voltage for motoris made through 12-circuit connector P1. Eighteen quick-connect terminals comprise field select taps for motor.—4—
ST1HIGH 3M1JW39T1T2M2D2T3R3SEC11K T17G1234567R21K 2WST15Y/Y2W/W1GC1C2RY/Y2Y1D10REDD11QC19R11K 2W5 – 301200ST14Y1ST11LST1O3AUX. HEATRANGEQC1AC/HPSIZEQC5AC/HPTYPEQC9AC/HPCFM TRIMQC12AC/HPDELAY5 – M.HP–EFF.QC10LOWONOFFQC155 – A94077Fig. 5—Easy Select Board Circuitry (FK4B)Fuse Data: 5-amp automotive-type ATC/ATO (tan)32v200 percent current opening time of 5 sec maximumA. Electrical ConnectionsEighteen 0.187-in quick-connect terminals are used to provide programming selections for operating modes of motor. The 5 selection modes arelisted below. For additional information, refer to Easy Select Configuration Taps section.AUX Heat Range—(Violet Wire)AC/HP Size—(Blue Wire)Type—(Orange Wire)AC/HP CFM Adjust—(Black Wire)AC/HP Time Delay—(Grey Wire)PROCEDURE 3—SEQUENCE OF OPERATION - FK4BA.Continuous Fan ModeThe thermostat closes circuit R to G. The G signal is sent directly to motor.B. Cooling Mode—Single Speed or 2-Speed HighThermostat closes circuits R to Y/Y2 and R to O (heat pump only) for single speed. A circuit from R to Y1 is also required for 2-speed high. TheY/Y2 signal is sent directly to motor.C.Cooling Mode—Two-Speed LowThermostat closes circuits R to Y1 and R to O (heat pump only). The Y1 signal is sent directly to motor.D.Electric Heat Heating ModeThermostat closes circuit R to W2, W3, or E.The terminal block positions W2, W3, and E are tied together by jumpers JW1 and JW2. These jumpers are provided for field staging of electricheater banks through use of thermostats. When staging is a requirement, installer cuts jumpers and wires in thermostats as is the common practicewith other fan coils. To ensure motor operation if any 1 of the inputs is energized, the 3 electric heater inputs are also interlocked through diodesD1, D2, and D3 to motor W input.E.Heat Pump Heating Mode—Single Speed or 2-Speed HighThermostat closes circuit R to Y/Y2 for single speed. A circuit from R to Y1 is also required for 2-speed high. The Y/Y2 signal is sent directlyto motor.F.Heat Pump Heating Mode—Two-Speed LowThermostat closes R to Y1. The Y1 signal is sent directly to motor.—5—
Table 1—Male/Female Quick-Connect Terminals (FK4B)Size Female Size Male0.250 X 0.032M2T3T2SEC10.187 X 0.032SEC2HUM1HUM2AUX1AUX2M1T1REDDescriptionMotor line voltage connection (230 vac 60 Hz)Transformer line voltage connection (230 vac 60 Hz)Transformer tap storage terminal for 208-vac leadSecondary connection from transformer (24 vac)This connection is common to chassis ground through eyelet marked GROUND SCREW REQUIRED.Secondary connection from transformer (24 vac)Low voltage ground for humidifier option (24 vdc)Low voltage output for humidifier option (24 vdc)Low voltage ground for auxiliary option (24 vdc)Low voltage output for auxiliary option (24 vdc)Common connection to blower motorCommon connection for transformerCommon to R screw terminal and SEC2Table 2—Connections on FK4B Screw Terminal ction for W2 signal from thermostatConnection for W3 signal from outdoor thermostatConnection for E signal from thermostatConnection for Y signal from thermostatConnection for G signal from thermostatConnection for O signal from thermostatThis connection is a field termination for use in connecting L lines of thermostat and outdoor unit together. There is no connection of this terminal with control circuity.Connection for low-speed compressor operationConnection for R signal to thermostat (24 vac)Connection for C terminal to thermostat (24 vac common)G. Heat Pump Heating With Auxiliary Electric HeatThermostat closes circuits R to Y/Y2 and/or R to Y1 with R to W2, W3, or E (and R to O in the case of defrost).See previously described modes for circuit paths.In the event that electric heating is called for by thermostat while heat pump is also operating in either heating or defrost mode, electric heatingsignal will appear at motor connector pin 1 as described previously. If necessary, the motor will modify its airflow output to provide an airflowwhich is defined as safe for operation of electric heater.H. CFM Select Configuration TapsThe CFM Select taps are used by installer to configure system. The motor is capable of discerning wave shapes on some of its inputs and usesthis capability to modify its operation to a pre-programmed table of airflows and can be modified in response to other inputs such as the need forde-humidification.I. Motor Control PowerThe motor control power is supplied from R circuit through printed circuit runs to motor control connector pin 6, through motor control harnessto motor. The C side of low-voltage control power circuit is connected by printed circuit runs to motor connector pins 4 and 5, then through motorcontrol harness to motor.J. Low-Voltage Circuit Fusing and ReferenceThe low-voltage circuit is fused by a board-mounted 5-amp automotive-type fuse placed in series with transformer SEC2 and R circuit. The Ccircuit of transformer is referenced to chassis ground through a printed circuit run at SEC1 connected to metal standoff marked GROUND SCREWREQUIRED.NOTE: A ground screw must be in place or erratic motor operation can result.K. Transformer, Motor, and Electric HeaterPower ConnectionsThe high-voltage (230-vac) power input to board is provided through electric heater connector pins 7 and 9. The high voltage is then connectedthrough printed circuit runs to motor power connections M1 and M2 and transformer power connections T1 and T3. Transformer connection T2is a dummy terminal used for unused primary power lead. The transformer secondary connections are made at SEC1 and SEC2 connectors.—6—
Table 3—Connections and Connector ctor12-PinPin No.Pin 1Pin 2Pin 3Pin 4Pin 5Pin 6Pin 7Pin 8Pin 9Pin 10Pin 11Pin 127-Pin Header Pin 1Pin 2Pin 3Pin 4Pin 5Pin 6Pin 7DescriptionCommon to E screw terminalCommon to W2 screw terminalCommon to C screw terminal, SEC1 terminal, and chassis groundCommon to C screw terminal, SEC1 terminal, and chassis groundNo connectionCommon to W3 screw terminalCommon to M2 and T3 quick-connects, 230 vac inputNo connectionCommon to M1 and T1 quick-connects, 230 vac inputNo connectionNo connectionNo connectionDiode OR output of E or W3 or W2 thermostat signalsThermostat G signalCommon to C, SEC1, and chassis groundCommon to C, SEC1, and chassis groundCommon to R and SEC2 (via 5-amp fuse)Thermostat Y/Y2 signalThermostat Y1 signalPROCEDURE 4—EASY SELECT CONFIGURATION TAPS - FK4BThe Easy Select taps are used by installer to configure system. The motor uses selected taps to modify its operation to a pre-programmed tableof airflows. Airflows are based on system size or mode of operation and those airflows are modified in response to other inputs such as the needfor de-humidification.(See Fig. 4.)The FK4B Fan Coil must be configured to operate properly with system components with which it is installed. To successfully configure a basicsystem (see information printed on circuit board located next to select pins), move the 5 select wires to pins which match components used.A. Auxiliary Heat RangeThe installer must select the auxiliary heat airflow approved for application with kw size heater installed. If no heater is installed, skip this step.Each select pin is marked with a range of heaters for which airflow (also marked) is approved. For increased comfort select the narrowest kw rangematching the heater size, for example, 0-10 for a 10-kw heater. This airflow must be greater than the minimum CFM for electric heater applicationwith the size system installed for safe and continuous operation. Note that airflow marked is the airflow which will be supplied in emergency heatmode and heating mode on air conditioners when electric heat is primary heating source. To ensure safe heater operation in heat pump heatingmode when electric heaters are energized, the motor will run the higher of heat pump efficiency airflow and electric heater airflow. The factoryselection is largest heater range approved. (See Fig. 4.)B. AC/HP SizeThe factory setting for air conditioner or heat pump size is largest unit meant for application with model of fan coil purchased. The installer needsto select air conditioner or heat
SERVICE MANUAL FA4, FB4, FC4, FD3, FE4, FF1, FG3, FH4, FK4, FV4, FX4, 40FK RESIDENTIAL FAN COIL UNITS Form: F-6SM Cancels: F-5SM / SM03-5 Printed in U.S.A. 02-05 Catalog No. 03FA-4A6. This symbol indicates a change since the last issue. SAFETY CONSIDERATIONS
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