Installation and Start-Up Instructions
Contents
1. factory shipped inset c Remove filler plate A and install air splitter B in place of filler plate d Install filler plate A as shown in horizontal right application e Remove condensate troughs C and install on opposite tube sheets f Install hose onto plastic spout Install horizontal pan on right side of coil assembly Slide coil assembly into casing Be sure coil bracket on each corner of vertical pan engages coil support rails pace eae A COIL HORIZONTAL LEFT SECONDARY PRIMARY FIELD DRAIN SUPPLIED DRAIN HANGING STRAPS 24 IN FRONT SERVICE CLEARANCE FULL FACE OF UNIT LOW VOLT ENTRY OPTIONS 1 3 4 IN E FILTER ACCESS CLEARANCE PRIMARY e DRAIN SECONDARY POWER DRAIN ENTRY OPTIONS A95292 Fig 4 Slope Coil in Horizontal Left Application COIL MOUNTING BLOWER U ASSEMBLY DYAN COIL SUPPORT RAIL SLOPE COIL SKI Ne LIS TXV SENSING BULB MUST BE DRAINEAN REFRIGERANT PRIMARY DRAIN INSULATED CONNECTIONS OVERFLOW HOLE SECONDARY DRAIN A99033 Fig 5 Slope Coil in Horizontal Right Application 9 Reinstall 2 snap in clips to correctly position and secure coil assembly in unit Be sure clip with large offset is used on right side of unit to secure horizontal pan 10 Remove 2 oval coil access panel plugs and reinstall into holes on left side of coil access panel and fitting panel 11 Remov2. COOL STAGE 1 24 VAC HOT RF REMOVE J1 JUMPER FOR DEHUMIDIFY MODES COOL STAGE 1 COOL STAGE 2 24vac HOT R F DEHUMIDIFY DEHUMIDIFY 24 VAC COMM 24 VAC COMM e C HUMIDIFY PR HUMIDIFY ROOFER 53 24 UN N A nA B Fa trey R OUTDOOR ada Oon OUTDOOR OUTDOOR SENSON OUTDOOR SENOR SENSO SENSO CONNECTIONI 94 TTT TTT TTT TTT CONNECTION S2 T rCrrnr rrr A98477 A98478 Fig 7 FK4C Fan Coil Wiring with 1 Speed Air Conditioner Fig 8 FK4C Fan Coil Wiring with 2 Speed Air Conditioner All units are shipped with power plug and stripped leads for connection of field wiring to units without electric heat 1 Connect 208 230v power leads from field disconnect to yellow and black stripped leads 2 Connect ground wire to unit ground lug 3 If unit contains accessory electric heater remove and discard power plug from fan coil and connect male plug from heater to female plug from unit wiring harness See Electric Heater Installation Instructions B 24 V Control System Connections to Unit Printed Circuit Board PCB Refer to unit wiring instructions for recommended wiring procedures Use No 18 AWG color coded insulated 35 C minimum wires to make low voltage connections between thermostat and unit If thermostat is located more than 100 ft from unit as measured along the low voltage wires use No 16 AWG color coded insulated 35 C minimum wires PCB is circuited for single s
3. ENH CONTINUOUS FAN Select desired speed 2 Install heater with Intelligent Heat Staging and remove W Jumper J2 except when using 5 8 or 1 kw heater 3 Remove Jumper J1 to activate all dehumidify modes Y 4 Complete wiring and install outdoor temperature sensor according to Installation Instructions THERMIDISTAT CONTROL SETTINGS G 1 Set DIP Switches Set the dip switches back of Thermidistat AUX HEAT KW CFM 0 30 020 O10 05 A M 1075 875 725 625 VIO li li i li AC HP SIZE M 036 030 024 018 maJ aw gt gt Oas AAAA x lalala SYSTEM TYPE M AC HP COMFORT HP EFF C 8 8 8 AC HP CFM ADJUST M NOM LO HI D Bk 8 8 8 O Control Board appropriately for specific system being installed ON OFF DELAY 2 Thermidistat Control Configurations C See Thermidistat Control Installation Instructions for detailed description e Option 5 Variable Speed Motors set to ON pad peut e Option 7 Super Dehumidify set to ON e Option 9 Intelligent Heat set to ON if installing with AUX2 HUM2 CEBD430226 01B_CESS430226 01B 2 5 a single speed heat pump 600000000000 24VAG e Option 12 Heaters during Defrost setting 2 is suggested for all heaters O HEATER MOTOR oY cO e Option 16 On R 22 systems set to ON for warmer heat below 40 F For Puro
4. See Fig 15 and 16 The FK4C Fan Coil 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 A AUX HEAT KW CFM Select heater range for size of electric heater 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 0 10 for 10 kw heater This airflow must be greater than the minimum CFM for electric heater application with the size system installed for safe and continuous operation See Tables 3 and 4 for airflow delivery and minimum CFM 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 ICM2 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 15 A as indicated B AC HP SIZE Select system size installed The factory s
5. adapter kit Check all factory wiring per unit wiring diagram and inspect factory wiring connections to be sure none were loosened in transit or installation A WARNING Before installing or servicing system always turn off all 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 A CAUTION Ifa disconnect switch is to be mounted on the unit select a location where drill or fastener will not contact electrical or refrigerant components Electrical shock can cause personal injury or death NOTE Before proceeding with electrical connections make certain that supply voltage frequency and phase are as specified on unit rating plate Be sure that electrical service provided by the utility is sufficient to handle the additional load imposed by this equipment See unit wiring label for proper field high and low voltage wiring Make all electrical connections in accordance with NEC and any local codes or ordinances that may apply Use copper wire only The unit must have a separate branch electric circuit with a field supplied disconnect switch located within sight from and readily accessible from the unit ae INDOOR CONTROL FAN COIL 1 SPEED INDOOR CONTROL FAN COIL 2 SPEED AIR CONDITIONER AIR CONDITIONER HEAT STAGE 2 O W2 HEAT STAGE 2 O w2 REMOVE J2 JUMPER wa vie REMOT JEJUM ER HEAT STAGE 1 W wi FOR HEAT STAGING HEAT STAGE 1
6. and clean or replace air filter each month or as required 2 Inspect cooling coil drain pan and condensate drain each cooling season for cleanliness Clean as necessary An inspection port is provided on all A coil delta plates Remove plastic plug to inspect 3 Inspect blower motor and wheel for cleanliness each heating and cooling season Clean as necessary 4 Inspect electrical connections for tightness and controls for proper operation each heating and cooling season Service as necessary Consult fan coil service manual available from equipment distributor for maintenance procedures A WARNING As with any mechanical equipment personal injury can result from sharp metal edges etc therefore care should be taken when removing parts Using Owner s User Manual furnished in outdoor unit the installing technician should explain to the consumer system operation with particular emphasis on indoor fan coil operation sounds and filter maintenance f5 QUICK REFERENCE GUIDE SET UP INSTRUCTIONS FOR WARMER HEATING TEMPERATURES AND SUPER HUMIDITY CONTROL IN COOLING EASY SELECT BOARD LOW VOLTAGE TERMINAL BLOCK 1 Configuration T a See Installation Tistiucti ns for detailed description SEC1 SEC2 5 AUX HEAT Set for heater size Ex 0 10 for 10 kw C C J a D AC HP SIZE Set for size of outdoor unit EASY SELECT H SYSTEM TYPE Select HP COMFORT AC HP CFM ADJUST Select LO ON OFF DELAY Select
7. finished ceiling and or living area building codes may require a field supplied secondary condensate pan to be installed under the entire unit Some localities may allow as an alterative the running of a separate secondary condensate line Consult local codes for additional restrictions or precautions When installing any fan coil over a finished ceiling and or living area installation of a secondary drain pan under entire unit to avoid damage to ceiling is recommended FK4C Fan Coils can be installed for upflow and horizontal left applications as factory shipped Units can be installed for horizontal right applications with field modifications Units may be converted for downflow applications using factory authorized accessory kit NOTE To ensure proper drainage for horizontal installations unit must be installed so it is within 1 8 in level of the length and width of unit A Upflow Installation If return air is to be ducted install duct flush with floor Set unit on floor over opening Only use return air opening provided All return air must pass through the coil See Fig 2 B Modular Units The FK4C Fan Coil in size 006 is a 2 piece modular unit Modular construction allows installer to disassemble unit into 2 components coil box and blower box for ease of installation See Fig 3 To disassemble unit remove rear corner brackets by removing 2 screws which secure brackets See Fig 3 Remove either 2 screws in each front corne
8. high heat pump heating airflow H Heat Pump Heating Mode 2 speed low 1 Thermostat closes circuits R to G and R to Y1 The fan coil delivers 2 speed heat pump heating low airflow I Heat Pump Heating with Auxiliary Electric Heat 1 Thermostat closes circuits R to G R to Y Y2 and or R to Y1 with R to W W1 or W2 and R to O 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 J Heat Pump Heating with Thermidistat Control See Fig 20 for Quick Reference Guide NOTE The indoor control used such as a Thermidistat must be capable of providing warmer heating operation mode and control must be configured as outlined in its installation instructions The system must be installed with appropriate outdoor temperature sensor Consult indoor control literature to determine if control is capable of providing warmer heating control outputs and for configuration instructions Consult indoor control and sensor instructions for installation and configuration details 1 If the outdoor temperature is in the range of 10 to 40 F the Thermidistat closes circuit R to Y Y2 for
9. single speed system R to Y1 or R to Y1 and Y Y2 for 2 speed system and opens circuit R to G The ICM2 motor reads the G signal to the fan coil If circuit R to G is closed 24 vac the motor will deliver airflow at the full heating requested value If circuit R to G is open 0 vac for maximum heating comfort the motor delivers reduced airflow to maximize the temperature and minimize the draft effect of the heated air leaving the fan coil Table 3 FK4C Airflow Delivery CFM OUTDOOR ELECTRIC HEATER KW RANGE FAN UNIT UNIT CAPACITY 0 5 0 10 0 15 0 20 soo es os os os os os o or 7 2400 so s 35 ms 5 os os ms 002 815 905 1040 675 835 875 815 HI Z O 980 1250 ns ss os os os oos noa ss 905 1040 mo 1100 1100 aso 1085 1250 90 LO 625 75 725 005 1040 1700 725 875 905 875 1140 1460 OUTDOOR ELECTRIC HEATER KW RANGE Genera oo a75 so 10851950 P1350 _ 150 1500 1500 o T A nn Z O 980 1085 1250 1250 1250 1270 Bo 1500 1450 no 1250 1350 1350 oo _ 1270 1460 1350 1350 1460 1525 1525 f iss 1450 Airflow not recommended for heater system size NOTE LO NOM and HI refer to AC HP CFM ADJUST selection Z O 14 Table 4 FK4C Minimum CFM for Electric Heater Application HEAT PUMP CFM UNIT HEA
10. thermostat with Intelligent Heat D Comfort Options Warmer Heating and Super Dehumidify Warmer heating and Super Dehumidify options are possible when the FK4C Fan Coil is installed with an outdoor temperature sensor needed for warmer heating only and a corporate Thermidistat Control See Procedure 8 I Comfort Options for complete description of these features Complete the system low voltage wiring as shown in Fig 7 8 9 or 10 5 INDOOR CONTROL FAN COIL 1 SPEED INDOOR CONTROL FAN COIL 2 SPEED HEAT PUMP HEAT PUMP RVS COOLING E Roy REMOVE J2 JUMPER HEAT COOL HEAT STAGE 3 Me FOR HEAT STAGING starr M e im m HEAT STAGE 2 W w1 HEAT STAGE 3 ETE HEAT COOL m HEAT COOL JUMPER FOR STAGE 1 LY 2 Y STAGE 2 LYS HEAT STAGING C FAN FAN y2 24vac HOT R F nr 24 VAC HOT DEHUMIDIFY MODES REMOVE J1 FOR DEHUMIDIFY DEHUMIDIFY MODES wal 24 VAC COMM 24 VAC COMM N N SSS HUMIDIFY _ R AMDFER A HUMIDIFY n HUMIDIFIER m 24 VAC 24 VAC RVS HEATING RVS HEATING R OUTDOOR C R OUTDOOR C OUTDOOR SENSOR OUTDOOR SENSOR SENSOR SENSOR CONNECTION S2 J CONNECTION S2 t 4 A98475 A98476 Fig 9 FK4C Fan Coil Wiring with Fig 10 FK4C Fan Coil Wiring with 1 Speed Heat Pump 2 Speed Heat Pump SECONDARY A PRIMARY A94067 Fig 11 Transformer Connections E Ground Connections Use UL listed conduit and conduit connector to connect s
11. CNF001 002 018 024 030 036 450 1275 FK4CNF003 024 030 036 042 525 1475 FK4CNF005 030 036 042 048 550 1700 FK4CNB006 036 042 048 060 550 2150 A Continuous Fan 1 Thermostat closes circuit R to G The blower runs at continuous fan airflow B Cooling Mode Single speed or 2 speed high 1 If indoor temperature is above temperature set point and humidity is below humidity set point thermostat closes circuits R to G R to Y Y2 and R to O The fan coil delivers single speed cooling airflow 2 Thermostat closes circuits R to G R to Y1 R to Y2 and R to O The fan coil delivers 2 speed high cooling airflow C Cooling Mode 2 speed low 1 If indoor temperature is above temperature set point and humidity is below humidity set point thermostat closes circuits R to G R to Y1 and R to O The fan coil delivers 2 speed low cooling airflow D Cooling Mode Dehumidification 1 If indoor temperature is above temperature set point and humidity is above humidity set point thermostat or Thermidistat Control closes circuits R to G R to O and R to Y Y2 or R to Y1 for 2 speed low and humidistat or Thermidistat opens R to DH The fan coil delivers airflow which is approximately 80 percent of the nominal cooling airflow to increase the latent capacity of the system E Cooling Mode Super Dehumidify Operation See Fig 20 for Quick Reference Guide NOTE The indoor control used such as a Thermidistat must be capabl
12. Installation and Start Up Instructions Direct Expansion Fan Coil 001 006 A98023 Fig 1 Model FK4C NOTE Read entire instruction manual before starting installation This symbol indicates a change from the last publication 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 The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer 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 Read these instructions thoroughly and follow all warnings or cautions attached to the unit Consult local building codes and National Electrical Code NEC for special requirements Recognize safety information This is the safety alert symbol A When you see this symbol on the unit and in instructions or manuals 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 the most serious hazards which will result in severe personal injury or death WA
13. MER HEATING AND SUPER DEHUMIDIFY See Fig 20 for Quick Reference Guide Warmer heating and Super Dehumidify options are possible when the FK4C Fan Coil is installed with an outdoor temperature sensor and a corporate Thermidistat Control 10 N m SEC1 SEC2 am an EASY SELECT AUX HEAT KW CFM 0 20 875 010 0 5 725 625 AC HP SIZE 030 024 018 8 a 8 SYSTEM TYPE HP COMFORT HP EFF yer CFM ADJUST LO HI BLK 8 8 ON OFF DELAY EEE Ql Du Wi We Y WY2 ela 30 90 ONTINUOUS FAN LOM MED HI 8 6 01B_CESS430226 01B NEL f AUX1 HUMI aI d HUM2 12 PIN MATE N LOCK ELECTRIC HEAT CONNECTOR A95276 Fig 16 PCB Wiring Arrangement NOTE The FK4C Fan Coil provides better than average humidity control and heated air temperature This configuration will improve the comfort provided by the heat pump system if more humidity removal or if warmer heating air is desired While providing this improved comfort the heat pump system will operate efficiently but not at the published HSPF or ARI SEER efficiency The following fan coil configuration is recommended for maximum heating and cooling dehumidifying comfort See Fig 15 AC HP SIZE Select system size i
14. RNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage A WARNING Before installing or servicing fan coil always turn off all power to unit There may be more than 1 disconnect switch Turn off accessory heater power if applicable Electrical shock can cause personal injury or death INTRODUCTION Model FK4C Fan Coil units are designed for flexibility and can be used for upflow horizontal or downflow applications These units are available for application in systems of 18 000 through 60 000 Btuh nominal cooling capacities Factory authorized field installed electric heater packages are available in 5 through 30 kw See Product Data for available accessory kits Form IM FK4C 06 Cancels IM FK4C 05 Printed in U S A 2 99 Catalog No 63FK 4C2 INSTALLATION PROCEDURE 1 CHECK EQUIPMENT Unpack unit and move to final location Remove carton taking care not to damage unit Inspect equipment for damage prior to installation File claim with shipping company if shipment is damaged or incomplete Locate unit rating plate which contains proper installation information Check rating plate to be sure unit matches job specifications PROCEDURE 2 MOUNT FAN COIL Unit can stand or lie on floor or hang from ceiling or wall Allow space for wiring piping and servicing unit IMPORTANT When unit is installed over a
15. TER SIZE KW SIZE 5 IO Heater Only s 018 a 030 A J Hester Only 675 700 1050 1050 _ fc oa oe i ee do ee ee A 1 S oo S o o o o o S s S E E or os o os i o s S S E o l o o a o o S S S S Se o S ef o S s S E o a o a o a OS ef a a a SO E NOTES 1 Heater Only Air conditioner with electric heater application 2 These airflows are minimum acceptable airflows as UL listed Actual airflow delivered will be per airflow delivery chart for Electric Heating Modes CARE AND MAINTENANCE For continuing high performance and to minimize possible equipment failure it is essential that periodic maintenance be performed on this equipment The only required maintenance that may be performed by the consumer is filter maintenance A WARNING Disconnect all power to unit before servicing field wires or removing control package The disconnect when used on access panel does not disconnect power to the line side of disconnect but does allow safe service to all other parts of unit If unit does not have a disconnect disregard the foregoing Instead make sure that a disconnecting means is within sight from and is readily accessible from the unit Disconnect all electrical power to unit before performing any maintenance or service on it A failure to follow this warning can cause electrical shock fire personal injury or death The minimum maintenance requirements for this equipment are as follows 1 Inspect
16. ations and wire per the EAC wiring schematic See Fig 17 C Humidifier Humidistat Connections Easy Select Board terminals HUM1 and HUM2 are provided for direct connection to the low voltage control of a humidifier through a standard humidistat See Fig 16 These terminals are energized with 24vac when G thermostat signal is present See Fig 18 Alternately the 24 vac signal may be sourced from the W and C terminal block connections when electric heaters are used as primary heating source When using a Thermidistat Control the 24 vac signal may be sourced directly from the Thermidistat HUM terminal See Figs 7 8 9 and 10 D Dehumidify Capability with Standard Humidistat Connection Latent capacities for systems using the FK4C Fan Coil 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 FK4C Fan Coil will detect humidistat contacts opening on increasing humidity and reduce its airflow to approximately 80 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 100 percent of selected cooling airflow To activate this mode remove Jumper J1 and wire in a standard humidistat See Fig 19 E Dehumidify and Super Dehumidify Capabilities This mo
17. d condensate drain fittings It is recommended that PVC fittings be used on the plastic condensate pan Do not over tighten Finger tighten plus 1 1 2 turns Use pipe dope A CAUTION Shallow running taps are inadequate and DO NOT allow proper condensate drainage See Fig 13 NOTE When connecting condensate drain lines avoid blocking filter access panel Prime both primary and secondary condensate traps after connecting to drain pan NOTE If unit is located in or above a living space where damage may result from condensate overflow a field supplied external condensate pan should be installed underneath the entire unit and a secondary condensate line with appropriate trap should be run from the unit into the pan Any condensate in this external condensate pan should be drained to a noticeable place As an alternative to using an external condensate pan some localities may allow the running of a separate 3 4 in condensate line with appropriate trap to a place where the condensate will be noticeable The owner of the structure must be informed that when condensate flows from the secondary drain or external condensate pan the unit requires servicing or water damage will occur Install traps in the condensate lines as close to the coil as possible See Fig 14 Make sure that the outlet of each trap is below its connection to the condensate pan to prevent condensate from overflowing the drain pan Prime all traps test for leaks and insulate
18. del fan coil is capable of responding to a signal from indoor system control thermostat thermidistat zoning control to operate in comfort control modes such as Super Dehumidify Mode Consult literature provided with indoor system control to determine if these operating modes are available and to see control set up instructions No special setup or wiring of fan coil is required FAN COIL 230 vac OR ae 115 VAC BRANCH CKT AUX1 AUX2 O G GND HOT NEUT A A A 4 a g E r ol m 3 S l l l l l PEETRE ee 24 VAC RELAY i NOG a L LA WHT TO EAC l EN LO come Eos i ERE O EE E A98625 Fig 17 EAC Relay Wiring Schematic 12 EASY SELECT BOARD TERMINAL BLOCK HUMIDISTAT J1 RET HUM 1 C 24 VAC I TO HUMIDIFIER Ul p HUMIDISTAT HUM 2 REMOVE Saa G JUMPER HUMIDIFIER WIRING A95317 A95316 Fig 18 Humidifier Wiring Fig 19 Humidistat Wiring for De Humidify Mode PROCEDURE 10 FK4C FAN COIL SEQUENCE OF OPERATION The FK4C will supply airflow in a range which is more than twice the range of a standard fan coil It is designed to provide nominal cooling capacities at a 50 F evaporator temperature and the required airflow which enables it to match with 4 air conditioner or heat pump system sizes Table 2 outlines the CFM range for the different FK4C Fan Coil sizes Table 2 CFM Range for FK4C Units FAN COIL SIZE SYSTEM SIZES CFM RANGE FK4
19. door unit service valves pati as DO NOT USE SHALLOW RUNNING TRAPS A95321 A95320 Fig 12 Recommended Condensate Trap Fig 13 Insufficient Condensate Trap A CAUTION A brazing shield MUST be used when tubing sets are being brazed to the unit connections to prevent damage to the unit surface Braze with Sil fos or Phos copper on copper to copper joints Wrap a wet cloth around rear of fitting to prevent damage to TXV A CAUTION To prevent damage to thermostatic expansion valve remove sensor bulb from vapor tube while brazing or soldering vapor connections Units have sweat suction and liquid tube connections Make suction tube connection first 1 Cut tubing to correct length 2 Insert tube into sweat connection on unit until it bottoms 3 Braze with Sil fos or Phos copper A CAUTION Wrap a wet cloth around rear of fitting to prevent damage to factory made joints 4 Evacuate coil and tubing system to 500 microns using deep vacuum method PROCEDURE 6 CONDENSATE DRAIN Units are equipped with primary and secondary 3 4 in FPT drain connections For proper condensate line installation see Fig 2 4 5 and 6 To prevent property damage and achieve optimum drainage performance BOTH primary and secondary drain lines should be installed and include properly sized condensate traps See Fig 12 and 14 Factory approved condensate traps are available Kit No KFAET0125ETK Be sure to install plastic push in plugs in unuse
20. e insulation knockouts on right side of coil access panel 12 Reinstall access and fitting panels aligning holes with tubing connections and condensate pan connections Be sure to reinstall metal clip between fitting panel and vertical condensate pan REFRIGERANT CONNECTIONS AIR SEAL ASSEMBLY HORIZONTAL RIGHT amp APPLICATION COIL BRACKET DRAIN PAN SUPPORT ONN BRACKET N COIL supront NN RAIL A BRACKET PRIMARY DRAIN HORIZONTAL DRAIN PAN HORIZONTAL LEFT PRIMARY DRAIN SECONDARY DRAIN HORIZONTAL RIGHT HORIZONTAL LEFT SECONDARY DRAIN HORIZONTAL RIGHT FACTORY SHIPPED HORIZONTAL LEFT APPLICATION A95286 Fig 6 A Coil in Horizontal Right Application Make sure liquid and suction tube grommets are in place to prevent air leaks and cabinet sweating F Downflow Installations To convert units for downflow applications refer to Installation Instructions supplied with kit for proper installation For FK4C unit sizes 001 and 003 use kit Part No KFADC0201SLP For FK4C unit sizes 002 005 and 006 use kit Part No KFADC0401ACL Use fireproof resilient gasket 1 8 to 1 4 in thick between duct unit and floor PROCEDURE 3 AIR DUCTS Connect supply air duct over outside of 3 4 in flange provided on supply air opening Secure duct to flange with proper fasteners for type of duct used and tape duct to unit joint Duct con
21. e of providing Super Dehumidify operation mode and control must be configured as outlined in its installation instructions Consult indoor control literature to determine if control is capable of providing Super Dehumidify inputs and for configuration instructions 1 If the indoor temperature is below the temperature set point and the humidity is above the humidity set point the Thermidistat closes circuit R to O opens circuits R to DH and R to G and cycles circuit R to Y Y2 for single speed system R to Y1 or R to Y1 and Y Y2 for 2 speed system The ICM2 motor reads the G signal to the fan coil while the heat pump is operating circuit R to Y Y2 for single speed system R to Y1 or R to Y1 and Y Y2 for 2 speed system closed 24 vac If circuit R to G is closed 24 vac the motor will deliver airflow at the full cooling or cooling plus dehumidify mode requested value If circuit R to G is open 0 vac for super dehumidify mode the motor delivers reduced airflow to maximize the humidity removal of the system while minimizing overcooling F Electric Heat Heating Mode 1 Thermostat closes circuit R to W W1 or W2 The fan coil delivers the selected electric heat airflow G Heat Pump Heating Mode Single speed or 2 Speed High 1 Thermostat closes circuits R to G and R to Y Y2 The fan coil delivers single speed heat pump heating airflow 73 2 Thermostat closes circuits R to G R to Y1 and R to Y Y2 The fan coil delivers 2 speed
22. etting 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 15 B as indicated C SYSTEM TYPE Select system type installed AC or HP The type of system must be selected 1 AC Air conditioner 2 HP COMFORT Heat Pump Comfort provides approximately 315 CFM per ton for higher normal heating air delivery temperature Provides approximately 350 CFM per ton cooling airflow for good humidity removal 3 HP EFF Heat Pump Efficiency provides same airflow for heating and cooling modes to increase overall HP efficiency approximately 350 CEM per ton The factory setting is AC See Fig 15 C as indicated D AC HP CFM ADJUST Select Medium Low or High airflow To provide airflow at rates described above the AC HP ADJUST select is factory set to the nominal nom tap The adjust selections HI LO will regulate airflow supplied for all operational modes except non heat pump heating modes HI provides 15 percent airflow over nominal unit size selected and LO provides 10 percent airflow below nominal unit size selected The adjust selection options are provided to adjust airflow supplied to meet individual installation needs for such things as no
23. ise comfort and humidity removal See Fig 15 D as indicated 9 LOW VOLTAGE TERMINAL BLOCK PRINTED CIRCUIT BOARD LA eleele SEC1 c om T EASY a j L2 l l oO T AUX HEAT KW CFM KW 0 20 O48 15 paN 0 5 5 A CFM 1100 f vio 0 1 1 11 H AC HP SIZE l W gt rp 036 _ 030_ __024_ 018 y oT iT itt pes fel c _ M y HP EFF 5 WYs ORN S A AG HP CFM ADJUST lt G NOM LO HI Ld D ak 8 8 O p o ON OFF DELAY i poss ae i c WHT ONTINUOUS FAN F M Lol MED H EL i pat YEL AUX2 HUM2 E a CEBD430226 01B _CESS430226 01B J J C J CLOKODODODOOOOORO 2AVAC HEATER MOTOR ony 50 MOLEX 12 PIN CONNECTOR A95275 Fig 15 Detail of FK4C Printed Circuit Board E ON OFF DELAY Select desired time delay profile Four motor operation delay profiles are provided to customize and enhance system operation See Fig 15 E as indicated Selection options are 1 2 3 The standard 90 sec off delay Factory setting at 100 percent airflow No delay option used for servicing unit or when a thermostat is utilized to perform delay functions A 30 sec on delay with no airflow 90 sec off delay at 100 percent airflow profile is used when it is desirable to allow system coils time to heat up cool down i
24. loss To convert units for horizontal right installations Nn A U NY Remove blower and coil access panels and fitting panel See Fig 5 Remove screw securing coil assembly to right side casing flange Remove coil assembly Insulate TXV sensing bulb with cork tape or other permanent insulating material See Fig 5 Lay fan coil on its right side and reinstall coil assembly with condensate pan down See Fig 5 Attach coil to casing flange using previously removed coil mounting screw ds Reinstall access panels and fitting panel aligning holes with tubing connections and condensate pan connections Make sure liquid and suction tube grommets are in place to prevent air leaks and cabinet sweating Install grommets after brazing E Horizontal Right Conversion of Units With A Coil To convert units for horizontal right installations Nun A U N e Remove blower and coil access panels See Fig 6 Remove metal clip securing fitting panel to condensate pan Remove fitting panel Remove 2 snap in clips securing A coil in unit Slide coil and pan assembly out of unit Remove horizontal drain pan support bracket from coil support rail on left side of unit and reinstall on coil support rail on right side of unit Convert air seal assembly for horizontal right a Remove air seal assembly from coil by removing 4 screws b Remove air splitter B from coil seal assembly by removing 3 screws See Fig 6
25. n applications set to OFF e Option 17 Select programmable or non programmable mode MOLEX 12 PIN CONNECTOR 3 Set desired humidity level on front of Thermidistat 50 to 55 RH recommended For dehumidification in cooling both dhu and cool must be displayed A98510 Fig 20 Set Up Instructions for Warmer Heating Temperatures and Super Humidity Control in Cooling 1999 CAC BDP P O Box 70 Indianapolis IN 46206 imfk4C06 16 Book Tab 1 3d 4 2e Catalog No 63FK 4C2
26. n conjunction with the airflow ENH enhanced selection provides a 30 sec on delay with no airflow plus 150 sec at 70 percent airflow no off delay for added comfort This profile will minimize cold blow in heat pump operation and could enhance system efficiency F CONTINUOUS FAN Select desired fan speed when thermostat is set on continuous fan 1 2 3 LO speed factory setting 50 percent cooling mode airflow MED speed move connector to MED 65 percent cooling mode airflow HI speed move connector of HI 100 percent cooling mode airflow See Fig 15 F as indicated G LOW VOLTAGE CIRCUIT FUSING AND REFERENCE The low voltage circuit is fused by a board mounted 5 amp automotive fuse placed in series with the transformer SEC2 and the R circuit The C circuit of the transformer is referenced to chassis ground through a printed circuit run at SEC1 connected to metal standoff marked with ground symbol H BASIC FAN COIL CONFIGURATION The following basic configuration of the fan coil will provide ARI rated performance of the heat pump 1 AUX HEAT KW CFM Select the heater range for the size electric heater installed 2 AC HP SIZE Select system size installed 3 4 5 SYSTEM TYPE Select system type HP EFF AC HP CFM ADJUST Select NOM ON OFF DELAY Select 0 90 profile 6 CONTINUOUS FAN Select desired fan speed when thermostat is set to continuous fan l COMFORT OPTIONS WAR
27. nection flanges are provided on unit air discharge connection When using FK4C units with 20 24 and 30 kw electric heaters maintain a 1 in clearance from combustible materials to discharge plenum and ductwork for a distance of 36 in from unit Use accessory downflow base to maintain proper clearance on downflow installations Use flexible connectors between ductwork and unit to prevent transmission of vibration When electric heater is installed use heat resistant material for flexible connector between ductwork and unit at discharge connection Ductwork passing through unconditioned space must be insulated and covered with vapor barrier A Ductwork Acoustical Treatment Metal duct systems that do not have a 90 elbow and 10 ft of main duct to first branch takeoff may require internal acoustical insulation lining As an alternative fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts Both acoustical lining and fibrous ductwork shall comply with National Fire Protection Association Standards 90A or B as tested by UL Standard 181 for Class 1 air ducts PROCEDURE 4 ELECTRICAL CONNECTIONS A Line Voltage Connections Units with 15 and 20 kw heaters are factory wired for dual circuit operation When single circuit operation is required 24 and 30 kw heaters are field convertible and 15 and 20 kw fused heaters require the use of factory authorized
28. nstalled AC HP CFM ADJUST Select LO ON OFF DELAY Select ENH profile Auk YN AUX HEAT KW CFM Select narrowest heater range to match size of electric heater installed skip this step if no heater is installed SYSTEM TYPE Select system type HP COMFORT for heat pump system or AC for air conditioner system CONTINUOUS FAN Select desired fan speed when thermostat is set to continuous fan 7 If the fan coil is installed with Intelligent Heat Staging capable electric heaters remove jumper J2 See Fig 15 NOTE If configuring to run warmer heating do not remove jumper J2 when using 5 8 or 10 kw heaters 8 Remove jumper J1 to activate dehumidify modes 9 Wire low voltage connections as shown in Figs 7 8 9 or 10 10 Configure Thermidistat or other warmer heating capable indoor control following its installation instructions for Super Dehumidify operation This configuration provides the following comfort enhancements a A 30 second blower on delay with 150 seconds at 70 percent airflow to allow the indoor coil to warm up or cool down before the blower is asked to deliver 100 percent airflow reducing the cold blow sensation at start up in heating and allowing the indoor coil to more quickly reach wet coil operating conditions in cooling b No blower off delay eliminates cold blow which may be associated with running the blower after shut down of the compressor and avoids re evaporation of condensed m
29. oisture after cooling dehumidifying operation c Lower airflow while the compressor is running to reduce draft effects and increase heating air temperature and improved humidity control during cooling operation d Intelligent Staging of the electric heater elements to more closely match heating load requirements and provide more consistent heating air temperatures PROCEDURE 9 ACCESSORY INSTALLATION A Accessory Electric Heaters Electric heaters may be installed with the FK4C Fan Coil per instructions supplied with the electric heater package See unit rating plate for factory approved electric heater kits NOTE Units installed without electric heat should have a field supplied sheet metal block off plate covering the heater opening This reduces air leakage and formation of exterior condensation B Electronic Air Cleaner Connections Because the ICM2 blower motor used in the FK4C Fan Coil is controlled by low voltage signals a switched 230 vac electronic air cleaner power signal is not available This signal is replaced by a 24 vac signal which is provided at PCB terminals AUX1 and AUX 2 See Fig 15 and 16 This signal is present whenever the G thermostat signal is present heat pump heating cooling and continuous blower modes When the FK4C Fan Coil is installed with an electronic air cleaner use EAC relay kit Part No KFAIRO201ACR or a field supplied 24 vac relay If EAC relay is field supplied use field supplied wiring termin
30. r of coil box or 2 screws in blower box Do not remove all 4 screws in each corner See Fig 3 Sections may now be separated by lifting top section from lower section To reassemble reverse above procedure Be certain to reinstall all fasteners when reassembling C Horizontal Installations Be sure installation complies with all applicable building codes that may require installation of a secondary condensate pan 1 Arrange support for unit by setting it in or above secondary condensate pan 2 When suspending unit from ceiling dimples in casing indicate proper location of screws for mounting metal support straps See Fig 4 FIELD SUPPLIED eae SUPPLY DUCT LOW VOLT ENTRY OPTIONS POWER ENTRY OPTIONS LO 24 IN FRONT SERVICE o CLEARANCE m UPFLOW DOWNFLOW SECONDARY DRAIN 11 UPFLOW DOWNFLOW 19 PRIMARY DRAIN A f FIELD MODIFIED A SIDE RETURN LOCATION FOR 21 SLOPE COIL UNITS ONLY UPFLOW DOWNFLOW SECONDARY DRAIN ie FIELD SUPPLIED RETURN PLENUM UPFLOW DOWNFLOW PRIMARY DRAIN A95621 Fig 2 Slope Coil Unit in Upflow Application sj 2 SCREWS REAR CORNER BRACKET 2 SCREWS COIL BOX A95293 Fig 3 Modular Unit Assembly D Horizontal Right Conversion of Units with Slope Coils NOTE The TXV sensing bulb must be insulated on slope coils in horizontal right and downflow applications Failure to insulate bulb will result in performance
31. tage heater operation When additional heater staging is desired using 2 stage or outdoor thermostats remove Jumper J2 on PCB Connect low voltage leads to thermostat and outdoor unit See Fig 7 8 9 or 10 C Intelligent Heat Option Intelligent Heat staging of the electric heat package is possible when the FK4C is installed as a part of a single speed heat pump system using a corporate 2 speed programmable thermostat model TSTATXXP2S01 B Thermidistat Control or zoning control and any 1 of the following electric heat packages relay heaters KFCEH1401N09 KFCEH1501F15 KFCEH1701C15 KFCEH1801F20 KFCEH1901C20 KFCEH2101F24 OR KFCEH2201F30 Complete system low voltage wiring as shown in Fig 7 8 9 or 10 NOTE Where local codes require thermostat wiring be routed through conduit or raceways splices can be made inside the fan coil unit All wiring must be NEC Class 1 and must be separated from incoming power leads A factory authorized disconnect kit is available for installation of 0 through 10 kw applications When electric heat packages with circuit breakers are installed the circuit breaker can be used as a disconnect Transformer is factory wired for 230 v operation For 208 v applications disconnect black wire from 230 v terminal on transformer and connect it to 208 v terminal See Fig 11 The secondary circuit of transformer is protected by a 5 amp fuse mounted on printed circuit board IMPORTANT Do not use outdoor
32. traps if located above a living area Condensate drain lines should be pitched downward at a minimum of 1 in for every 10 ft of length Consult local codes for additional restrictions or precautions A CAUTION Never operate unit without a filter or with filter access door removed Damage to blower motor or coil can result IMPORTANT Factory authorized filters must be used when locating the filter inside the unit See Table 1 For those applications where access to an internal filter is impractical a field supplied filter must be installed in the return duct system PROCEDURE 7 UNIT START UP Refer to outdoor unit Installation Instructions for system start up instructions and refrigerant charging method details 19s 2 ka FILTER ACCESS PANEL SECONDARY DRAIN REQUIRED USE FACTORY KIT OR S FIELD SUPPLIED TRAP PRIMARY TRAP REQUIRED USE FACTORY KIT OR FIELD SUPPLIED TRAP A99040 Fig 14 Condensate Trap and Unit Table 1 Filter Kits PART NUMBER SIZE USED WITH FILTER KIT KFAFK0212MED 001 002 12 PACK KFAFK0312LRG 003 005 KFAPKO412XXL PROCEDURE 8 EASY SELECT CONFIGURATION TAPS EASY SELECT taps are used by the installer to configure a system ICM2 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
33. upply wire s to unit and obtain proper grounding Grounding may also be accomplished by using grounding lug provided in control box Use of dual or multiple supply circuits will require grounding of each circuit to ground lugs provided on unit and heaters A WARNING The cabinet must have an uninterrupted or unbroken ground according to NEC ANSI NFPA 70 and local codes 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 electrical shock fire or death PROCEDURE 5 REFRIGERANT TUBING CONNECTION AND EVACUATION This fan coil is supplied with an R 22 TXV factory installed If installing with a Puron system the TXV must be replaced using a Puron R 410A TXV unit See outdoor unit literature for correct TXV Kit number See Dimensional Drawing for tube connection sizes type and locations Use accessory tubing package or field supplied tubing of refrigerant grade Insulate entire suction tube if field supplied tubing is used Tubing package has an insulated suction tube Do not use damaged dirty or contaminated tubing because it may plug refrigerant flow control device When tubing package is used and sweat connections are made within 60 sec coil and tubing system does not require evacuation Always evacuate coil and field supplied tubing to 500 microns before opening out
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