INSTALLATION INSTRUCTIONS Fan Coils FCM4X24−60
Contents
1. 2 PERSONAL INJURY AND OR PROPERTY DAMAGE Mount Fan 01 2 HAZARD Alf DUCIS ste wate tinea pee ake elec 6 Failure to carefully read and follow this warning could Electrical Connections 0 0 00ee eee 7 result in equipment malfunction property damage ersonal injur th Refrigerant Tubing Connection amp Evacuation 9 P 5 des Condensate Drai 9 Installation or repairs made by unqualified persons OTE ANSAGE LAI Aa toan RR ETa could result in equipment malfunction property dam Unit Stat Upi 10 age personal injury and or death Accessory Installation 1 5 10 The information contained in this manual is intended Start Up and Troubleshooting 0 11 for use by a qualified service technician familiar with safety procedures and equipped with the proper FCM4X Fan Coil Sequence of Operation 15 tools and test instruments CARE AUD MAINTENANCE Installation must conform with local building codes R 410A Quick Reference Guide 17 and with the National Electrical Code NFPA70 current edition 496 01 4201 01 11 29 11 INSTALLATION INSTRUCTIONS INTRODUCTION Model FCM4X fan coils are designed to be installed with the Observer Communicating Wall Control The FCM4X2. B from coil seal assembly by See Fig 6 inset c Remove filler plate A and install air splitter B in place of filler plate 496 01 4201 01 INSTALLATION INSTRUCTIONS 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 7 Install hose onto plastic spout 8 Slide coil assembly into casing Be sure coil bracket on each corner of vertical pan engages coil support rails 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 two oval fitting caps from left side of the coil access panel and fitting panel Fan Coils FCM4X 11 Remove insulation knockouts on right side of coil access panel 12 Remove 2 oval coil access panel plugs and reinstall into holes on left side of coil access panel and fitting panel 13 Install condensate pan fitting caps from Step 10 in right side of coil door making sure that cap snaps and seats cleanly on back side of the coil door Make sure no insulation interferes with seating of cap 14 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 Make sure liquid and suction tube grommets are in
3. 7 HORIZONTAL PRIMARY DRAIN HORIZONTAL LEFT SECONDARY DRAIN HORIZONTAL LEFT REFRIGERANT CONNECTIONS A00072 Remove screw securing coil assembly to right side casing flange 3 Remove coil assembly 4 Lay fan coil on its right side and reinstall coil assembly with condensate pan down 5 Attach coil to casing flange using previously removed coil mounting screw 6 Make sure pan cap in fitting door is properly seated on fitting door to retain low air leak rating of the unit 7 Add gaskets included in kit per kit instructions 8 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 1 Remove blower and coil access panels See Fig 6 2 Remove metal clip securing fitting panel to condensate pan Remove fitting panel 3 Remove 2 snap in clips securing 60 in unit 4 Slide coil and pan assembly out of unit 5 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 6 Convert air seal assembly for horizontal right a Remove air seal assembly from coil by removing 4 screws b Remove air splitter removing 3 screws
4. Check for faults in wiring connecting sensor to OAT terminals Using an Ohmmeter check resistance of thermistor for a short or open condition If thermistor is 14 496 01 4201 01 INSTALLATION INSTRUCTIONS shorted or open replace it to return the system to normal operation If fault is in the wiring connections correcting the fault will clear the code and return the system to normal operation NOTE If fault condition is an open thermistor or a wiring problem that appears to be an open thermistor and the power to the fan coil control is cycled off the fault code will be cleared on the next power up but the fault will remain and system operation will not be as expected This is because on power up the fan coil control cannot discern the difference between an open sensor or if a sensor is not installed F Emergency Heating and Cooling Modes Fan coil control can provide emergency heating or cooling using a common heat cool thermostat in the event that there are no system communications fault is in Wall Control and no replacement is immediately available To activate these modes the thermostat and outdoor unit must be wired as a common heating cooling system to fan coil control RGWYOC terminals NOTE These emergency modes do not provide the level of comfort and efficiency expected by the consumer and should only be activated when Wall Control cannot be replaced immediately Procedure 10 FCM4X Fan Coil Sequence of Op
5. 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 If unit contains an 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 For 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 Check all factory wiring per unit wiring diagram and inspect factory wiring connections to be sure none were loosened in transit or installation Fan Coils FCM4X 4 amp WARNING ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death Before installing or servicing unit always turn off all power to unit There may be more than 1 disconnect switch Turn off accessory heater power if applicable WARNING ELECTRICAL SHOCK or UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury death and or unit damage If a disconnect switch 15 to be mounted on unit
6. is required as Wall Control monitors indoor humidity When commanded to operate humidifier the fan coil control will energize the HUM output to turn humidifier on and de energize HUM output to turn humidifier off Wire HUM and terminals directly to humidifier as shown in Fig 9 or 10 E System Shutdown Accessories To shutdown the system through a shutdown accessory such as a condensate overflow switch break the R terminal connection to the unit OD or ID that you wish to shutdown Fan Coils FCM4X Procedure 9 Start Up and Troubleshooting NOTE Always check high and low voltage supply to the fan coil components Check the integrity of the plug receptacle connections and fan coil wiring harness prior to assuming a component failure A LED Description LEDs built into fan coil control provide installer or service person information concerning operation and or fault condition of the fan coil control and ECM motor This information is also available at the Wall Control in text with basic troubleshooting instructions Careful use of information displayed will reduce the need for extensive manual troubleshooting The amber LED located at bottom center of control adjacent to motor harness plug is motor status LED and it is labeled MOTOR A second amber LED located in upper right center of control adjacent to System Communications connector DX DX CR is the System Status LED and it is labeled STATUS The green
7. select a location where drill and fasteners will not contact electrical or refrigeration components WARNING ELECTRICAL SHOCK or UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death Field wires on the line side of the disconnect remain live even when the pull out is removed Service and maintenance to incoming wiring can not be per formed until the main disconnect switch remote to the unit is turned off 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 factory authorized disconnect kit is available for installation of O 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 t
8. LED labeled COMM is also located adjacent to System Communications connector below STATUS LED and is used as an indicator of system communications status Status Codes will be displayed on the STATUS LED using the following protocol 1 The number of short flashes indicates first digit of code 2 The number of long flashes indicates second digit of code 3 A short flash is 0 25 seconds on A long flash is 1 second on 4 The time between flashes is 0 25 seconds 5 The time between last short flash and first long flash is 1 second 6 The LED will be off for 2 5 seconds before repeating code 496 01 4201 01 11 INSTALLATION INSTRUCTIONS Figure 14 Detail of FCM4X Printed Circuit 9 Board Connections FUSE 3AMP B Fan Coil Control Start Up and Communications Troubleshooting On power up green COMM LED will be turned off until successful system communications are established this should happen within 10 seconds Once communications with Wall Control are successful COMM LED will be lit and held on At the same time amber STATUS LED will be lit and held continuously on until a request for operating mode is received The STATUS LED will be on any time fan coil is in idle mode If at any time communications are not successful for a period exceeding 2 minutes fan coil control will only allow emergency heating or cooling operation using a common thermostat a non communicating outdoor unit and the R C Y
9. Wall Control with an outdoor air temperature sensor can be used to lockout supplemental heat above 40 F 4 4 C except for heat pump defrost cycle Refer to Wall Control Instructions NOTE Outdoor air temperature sensor is factory installed on communicating single and two stage AC and HP units For non communicating outdoor units install the outdoor air temperature sensor shipped with the Wall Control D Ground Connections 4 amp WARNING ELECTRICAL SHOCK HAZARD Failure to establish uninterrupted or unbroken ground could result in personal injury and or death 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 See Ground Conduit Note below NOTE Use UL listed conduit and conduit connector to connect supply wire s to unit and obtain proper grounding If conduit connection uses reducing washers a separate ground wire must be used Grounding may also be accomplished by using grounding lug provided in control box Use of dual or multiple supply circuits will require 8 496 01 4201 01 INSTALLATION INSTRUCTIONS grounding of each circuit to ground lugs provided on unit and heaters Procedure 5 Refrigerant Tubing Connection and Evacuation Use accessory tubing package o
10. and cooling season Service as necessary Consult Technical Service Manual available equipment distributor for maintenance procedures A CAUTION CUT HAZARD Failure to follow this caution may result in personal requirements for this from injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing and gloves when handling parts Using the Owner s User Manual furnished in outdoor unit the installing technician should explain system operation to the consumer with particular emphasis on indoor fan coil operation sounds and filter maintenance 496 01 4201 01 15 INSTALLATION INSTRUCTIONS Fan Coils FCM4X Table 2 FCM4X Fan Coil Airflow Delivery Chart CFM Electric Heating Models ELECTRIC HEATER kW RANGE MODEL FCM4X OUTDOOR UNIT CAPACITY BTUH 5 7 9 10 15 20 24 25 30 EMERGENCY 625 625 675 775 950 18 000 625 625 675 24 24 000 650 725 775 900 30 000 800 875 875 925 1125 36 000 975 975 975 1025 1125 EMERGENCY 675 700 775 850 1050 24 000 675 875 875 1100 1150 36 30 000 800 875 875 1100 1150 36 000 975 975 1025 1150 1250 42 000 1125 1125 1125 1150 1350 EMERGENCY 675 700 775 850 1050 1400 1425 30 000 800 875 875 1100 1150 48 36 000 975 975 1025 1150 1250 42 000 1125 1125 1125 1150 1250 48 000 1305 1305 1305 1305 1350 1500 1600 EMERGENCY 1050 1050 1050 1050 1125 1750 1750 36 000 1050 1050
11. coil sizes installed NOTE Fan coil control will not operate electric heater until this Status Code is resolved If the heater size is set through the Wall Control the heater will be operated as a single stage heater If staging is desired the IDR value must be read in by the fan coil control STATUS CODE 36 HEATER OUTPUT NOT SENSED WHEN ENERGIZED Fan coil control is provided with circuitry to detect presence of a 24VAC signal on Electric Heater stage 1 and stage 2 outputs If fan coil control energizes either heater stage and does not detect the 24VAC signal on output Status Code 36 will be displayed on the STATUS LED Fan coil control will continue to energize heater output s and adjust blower operation to a safe airflow level for energized electric heat stage s To find the fault Check for 24VAC on heater stage outputs Fan coil control or sensing circuit may be bad NOTE It may be useful as an electric heater troubleshooting procedure to disconnect the system communications to force Status Code 16 enabling of emergency heat mode It is difficult to know which heater output is energized or not energized in normal operation When fan coil is operated in emergency heat mode using electric heaters both outputs are energized and de energized together Terminal strip inputs to control can then be connected R to W to turn on both electric heat outputs Heater output sensing circuits can then be checked to resolve Status Code 36 or 37
12. place to prevent air leaks and cabinet sweating Slope Coil in Horizontal Right Application COIL MOUNTING SLOPE COIL SKI DRAINPAN REFRIGERANT CONNECTIONS BLOWER ASSEMBLY PRIMARY DRAIN SECONDARY DRAIN A03001 496 01 4201 01 INSTALLATION INSTRUCTIONS Fan Coils FCM4X A Coil in Horizontal Right Application REFRIGERANT CONNECTIONS COIL support N C RAIL AIR SEAL ASSEMBLY HORIZONTAL RIGHT APPLICATION WAT COIL O BRACKET O DRAIN PAN SUPPORT N BRACKET N i COIL 5 support RAIL Ves COIL cao HORIZONTAL DRAIN PAN PRIMARY DRAI HORIZONTAL RIGHT A 2 SECONDARY DRAIN HORIZONTAL RIGHT F DOWNFLOW INSTALLATION A CAUTION PRODUCT OR PROPERTY DAMAGE HAZARD Failure to follow this caution may result in product or property damage The conversion of the fan coil to downflow requires special procedures for the condensate drains on both A coil and Slope coil units The vertical drains have an overflow hole between the primary and secondary drain holes This hole is plugged for all applications except downflow and must be used for downflow During conversion process remove plastic cap cov ering vertical drains only and discard Remove plug from overflow hole and discard At completion of downflow installation caulk around vertical pan fit ting to door joint to retain low air leak performance of the u
13. problems STATUS CODE 41 BLOWER MOTOR FAULT If MOTOR LED is lit and flashing and motor does not run Fan Coils FCM4X 1 Check STATUS LED If STATUS LED is indicating Status Code 41 motor control has detected that the motor will not come up to speed within 30 seconds of being commanded to run or that the motor has been slowed to below 250 rpm for more than 10 seconds after coming up to speed Motor wiring harness and fan coil control are operating properly do not replace 2 Check to be sure that the blower wheel is not rubbing the housing 3 Check motor to be sure that the motor shaft is not seized motor Control Module must be removed and electronics disconnected from windings to perform this check properly 4 Check motor windings section following instructions in Section C ECM Motor Troubleshooting If all these checks are normal the motor Control Module may need replacement STATUS CODE 16 SYSTEM COMMUNICATION FAULT On initial power up and at any time system communications are not successful for a period exceeding 2 minutes following successful communications the fan coil control will only allow emergency heating or cooling operation using a common thermostat a non communicating outdoor unit and the RGWYO outdoor unit terminal strip connections and will display Status code 16 on the amber STATUS LED see section E Emergency Heating and Cooling Modes No further fan coil troubleshooting information will be avail
14. system level functions and the factory supplied outdoor unit OAT will be used for outdoor unit control functions Using two wires of field supplied thermostat wire cable wire one lead of thermistor to one screw terminal and the other lead to remaining screw terminal there is no polarity to be observed It is strongly recommended that two wires be used to connect the thermistor to eliminate noise interference in temperature reading If there are not two spare wires available in cable one wire may be used to connect thermistor to OAT screw terminal 1 and the other lead of the thermistor can be wired to 24VAC COM C wire OAT screw terminal 1 is terminal located closest to the DX DX CR system communications and is marked with a small number 1 next to the terminal strip NOTE Mis wiring OAT inputs will not cause damage to either fan coil control or thermistor If the thermistor is wired incorrectly no reading will appear at Wall Control Re wire thermistor correctly for normal operation C Electronic Air Cleaner Connections In communicating mode the G signal isn t active on this control board Only electric air cleaners that do not rely on the HVAC system to activate the electronic air cleaner should be used with communicating systems See Electric air cleaner instructions for installation D Humidifier Connections The fan coil control terminal marked HUM is provided for low voltage 24VAC control of a humidifier No humidistat
15. 1100 1350 1350 EN gt gt 60 42 000 1125 1125 1150 1350 1350 48 000 1300 1300 1300 1350 1500 1750 1750 60 000 1625 1625 1625 1625 1750 1750 1750 16 496 01 4201 01 INSTALLATION INSTRUCTIONS Fan Coils FCM4X R 410A REFRIGERANT QUICK REFERENCE GUIDE R 410A refrigerant operates at 50 70 percent higher pressures than R 22 Be sure that servicing equipment and replacement components are designed to operate with R 410A refrigerant R 410A refrigerant cylinders are rose colored Recovery cylinder service pressure rating must be 400 psig DOT 4BA400 or DOT BW400 R 410A refrigerant systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose when charging into suction line with compressor operating Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low side retard Use hoses with 700 psig service pressure rating Leak detectors should be designed to detect HFC refrigerant R 410A refrigerant as with other HFCs is only compatible with POE oils Vacuum pumps will not remove moisture from oil Do not use liquid line filter driers with rated working pressures less than 600 psig Do not leave R 410A refrigerant suction line filter driers in line longer than 72 hours Do not install a suction line filter drier in liquid line POE oils absorb moisture rapidly Do not expose oil to atmosphere POE oils may cause damage to certain plastics and roofing materials W
16. DRAIN UPFLOW DOWNFLOW PRIMARY DRAIN Fan Coils FCM4X Slope Coil Unit in Upflow Application FIELD SUPPLIED SUPPLY DUCT LOW VOLT ENTRY OPTIONS 1 1 2 38 1 mm FIELD MODIFIED SIDE RETURN LOCATION FOR 36 UNITS ONLY T FIELD SUPPLIED RETURN PLENUM A07139 Slope Coil in Horizontal Left Application Factory Ready unit only FIELD SUPPLIED HANGING STRAPS LOW VOLT ENTRY OPTIONS POWER ENTRY OPTIONS A COIL HORIZONTAL LEFT PRIMARY oar DARY DRAIN 24 36 48 21 533 4 mm 60 24 609 6 mm FRONT SERVICE CLEARANCE FULL FACE OF UNIT 4 3 4 44 45 mm FILTER ACCESS CLEARANCE PRIMARY DRAIN SECONDARY DRAIN A07140 496 01 4201 01 INSTALLATION INSTRUCTIONS Fan Coils FCM4X A Coil in Horizontal Left Application FACTORY SHIPPED HORIZONTAL LEFT APPLICATION COIL BRACKET COIL SUPPORT RAIL DRAIN PAN SUPPORT BRACKET K COIL a BRACKET DRAIN PAN AIR SEAL ASSEMBLY Figure4 Modular Unit Assembly BLOWER BOX REAR CORNER BRACKET 2 SCREWS COIL BOX D Horizontal Right Conversion of Units with Slope Coils NOTE Gasket kit number EBACO1GSK is required for horizontal slope coil conversion to maintain low air leak low sweat performance 1 Remove blower and coil access panels and fitting panel See Fig 5
17. INSTALLATION INSTRUCTIONS Fan Coils FCM4X24 60 These instructions must be read and understood completely before attempting installation Safety Labeling and Signal Words DANGER WARNING CAUTION and NOTE Signal Words in Manuals The signal words DANGER WARNING The signal word WARNING is used throughout this CAUTION and NOTE are used to identify levels of manual in the following manner hazard seriousness The signal word DANGER is only used on product labels to signify an immediate WARN NG hazard The signal words WARNING CAUTION and NOTE will be used on product labels and The signal word CAUTION is used throughout this throughout this manual and other manuals that may manual in the following manner apply to the product DANGER Immediate hazards which will result in A CAUTION severe personal injury or death WARNING Hazards or unsafe practices which Signal Words on Product Labeling could result in severe personal injury or death Signal words are used in combination with colors CAUTION Hazards or unsafe practices which and or pictures on product labels may result in minor personal injury or product or property damage NOTE Used to highlight suggestions which will result in enhanced installation reliability or operation TABLE OF CONTENTS INTHOGUCTION a esis i ey Se 2 INSTALLAN ON e cates Sentra S E A WARNING Check Equipment
18. LED Clearing the indicated fault when multiple faults exist will cause the next highest priority Status Code to be flashed All existing faults as well as a fault history can be viewed at Wall Control STATUS CODE 45 CONTROL BOARD TEST FAULT Fan coil control has failed internal start up tests and must be replaced No other service procedure will correct STATUS CODE 37 HEATER OUTPUT SENSED ON WHEN NOT ENERGIZED Fan coil control is provided with circuitry to detect presence of a 24VAC signal on Electric Heater stage 1 and stage 2 outputs If fan coil control detects a 24VAC signal on either heater stage output and it is not supplying signal Status Code 37 will be displayed on STATUS LED Fan coil control will turn off output and command blower motor to supply an airflow determined to be safe for current operation mode with electric heaters energized To find the fault 1 Stop all system operations at Wall Control and check heater stage 24VAC outputs 2 Disconnect electric heater at plug receptacle 2 and check heater wiring for faults See Status Code 36 for more information STATUS CODE 44 MOTOR COMMUNICATION FAULT The MOTOR LED is connected to the blower motor communication and works with the fan coil control microprocessor and STATUS LED to provide fan coil operation and troubleshooting information When motor is commanded to operate the MOTOR LED will be turned on and will flash each time instructions are se
19. N INSTRUCTIONS 4 Check motor and motor Control Module following the instructions in Section C ECM Motor Troubleshooting STATUS CODE 26 INVALID HEATER SIZE On initial power up fan coil control will write into memory electric heater size as read from heater if heater is provided with Identifier Resistor IDR Heater size must be valid for combination of indoor and outdoor components installed Fan coil control will read IDR value connected to pins 5 and 8 of heater harness connector If no resistor is found system Wall Control will prompt installer to verify that no heater is installed Verifying that this is correct will establish that fan coil is operating without an electric heater accessory Upon choosing negative option installer will be prompted to select heater size installed from a list of valid heater sizes for fan coil and outdoor unit size installed If heater ID resistor value read is invalid Status Code 26 will be displayed on STATUS LED If heater installed is equipped with a resistor connected to pins 5 and 8 of heater harness connector and Status Code 26 is displayed on STATUS LED 1 Check wiring harness connections to be sure connections are secure 2 If symptoms persist disconnect wiring harness at fan coil control heater header and check for a resistance value greater than 5000 ohms 3 Check for proper wiring of resistor assembly 4 Make sure heater size installed is an approved size for outdoor unit and fan
20. O W outdoor unit terminal strip connections and will display Status Code 16 System Communication Fault on amber STATUS LED No further fan coil troubleshooting information will be available at Wall Control until communications are re established If COMM LED does not light within proper time period and Status Code is not displayed System Fan Coils FCM4X 1 Check system transformer high and low voltage to be sure the system is powered 2 Check fuse on fan coil control to be sure it is not blown If fuse is open check system wiring before replacing it to be sure a short does not cause a failure of replacement fuse If COMM LED does not light within proper time period and Status Code is displayed Check system wiring to be sure Wall Control is powered and connections are made DX to DX DX to DX etc and wiring is not shorted Mis wiring or shorting of the DX DX CR communications wiring will not allow successful communications NOTE Shorting or mis wiring low voltage system wiring will not cause damage to fan coil control or Wall Control but may cause low voltage fuse to open ECM Motor Troubleshooting The ECM motor used in this product consists of two parts the Control Module and the motor winding section Do not assume motor or module is defective if it will not start Use the designed in LED information aids and_ follow troubleshooting steps described below before replacing motor Control Module or e
21. able at the Wall Control until communications are reestablished Check system wiring to be sure the Wall Control is powered and connections are made DX to DX DX to DX etc and wiring is not shorted Mis wiring or shorting of the DX DX CR communications wiring will not allow successful communications Correcting wiring faults will clear the code and reestablish communications Shorting or mis wiring the low voltage system wiring will not cause damage to fan coil control or to Wall Control but may cause the low voltage fuse to open STATUS CODE 46 BROWNOUT CONDITION If the secondary voltage of the transformer falls below 15VAC for a period exceeding 4 seconds Status Code 46 will be displayed on STATUS LED If system includes a non communicating outdoor air conditioner or heat pump the Wall Control will command the fan coil to turn off Y output controlling compressor When secondary voltage rises above 17VAC for more than 4 seconds the brownout condition is cleared and normal system operation will resume subject to any minimum compressor off delay function which may be in effect Brownout does not affect blower or electric heater operation STATUS CODE 53 OUTDOOR AIR TEMPERATURE SENSOR FAULT If an OAT sensor is found at power up input is constantly checked to be within a valid temperature range If sensor is found to be open or shorted at any time after initial validation Status Code 53 will be displayed at amber STATUS LED
22. an Coils FCM4X 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 WARNING ELECTRICAL SHOCK HAZARD Failure to establish uninterrupted or unbroken ground could result in personal injury and or death 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 Discon nect all electrical power to unit before performing any maintenance or service on it The minimum maintenance equipment are as follows 1 Inspect 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
23. eration The FCM4X Fan Coil is designed for installation with an Observer Communicating Wall Control This fan coil will not respond to commands provided by a common thermostat except under certain emergency situations described in Procedure 9 Start Up and Troubleshooting The Wall Control uses temperature humidity and other data supplied from indoor and outdoor system components to control heating or cooling system for optimum comfort The fan coil will be commanded by Wall Control to supply airflow and in the case of a non communicating outdoor unit Air Conditioner or Heat Pump control The fan coil will operate blower at requested airflow for most modes The nominal requested airflow will be 350 cfm per ton of nominal cooling capacity as defined by outdoor unit size Actual airflow request will be adjusted from nominal using indoor and outdoor temperature and indoor humidity data to optimize the system operation for occupant comfort and system efficiency Refer to Wall Control literature for further system control details Airflow during electric heater operation must be greater than a minimum level for safe operation If Wall Control instructs fan coil to turn on electric heat and the requested airflow is less than the minimum value required for safe operation of installed heater the fan coil control will override requested value with the value shown in Table 2 FCM4X Fan Coil Airflow Delivery Chart Electric Heating Modes F
24. erminal See Fig 8 496 01 4201 01 INSTALLATION INSTRUCTIONS Transformer Connections SECONDARY A94067 B 24 V Control System Connections to Unit Printed Circuit Board PCB Use No 18 AWG color coded insulated 85 C minimum wires to make low voltage connections between Wall Control and unit If Wall Control is located more than 100 ft from unit as measured along the low voltage wires use No 16 AWG color coded insulated 85 C minimum wires or in accordance with local codes Connect low voltage leads to Wall Control and outdoor unit See Fig 9 or 10 NOTE Where local codes require Wall Control wiring be routed through conduit or raceways splices can be made inside fan coil unit All wiring must be NEC Class and must be separated from incoming power leads Fan Coil Wiring with Non Communicat ing Single Stage AC HP Wall Control Fan Control Outdoor Air Thermistor if used Humidifier 07119 NOTE Two stage non communicating AC and HP wiring require daughter board NAX00101DB Fan Coils FCM4X Figure 10 Fan Coil Wiring Communicating AC HP Communication Wall Control Fan Control Humidifier Manufactured Housing In manufactured housing applications the Code of Federal Regulations Title 24 Chapter XX Part 3280 714 requires that supplemental electric heat be locked out at outdoor temperatures above 40 F 4 4 C except for a heat pump defrost cycle The
25. erty damage The conversion of the fan coil to downflow requires special procedures for the condensate drains on both A coil and Slope units The vertical drains have an overflow hole between the primary and secondary drain holes This hole is plugged for all applications except downflow but must be used for downflow During the conversion process remove the plastic cap covering the vertical drains only and discard Re move the plug from the overflow hole and discard At completion of the downflow installation caulk around the vertical pan fitting to door joint to retain the low air leak performance of the unit To connect drains the cap openings must be removed Use a knife to start opening near tab and using pliers pull tab to remove disk Clean edge of opening if necessary and install the condensate line Finally caulk around lines where they exit fitting to retain low leak rating of the unit Units are equipped with primary and secondary 3 4 in FPT drain connections For proper condensate line installation see Figures 1 2 3 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 Figures 11 and 12 Factory approved condensate traps are available Be sure to install plastic push in plugs in unused condensate drain fittings It is recommended that PVC fittings be used on plastic condensate pan Do no
26. fan coils will provide airflow at a rate commanded by the Wall Control The nominal airflow ton rate is 350 CFM ton The Wall Control will modify the commanded airflow under certain operating modes Refer to the Wall Control literature for further system control details This fan coil will not respond to commands from a common thermostat except under certain emergency situations explained in this document The instructions contained herein provide guidance to successfully install this fan coil Model FCM4X fan coil units are designed for flexibility and can be used for upflow horizontal or downflow applications These units are designed specifically for 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 FCM4X unit can stand or lie on floor or hang from ceiling or wall Allow space for wiring piping proper trapping and servicing unit IMPORTANT When unit is installed over a finished ceiling and or living area building codes may require and it is recommended by the factory a field supplied secondary condensate pan to be installed under the entire unit Some locali
27. ide of 3 4 in flange provided on supply air opening Secure duct to flange with proper fasteners for type of duct used and seal duct to unit joint Duct connection flanges are provided on unit air discharge connection When using FCM4X 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 36 914 4 mm 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 496 01 4201 01 INSTALLATION INSTRUCTIONS 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 Fiqure 7 Mobile Home or Manufactured Hous 9 ing Applications 4 101 6 mm MAX SECURE FAN COIL TO STRUCTURE UNIT AWAY FROM WALL PIPE STRAP TYPICAL BOTH SIDES OR UNIT AGAINST WALL 1 8 3 18 mm THICK ANGLE MOUNTING BRACKET TYPICAL BOTH SIDES o7 4 DOWNFLOW o BASE KIT EBAC NCB x SECURE UNIT TO FLOOR ANGLE BRACKET OR PIPE STRAP A07141 4 101 6 mm MAX 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
28. nit In this application field conversion of the evaporator coil is required using accessory downflow kit along with an accessory base kit NOTE To convert units for downflow applications refer to Installation Instructions supplied with kit for proper installation For unit size 36 use kit Part No EBACO1DFS For unit sizes 24 48 and 60 use kit Part No EBACO2DFA Use fireproof resilient gasket 1 8 to 1 4 in thick between duct unit and floor NOTE Gasket kit number EBACO1GSK is also required for all downflow applications to maintain low air leak low sweat performance A00071 G Manufactured and Mobile Home Applications 1 Fan coil unit must be secured to the structure using field supplied hardware 2 Allow a minimum of 24 in clearance from access panels 3 Recommended method of securing for typical applications a If fan coil is away from wall attach pipe strap to top of fan coil using No 10 self tapping screws Angle strap down and away from back of fan coil remove all slack and fasten to wall stud of structure using 5 16 in lag screws Typical both sides of fan coil b If fan coil is against wall secure fan coil to wall stud using 1 8 in thick right angle brackets Attach brackets to fan coil using No 10 self tapping screws and to wall stud using 5 16 in lag screws See Fig 7 Procedure 3 Air Ducts Housing Connect supply air duct over outs
29. nnect the motor harness at the fan coil control If motor continues to run fan coil control is good and Control Module on motor may need replacement STATUS CODE 25 INVALID MOTOR MODEL SELECTION On initial start up fan coil control shall poll motor for its size data and check fan coil size data stored in fan coil control memory 1 If motor size is incorrect for fan coil size or fan coil size data is invalid Status Code 25 will be displayed on STATUS LED 2 If model size data is missing as is the case when a replacement fan coil control is installed system Wall Control will prompt installer to enter correct model size from a list of valid sizes 3 If motor size is incorrect for model size motor must be replaced with proper size motor Fan coil control will not respond to operation requests until this fault condition is resolved STATUS CODE 27 INVALID OUTDOOR UNIT SIZE On initial power up fan coil control will write into memory outdoor unit size as provided by Wall Control in a fully communicating system 1 If outdoor unit size is invalid Status Code 27 will be displayed on STATUS LED 2 Wall Control will prompt the installer to choose size from a list of valid sizes for application with fan coil 3 Check communications wiring to be sure Wall Control has established communications with outdoor unit or select proper size from valid size list provided at Wall Control 496 01 4201 01 13 INSTALLATIO
30. nt to the motor When the motor is commanded to stop the MOTOR LED will be turned off The MOTOR LED will not flash to indicate communications when it is turned off Fan Coils FCM4X Fan coil control is constantly communicating with the motor even when the motor and MOTOR LED are off If motor does not acknowledge receipt of communications the control will display Status Code 44 on STATUS LED and continue to try to communicate with the motor If motor acknowledges communication Status Code will be cleared If MOTOR LED is lit and flashing and motor does not run 1 Check the STATUS LED If STATUS LED is indicating a Status 44 code check the motor wiring harness for proper connection to control and motor receptacles 2 Check motor wiring harness to be sure all wiring complies with wiring diagram description makes a complete circuit from connector to connector and is not shorted 3 Check 12 Vdc low voltage supply to motor at pins 1 and 2 of motor header connection to fan coil control If all checks are normal fan coil control is good and Control Module on motor may need replacement Check motor and Motor Control Module following the instructions in Section C ECM Motor Troubleshooting Shorted or mis wiring of the low voltage motor harness wiring will not cause damage to fan coil control or to motor Control Module If the MOTOR LED is off STATUS LED is indicating a Status Code 44 and motor is running Disco
31. ntire motor Motor Control Module is available as a replacement part VERIFY MOTOR WINDING SECTION WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury possible equipment damage After disconnecting power from the ECM motor wait at least 5 minutes before removing the control sec tion Internal capacitors require time to discharge Before proceeding to replace a motor Control Module 1 Check motor winding section to be sure it is functional 2 Remove motor Control Module section and unplug winding plug Motor shaft should turn freely resistance between any two motor leads should be similar and resistance between any motor lead and unpainted motor end should exceed 100 000 ohms 3 Failing any of these tests entire ECM motor must be replaced 4 Passing all of the tests motor Control Module alone can be replaced MOTOR TURNS SLOWLY 1 Low static pressure loading of blower while access panel is removed will cause blower to run slowly Particularly at low airflow requests This is normal do not assume a fault exists NOTE Blower motor faults will not cause a lockout of blower operation Fan coil control will attempt to run the blower motor as long as Wall Control maintains a demand for airflow Fan coil control will not operate electric heaters while a fault condition exists The fan coil control communicates with the motor at least once every 5 seconds even when the m
32. on in the condensate pan and drain connection area and when brazing tubing These units are available for application in systems of 24 000 through 60 000 Btuh nominal cooling capacities Factory authorized field installed electric heater packages are available in 5 through 30 kW See Specifications for available accessory kits B Upflow Installation If return air is to be ducted through a floor set unit on floor over opening and use 1 8 3 18 mm to 1 4 6 35 mm thick fireproof resilient gasket between duct unit and floor Side return is a field option on slope coil models Cut opening per dimensions See Fig 1 A field supplied bottom closure is required All return air must pass through the coil C Horizontal Installations Units must not be installed with access panels facing up or down 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 2 2 496 01 4201 01 INSTALLATION INSTRUCTIONS POWER ENTRY OPTIONS 24 17 5 444 5 mm 36 48 21 533 4 60 24 609 6 FRONT SERVICE CLEARANCE UPFLOW DOWNFLOW SECONDARY DRAIN UPFLOW DOWNFLOW PRIMARY DRAIN UPFLOW DOWNFLOW SECONDARY
33. otor is idle If during operation the fan coil control does not communicate with the motor 12 496 01 4201 01 INSTALLATION INSTRUCTIONS for more than 25 seconds the motor will shut itself down and wait for communications to be reestablished D Using Motor LED in Troubleshooting The MOTOR LED is connected to the blower motor communication line and works with the fan coil control microprocessor and the STATUS LED to provide fan coil operation and troubleshooting information When the motor is commanded to operate the MOTOR LED will be turned on and will flash each time instructions are sent to the motor When the motor is commanded to stop the MOTOR LED will be turned off If the MOTOR LED is lit flashing and the motor is running or if the MOTOR LED is off and the motor is stopped operation is normal and no motor fault exists If the MOTOR LED is lit flashing and the motor does not run or if the MOTOR LED is off and the motor is running check the STATUS LED for the Status Code Refer to the troubleshooting instructions for the indicated Status Code in Section E Fan Coil Troubleshooting E Fan Coil Troubleshooting Fan coil faults indicated by flashing codes on the amber system STATUS LED can be resolved using troubleshooting information provided below Codes are listed in order of their priority highest to lowest Though multiple faults can exist at any time only the highest priority code will be displayed on STATUS
34. r 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 Always evacuate coil and field supplied tubing to 500 microns before opening outdoor unit service valves CAUTION PRODUCT DAMAGE HAZARD Failure to follow this caution may result in product or property damage A brazing shield MUST be used when tubing sets are being brazed to the unit connections to prevent dam age to the unit surface and condensate pan fitting caps 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 connection using silver bearing or non silver bearing brazing materials Do not use solder materials which melt below 800 F 427 C Consult local code requirements A CAUTION PRODUCT DAMAGE HAZARD Failure to follow this caution may result in product or property damage Wrap a wet cloth around rear of fitting to prevent dam age to TXV and factory made joints 4 Evacuate coil and tubing system to 500 microns using deep vacuum method Fan Coils FCM4X Procedure 6 Condensate Drain A CAUTION PRODUCT DAMAGE HAZARD Failure to follow this caution may result in product or prop
35. rap all filter driers and service valves with wet cloth when brazing A factory approved liquid line filter drier is required on every unit Do NOT use an R 22 TXV If indoor unit is equipped with an R 22 TXV or piston metering device it must be changed to a hard shutoff R 410A refrigerant TXV Never open system to atmosphere while it is under a vacuum When system must be opened for service recover refrigerant evacuate then break vacuum with dry nitrogen and replace filter driers Evacuate to 500 microns prior to recharging Do not vent R 410A refrigerant into the atmosphere Do not use capillary tube coils Observe all warnings cautions and bold text All indoor coils must be installed with a hard shutoff R 410A refrigerant TXV metering device International Comfort Products LLC 496 01 4201 01 Lewisburg TN 37091 USA 17
36. sformer circuit is referenced to chassis ground through a printed circuit run at SEC2 and metal PC board mounting eyelets Check to be sure PC Board is mounted securely using both factory installed screws NOTE Mis wiring or shorting any of the low voltage connections may cause the low voltage fuse to open but will not damage the Wall Control or fan coil control Simply rewire and replace fuse to correct fault Procedure 8 Accessory Installation A Accessory Electric Heaters Electric heaters may be installed with the fan coil per instructions supplied with electric heater package See unit rating plate for factory approved electric heater kits B Outdoor Air Thermistor OAT A 2 screw terminal strip is provided for connection of an outdoor temperature thermistor This strip is marked OAT The installation of an outdoor temperature sensor using the fan coil OAT terminals is optional If the outdoor unit is not equipped for communications fan coil OAT input can be used to supply outdoor temperature data for system level functions and for temperature display on Wall Control Communicating outdoor units are shipped with a factory installed OAT This factory installed OAT is used for all outdoor unit specific and system level functions 10 496 01 4201 01 INSTALLATION INSTRUCTIONS requiring outdoor temperature if an OAT is not added to fan coil If an OAT is added in the fan coil the fan coil connected OAT will be used for
37. t over tighten Finger tighten plus 1 1 2 turns Use pipe dope Figure 11 Recommended Condensate Trap 496 01 4201 01 INSTALLATION INSTRUCTIONS Figure 12 Condensate Trap and Unit FILTER ACCESS PANEL SECONDARY DRAIN WITH APPROPRIATE TRAP REQUIRED USE FACTORY KIT OR FIELD SUPPLIED TRAP PRIMARY TRAP REQUIRED USE FACTORY KIT OR FIELD SUPPLIED TRAP OF SUFFICIENT DEPTH STANDARD P TRAPS ARE NOT SUFFICIENT SEE FIGURE OF RECOMMENDED CONDENSATE TRAP CAUTION PRODUCT DAMAGE HAZARD Failure to follow this caution may result in product or property damage Shallow running traps are inadequate and DO NOT al low proper condensate drainage See Fig 13 Figure 13 Insufficient Condensate Trap DO NOT USE SHALLOW RUNNING TRAPS 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 entire unit and a secondary condensate line with appropriate trap should be run from 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 use of a separate 3 4 in condensate line with appropriate
38. ties may allow the alterative of running a separate secondary condensate line Consult local codes for additional restrictions or precautions FCM4X fan coils can be installed for upflow and horizontal left applications as factory shipped See Figures 1 2 and 3 FCM4X units can be installed for horizontal right applications with field modifications FCM4X units may be converted for downflow applications using factory authorized accessory kits NOTE To ensure proper drainage for horizontal installations unit must be installed so it is within 1 8 3 18 mm level of the length and width of unit A Modular Units The FCM4X60 Fan Coil are 2 piece modular units Modular construction allows installer to disassemble unit into 2 components coil box and blower box for ease of installation To disassemble unit remove rear corner brackets by removing 2 screws which secure brackets Remove either 2 screws in each front corner of coil box or 2 screws in blower box See Fig 4 Do not remove all 4 screws in each corner 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 Fan Coils FCM4X R 410A refrigerant and must be used only with R 410A refrigerant air conditioners and heat pumps as shipped These units are designed to meet low air leak requirements currently in effect Because of this units need special attenti
39. trap to a place where 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 Fan Coils FCM4X Install traps in condensate lines as close to the coil as possible See Fig 12 Make sure that the outlet of each trap is below its connection to the condensate pan to prevent condensate from overflowing drain pan Prime all traps test for leaks and insulate traps if located above a living area A CAUTION PRODUCT DAMAGE HAZARD Failure to follow this caution may result in product or property damage Never run unit without a filter or with filter access door removed 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 return duct system Table 1 Filter Kits PART NUMBER SIZE USED WITH FILTER KIT EBAC01FKM 24 12 PACK EBAC01FKL 36 48 EBAC01FKX 60 Procedure 7 Unit Start Up Refer to outdoor unit Installation Instructions for system start up instructions and refrigerant charging method details A Low Voltage Circuit Fusing and Reference The low voltage circuit is fused by a board mounted 3 amp automotive fuse placed in series with transformer SEC1 and R circuit The C circuit of tran
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