Carrier FX4D Instruction manual

DIRECT EXPANSION FAN COIL UNITS
FOR PURON® REFRIGERANT
SIZES 019 TO 061
FX4D
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability, or
operation.
WARNING
!
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ELECTRICAL OPERATION HAZARD
HEATER PACKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Failure to follow this warning could result in personal injury
or death.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Step 1 -- Check Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 2 -- Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 3 -- Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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. Lock out and tag switch
with a suitable warning label.
Step 4 -- Electrical Connections . . . . . . . . . . . . . . . . . . . . . . 4
Step 5 -- Refrigerant Tubing Connection and Evacuation . . . 7
Step 6 -- Refrigerant Flow--Control Device . . . . . . . . . . . . . . 7
CAUTION
!
Step 7 -- Condensate Drains . . . . . . . . . . . . . . . . . . . . . . . . . 8
CUT HAZARD
Step 8 -- Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Failure to follow this caution may result in personal injury.
Step 9 -- Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . 9
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing and gloves when
handling parts.
START--UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 10
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 10
AIRFLOW PERFORMANCE TABLES . . . . . . . . . . . . . . . . 11
PURONR (R--410A) QUICK REFERENCE GUIDE . . . . . . 12
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, 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 kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit. Consult local
building codes and the current editions of the National Electrical
Code (NEC) NFPA 70.
In Canada, refer to the current editions of the Canadian Electrical
Code CSA C22.1.
.
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instruction 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. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which may result in minor personal
INTRODUCTION
Model FX4D is designed for flexibility and can be used for
upflow, horizontal, or downflow (kit required) and manufactured
and mobile home applications. These units are designed to meet
the low air leak requirements currently in effect. Because of this,
the units need special attention in the condensate pan and drain
connection area and when brazing tubing. These units are designed
specifically for Puronr refrigerant and must be used only with
Puronr refrigerant air conditioners and heat pumps as shipped.
These units are available for systems of 18,000 through 60,000
Btuh nominal cooling capacity. Factory--authorized, field--installed
electric heater packages are available in sizes 5 through 30kW. See
Product Data literature for available accessory kits.
HEATER PACKAGES
This unit may or may not be equipped with an electric heater
package. For units not equipped with factory--installed heat, a
factory--approved, field--installed, UL listed heater package is
available from your equipment supplier. See unit rating plate for a
list of factory--approved heaters. Heaters that are not factory
approved could cause damage which would not be covered under
the equipment warranty. If fan coil contains a factory--installed
heater package, minimum circuit ampacity (MCA) and maximum
fuse/breaker may be different than units with a same size
field--installed accessory heater. The difference is not an error and
is due to calculation diferences per UL guidelines.
INSTALLATION
!
Step 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.
UNIT 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
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. Remove 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.
FX4D
Step 2 — Mount Unit
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 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 alternative, the running of a
separate, secondary condensate line. Consult local codes for
additional restrictions or precautions.
A. Upflow Installation
If return air is to be ducted through a floor, set unit on floor over
opening and use 1/8 to 1/4--in (3 to 6 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.
FIELD SUPPLIED
SUPPLY DUCT
POWER ENTRY
OPTIONS
LOW VOLT
ENTRY
OPTIONS
019 - 049 21" (533 mm) FRONT SERVICE
061
24" (610mm) CLEARANCE
UNIT
A
019, 025
17" (432 mm)
031
19" (483 mm)
A COIL
UNITS
UPFLOW/DOWNFLOW
SECONDARY DRAIN
CAUTION
NOTE: To convert units for downflow applications, refer to
Installation Instructions supplied with kit for proper installation.
For slope fan coils, use kit Part No. KFADC0201SLP. For A--coils,
use kit Part No. KFADC0401ACL. Use fireproof resilient gasket,
1/8 to 1/4--in (3 to 6 mm) thick, between duct, unit, and floor.
NOTE: Gasket kit number KFAHD0101SLP is also required for
all downflow applications to maintain low air leak/low sweat
performance.
C. Horizontal Installation
Units must not be installed with access panels facing up or down.
All other units are factory built for horizontal left installation. (See
Fig. 2 and 3.) When suspending unit from ceiling, dimples in
casing indicate suitable location of screws for mounting metal
support straps. (See Fig. 2.)
For horizontal applications having high return static and humid
return air, the Water Management Kit, KFAHC0125AAA, may
need to be used to assist in water management.
1.5" (38 mm)
19" (483 mm)
UPFLOW/DOWNFLOW
PRIMARY DRAIN
A-COIL
HORIZONTAL LEFT
2.5"
(64 mm)
A
FIELD MODIFIED
SIDE RETURN
LOCATION FOR
SLOPE COIL
UNITS ONLY
UPFLOW/DOWNFLOW
SECONDARY DRAIN
UPFLOW/DOWNFLOW
PRIMARY DRAIN
SECONDARY
DRAIN
FIELD
SUPPLIED
HANGING
STRAPS
FIELD SUPPLIED
RETURN PLENUM
PRIMARY
DRAIN
018-048 21" (533 mm)
060-060 24" (610 mm)
FRONT SERVICE
CLEARANCE
(FULL FACE
OF UNIT)
UNIT
A09382
Fig. 1 -- Slope Coil Unit in Upflow Application
B. Downflow Installation
In this application, field conversion of the evaporator is required
using accessory downflow kit along with an accessory base kit.
Use fireproof resilient gasket, 1/8 to 1/4--in (3 to 6 mm) thick,
between duct, unit, and floor.
LOW VOLT
ENTRY
OPTIONS
1.75" (44 mm)
FILTER ACCESS
CLEARANCE
PRIMARY
DRAIN
POWER
ENTRY OPTIONS
SECONDARY
DRAIN
A07566
Fig. 2 -- Slope Coil Unit in Horizontal Left Application
2
A
COIL
BRACKET
FA CT OR Y SHIPPED
HORIZONTAL LEFT
APPLICATION
COI L
SUPPORT
RAIL
B
C
DRAIN PA N
SUPPORT
BRACKET
COIL
BRACKET
HORIZONTAL
DRAIN PAN
6. Make sure the pan cap in the fitting door is properly seated
on the fitting door to retain the low air leak rating of the
unit.
7. Add gaskets from kit KFAHD per kit instructions.
8. Align holes with tubing connections and condensate pan
connections, and reinstall access panels and fitting panel.
Make sure liquid and suction tube grommets are in place to prevent
air leaks and cabinet sweating. Install after brazing.
COIL MOUNTING
SCREW
PRIMARY DRAIN
HORIZONTAL LEFT
AIR SEAL
ASSEMBLY
BLOWER
ASSEMBLY
SECONDARY DRAIN
HORIZONTAL LEFT
REFRIGERANT
CONNECTIONS
A00072
Fig. 3 -- A--Coil in Horizontal Left Application
(Factory Ready)
COIL
SUPPORT
RAIL
CAUTION
SLOPE COIL
SKI
DRAINPAN
PROPERTY DAMAGE HAZARD
REFRIGERANT
CONNECTIONS
Failure to follow this caution may result in product or property
damage.
For optimum condensate drainage performance in horizontal
installations, unit should be leveled along its length and width.
NOTE: Modular units can be disassembled and components
moved separately to installation area for reassembly. This process
accommodates small scuttle holes and limiting entrances to
installation sites. (See Fig. 4.)
FX4D
!
PRIMARY DRAIN
SECONDARY DRAIN
A03001
Fig. 5 -- Conversion for Horizontal Right Applications
Using a Slope Coil
Horizontal Right Conversion of Units With A--Coils
1. Remove blower and coil access panels. (See Fig. 6.)
A
REFRIGERANT
CONNECTIONS
AIR SEAL
ASSEMBLY
HORIZONTAL
RIGHT
APPLICATION
COIL
SUPPORT
RAIL
COIL
BRACKET
B
C
DRAIN PAN
SUPPORT
BRACKET
BLOWER BOX
COIL
SUPPORT
RAIL
2 SCREWS
2 SCREWS
COIL
BRACKET
HORIZONTAL
DRAIN PAN
PRIMARY DRAIN
HORIZONTAL RIGHT
SECONDARY DRAIN
HORIZONTAL RIGHT
REAR CORNER
BRACKET
A00071
2 SCREWS
Fig. 6 -- Conversion for Horizontal Right Applications
Using A--Coil
2. Remove metal clip securing fitting panel to condensate pan.
Remove fitting panel.
3. Remove 2 snap--in clips securing A--coil 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. (See Fig. 7.)
COIL BOX
A95293
Fig. 4 -- Removal of Brackets on Modular Units
Horizontal Right Conversion of Units With Slope Coils
NOTE: Gasket kit number KFAHD0101SLP is required for
horizontal slope coil conversion to maintain low air leak/low sweat
performance.
1. Remove blower and coil access panel and fitting panel. (See
Fig. 5.)
2. Remove coil mounting screw securing coil assembly to
right side casing flange.
3. Remove coil assembly.
4. Lay fan coil unit on its right side and reinstall coil assembly
with condensate pan down. (See Fig. 5.)
5. Attach coil to casing flange using coil mounting screw previously removed.
3
b. If fan coil is against wall, secure fan coil to wall stud
using 1/8--in (3 mm) 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. 8.)
DRAIN PAN
SUPPORT BRACKET
4” (102mm) MAX
SECURE FAN COIL TO STRUCTURE
UNIT AWAY FROM WALL
PIPE STRAP
(TYPICAL BOTH SIDES)
OR
UNIT AGAINST WALL
.125" (3mm)
MOUNTING BRACKET
(TYPICAL BOTH SIDES)
A07571
FX4D
Fig. 7 -- Drain Pan Support Bracket
6. Convert air--seal assembly for horizontal right.
a. Remove air--seal assembly from coil by removing 4
screws. (See Fig. 6.)
b. Remove air splitter (B) from coil seal assembly by removing 3 screws. (See Fig. 3--factory shipped inset.)
c. Remove filter plate (A) and install air splitter (B) in
place of filter plate.
d. Install filter 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 horizontal pan on right side of coil assembly.
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 offsets is used
on right side of unit to secure horizontal pan.
10. Remove two oval fitting caps from the left side of the coil
door and fitting panel.
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 item 10) in the
right side of the coil door making sure that the cap snaps
and seats cleanly on the back side of the coil door. Make
sure no insulation interferes with seating of the cap.
14. Reinstall access 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 place to prevent
air leaks and cabinet sweating.
D. Manufactured and Mobile Home Housing Applications
1. Fan coil unit must be secured to the structure using field-supplied hardware.
2. Allow a minimum of 24--in (610 mm) 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.
DOWN FLOW
BASE KIT (KFACB)
SECURE UNIT TO FLOOR
ANGLE BRACKET OR PIPE STRAP
4” (102mm) MAX
A07567
Fig. 8 -- A--Coil
Step 3 — Air Ducts
Connect supply--air duct over the outside of 3/4--in (19 mm)
flanges provided on supply--air opening. Secure duct to flange,
using proper fasteners for type of duct used, and seal duct--to--unit
joint. If return--air flanges are required, install factory--authorized
accessory kit.
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.
Units equipped with 20--30kW electric heaters require a 1--in (25
mm) clearance to combustible materials for the first 36--in (914
mm) of supply duct.
Ductwork Acoustical Treatment
Metal duct systems that do not have a 90_ elbow and 10--ft (3m) 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 as tested by UL Standard 181 for Class
1 air ducts.
Step 4 — Electrical Connections
All products from the factory protect the low voltage circuit with a
5 amp automotive type fuse inline on the wire harness. Speed
selections are made at the fan motor by selecting taps 1, 2 or 3 with
the blue wire (see section E). The motor is pre--programmed with
the time delay circuit on some of the speed taps ( see section E for
clarification).
When a factory--approved accessory control package has been
installed, check all factory wiring per unit wiring diagram and
inspect factory wiring connections to be sure none were loosened
in transit or installation. If a different control package is required,
see unit rating plate.
4
!
CAUTION
FAN COIL
THERMOSTAT
RED
R
PROPERTY DAMAGE HAZARD
G
Failure to follow this caution may result in product or
property damage.
W
R
GRY
G
WHT
W2
WHT
BLU
If a disconnect switch is to be mounted on unit, select a
location where drill or fastener will not contact electrical or
refrigerant components.
W3
VIO
E
BRN
C
AIR COND.
C
Before proceeding with electrical connections, make certain that
supply voltage, frequency, phase, and ampacity are as specified on
the unit rating plate. See unit wiring label for proper field high-and low--voltage wiring. Make all electrical connections in
accordance with the 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.
On units with a factory--installed disconnect with pull--out
removed, service and maintenance can be safely performed on only
the load side of the control package.
!
Y
Y
A09383
Fig. 9 -- Wiring Layout Air Conditioning Unit
(Cooling Only)
RED
R
R
GRY
G
W
G
WHT
W2
WHT
BLU
WARNING
FX4D
FAN COIL
THERMOSTAT
W3
VIO
E
BRN
C
ELECTRICAL SHOCK HAZARD
AIR COND.
C
Failure to follow this warning could result in personal injury
or death.
Y
Y
Field wires on the line side of the disconnect found in the fan
coil unit remain live, even when the pull--out is removed.
Service and maintenance to incoming wiring cannot be
performed until the main disconnect switch (remote to the
unit) is turned off. Lock out and tag switch with a suitable
warning label.
A09384
Fig. 10 -- Wiring Layout Air Conditioning Unit
(Cooling and 1--Stage Heat)
THERMOSTAT
R
G
A. Line Voltage Connections
If unit will contain 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.)
For units without electric heater:
1. Connect 208/230v power leads from field disconnect to yellow and black stripped leads.
2. Connect ground wire to unit ground lug.
NOTE: Units installed without electric heat should have a
field--supplied sheet metal block--off plate covering the heater
opening. This will reduce air leakage and formation of exterior
condensation.
B. 24--v Control System
Connection To Unit
Wire low voltage in accordance with wiring label on the blower.
(See Fig. 9 through 14.) Use no. 18 AWG color--coded, insulated
(35_C minimum) wire to make the low--voltage connections
between the thermostat, the unit, and the outdoor equipment. If the
thermostat is located more than 100--ft (30 m) from the unit (as
measured along the low--voltage wire), use no. 16 AWG
color--coded, insulated (35_C minimum) wire. All wiring must be
NEC Class 1 and must be separated from incoming power leads.
Refer to outdoor unit wiring instructions for any additional wiring
procedure recommendations.
C
W2
E
FAN COIL
RED
GRY
BRN
R
HEAT PUMP
(CONTROL)
R
G
C
C
WHT W
2
BLU
W3
VIO
E
L
W2
O
O
Y
Y
A09385
Fig. 11 -- Wiring Layout Heat Pump Unit
(Cooling and 2--Stage Heat with No Outdoor Thermostat)
5
FAN COIL
THERMOSTAT
R
RED
G
GRY G
BRN
C
HEAT PUMP
(CONTROL)
R
R
C
C
WHT W
2
VIO
E
W2
E
THERMOSTAT
W2
BLU W
3
ODTS
L
O
Y
Y
C
C
C
W2
W2
W3
W2
E
E
ODTS
RED
R
HEAT PUMP
(CONTROL)
R
R
G
GRY G
C
BRN C
W2
WHT W
2
E
Y
A09388
Fig. 14 -- Wiring Layout Heat Pump Unit
(Cooling and 2--Stage Heat for Manufactured Housing)
Transformer Information
Transformer is factory--wired for 230v operation. For 208v
applications, disconnect the black wire from the 230v terminal on
transformer and connect it to the 208v terminal. (See Fig. 15.)
SECONDARY
C
BLU ODTS1
W3
VIO
E
ODTS2
L
O
W2
BRN
RED
O
Y
Y
YEL
230
O
208
C
FX4D
R
G
Y
Fig. 12 -- Wiring Layout Heat Pump Unit
(Cooling and 2--Stage Heat with 1 Outdoor Thermostat)
FAN COIL
R
R
O
A09386
THERMOSTAT
HEAT PUMP
(CONTROL)
G
L
O
FAN COIL
BLK
PRIMARY
A05182
Fig. 15 -- Transformer Connections
C
1
4
7
C
9
6
Heater Staging
3
!
EMERGENCY HEAT RELAY
A09387
CAUTION
PROPERTY DAMAGE HAZARD
Fig. 13 -- Wiring Layout Heat Pump Unit (Cooling and
2--Stage Heat with 2 Outdoor Thermostats)
Failure to follow this caution may result in product or
property damage.
If W2, W3, and E on any 3 stage heater (18, 20, 24, or
30kW) are individually connected as with outdoor
thermostats or any other situation, emergency heat relay must
be used. This relay is in kit Part No. KHOT0201SEC and is
normally used with kit Part No. KHAOT0301FST for 2
outdoor thermostat systems.
The controls are factory circuited for single--stage operation. For
2--stage operation, use outdoor thermostat kit Part No.
KHAOT0301FST, and for 3--stage use both kits Part No.
KHAOT0201SEC and KHAOT0301FST.
6
When 2 stages are desired, cut W3 at the W2 wire nut, strip and
reconnect per the thermostat kit instruction. (See Fig. 12.) When 3
stages are desired, cut the W2 wire nut off and discard. Strip W2,
W3, and E and reconnect per thermostat kit instructions. (See Fig.
13.)
NOTE: When 3 stages are used or anytime the E terminal is not
tied to W2, the emergency heat relay, part of outdoor kit Part No.
KHAOT0201SEC must be used.
C. 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_C), except for a heat pump defrost cycle. Refer to
Fig. 14 for typical low voltage wiring with outdoor thermostat.
D. Ground Connections
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
According to NEC, ANSI/NFPA 70, and local codes, the
cabinet must have an uninterrupted or unbroken ground to
minimize personal injury if an electrical fault should occur.
The ground may consist of electrical wire or metal conduit
when installed in accordance with existing electrical codes. If
conduit connection uses reducing washers, a separate ground
wire must be used.
NOTE: Use UL--listed conduit and conduit connector for
connecting supply wire(s) to unit to obtain proper grounding.
Grounding may also be accomplished by using grounding lugs
provided in control box.
E. Minimum CFM and Motor Speed Selection
Units with or without electric heaters require a minimum CFM.
Refer to the unit wiring label to ensure that the fan speed selected is
not lower than the minimum fan speed indicated. Fan speed is
selected at the motor. To change motor speeds disconnect the blue
fan lead from terminal two and move to desired speed tap; low
(one), medium (two), and high (three). Speed taps one, two and
three have a 90 second blower time delay pre--programmed into the
motor. Speed tap (four) is used for electric heat only (with 0 second
blower time delay) and the white wire must remain on tap four.
Speed tap (five) is the same CFM as speed tap three, but has a 0
second blower time delay pre--programmed into the motor (see
Airflow Performance Table 1 for actual CFM for each tap). See
Fig. 16.
NOTE: In low static applications, lower motor speed tap should
be used to reduce possibility of water being blown off coil.
A09390
Fig. 16 -- Motor Speed Selection
Step 5 — Refrigerant Tubing Connection and
Evacuation
Use accessory tubing package or field--supplied tubing of
refrigerant grade. Suction tube must be insulated. Do not use
damaged, dirty, or contaminated tubing because it may plug
refrigerant flow--control device. ALWAYS evacuate the 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 damage 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.
4. Evacuate coil and tubing system to 500 microns using deep
vacuum method.
!
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 damage to
TXV and factory--made joints.
Step 6 — Refrigerant Flow--Control Device
The FX4D is equipped with PuronR refrigerant TXV. Use outdoor
units designed for PuronR refrigerant only.
7
FX4D
!
1 2 3 4 5
!
CAUTION
PRODUCT OPERATION HAZARD
Failure to follow this caution may result in improper product
operation.
FILTER
ACCESS
PANEL
If using a TXV in conjunction with a single--phase
reciprocating compressor, a compressor start capacitor and
relay are required. Consult outdoor unit pre--sale literature for
start assist kit part number.
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)
Step 7 — Condensate Drains
FX4D
To connect drains, the cap openings must be removed. Use a knife
to start the opening near the tab and using pliers, pull the tab to
remove the disk. Clean the edge of the opening if necessary and
install the condensate line. Finally caulk around the lines where
they exit the fitting to retain the low leak rating of the unit.
!
A03003
Fig. 18 -- Condensate Trap and Unit
!
CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
UNIT OR PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
Shallow running traps are inadequate and DO NOT allow
proper condensate drainage. (See Fig. 19.)
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.
Remove 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.
Units are equipped with primary and secondary 3/4--in. FPT drain
connections. For proper condensate line installations see Fig. 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 Fig. 17 and 18.) Factory--approved condensate traps are
available. It is recommended that PVC fittings be used on the
plastic condensate pan. Finger--tighten plus 1--1/2 turns. Do not
over--tighten. Use pipe dope.
UNIT
2” MIN
(51 mm)
2” MIN
(51 mm)
A03002
Fig. 17 -- Recommended Condensate Trap
CAUTION
DO NOT USE SHALLOW RUNNING TRAPS!
A03013
Fig. 19 -- Insufficient Condensate Trap
NOTE: When connecting condensate drain lines, avoid blocking
filter access panel, thus preventing filter removal. After connection,
prime both primary and secondary condensate traps.
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 use of a separate 3/4--in (19 mm) 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. 18.) 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 traps if located above a living area. Condensate drain lines
should be pitched downward at a minimum slope of 1--in (25 mm)
for every 10--ft (3 m) of length. Consult local codes for additional
restrictions or precautions.
8
Step 9 — Sequence of Operation
A. Humidifier
Connect humidifier and humidistat to fan coil unit as shown in Fig.
20 and Fig. 21. The cooling lockout relay is optional.
A. Continuous Fan
Thermostat closes R to G. G energizes fan relay on PCB which
completes circuit to indoor blower motor. When G is de--energized,
there is a 90 second delay before relay opens.
NOTE: Speed taps 1, 2 and 3 have a 90 second blower off delay.
Speed taps 4 and 5 have 0 second blower off delay.
B. Cooling Mode
Thermostat energizes R to G, R to Y, and R to O (heat pump only).
G energizes fan relay on PCB which completes circuit to indoor
blower motor. When G is de--energized, there is a 90 second delay
before fan relay opens.
NOTE: Speed taps 1, 2 and 3 have a 90 second blower off delay.
Speed taps 4 and 5 have 0 second blower off delay.
C. Heat Pump Heating with Auxiliary Electric Heat
Thermostat energizes R to G, R to Y, and R to W. G energizes fan
relay on PCB which completes circuit to indoor blower motor. W
energizes electric heat relay(s) which completes circuit to heater
element(s). When W is de--energized, electric heat relay(s) open,
turning off heater elements. When G is de--energized there is a 90
second delay before fan relay opens.
NOTE: Speed taps 1, 2 and 3 have a 90 second blower off delay.
Speed taps 4 and 5 have 0 second blower off delay.
D. Electric Heat or Emergency Heat Mode
Thermostat closes R to W. W energizes electric heat relay(s) which
completes circuit to heater element(s). Blower motor is energized
through normally closed contacts on fan relay. When W is
de--energized, electric heat relay(s) opens.
FAN COIL
THERMOSTAT
RED
R
R
GRY
G
W2
WHT
E
C
C
WHT W
2
BLU
W3
VIO
E
L
W2
O
O
Y
Y
FAN HUMIDIFIER
115V
R
G
BRN
C
HEAT PUMP
(CONTROL)
RELAY
M
HUMIDISTAT
START--UP PROCEDURES
Refer to outdoor unit Installation Instructions for system start--up
instructions and refrigerant charging method details.
!
A09391
Fig. 20 -- Wiring Layout of Humidifier to Heat Pump
CAUTION
UNIT COMPONENT HAZARD
RED
R
GRY
G
W
Failure to follow this caution may result in product damage.
FAN COIL
THERMOSTAT
WHT
WHT
BLU
VIO
BRN
W2
Never operate unit without a filter. Damage to blower motor
or coil may result. Factory authorized filter kits must be used
when locating the filter inside the unit. For those applications
where access to an internal filter is impractical, a
field--supplied filter must be installed in the return duct
system.
W3
CARE AND MAINTENANCE
R
G
E
AIR COND.
C
C
Y
Y
HUMIDISTAT
FAN HUMIDIFIER
115V
To continue high performance and minimize possible equipment
failure, it is essential that periodic maintenance be performed on
this equipment. Consult your local dealer as to the proper
frequency of maintenance contract.
The ability to properly perform maintenance on this equipment
requires certain mechanical skills and tools. If you do not possess
these, contact your dealer for maintenance. The only consumer
service recommended or required is filter replacement or cleaning
on a monthly basis.
M
A09389
Fig. 21 -- Wiring Layout of Humidifier to Fan Coil
With Electric Heat
9
FX4D
Step 8 — Accessories
AIRFLOW PERFORMANCE TABLES
Table 1 – Airflow Performance (CFM)
MODEL & SIZE
BLOWER SPEED
Tap 5
Tap 4
Tap 3
Tap 2
Tap 1
Tap 5
Tap 4
Tap 3
Tap 2
Tap 1
Tap 5
Tap 4
Tap 3
Tap 2
Tap 1
Tap 5
Tap 4
Tap 3
Tap 2
Tap 1
Tap 5
Tap 4
Tap 3
Tap 2
Tap 1
Tap 5
Tap 4
Tap 3
Tap 2
Tap 1
Tap 5
Tap 4
Tap 3
Tap 2
Tap 1
FX4D 019
FX4D
FX4D 025
FX4D 031
FX4D 037
FX4D 043
FX4D 049
FX4D 061
0.10
776
683
683
631
625
956
825
825
726
631
1189
1041
1041
924
779
1363
1237
1237
1095
1014
1519
1437
1437
1257
1237
1757
1664
1664
1459
1301
2030
1811
1811
1665
1462
0.20
745
644
644
563
524
920
795
795
695
563
1151
998
998
876
693
1332
1206
1206
1058
885
1490
1403
1403
1226
1206
1725
1626
1626
1420
1241
1995
1775
1775
1632
1418
EXTERNAL STATIC (in. wc)
0.30
0.40
696
660
589
548
589
548
500
443
457
417
891
851
757
722
757
722
635
598
500
443
1104
1050
944
886
944
886
817
752
628
571
1294
1253
1160
1121
1160
1121
1007
951
773
673
1454
1419
1366
1333
1366
1333
1191
1141
1160
1121
1693
1653
1593
1552
1593
1552
1379
1336
1195
1150
1961
1927
1740
1703
1740
1703
1593
1556
1371
1327
0.50
609
494
494
409
367
816
674
674
543
409
1003
837
837
704
526
1207
1070
1070
888
609
1379
1294
1294
1090
1070
1614
1517
1517
1298
1102
1888
1664
1664
1507
1278
0.60
572
461
461
361
319
780
634
634
509
361
959
772
772
660
476
1157
1013
1013
824
549
1332
1245
1245
1033
1013
1576
1477
1477
1259
1039
1842
1613
1613
1453
1228
--- Shading --- Airflow outside 450 cfm/ton.
NOTES:
1. Airflow based upon dry coil at 230v with factory approved filter and electric heater (2 element heater sizes 019 through 037, 3 element heater sizes
043 through 061).
2. Airflow at 208 volts is approximately the same as 230 volts because the X13 motor is a constant torque motor. The torque doesn’t drop off at the
speeds the motor operates.
3. To avoid potential for condensate blowing out of drain pan prior to making drain trap:
Return static pressure must be less than 0.40 in. wc.
Horizontal applications of 043 --- 061 sizes must have supply static greater than 0.20 in. wc.
4. Airflow above 400 cfm/ton on 049 --- 061 size could result in condensate blowing off coil or splashing out of drain pan.
Table 2 – Air Delivery Performance Correction Component Pressure Drop (in. wc) at Indicated Airflow (Dry to Wet Coil)
FX
Size
019
025
031
037
043
049
061
500
0.034
0.016
--- ----- ----- ----- ----- ---
600
0.049
0.027
--- ----- ----- ----- ----- ---
700
0.063
0.038
--- ----- ----- ----- ----- ---
800
--- --0.049
0.049
--- ----- ----- ----- ---
900
--- --0.059
0.059
--- ----- ----- ----- ---
1000
--- ----- --0.070
0.055
--- ----- ----- ---
1100
--- ----- --0.080
0.064
--- ----- ----- ---
CFM
1200 1300
--- ----- ----- ----- ----- ----- --0.073 0.081
0.049 0.056
--- ----- ----- ----- ---
10
1400
--- ----- ----- ----- --0.063
0.038
--- ---
1500
--- ----- ----- ----- --0.070
0.043
--- ---
1600
--- ----- ----- ----- ----- --0.049
0.027
1700
--- ----- ----- ----- ----- --0.054
0.031
1800
--- ----- ----- ----- ----- --0.059
0.035
1900
--- ----- ----- ----- ----- ----- --0.039
2000
--- ----- ----- ----- ----- ----- --0.043
AIRFLOW PERFORMANCE TABLES (cont.)
Table 3 – Factory--Installed Filter Static Pressure Drop (in. wc)
FX SIZE
019
025 --- 031
037--- 049
061
400
0.020
-------
600
0.044
0.022
-----
800
0.075
0.048
-----
CFM
1200
--0.100
0.070
---
1000
--0.072
0.051
---
1400
----0.092
---
1600
----0.120
0.086
1800
----0.152
0.105
2000
------0.130
HEATER
ELEMENTS
kW
0
1
2
3
4
0
3, 5
8, 10
9, 15
20
EXTERNAL STATIC
PRESSURE
CORRECTION
+.02
+.01
0
–.02
–.04
FX
043 --- 061
HEATER
ELEMENTS
kW
0
2
3
4
6
0
8, 10
9, 15
20
18, 24, 30
11
EXTERNAL STATIC
PRESSURE
CORRECTION
+.04
+.02
0
–.02
–.10
FX4D
Table 4 – Electric Heater Static Pressure Drop (in. wc)
FX
019 --- 037
PURONR (R--410A) QUICK REFERENCE GUIDE
S
FX4D
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
Puron refrigerant operates at 50--70 percent higher pressures than R--22. Be sure that servicing equipment and replacement
components are designed to operate with Puron refrigerant.
Puron refrigerant cylinders are rose colored.
Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
Puron 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.
Puron 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 Puron 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.
Wrap 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 a R--22 TXV or piston metering device, it must be changed to a hard--shutoff Puron 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 Puron 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 Puron refrigerant TXV metering device.
Copyright 2009 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231
Printed in U.S.A.
Edition Date: 07/09
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
12
Catalog No: IM---FX4D---01
Replaces: NEW