Installation and Start-Up Instructions

Direct Expansion

Fan Coil

002-007

FK4A

NOTE:

Read the entire instruction before starting the installation.

INTRODUCTION

Model FK4A Fan-Coil Units are designed for flexibility in a variety of applications for upflow, horizontal, or downflow applications.

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 3 through 30 kw. See product data for accessory kits available.

WARNING: Before installing or servicing fan coil, always turn off all power to unit. There may be more than one disconnect switch. Turn off accessory heater power if applicable. Electrical shock can cause personal injury or death.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance.

The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warning or cautions attached to the unit. Consult local building codes and National Electrical Code

(NEC) for special requirements.

It is important to recognize safety information. This is the safety-alert symbol manuals, be alert to the potential for personal injury.

. When you see this symbol on the unit and in instructions or

Understand the signal word—DANGER, WARNING or 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 that could result in personal injury or death.

CAUTION is used to identify unsafe practices, which would result in minor personal injury or product and property damage.

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 rating plate on unit, which contains information needed to properly install unit. Check rating plate to be sure unit matches job specifications.

PROCEDURE 2—MOUNT FAN COIL

Unit can stand or lie on floor, or hang from ceiling or wall. Allow space for wiring, piping, and servicing unit.

IMPORTANT:

When fan coil is installed over a finished ceiling and/or living area, building codes (CABO M-1701.2,UMC 1205,SBCCI 603.4) may require a field-fabricated secondary condensate pan to be installed or unit to have a secondary condensate line. The FK4A Fan Coils are equipped with 3/4-in. primary and secondary drain connections.

When installing any fan coil over a finished ceiling and/or living space, installation of a secondary drain pan under entire unit to avoid damage to ceiling, is recommended.

The FK4A Fan-Coil Units can be installed for upflow and horizontal-left applications as factory shipped. Units can be installed for horizontal-right applications with field modifications. Units may be converted for downflow applications using factory-authorized accessory kit.

NOTE:

To ensure proper drainage for horizontal installations, unit must be installed such that it is level within 1/8 in. in both length and width of unit.

A.

Upflow Installation

If return air is to be ducted, install duct flush with floor. Set unit on floor over opening. Use fireproof resilient gasket, 1/8- to 1/4-in. thick, between duct, unit, and floor.

Only use return-air opening provided. All return air must pass through the coil.

Form: IM-FK4A-02 Cancels: IM-FK4A-01 Printed in U.S.A.

2-92 Catalog No.

92-33FK-4A2

Fig. 1—Model FK4A

A90145

MODEL

FK4A

002

003

004

005

006, 007

In

42-11/16

49-5/8

53-7/16

53-7/16

59-3/16

A

(mm)

1084.3

1260.5

1357.3

1357.3

1503.4

In

17-5/8

17-5/8

21-1/8

21-1/8

24-11/16

B

(mm)

447.5

447.5

536.5

536.5

627.0

In

15-3/4

15-3/4

19-1/4

19-1/4

22-3/4

C

(mm)

400.1

400.1

489.0

489.0

577.9

In

16

16

19-1/2

19-1/2

23

D

(mm)

406.4

406.4

495.3

495.3

584.2

Fig. 2— Dimensional Drawing

—2—

In

10-3/4

15-11/16

15-1/2

15-1/2

25-1/4

E

(mm)

273.1

398.5

393.7

393.7

641.4

A90163

In

—

—

25-1/8

25-1/8

25-1/8

F

(mm)

—

—

638.2

638.2

638.2

B.

Horizontal Installations

Be sure installation complies with all applicable building codes that may require installation of a secondary condensate pan.

1. Arrange support for unit, setting it in or above secondary condensate pan.

2. When suspending unit from ceiling, dimples in casing indicate proper location of screws for mounting metal support straps. (See Fig. 4,

Note *2.)

C.

Modular Units

The FK4A Fan-Coil Units in sizes 004, 005, 006, and 007 are of a two-piece modular construction. Modular construction allows installer to disassemble unit into two components, coil box and blower box, for ease of installation. (See Fig. 5.)

To disassemble unit, remove rear corner brackets by removing the two screws which secure brackets. (See Fig. 5.) Remove at front corners, either two screws in each corner of coil box, or two screws in blower box. Do not remove all four screws in each corner. (See Fig. 5). Sections may now be separated by lifting top section from lower section.

To reassemble, reverse procedure above. Be certain to reinstall all fasteners when reassembling.

D.

Horizontal Right Conversion of Units

To convert units for horizontal right installations:

1. Remove blower and coil access panels. (See Fig. 6.)

2. Remove fitting door clip to plastic condensate pan and remove fitting door.

3. Remove snap-in shipping clip securing A-coil in unit.

4. Remove coil assembly.

5. Remove metal horizontal drain pan from coil assembly.

6. Remove horizontal drain pan support bracket from coil support rail and re-install to the opposite side coil support rail.

7. Remove condensate drain plugs from one side of horizontal drain pan and install in drain connection openings on opposite side.

8. Convert air-seal assembly for horizontal right.

a. Remove air-seal assembly from coil by removing four screws.

b. Remove air splitter (B) from coil seal assembly by removing three screws. (See Fig. 7, factory-shipped inset.) c. Remove filler plate (A) and install air splitter (B) in place of filler plate.

d. Install filler plate (A) as shown in horizontal right application inset Fig. 7.

e. Remove condensate troughs (C) and install on opposite tube sheets. (See Fig. 7 insets.) f. Install hose onto plastic spout.

9. Install horizontal pan on right side of coil assembly with plugged condensate openings to rear of assembly.

A90167

Fig. 3—Horizontal and Upflow Installation Clearances

—3—

A90166

10. Slide coil assembly into casing. Be sure clips on each corner engage coil support rails. (See Fig. 7.)

11. Remove condensate drain knockouts from right side of coil access panel.

12. Reinstall access panels and fitting door, aligning holes with tubing connections and condensate pan connections.

Make sure liquid and suction grommets are in place to prevent air leaks and cabinet sweating.

E.

Downflow Installations

To convert units for downflow applications, refer to installation instructions supplied with kit for proper installation of kit.

PROCEDURE 3—AIR DUCTS

Connect the supply-air duct over the outside of the 3/4-in. flange provided on the supply-air opening. Secure the duct to the flange, using proper fasteners for the type of duct used, and tape the duct-to-unit joint.

Duct connection flanges are provided on unit air-discharge connection. If return-air flanges are required, install factory- authorized accessory kit.

Refer to installation instructions supplied with kit for proper installation of kit.

When using FK4A units with 20-, 24-, and 30-kw electric heaters, maintain a 1-in. clearance from combustible materials, to discharge plenum and ductwork, for a distance of 36 in. from the unit. Use an accessory downflow base to maintain proper clearance on downflow installations.

Use flexible connectors between ductwork and unit to prevent transmission of vibration. When electric heater is installed, use heat resistant material for flexible connector between ductwork and unit at discharge connection. Ductwork passing through unconditioned space must be insulated and covered with vapor barrier.

DUCTWORK ACOUSTICAL TREATMENT—Metal duct systems that do not have one 90 degree elbow and 10 ft of main duct to first branch take off may require internal acoustical insulation lining.

PROCEDURE 4—ELECTRICAL CONNECTIONS

A.

Line-Voltage Connections

Units with 15-, 20-, and 30-kw heaters are factory wired for dual-circuit operation. When single-circuit operation is desired, install factory-authorized adapter kit for fused models only.

Check all factory wiring per unit wiring diagram and inspect factory wiring connections to be sure none were loosened in transit or installation.

WARNING: Before installing or servicing system, always turn

″

off

″

all power to system. There may be more than one disconnect switch. Turn off accessory heater power if applicable. Electrical shock can cause personal injury or death.

CAUTION: If a disconnect switch is to be mounted on the unit, select a location where drill or fastener will not contact electrical or refrigerant components.

NOTE:

Before proceeding with electrical connections, make certain that supply-voltage, frequency, and phase are as specified on the 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 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 to the unit.

B.

24-Volt Control System Connections to Unit Printed-Circuit Board

Refer to unit wiring instructions for recommended wiring procedures. Use No. 18 AWG color-coded, insulated (35 C minimum) wires to make the low-voltage connections between the thermostat and the unit. If the thermostat is located more than 100 ft from the unit (as measured along the low-voltage wires), use No. 16 AWG color-coded, insulated (35 C minimum) wires. Printed-circuit board is circuited for single-stage heater operation. When additional heater staging is desired using 2-stage or outdoor thermostats (see applicable outdoor unit instructions), break off jumper tabs on printed-circuit board. (See Fig. 8.)

1. The 3-, 5-, 8-, and 10-kw heaters are single stage only.

2. The 15- and 20-kw heaters are adaptable for 2-stage operation.

3. The 24- and 30-kw heaters are adaptable for up to 3-stage operation.

Connect low-voltage leads to themostat and outdoor unit. (See Fig. 10.)

NOTE:

Where local codes require thermostat wiring be routed through conduit or raceways, splices can be made inside the fan unit. All wiring must be NEC Class l and must be separated from incoming power leads.

A factory-authorized disconnect kit is available for installation of 0- thru 10-kw applications. When electric heat packages with circuit breakers are installed, the circuit breaker can be used as a disconnect.

NOTE:

Transformer is factory wired for 230-volt operation. See Fig. 11 for transformer connections. When using 208-volt supply, connect red primary lead to T2 and connect blue primary lead to T3.

The secondary circuit of the transformer is protected by a 5-amp fuse mounted on the printed-circuit board.

—4—

—5—

Fig. 5—Removal of Front and Rear Corner

Brackets on Modular

A90168

Fig. 6— FK4A Fan Coil with A-Coil as Factory Shipped

A90148

A90175

Fig. 7— FK4A Conversion for Horizontal Right Applications

PROCEDURE 5—GROUND CONNECTIONS

Use UL-listed conduit and conduit connector for connecting supply wire(s) to unit and obtaining proper grounding. Grounding may also be accomplished by using grounding lug provided in control box. Use of dual or multiple supply circuits will require grounding of each circuit to ground lugs provided on unit and heaters.

—6—

WARNING: The cabinet must have an uninterrupted or unbroken ground according to NEC, ANSI/NFPA 70 and local codes to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes. Failure to follow this warning could result in an electrical shock, fire, or death.

WARNING: Make sure unit power is disconnected before proceeding with Motor Speed Selection. Electrical shock can cause personal injury or death.

A.

Minimum Cfm and Motor Speed Selection

Fan coil units with or without electric heaters require a minimum cfm per ton. Refer to the fan coil wiring label or Table 1 to ensure that the fan speed selected is no lower than the minimum indicated. See Fig. 12 for identification of the ICM blower motor speed adjustment taps.

Fan coil is shipped from the factory with speed taps selected as shown in Table 2. Speed adjustment is done at an 11-pin connector on the motor.

The speed adjustment connector is accessed by breaking the 230vac power to the unit and unplugging the four-pin high-voltage connector at the motor. The speed adjustment access cover is then free to slide open, covering the high-voltage receptacle. (See Fig. 12.)

B.

Motor Speed Adjustment (Refer to Tables 1, 2, and 3)

The speed adjustment connector has 11 pins, with pin No. 1 nearest the six-pin control connector. There are three 1-pin single-lead connectors installed. The red lead sets heat speed for electric heater operation. The white lead turns the motor

″ on

″ and sets low speed for the continuous fan mode or dehumidification mode. The black lead sets high speed for cool and heat pump modes.

The indoor airflow settings are shown in Table 1. When adjustment is required for any speed setting, move the proper jumper up one pin to increase airflow or down one pin to decrease airflow. Move speed selectors one pin at a time to avoid overadjusting.

Table 1—ICM Blower Motor Speed Tap

Selection Table

FAN COIL SIZE 002 003 004 005

006

4 TON

006

5 TON

Tap 10 & 11

Tap 9

Tap 8

Tap 7

Tap 6

Tap 5

Tap 4

Tap 3

Heater Size (kW)

3

5

8,9

10

15

18,20

24

30

—

—

—

—

885/.5

900/.1

785/.1

610/.1

875

875

875

875

875

1060

—

—

—

CFM/ESP At Listed Speed Tap

—

—

—

1080/.5

1065/.15

—

1240/.5

1255/.15

1125/.15

935/.15

805/.15

630/.15

—

1050

970

970

970

1040

—

—

980/.15

840/.15

635/.15

655/.15

Minimum Cfm For Electric Heat

—

—

875

875

1000

1000

—

—

1400/.5

1495/.15

1395/.15

1270/.15

1140/.15

1000/.15

860/.15

—

—

875

875

1000

1000

1400

1400

—

—

—

1760/.5

1670/.2

1450/.2

1260/.2

960/.2

—

—

900

900

1040

1040

1750

1750

2150/.5

2190/.2

2040/.2

1870/.2

1670/.2

1450/.2

1260/.2

960/.2

—

—

900

900

1040

1040

1750

1750

UNIT SIZE

002

003

004

005

006, 007

RED

5

6

7

9

9

Table 2—Speed Selector

Factory Settings

BLACK

4

5

6

8

8

WHITE

3

4

5

7

7

Note: The settings for the 006 and 007 size units are for 5-ton application. For 4-ton applications refer to Table 1 for proper speed tap selection.

—7—

Table 3—Motor Speed Adjustment Jumper Effect On Operating Modes

OPERATING

MODE

Continous

Fan

Cooling

Heat Pump

Heating

HP Htg +

Aux Heat

Emergency

Heat

Cooling +

Dehumidity

No Jumper

Low

(Wht Tap)

High

(Blk Tap)

High

(Blk Tap)

Heat 1

(Red Tap)

Heat 1

(Red Tap)

Low

(Wht Tap)

TOP SPEED/JUMPER LOCATION

F2-F3 F3-F4

Heat 1

(Red Tap)

Heat 1

(Red Tap)

Low

(Wht Tap)

Heat 1

(Red Tap)

Heat 1

(Red Tap)

Heat 1

(Red Tap)

Heat 1

(Red Tap)

Heat 1

(Red Tap)

Heat 1

(Red Tap)

Heat 1

(Red Tap)

Heat 1

(Red Tap)

Heat 1

(Wht Tap)

F2-F4

High

(Blk Tap)

High

(Blk Tap)

High

(Blk Tap)

Heat 1

(Red Tap)

Heat 1

(Red Tap)

High

(Blk Tap)

The blower motor as shipped is wired to provide three-speed operation as described above.(No Jumper) If less than three-speed operation is desired, use the jumpers provided for the fan-coil control board according to Table 3. Be sure to reinstall motor leads after jumper installation.

1. To operate single speed for all modes, install the black lead on pin No. 11, the white lead on pin No. 1 and the red lead on the speed desired.

Install the provided jumper wire from F2 to F3 on the fan-coil control board. The blower motor will run at the speed selected by the red lead for all modes of operation.

2. To operate as a two-speed blower where a different speed is desired for continuous fan mode or for dehumidification speed, install the black lead on pin No. 11, the white lead on the desired speed for continous fan or dehumidification, and the red lead on the desired speed for all other modes. Install the provided jumper from F3 to F4 on the fan-coil control board. To operate dehumidification speed, wire in a standard accessory humidistat, which is configured to close contacts on decrease of humidity. (See Fig. 9.)

3. To operate as a two-speed blower where a different speed is desired for electric heat mode than for all other modes, install the black lead on the speed desired for all other modes, install the red lead on the speed desired for electric heat mode, and install the white lead on pin

No. 1. Install the provided jumper from F2 to F4 on the fan-coil control board.

C.

Dehumidification Speed Option

The blower motor may be wired to provide a lower blower speed for increased humidity removal. A standard accessory humidistat which closes its contacts on humidity decrease must be used for this option. To activate this option, the humidistat contacts must be wired as shown in Fig. 9.

When a call for dehumidification speed is received, the blower will run at the speed determined by the white speed tap selection (low speed).

NOTE:

HEAT speed may be adjusted so that the blower speed is higher or lower than that required for heat pump cooling (HIGH speed) operation. However, do not adjust the LOW speed (White tap) to a speed that is higher than either the HIGH speed (Black tap) or the HEAT speed

(Red tap).

WARNING: Make sure control compartment access panel is closed before restoring power to unit. Failure to follow this warning could cause personal injury or death resulting from electrical shock or moving parts.

Fig. 8—Jumper Tabs on Printed-Circuit Boards

A90150

—8—

Fig. 9—Optional Field Wiring for

Dehumidification Mode

A90267

A88285

Fig. 10—Typical Circuit Connections—Heat Pump

Without Outdoor Thermostats Fig. 11—230V Transformer Connections

A90169

PROCEDURE 6—CONNECT REFRIGERANT TUBING

See Fig. 2 for tube connection sizes, type and locations. Use accessory tubing package or field-supplied tubing of refrigerant grade. Insulate entire suction tube if field-supplied tubing is used. Tubing package has an insulated suction tube. Do not use damaged, dirty, or contaminated tubing because it may plug refrigerant flow control. When tubing package is used and sweat connections are made within 60 seconds, coil and tubing system does not require evacuation. Always evacuate if field-supplied tubing is used.

CAUTION: A brazing shield MUST be used when tubing sets are being brazed to the unit connections to prevent damage to the unit surface.

Units have sweat suction- and liquid-tube connection. Make suction-tube connection first.

1. Cut tubing to correct length.

2. Insert tube into sweat connection on unit until it bottoms.

3. Solder with low-temperature 430 F silver alloy solder.

NOTE:

Wrap a wet cloth around rear of fitting to prevent damage to factory-made joints.

4. Evacuate coil and tubing system if connections are not made within 60 seconds or tubing package is not used.

PROCEDURE 7—CONDENSATE DRAIN

CAUTION: For horizontal installations use plastic fittings provided. Use pipe dope. Do not overtorque (hand tight plus one & one-half turns).

The condensate pan has primary and secondary drain connections to meet all applicable FHA, BOCA, SBCCI, UMC, and CABO building requirements. See Fig. 4 for drain connection locations. For horizontal installations, be sure that condensate fittings supplied are used at appropriate primary and secondary connections. (See Fig. 14.) These connections have 3/4-in. female pipe threads. All condensate drains should be a minimum of 7/8-in. OD copper or plastic tubing or 3/4-in. galvanized iron pipe. The drain should be pitched downward at a minimum slope of 1 in. in 10 ft. If the coil is located in or above a living space where damage may result from condensate overflow, a separate 3/4-in. drain must be provided from the secondary drain connection. Run secondary drain to a place where it is noticeable when used. For horizontal installations with secondary drains, use the dam fitting supplied with unit.

NOTE:

When connecting condensate drain, avoid blocking filter access door thus preventing removal of filter.

—9—

Fig. 13—Condensate Trap

A90173

Fig. 12—Motor With Speed Adjustment

Access Cover Open

A89206

Fig. 14—Primary/Secondary Fittings

A90347

Install a 3-in. trap in condensate drain as close to coil as possible. Make sure that top of trap is below connection to coil to prevent condensate from overflowing drain pan. Prime trap with water. Insulate drain if located above a living area, and test for leaks. Consult local codes for additional restrictions or precautions. (See Fig. 13.)

result.

CAUTION: Never operate unit without a filter or with filter access door removed. Damage to blower motor or unit may

PROCEDURE 8—UNIT START-UP

Refer to outdoor unit installation instructions for system start-up instructions and refrigerant charging method details.

PROCEDURE 9—SEQUENCE OF OPERATION

A.

Condensing Unit

COOLING

When the themostat

″ calls for cooling,

″ the circuit between R and G is completed and the blower motor ON/OFF line is energized through the fan-coil control board F2 connection. The circuit between R and Y is also completed; this completed circuit will energize the HIGH-speed tap on the blower motor through the fan-coil control board F4 connection causing the blower motor to run at high speed, and the compressor contactor causing the compressor and outdoor fan motor to run.

HEATING

When the thermostat

″ calls for heat

″ and the FAN switch is set on AUTO, the circuit between R and W is completed. The heater sequence (SEQ) will then be energized which will energize both the ON/OFF line (F2 on the fan-coil control board) and the HEAT line (F3 on the fan-coil control board) causing the blower to operate at electric heat speed. There will be a time delay while the sequencer times out.

B.

Heat Pump

COOLING

On a

″ call for cooling,

″ the thermostat completes circuits R-O, R-Y, and R-G. Circuit R-O energizes the reversing valve, switching it to the cooling position. Circuit R-G energizes the blower ON/OFF line (F2) through the fan-coil control board. Circuit R-Y energizes the blower motor HIGH line (F4) through the fan-coil control board and the compressor contactor. These actions cause the blower motor to run at high speed and the compressor and outdoor fan motor to operate.

HEATING

On a

″ call for heating,

″ the thermostat completes circuits R-G, and R-Y. Circuit R-G energizes the blower ON/OFF line (F2). Circuit R-Y energizes the blower HIGH speed line (F4) and the compressor contactor. These actions cause the blower to run at high speed and compressor and outdoor fan motor to operate.

—10—

Should the temperature continue to fall, circuit R-W is completed through the second-stage room thermostat bulb. Circuit R-W energizes a sequencer and the blower HEAT 1 line (F3), bringing on the supplemental electric heat and causing the blower to run at electric heat speed. When the thermostat second stage is satisfied, its contacts open, de-energizing the sequencer. After a short delay, while the sequencer cools, the supplemental electric heater is de-energized and the blower motor returns to high speed.

C.

Continuous Fan

If the continuous fan switch is in the ON position, circuit R-G is completed causing the blower motor ON/OFF line to be energized through the fan-coil control board. The blower motor will operate at the selected continuous fan speed until another mode is energized through the room thermostat.

D.

Electronic Air Cleaner Relay

The fan-coil control board is equipped with an electronic air cleaner relay. Any time the blower motor ON/OFF line (F2) is energized, the fan coil control board will also energize the electronic air cleaner relay to supply 240vac through connections EAC1 and EAC2.

Should the emergency heat mode be selected for operation, the electronic air cleaner contacts will be energized through the electric heater interlock circuitry.

CARE AND MAINTENANCE

For continuing high performance, and to 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 and the availability of a 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 maintenance.

WARNING: Disconnect all power to the unit before servicing the field wires or removing the control package. The disconnect (when used) on the access panel does not disconnect power to the line side of the disconnect, but does allow safe service to all other parts of the unit. If the unit does not have a disconnect, disregard the foregoing. Instead, make sure that a disconnecting means is within sight from, and is readily accessible from, the unit. Disconnect all electrical power to the unit before performing any maintenance or service on it. A failure to follow this warning can cause electrical shock, fire, personal injury, or death.

The minimum maintenance requirements for this equipment are as follows:

1. Inspect and clean or replace air filter each month or as required.

2. Inspect cooling coil, drain pan, and condensate drain each cooling season for cleanliness. Clean as necessary. An inspection port is provided on all A-coil delta plates. Remove plastic plug to inspect.

3. Inspect blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.

4. Inspect electrical connections for tightness and controls for proper operation each heating and cooling season. Service as necessary.

WARNING: As with any mechanical equipment, personal injury can result from sharp metal edges, etc; therefore, be careful when removing parts.

PROCEDURE 1—FILTER ASSEMBLY

To clean or replace air filter, push plastic connectors toward center of unit and remove filter access door outward. Push filter up and back into unit, then slide filter out. Clean filter by using cold water and allow filter to dry. No oiling or coating of filter is required. New filters are available from your local distributor. Place filter in slot with cross-mesh binding up or facing the cooling coil, and replace filter access door.

WARNING: Because of possible damage to the equipment or personal injury, the maintenance items below should be performed by a trained service person. Consumer service in these areas is not recommended.

PROCEDURE 2—COOLING COIL, DRAIN PAN, AND CONDENSATE DRAIN

The cooling coil is easily cleaned when it is dry; therefore, inspect the coil and clean (if necessary) before each cooling season. To check or clean the cooling coil, remove the coil access panel. If the coil is coated with dirt or lint, vacuum it with a soft brush attachment.

Be careful not to bend the coil fins. If the coil is coated with oil or grease, clean it with a mild detergent-and-water solution. Rinse the coil with clear water. Be careful not to splash water on the insulation.

Inspect the drain pan and condensate drain at the same time the cooling coil is checked. Clean the drain pan and condensate drain by removing any foreign matter from the pan. Flush the pan and drain tube with clear water.

If the drain tube is restricted, it can generally be cleared by high-pressure water. Cut the plastic line and work outside the condensate pan and away from the coil to clear the drain tube.

CAUTION: Do not use caustic household drain cleaners in the condensate pan or near the coil. Drain cleaners can quickly destroy coils.

—11—

PROCEDURE 3—BLOWER MOTOR AND WHEEL

Clean the blower motor and wheel when the cooling coil is cleaned.

CAUTION: Disconnect electrical power before removing any access panels.

To clean blower motor or blower wheel, remove blower access panel. Remove motor leads from printed-circuit board. Note lead location for ease of reassembly. Remove two (outside) screws holding blower/motor assembly against the blower-deck flange and slide assembly out of cabinet.

Remove screw with green wire from blower housing. Mark the blower wheel, motor and motor support in relation to the blower housing before disassembly to ensure proper reassembly. (Note position of blades on wheel.) Loosen set-screw holding blower wheel onto motor shaft.

Remove three bolts holding motor mount to blower housing and slide motor and mount out of housing. Further disassembly should not be necessary as adequate clearance is available to clean. Remove blower wheel from housing by removing cutoff plate from blower housing outlet.

Note wheel orientation and cutoff location for reassembly. The blower motor and wheel may be cleaned by using a vacuum with a soft-brush attachment. Remove grease with a mild solvent such as hot water and detergent. Be careful not to disturb the balance weights (clips) on the blower-wheel vanes. Also, do not drop or bend wheel, as balance will be affected.

To reassemble blower, place blower wheel back into housing. Be sure to position correctly for proper location. Reassemble cutoff plate to housing, using identified holes from disassembly procedure. Position motor and mount in same position as before when blower housing was in unit. Secure motor mount to housing, using bolts removed. Make sure mount or motor is grounded to blower housing. Locate blower wheel setscrew over flat on motor shaft. Rotate wheel in housing. It should not rub housing and should be centered in inlet opening. If not, loosen setscrew and align as necessary. Attach green wire to blower housing with screw. Slide blower assembly on to blower deck. Make sure (once blower is within the unit envelope) to force blower assembly toward control box while sliding assembly into unit to ensure that blower assembly engages deck properly.

Fasten blower assembly to deck with screws previously removed. Reconnect electrical leads to printed-circuit board. Reconnect electrical power to unit and test blower for proper rotation.

PROCEDURE 4—ELECTRICAL CONTROLS AND WIRING

WARNING: Before installing or servicing system, always turn off all power to system. Turn off accessory heater power if applicable. Electrical shock can cause personal injury or death.

With ALL power disconnected, inspect all electrical connections for tightness. Tighten all screws on electrical connections. If any discolored or burned connections are noticed, disassemble the connection, clean all parts and stripped wire and reassemble properly and securely. Electrical controls are difficult to check without proper instrumentation; therefore, reconnect electrical power to unit and observe unit through one complete operating cycle. If there are any discrepancies in the operating cycle, contact your dealer and request service.

PROCEDURE 5—REFRIGERANT CIRCUIT

The refrigerant circuit is difficult to check for leaks without proper equipment. Therefore, if low cooling performance is suspected, contact your local dealer for service.

PROCEDURE 6—OWNER/USER INSTRUCTION

Using the user manual furnished in outdoor unit, explain system operation with particular emphasis on indoor fan-coil operation sounds.

© 1991 RESCO P.O. Box 1667, Indianapolis, IN 46206 14037

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1/3a,4/2c Catalog No. 92-33FK-4A2