Bryant FA4A User's Manual

AUG/14/2008/THU 03:45 PM UTC TECH PUB FAX No, 317 240 5667 P, 00]
Service Manual
FAN COIL UNITS
- —
: "3 EL : Page В
SAFETY CONSIDERATIONS Kaas A PO [-3
INTRODUCTION sananrorVro momen nana LA aaa AaBLaSaanAa2anRUn eve ers eee RITES 3
PRODUCT OFFERING... porstasa unes au RP.
FAN MOTOR SPEED TAPS ... EE N
FA4A, FB4A, FC4B, ; ¿AND FH4A CIRCUIT BOARD
FUNCTION AND ‘TROUBLESHOOTING EE Trans 3-6
* Printed Circuit Board. (PCB) Component Layout and Description
» Unit Functions +4 RE 3 =
+ Troubleshooting PCB En
ELECTRIC HEATER FUNCTION |
AND TROUBLESHOOTING . engeren caciaianeaa 7
+ Description of Electric Heater Components
» Troubleshooting KFA and EFB Series Electric Heaters
FE4B FAN COIL DESCRIFTION E”
— AND TROUBLESHOOTING . A 7-15
= Integrated Controls and Motor (ICM2)
-= PCB Layout and Description
+ Sequence of Operation bo an
«‘Basy Select Configuration Taps-
» Troubleshooting PCB OR 5
* Troubleshooting ICMZ
» Condensed Version of Troubleshooting FK4B Motor
. and Controls
+ Accessories
THERMOSTATIC EXPANSION VAL VES (ГМ) мана 15
« Problems Affecting TXV
PISTON BODY CLEANING OR REPLACEMENT Ne 15-16
LIQUID TUBE STRAÎNEE AD
COIL/CONDENSATE PAN REMOVAL.
AND REPLACEMENT ......... inning 16-17
* A-Coil Units -
= Slope Coil Units |
CARE AND MAINTENANCE ….…s.disasstanÿFésanans 17-18
" Filter Assembly “iin
+ Cooling Coil, Drain Pan, and Condensate Drain
* Blower Motor and Wheel :
FELA/FF1E SERVICE AND TROUBLESHOOTING an... 18-21
* Fan Motor 0 | a -
* Electric Heater Service
Cleaning or Replating Refrigerant Flow:Control Device
" Liquid Tube Strainer - о Вол
= Sequence of Operation : Ме
. + Care and Maintenance o
FD3A SERVICE AND TROUBLESHOOTING sansannanenens 21-23
as
« Fan Motor
* Electric Heater Service
+ Cleaning or Replacing Refrigerant Flow-Control Device
« Liquid Tube Strainer
+ Care and Maintenance
FG3A SERVICE AND TROUBLESHOOTING......—.... 23-24
* Service
* Maintenance
- a “Cancels: SMO3-1 SMo3-2
RER a 1-1-95
ta o"
+ |
: o
| а
de
18
о
AS2071
i oh.
ao Fig. 1 Typical Fan Coll
КАЧА, FE4A, AND FC4B SMART HEAT CIRCUIT BOARD
“FUNCTION AND TROUBLESHOOTFTING.......... ..—— 24-25
* PCB Component Layout, Description, and Function
a Unit Functions
* Smart Heat Operation
* Electrical Operating Sequences and Troubleshooting
, Mu
+ SAFETY CONSIDERATIONS
Ifiproper installation, adjustment, alteration, service, maintenance,
Or ‘use cap cause explosion, fire, cleetrical shock, or other
conditions which may cause personal injury or property damage.
Consult à qualified installer, service agency, ot your distributor ox
bránch for information or assistance. The qualified instalier or
aheney must use factory-authorized kits or accessories when
modifying this.product. Refer to the individual installation instruc-
tions packaged with the kits or accessories for detailed informa-
бор,
Follow all safety codes. Wear safety glasses and work gloves. Use
quénching cloth for brazing operations. Have fire extinguisher
available. Réad these instructions thoroughly and follow all
warnings or cautions attached to the unit, Consult local building
codés and National Electrical Code (NEC) for special installation
requirements.
It is important to recognize safety information. This is the
safety-alert symbol . When you sec this symbol on the unit or in
instructions and manuals, be alert to the potential for petsonal
injury.
Understand the signal words DANGER, WARNING, and CAU-
TION. These words are used with the safety-alert symbol, DAN-
GER identifies the most serious hazards which will result in severe
UTC TECH PUB
AUG/14/2008/THU 03:45 PM
FAX No, 317 Z40 5067
P, 007
A- ANC
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K - ICM Motor
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AUG/14/2008/THU 03:45 PM
UTC TECH PUB
FAX No, 317 240 5067
TABLE 1—PRODUCT OFFERING
P, 003
MODEL UNIT SIZE DESCRIPTION CABINET
FASANF 018-060 ‚| Митра!ве Single Piece ]
FE4ANE 042-070 Multipoise Modular
() ЕВААМЕ — 018-060 Multipoise Single Piece
- FB4ASB 042-060 Me Modular
FB4ASF 018-060 M Single Place
____ FGIBNB 042-070 Multipoise Modular
a FCABNF 024-060 — Multipolse Single Plece
~~ FDSANA 018-030- Horizontal Single Piece
FF1A/FF1BNA — 018-030 Vertical Single Place
FG3ANA 024, 036, 048, 060 Horizontal/|Smalt Commercial Single Piece
FHAANB | 003, 004 —_ Multipolsa Modular
FH4ANF 001-004 “ Multipoise Single Piece
EKABNB 005,006 Multipoise Modular
FKABNF 001-004 Multipalse — Single Place
NOTE: Mullipoise units are approved Tor upfow, downflow, and horizontal left and right applications.
TABLE 2—FAN MOTOR SPEED TAPS
косе. e “ree | emo | We | emm | como
FAJA 018-036 2 Black — ‘Blue Yellow
FAJA 042.060 a Black Blue Red Yellow
FB4A 018-070 a Black Blua Rad Yellow
FCAB 024-070 3 Black Blue Red Yellow
FD3A QU 018-030 2 Black ms Red Yellow
FF1A/FF1B 018-030 2 Black = Red | Violet
FG3A 024, 036, 048, 080 {+ — — — —
© FHaA 001-004 3 Black Blue Red Yellow
*Belt drive, LS o | в
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result an minor personal
injury or product and property damage.
INTRODUCTION
The "F" series fan coi) units are designed for flexibility in a variety
of applications, meeting upflow, horizontal, or downflow require-
ments. Units are available in 1-1/2 through 5 ton nominal cooling
capacities. Factory-authornized, field-imnstalled electric heater pack-
ages are available in 3 through 30 kilowatts.
WARNING: Before installing or servicing fan coil,
always tum off all power to unit. There may be more than
ZN | 1 disconnect switch. Turn off accessory heater power if
applicable. Electrical shock can cause personal injury or
death.
UNIT IDENTIFICATION
The 16 position numbering chart allows identification of all
available fan coil units. (See Fig. 2.)
FA4A, FB4A, FC4B, AND FH4A CIRCUIT BOARD
FUNCTION AND TROUBLESHOOTING
This section of the service manual describes the CESO130003
PCB by examining the functional operation of the PCB compo-
nents.
I. PRINTED CIRCUIT BOARD (PCB) COMPONENT
LAYOUT AND DESCRIPTION :
Layout of the actual PCB is depicted in Fig. 3.
1. The low-voltage stripped leads are used to connect the 24-v
side of transformer to indoor thermostat and outdoor
section.
2. A S-smp fuse is used to protect the low-voltage transformer
secondary.
3. The fan relay 36 controlled by thermostat and turns fan on
and off.
à. À plug is used as the connection for PCB power and electric
beaters, Note the pin numbers on plug.
5. A time-delay relay circuit keeps fan motor running for 50
sec after C 15 de-energized.
II. UNIT FUNCTIONS
A. Transformer
1. Proper Wiring of Transformer Primary or High Side
Yellow wire from Molex plug is wired to C terminal on
transformer and black wire from PCB relay (normally-
open) terminal is wired to 208V or 230V terminal on
transformer, Units are factory wired. at 230V terminal..
2. Proper Witing of Transformer Secondary or 24.v Side
Red wire of transformer 1s wired to T terminal on PCB and
brown wire of transformer iz wired to C terminal on PCB.
NOTE: T terminal on PCB is used to protect transformer. T
terminal is connected through the fuse to R terminal on PCB,
B. Indoor Fan
1. Wiring
Indoor fan motor yellow lead is wired to C terminal on
transformer. The red, blue, or black speed lead is wired to
SPT terminal on fan relay part of PCB. Units are factory
wired on medium speed (blue lead connected),
NOTE: Unused fan speed leads must be capped or taped off to
prevent direct short to cabinet surface,
AUG/14/2008/THU 03:45 PM UTC TECH PUB
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— EAN RELAY
Fig. 3—Fan Coll Printed-Clreuit Board
#. Functional Control
a. Thermostat and Relay Control
When thermostat calls for the fan in cooling, heat pump,
heating, or fan-only mode, a 24-vdc signal 18 sent to
relay. This canses the relay to close its normally-open
contacts, turning on fan, When thermostat no longer calls
for the fan, the signal sent to relay 15 turned off and relay
opens causing fan to turn off after a 20-sec fan-off delay,
‚ В. Sequencer Interlock
The fan will also operate whenever there is a call for
electric heat, even if fan relay is not energized. This
happens because fan 16 interlocked with first stage of
electric heat through the normally-closéd contact of fan
relay.
NOTE: The fan interlock is only connected to first stage electric
heat W2, W3 and E do not contain an interlock with fan. See
outdoor thermostat Installation Instructions when electric heat
stacing is desired;
C. Electric Heat
When thermostat calls for electric heat, a 24-vac signal is sent to
PCB through WZ, causing first stage to turn on, W3 and E also
receive signal if wired in with W2. The signal sent to W2 causes
first stage to tum on. If W3 and E arc not wired to Wz, the
sequencers can be controlled individually to stage additional
electric heat. The sequence control is described in the following
section:
1. W2
When thermostat sends a signal to W2, a 24-vac signal is
applied across sequencer number 1, causing it to close after
a short delay. When sequencer number 1 closes, first stage
of electric heat is energized. In straight electric heat, fan is
also energized through the normally-ciosed contacts. of fan
relay. In cooling, heat pump, or manual fan mode, fan will
already be running since fan relay would have bean
energized, When thermostat stops calling for electric heat,
the Z4-vac signal to sequencer number 1 turns off and
sequencer opens after a delay of 60 to 90 sec, When
sequencer opens, first stage of heat turns off along with fan,
providing thermostat is not calling for the fan.
2, W3
When a signal is sent to W3, a 24-vec signal to sequencer
number 2 causes sequencer to close, with second stage of
electric heat turning on after a short delay. The 24-vac
Pa LOW
VOLTAGE
FUSE
FAX No, 317 240 5067 P, 004
— PCB BLOCK WIRING
No KA NG TIME
Ser _ DELAY |
FUSE
\
G A T С
RAN A
ABd345
signal applied to sequencer number 1 Cánses tanto: ‘operate.
Timing is such that sequencer nimbér fWil Tor On: before
sequencer number 2. When. signal to'WS7i5 tuméd off,
sequencer number 2 opens: “after a short delay. If; Wa is also
satisfied, first stage of. electric heat and-fan- will also turn
off, providing thermostat is not calling for the fan .
d's a
3. E - TINTA
a
When thermostat sends.a signal 10,E, a 24-vac signal is sent
to sequencer nümber 3; The ?24Vac* signal applied to
sequencer number 3 turns on third” stake of electric heat.
The 24-vac signal applied to sequencer number 1 turns on
first stage of electric hear arid fin. When thermüstat stops
calling for electric heat, the Signal to ‘Séquérièers L 2, and 3
are turned off, "and sequenters open. This ( cases electric
heat to turn off with fan providing Hermóstatis'nót calling
for the fan. orm a
NOTE: Electric heaters are factory wired with All Stages tied
together. If independent staging 15 desired, "consult oùtdgor ther.
mostat Installation Instructions. en
Il. TROUBLESHOOTING PCB a
Use wiring schematic shown in Fig. 4 ава guide in roublestosing :
PCB unless otherwise noted:
MNAE
A. If Fan Will Not Turn On from Theriostil"
IF THERE IS NO HIGH VOLTAGE TO PCB:
1. Check plug/receptacle connection. This supplies power
from heaters to PCB. Be sure plug is connected properly.
‚ 2. Check sequencer number 1 and plug wiring. Yellow wire
should be connected to pin number 2 of plug and to limit
switch. Black wire should be connected to pin number 7 of
plug and to seghencer number 1. |
3. Check power leads L! and L2. H these are not receiving
power, system cannot function,
IF FCB HAS HIGH VOLTAGE APPLIED TO IT:
1. Check low-voltage transformer leads R (red) and C
(brown). Be sure they are wired to correct locations.
2. Check output voltage of transformer secondary side R (ted)
and C (brown). Be sure transformer output is between 18
and 30 vac. If transformer output is incorrect and trans-
former is receiving correct input voltage (208v or 230у),
then transformer needs to be replaced with recommended
transformer. If no problem exists with transformer secand-
ary, proceed to items 3 and 4.
SNA ALA —— Ar
AUG/14/2008/THU 03:46 PM
UTC TECH PUB
FAX No, 317 240 5067
P, 005
COMPONENTS,
9. 1 PHASE HEATERS ARE SHOWN WIRED FOR SINGLE SUPPLY CIAGUN,
10. USE 60 AMP CLASS K FUSES ONEY, FOR REPLACEMENT.
(BLU OR RED).
12, CONNECT RTO A, & TO G, ETC. SEE OUTDOOR INSTRUCTION FOR DETAILS.
13. IF WIRE CRIMF IS REMOVED AN EMERGENCY HEAT RELAY |G REQUIRED.
(SEE QUTDOOR-THERMQETAT INSTRUCTIONS)
19, (3) SPEED MOTOR SHOWN. OPTIONAL (2) SPEED MOTOR USES Hl (BLK) AND LOW
THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING CAUTION:
( WOT BUITABLE FIR USE ON SYSTEMS EXCEEDING
BLOWER MOTOR 160V TO GROUND
ROTATION ATTENTION:
{30KW 1PH SCHEMATIC DIAGRAM ) E. LEGEND
FIELD POWER WIRING > DISCONNECT PER NEC CAP CAPACITOR LS LUMITBWITCH
ак COM COMMON MARKED TERMINAL
; HVT FOR VOLTS 2 HEMIZ FLOW VOLTAGE FUSE —— PLUG AND RECEPTACLE
a E) (o) fo] END | FM FAN MOTOR РСВ PRINTED CIRCUIT BOARD
+ EEE NOTE A] desa -———— FIELD POWER WIRING SEQ SEQUENCER
No | | FR POBFANRELAY TRAN TRANSFORMER
| | FU LNEFUSE (J) UNMARKED TERMINAL
x GND | EQUIPMENT GROUND RECP RECEPTACLE
HVTE HIGH VOLTAGE TERM BLOCK CA CIRCUIT BREAKER
НТА HEATER
FIELD POWER WIRING
EDOLING CONTROL ONLY
FIELD
POWER
WIRING
YEL ВК PLUS
во? 8 1 4
| RAC 24VAC 24VAC
Ma 9 m7 | 3 2 8 1 4 2
LE RESF
(ОКУ ЗРН SCHEMATIC DIAGRAM _)
FIELD POWER WIRING DISCONNECT PER NEG
HVTE ! SEE RATING FLATE FOR VOLTS & HERTZ
[
YEL we Е | E В E END | BEE NOTE #1 |
3 I i
ae fe © / —
Wa |
WHT spe NOTE ma,
BARRIER BEC NOTE #12.
VEL COM GANYEL-GNE INDOOR OUTDOOR
NOTES: ff THERMOSTAT UNIT
1. USE COPPER WIRE (75°C MIN) ONLY BETWEEN DISCONNECT SWITCH AND UNIT,
2 TO BE WIRED IN ACCOACANGE WITH NEG AND LOCAL CODES,
a3, TRANEEORMER PRIMARY LEADS, BLUE 208, RED 230V.
4 IF ANY OF THE ORIGINAL WIRE, AS SUPFLIED, MUST BE REPLACED,
USE THE SAME OR ECUIVALENT TYPE WIRE.
B. REPLACE LOW VOLTAGE FUSE WITH NO GREATER THAN 5 AMF FUSE,
6. 20KW HEATER USES ONE DOUBLE POLE LS ON MIDDLE TOP ELEMENT.
7, 18,24 AND B0KW HEATERS USE DOUBLE POLE LIMIT SWITCHES.
A. LARGEST HEATERS ARE SHOW, GMALLER HEATERS WILL HAVE FEWER ELEMENTS AND
[221214101 REY. C | | E — =
T TT e
|_5 11 7 IM
AA346
Fig. 4—Wiring Diagram
3. Check low-voltage fuse shown in Fig. 3. If fuse is blown,
replace it. The transformer cannot supply power to board
with fuse blown or loose. If fuse blows when unit has power
applied to 1t, the system most likely has 1 of the following
problems:
a. Check all 24-v wiring for an electrical short.
b. The maximum load on transformer is 40 va. If load on
transformer 15 excessive, the low-voltage 5-amp fuse
will blow to protect transformer. If load exceeds va
rating of transformer, a larger va rated transformer needs
to be installed, Check sequencers for excessive current
draw.
é, Check wiring of heaters. If a heater is miswired, fuse
may blow. If a heater is miswired, correct miswiting by
comparing it to heater wiring label.
4. Check connections on primary side of transformer. If they
are not connected properly, the low-voltage terminal board
cannot supply the 24-v signal to energize fan relzy. If
transformer is receiving correct primary voltage but 15 mot
putting out correct secondary voltage, transformer needs to
be replaced,
AUG/14/2008/THU 03:46 PM
UTC TECH PUB
В. If Electric Heat Stages Will Not Turn On But Fan Will
Turn On:
IF THERE IS NC HIGH VOLTAGE TO PCB:
1. Check plug connection between heaters and board. This
supplies power to transformer and fan. Be sure plug is
connected properly.
2. Check sequencer number 1 and plug wiring. Yellow wire
should be connected to pin number 9 of plug and to limit
switch. Black wire should be connected to pin number 7 of
plug and to sequencer number 1.
3. Check incoming high-voltage power leads. If these arc not
TIECCiving power, system cannot function.
IF PCB HAS HIGH VOLTAGE APPLIED TO IT:
1. Check low-voltage transformer leads R (red) and C
(brown). Make sure they are wired to correct location. The
unit will not function without proper connections.
2. Check output voltage of transformer secondary side R (red)
and C (brown), If transformer ontput is low (less than 18
vac), refer to items 3 and 4 of previous If PCB Has High
Voltage Applied To It section.
IF TRACES ARE OVERHEATED ON BACK OF PCB:
Usnally whenever a trace is blown on PCB, it means cither there
has been a high-voltage short or high voltage has been applied to
low-voltage circuit. This can be prevented by making sure PCB is
wired correctly before PCB has power applied to 1t.
C. If PCB Fuse Keeps Blowing:
When low-voltage fuse blows, it means transformer would have
blawn if fuse had not been in circuit to protect it. The fuse usually
blows when thers is a high current draw on transformer, high
voltage applied to low-voltage circuit, or a direct secondary short.
When there is a high current draw on transformer, it 1s most likely
because transformer has been shorted or system is trying to draw
more va than transformer rating allows. When fuse blows because
of high voltage, the system has mixed high- and low-voltage
signals.
1. Check wiring of sequencers as shown in Fig. 4. Be sure
transformer is not shorting out because thermostat wires are
miswired.
2. Check wiring of sequencers as shown in Fig. 4. Be sure
low-voltage and high-veltage wining 15 connected to proper
SeQUENCETS.
3. Check va draw on transformer. If va draw is more than va
rating of transformer, fuse will blow. If this 15 the case,
replacé transformer with one that has a higher va rating and
meets system specifications.
D. If Fan Runs Continuously:
1. If PCB has no low-voltage powet, check blue and black fan
leads. These may be switched at sequencer,
. 2. If PCB has low-voltage power, check fan relay to see if it is .
opening and closing. It may be stuck in the normally-closed
position due to debris in relay.
E. Transformer Failure:
1. Check 208-v and 230-v transformer connections, They may
be miswired.
ELECTRIC HEATER FUNCTION AND
TROUBLESHOOTING
This section describes KFA and KFB series electric heaters by
examining the functional operation of these heaters,
I. DESCRIPTION OF ELECTRIC HEATER
COMPONENTS
A, Limit Switch
The limit switch is a temperature-sensitive control whose function
is to prevent system from overheating in abnormal conditions. The
temperature settings often vary from heater to heater due to
FAX No, 317 240 5067 P, 006
variations in airflow patterns and element radiant heat conditions.
The devices are sized to remain on-line under heat pump condi-
tions (115% air off coil) and minimum CFM, but {rip to prevent
outlet air conditions above 200°F or excessive component or duct
temperatures.
The device itself consists of a bimetallic disc, which when
overheated "snaps through" to open a normaliy-closed high-
voltage, high-current switch. When system temperatures cool
sufficiently, the switch will automatically reset to its closed
position. Normal failure mode for this switch is open.
If a limit switch has been determined to be defective, NEVER
EYPASS THE LIMIT SWITCH. When replacing limit switch,
ensure that it is replaced with a limit switch of identical opening
temperature and closing differential. Limits switches are typically
color coded to identify their range.
B. Sequencer
The sequencer is essentially a thermally activated time-delay relay
normally activated by low-voltage control signals from thermostat.
The typical sequencer is a 1- or 2-pole normally-open device
which energizes within 10 to 30 sec after application of control
signal and de-enerpizes 60 to 90 sec after control signal is
removed.
In simplistic terms, the sequencers which we use are nothing more -
than normally-open limit switches which sit on top of a small
resistive heater. When voltage is applied to this heater, a positive
température coefficient resistor (BTC), heat is supplied to a
bimetallic disc which "snaps through" and closes switch.
The time required for PTC to heat to a sufficient point controls ON
timing of device. The time required for disc to cool down when
power is removed controls OFF time of device. The FTC can be
varied to provide varied timing. Typically a short ON equates to a
long OFF. ;
Because this is a thermally-activated device, ambient conditions
affect the ON/OFF cycle. Higher ambient temperature means
shorter ON times and longer OFF times.
These sequencers may be "ganged up" to 3 on 4 common mounting
plate to control up to 6 heater elements. In this situation, PICs are
different in each sequencer to provide a staged ON of a minimum
of 10 sec between each sequencer — 3 stages of 2 elements since
the KFA and EFA series Heaters use sequencers in which both
switches of the 2-pole sequencer close simultaneously. Older
models used seguencers which had a minimum delay of 10 sec
between cach switch,
Application of these devices is such that the first switch ON not
only turns on first heater element, but also ensures that indoor fan
is energized, because first ON is last OFF. This ensures fan
remains ON until the last heater de-cnergizes.
C. Positive Temperature Coefficient (PTC) .
The PTC heater is essentially a resistor. It will operate on either
AC or DC voltages. It should be noted that because resistance of
PTC increases as it heats, initial current inrush is higher than its
steady state condition.
N. TROUBLESHOOTING KFA AND KFB SERIES
ELECTRIC HEATERS
A. Discolored Wire Insulation at Terminal
Check quick-connect terminal at discoloration. Connection may be
loose, creating a high resistance through connection point.
B. Fuse Failure
1. Check for shorted wire. Replace wire. Never try to fix wire
using electrical tape.
2. Check shorted element. If clement is shotted, replace
heater.
C. No Heat
1. Check fuse for failure. If fuse has failed, refer to Fuse
Failure section.
AUG/14/2008/THU 03:46 PM
(J
UTC TECH PUB
2, Check for fanlty transformer. Check output voltage of
transformer secondary side R (red) and C (brown). Make
sure output is between 18 and 30 vac. If output voltage is
low and input voltage tests normal, replace transformer,
3. Check for miswired heater plug harness.
4, Check limit switch or sequencer failure. These switches
should have failed in open position. If output voltage is zero
v, replace switch,
D. Heater WII Not Turn Off
1. Check low-voltage wiring for miswire.
2. Check for shorted elements to ground.
3. Replace sequencer contacts. They may be stuck closed,
E. Nuisance Trips
1. Check for low airflow due to dirty filters, blocked registers,
or undersized duct.
2. Check blower motor and wheel for proper operation,
Excessive current draw of motor will cause internal over-
load to trip.
3. The fan speed may be low.
FK4B FAN COIL DESCRIPTION
AND TROUBLESHOOTING
The FE4B is similar to the discontinued FK4A only in that they
both have integrated controls and motor (ICM) and their own
spécial circurt board, The greatest difference between the 2 models
is the way each goes about delivering air.
Setting up desired airflow on the FK4B is obtained by the
selections made on Easy Select circuit board. The motor delivers
requested airflow as defined by signals received from Easy Select
Board and its internal programming, The major difference is that
the FE4B motor reacts to changes in system static pressures to
maintain constant airflow.
Unlike conventional fan coils where static pressure affects airflow,
the FK4B is a constant airflow unit. The blower delivers requested
airflow up to about 0.7 in. of static pressure. The ICMZ is
pre-programmed and contams arrflows Tor ali modes of opération.
Blower characteristics (airflow, torgue, and speed-vs-static pres-
sure) are known from laboratory testing. If any 3 characteristics are
known, the fourth 15 defined.
Requested airflow Js known because of Easy Select board con-
figuration and thermostat signals. Torque is known because it is
directly related to armature current which is measured by motor
control, Speed is measured from ats generated back EME. This
information is entered into an expression which calculates torque
from speed and airflow numbers. If calculation does not match
stored blower characteristics, torque 15 adjusted every 0.5 sec until
agreement is reached. The unit does not directly measure static
pressure, but does react to a change in static to maintain constant
airflow.
L INTEGRATED CONTROLS AND MOTOR (ICM2)
The ICM? is similar to the ICM1 used in FR4A series units, but
cannot be used as à replacement without some modification to
FE4A unit. Consult SME 93-0052 for motor conversion kit. The
electronics of motor are built Into rear of motor, deriving the name
ICM. (See Fig. 5.)
An ICM 15 first fed high voltage AC power through the 5-pin
connector. The AC power is then rectified to DC by a diode
module. After rectification, DC signal is electronically communi-
cated and fed in sequential order to 3 stator windings. The
frequency of communication pulses determines motor speed. The
rotor is permanently magnetized.
An ICM 15 powered with high voltage at all times. The motor will
not run with high voltage alone. Low voliage must be applied to
contro] plug to run moter.
FAX No, 317 240 5067
—7—
P, 007
II. PCB LAYOUT AND DESCRIPTION
NOTE: Layout of actual PCB is depicted in Fig. 6 and 7.
The control is a single PCB which interfaces a variable-speed
ICM with other system components.
Power for system is supphéd from à 230-vac, 60-Hz line. Class 2
voltage (24 vac nom.), used for thermostat connections, is derived
from a transformer located in close proximity io control. The
primary and secondary of transformer are connected to control
board. The Z4-vac secondary circuit includes a socket, soldered
into circuit at SEC2, to receive a 5-amp automotive-type fuse.
Connection to heater panel 15 made through 12-circuit connector
Pi, Connections to thermostat are made at screw terminals. Line
voltage for ICM2 is made through 7-circuit connector P2. Eighteen
quick-connect terminals comprise field select taps for motor.
Fuse Data: 5 amp automotive-type ATC/ATO (tan)
32v
200 percent current ópening time of 5 sec maximum
A. Electrical Connections
Eighteen 0.187-in quick-connect terminals are used to provide
programming selections for operating modes of ICM2. The 5
selection modes are listed below, For additional information, refer
to Easy Sclect Configuration Taps section.
AUX Heat Range — (Violet Wire)
AC/HP Size — (Blue Wire)
Type— (Orange Wire)
АС/НР СЕМ Adjust— (Black Wire)
AC/HP Time Delay — {Grey Wire)
ll. SEQUENCE OF OPERATION
A. Continuous Fan Mode
The thermostat closes circuit K to G, The G signal ls sent directhy
to ICMZ.
B. Cooling Mode—Single Spead or 2-Speed High
Thermostat closes circuits R to Y/Y2 and R to O (heat pump only)
for single speed. A circuit from R to Y1 15 also required for
2-speed high. The Y/Y?Z signal is sent directly to ICM2.
G. Cooling Mode—Two-5peed Low
Thermostat closes circuits K to Yl and K to O (heat pump only).
The Y1 signal is sent directly to TCM».
D. Electric Heat Heating Mode
Thermostat closes circuit K to WZ, W3, or E,
The terminal block positions W2, W3, and E ars tied together by
jumpers JW1 and JW2. These jumpers are provided for field
staging of electric heater banks through use of thermostats. When
staging is a requirement, installer cuts jumpers and wires in
thermostats as is the common practice with other fan coils. To
ensure motor operation if any 1 of the inputs is energized, the 3
electric heater inputs are also interlocked through diodes 131, D2,
and D3 to motor W input.
E. Heal Pump Heating Mode—Single Speed or 2-Spead
High
Thermostat closes circuit R to Y/Y2 for single speed. A circuit
from R to Y1 is also required for 2-speed high. The Y/Y2 signal
is sent directly to TCM?,
F. Heat Pump Heating Mode—Two-Spead Low
Thermostat closes R to Y1. The Y1 signal is sent directly to ICM2.
С. Heat Pump Heating With Auxlifary Electric Heat
Thermostat closes circuits B to Y/YZ2 and/or Eoto Y 1 with KE to WZ,
W3, or E (and E to O in the case of defrost).
See previously described modes for circuit paths.
In the event that electric heating is called for by thermostat while
heat pump 15 also operating in either heating or defrost mode,
electric heating signal will appear at motor connector pin 1 as
described previously. If necessary, the motor will modify its
airflow output io provide an airflow which 1g defined as safe for
operation of electric heater.
AUG/14/2008/THU 03:47 PM
UTC TECH PUB
DO NOT REMOVE —
OPTIONAL
SAFETY
GROUND
mo | —
RAN |
HOLE
FAX No, 317 240 5067 Р. 006
OPTIONAL SAFETY GROUND
NEE OE
POWER CONNECTOR
===
сэ] оу па Котт
Tefal ls etal
CONTROL CONNECTOR
AS84075
Fig. 5—FK4B ICM2 Motor
H. CFM Select Configuration Taps
The CFM Select taps are used by installer to configure system. The
ICM2 is capable of discerning wave shapes on some of its inputs
and uses this capability to modify its operation to a pre-
programmed table of airflows and can be modified in response to
other inputs such as the need for de-humidification.
l. 1CM: Control Power
The TCM2. control power is supplied from R circuit through
printed-circuit runs to motor control connector pin 6, through
motor control harness to motor. The © side of low-voltage control
power circuit is connected by printed-circuit runs to motor
connector pins 4 and 5, then through motor control harness to
motor,
J. Low-Voltage Circuit Fusing and Reference
The low-voltage cirenit is fused by a board-mounted 5-amp
antomotive-type fuse placed in series with transformer SEC2 and
R circuit. The C circuit of transformer is referenced to chassis
ground through a printed-cirouit run at SECI connected to metal
standoff matked GROUND SCREW REQUIRED,
NOTE: A ground screw must be in place or erratic motor
operation can result.
K. Transformer, Motor, and Electric Heater Power
Connections
The high-voltage (230-vac) power input to board is provided
through electric heater connector pins 7 and 9. The high voltage 1s
then connected through printed-circuit mns to motor power con-
nections M1 and M2 and transformer power connections T1 and
T3. Transformer connection T2 is a dummy terminal used for
unused primary power lead. The transformer secondary connec-
tions ate made at SEC1 and SEC2 connectors.
IV. EASY SELECT CONFIGURATION TAPS
The Easy Select taps are used by installer to configure system. The
ICMZ uses selected taps to modify its operation to a pre-
programmed table of airflows. Airflows até based on system size
or mode of operation and those airflows are modified in response
to other inputs such as the need for de-humidification. (See Fig. 6.)
The FE4B Fan Coil must be configured to operate properly with
system components with which it is installed, To successfully
configure a basic system (see information printed on circuit board
located next to select pins), move the 5 select wires to pins which
match components used,
A. Auxiliary Heat Range
The installer must select the auxiliary heat airflow approved for
application with kw size heater installed. If no heater is installed,
skip this step. Each select pin is marked with a range of heaters for
which airflow (also marked) is approved. The heater installed must
fall within range selected for safe and continuous operation, It 1s
appropriate to mention that airflow marked is the airflow which
will be supplied in emergency heat mode and heating mode on air
conditioners whett electric heat is primary heating source. To
ensure safe heater operation in heat pump heating mode when
СЭ
"
se
AUG/14/2008/THU 03:47 PM UTC TECH PUB FAX No, 317 240 5667 P, 00%
LOW VOLTAGE
TERMINAL BLOCK NN
EASY SELECT
[AUX HEAT HANGE —
re, pm | 02 | mw | US, st,
CH 1200 100d К НО —
via | Co Co) Ca =) to
ACIHP — SIZE ae
PRINTED
= НЕ | 88| 96| CIRCUIT
BOARD
E
AN | AL HF-CONFORT HPF EH
ACHE GEM ADJUST
u MED Hi
ax | Co | cs | е=5
ACHP TIME DELAY =
oN & E ñ ta
w w1w (5 |" :
MOL av | YE te WEZ2-E JUMPER
QLEX 7-PIN — | JRD STAGE
CONNECTOR (1) Nee >
MOTOR =
¡ea — ru
Е cooooo|l va Da Wo2-.W3 JUMPER
GROUND ND STAGE
SCH re
RED BEE rd)
REQUIRE =] ==] =
HV
»—=15-IN. MALE
Me-IN, MALE —y аа FASTON
„FASTON OO OC] AMP-TYP
— 9) PLCS
(21) PLUS OOO В)
CES0130007—D0 Q |
AMF 12-FIN MATE-N-LOGK
CONNECTOR (1)
A84076
6—Easy Select Board
heat
Fl
electric heaters are energized, the ICM2 will run the higher a 1. The standard 90 sec off delay (factory setting).
pump efficiency airflow and electric heater airflow. The factory
selection is largest heater range approved. (See Fig. 6.)
B. AC/HP Size
The factory setting for air conditioner or heat pump size is largest
2. No delay option uséd for servicing unit or when a thermo-
stat 18 utilized to perform delay functions.
3. A 30 ser 0n/90 sec off delay profile used when it is
desirable to allow system coils time to heat up/coo] down
O)
"mm
unit meant for application with model of fan coil purchased. The
installer needs to select air conditioner or heat pump size to ensure
that airflow delivered falls within proper range for size of unit
installed in all operational modes. (See Fig. 6.)
C. System Type
The type of system must be selected.
1. AC air conditioner
2. HP-COMFORT — provides same airflow as air conditioner
selection (approximately 375 CFM/tom)
3. HP-EFF —provides most efficient airflow for heating and
cooling modes {approximately 410 CFM/fton heating and
375 CEM/ton cooling)
The factory setting 1s AC, (See Fig. 6.)
D. AC/HP CFM Adjust
Select low, medium, or high airflow. To provide any of these
airflows, AC/HF ADJUST select must be moved to MED position.
The factory selection is LO, The adjust selections HIZO will
regulate airflow supplied for all operational modes, except non-
heat pump heating modes, +10 percent and -10 percent respec
tively. The adjust selection options are provided to adjust airflow
supplied to meet individual installation needs for such things as
noise, comfort, and humidity removal. (See Fig, 6.)
E. AC/HP Time Delay
Select desired time delay profile. Four motor operation delay
profiles are provided to customize and enhance system operation.
(See Fig. 6.) The selection options ars:
prior to airflow. This profile will minimize cold blow in
heat pump operation and could enhance system efficiency.
4. ENH, enhanced selection provides a 30 sec on/180 sec off
delay ut half airflow, adding comtfort'and efficiency.
V. TROUBLESHOOTING PCB
Use Fig. 7 and 8 and Tables 3, 4, and 5 as guides in troubleshoot-
ing PCB unless otherwise noted.
A. [If Fan Will Not Turn On From Thermostat:
IF THERE 15 NO HIGH VOLTAGE TO PCE:
1. Check connection of 12-pin plug from heaters to receptacle
on Easy Select board. This supplies power to PCB. Be sure
plug is connected properly,
2. Check sequencer number 1 and plug wiring. Yellow wire
should be connected to pin number 9 of plug and to limit
switch. Black wire should be connected to pin number 7 of
plug and to sequencer number 1.
3. Check power leads L1 and L2. If these are not receiving
powet, system cannot function.
IF PCB HAS HIGH VOLTAGE APPLIED TO IT:
1. Check low-voltage transformer leads (red and brown), Be
sure they are wired to correct locations, (Sec Fig, ó and 8.)
AUG/14/2008/THU 03:47 PM UTC TECH PUB FAX No, 317 240 5667 F010
— — == === === == = =
= = == А АМ ИМ ЗЧ КН Е р =, == == === === == —
|
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| sm | 5—30 5—20 в —10 os
| 4 | AUX. HEAT 1200 1900 aoû EDO
DA хе! eL e 11 ae LA? acs
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CPM TRIM
ON 0 30 30 o
ÖFF 90 se _ 30 4 о à
AC/HP acis. 1] ace. TIT] ae? am LI
DELAY
АЭ407 7
Fig, 7--Fasy Select Board Circultry
2, Check output voltage of transformer secondary side SEC? e. Check wiring of heaters. If a heater is miswired, fuse
and SECI. Be sure transformer output is around 24 vac. If may blow. If a heater is miswired, correct miswiring.
sanstorner Ig 1 208 ane an yen mf DB 4. Check T1, T2, and T3 connections on primary side of
ПВР Imput VOUREE (= 3 ; transformer. If they are not connected properly, low-voltage
needs to be replaced with recommended transformer. If . 24-v sional t то $
transformer output 15 24 vac, proceed to items 3 and 4. terminal board cannot supply «РУ ЗЕПЕ! КО BREEZE tal
Ё motor. If transformer is receiving correct primary voltage
3. Check low-voltage fuse shown in Fig. 6. If fuse is blown, but is not putting out correct secondary voltage, transformer
replace it, The transformer cannot supply power to board needs to be replaced.
with fuse blown or loose. If fuse blows when unit has power |
applied to it, the system most likely has 1 of the following В. If Electric Heat Stages Will Not Turn On But Fan WIN
problems: Turn On:
a. Check control circuit for a short or miswiring problem. 1. Check wiring of sequencers, Pay particular attention to
b. The maximum Joad on transformer is 40 va. If load on high- and low-voltage wiring of sequencers. ( }
transformer is excessive, the low-voltage 3-amp use 2. Check plug wiring to make sure that it is wired correctly. ait
will blow to protect transformer. If load exceeds va
rating of transformer, a larger va tated transformer needs 3, Check voltage to sequencer. Sequencer number 1 receives a
to be installed. Check sequencers for excessive current 24-vac signal. If it ig receiving correct voltage, check to see
draw. if sequencer is closing. If sequencer is not closing but is
= 10 —
AUG/14/2008/THU 03:47 PM UTC TECH PUB
м
1
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e
FAX No, 317 240 5067 P, UN
TABLE 3—MALE/FEMALE QUICK-CONNECT TERMINALS
SIZE FEMALE | SIZE MALE n DESCRIPTION
Ш M2 Motor line voltage connection (230 var 60 Hz)
IE Transformer line voltage connection (230 vaé 60 Hz) ————
TZ — Transformer tap storage terminal for 208-vac lead a
ВЕС! Secondary connection fram transformer (24 vac)
This connection is common to chassis ground through eyelet marked GROUND SCREW REQUIRED.
0.200 X 0.032 SEC a Secondary connection from transformer (24 vac)
HUM1 Low voltage ground for humidifier option (24 мас)
HUM2 Low voltaga output for humidifier option (24 мос)
AUX1 Low voltage ground for auxillary option (24 vdc) _
AUXZ Low voltage output for auxiliary option (24 vdg)
M1 Common connection to blower motor
0.187 X 0.032 Ti —| Common connection for transformer
RED | Common ta R scraw terminal and SEC2
TABLE 4--CONNECTIONS ON SINGLE BARRIER STRIP MOUNTED, CROSS SLOTTED, CAPTIVE BINDING HEAD
SCREW
TERMINAL | DESCRIPTION _
wz Connection for W2 signal from thermostat
wa Connection for W3 signal from outdoor tharmostat
E TT Connection for E signal from thermostat _
Y/Y2 Connection for ¥ signal from thermostat o
G Connection for G signal from thermostat
o Connection for O signal from thermostat nn
L This connection ls a field termination for use in connecting L lines of thermostat and outdoor unit together. There ls no
connection of this terminal with control ciroulty.
YE | Connaction for low-speed compressor operation _
R Connection for R signal to tharmostat (24 vac)
с Connection for C terminal to thermostat (24 ves common)
TABLE 5-—CONNECTIONS AND CONNECTOR
TYPE TYPE
CONNECTION CONNECTOR FIN NO. о DESCRIPTION
o Ри Common to E screw terminal
Pin 2 Common to W2 screw terminal
Pin 3 Common to C screw terminal, SEC1 terminal, and chassis ground
Fin 4 Common to © screw terminal, SECT terminal, and chassis ground
— Pins No connection _ но
Heatar Pin 6 Common to W3 screw terminal
Connection 12-Pin Pin 7 Common to M2 and T3 quick-connects, 230 vac input
© Phe No connection
Fin 8 Common te Mi and Ti quick-connects, 230 vac input
Pin 10 No connection - i _
Pin 11 No connection
Pin 12 No connection Lo
Pin 1 Diode OR output of E or W3 or W2 thermostat signals |
Ping Thermostat G signal
Fin 3 Common to 6, SÉCT, and chassis ground
IGM2 Motor 7-Pin Header Pin 4 Common to C, SECT, and chassis ground
Pin 5 Common to Fi and SECE (via 5- -amp-fus fuse)
Ping Thermostat Y/Y2 signal |
Pin 7 Thermostat Y1 signal .
receiving correct voltage, replace sequencer. If sequencer is
closing, check high-voltage wiring as discussed in items 1
and 2,
IF THERE ARE BLOWN DIODES:
If diodes are blown, it is probable electtic heater plug is miswired.
Correct miswiring,
NOTE; Board will need to be replaced if diode is bad,
—11—
IF TRACES ARE OVERHEATED ON BACK OF PCB:
Usually whenever there is a trace blown on PCB, it means either
there has been a high-voltage short or high voltage has been
applied to low-voltage circuit. This can be prevented by making
sure PCB is wired correctly before PCB has power applied to it.
AUG/14/2008/THU 03:47 PM UTC TECH PUB FAX No, 317 240 5667 P. 012
THIS COMPARTMENT MUST BE CLOSED EXCEFT FOR SERVIGING NOT CUA TION: SYSTEMS
EXCEEDING 1504 TÜ GROUND
BLOWER MOTOR |
ATTENTION:
NE CONVIENT PAS AUX INSTALLATIONS
| DE PLUS DE 150 VV A LA TERRE
(GokW 1PH SCHEMATIC DIAGRAM)
FIELD PCAWER WIRING BISGONNECT FER МЕС
‘ “DIEGONNECT PEANEC > : .
FIELD POWER WIRING | I E 1
. LEE MATIC PLATE | I jane |
o HTA D El FOR VOLTS & HERTZ ! ! ' I
== = = = = = = = = ооо Em wm mm Em Em Em Em mE Em Em Em Em Em кн кн он f SEENOTE 1 y. D D
1
EEE RATING PLATE
YEL FOR VOLTS 6 HERTZ T PLUG
| (SEE NDTE 1)
NENE 7
COOLING CONTROL WIRING
. _ COOLING CONTROL OMLY
AUX HEAT RANGE
———m 4-00 0 OP |
; ACHP SIZE A Po
O 24VAC a
ax | | = +0 0.0 068 + - :
CIF AC HF-CONFORT HP-EFF [о — — -
LOAN + Lt
- МОНРО СЕМ ТАМ a
——u«u—5 © © |
ACHP DELAY OMOFF
naa Aon. 3080 ofa
——e}0 OO Q |
I)
AED |
— a DONE ||
| TRAN =" AUXI HUMI 1
BLK —— -
GOMMON ver COTE
RED DD NA AC AD AURA TAE ALEA
__ dl a AUX> HUMZ INDOOR THERMOSTAT
E |
| I
ax PCB
PLE 3 (5ER NOTE 3) YEL ———
M2 GANEL
ss Ha] |
| ver ORN | GRN SALAIAZ A -T —+— =
RECA 3
me [nda nor NL PES : 1
\ A A
To Jub on 7
ERN RED | RED
PLUG 4 e неее:
2] CEE
2e po O T RECP 4
NOTES: - LEGEND =
EE о. O wacoTEWMNAL LB LIMIT SWITCH
E. Transformer primary leads: BLUE 208Y, RED 230V. = UNMARKED TERMINAL ICM FAN MOTOR
4, To be wired in aceordandos with NEC and local codes. a... FIELD POWER WIRING TRAN TRANSFORMER
5. If any of the original wire, as supplled, must ba replaced, use the same or equivalent type wire —— PLUG AND RECEPTACLE GND EQUIPMENT GROUND
: FU FUSE
6. Replace low voltaga fuse with no greatar than 5 amp fuse, AUX IA JUMPER RECP RECEPTACLE
7, Fuse is wired in series between transformer SECZ and low volage "A" circuit. CH CIRCUIT BREAKER
8. ROKW heater uses ona double pole LS on middie top element. FCB PRINTED CIRCUIT BOARD
8. 15, 24 and 30KW heaters use double pole fimit switches. HPTE HEAT FUMP TEAM BRL F LOW VOLTAGE FUSE
10. Largaat heaters are shown, smaller heaters will have fewer elements and LVTB LOW VOLT TEAM BAD
somponents. SEQUENCER
11. 4 phase heaters arg shown wired for single su у clreult. Multiple =a NEATEA
H
supply circuits may be wired dIrgotly to fu=={C.B."5. HVTB | HIGH VOLTAGE TERMINAL BOX _
HLIM HUMICIFIEA .
jh
; rere] и
A94078
Fig. 8—FRAB Wiring Diagram
—12—
AUG/14/2008/THU 03:46 PM UTC TECH PUB FAX No, 317 240 5667 F013
TABLE 6—MOTOR CONTROL TEST VALUES
VOLTAGES—7-PIN PLUG Pz
OPERATING MODE SCREW TERMINALS W a С © В МАО Y
Pin 1 Fin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 |
MH Electric Heating | R | wa | ws* | E* 24vde | O | © 0 | 24vac 0
a 1-Sposd A/C Cooling | R YY | à _ 0 24 vac 0 0 24 vac | 24 vac Ü
—2-5peed A/C, Low Speed — Cooling | A | Yi G 0 24vac | 0 0 | 24vac 0 24 vag
2-Spead A/C, High Speed Cooling | В | Y/YE G 0 24 vac 0 0 24 мас | 24 мас | O
_ 1-Speed HP Cooling | R | YY2 | G | 0 о | 24 мас | O 0 | 24vac | 24 veo 0
1-5peed HP Heating | A | YY2 | G 0 24 vat | O 0 | 24vac | 24vac | ©
2-Speed HP, Low Speed Cooling | R Y1 G | O 0 24vac | O 0 24 vag 0 24 vac
2-5peed HP, Low Speed Heating В | Yi G 0 24 vac 0 D 24 vac 0 24 vac
_2-Speed HP, High Speed | Cooling | R | Y/Y2 V1 G o 24 vac 0 0 24 vac | 24 vac 24 vac
2-Speed HP, High Speed Heating | R | 2 У G 0 24 var o | O 24 vac | 24 vac | 24 vac
Continuous Fan RÍ G 0 24 vac 0 0 24 vac 0 0
+
С. If PCB Fuse Keeps Blowing:
When low-voltage fuse blows, it means transformer would have
blown if fuse had not been in circuit to protect it. The fuse usually
blows when there is a high current drawn on transformer, high
voltage applied io low-voltage circuit, or a direct secondary short.
When there is a high current drawn on transformer, it is most likely
because transformer has been shorted or system is trying to draw
more va than transformer rating allows. When fuse blows because
of high voltage, the system has mixed high- and low-voltage
signals.
1. Check transformer and thermostat wiring. (See Fig. 6 and
8.) Be sure transformer is not shorting out because thermo-
stat wires are miswired.
2. Check wiring of sequencers. (See Fig. 6 and 8.) Be sure
low-voltage and high-voliage wiring are connected to
proper sequencers,
3, Check va draw on transformer. If va draw is more than va
rating of transformer, fuse will blow. If this is the case,
replace transformer with one that has a higher va rating and
meets system specifications,
VI. TROUBLESHOOTING ICM2 FAN MOTOR
A. If Motor Does Not Run:
1. With power turned off, check all plugs and receptacles on
circuit board and at motor for any deformation that may
cause a bad connection. Be sure all plugs are placed fully
seated.
2. Verify that thers are approximately 230v at terminals M1
and M2. If not, determine if high voltage is entering board. |
It enters through black and yellow wires at pins 7 and 9 in
12-pin plug.
3, Verify that there 15 a low-voltage control signal to motor.
The motor receives its control signals through the 7-pin
motor plug P2. The voltage output of each pin in plug will
be different for each mode of operation. Table 6 lists circuit
board screw terminals that have 24 vac present (powered by
thermostat) and lists voltage that is present at each pin of
7-pin plug for each operating mode. Tests should be taken
between points listed and common (C screw terminal). If all
values of any 1 of operating modes checks OK and motor
fails to run, then motor is defective and.should be replaced.
В. If Motor Does Not Run Smoothly:
First verify that the cause is not an out-of-balance or damaged
blower wheel, If it is not blower wheel, motor 15 defective and
should be replaced.
Pin 1 @ 24 vic with or without jumpers when ever any Individual heater input or any combination of héater inputs aré energlzed,
C. HMotor Shaft Does Not Rotate Smoothly:
‘When manually turning shaft of ICM, the shaft does not rotate
smoothly. The shaft has steps during rotation and 1s referred to as
motor cogging. The cogging i8 caused by permanent magnets
passing cach pole of motor. However, shaft should not require
excessive force to turn. If shaft is VERY difficult to turn, motor
contro] ot bearings have failed and motor must be replaced.
D. if Motor Does Not Stop Running
1. Check for good ground between motor ground lead and
transformer common lead.
2. If motor continues to min, remove all thermostat wires, If
motor stops, replace circuit board.
3, If motor continues to run, remove the 7-pin plug. If motor
continues to run, replace motor.
Vil, CONDENSED VERSION OF TROUBLESHOOTING
FR4B MOTOR AND CONTROLS
This section provides a quick summary of how to troubleshoot the
ЕКАВ. Н more information is needed, refer to appropriate sections
of this service manual.
+ MOTOR
~ If motor is hard to turn manually, replace motor.
- H motor does not mn, check the components listed below
according to their instructions.
-- If motor runs in some operation modes end not in others,
check for a good ground connection between motor ground
lead and circuit board screw marked "ground screw" and
check the room thermostat and wiring hamess according to
Instructions listed below.
~ If motor does not stop running, remove the 7-pin plug from
circuit board. If motor continues to run, replace motor, If
motor stops running; 1t 15 either the circuit board or thermo-
stat causing the problem, Test whether thermostat is at fault
by disconnecting it from the board.
+ CIRCUIT BOARD
- Check 5-amp fuse,
- Check for 230v between terminals M1 and M2. If no voltage
is present, check power to board. 230-v power enters the
board through the black and yellow lead in the 12-pin plug.
~ Check for 24v between SECI and SEC2, If no voltage is
present, check the transformer.
- Check for burn traces or burnt components, If bum spots are
present, replace board.
AUG/14/2008/THU 03:48 PM
UTC TECH PUB
+ ROOM THERMOSTAT
- Remove thermostat wires from the circuit board,
- Jumper screw terminals (1 at a time) R-G, R-Y/Y2, R-Y1,
and R-WZ. If motor runs in all cases, thermostat is bad.
Replace thermostat. If motor does not run, or runs in some
cases but not in others, continue by checking the wiring
| harness.
+ WIRING HARNESS
- Shut off power to unit.
- Remove 5-pin plug from motor.
A | CAUTION: Never remove 5-pin high voltage plug from
the motor with the power on. |
- Remove 16-pin plug from motor. .
- Replace 5-pin plug and turn on power,
- Check for 24y between pin-1 and pin-12 on the 16-pin plug.
If no voltage is present, replace wiring fidrness. (See Fig. 9.)
- If voltage is present, jumper screw terminal R-Y/Y2 on
circuit board apd check for 24v between pin-12 and pin-14 on
16-pin plug. (See Fig. 9.) If no voltage is present, replace
hamess.
- If 24v is present, the motor is bad. Replace motor,
16][15 [14 3 12111 |hol[ a
8 7 6 |[5||4||8 2 [1
16-PIN PLUG
A94375
Fig. 9—Wiring Harness 16-Pin Plug
VIIL ACCESSORIES
A. Electronic Air Cleaner (EAC)
Familiar 230-vac EAC control/power signal FACI1 and EAC? is
not available, because the ICMZ blower motor used in the FK4B
Fan Coil is controlled by low-voltage signals. This signal is
replaced by a Z24.-vdc signal which is provided at ciréuit board
terminals AUX1 and AUX2, (See Fig 6.)
This signai is present when either G or W is present and is active
in all heating and cooling modes. Because 24-уйс relays may not
be readily available to installer, a kit exists, KFAIR0101ACR,
containing a 24-vde relay which mounts directly inside FAC
cabinet. User-supplied 110 vac is switched by relay to power air
cleaner when G or W are present. (See Fig. 10 and 11.)
In heat pump applications, the О signal is present in both cooling:
and heating modes, permitting EAC to be controlled from G signal
only. For this application, a user-supplied 24-vac relay can be
driver by (5 terminal eliminating need for relay kit.
B. FKA4B De-Humidify Mode
NOTE: Humidistat must open on humidity rise.
Latent capacities for systems using the FK4B Fan Coil are better
than average systems, If increased latent capacity is an application
requirement, the FK4B can be wired to pravide this requirement by
adjusting its airflow in response to standard humidistat input. Fig.
12 illustrates the wiring connections to activate de-humidify mode.
Carefully consult product airflow data for cooling and dehumidi-
fying mode,
THERMOSTATIC EXPANSION VALVES (TXV)
The FC4B and FE4B Fan Coils are factory equipped with a hard
shutoff (HSO) TXV,
— 1d —
FAX No, 317 240 5067
MOUNT FLUSH WITH
THESE TWO EDGES
AS32186
Fig. 10—Mounting KFAIRO101ACR Relay Kit
FK4B 110 VAC BRANCH CKT
AUX1 AUX? GND HOT NEUT
} } À À
=
E E
ор юр =
(FAC 1
| PLUG
EE
o
¡24 VDC RELAY |
i |
| |
! |
| i
Li
AS32117
Fig. 1T—KFAIR0101ACR Relay Kit Wiring ~~
Schematic
HUMIDISTAT
RED WIRE
FROM ICM2 —— | | Г\_ 10 PCB TERMINAL
MOTOR | ТО РОВ ТЕРМ
HUMIDISTAT WIRING FOR
DE-HUMIDIFY MODE
AS32215
Fig. 12-—Humidistat Wiring for De-Humidify Mode
The hard shutoff TXV has no bleed port and allows no bleed-
through after system is shutdown, No pressure equalization occurs.
A. start capacitor and telay must be installed on single-phase
reciprocating compressors to boost torque to compressor motor so
it may overcome the unequalized system pressures.
AUG/14/2008/THU 03:48 PM
UTC TECH PUB
The standard TXV is a bi-flow metering device that is used in
condensing and heat pump systems to adjust to changing load
conditions by maintaining a preset superheat temperature at outlet
of evaporator coil. The volume of refrigerant metered through
valve scat is dependent upon the following:
1. Superheat temperature sensed by sensing bulb on suction
tube at outlet of evaporator coll. As long as this bulb
contains some liquid refrigerant, this temperature is con-
verted into pressure pushing downward on the disphregm,
which opens the valve via push rods.
2. The suction pressure at outlet of evaporator coil is trans-
ferred via the external equalizer tube to underside of
diaphragm,
3. The needle valve on pin carrier is spring-loaded, which also
exerts pressure on underside of diaphragm via push rods,
which closes valve. Therefore, bulb pressure squals evapo-
rator pressure at outlet of coil plus spring pressure. If load
increases, temperature increases at bulb, which increases
pressure on topside of diaphragm, which pushes pin carrier
away from seal, opening valve and increasing flow of
refriperant. The increased refrigerant flow causes increased
leaving evaporator pressure which is transferred via the
equalizer tube to underside of diaphragm, with which the
pin carrier spring pressure closes valve. The refrigerant
flow is effectively stabilized to load demand with negligible
change in superheat.
The bi-flow TXV is used on split system heat pumps. In cooling
mode, TAV operates the same as a standard TXV previously
explained. However, when system is switched to heating mode of
aperstion, refrigerant flow is reversed. The bi-flow TXV has an
additional internal check valve and external tubing. These addi-
tions allow refrigerant to bypass TAV when refrigerant flow is
reversed with only a 1- to 2-psig pressuré drop tlirough device.
When heat pump switches to defrost mode, refrigerant flows
through a completely open (not throttled) TXV. The bulb senses
the residual heat of outlet tube of coil that had been operating in
heating mode (abont B5°F and 155 psig). This temporary, not
FAX No, 317 240 5067
throttled valve, decreases indoor pressure drop, which in tum |
increases refrigerant flow rate, decreases overall defrost time, and
enhances defrost efficiency.
l. PROBLEMS AFFECTING TXV
A. Low Suction Pressure
1. Restriction in TXV
2. Low refrigerant charge
3. Low indoor load
4. Low evaporator airflow _
B. High Suction Pressure
1. Overcharging
2, Sensing bulb not secure to vapor tube
3. High indoor load
4, Large evaporator face area
When installing or removing TXV, wrap TXV with a wet cloth,
When reattaching TXV, make sure sensing bulb 15 in good thermal
contact with suction tube.
PISTON BODY CLEANING OR REPLACEMENT
A | CAUTION: Do not vent refrigerant to atmosphere. Re-
cover during system repair or final unit disposal.
~15 —
P, 015
CAUTION: Damage may occur to the scroll compressor
AN | if operated at a negative suction pressure during a system
pumpdown.
1. Pomp down outdoor unit. Close service valves at outdoor
unit.
2. Recover remaining refrigerant from tubing and coil through
gage port on vapor-tube service valve.
3. Disconnect refrigerant (liquid) tbe from piston body, (See
Fig. 13.)
4. Avoid damaging seal ring or machined surfaces on piston,
bore, and retainer.
5. Using small wire with a hook on end of it, remove piston
from body,
TEFLON SEAL — == PISTON
PISTON ss 7
RETAINER HEX BODY
‘BRASS
HEX NUT
A93530
Fig. 13—Rafrigarant Flow-Control Device
(For FA, FB, and FF)
"CAUTION: When cleaning the piston arifice, be careful
A | not to scratch or enlarge the opening, as this will affect
‘| operation.
. Install new or cleaned piston into body.
6
7. Replace seal ring on retainer.
5. Reconnect refmigerant tube to piston body,
9
- Pressutize tubing and coil, then leak check.
10. Evacuate tubing and coil as necessary.
GAUTION: Use a backup wrench and do not over
A | tighten, as deformation of the piston body will occur, |-
| causing ‘the piston to lodge in a partially open or cloged|
position.
LIQUID TUBE STRAINER
The TAV and refrigerant flow-control device is protected on the
indoor coil by a wire mesh strainer. It is located inside the 3/8-in.
liquid tube at field braze joint just outside unit caging. Access to
strainer is through field braze joint.
COIL/CONDENSATE PAN REMOVAL
AND REPLACEMENT
[. A-COIL UNITS
If it is determined that system does not have leaks and refrigerant
is not contaminated, proceed as follows:
1. Recover system refrigerant.
AUG/14/2008/THU 03:46 PM UTC TECH PUB
HORIZONTAL |
CONDENSATE EXPANSION DEVICE
(TXV SHOWN)
HORIZONTAL
PAN CLIP
COIL TOF SEAL
DELTA PLATE
VERTICAL
CONDENSATE
COIL. BRAGKET PAN
(4 PER UNIT) SCREWS
| DELTA PLATE TO
PAN (4 PER UNIT) —
АВОРЕВ
Fig. 14—A-Coil Component Location
. Attach manifold/gage set to service valves,
. Front seat (close) liquid tube service valve.
. Start umt in cooling mode. -
. Run unit until vapor pressure reaches 5 psig (35KFa).
. Tura off electrical supply to outdoor unit.
hor Cu с со
. Front seat vapor service valve.
g. Recover any remaining refrigerant.
NOTE: All outdoor unit coils will hold only factory-supplied
amount of refrigerant. Excess refrigerant, such as in long-tube
applications, may cause compressor internal pressure relief valve
to open (indicated by sudden rise in vapor pressure) before vapor
pressure reacties 5 psig (35kPa). If this occurs, tum off electrical
supply to outdoor unit immediately, front seat vapor service valve,
and recover any remaining refrigerant,
2. Turn off electrical supply to indoor unit.
3. Disconnect condensate drain tube,
4. Disconnect liquid apd vapor tubes from indoor coil. Use a
tubing cutter to cut tubes.
NOTE: If a torch is used to unbraze tube set, protect fitting panel
with a wet cloth or braze shield, as necessary. —
5. Remove coil access panel.
6. Remove clip securing fitting panel to condensate drain pan.
Remove fitting panel.
7. Remove any shipping clips, including horizontal pan clip,
and slide coil/condensate pan assembly out of unit.
8. Upflow or Horizontal Applications Only — Rémove hori-
zontal condensate drain pan from coil/condensate pan
assembly. (See Fig. 14.)
FAX No, 317 240 5067 P, 016
9. Remave 4 coil brackets. (See Fig. 14.) |
10. Remove screws at delta plates and remove coil from vertical
condensate drain pan, (See Fig, 14.)
11. Horizontal Applications Only —Remove coil top seal
(attached with, 4 screws) and J-shaped tube from original
col and instal] it in same position on new coil. (See Fig,
14.)
12, Place coil assembly in plastic condensate pan and secute
using 4 screws through delta plate, (See Fig. 14.
13. Horizontal and Upflow Applications Only — Attach 4 coil
brackets to coil/pan assembly. (See Fig. 14.)
14, Horizontal Applications only — Place horizontal conden-
sate pan into position on coil/pan assembly,
NOTE: Installation of hotizantal condensate pan Is not necessary
for upflow or downflow applications.
15. Slide complete assembly into unit.
16. Reinstall fitting panel and reconnect clip securing fitting
panel to condensate drain pan.
17. Horizontal Applications (nly — Reinstall horizontal pan
clip. Secure with 1 screw. (Sec Fig, 14.)
18. Reinstall coil access panel.
19. Reconnect liquid and vapor refrigerant tubes, and conden-
— gate drain tube. Install filter-drier(s), if necessary.
ea . a
20, Evacuate tube set and indoor col, back seat (open) liquid
and vapor service valves,
21. Turn on electrical supplies to indoor and outdoor units.
22. Check system refrigerant charge and operation. See "Split-
System Residential Air Conditioners and Heat Pumps
Service Manual" fór further information,
ll. SLOPE COIL UNITS
COL SUPPORT COLUMN
COL TOP'SEAL (FARTIALL Y HIDDEN)
SCREW (TO CASING)
= DISTRIBUTOR
TUBE
EXPANSION
DEVICE
A | =
\ a | 0)
:
SCREW
(PAN TO COIL)
LIQUID TUBE
FIELD CONNECTION
RCN 4 CONDENSATE PAN
A90269
Fig. 15--Slope Coll Component Location
If it is determined that system does not have leaks and refrigerant
is not contaminated, proceed as follows:
1. Recover system refrigerant.
AUG/14/2008/THU 03:49 PM
UTC TECH PUB
a. Attach manifold/gage set to service valves.
b. Front seat (close) liquid tube service valve,
&. Start unit in cooling mode.
d. Run unit until vapor pressure reaches 5 psig (35kPa).
e, Turn off electrical supply to outdoor unit.
f. Front seat vapor service valve.
g. Recover any remaining refrigerant.
NOTE: All outdoor unit coils will hold only factory-supplied
amount of refrigerant. Excess refrigerant, such as in long-tube
applications, may cause compressor internal pressure relief valve
to open (indicated by sudden rise in vapor pressure) before vapor
pressure reaches 5 psig (35kPa). Tf this occurs, turn off electrical
supply to ontdoor unit immediately, front seat vapor service valve,
and recover any remaining refrigerant,
2. Turn off electrical supply to indoor unit.
3. Disconnect condensate drain tube,
4. Disconnect liquid and vapor tubes from indoor coil. Use
either a tubing cutter to cut tubes or a torch to unbraze tubes
as required.
NOTE; If a torch is used to unbraze line set, protect fitting panel
with a wet cloth or braze shield, as necessary. System contains oil
vapors which may ignite when exposed to a flame.
5. Remove coil access and fitting panels.
6. Remove 1 screw securing coil to unit casing.
7. Remove coil/pan assembly from unit.
3
, Place assembly on-a at surface. Remoye-2 gcrews secuting
coil support columns to pan. (See Fig. 15.)
9. Rotate columns 90°, pull away from coil, and remove
columns from assembly.
10. Remove remaining 2 screws securing coil to condensate
pan.
11. Remove coil from condensate pan,
12. Remove coil top seal. (See Fig. 15.)
13. Install new coil into condensate pan -nsing 2 original screws
and 2 support columns,
NOTE: Correct coil position in condensate pan is essential to
reliable operation.
14. Install new coil/pan assembly into unit. Secure with 2
screws previously temoved from unit casing.
15. Reinstall coil access and fitting panels.
16. Reconnect liquid and vapor refrigerant tubes, and conden-
sate drain tube. Install filter-drier(s), if necessary.
17. Evacuate tube set and indoor coil, back seat (open) liquid
and vapor service valves.
18. Turn on electrical supplies to indoor and outdoor units.
19. Check system refrigerant charge and operation. See "Split-
System Residential Air ‘Conditioners and Héat-Pumps
Service Manual" for further information.
CARE AND MAINTENANCE
To continue high performance, and minimize possible equipment
failure, it is essential periodic maintenance bé performed on this
equipment, |
The ability to properly perform maintenance on this equipment
requires certain mechanical skills and tools. The only consumer
service recommended or required is filter maintenance. (See Filter
Assembly.)
FAX No, 317 240 5067
—17—
P, 017
WARNING: Disconnect all power to the unit before
servicing the field wires or removing the control package.
A 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.
Electrical shock can cause personal injury ot 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. Replace plug after inspec-
tion.
3. Inspect blower motor and wheel for clesnliness each
heating and cooling season. Clean as necessary.
4. Inspect electrical connections for tightness and controls for
proper operation each heating and cooling seagon. Service
AS MÉCESSATY.,
WARNING: As with’ any mechanical” equipment, per-
A sonal injury can result from sharp métal edges. Be careful
| when, removing parts,
ire a
vi
i
|. FILTER ASSEMBLY
To clean or replace air filter, push plastic connectors toward center
of unit and remove filter access panel outward. Push filter up and
back into unit. Then slide filter out. Clean filter by ising cold
water and mild detergent. Rinse 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 cooling coil and replace filter access panel.
IE COOLING COIL, DRAIN PAN, AND CONDENSATE
DRAIN
The cooling coil is easily cleaned when it is dry. Inspect the evil
and clean (if necessary) before cach cooling season. To check or
clean cooling coil, refhove coil access panel. If coil is coated with
dirt or lint, vacuum НМА a soft brush attathment.
Be careful not to bend coil fins. If coil is coated with oil or grease,
clean it with a mild detergent and water solution. Rinse coil
thoroughly with clear water: .Be careful not.to splash water on
insulation. | пм | |
Inspect drain pan and condensate drain at the same time cooling
coil is checked. Clean drain pan and condensate drain by removing
any foreign matter from pan. Flush pan and drain tube wath clear
walter. | |
If drain tube is restricted, it can generally be cleared by high=
pressure water, Cut plastic line and, work outside condensate pan
and away from coil to clean drain tube. -
CAUTION: Dg not use caustic houscheold drain cleaners
A | in the condensate pan or near the coil. Drain cleaners can
quickly destroy a coil.
Uli. BLOWER MOTOR AND WHEEL
Clean blower motor and wheel when cooling coil is cleaned.
AUG/14/2008/THU 03:49 PM UTC TECH PUB
CAUTION: Disconnect electrical power before remove
ing any access panels,
A
To clean blower motor or blower wheel:
1. Remove blower access panel.
Remove motor leads from PCB. Note lead location for case
of reassembly.
2,
- Remove 2 outside screws holding blower/motor assembly
against blower-deck flange and slide assembly out of
cabinet,
. Remove screw in strap holding motor capacitor to blower
housing and slide capacitor out from under strap. Remove
screw with green wire from blower housing. Mark blower
wheel, motor, and motor support in relation to blower
housing before disassembly to ensure proper reassembly.
Note position of blades on wheel.
. Loosen setscrew holding blower wheel onto motor shaft.
. Remove 3 bolts holding motor mount to blower housing and
slide motor and mount out of housing. Further disassembly
should not be necessary &s adequate clearance is available.
. Remove blower wheel from housing by removing cutoff
plate from blower housing outlet. Note wheel oriéntation
and cutoff location for reassembly. The blower motor and
wheel may be cleaned by using a vacuum with a soft-brush
attachment.
& Remove gtease with a mild solvent such as hot water and
detergent. Be careful not to disturb balance weights (clips)
on blower-wheel vanes, Also, do not drop or bend wheel, as
balance will be affected,
To reassemble blower:
1. Place blower wheel back into housing. Be sure to position
correctly for proper location.
Reassemble cutoff plate to housing using identified holes
trom disassembly procedure.
. Position motor and mount in same position as when blower
housing was in unit. Secure motor mount on housing, using
removed bolts. Make sure mount or motor 15 grounded to.
blower lioúsing, |
. 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.
. Secure Motor capacitor under strap and tighten strap screw.
. Slide blower assembly to blower deck. Be sure (once
blower is within the unit casing) 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 PCB.
10. Reconnect electrical power to unit and test fan for proper
rotation.
—18—
FAR No. 317 240 5667 P, 015
FF1A/FF1B SERVICE AND TROUBLESHOOTING
WARNING: Before installation or servicing system,
always turn off main power to system. There may be
more than 1 disconnect switch. Turn off accessory heater
power if applicable, Electrical shock can cause personal
injury or death.
Л
L FAN MOTOR
Thé motor is Z-specd direct drive. High-speed lead is black,
low-speed lead is red, and common lead ts violet. Be sure proper
blower speed has been selected, For units with electrical heat,
low-speed tap can be used. For cooling, use high-speed tap.
The motor is turned on through 2 different routes: The first occurs
when thermostat calls for the fan in cooling, heat pump, or
fan-only mode. A 24-vac signal is sent to relay, causing relay to
close its normally-open contacts, turning fan on. The second
occurs When there js a call Tor electric heat. A 24-vace signal 18 sent
to heater sequencer, causing it to close, directing 230v through the
normally-closed contact of fan relay, tuming fan on. The fan
remains on until sequencer opens, Refer to FF1A/FF1B typical
wining diagram shown in Fig. 16,
If motor does run, test motor for an open winding or a winding
shorted to motor case. If any 1 of the 2 ts present, replace motor.
Il. ELECTRIC HEATER SERVICE
Service can be completed with heater in place. Shut off power
before servicing.
A. Limit Switch
Malfunction prevents heating element from coming on. Replace
switch if malfunction occurs.
B. Sequencer
Malfunction causes heater not to come on or never shut off,
Replace sequencer.”
C. Transformer
A 40-va transformer supplies 24-v power for control circuit.
Replace transformer if faulty.
NOTE: Transformer is fused. Do not short circuit.
D. Fan Relay
Malfunction causes unit fan not to run or ma continuously.
Replace relay,
Ш. CLEANING OR REPLACING REFRIGERANT FLOW-
CONTROL DEVICE
Refer to Fig. 13 and instructions given in Piston Body Cleaning or
Replacement section above,
IV. LIQUID TUBE STRAINER
The refrigerant flow-control device is protected by a wire mesh
strainer. It is located inside the 3/8-in. liquid tube at field braze
joint next to flow-control device. Access to strainer is through field
braze joint,
V. SEQUENCE OF OPERATION
Refer to Fig, 16,
A. Condensing Unit
COOLING
When thermostat calls for cooling, the circuit between R and G is
complete and single-pole single-throw relay FR is energized. The
normally-open contacts close cansing blower to operate, The
circuit between R and Y is also complete. This completed circuit
causes contactor in outdoor unit to close which starts COMpressor
and outdoor fan.
AUG/14/2008/THU 03:49 PM UTC TECH PUB
FAX No, 317 240 5067
* SCHEMATIC DIAGRAM FOR 2, 9, & 5 KW HEATERS
BLK
SEE RATING PLATE
cs FOR VOLTS & HZ
DISCONNECT
IFA (TDR OPTIONAL) MOTOR
COMPONENT ARRANGEMENT
CAP _— |
TRANS | 24V | e —
I Il ]
BLK 208 280 (4) :
COM BLU RED
RED
MEW
VID
CHASSIS
BAN GROUND
FIELD
POWER . DISCONNECT
SURELY HTR1 [ HTR2 — -
CHÁBEIS” 7 RED ELU > ? à | 5
ROUND TRANG See rT ‘
RED BAN от 2)
[RI vo Ss E (5) TRANS Y WHEN EQUIPFED © 55 | |
Tromso ann : E WHEN EQUIPPED A
CHASSIS BAN Ge
GROUND
MOTOR SPEED SELECTION
SEE RATING PLATE
FOR VOLTS 8 HZ
DISCONNECT
Ho. "2,
= |
OPTIONAL JER/TDR DD VIO = Hi = BLACK LOW = RED COMMON = VIO
SCHEMATIC DIAGRAM FOR 7.6 & 11 KW HEATERS FIELD WIRE TEMP
SEE RATING PLATE BLK IFA (TOR OPTIONAL) MOTOR CAP HEAT PKG. SIZE RATING
FOR VOLTS & HZ 2 KW 14 90°C
З КМ 12 90°C
5 KW 40 50°C
: 8 °
DISCONNECT Few 5 90°C
' 0 (COOLING) 14 90%
POWER LEGEND
SURELY. O MARKED TERMINAL
CHASIS > O UNMARKED TERMINAL
GHOUND LS LIMIT SWITCH
FR FAN RELAY
RED IFA INDOOR FAN RELAY
VIO IFR/TD INDOOR FAN RELAY/TIME DELAY
SEQ SEQUENGER
ORN (FR)
TE om (85° GAP CAPACITOR
HTR HEATER
TRANS TRANSFORMER
e rn vio} | TC FIELD POWER WIRING
OPTIONAL IER/TDR e OPTIONAL WIRING
A — FUSE
DIAGRAM FOR COOLING CONTROL
ВОНЕМАЦе ВАЗ + CHASSIS GROUND
FR TDR OPTIONAL) MOTOR САР
- NOTES
UNIT WIRED'FOR 250V OPERATION USING
BLACK AND RED TRANSFORMER PRIMARY
LEADS, FOR 208V OPERATION, USE BLACK
AND BLUE TRANSFORMER PRIMARY LEADS.
OPTIONAL IFR/TDR
FIELD 2 UNUSED TRANSFORMER LEADS MUST RE TAPED
POWER . AND LOOPED.
UE vo
o 3. IF ANY OF THE ORIGINAL WIRE, AS
CHASSIS + RED [—BLU - BLK SUPPLIED, MUST BE REPLACED, USE THE
GROUND A == SAME OR EQUIVALENT WIRE.
TRANS = ; ALE
RED TT BAN
R RED TRANS 4, FIELD WIRING, USE COPPER CONDUCTORÉS,
ORN (Fr SÓN ONLY.
т=т ВАМ ——BAN 5. FAN RELAY #4 1S A DEAD TERMINAL FOR
LE] CHASSIS UNUSED MOTOR LEAD STORAGE. TO CHANGE
GROUND MOTOR SPEEDS, EXCHANGE THE BLACK AND
RED MOTOR LEADS ON THE FAN RELAY.
CHÂSSIS
GROUND
316596 - 401 REV.B
Fig. 16—FF1A/FF1B Typical Unit Wiring Label
—19—
A9T140
AUG/14/2008/THU 03:50 PM UTC TECH PUB
HEATING
When thermostat calls for heating and FAN switch is set on
AUTO, the circuit between R and W is complete. The heater
sequence SEQ is energized which closes contacts of relay, There
will be a time delay, This completed circuit energizes all heating
elements HTR and blower motor.
B. Heat Pump
COOLING
On a call for cooling, the thermostat makes circuits R-O, R-Y, and
R-G. Circuit R-O cnergizes reversing valve, switching it to cooling
position. Circuit R-Y energizes contactor starting outdoor fan
motor and compressor. Circuit R-G energizes indoor ynit blower
relay starting indoor blower motor. When thermostat is satisfied,
its contacts open de-energizing contactor reversing valve and
blower relay. This stops compressor and fan пов,
HEATING
On a call for heating, the thermostat makes circuits R-Ÿ and R-G,
Circuit R-Y energizes contactor starting outdoor fan motor and
compressor. Circuit R-G energizes indoor blower relay starting
blower motor. Should temperature continue to fall, R-W circuit is
made through second-stage room thermostat bulb: Circuit R-W
energizes 8 sequencer bringiñg on supplemental electric heat.
When thermostat is satisfied, Из contacts open de-energizing
contactor and sequencer. All heaters and motors should stop.
VI. CARE AND MAINTENANCE
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.
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
a5 Necessary.
WARNING: As with any mechanical equipment, per-
A | sonal injury can result from sharp metal edges. Be careful
when removing parts.
A. Air Filter
To clean or replace air filter, grasp it at bottom and lift it out of
unit. Clean filter using cold water: Rinse clean and let dry. Oiling
or coating of filter is not required. To replace, stand filter in rack
with binding facing coil. Press top edge under access panel.
NOTE: Steel rods in filter prevent it from being pulled into coil.
Retain these rods and reinstall after cleaning or before replacement
if new filter is used.
A | CAUTION: Never operate unit without a filter,
B, Cooling Coil, Drain Pan, and Condensate Drain
The cooling coil is casily cleaned when it is dry. Inspect coil and
clean (if necessary) before each cooling season. To check or clean
cooling coil, remove blower/heater access panel to gain full access
to cooling coil. If coil is coated with dirt or lint, vacuum with a soft
brush attachment,
Be careful not to bend coil fins. If coil is coated with gil or grease,
clean it with a mild detergent-and-water solution. Rinse coil with
clear water. Be careful not to splash water onto insulation.
—20—
FAX No, 317 Z40 5067 E, UU
Inspect drain pan and condensste drain at seme time cooling coil
is checked. Clean drain pan and condensate drain by removing any
foreign matter from pan. Flush pan and drain tube with clear water.
If drain tube is restricted, it. can generally be cleared by high-
pressure water, Cut plastic line and work outside condensate pan
and away from coil to clear drajn tube.
NOTE: There MUST be a trap in condensate line. Trap must be
at least 3-in. deep, not higher than the bottom of unit condensate
drain opening, and pitched downward to an open drain or sump.
CAUTION; Do not nse canstic household drain cleaners
A in condensate pan ot pear coil, Drain cleaners can quickly
destroy coils,
C. Blower Motor and Wheel
Clean blower motor and wheel when cooling coil is cleaned.
To clean or service wheel or motor, proceed as follows:
1. Pull unit disconnect (when used) and remove blower access
panel.
2. Disconnect motor electrical leads from control box and
capacitor. Mark location of wires for reassembly.
3. Remove 3 bolts holding motor mount to blower housing
while supporting motor shell with hand.
4. Pull motor inlel nang and blower wheel assembly out of
blower housing.
5. With blower wheel, inlet ring, and motor mount still
attached to motor, place motor on flat, horizontal surface,
shaft up. Mark position of wheel on motor shaft for
reassembly.
6. Loosen blower wheel setscrew and remove blower whee]
from motor shaft.
NOTE: Further disassembly of motor and mount is not necessary
as adequate clearance is available to clean motor.
7. Clean blower motor and wheel using 2 vacuum with a soft
brush attachment. Remove grease with a mild solvent such
as hot water and detergent. Be careful not to disturb balance
weights (clips) on blower wheel vanes, Do not drop or bend
wheel as balance will be affected.
To reassemble unit, proceed as follows:
1. Flace motor with mount attached on flat, horizontal surface
with shaft up.
2. Set ihlet ring On op of motor mount gromniets: Center inlet.
rng flush on all 3 grommets.
3. Slide blower wheel onto motor shaft with setscrew upward
and abgned with shaft flat portion. Vertically position
wheel along shaft to position marked during disassembly.
NOTE: If previous shaft was not marked or if replacing previous
motor, set blower wheel position by sliding blower wheel along
motor shaft to 1-1/8 in. above rubber grommets. (See Fig, 17.)
4. Hold blower whee] in place and carefully tighten setscrew,
5. Position motor and blower wheel assembly to blower
housing as originally oriented.
6. Secure motor mount to blower housing using bolts previ-
ously removed.
7. Attach green wire to blower housing with screw.
8. Connect electrical and capacitor leads to original terminals,
9. Replace blower access door and tighten all 4 screws,
10. Reinsert disconnect pullout only after blower access door is
secured. Test blower for proper operation.
AUG/14/2008/THU 03:50 PM
UTC TECH PUB
FAX No, 317 240 5067
P, 021
-
1
a
1
1
Ha
wma
a
1
и
i
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i
1
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1
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BLOWER
DA WHEEL
— INLET
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GROMMET
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A86006
Fig. 17—FFiA/FF1B Motor, Inlet Ring, and Blower Wheel Assembly
FD3A SERVICE AND TROUBLESHOOTING
WARNING: Before installation or servicing system,
always turn off main power to system. There may be
A more than 1 disconnect switch Turn off accessory hestér
power if applicable, Electrica! 'shock can cause personal
injury or death.
1. FAN MOTOR
The motor is 2-speed direct drive. High-speed lead is black,
low-speed lead is red, and common lzad is yellow,
NOTE: Unused fan speed leads must be tapped off to prevent
direct short to cabinet surface,
The motor is turned on through 2 different routes. The first occurs
when thermostat calls for the fan in cooling, heat pump, or
fan-only mode. A 24-vac signal 15 sent to relay, causing relay to
close its norrpally-open contacts, turning fan on. The second
occurs when there 15 à call for electric heat. À Z4-vac signal is sent
to heater sequencer, causing it to close, directing 230v through the
normally-closed contact of fan. relay, turnmg fan on. The fan
remains on until sequencer opens. Refer to FD3A typical wiring
diagram shown in Fig. 18.
Il. ELECTRIC HEATER SERVICE
Service can be completed with heater in place. Shut off power
before servicing.
A. Limit Switch
Malfunction prevents heating element from coming on. Replace
switch if malfunction occurs. :
B. Sequencer
Malfunction causes heater not to come on or never shut off,
Replace sequencer.
С. Transformer
A 60-va transformer supplies 24-v power for control circuit.
Replace transformer if faulty.
NOTE: Transformer is fused. Do not short circuit.
—21—
D. Fan Relay
Malfunction causes unit fan mot to run or run continunousty.
Replace relay. . .'
E. Heater Removal
Disconnect wiring, remove 2 sheet metal screws, and pull heater
out through open hinged access panel. When replacing heater,
- Ensure éôrientation of heater element is same as when removed.
HL CLEANING OR REPLACING REFRIGERANT ELOW-
CONTROL DEVICE
1. Pump down outdoor unit, Close service valves at outdoor
unit. |
CAUTION: Damage may occur to the seroll compressor
À | if operated at a negative suction pressure during a system
pumpdown.
2. Bleed and (if possible) recover remaining refrigerant from
tubing and coil through gage port on vapor-tube service
valve.
3. Disconnect liquid refrigerant tube from refrigerant flow-
control device. Refer to Fig, 19.
4, Remove refrigerant flow-control device piston retainer.
Avoid damaging O-ring or machined surfaces on piston,
bore, and retainer,
5. Using small wire with a hook on end of it, remove piston
from refrigerant flow-control device body,
A CAUTION: When cleaning piston orifice, be careful not
to scratch or enlarge opening as this will affect operation.
AUG/14/2008/THU 03:50 PM
UTC TECH PUB
FAX No, 317
240 5567
lp — SEENOTE#4 oy ry VEL = SCHEMATIC DIAGRAM YEL —O L8-1
Ly FIELD POWER SUPPLY el а YE YEL — 0 LS-2
SEQ (1)— BLK и
БЕО (3) (бетона HTR-2 18.2
TB (2) O Bree Wor VEL =/4TB
FR (3)— BLK SEQ —— |
SE (formanau DANA SER do 1 vio РОСТ
TB (2) rm YEL TB
NOTE #2
a o Ч FC or
SEQ BAN—OH VIO L5-2
TRANS J | | ae — TRANS
TE #1 y VEL
FA {3 )—ReD BLK— FCT |
__ TRANS GAN
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OR; SEQ
OM | @H--A_—vo = ую RCAC Gia TRANS
В 8 ! BAN FR
A | | ERN—5)5EQ
T !(@+--—om CAN (Fr)
[Of AA BRN
COMPONENT ARRANGEMENT — -
RED BRN SEE NOTE #4 __ = |
YEL бес © «Ретро? FIELD POWER WIRING J
BLK HRN nens
8 our EB ———. |
mm DISCONNECT
> = = YEL NER
/ (OPTIONAL) —-BRN FE Ll RED Eu.
TRANS BLU
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BAN ———RED RED—-————— KR) О Е
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вк! vIO ую NE A
3 — A
- LEGEND - NOTES:
не 1. TRANSFORMER PIGTAILS:
= FIELO POWER WIRING 7 — (OPTIONAL) > N BLUE 208V; RED 230V: INSULATE
— = FIELD GROUND W!
TT EE CONO wea JL FOSIBLELINK, | - AN MOTOR PIGTALS: RED LOW:
JH FIELD SPLICE ==— WIRE SLEEVE BLACK HIGH, INSULATE UNUSED
—& JUNCTION LEAD,
O MARRED CONNECTION 3. FAN MOTOR THERMALLY
О UNMARKED CONNECTION PROTECTED
FC FAN CAPACITOR 4, SUTABLE FOR USE WITH COPPER
FR FAN RELAY OR COPPER CLAD ALLIMINUM
НТА HEATE CONPLIGCTORS RATED FOR 75°C
IFM INDOOR FAN MOTOR MINIMUM. FOR COPPER USE 6
LS LIMIT SWITCH AWG. FOR COPPER CLAD
QT QUAD TERMINAL ALUMINUM USE 4 AWG.
SEQ SEQUENCER
тв ER OX и
ы 4009500784 REV. GC
Fig. 18—FD3A Typical Wiring Diagram
— 72 —
P, 022
A94376
AUG/14/2008/THU 03:50 PM UTC TECH PUB
THHEAD
PROTECTOR
RUBBER
PISTON O-RING
BODY
A a
N RETAINER
Âg2218
PISTON
Fig, 19—Refrigerant Flow-Control Device
' (For FD3A and FG3A)
CAUTION: Use a backup wrench and do pot over-
tighten as deformation of refrigerant flow-control device
A | body will occur, causing piston to lodge in a partially
open or closed position. |
6. Install new or cleaned piston in refrigerant flow- control
device body, |
7. Install new retainer (because of probable damage which
occurred in initial removal).
8, Reconnect refrigerant tube to refrigerant flow-control de-
vice,
0. Pressurize tubing and coil, then ledk-check.
10. Evacuate tubing and coil as necessary.
- IV. LIQUID TUBE STRAINER
The refrigerant How-control device 15. protected on indoor cor by
a wire mesh strainer. If strainer becomes plugged:
1. Complete items 1 end 2 under Cleaning or Replacing
Refrigerant Flow-Contro] Device section.
2. Loosen flare fitting joint commecting refrigerant flow-
control device to coil liquid refrigerant tube.
3. Remove sheet metal screw holding bracket clip in place.
Screw is located between coil and refrigerant flow-control
device,
4. Pull bracket clip out.
3, Remove refrigerant flow-control device assembly.
6. Pull strainer out of coil liquid refrigerant tube and replace
with new strainer,
V. CARE AND MAINTENANCE
WARNING: Hinged access panel contains electrical
A components and is heavy. Support panel when lowering
to clean unit to avoid personal 1 injury.
WARNING: Disconnect electrical power to all circuits
A | before servicing unit. Failure to do so may result in|
personal injury from electrical shock or moving: parts.
WARNING: As with any mechanical equipment, per-
4 — A | sonal injury can result from sharp metal edges, Be careful
\ when removing parts. |
The minimum maintenance requirements for this equipment arc as
follows:
—_23—
FAX No, 317 Z40 5067 F023
1. Inspect and clean or replace field-supplied air filter each
Month or as required.
2. Inspect cooling coil, drain pan, and condensate drain each
cooling season for cleanliness. Clean as necessary. (To be
performed by trained personnel.)
3. Inspect blower motor and wheel for cleanliness cach
heating and cooling season. Clean as necessary.
4, Inspect electrical connections for tightness and controls for
proper operation each heating and cooling season. Service
a5 Necessary,
NOTE: Never operate without a filter or with hinged access door
open. Damage to blower motor may result.
A. Cooling Coll, Draln Pan, and Condensate Drain
Remember to disconnect electrical power before opening hinged
access panel,
The cooling coil is easily cleaned when dry. Inspect coil and clean
(if necessary) before each cooling season. If coil inlet face is
coated with dirt or lint, vacuum with a soft brush attachment.
Be careful not to bend coil fins. If coil is coated with oil or grease,
clean it with a mild detergent-and-hot water solution. Rinse coil
with clear water. Be careful not to splash water onto insulation.
Inspect:drain pan and condensate drain at seme time cooling coil
is checked. Clean drain pan and condensate drain by removing any
foreign matter from pan, Flush pan and drain tube with clear water.
Clear drain liné ifrrestricted.
NOTE: There MUST be a trap in condensate line. Trap must be
at least 3-in..deep, not higher than the bottom of unit condensate
drain opening, and pitched downward to an open drain or sump.
B. Blower Motor and Wheel
Clean blower motor and wheel when cooling coil is cleaned.
Lubricate motor every 5 years if motor is used on. intermittent
operation (thermostat FAN switch at AUTO position), or every 2
years if motor is in continuous operation (thermostat FAN switch
at ON position). Remove motor 10 lubricate, Put approximately 8
drops of SAE 10 nondetergent oil in each oil hole, Do not dveroil
motor, Plug hole securely 50 that cil does not drip when hinged
access panel is lowered 10 Open position.
Blower motor and wheel may be cleaned using a vacuum with a
soft brush attachment. Remove grease with a mild solvent suéh as
hot water and detergent. Be careful not to disturb balance weights
(clips) on blower wheel vanes. Do not drop or bend wheel as
balance will be affected.
FG3A SERVICE AND TROUBLESHOOTING
L SERVICE
À. Motor
Ball bearing oilers are provided on blower motor. Use electric
motor oil or SAE 10 or 20 nondetergent oil. Check motor mount
bracket anid’ base bolis. Tighten as required.
В. Blower
Check ball bearings for wear. Ball bearings are self-aligning and
grease packed. Replace as required. Check thrust collars for end
play and alignment of wheel. Check blades for accumulation of
dirt. Clean as required. Check mounting brackets, base bolts, and
isolation material.
See Fig. 20 for diagram of internal wiring for blower coil
assembly. Control box (standard 4-in. junction box) is mounted on
refrigerant connection side of unit. All leads pass through strain
relief where they enter control box. Wiring inside cabinet is
located so it does not come in contact with moving parts or sharp
edges, |
C. Pulley and Belts
Check belt tension and pulley alignment (See Fig. 21.) Belt
tension is adjusted by motor tailpiece bolt, A deflection of about
3/4 in. to 1 in. per foot of span should be obtained by pressing belt
- Е)
AUG/14/2008/THU 03:51 UTC TECH PUB
с A a
"BLOWER Y o Y uN
MOTOR 0-L——-d a —
Lo V +, GROUND
GROUND LEAD
AS11S1
Flg. 20—Wiring Schematic
firmly. Lock adjusting bolt in position after adjustment is made.
Align pulley grooves by locating motor pulley an motor shaft or by
moving entire motor along motor mounting bracket. Adjust blower
speed by loosening setscrew in outer (moveable) pulley face and
turning this face (half or full turns) so that adjusting setscrew is
positioned precisely over the flat on pulley hub. Speed is reduced
by adjusting pulley faces so they are further apart; speed is
increased with faces closer together. Check pulley setscrews and
bolts,
MUST BE
PARALLEL
FOR PROPER
ALIGNMENT
/)
PULLEY ALIGNMENT
BELT ADJUSTMENT
A91150
Fig. 21—~Checking Pulley Alignment and Tightness
D. Cleaning or Replacing Refrigerant Flow-Control
Devica
Refer to Fig. 19 and instructions given in FD3A Service and
Troubleshooting section above,
li, MAINTENANCE
WARNING: Disconnect electrical power to all circuits
A | before servicing unit, Failure to do so may result in
personal injury from electrica! shock or moving parts.
WARNING: As with any mechanical equipment, per-
when | removing parts.
A. Return-Air Fliter
To clean or replace air filter, remove screws and filter access door.
slide out filter. For washable type filters, clean with hot soapy
water. Rinse clean and let dry.
New filters are available from a local distributor. Place filter in slot
with filter arrow facing-direction of airflow. Replace filter access
doors with screws previously removed.
CAUTION: Never operate unit without a filter or with
A filter access door removed, Damage to blower motor may
result.
A | sonal i injury can result from sharp metal edges. Be careful
— 4 —
FAX No, 317 Z40 5067 Р 024
В. Coil, Drain Pan, and Condensate Draln
A CAUTION: Disconnect electrical power before remov-
ing any access panels or electrical shock may result,
The coil is easily cleaned when dry. To check or clean coil, remove
coil access panel. If coil 1s coated with dirt or lint, vacuum with à
soft brush attachment.
Be careful not to bend fins, If coil is coated with oil or grease, it
may be cleaned with mild detergent and water solution. Rinse coil
with clean water, Be careful not to splash water on msulation or
filter.
Check drain pan and condensate.drain at samc time cooling coil is
checked. Clean drain pan and condensate drain by removing any
foreign matter from pan, Check for mst and holes. Flush pan and
drain tube. with clear water. If drain is restricted, clean with
high-pressure water. If this does not work, use a plumber’s snake
or similar probe device. Repitch drain pan to promote proper
drainage.
FA4A, FB4A, AND FC4B SMART HEAT CIRCUIT BOARD
FUNCTION AND TROUBLESHOOTING
l. PCE COMPONENT LAYOUT, DESCRIPTION, AND
FUNCTION
NOTE: All voltages are AC unless otherwise specified.
1. The low-voltage terminal board is used to conpect indoor
thermostat to low, 24=v side of transformer and to serve as
a junction between indoor thermostat and outdoor section.
a, K terminal is used to Connect secondary side of trans-
former to thermostat and outdoor unit. В is fused.
b, C terminal 18 used to connect transformer secondary
common for thermostat and outdoor unit.
с, Y terminal provides input signal from thermostat signal-
ing heat pump operation,
d. G terminal provides input signal from thermostat s1gnal-
in contifiudus Жан’ operation,
e. O terminal provides mput and junction terminal for
reversing valve signal,
f. W2D terminal provides input from outdoor unit (heat
pump} signaling control board that heat pump is in
defrost.
g. W2T terminal provides input from thermostat signaling
for supplemental or emergency heat.
h. W3 terminal provides input from outdoor thermostat. -
W3 and W2T are factory connected by JW1. This input
is used only if an outdoor thermostat is required by local
codes.
i. У, terminal provides output from control board to
energize outdoor unit (heat pump) contactor.
2. Jumper wires (TW1 and JW2) (See Fig. 22.)
a. JTW] connects WZT to W3 to limit staging of electric
heat with use of an outdoor thermostat. See Table 7 for
staging. Smart Heat PCB controls staging to the extent
that this feature is unnecessary unless required by local
codes ar regulations.
b. Cutting TW? sets Emart Heat PCB in efficiency mode.
With JW2 cut, there is no loss of performance due to
reduced indoor blower speed when heat pump is oper-
ating near balance pomt. This jumper may need to be cut
if selected cooling fan speed is the same as required
minimum motor LO speed tap selection. With JWZ cut,
fan terminal LO becomes a dummy terminal,
С)
AUG/14/2008/THU 03:51
A
UTC TECH PUB
| cePL130121-01 ——
FAX No, 317 240 5067
P. 025
LOW VOLTAGE
TERMINAL
BOARD
JW
(CUT WHEN
OUTDOOR
THERMOSTAT
15 USED)
ый ИЗ
(HIGH FAN
i. ONLY WHEN
та GUT)
iz
=
| Зы |
| RECEPTACLE
aw а за
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7 E
"a i. A EN .
y o ,
3. A fuse is used to protect low-voltage transformer and FCB, -
4 AUX+ and AUX- are connections for - airs conditioning
accessories (EAC, humidifier, etc.)
a. Fl, FZ, HI, and LO are connections for indoor fan,
6. The S-pin receptacie connects heater package wiring har
MESS.
7. SEC1 and SEC? are used to connect secondary side of
transformer to PCB. SECIÍ is connected to equipment
ground.
fl. UNIT FUNCTIONS
A. Transformer
NOTE: Terminals T1, T2 (if used), and T3 are wired to primary
or high side of transformer. The 208-v terminal’ ‘(or blue wire if
transformer has primary” leads) is used оп T3. for 208% ‘applica*"
. tions, The 230-v terminal (br ré wire) is tdi on T3 for 230%
Не, 7
applications. T2 is a dummy terminal. Cate pod
B. Electric Heat ° Se
NOTE: When troubleshooting elements, position themnostat 10
emergency heat. Wait approximately 12 minutes for all elements to
come OT, |
1. When thermostat calls for electric heat, a 24-1 y signal i is sent
to PCB through W2T, The PCB energizes first stage of
electric heat.
Fig. 20--Smart Heat Printed-Circuit Board (FEB)
A127
2. The first 2 stages come on if W2T and Y are energized at
the same time. After each 10 minutes WAT 15 energized,
another stage of electric heat is energized.
3. As W2T is de-energized, electric heat stages down in Es
minute steps with the exception of first step. The first step
will be on only half as long as-it was prior to W2T
de-energizing. = ye
4. When WIT is energized by itself, JW1 is cut, and an
outdoor thermostat is used and is open, stáging 18 limited as
in Table 7, | -
5, Whenboth W3 and W2T are encrgized without JW1 being
cut’ or with outdoor thermostat closed, system operation
stages: Heat up to maximum level if signal 25 energized for
— proper amount of time,
6. Trotily"W3 is energized, there is no effect on PCB, No heat
‘energized.
C. Aécessdries Cy
Terminals AUX+ and AUX- are energized with 24 vdc when fan
is energized. The acceséôry kit EFAIROLOACE is used to
connect an EAC or humidifier.
NOTE: "Loads cannot be connected directly to AUX+ and AUX»,
Use the specified kit only.
D. Blower
1. Blower On Delay —To optimize comfort, there is a 30-sec
blower on delay in heat pump heating mode only.
TABLE 7—ELECTRIC HEATER STAGE LIMITING
STAGES (KW OPERATING)
HEATER PART NO. WET Only (JW1 cut) _ WET and Wa
| _ Heater Siage 1 2 3 4
— KFAEH2201H10 10 kw Non-Fused | — 3 6 9 9
KFAEH2301H15 15 kw Fused 3 8 11 __15
KFAEH2401H20 20 kw Fused 5 10 15 20
AUG/14/2008/THU 03:51
UTC TECH PUB
à Blower Off Delay — Smart Ecat control uses a 60-sec off
blower delay, as onposed to the standard 90-sec delay.
fll. SMART HEAT OPERATION
A. Cooling
The Smart Heat option controls cooling mode in same manner as
conventional heat pumps are controlled. The fan has a 90-sec delay
ofi/on cycle down,
B. Heat Pump Heating
The Smart Heat option does not control heating in the conventional
method. The PCB energizes compressor 30 sec before indoor fan
is energized. This allows indoor coil to heat up eliminating
cold-blow on start-up.
The electric heat is staged-on to allow continuous operation of heat
pump and electric resistance heat below balance point (below point
where heat pump cannot maintain dwelling temperature without
supplemental heat) independent of outdoor thermostats.
Although PCR has provisions for an outdoor thermostat, it is not
needed for staging. On cycle down, indoor fan remains on 60 sec
ta recover heat stored in indoor coil,
GC. Defrost
The Smart Heat PCB stages the correct amount of supplemental
heat during defrost. If tag much heat 15 added, system stays in
defrost for completion of defrost cycle even though thermostat is
satisfied. On next cycle, 1 less element is energized during next
defrost period.
NOTE: I 24-v power from thermostat is interrupted while unit is
in defrost mode, the defanlt cycle will be completed before unit
shuts down.
D. Troubleshooting Printed-Clrcult Board
(Diagnostic LED)
The PCE of Smart Heat option heater package contains a micro-
processor which controls fan operation, fan speed, outdoor unit,
and heater elements. For troubleshooting, a service LED indicates
condition of PCE, See Table 8 for LED flash codes,
TABLE 8—LED CODES FOR SMART HEAT PCB
FLASH CONDITION | INPUT SIGNALS | SYSTEM OPERATION
; No Fower or
No Lighi/Mash - O _ Board Failure
Steady Light — “Board Failure
— Stand By Condition
Steady Flash or Fan Only
Haat Pump Only
1 Flash Y only Operating
Heat Pump Plus
2 Flashes Y and/or W2T i Sequencer
Heat Pump Plus
| 3 Flashes ms y and/or WaT 2 Sequencers _
nan | Heat Pump Plus
4 Flashes Y and/or WaT 3 Sequencers
~ 5 Flashes Y, O an Сео! Моде
6 Flashes Y, W2D, and/or W2T Defrost Mode
7 Flashes WaT Emergency Heat Mode
IV. ELECTRICAL OPERATING SEQUENCES AND
TROUBLESHOOTING
NOTE: Refer to Table ¢ for proper input and output voltages.
A. Ready-To-Start
In ready-to-start (standby) mode, LED gn board indicates a steady
flash,
In this mode, 24-v power should be available at control's low
voltage terminal strip terminals R and C. If 24v is not present
across R and C, check the following:
FAX No, 317 240 5662 P. 026
+ Is low-voltage fuse on control board good?
* Are line voltage fuses FUL and FU2 good?
» Is LED on control on steadily or not on at all? Both of these
indications signal a possible board failure.
« Is 208/230-v power available to control across pins 7 and ©
of 9-pin connector? Ts connection to board tight?
B. Continuous Fan
On a call for continuous fan, thermostat provides a 24-v input
signal to {5 terminal on low-voltage terminal strip. Sensing this
signal, the microprocessor energizes a relay on control to provide
power to high-speed winding of fan motor, at 1. The fan continues
to run until fan switch on thermostat is tumed off.
During continuous fan operation with no call for heating or
cooling, LED indicates a steady flash, the same indication seen
when system 18 in standby,
The call for continuous fan operation signal can be checked by
placing voltmeter leads across terminals G and C of controls
low-voltage terminal strip. If 24v 15 not seen across these termi
nals, check for the following:
* Is 24v available across R and C7? If not, refer to Ready-To-
Start section for items to check if 24v is not available.
« Is thermostat fûnction switch set for continuous operation?
Confirm fan operation. Voltage to operate fan can be confirmed by
placing voltmeter leads across terminals F1 and HI on control. The
reading should be 208/230v: If 208/230v is not observed, check the
following:
» Ts 208/230v available at pins 7 and 9 of 9-pin connector? Is
connection to board tight?
* Arc line voltage fuses FU1 and TUZ good?
If 208/230v is available across terminals F1 and HI and fan does
nat operate, check the following:
* 15 fan motor capacitor good?
* Is blower wheel jammed or loose? Are there any other
mechanical problems preventing fan operation?
C. Cooling
On & call for cooling, room thermostat provides input signals to
control board at terminals Y and 0. The O signal is also available
to heat pump to energize reversing valve.
When it receives Doth these signals, the microprocessor responds
by providing a Z4-v output signal at the Ÿ, terminal. This output
signal energizes contactor in heat pump and starts compressor.
There is à à to 5 sec delay in output of т, signal.
At the same time, control energizes fan coil's fan motor on high
speed through terminals F1 and HI, The LED indicator on control
signals 5 flashes, indicating cooling operation.
The call for cooling signals can be confirmed by placing voltmeter
"leads across low-voltage terminals Ÿ, О, Ÿ, and © The reading
should be 24v. If 24v is not available, check the following:
* Is 24v available across R and C7? See Ready-To-Start section
for items to check if 24v is not available.
+ Is thermostat function switch set in COOL position with
thermostat calling for cooling?
Assuming heat pump has power and is adequately charged, it
should be running at this time in cooling mode, Indoor fan should
also be running at this time. If indoor fan is not running, refer to
Continuous Fan section for items to check.
D, Heating (Compressor Only)
On a call for heai, room thermostat provides an input signal to
control board at terminal Ÿ. This signal causes the microprocessor
to provide a 24.v output signal at terminal Yo to energize contactor
in heat pump. There is a 3 to 5 sec delay in output of Y, signal.
5
AUG/14/2008/THU 03:51 PM
<.
UTC TECH PUB
FAX No, 317 240 5067
P, 027
TABLE 9—TROUBLESHOOTING VOLTAGE READINGS AND TEST POINTS
INPUT VOLTAGES
LOCATION NORMAL READING PURPOSE _
L1 and L2 208/230 vac Main power supply Input.to fan coil.
L3 and La o 208/230 vac Power to electric heaters
9-pin connector -
7 and 9 208/230 vac,. ‚Power lo smart control
Ti and T3 208/230 vac Ромиет 19 (галятогтлег
SECT and SEC? _ 24 мас _ Power from transformer secondary —
R and 24 vac _ Power ffom transformer secondary “
Gand C 24 vac "Gall for continuous fan signal from room thermostat
Yand C 24 vac Call for heat/coal signal from room thermostat _
O and € 24 var Signal to energize revarsing valve from room thermostat (cooling). Also present
| during defrost,
| W2T and C 24 vac | Сай for electric heat from room thermostat `
__ W2D and C „24 мас Defrost tnitlation signal from heat pump
OUTPUT VOLTAGES
LOCATION _ NORMAL HEADING | PURPOSE
HI and Fl 208/280 vac Power to blower motor (high speed)
LO and.F1 N 208/230 vac Pawar to blower motor (low speed)
— Y, ande бо 24 vac Power to energize contaétor in heat pump (heat and cool modes)
> B-pin connector 24 vde Power to anerglza SEG 1
1 andá _ NOTE: Sequencers use DC voltage
9-pin connector
i Pand4 > 24 vde Power to anarglze SEQ 2
_ abn Connector 24 vde N Power to energize SEQ 3
vac—volts AC
vde—volts DC
Thirty sec after Y is energized, control energizes fan motor. It may
run on high or low speed, depending on its operation in previous
cycle,
Compressor operation in current cycle is monitored by the smart
control to determine whether a fan speed change is required for
enhanced indoor comfort. The LED indicator on control signals 1
flash, indicating compressor operation only with no electric heat.
The call for heat signals can be confirmed by placing voltmeter
leads across low-voltage terminals Y, Y,, and С; The readings
should be 24у, Tf 24v is not available, check the following:
“ Is 24v available across R and'C? See Ready-To-Gtart section
for items to cheëk if 24v is not available.
* Is thermostat function switch set in HEAT position with
thermostat calling for heat?
Assuming heat pump has power and is adequately charged, it
should be running at this time in heating mode. Indoor fan should
Continous Fan section foritems to check. When room thermostat
is satisfied, indoor fan continues to run an additional 60 sec to
recover heat remaining in indoor coil.
E. Heating (Compressor and Electric Heat)
If heat pump alone cannot satisfy heat requirements of structure,
room thermostat calls for additional heat by way of an input to W2
terminal of control, When this occurs, control begins sequencing
on electric heaters by energizing the first sequencer. Indoor fan
should be running at this time.
H room temperature requirements cannot be met, additional stages
of electric heat are energizcd through the other 2 seguencers, at 2.
The logic of control determines how much and how soon these
additional stages are brought on. By observing LED status light,
the number of operating stages of electric heat can be determined.
The control also varies indoor fan speed depending on number of
energized stages of heat Tn general, the more stages of electric
heat, the higher the fan speed.
‚ 80 Бе running at this time. Tf indoor fan is not mining, refer to...
—27—
There 15 no hard and fast rule for determining exactly when stages
will be energized since microprocessor in the smart control
constantly momtors duration of previous heating cycle, setting о?
room thermostat, and number of stages of heat needed in previous
cycle to satisfy room thermostat, Rather than try to détermine what
should be operating when, service technicians should check LED
status hight to see how many stages of electric heat are energized
at A given time and confirm operation of sequencer using a
voltmeter. If 2 quick check of all stages is desired, set room
thermostat as high as it will go. With a constant signal on W2T
terminal, sequencers energize every 10 minutes until al] heaters are
оп.
The previous paragraphs described how to check for low-voltage
inputs to control by placing voltmeter leads across low-voltage
terminal strip and checking for 24v, The call for electric heat can
be confirmed by placing voltmeter leads across W2T and С.
To check for operation of sequencers, check directly across
appropriate sequencer coil for 24 volts DC,
NOTE: All sequencer coils are powered by 24 volts DC. This
voltage 18 generated internally by the smart control.
In this example, sequencer 1 is being checked, The procedure is
the same for all other sequencers. If 24 volts DC is not observed,
check the following:
* Is room thermostat calling for electric heat? This can be
confirmed by checking for 24 volts AC between low-voltage
terminal strip terminals W2T and C.
* Is LED flashing appropriate code for number of sequencers
energized? In this example, Z flashes should be visible,
indicating 1 seguencer is energized. Indicator tells how many
sequencers are energized, but does not tell which ones are.
* Is 9-pin connector for heater package tightly secured to
control board?
AUG/14/2008/THU 03:52 PM UTC TECH PUB
F. Checking Sequencer Operation
To check for operation of power circuit of sequencer, place
voltmeter leads across sequencer terminal 1 of sequencer 1 and
terminal 4 of limit switeh 3. The reading should be 208/230v, and
heater should be energized.
If 208/230v is not observed at terminals specified, check the
following:
" Are fuses FU3 and FU4 good?
5 Is limit switch LS3 open? If so, check fan coil air filter or air
distribution system for blocking or restriction that might
reduce airflow snd cause limit switch to open.
Operation of heaters can be confirmed further by using a clamp-on
ammeter in circuit shown to verify cutrent is flowing through
heaters, Amperage readings will depend on size of heater. The
procedure for checking other sequencers in system is identical to
that just described.
G. Emergency Heat
Emergency heat mode requires that room thermostat be placed in
EMERGENCY HEAT position, This locks out and prevents
operation of heat pump outdoor unit, Tn this mode, heat is provided
exclusively by electrical héaters in fan çoil. —
In this mode, room thermostat, at 1, provides an emergency heat |
input signal to smart control at terminal WZT. If jumper J W1, at 2,
has not been ént and an outdoor thermostat installed to control
electric heat stages, that:same input signal is applied to terminal --
W3. For this example, assume thät jümper JW1 has not been cut.
Eventually, the total number of heaters is eycled on. In emergency
heat mode, LED indicator signals 7 flashes.
The amount of emergency heat available depends on whether
jumper TW1 is cut-and the number of heatinié elements. Table 10) -
iltustrates results under various conditions. The heaters cycle on
every 5 minutes until maximum level is reached.
FAX No, 317 240 5067 P, 02e
TABLE 10—EFFECT OF JW1 ON EMERGENCY HEAT
JW cur |
4 elements | 3 elements
50% 66.7%
JW1 not cut | |
4 elements 3 elements
100% 100%
* Outdoor thermostat opens
With JW1 cut, an outdoor thermostat (if closed) could cycle on
additional heaters and system would perform as if JWI was not
cut. In effect, closed outdoor thermostat replaces cut jumper,
H. Defrost
In defrost mode, LED indicator signals 6 flashes. Defrost is
initiated by heat pump and is signalled to smart control by an input
to W2D terminal. During defrost, outdoor unit switches to cooling
mode, making it necessary to cycle on electric heaters to temper
indoor air.
If electric heaters were not energized prior to defrost, smart control
energizes sufficient elements to temper air. If heaters were
energized priorto defrost, additional heaters may or may not be
cycled on to provide additional heat.
A defrost initiation signal can be confirmed by attaching voltmeter
leads across low-voltage terminals W2D and C. If 24v is not
observed, check the following:
» Is 24v available across R and C? Sce Ready-To-Start section
for items to check if 24v is not available,
» Is there continuity in thermostat leads between heat pump
and smatt control?
+ Is defrost control in heat pump operating properly?
AUG/14/2008/THU 03:52 PM UTC TECH PUB FAX No, 317 240 5667 P. 024
И BE CL — CAUTION:
THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITAGLE FOR USE DN SYSTEMS EXCEEDING
BLOWER MOTOR 150 TO GROUND
(y ROTATION ATTENTION:
| NE GONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150
| | V À LA TERRE N De
a SCHEMATIC DIAGRAM } _ (COMPONENT ARRANGEMENT)
Un POWER WIRING DISCONNECT PER NEG — em
BEE RATING PLATE \
FOR VOLTS & HERTZ LA ®
E SEE NOTE #1 7
| Bk ® ©
BLK SYSTEM TRANSFORMER: 40.0VA COM
sens | - FAN COILHEATER: ev aaa 1
YEL L52 HTRZ EL | ha | REMAINING YA AVAILABLE: 18.7% RED —
ео | 7 Ke) Ta я
BLK. =
| XEORM | PCB 1
| Op № O .
| С Y | © (5) =
| T HE
210 МАС - |
А
С
= A Е НАУ
7 LEADS
| FAN MOTOR THERMALLY PROTECTED o
a
HET | LED FLASH CODES
т
Г
AED "р
Ш | Г NO POWER OR
| EE NOTE #3]
SA = | OLGA OA FLASH] SOARD FAILURE
vorEs: ECO INDOOR THERMOSTAT > rom
1. USE COPFEA WIRE [75°C MIN) ONLY BETWEEN Ce
DISCONNECT SWITCH AND LINIT. SEE NOTES #2, #7,AND #8 STEADY FLASH STAND BY CONDITION
2. CONNECT LOW VOLTAGE WIRING AS SHCIWN (2VAC). | LEGEND = E a EAT
3. CONNECT TRANSFORMER PRIMARY TO THE PROPER SE 1 FLASH HEAT PUP HEAT
VOLTAGE TERMINAL о ---- ERATING |
GAP CAPACITOR LED DIAGNOSTICLIGHT SE
5 TE ANY OETUC ORIGINAL WIRE, AS BUFPUED MUSTBE | COMM COMMON LVTB LOW VOLT TERM BRD. | 2 LASHES 1 SEQUENCER_.
| REPLACED, USE THE SAME OR EQUIVALENT TYPE WIRE Fo LOWVOLT FUSE SEQ SEQUENCER 3 FLASHES HEAT PUMP PLUS
| в. HEPLACE LOW VOLTAGE FUSE WITH NO GREATER THAN FW FAN MOTOR TRAN TRANSFORMER a 2 SEQUENCERS
£ AMP FUSE GND EQUIPMENT GROUND 4 FLASHES HEAT BLIMP PLUS
7. REFER TO THERMOSTAT INSTRUCTIONS FORE" JUMPER | | HPLV HEAT PUMPLOWVOLT XFORM PUB THAN TERMINALE 3 SEQUENCERS
INSTALLATION, HTR HEATER == FELD LOW VOLTAGE | Cl acHES COOL MODE
8. DO NOT CONNECT THEAMOSTAT "E" TO PCS "WE. JUS UMIT SWITCH 1 HPLY LEADS
MINIMUM MOTOR LO SPEED TAP SELECTION _ (0 MARKED TERMINAL 8 FLASHES DEFROST MODE
FAN COIL SIZE |030 |033 |076|038 |042 [648 1660 |070 322951101 PM PCEJUMPER (Y) ; oes EMERGENCY HEAT
(MOTOR SPEED AT 20 KW MEDJMED| LC | LO | LD | LO [KO [LO REV. B ® UNMARKED TERMINAL Mabe
Asaizz
Fig. 23—Smart Heat Typical Wirlng Diagram {Molor Speed at 20kw Shown)
—29—
AUG/14/2008/THU 03:52 PM UTC TECH PUB FAX No, 317 240 5667 Р. 030
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© 1935 BOP Cg, » P,0. Box 70 = Indianapolis, IN 46206 Printad in U.5.A. — 30 — 14072 Catalog No. D2-33FA-416