Bryant-Carrier FB4, FE4, FF1E, FFM, FH4 User Manual

...

FB4, FE4, FF1E, FFM,FH4,FV4, FX4, FZ4, PF4

Service and Maintenance Instructions

Residential Fan Coil Units

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS 1........................

INTRODUCTION 1..................................

FAN COIL DESCRIPTION AND TROUBLESHOOTING 2..

FY5, FH4, PF4 (even sizes), and FF1E (even sizes), 2......

FB4C, FX4D, PF4 (odd sizes) and FF1E (odd sizes) 5......

FV4 7.........................................

FFM 18........................................

ELECTRIC HEATER FUNCTION

AND TROUBLESHOOTING 23........................

FB4, FE4, FF1E, FH4, FV4, FX4, FZ and PF4 23.........

FFM 23........................................

CARE AND MAINTENANCE 24.......................

FB4, FE4, FH4, FV4, FX4, FZ4, and PF4 24.............

FF1E and FFM 25..................................

REFRIGERANT FLOW--CONTROL DEVICE 27..........

ThermostaticExpansion Valve (TXV) 27................

Piston Body Cleaning and Replacement 28...............

ALUMINUM COIL REPAIR 29........................

COIL & CONDENSATE PAN REMOVAL

and REPLACEMENT (FB4, FE4, FX4 ,FV4 and FZ) 29.....

PURON QUICK REFERENCE GUIDE 32................

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory--authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes and the current editions of the National Electrical Code (NEC) NFPA 70.

In Canada, refer to the current editions of the Canadian Electrical Code CSA C22.1.

Recognize safety information. This is the safety--alert symbol When you see this symbol on the unit and in instruction manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING,and

CAUTION. These words are used with the safety--alert symbol. DANGER identifies the most serious hazards which will result in

severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

WARNING

UNIT OPERATION AND SAFERTY HAZARD

Failure to follow this warning could result in personal injury or death.

Puron (R--410A) systems operate at higher pressures than R--22 systems. Do not use R--22 service equipment or components on R--410 equipment. Ensure service equipment is rated for R--410.

INTRODUCTION

The “F” and “PF” series fan coil units are designed for flexibility in a variety of applications that meet upflow, horizontal, or downflow requirements. Units are available in 1--1/2 through 5 ton nominal cooling capacities. Factory--authorized, field--installed electric heater packages are available in 3 through 30 kilowatts.

WARNING

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing or servicing unit, always turn off all power to unit. There may be more than one disconnect switch. Turn off accessory heater power if applicable. Lock out and tag switch with a suitable warning label.

FAN COIL DESCRIPTION

AND TROUBLESHOOTING

FY5, FH4, PF4 (even sizes)

and FF1E (even

FAN MOTOR

The motor is two or three speed direct drive. High--speed lead is black, low--speed lead is red, and common lead is yellow. Be sure proper blower speed has been selected..

The motor is turned on through two 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 is a call for electric heat. A 24--Vac signal is sent to heater sequencer/relay, causing it to close, directing 230V through the normally closed contact of fan relay, turning fan on. The fan remains on until sequencer/relay opens.

If motor does run, test motor for an open winding or a winding shorted to motor case. If either is present, replace motor.

ELECTRIC HEATER SERVICE

Service can be completed with heater in place. Shut off power before servicing.

A. Limit Switch

Refer to Electric Heater Function and Troubleshooting section of this manual.

B. Sequencer

Refer to Electric Heater Function and Troubleshooting section of this manual.

C. Transformer

A 40--VA transformer supplies 24--V power for control circuit. Check for 208/230V on primary side of transformer. If present, check for 24V on secondary side.

NOTE: Transformer is fused. Do not short circuit.

D. Fan Relay

Relay coil is 24--V. Check for proper control voltage. Replace relay if faulty.

CLEANING OR REPLACING REFRIGERANT FLOW--CONTROL DEVICE

Refer to Fig. 25 and instructions given in “Piston Body Cleaning or Replacement” section.

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.

SEQUENCE OF OPERATION

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 causing 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.

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

sizes),

On a call for cooling, the thermostat makes circuits R--O, R--Y, and R--G. Circuit R--O energizes reversing valve, switching it to cooling position. Circuit R--Y energizes contactor starting outdoor fan motor and compressor. Circuit R--G energizes indoor unit 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 motors.

HEATING On a call for heating, the thermostat makes circuits R--Y 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 a sequencer bringing on supplemental electric heat.

When thermostat is satisfied, its contacts open de--energizing contactor and sequencer. All heaters and motors should stop.

CES013003--00, 01 (HK61EA002, HK61EA006) CONTROL BOARDS

This section of the service manual describes the CESO130003--00 and --01 PCB by examining the functional operation of the PCB components.

Printed Circuit Board (PCB) Component

Layout of the actual PCB is depicted in Fig. 1 and Fig. 2.

1. The low--voltage stripped leads are used to connect the

24--V side of transformer to indoor thermostat and outdoor section.

2. A 5--amp fuse is used to protect the low--voltage trans-

former secondary.

3. The fan relay is controlled by thermostat and turns fan on

and off.

4. A plug is used as the connection for PCB power and electric

heaters. Note the pin numbers on plug.

5. A time--delay relay circuit keeps fan motor running for ap-

proximately 90 seconds after G is de--energized. The time-delay can be defeated by cutting jumper JW1 on the CES0130003--01, HK61EA002 and HK61EA006.

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 208--V or 230--V terminal on transformer. Units are factory wired at 230--V terminal.

2. Proper Wiring of Transformer Secondary or 24--V Side

Red wire of transformer is wired to T terminal on PCB and brown wire of transformer is wired to C terminal on PCB.

NOTE: T terminal on PCB is used to protect the 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.

2. Functional Control

a. Thermostat and Relay Control

When thermostat calls for the fan in cooling, heat pump, heating, or fan--only mode,a 24--Vacsignal issentto relay. This causes the relay to close its normally--open contacts, turningon fan.Whenthermostatno longercallsforthefan,

thesignalsentto relayis turned offandrelayopens causing fan to turn off after a 90--second fan--off delay.

b. Sequencer/Electric Heat Relay Interlock

The fan willalso operate whenever thereis acall forelectric heat, even if fan relay is not energized. This happens because fan is interlocked with first stage of electric heat through the normally--closed 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 staging is desired.

C. Electric Heat

When thermostat calls for electric heat, a 24--Vac signal is sent to sequencer/heat relay through W2, causing first stage to turn on. W3 and E also receive signal if wired in with W2. If W3 and E are not wired to W2, the sequencers/heat relays 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/relay No. 1, causing it to close. When sequencer/relay No. 1 closes, first stage of electric heat is energized. In straight electric heat, fan is also energized through the normally closed contacts of fan relay. In cooling, heat pump, or manual fan mode, fan will already be running since fan relay would have been energized. When thermostat stops calling for electric heat, the 24--Vac signal to sequencer/relay No. 1 turns off and sequencer opens after a delay of 60 to 90 seconds. Heaters equipped with relays will be de--energized immediately. When sequencer/relay 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--Vac signal to sequencer/ relay No. 2 causes it to close, with second stage of electric heat turning on. The 24--Vac signal applied to sequencer/relay No. 1 causes fan to operate. Timing is such that sequencer/relay No. 1 will turn on before sequencer/relay No. 2. When signal to W3 is turned off, sequencer/relay No. 2 opens. If W2 is also satisfied, first stage of electric heat and fan will also turn off, providing thermostat is not calling for the fan.

3. E

When thermostat sends a signal to E, a 24--Vac signal is sent to sequencer/relay No. 3. The 24--Vac signal applied to sequencer/relay No. 3 turns on third stage of electric heat. The 24--Vac signal applied to sequencer/relay No. 1 turns on first stage of electric heat and fan. When thermostat stops calling for electric heat, the signal to sequencers/relays 1, 2, and 3 are turned off, and sequencers/relays open. This causes electric heat to turn off with fan, providing thermostat is not calling for the fan.

NOTE: Electric heaters are factory wired with all stages tied

together. If independent staging is desired, consult outdoor thermostat installation instructions, or corporate thermostat instructions.

TROUBLESHOOTING THE PRINTED CIRCUIT BOARD (CES013000--00, 01 / HK61EA002 / HK61EA006)

Use wiring schematics shown in Fig. 1, and Fig. 2 as a guide in troubleshooting PCB unless otherwise noted.

A. IfFanWillNotTurnOnfromThermostat:

IF THERE IS NO HIGH VOLTAGE TO TRANSFORMER:

1. Check plug/receptacle connection. This supplies power

from heaters to PCB Fan Relay. Be sure plug is connected properly.

2. Check sequencer/relay No. 1 and plug wiring. Yellow wire

should be connected to Pin No. 9 of plug and to limit switch. Black wire should be connected to Pin No. 7 of plug and to sequencer/relay No. 1.

3. Check field power leads L1 and L2. If these are not receiv-

ing power, system cannot function.

IF TRANSFORMER 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 (red)

and C (brown). Be sure transformer output is between 18Vac and 30Vac. If transformer output is incorrect and transformer is receiving correct input voltage (208V or 230V), then transformer needs to be replaced with recommended transformer. If no problem exists with transformer secondary, proceed to items 3 and 4.

3. Check low--voltage fuse shown in Fig. 1 or Fig. 2. If fuse is

blown, replace it with an identical 5--amp fuse. The transformer cannot supply power to board with fuse blown or loose. If fuse blows when unit has power applied to it, the system most likely has one 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 is excessive, the low--voltage5--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/relays for excessive current draw.

c. Check wiring of heaters. If a heater is miswired, fuse may

blow. Ifa heateris miswired, correctmiswiring by comparing it to heater wiring label.

4. Check connections on primary side of transformer. If they

are not connected properly, the transformer secondary cannot supply the 24--V signal to energize fan relay. If transformer is receiving correct primary voltage but is not putting out correct secondary voltage, transformer needs to be replaced.

B. If Electric Heat Stages Will Not Turn On But Fan Will

Turn On :

IF THERE IS NO HIGH VOLTAGE TO TRANSFORMER:

1. Check plug connection between heaters and board. This

supplies power to transformer and fan. Be sure plug is connected properly.

2. Check sequencer/relay No. 1 and plug wiring. Yellow wire

should be connected to Pin No. 9 of plug and to limit switch. Black wire should be connected to Pin No. 7 of plug and to sequencer/relay No. 1.

3. Check incoming high--voltage power leads. If these are not

receiving power, system cannot function.

IF TRANSFORMER HAS 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 output is low (less than 18Vac), refer to items 3 and 4 of previous “If Transformer Has High Voltage Applied To It” section.

IF TRACES ARE OVERHEATED ON BACK OF PCB:

Usually whenever a trace is 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.

C. If Transformer 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 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 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 wiring of sequencers/relays as shown in Fig. 1 and Fig. 2. Be sure transformer is not shorting out because ther-

mostat wires are miswired.

2. Check wiring of relays as shown in Fig. 1 And Fig. 2.Be

sure low--voltage and high--voltage wiring is correct.

3. Check VA draw on transformer. If VA draw is more than

VA rating of transformer, fuse will blow. If this is the case,

1005-161

R2 R3 C3 R6

R11

1005-83-161ACPC-E

94V-0

C1C2

R10 R9

LR40061

CESO130003-01

HSCI

TRG C

5 AMP

SPT

replace 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 power, check blue and black fan

leads. These may be switched at sequencer/relay.

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:

Check 208--V and 230--V transformer connections. They may be miswired.

LOW

JW1

VOLTAGE FUSE

PCB BLOCK WIRING

SPT

DELAY

TIME

FAN

RELAY

FUSE

GRTC

FAN RELAY

Fig. 1 -- Fan Coil Printed Circuit Board (CES013003--00, 01 / HK61EA002)

HSCI

C C

C T G

5 AMP

JW1

FAN

RELAY

SPT

R2 R3 C3 R6

R11

94V-0

CPC-E

C1C2

R10 R9

LR40061

Fig. 2 -- Fan Coil Printed Circuit Board (HK61EA006)

A97020

A03010

312753

T-O-D 60TX11

HH19ZA945

C9725

L145-55F

312753

T-O-D 60TX11

HH19ZA945

C9725

L145-55F

SPT

FAN

RELAY

FF1E CONTROL BOX

Fig. 3 -- Electric Heater Control Box

WARNING

ELECTRIC SHOCK HAZARD

DISCONNECT REMOTE POWER SUPPLY BEFORE OPENING PANEL.

PULL TO OPEN

322861-101 REV. A

A13032

FB4C, FX4D, PF4, FF1E, and FZ (odd sizes)

FAN MOTOR

The multi--speed ECM motor used with this product contains two parts: the control module and the motor winding section. Do not assume the motor or module is defective if it will not start. Go through the steps described below before replacing control module or entire motor. The control module is available as a replacement part.

A. It is normal for the motor to rock back and forth on startup. Do

not replace the motor if this is the only problem identified.

B. If the motor is not running:

1. Check for proper high voltage and ground at the L,G, and N connections at the motor. Correct any voltage issue before proceeding to the next step.

2. The motor is communicated through 24--Vac signals to the 1,2,3,4,5 and C (common) terminals. Not all taps are programmed, if low voltage is applied to an non--programmed terminal, the motor will not operate, which is normal. Verify the part number of the motor matches the correct replacement motor part number for the unit model number.

3. Initiate a demand from the thermostat and check the voltage between C (common) and terminal 1-- 5. If voltage is present and the motor isn’t operating, then the motor/control module is failed.

C. Prior to installing the replacement control module, the motor

section condition needs to be verified.

1. Check to see if the blower wheel spins freely.

2. To check for short to ground, use an ohmmeter to measure the resistance from any one of the motor connector pins to the aluminum end plate of the motor. This resistance should be greater than 100,000 ohms.

3. Check the motor phase--to--phase resistance between each of the leads in the three--pin motor connector. The lead--to-lead resistance across any two leads should be less than 20 ohms. Each lead--to--lead resistance should be the same within --/+ 10 percent.

4. If any motor fails any of the three tests, do not install a new control module. The new control can fail if placed on a defective motor.

The prior fan coil models with multi--speed ECM blower motors used a printed circuit board, similar to the PSC models. The current fan coils do not use the printed circuit board and rely on the motor control programming to provide the off--delay timing.

Another design aspect of the control board was to provide a resistor in the “G” circuit in case a power stealing thermostat was used. This resistor is no part of the wiring harness, as shown on wiring diagram. The resistor is a 2--watt, 1500--ohm resistor.

If the resistor has failed open, a likely cause is due to the power stealing thermostat. Connecting C (common) may resolve the issue. Having an open resistor should not affect the operation of the motor.

Fan Speed Selection

The fan speed selection is done at the motor connector. Units with or without electric heaters require a minimum CFM. Refer to the unit wiring label to ensure that the fan speed selected is not lower than the minimum fan speed indicated.

To change motor speeds disconnect the BLUE fan lead from motor connector terminal No. 2 (factory default position) and move to desiredspeed-tap;1,2,3,or5.

Speed-taps 1, 2, and 3 have a 90--second blower off time delay pre-programmed into the motor. Speed-tap 4 is used for electric heat only (with 0 second blower time delay) and the WHITE wire should remain on tap 4. Speed-tap 5 is used for high static applications, but has a 0--second blower time delay pre-programmed into the motor. See Airflow Performance tables for actual CFM. Also, see Fig. 4 for motor speed selection location.

NOTE: In low static applications, lower motor speed tap should be used to reduce possibility of water being blown off coil.

Tap 1 Low 90 sec off delay

Tap 2 Medium 90 sec off delay

Tap 3 High 90 sec off delay

Tap 4 Electric heat † 0 sec off delay

Tap 5 Max ‡ 0 sec off delay

† electric heat airflow is same CFM as Tap 3, except 0 sec off delay ‡ high static applications, see airflow tables for max airflow

1 2 3 4 5

NAMEPLATE

LABEL

Speed Taps may be located on motor, or on plug close to motor.

1 2 3 4 5

NAMEPLATE

LABEL

CLGN

A11048

Fig. 4 -- Motor Speed Selection for FB4C, FX4D, FZ4A & PF4

(odd sizes)

OPTIONAL SAFETY GROUND

DRAIN HOLE

OPTIONAL SAFETY GROUND

CONTROL

POWER

DRAIN HOLE

Fig. 5 -- FV4 Motor / ECM5.0 Motor

12345

POWER CONNECTOR

10 11 12 13 14 15 16

12345678

CONTROL CONNECTOR

A13028

ENDSHIELD

DRAIN HOLE

A98201

Fig. 6 -- FV4 Motor / ECM2.3 Motor

FV4

Constant Air Flow

Unlike fan coils using induction motors where static pressure affects airflow, these fan coils are constant airflow units. The blower delivers requested airflow regardless of static pressure. Consult fan coil Product Data for static pressure limits. The ECM2.3/5.0 is pre--programmed and contains airflow tables for all modes of operation. Blower characteristics (requested airflow, torque, and speed) are known from laboratory testing If any two characteristics are known, the third is defined.

Requested airflow is known from Easy Select board configuration and thermostat signals. Torque is known because it is directly related to stator current, which is measured by motor control. Speed is measured by counting back EMF pulses from stator windings. This information is entered into an expression that calculates torque from speed and airflow numbers. If calculation does not match stored blower characteristics, torque is adjusted until agreement is reached. This calculation and adjustment is performed every 0.8 seconds while motor is in operation. There is no direct measure of static pressure, but unit does react to a change in static to maintain constant airflow. A change in pressure will result in a change in stator speed and torque. The motor will begin to adjust on the next sampling, calculate new desired speed and torque, and adjust as necessary.

INTEGRATED CONTROLS AND MOTOR ECM2.3/5.0

An ECM2.3/5.0 is fed high voltage AC power through the 5--pin connector. (See Fig. 6 or Fig. 5.) The AC power is then internally rectified to DC by a diode module. After rectification, DC signal is electronically communicated and fed in sequential order to three stator windings. The frequency of these commutation pulses determines motor speed. The rotor is permanently magnetized.

An ECM2.3/5.0 is powered with high voltage at all times. The motor will not run with high voltage alone. Low voltage must be appliedtocontrolplugtorunmotor.

ECM2.3/5.0 Control Power

The ECM2.3/5.0 control power is supplied from R circuit through printed circuit runs to motor control Connector--Pin 8, through motor control harness to motor. The C side of low--voltage control power circuit is connected by printed circuit runs to motor Connector --Pins 9, 10, and 11 then through motor control harness to motor.

Low--Voltage Circuit Fusing and Reference

The low--voltage circuit is fused by a board--mounted 5--amp automotive--type fuse placed in series with transformer SEC2 and R circuit. The C circuit of transformer is referenced to chassis ground through a printed circuit run at SEC1 connected to metal standoff marked.

NOTE: The PCB must be mounted with two screws and motor

ground lead secured to blower housing or erratic motor operation can result.

Transformer, Motor, and Electric Heater Power Connection

Transformer high voltage supplied from electric heater package or high voltage leads through 12--pin heater connector plug/recp2. The ECM2.3/5.0 power connections are made at the transformer primary terminals. The transformer secondary connections are made at SEC1 and SEC2 connectors.

PCB LAYOUT AND DESCRIPTION (FV4)

NOTE: Layout of actual PCB is depicted in Fig.7.

The Easy Select Board is the interface between the ECM motor and other system components. The board offers choices of electric

heater size, outdoor unit size and type, comfort or efficiency settings, on and off delay profiles, and continuous fan speed. The installer should select the correct size of components that are being installed in each installation. If no selections are made, the factory default settings are for the largest heater, largest outdoor unit, AC system type, nominal airflow adjust, and 0/90 time delay.

NOTE: Outdoor unit model should have an AHRI rating with the

variable speed fan coil. Some outdoor unit models will not work properly with this fan coil.

Power for system is supplied from a 230--Vac, 60--Hz line. Class 2 voltage (24 Vac nom.), used for thermostat connections, is derived from transformer located in close proximity to PCB. The 24--Vac secondary circuit includes 5--amp automotive--type fuse in SEC2 circuit.

Connection to heater panel is made through 12--pin connector PL--1. Connections to thermostat are made at screw terminals. Twenty--one pin terminals comprise field select taps for motor.

Fuse Data: 5--amp automotive--type ATC/ATO (tan)

32V 200 percent current opening time of five seconds maximum

Electrical Connections

Twenty--one 0.110--in pin terminals are used to provide programming selections for operating modes of ECM2.3/5.0. The 6 selection modes are listed below. For additional information, refer to Easy Select Configuration Taps section.

AUX Heat Range—(Violet Wire) AC/HP Size—(Blue Wire) Type—(Orange Wire) AC/HP CFM Adjust—(Black Wire) AC/HP Time Delay—(Grey Wire) Continuous Fan—(Yellow Wire)

SEQUENCE OF OPERATION (FV4)

A. Continuous Fan Mode

The thermostat closes circuit R to G. The unit delivers the airflow selected for fan only operation.

B. Cooling Mode—Single Speed or Two--Speed High

Thermostat closes circuits R to G, R to Y/Y2 and R to O (heat pump only). A circuit R to Y1 is required for two--speed high operation. Airflow delivered the airflow selected by AC/HP SIZE selection and CFM ADJUST selection.

C. Cooling Mode—Two--Speed Low

Thermostat closes R to G and R to Y1 and R to O (heat pump only). Unit delivers two--speed low airflow for AC/HP SIZE and CFM ADJUST selected.

D. Cooling + Dehumidify Mode (Thermidistat or Comfort

Zone II--B and Single--Speed Outdoor Unit Installed)

J1 jumper must be pulled from Easy Select Board. Control closes R to G, R to Y/Y2, and R to O (heat pump only) and open R to DH. Dehumidification is active when 24Vac is removed from DH terminal. Unit delivers 20 percent less airflow.

E. SuperDehumidify Mode

(Thermidisat or Comfort ZoneII--B indoor control, Single--Speed OutdoorUnit)

This mode is only activated by the indoor control when COOL to DEHUMIDIFY and SUPERDEHUMIDIFY are configured at the control and there is a call for dehumidfication without a call for cooling. The control closes R to Y/Y2, R to O (heat pump only) and opens R to DH and R to G. This signals the fan coil to run at minimum airflow for maximum humidity removal. The control will cycle the equipment 10 minutes on and 10 minutes off until satisfied.

Table 1 – Motor and Modules

Model Size Motor Type Current Blower Motor P/N

FV4B_002 ECM2.3 HD44AE131 RMOD44AE131 FV4B_003 ECM2.3 HD44AE132 RMOD44AE132 FV4B_005 ECM2.3 HD44AE133 RMOD44AE133

FV4B_006 ECM2.3 HD46AE244 RMOD46AE244 FV4C_002 (Series A) ECM2.3 HD44AR131 RMOD44AR131 FV4C_003 (Series A) ECM2.3 HD44AR132 RMOD44AR132 FV4C_005 (Series A) ECM2.3 HD44AR133 RMOD44AR133 FV4C_006 (Series A) ECM2.3 HD46AR244 RMOD46AR244 FV4C_002 (Series B) ECM5.0 HD44AR120 HK44ER120 FV4C_003 (Series B) ECM5.0 HD44AR121 HK44ER121 FV4C_005 (Series B) ECM5.0 HD44AR122 HK44ER122 FV4C_006 (Series B) ECM5.0 HD46AR223 HK46ER223

Required Control Module Replacement Kit Number

SEC1

EASY SELECT

AUX/HEAT KW/CFM

0-20

0-30

875

1075

VIO

AC/HP SIZE

036 030 024 018

BLU

SYSTEM TYPE

AC HP-COMFORT HP-EFF

ORN

AC/HP CFM ADJUST

NOM LO HI

BLK

ON/OFF DELAY

309000ENH

WHT

CONTINUOUS FAN

LO MED HI YEL

YEL

PL1

HEATER/MOTOR

Fig. 7 -- Easy Select Board

SEC2

0-10 725

0-5

625

5 AMP.

MAX.

D5D2

AUX1 HUM1

AUX2

YYWWX

STI

24VAC

GRY

HUM2

Y/Y

HK61EA006

A13029

AUX1

HUM1

AUX2

HUM2

GRY

/4"

AUX HEAT

KW/CFM

SYSTEM DIAGRAM

AC/HP

SIZE

HEATER/MOTOR

987654321

DIODE LOGIC

SYSTEM

TYPE

121110

AC/HP CFM

ADJUST

SEC1 SEC2

ON/OFF

DELAY

5 AMP

Fig. 8 -- Easy Select Board Schematic

CONTINUOUS

FAN

Y/Y

A96431

Table 2 – Connections and Connectors (FK4, FV4)

Type Connection Type Connector Pin No. Description

Pin 1 Common to screw terminal G Pin 2 Common to screw terminal Y/Y2 through diode D3 Pin 3 Common through Y1 through diode D2 Pin 4 Common to W2 screw terminal Pin 5 Common to W2 screw terminal

Heater Connection 12-Pin

Pin 6 Common to W1 screw terminal Pin 7 Common to W1 screw terminal Pin 8 R 24Vac

Pin 9 Common to transformer C Pin 10 Common to transformer C Pin 11 Common to transformer C

Pin 12 Common to DH screw terminal

Table 3 – Typical Operating Modes

Operating Mode Terminals Energized

Heat Pump Only Heating R, Y/Y2, G, DH

Heat Pump Only Heating + Super Comfort Heat Mode R, Y/Y2, DH

Heat Pump Heating + Auxiliary Heat (non-staged) R, Y/Y2, G, DH, W2

Cooling R, Y/Y2, G, DH, O

Cooling + Dehumidification R, Y/Y2, G, O

Cooling + Superhumidification R, Y/Y2, O

F. Heat Pump Heating Mode — Single Speed or Two--Speed

High

Thermostat closes R to Y/Y2 and R to G. A circuit R to Y1 is required for two--speed high operation. The unit delivers airflow selected by AC/HP SIZE selection and CFM ADJUST selection. Selected delay profile is active in this mode.

G. Heat Pump Heating Mode — 2--Speed Low

Thermostat closes R to G and R to Y1. Unit delivers two--speed low airflow for AC/HP SIZE and CFM ADJUST selected. Selected delay profile is active in this mode.

H. Non--Staged Auxiliary with Heat Pump Heating Mode

Thermostat should already have closed R to G, R to Y2 for heat pump heating operation. With J2 jumper in place, energizing either W1 or W2 will produce the W2 airflow. This is the greater of heat pump heating and auxiliary heat airflow plus an additional 15 percent. The elected delay profile is not active in this mode.

I. Staged Auxiliary Heat with Heat Pump Heating Mode

The auxiliary heat can be staged by removing the J2 jumper that ties W1 and W2 terminals together. Staging can be done by using outdoor thermostats or by using the Intelligent Heat Staging option where the indoor control can be configured for three--stage electric heat. The unit will automatically adjust airflow when the different stages of heat are energized. The airflow delivered will depend on the heat pump size selected and electric heat size selected. The greater of the two airflows will be delivered. The selected delay profile is not active in this mode.

J. Electric Heat without Heat Pump

Thermostat closes R to W and thermostat should be set up to energize G with W. This is due to the Super Comfort Heat programming in the motor. Energizing W without G will result in 25% lower airflow delivery. The selected delay profile is not active in this mode.

K. Super Comfort Heat Mode

This is a special heating mode only available on FV4 fan coils combined with a Thermidistat Control or Comfort Zone II--B. When this option is selected, the indoor control will monitor the outdoor temperature. The control will drop the G signal to the fan coil when the outdoor temperature is between 10_ and 40_ F. Th is triggers the motor to slow to approximately 213 CFM per ton. The heaters will stage as needed during this mode and the motor will

adjust airflow as required. Below 10_ F., the W1 control output will automatically energize on a call for heat. The ECM2.3/5.0 power connections are made at the transformer primary terminals. The transformer secondary connections are made at SEC1 and SEC2 connectors.

EASY SELECT CONFIGURATION TAPS

The Easy Select taps are used by installer to configure system. The ECM2.3/5.0 uses selected taps to modify its operation to a pre--programmed table of airflows. Airflows are based on system size and mode of operation and those airflows are modified in response to other inputs such as the need for de--humidification. (See Fig. 7.)

The FV4 Fan Coils 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 six select wires to pins which match components used, along with homeowner preferences.

A. Auxiliary Heat Range

The installer must select the auxiliary heat airflow approved for application with kW size heater installed. Each select pin is marked with a range of heaters for which airflow (also marked) is approved. For increased comfort select the narrowest kW range matching the heater size, for example, 0--10 for a 10--kW heater. This airflow must be greater than the minimum CFM for electric heater application with the size system installed for safe and continuous operation. Note that airflow marked is the airflow which will be supplied in emergency heat mode and heating mode on air conditioners when electric heat is primary heating source. To ensure safe heater operation in heat--pump heating mode, when electric heaters are energized, the ECM2.3/5.0 will run the higher of heat pump airflow and electric heater airflow. The factory default selection is largest heater range approved. (See Fig. 7.)

B. AC/HP Size

The factory default setting for air conditioner or heat pump size is largest 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. 7.)

Unpack unit and move to final location. Remove carton taking care not to damage unit. Inspect equipment for damage prior to

installation. File claim with shipping company if shipment is damaged or incomplete.

Locate unit rating plate which contains proper installation information. Check rating plate to be sure unit matches job specifications.

C. System Type

The type of system must be selected.

1. AC—air conditioner (approx. 350 CFM/ton)

2. HP--COMFORT—provides lower airflow than air condi-

tioner selection (approximately 315 CFM/ton) in heating mode. In cooling mode supplies 350 CFM/ton.

3. HP--EFF—provides same airflow for heat pump heating

and cooling modes (approximately 350 CFM/ton).

The factory setting is AC. (See Fig. 7.)

D. AC/HP CFM Adjust

Select low, nominal, or high airflow. The factory selection is NOM. The adjust selections HI/LO will regulate airflow supplied for cooling and heat pump heating modes only, +15 percent and --10 percent respectively. 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. 7.)

E. ON/OFF Delay

NOTE: ON/OFF Delay is active only in cooling and heat pump

only heating modes. In auxiliary heat mode or emergency heat mode, the ON delay is 0 seconds and the OFF delay is fixed and cannot be overridden.

Select desired time delay profile. Four motor--operation delay profiles are provided to customize and enhance system operation. (See Fig. 7.) The selection options are:

1. The standard 90--seconds off delay (factory setting 0/90).

2. No delay option used for servicing unit or when a thermo-

stat is utilized to perform delay functions (0/0).

3. A 30--seconds on/90--seconds off delay profile used when it

is desirable to allow system coils time to heat up/cool down prior to airflow. This profile will minimize cold blow in heat pump operation and could enhance system efficiency (30/90).

4. ENH, enhanced selection provides a 30--seconds

on/150--seconds at 70 percent airflow and no off delay.

F. Continuous Fan

Select desired continuous--fan profile LO, MED, or HI. Airflow are provided to customize and enhance the continuous fan functions. (See Fig. 7.) The possible selections are:

1. LO—provides 50 percent of Y/Y2 Cool airflow.

2. MED—provides 65 percent of Y/Y2 Cool airflow (71 per-

cent on 006 model).

3. HI—provides 100 percent of Y/Y2 Cool airflow.

The factory setting is LO. NOTE: If applied to two--speed unit, do not select continuous fan

as HI since low speed cooling will also run at HIGH airflow and insufficient dehumidification may result.

G. Easy Select Board Jumpers

J1 -- This jumper must be pulled to activate dehumidification mode. The jumper connects R to DH. With the jumper in, the DH terminal is always energized. With the jumper pulled, the DH terminal is de--energized. A control such as the Thermidistat must be used to supply the 24--V signal when there is no call for dehumidification, and turn off the 24--V when there is a call for dehumidfication.

J2 -- This jumper activates heat staging. The jumper connects the W1 and W2 terminals together. If either is energized, W2 airflow is delivered. With the jumper pulled, there are separate airflows for W1 and W2.

H. Airflow Delivery

These units deliver airflow depending on the system sizeselections and operating mode. The thermostat energizes a combination of terminals on the Easy Select Board which tells the motor what CFM to deliver. The following are typical operating modes and the terminals that should be energized on the Easy Select Board.

NOTE: The DH terminal on the Easy Select Board is for

dehumidification. It is de--energized on a call for dehumidification.

I. Variable Speed Motor Logic Sequence:

The ECM motors in these fan coils are programmed to deliver a variety of airflows. The motor goes through:

COOLING The nominal cooling airflow for these fan coils is 350 CFM per

ton. Selecting the HI adjust tap increases the airflow to 400 CFM per ton. The LO tap decreases airflow to 315 CFM per ton. The low adjustment is only active during normal cooling mode. Removing the signal from the DH terminal reduces the airflow to 80 percent of cooling airflow. Removing the G signal for Superdehumidify reduces the airflow to 50 percent of cooling.

HEATING

The base heat pump only heating airflow is determined by the SYSTEM TYPE selection on the Easy Select Board. If HP--EFFICIENCY is selected, the airflow is the same as Cooling. IF HP--COMFORT is selected, the airflow is 315 CFM per ton. The airflow will adjust up if necessary when auxiliary heating is required. When both the Y/Y2 and W1 or W2 terminals are energized, the motor will run the higher of the heat pump or electric heat airflows. During Super Comfort Heat mode, the indoor control removes the G signal from the board. This slows the motor to 75 percent of heat pump airflow. If the CFM adjust is set to LO, it will deliver 67.5 percent of heat pump airflow during Super Comfort Heat mode.

TROUBLESHOOTING

A. Troubleshooting Easy Select Board (FV4)

If Traces Are Overheated on Back of PCB:

Usually whenever there is a trace broken 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 fan coil has power applied to it.

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 to 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 Vac 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. 7.) Be

sure transformer is not shorting out because thermostat wires are miswired.

2. Check wiring of relays. (See Fig. 7.) Be sure low--voltage

and high--voltage 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.

B. Troubleshooting Common Problems

Airflow Too Low:

Y1 instead of Y/Y2 on single--speed air conditioner or heat pump application. Y1 input is only for two--speed applications. Using this terminal will deliver about 60 percent of full cooling airflow.

Wrong Easy Select Board selection. Selecting an outdoor unit or electric heater smaller than actually installed will result in low airflow for the application.

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