Carrier 40FKA Installation And Setup Instructions

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40FKA
Comfort Heat Pump System
002-006
Installation and Set-up Instructions
NOTE: Read entire instruction manual before starting installa-
tion.
See Back Page for QUICK REFERENCE COMFORT HEAT SET-UP INSTRUCTIONS.
Improper installation,adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other condi­tions which may cause personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions pack­aged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all
warnings or cautions attached to the unit and in installation instructions or manuals. Consult local building codes and National Electrical Code (NEC) for special requirements.
Recognize safety information. This is the safety-alert symbol When you see this symbol on the unit and in instructions or 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 would result in minor personal injury or product and property damage.
INTRODUCTION
Model 40FKA Fan Coil units are designed for flexibility and can be used for upflow, horizontal, or downflow applications. A
.
40FKA FAN COIL
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4 Tab 2e 3d
PC 101 Catalog No. 534-021 Printed in U.S.A. Form 40FK-1SI Pg 1 5-98 Replaces: New
THERMIDISTAT ™
CONTROL
OUTDOOR TEMPERA TURE SENSOR
A98049
Fig. 1—Comfort Heat Pump System
FPT
4
3
ID SWEAT
8
7
ID SWEAT,
4
3
ID SWEAT
003, 005, & 006 -
8
3
8
7
4
3
OPTIONAL FIELD
11
16
1
22
16
3
10
OUTLET AIR
1
8
1
2
7
ALTERNATE
DIA KNOCKOUT
8
7
for service.
of unit model number.
NOTE: Series designation is the 14th position
Allow 21 In. from front
NOTE:
FOR LOW VOLTAGE
CONVERTED RIGHT
SIDE RETURN
OPENING
(SLOPE COIL
UNITS ONLY)
,
8
, 2DIA
32
3
ALTERNATE
KNOCKOUTS FOR
1
19
HIGH VOLTAGE
POWER WIRING
OPPOSITE SIDE
INLET AIR
CONTROL WIRING
LIQUID LINE
CONNECTION
H
FOR
UNITS
MODULAR
J
MAX.
will have a
2
1
1
two-piece
cabinet.
2
1
2
OPENING
16
13
19
RIGHT SIDE VIEW
A98276
INLET AIR
NOTE: Modular units
4
1
1
16
11
4
1
1
A
SLOPE COILS
AND "A" COILS
RIGHT APPLICATIONS
DOWNFLOW OR HORIZ
E
2
1
9
ACCESS PANEL CONFIG FOR
SUCTION LINE
CONNECTION
DOWNFLOW APPLICATIONS
TOP VIEW
LIQUID:
CONDENSATE PAN CONNECTIONS:
UNIT REFRIGERANT CONNECTION SIZES
SUCTION: 002 -
1
DIA KNOCKOUTS
8
FOR LOW VOLTAGE
CONTROL WIRING
7
8
3
, 2DIA KNOCKOUTS
1
32
3
, 1
8
FOR HIGH VOLTAGE POWER WIRING
7
B
16
8
7
1
15
1
DISCONNECT OR CIRCUIT
BREAKER LOCATION
BLOWER, CONTROL, & ELECTRIC
HEATER ACCESS PANEL
C
16
15
LIQUID LINE
CONNECTION
16
16
1
11
3
4
COIL ACCESS PANEL
LIQUID LINE
CONNECTION
FITTING
PANEL
8
5
2
4
3
10
16
SUCTION LINE
3
CONNECTION
6
5
16
7
10
SLOPE COIL DETAILS
CONNECTION LOCATIONS
SHOWN FOR UPFLOW
OR HORIZ LEFT APPLICATIONS
FILTER ACCESS
PANEL
D
INLET AIR
OPENING
DETAILS CONNECTION LOCATIONS
FRONT VIEW SHOWN WITH "A" COIL
1
FOR UPFLOW OR HORIZ APPLICATIONS
A BCD E F G
In. In. In. In. In. In. In.
002 42-11/16 17-5/8 15-3/4 15-5/8 10-3/4 18-9/16 18-1/4
003 53-7/16 21-1/8 19-1/4 19-1/8 19-3/16 26-15/16 27-1/2
005 53-7/16 21-1/8 19-1/4 19-1/8 19-1/2 27-1/4 26-15/16
UNIT SIZE
40FKA
Fig. 2—Dimensional Drawing
006 59-3/16 24-11/16 22-3/4 22-11/16 25-1/4 32-15/16 32-5/8
2
16
3
2
TYP
(2 PLACES)*
PRIMARY DRAIN
SECONDARY DRAIN
16
TYP*
5
G
8
TYP*
8
TYP*
7
2
1
TYP*
16
11
1
16
5
HORIZ RIGHT
1
(FIELD CONVERTED)
2
F
SECONDARY DRAIN
PRIMARY DRAIN
16
TYP*
5
7
2
1
TYP*
2
1
1
4
1
1
A95536
HORIZ RIGHT
(FIELD CONVERTED)
8
7
8
7
7
5
SECONDARY DRAIN
G
16
16
13
TYP*
1
3
2
TYP
(2 PLACES)*
1
TYP
(2 PLACES)*
16
13
TYP*
1
AIRFLOW
SLOPE COIL
16
TYP
7
AIRFLOW
4
1
3
(4 PLACES)*
1
TYP
PRIMARY DRAIN
16
5
1
F
(2 PLACES)*
16
13
TYP*
1
SECONDARY DRAIN
PRIMARY DRAIN
SECONDARY DRAIN
16
/
7
TYP
1
8
PRIMARY DRAIN
7
2
SECONDARY DRAIN
5
16
3
TYP*
2
(2 PLCS)
16
16
3
1
5
8
7
2
1
(4 PLACES)*
TYP
(2 PLACES)*
8
⁄ 2
4
1
2
2
1
1
16
TYP*
11
1
5
2
8
TYP*
7
AIRFLOW
DOWNFLOW
(FIELD CONVERTED)
16
TYP 
(4 PLACES)*
7
UPFLOW
(AS SHIPPED)
AIRFLOW
HORIZ LEFT
(AS SHIPPED)
TYP*
4
8
3
1
4
3
F
1
TYP
(2 PLACES)*
PRIMARY DRAIN
SECONDARY DRAIN
PRIMARY DRAIN
PRIMARY DRAIN
16
13
TYP*
1
SECONDARY DRAIN
16
7
3
16
11
2
″
16
3
TYP
(2 PLACES)*
2
16
5
8
7
5
4
1
1
2
1
1
2
TYP*
1
TYP
(4 PLACES)*
4
3
8
4
1
3
TYP*
8
7
7
DOWNFLOW
(FIELD CONVERTED)
A–COIL
UPFLOW
(AS SHIPPED)
HORIZ LEFT
(AS SHIPPED)
H J COIL CONFIGURATION SHIPPING WEIGHT
In. In. Slope "A" Lb.
002 Yes 132
UNIT SIZE
003 19 Yes 151
005 Yes 169
40FKA
Fig. 3—Dimensional Drawing
006 34-1/16 Yes 204
PANEL, AND BACK OF CABINET. IN CABINET BOTTOM, HOLES PROVIDED
.136 IN. DIA. HORIZONTAL HANGING HARDWARE TO BE FIELD
SUPPLIED.
* HORIZONTAL MOUNT LOCATIONS - DIMPLES PROVIDED IN TOP 
8
7
TYP*
3
Carrier Thermidistat™ Control (TSTATCCPRH01-B) is included with the 40FKA unit. See Back Page for QUICK REFERENCE
COMFORT HEAT SET-UP INSTRUCTIONS.
These units are available for application in systems of 18,000 through 60,000 Btuh nominal cooling capacities. (See Fig. 2 and
3.) Factory-authorized, field-installed electric heater packages are available in 5 through 30 kw. See Product Data for available accessory kits.
Before installing or servicing fan coil, always turn off all power to unit. There may be more than 1 disconnect switch. Turn off accessory heater power if applicable. Electrical shock can cause personal injury or death.
INSTALLATION
Step 1—Check Equipment
Unpack unit and move to final location. Removecarton 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.
Step 2—Mount Fan Coil
Unit can stand or lie on floor, or hang from ceiling or wall. Allow space for wiring, piping, and servicing unit.
IMPORTANT: When unit is installed over a finished ceiling and/or living area, building codes may require a field-supplied secondary condensate pan to be installed under the entire unit. Some localities may allow as an alterative the running of a
separate, secondary condensate line. Consult local codes for additional restrictions or precautions.
When installing any fan coil over a finished ceiling and/or living area, installation of a secondary drain pan under entire unit to avoid damage to ceiling is recommended.
40FKA Fan Coils can be installed for upflow and horizontal-left applications as factory shipped. Units can be installed for horizontal-right applications with field modifications. Units may be converted for downflow applications using factory-authorized accessory kit.
NOTE: To ensure proper drainage for horizontal installations, unit must be installed so it is within 1/8 in. level of the length and width of unit.
UPFLOW INSTALLATION If return air is to be ducted, install duct flush with floor. Set unit
on floor over opening. Only use return-air opening provided. All return air must pass
through the coil. (See Fig. 4.) MODULAR UNITS The 40FKA Fan Coil in size 006 is a 2-piece modular unit.
Modular construction allows installer to disassemble unit into 2 components, coil box and blower box, for ease of installation. (See Fig. 5.)
To disassemble unit, remove rear corner brackets by removing 2 screws which secure brackets. (See Fig. 5.) Remove either 2 screws in each front corner of coil box, or 2 screws in blower box. Do not remove all 4 screws in each corner. (See Fig. 5.) Sections may now be separated by lifting top section from lower section.
To reassemble, reverse above procedure. Be certain to reinstall all fasteners when reassembling.
POWER ENTRY
24-IN. FRONT SERVICE
A COIL
UNITS
UPFLOW/DOWNFLOW
SECONDARY DRAIN
UPFLOW/DOWNFLOW
PRIMARY DRAIN
UPFLOW/DOWNFLOW
SECONDARY DRAIN
UPFLOW/DOWNFLOW
PRIMARY DRAIN
OPTIONS
CLEARANCE
1 1⁄2″
2 1⁄2″
FIELD SUPPLIED SUPPLY DUCT
LOW VOLT ENTRY OPTIONS
UNIT
003
19
A
FIELD SUPPLIED RETURN PLENUM
A
19 In.
FIELD MODIFIED SIDE RETURN LOCATION FOR SLOPE COIL UNITS ONLY
Fig. 4—Slope Coil in Upflow Application
A98263
4
HORIZONTAL INSTALLATIONS Be sure installation complies with all applicable building codes
that may require installation of a secondary condensate pan.
1. Arrange support for unit by setting it in or above secondary condensate pan.
2. When suspending unit from ceiling, dimples in casing indicate proper location of screws for mounting metal support straps. (See Fig. 6.)
HORIZONTAL-RIGHT CONVERSION OF UNITS WITH SLOPE COILS
To convert units for horizontal right installations:
1. Remove blower and coil access panels and fitting panel. (See Fig. 7.)
2. Remove screw securing coil assembly to right side casing flange.
3. Remove coil assembly.
4. Lay fan coil on its right side and reinstall coil assembly with condensate pan down. (See Fig. 7.)
5. Attach coil to casing flange using previously removed coil mounting screw.
6. Reinstall access panels and fitting panel, aligning holes with tubing connections and condensate pan connections.
Make sure liquid and suction tube grommets are in place to prevent air leaks and cabinet sweating. Install grommets after brazing.
HORIZONTAL RIGHT CONVERSION OF UNITS WITH A-COIL
To convert units for horizontal right installations:
1. Remove blower and coil access panels. (See Fig. 8.)
2. Remove metal clip securing fitting panel to condensate pan. Remove fitting panel.
3. Remove 2 snap-in clips securing A-coil in unit.
4. Slide coil and pan assembly out of unit.
BLOWER BOX
2 SCREWS
2 SCREWS
REAR CORNER BRACKET
COIL BOX
2 SCREWS
A95293
Fig. 5—Modular Unit Assembly
5. Remove horizontal drain pan support bracket from coil support rail on left side of unit and reinstall on coil support rail on right side of unit.
6. Convert air-seal assembly for horizontal right. a. Remove air-seal assembly from coil by removing 4 screws. b. Remove air splitter (B) from coil seal assembly by remov-
ing 3 screws. (See Fig. 8—factory-shipped inset.)
c. Remove filler plate (A) and install air splitter (B) in place
of filler plate.
d. Install filler plate (A) as shown in horizontal right appli-
cation.
e. Remove condensate troughs (C) and install on opposite
tube sheets.
f. Install hose onto plastic spout.
7. Install horizontal pan on right side of coil assembly.
8. Slide coil assembly into casing. Be sure coil bracket on each corner of vertical pan engages coil support rails.
9. Reinstall 2 snap-in clips to correctly position and secure coil assembly in unit. Be sure clip with large offset is used on right side of unit to secure horizontal pan.
10. Remove 2 oval coil access panel plugs and reinstall into holes on left side of coil access panel and fitting panel.
11. Remove insulation knockouts on right side of coil access panel.
12. Reinstall access and fitting panels, aligning holes with tubing connections and condensate pan connections. Be sure to reinstall metal clip between fitting panel and vertical conden­sate pan.
Make sure liquid and suction tube grommets are in place to prevent air leaks and cabinet sweating.
DOWNFLOW INSTALLATIONS To convert units for downflow applications, refer to Installation
Instructions supplied with kit for proper installation. For 40FKA unit size 003, use kit Part No. KFADC0201SLP. For 40FKA unit sizes 002, 005, and 006 use kit Part No. KFADC0401ACL. Use fireproof resilient gasket, 1/8- to 1/4-in. thick, between duct, unit, and floor.
Step 3—Air Ducts
Connect supply-air duct over outside of 3/4-in. flange provided on supply-air opening. Secure duct to flange with proper fasteners for type of duct used, and tape duct-to-unit joint.
Duct connection flanges are provided on unit air discharge connection.
When using 40FKAunits with 20-,24-, and 30-kwelectric heaters, maintain a 1-in. clearance from combustible materials to discharge plenum and ductwork for a distance of 36 in. from unit. Use accessory downflow base to maintain proper clearance on down­flow installations.
Use flexible connectors between ductwork and unit to prevent transmission of vibration. When electric heater is installed, use heat resistant material for flexible connector between ductwork and unit at discharge connection. Ductwork passing through unconditioned space must be insulated and covered with vapor barrier.
DUCTWORK ACOUSTICAL TREATMENT Metal duct systems that do not have a 90° elbow and 10 ft of main
duct to first branch takeoff may require internal acoustical insula­tion lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of
5
A-COIL HORIZONTAL LEFT
LOW VOLT ENTRY OPTIONS
POWER ENTRY OPTIONS
FIELD SUPPLIED HANGING STRAPS
UNIT
SECONDARY DRAIN
PRIMARY DRAIN
SECONDARY DRAIN
Fig. 6—Slope Coil in Horizontal-Left Application
PRIMARY DRAIN
24-IN. FRONT SERVICE CLEARANCE (FULL FACE OF UNIT)
1 3/4 IN. FILTER ACCESS CLEARANCE
A95292
COIL
SUPPORT
RAIL
SLOPE COIL
SKI
COIL MOUNTING SCREW
DRAINPAN
REFRIGERANT CONNECTIONS
BLOWER ASSEMBLY
PRIMARY DRAIN
OVERFLOW HOLE
SECONDARY DRAIN
A95288
Fig. 7—Slope Coil in Horizontal-Right Application
6
COIL
SUPPORT
RAIL
COIL
BRACKET
DRAIN PAN
SUPPORT
BRACKET
COIL
SUPPORT
RAIL
COIL
BRACKET
HORIZONTAL
DRAIN PAN
PRIMARY DRAIN
HORIZONTAL RIGHT
SECONDARY DRAIN
HORIZONTAL RIGHT
REFRIGERANT
CONNECTIONS
Fig. 8—A-Coil in Horizontal Right-Application
AIR SEAL ASSEMBLY
PRIMARY DRAIN HORIZONTAL LEFT
SECONDARY DRAIN HORIZONTAL LEFT
A
HORIZONTAL
RIGHT
APPLICATION
B C
A
FACTORY SHIPPED
HORIZONTAL LEFT
APPLICATION
B
C
A95286
SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with National Fire Protection Association Standards 90A or B as tested by UL Standard 181 for Class 1 air ducts.
Step 4—Electrical Connections
LINE-VOLTAGE CONNECTIONS Units with 15- and 20-kw heaters are factory wired for dual-circuit
operation. When single-circuit operation is required, 24- and 30-kw heaters are field convertible, and 15- and 20-kw fused heaters require the use of factory-authorized adapter kit.
Check all factory wiring per unit wiring diagram and inspect factory wiring connections to be sure none were loosened in transit or installation.
Before installing or servicing system, always turn off all 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.
If a disconnect switch is to be mounted on the unit, select a location where drill or fastener will not contact electrical or refrigerant components. Electrical shock can cause personal injury or death.
NOTE: Before proceeding with electrical connections, make certain that supply voltage, frequency, and phase are as specified on unit rating plate. Be sure that electrical service provided by the utility is sufficient to handle the additional load imposed by this equipment. See unit wiring label for proper field high- and low-voltage wiring. Make all electrical connections in accordance with NEC and any local codes or ordinances that may apply. Use copper wire only. The unit must have a separate branch electric circuit with a
field-supplied disconnect switch located within sight from, and readily accessible from the unit.
All units are shipped with power plug and stripped leads for connection of field wiring to units without electric heat.
1. Connect 208/230v power leads from field disconnect to yellow and black stripped leads.
2. Connect ground wire to unit ground lug.
3. If unit contains accessory electric heater, remove and discard power plug from fan coil and connect male plug from heater to female plug from unit wiring harness. (See Electric Heater Installation Instructions.)
24-V CONTROL SYSTEM CONNECTIONS TO UNIT PRINTED-CIRCUIT BOARD (PCB)
Refer to unit wiring instructions for recommended wiring proce­dures. Use No. 18 AWG color-coded, insulated (35°C minimum) wires to make low-voltage connections between thermostat and unit. If thermostat is located more than 100 ft from unit (as measured along the low-voltage wires), use No. 16 AWG color­coded, insulated (35°C minimum) wires. PCB is circuited for single-stage heater operation. When additional heater staging is desired using 2-stage or outdoor thermostats, see applicable outdoor unit instructions. Remove Jumper J2 on PCB to enable staging.
1. The 5-, 8-, and 10-kw heaters are single stage only.
2. The 15- and 20-kw heaters are adaptable for 2-stage operation.
3. The 24- and 30-kw heaters are adaptable for up to 3-stage operation.
Connect low-voltage leads to thermostat and outdoor unit. (See Fig. 9, 10, 11, and 12.)
INTELLIGENT HEAT OPTION Intelligent Heat staging is an element of the Comfort Heat Pump
System. It requires the use of any one the following electric heat packages:
7
INDOOR CONTROL
HEAT STAGE 2
N/A
HEAT STAGE 1
COOL STAGE 1
FAN
24 VAC HOT
DEHUMIDIFY
24 VAC COMM
HUMIDIFY
N/A
OUTDOOR
SENSOR
CONNECTION
O/W2
Y1/W2
W/W1
Y/Y2
G
R
DHUM
C
HUM
B S1 S2
40FKA
FAN COIL
W2
Y1
W1
Y/Y2
G R
O
DH
C
HUMIDIFIER
(24 VAC)
OUTDOOR
SENSOR
1-SPEED
AIR CONDITIONER
REMOVE J2 JUMPER FOR HEAT STAGING
Y
REMOVE J1 JUMPER FOR DEHUMIDIFY MODES
C
INDOOR CONTROL
HEAT STAGE 2
HEAT STAGE 1
COOL STAGE 1 COOL STAGE 2
FAN
24 VAC HOT
DEHUMIDIFY
24 VAC COMM
HUMIDIFY
N/A
OUTDOOR
SENSOR
CONNECTION
O/W2
W/W1
Y1/W2
Y/Y2
G
R
DHUM
C
HUM
B S1 S2
40FKA
FAN COIL
W2 W1
Y1
Y/Y2
G R
O
DH
C
HUMIDIFIER
(24 VAC)
OUTDOOR
SENSOR
2-SPEED
AIR CONDITIONER
REMOVE J2 JUMPER FOR HEAT STAGING
Y1 Y2
R
REMOVE J1 JUMPER FOR DEHUMIDIFY MODES
C
A98232
Fig. 9—40FKA Fan Coil with 1-Speed Air Conditioner
sequencer heaters KFAEH2501N09, KFAEH2601F15,
KFAEH2801C15, KFAEH1001F24, KFAEH1101F30; or
relay heaters KFCEH1401N09, KFCEH1501F15, KFCEH1701C15, KFCEH1801F20, KFCEH1901C20, KFCEH2101F24, KFCEH2201F30.
NOTE: Relay heaters are suggested to maximize comfort during defrost.
Complete system low-voltage wiring as shown in Fig. 9, 10, 11, and 12.
NOTE: Where local codes require thermostat wiring be routed through conduit or raceways, splices can be made inside the fan coil unit. All wiring must be NEC Class l and must be separated from incoming power leads.
A factory-authorized disconnect kit is available for installation of 0- through 10-kw applications. When electric heat packages with circuit breakers are installed, the circuit breaker can be used as a disconnect.
Transformer is factory wired for 230-v operation. For 208-v applications, disconnect black wire from 230-v terminal on trans­former and connect it to 208-v terminal. (See Fig. 13.)
The secondary circuit of transformer is protected by a 5-amp fuse mounted on printed-circuit board.
IMPORTANT: Do not use outdoor thermostat with Intelligent Heat.
COMFORT OPTIONS — SUPER COMFORT HEAT AND SUPER DEHUMIDIFY
Super Comfort Heat and Super Dehumidify options are possible when the 40FKA Fan Coil is installed with an outdoor temperature sensor (Comfort Heat only) and the factory supplied Thermidis­tat™ Control. Complete the system low voltage wiring as shown in Fig. 9, 10, 11, and 12.
A98233
Fig. 10—40FKA Fan Coil with 2-Speed Air Conditioner
GROUND CONNECTIONS Use UL listed conduit and conduit connector to connect supply
wire(s) to unit and obtain proper grounding. Grounding may also be accomplished by using grounding lug provided in control box. Use of dual or multiple supply circuits will require grounding of each circuit to ground lugs provided on unit and heaters.
The cabinet must have an uninterrupted or unbroken ground according to NEC, ANSI/NFPA 70 and local codes to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes. Failure to follow this warning could result in an electrical shock, fire, or death.
Step 5—Connect Refrigerant Tubing
This fan coil is supplied with an R-22 TXV factory installed. If installing with a Puron system, the TXV must be replaced using a Puron (R-410A) TXV unit. See outdoor unit literature for correct Kit number.
See Dimensional Drawing for tube connection sizes, type, and locations. Use accessorytubing package orfield-supplied tubing of refrigerant grade. Insulate entire suction tube if field-supplied tubing is used. Tubing package has an insulated suction tube. Do not use damaged, dirty, or contaminated tubing because it may plug refrigerant flow control device. When tubing package is used and sweat connections are made within 60 sec, coil and tubing system does not require evacuation. Always evacuate if field­supplied tubing is used.
A brazing shield MUST be used when tubing sets are being brazed to the unit connections to prevent damage to the unit surface.
8
INDOOR CONTROL
40FKA
FAN COIL
1-SPEED
HEAT PUMP
SECONDARY
RVS COOLING
HEAT STAGE 3
HEAT STAGE 2
HEAT/COOL
STAGE 1
FAN
24 VAC HOT
DEHUMIDIFY
24 VAC COMM
HUMIDIFY
RVS HEATING
OUTDOOR
SENSOR
CONNECTION
O/W2
Y1/W2
W/W1
Y/Y2
G
R
DHUM
C
HUM
B S1 S2
O W2
W1
Y/Y2
G
R
Y1
DH
C
HUMIDIFIER
(24 VAC)
OUTDOOR
SENSOR
REMOVE J2 JUMPER FOR HEAT STAGING
REMOVE J1 JUMPER FOR DEHUMIDIFY MODES
O
W2
Y
R
C
A98234
Fig. 11—40FKA Fan Coil with 1—Speed Heat Pump
BRN RED
C
208
230
YEL BLK
PRIMARY
A94067
Fig. 13—Transformer Connections
2. Insert tube into sweat connection on unit until it bottoms.
3. Solder with low-temperature 430°F silver alloy solder.
Wrap a wet cloth around rear of fitting to prevent damage to factory-made joints.
4. Evacuate coil and tubing system if connections are not made within 60 sec or tubing package is not used.
INDOOR CONTROL
RVS COOLING
HEAT/COOL
STAGE 1
HEAT STAGE 3
HEAT/COOL
STAGE 2
FAN
24 VAC HOT
DEHUMIDIFY
24 VAC COMM
HUMIDIFY
RVS HEATING
OUTDOOR
SENSOR
CONNECTION
O/W2
Y1/ W2
W/W1
Y/Y2
G
R
DHUM
C
HUM
B S1 S2
40FKA
FAN COIL
O Y1
W1
W2
Y/Y2
G
R
DH
C
HUMIDIFIER
(24 VAC)
OUTDOOR
SENSOR
2-SPEED
HEAT PUMP
REMOVE J2 JUMPER FOR HEAT STAGING
REMOVE J1 FOR DEHUMIDIFY MODES
W2
W3
O
Y1
Y2
R
C
A98235
Fig. 12—40FKA Fan Coil with 2—Speed Heat Pump
To prevent damage to thermostatic expansion valve, remove sensor bulb from vapor tube while brazing or soldering vapor connections.
Units have sweat suction and liquid tube connections. Make suction tube connection first.
1. Cut tubing to correct length.
Step 6—Condensate Drain
Units are equipped with primary and secondary 3/4-in. FPT drain connections. For proper condensate line installation see Fig. 4, 6, 7, and 8. To prevent property damage and achieve optimum drainage performance, BOTH primary and secondary drain lines should be installed and include properly sized condensate traps. (See Fig. 14 and 16.) Be sure to install plastic push-in plugs in unused condensate drain fittings. It is recommended that PVC fittings be used on the plastic condensate pan. Do not over-tighten. Finger-tighten plus 1-1/2 turns. Use pipe dope.
Shallow running taps are inadequate and DO NOT allow proper condensate drainage. (See Fig. 15.)
NOTE: When connecting condensate drain lines, avoid blocking filter access panel. Prime both primary and secondary condensate traps after connecting to drain pan.
NOTE: If unit is located in or above a living space where damage may result from condensate overflow, a field-supplied external condensate pan should be installed underneath the entire unit, and a secondary condensate line (with appropriate trap) should be run from the unit into the pan. Any condensate in this external condensate pan should be drained to a noticeable place. As an alternative to using an external condensate pan, some localities may allow the running of a separate 3/4-in. condensate line (with appropriate trap) to a place where the condensate will be notice­able. The owner of the structure must be informed that when condensate flows from the secondary drain or external condensate pan, the unit requires servicing, or water damage will occur.
Install traps in the condensate lines as close to the coil as possible. (See Fig. 16.) Make sure that the outlet of each trap is below its connection to the condensate pan to prevent condensate from overflowing the drain pan. Prime all traps, test for leaks, and insulate traps if located above a living area.
9
UNIT
2 1⁄4
2 1⁄4
DO NOT USE SHALLOW RUNNING TRAPS!
A95321
Fig. 14—Recommended Condensate Trap
PRIMARY TRAP
(FIELD-SUPPLIED
TRAP REQUIRED)
Fig. 16—Condensate Trap and Unit
Condensate drain lines should be pitched downward at a minimum of 1 in. for every 10 ft. of length. Consultlocal codes for additional restrictions or precautions.
Never operate unit without a filter or with filter access door removed. Damage to blower motor or coil can result.
IMPORTANT: Factory authorized filters must be used when locating the filter inside the unit. (See Table 2.) For those applications where access to an internal filter is impractical, a field-supplied filter must be installed in the return duct system.
A95320
Fig. 15—Insufficient Condensate Trap
FILTER ACCESS PANEL
SECONDARY DRAIN (FIELD-SUPPLIED TRAP REQUIRED)
A98239
Step 8—Easy Select Configuration Taps (Detail for Quick Reference Guide on back page.)
EASY SELECT taps are used by the installer to configure a system. ICM2 motor uses the selected taps to modify its operation to a pre-programmed table of airflows. Airflows are 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. 19 and 17.)
The 40FKA 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 label located next to select pins), move the 6 select wires to the pins which match the components used.
Table 2—Filter Kits
PART NUMBER SIZE USED WITH
FILTER KIT
(12 PACK)
Step 7—Unit Start-Up
Refer to outdoor unit Installation Instructions for system start-up instructions and refrigerant charging method details.
KFAFK0212MED 002,
KFAFK0312LRG 003, 005
KFAFK0412XXL 006
AUX HEAT KW/CFM – SELECT HEATER RANGE FOR SIZE OF ELECTRIC HEATER INSTALLED
Installer must select the auxiliary heat airflow approved for application with kw size heater installed. If no heater is installed, this step can be skipped. 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. The heater installed must fall within the range selected 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
10
SEC1 SEC2
EASY SELECT
AUX HEAT KW/CFM
0-30
0-20
1075
VIO
036 030 024 018
BLU
AC
ORN
AC/HP CFM ADJUST
NOM HI
BLK
09030900
WHT
YEL
CEBD430226-01B CESS430226-01B
0-10
875
725
AC/HP SIZE
SYSTEM TYPE
HP-COMFORT
LO
ON/OFF DELAY
0
CONTINUOUS FAN
MED HI YELLO
HEATER/MOTOR
TM
0-5 625
HP-EFF
ENH
J1
J2
AUX1 HUM1
AUX2
24VAC
GRY
HUM2
D
W W
Y/Y
H
R
1
2
Y
1
2
G O C
ELECTRIC HEAT CONNECTOR
12-PIN MATE-N-LOCK
Fig. 17—PCB Wiring Arrangement
electric heat is the primary heating source. In heat pump heating mode when electric heaters are energized, the ICM2 will run the higher of heat pump heating airflow and electric heater airflow to ensure safe heater operation. The factory selection is the largest heater range approved. (See Fig. 19, A as indicated.)
AC/HP SIZE – SELECT SYSTEM SIZE INSTALLED The factory setting for air conditioner or heat pump size is the
largest unit meant for application with the model of fan coil purchased. Installer needs to select air conditioner or heat pump size to ensure that airflow delivered falls within proper range for the size unit installed. This applies to all operational modes with the exception of electric heat modes. (See Fig. 19, B as indicated.)
A95276
SYSTEM TYPE – SELECT SYSTEM TYPE INSTALLED AC OR HP
The type of system must be selected:
1. AC — Air conditioner
2. HP-COMFORT — Provides approximately 315 CFM per ton for higher normal heating air delivery temperature. Provides approximately 350 CFM per ton cooling airflow for good humidity removal.
3. HP-EFF — Provides same airflow for heating and cooling modes; approximately 350 CFM per ton.
The factory setting is AC. (See Fig. 19, C as indicated.)
11
AC/HP CFM ADJUST – SELECT MEDIUM, LOW, OR HIGH AIRFLOW
To provide airflow at rates described above, the AC/HP ADJUST select is factory set to the nominal (nom) tap. The adjust selections HI/LO will regulate airflow supplied for all operational modes, except non-heat pump heating modes, +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. 19, D as indicated.)
ON/OFF DELAY – SELECT DESIRED TIME DELAY PRO­FILE
Four motor operation delay profiles are provided to customize and enhance system operation. (See Fig. 19, E as indicated)
Selection options are:
1. The standard 90 sec off delay (Factory setting) at 100 percent airflow.
2. No delay option used for servicing unit or when a thermostat is utilized to perform delay functions.
3. A 30 sec on delay with no airflow/90 sec off delay at 100 percent airflow profile is used when it is desirable to allow system coils time to heat-up/cool-down in conjunction with the airflow.
4. ENH, enhanced selection, provides a 30 sec on delay with no airflow/ plus 150 seconds at 70 percent airflow/no off delay for added comfort. (This profile will minimize cold blow in heat pump operation and could enhance system efficiency.)
CONTINUOUS FAN — SELECT DESIRED FAN SPEED WHEN THERMOSTAT IS SET ON CONTINUOUS FAN
1. LO speed — factory setting, 50 percent cooling mode airflow
2. MED speed — move connector to MED, 65 percent cooling mode airflow.
3. HI speed — move connector of HI, 100 percent cooling mode airflow. (See Fig. 19, F as indicated.)
LOW-VOLTAGE CIRCUIT FUSING AND REFERENCE The low-voltage circuit is fused by a board-mounted 5-amp
automotive fuse placed in series with the transformer SEC2 and the R circuit. The C circuit of the transformer is referenced to chassis ground through a printed circuit run at SEC1 connected to metal standoff marked with ground symbol.
BASIC FAN COIL CONFIGURATION The following basic configuration of the fan coil will provide the
ARI rated performance of the heat pump.
1. AUX HEAT KW/CFM — Select the heater range for the size electric heater installed.
2. AC/HP SIZE — Select system size installed.
3. SYSTEM TYPE — Select system type HP-EFF.
4. AC/HP CFM ADJUST — Select NOM.
5. ON/OFF DELAY — Select 0/90 profile.
6. CONTINUOUS FAN — Select desired fan speed when thermostat is set to continuous fan.
COMFORT OPTIONS — SUPER COMFORT HEAT AND SUPER DEHUMIDIFY MODES
Super Comfort Heat and Super Dehumidify options are possible when the 40FKA Fan Coil is installed with an outdoor temperature sensor and the factory supplied Thermidistat™ Control (Comfort
Heat only; Super Dehumidify does not require an outdoor tem­perature sensor). The following fan coil configuration is recom­mended for maximum heating and cooling/dehumidifying com­fort:
NOTE: The 40FKA Fan Coil provides better than average hu­midity control and heated air temperature. This configuration will improve the comfort provided by the heat pump system if more humidity removal or if warmer heating air is desired. While providing this improved comfort, the heat pump system will operate efficiently, but not at the published ARI SEER or HSPF efficiencies.
If the installed heat pump system uses Puron refrigerant, the fan coil configuration below will provide excellent comfort, but DO NOT activate the indoor control Comfort Heat configuration option. Excessive use of the PressureGuard device could result in its premature failure.
1. AUX HEAT KW/CFM — Select narrrowest heater range to match size of electric heater installed (skip this step if no heater is installed).
2. AC/HP SIZE — Select system size installed.
3. SYSTEM TYPE — Select system type HP-COMFORT (for heat pump system) or AC (for air conditioner system).
4. AC/HP CFM ADJUST — Select LO.
5. ON/OFF DELAY — Select ENH profile.
6. CONTINUOUS FAN — Select desired fan speed when thermostat is set to continuous fan.
7. If the fan coil is installed with Intelligent Heat Staging capable electric heaters, remove jumper J2.
NOTE: If configuring to run Super Comfort Heat, do not remove jumper J2 when using 5-, 8-, or 10-kw heaters.
8. Remove jumper J1 to activate dehumidify modes.
9. Wire low voltage connections for Comfort Options as shown in Figs. 9, 10, 11, and 12.
10. Configure Thermidistat (or other Super Dehumidify/Super Comfort Heat capableindoor control) following its installation instructions for Super Dehumidify and Super Comfort Heat operation.
This configuration provides the following comfort enhancements:
a. A 30 second blower on delay with 150 seconds at 70
percent airflow to allow the indoor coil to warm up or cool down before the blower is asked to deliver 100 percent airflow reducing the cold blow sensation at start up in heating and allowing the indoor coil to more quickly reach wet coil operating conditions in cooling.
b. No blower off delay eliminates cold blow which may be
associated with running the blower after shut down of the compressor and avoids re-evaporation of condensed mois­ture after cooling/dehumidifying operation.
c. Lower airflow while the compressor is running to reduce
draft effects and increase heating air temperature and improved humidity control during cooling operation.
d. Intelligent Staging of the electric heater elements to more
closely match heating load requirements and provide more consistent heating air temperatures.
12
HUMIDISTAT
HUM 1
(C)
HUM 2
(G)
24-VAC
HUMIDIFIER WIRING
TO HUMIDIFIER
A95317
Fig. 18 — Humidifier Wiring
Step 9—ACCESSORY INSTALLATION
ACCESSORY ELECTRIC HEATERS Electric heaters may be installed with the 40FKA Fan Coil per
instructions supplied with the electric heater package. NOTE: It is not necessary to cover the opening for accessory
heaters. The unit will perform properly without this opening covered.
ELECTRONIC AIR CLEANER CONNECTIONS Because the ICM2 blower motor used in the 40FKA Fan Coil is
controlled by low-voltage signals, a switched 230-vac electronic air cleaner power signal is not available. This signal is replaced by a 24-vac signal which is provided at PCB terminals AUX1 and AUX 2 (See Fig. 17 and 19.) This signal is present whenever the G thermostat signal is present (heat pump heating, cooling and continuous blower modes). When the 40FKA Fan Coil is installed with an electronic air cleaner, use EAC relay kit Part No. KFAIR0201ACR or a field supplied 24-vac relay.
NOTE: The 40FKA blower operates in some modes without a G signal. If the 40FKA Fan Coil is installed with an air conditioner and electic heat isthe primary sourceof heat, install a thermostat which turns on the G output with a call for heat or a corporate thermostat with its "fan on with W operation" enabled to energize an air cleaner or humidifier through the AUX and HUM outputs of the Easy Select PC board. Alternately an airflow sensor may be installed with the air cleaner.
HUMIDIFIER CONNECTIONS Terminals HUM1 and HUM2 are provided for direct connection to
the low-voltage control of a humidifier through a standard humi­distat. (See Fig. 17.) These terminals are energized with 24vac when G thermostat signal is present. (See Fig. 18.) Alternately, the 24-vac signal may be sourced from the W and C terminal block connections when electric heaters are used as the primary heating source. When using a Thermidistat™ Control the 24-vac signal may be sourced directly from the HUM terminal. (See Figs. 9, 10, 11, and 12.)
Step 10—40FKA Fan Coil Sequence Of Operation
The 40FKA will supply airflow in a range which is more than twice the range of a standard fan coil. It is designed to provide nominal cooling capacities at a 50°F evaporator temperature and the required airflow which enables it to match with 4 air condi­tioner or heat pump system sizes. Table 1 outlines the CFM range for the different 40FKA Fan Coil sizes.
Table 1–CFM Range for 40FKA Units
FAN COIL SIZE SYSTEM SIZES CFM RANGE
40FKA002 018, 024, 030, 036 450-1275 40FKA003 024, 030, 036, 042 525-1475 40FKA005 030, 036, 042, 048 550-1700 40FKA006 036, 042, 048, 060 550-2150
CONTINUOUS FAN
1. Thermostat closes circuit R to G The blower runs at continuous fan airflow.
COOLING MODE — SINGLE SPEED OR 2-SPEED HIGH
1. Thermostat closes circuits R to G, R to Y/Y2 and R to O The fan coil delivers single speed cooling airflow.
2. Thermostat closes circuits R to G, R to Y1, R to Y2 and R to O The fan coil delivers 2-speed high cooling airflow.
COOLING MODE — 2-SPEED LOW
1. Thermostat closes circuits R to G, R to Y1 and R to O The fan coil delivers 2-speed low cooling airflow.
COOLING MODE — DEHUMIDIFICATION
1. Thermostat or Thermidistat closes circuits R to G, R to O, and R to Y/Y2 (or R to Y1 for 2-speed low), and humidistat or Thermidistat opens R to DH The fan coil delivers airflow which is approximately 80 percent of the nominal cooling airflow to increase the latent capacity of the system.
COOLING MODE — SUPER DEHUMIDIFY OPERATION NOTE: The indoor control used, such as a Thermidistat, must be
capable of providing Super Dehumidify operation mode and control must be configured as outlined in its installation instruc­tions. Consult indoor control literature to determine if control is capable and for configuration instructions.
1. If the indoor temperature is below the temperature set point and the humidity is greater than the humidity set point, the Thermidistat closes circuit R to O, opens circuits R to DH and R to G, and cycles circuit R to Y/Y2 (for single speed system R to Y1, or R to Y1 and Y/Y2 for 2-speed system).
The ICM2 motor reads the G signal to the fan coil while the heat pump is operating, circuit R to Y/Y2 for single speed system, R to Y1 or R to Y1 and Y/Y2 for 2-speed system, closed (24 vac). If circuit R to G is closed (24 vac), the motor will deliver airflow at the full cooling or cooling plus dehumidify mode requested value. If circuit R to G is open (0 vac) for super dehumidify mode, the motor delivers reduced airflow to maximize the humidity removal of the system while minimizing overcooling.
ELECTRIC HEAT HEATING MODE
1. Thermostat closes circuit R to W/W1, or W2 The fan coil delivers the selected electric heat airflow.
HEAT PUMP HEATING MODE — SINGLE SPEED OR 2-SPEED HIGH
1. Thermostat closes circuits R to G and R to Y/Y2 The fan coil delivers single speed heat pump heating airflow.
2. Thermostat closes circuits R to G, R to Y1 and R to Y/Y2 The fan coil delivers 2-speed high heat pump heating airflow.
HEAT PUMP HEATING MODE — 2-SPEED LOW
1. Thermostat closes circuits R to G and R to Y1 The fan coil delivers 2-speed heat pump heating low airflow.
HEAT PUMP HEATING WITH AUXILIARY ELECTRIC HEAT
1. Thermostat closes circuits R to G, R to Y/Y2 and/or R to Y1 with R to W/W1 or W2 (and R to O in the case of defrost)
In the event that electric heating is called for by the thermostat while the heat pump is also operating in either heating or defrost modes, the motor will modify its airflow output, if necessary, to provide an airflow which is defined as safe for the operation of the electric heater during heat pump operation. That airflow is the greater of the heat pump heating airflow and the electric heater only airflow.
13
HEATING MODE — COMFORT HEAT OPERATION NOTE: The indoor control used, such as a Thermidistat, must be
capable of providing Comfort Heat operation mode and control must be configured as outlined in its installation instructions. The system must be installed with appropriate outdoor temperature sensor. Consult indoor control literature to determine if control is capable and for configuration instructions. Consult indoor control instructions and sensor instructions for sensor installation details.
1. If the outdoor temperature is in the range of 10° to 40°F, the Thermidistat closes circuit R to Y/Y2 (for single speed system R to Y1, or R to Y1 and Y/Y2 for 2-speed system) and opens circuit R to G.
The ICM2 motor reads the G signal to the fan coil. If circuit R to G is closed (24 vac), the motor will deliver airflow at the full heating requested value. If circuit R to G is open (0 vac) for maximum heating comfort, the motor delivers reduced airflow to maximize the temperature and minimize the draft effect of the heated air leaving the fan coil.
CARE AND MAINTENANCE
For continuing high performance, and to minimize possible equipment failure, it is essential that periodic maintenance be performed on this equipment. The only required maintenance that may be performed by the consumer is filter maintenance.
Disconnect all power to unit before servicing field wires or removing control package. The disconnect (when used) on access panel does not disconnect power to the line side of disconnect, but does allow safe service to all other parts of unit. If unit does not have a disconnect, disregard the foregoing. Instead, make sure that a disconnecting means is within sight from, and is readily accessible from, the unit. Disconnect all electrical power to unit before performing any maintenance or service on it. A failure to follow this warning can cause electrical shock, fire, personal injury, or death.
The minimum maintenance requirements for this equipment are as follows:
1. Inspect and clean or replace air filter each month or as required.
2. Inspect cooling coil, drain pan, and condensate drain each cooling season for cleanliness. Clean as necessary. An inspec­tion port is provided on all A-coil delta plates. Remove plastic plug to inspect.
3. Inspect blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.
4. Inspect electrical connections for tightness and controls for proper operation each heating and cooling season. Service as necessary.
Consult fan coil service manual available from equipment distribu­tor for maintenance procedures.
As with any mechanical equipment, personal injury can result from sharp metal edges, etc, therefore, care should be taken when removing parts.
Using Owner’s/User Manual furnished in outdoor unit, the install­ing technician should explain to the consumer system operation with particular emphasis on indoor fan coil operation sounds and filter maintenance.
14
15
QUICK REFERENCE GUIDE
COMFORT HEAT PUMP SET-UP INSTRUCTIONS
LOW VOLTAGE TERMINAL BLOCK
SEC1 SEC2
EASY SELECT
AUX HEAT KW/CFM
0-30
0-20
1075
A
B
C
D
E
F
VIO
BLU
ORN
BLK
WHT
YEL
875
AC/HP SIZE
036 030 024 018
SYSTEM TYPE
HP-COMFORT
AC
AC/HP CFM ADJUST
NOM HI
ON/OFF DELAY
09030900
CONTINUOUS FAN
MED HI YELLO
CEBD430226-01B CESS430226-01B
HEATER/MOTOR
TM
0-10
0-5
725
625
HP-EFF
LO
ENH
0
MOLEX 12-PIN CONNECTOR
J1
J2
AUX1 HUM1
AUX2
24VAC
GRY
HUM2
D
W W
Y
Y/Y
G O
EASY SELECT BOARD
1. Configuration Taps (See Installation Instructions, for detailed description.)
H
R
1
A. AUX HEAT - Set for heater size (Ex: 0-10 for 10 kw) B. AC/HP SIZE - Set for size of outdoor unit C. SYSTEM TYPE - Select "HP COMFORT" D. AC/HP CFM ADJUST - Select "LO"
1
E. ON/OFF DELAY - Select "ENH" F. CONTINUOUS FAN - Leave on "LO"
2
2. Install heater with Intelligent Heat Staging, and remove Jumper J2, except when using 5-, 8-, or 10-kw heater.
3. Remove Jumper J1 to activate all dehumidify modes.
4. Complete wiring and install outdoor temperature sensor according
2
to Installation Instructions.
THERMIDISTAT™ CONTROL SETTINGS
C
1. Set "DIP Switches" - Set the dip switches appropriate for the specific system being installed.
2. Thermidistat Control Configurations (See Thermidistat™ Control Installation Instructions for detailed description.)
• Option 5 (Variable Speed Motors) - set to ON
• Option 7 (Super Dehumidify) - set to ON
• Option 9 (Intelligent Heat) - set to ON if installing with a single speed heat pump
• Option 12 (Heaters during Defrost) - setting "2" is suggested for all heaters
• Option 16 (Super Comfort Heat) - set to ON for R-22 systems. For Puron applications, set to OFF.
Fig. 19—40FKA Printed CIrcuit Board with Comfort Heat Pump Set-up Guide
A98290
Copyright 1998 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 40fk1si
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4 Tab 2e 3d
PC 101 Catalog No. 534-021 Printed in U.S.A. Form 40FK-1SI Pg 16 5-98 Replaces: New
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