Carrier 40FS User Manual

r«) 11 w<0 11

Carrier Corporation • Syracuse, N.Y. 13221

Fan Sections and Accessory Electric Heaters

CONTENTS

SAFETY CONSIDERATIONS MODULAR SYSTEM

INTRODUCTION..................................................2,3

INSTALLATION...................................................3-9

Step 1 — Inspect Equipment Step 2 — Determine Position of Unit by

Airflow Direction.................................................. 3

Step 3 — Assemble Required Unit Step 4 — Connect Ductwork to Unit Supply and Return Air Openings Step 5 — Insulate Ductwork Step 6 — Install Accessory Cooling Control Kit (cooling-only applications) ... 9 Step 7 — Install Accessory Humidity Control Kit (28TQ applications only)

ELECTRICAL DATA AND WIRING ..................9-16

Step 8 — Install Branch Circuit

Disconnect Switch(es) per NEC .........................9

Step 9 — Route Line Power Leads

into Unit

................................................................

Step 10 — Connect Ground Leads Step 11 — Set Fan Motor Speed(s) Step 12 — Connect Control Power

Wiring (24-v)

.......................................................

START-UP........................................................... 16

FAN SECTION SERVICE

ELECTRIC HEATER SERVICE.......................... 17

^ Table 1 — Physical Data and Dimensions

MODEL 40FS OPERATING WT (lb) 60 65 72 FAN

Rpm, 60 Hz

Air Discharge Nominal Cfm

PSC Motor — Hp

DIMENSIONS (ft-in.)

Length A Width B Height C

DUCT INLET (ft-in.)

DUCT OUTLET (ft-in.)

FILTER (1-in. thick)*

No.

Size (in.)

PSC — Permanent Split Capacitor *40FS units factory equipped with permanent fi Iter and reversible rack with

s/s-in. duct connection flange.

075 1 120 ! 160 200 220

625-800

(2-speed)

Upflow-

Horizontal

750 Mo

2-0’Me

D E

F G

...........................

..............................

...................

.....................

................................

..................

...................................

(Fig. 1)

Centrifuga

(1-speed)

Upflow

l-llMe

— Direct Dr

1-9%

-lOMe

1-7

1-178

800

(3-s

Upflow-[

Hori

1250

1-7%

975

1150

1 1

0-97s

21x24V4 I 21x203/4 | 21x24V4

-1100

peed) lownflowzontal

1750 1 2000

9,10

% 1 1

2-0’Me

1-11’/Í6

Page

. 2

3-7 7,8

40FS FAN SECTION SUPPLY AIR

■

CLEARAtjeSHOLEP (AONEAGMDE) FOR ATTACHING ELEC. HE.?çte AND C0ÛM3 COI OR FI LTÉ® SECTION »

■ ^FILTER RACK MAY BE TURNED OVER TO PROVIDE EXTERNAL |-IN. DUCT CONNECTION FLANGE.

DUCT CONNECTION „7FLANGE (SUPPLY AIR) O/'^s

f HOLE FOR

CONTROL WIRING

OPENING

k /

HEATER ACCESS DOOR

I HOLE FOR

LINE POWER

/WIRING

ALTERNATE

(INTERNAL) .

, POSITION OF I

FILTER SECTION FLANGES*

FILTER

'SECTION

PULL RINGS FOR

-FILTER MEDIA REMOVAL

q¿'(40FS9I6,40FQ9I6,

' ■^I638HQ9000)

. OR

2-04 (40FS920,40FQ920,

—/ 38HQ900I)

0'-9"

l| HOLE WITH CONCENTRIC

KO'S: .

I'i,

FOR POWER WIRING

ELECTRIC HEATERS

(All 38HQ, 40FS,FQ Models except 40FS916320CD

thru JR, 40FS916500EH, GM and HV)

(40FS916320CD thru JR, 40FS916500 EH, GM and HV)

Certified dimension drawings are available on request.

Fig. 1 — Dimensions and Connections

Carrier Corporation 1983

Form 40FS-11SI

SAFETY CONSIDERATIONS

Installation and servicing of air conditioning equipment can be hazardous due to system pres sure and electrical components. Only trained and qualified service personnel should install, repair or service air conditioning equipment.

Untrained personnel can perform basic mainte nance functions of cleaning coils and filters and replacing filters. All other operations should be per formed by trained service personnel. When working on air conditioning equipment, observe precautions in the literature, tags and labels attached to the unit and other safety precautions that may apply.

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations.

Table 2 — Height Dimensions of Assembled Units

MODULAR UNIT ASSEMBLIES

Cooling and Heating Unit

Cooling Unit 1 —

—

Coil

28H0036020

28HQ042030 28HQ048020

28H0042020

28HQ048020

28HQ060020 28VQ060020 28TQ060

28HQ036020 28VQ036020 28HQ042030

28HQ048020 28HQ042020

28HQ048020 28HQ060020 28VQ060020

-»

—

- — - -

*Total height may vary slightly depending on electric heater model used. fLength dimension of assemblies in the horizontal position are same as

height dimension of units assembled for upflow airflow.

iAII height dimensions include 40FS filter section.

28VQ036020 28VQ042030

28VQ048030 28VQ042020

28VQ048020

28TQ042

280X036 280X042

— — —

28VQ042030

28VQ048030 28VQ042020

28VQ048020

- - - -

— — —

- - -

— — —

- -

W.ARMNCi: llefore performing service or maintenance operations on unit, turn off main power switch to unit. Turn off accessoi\ healer power switch if applicable, filectrical shock

could cause personal injury.

MODULAR SYSTEM INTRODUCTION

Field assemble the required 28 Series directexpansion (encased) coil and/or 40FS,40FQ,38HQ accessory electric heater to 40FS fan section. Combine fan section and coil for a split system fan coil; fan section and accessory electric heater for an electric furnace; fan section, coil and electric heater for a heating and cooling unit. (See Table 2 for total height dimension of assembled units.)

Heating Unit

Fan Section

■ -

28VH002/004 40FS075/1 20 28VH002/004 40FS075/120

40FS160

40FS200

40FS200.220

40FS160 40FS160

40FS200

40FS200.220

40FS160

40FS200.220

**For use with 38HQ227 and 234 only. ttTotal height for 28QX coil with fan section and electric heater. NOTE: 020.030 denotes dimensional variation within 28HQ/VQ models. Refer to 28HQ/VQ literature for exact dimensions.

TOTAL HEIGHT'i (ft-in.)

Airflow

Upflow

Elec Heater

40FS,FO916

38HQ9000**

40FS.F0916

38HQ9000**

40FS91 6,920

40F0920

38H09001*

40FS91 6,920

40FQ920

38H0900T*

—

40FS,FO916

38H09000**

40FS916,920

40FO920

38HQ9001**

40FS920EH

(or Horizontal)t

3-11’^X6

SM,

4- 3=46 5- OVsft

4- 7’4e

3- 3=46 3-10’/4

7Va

3-1IV,6 3-11V,6

2-4=46

4- 7Ve

— 3-1IV,6 —

Downflow

4- OVe

7Va

4- 3=46 5- 0%tt

4- 8’46

3- 4=46 3-10%

3- 7%

—

Table 3 — Installation and Usage Data (See Modular System Introduction, Page 3)

COIL

FAN

SECTION

40FS075 28VH002 40FS120 28VH004

40FS160

40FS200, 40FS220Í

Upflow

280X036, 280X042

*Electric heater for use with 208/230 V, 40FS units only. Refer to Electrical

Data and Wiring, Table 4, for fan section/electric heater usage and com plete electric heater model numbers.

(Draw-Thru Airflow)

Upflow,

Downflow

Upflow

28VQ036, 28VQ042

28VO042, 28VO048, 28V0060

Horizontal

28VH002t

— —

28HO036, 28HO042

28H0042, 28H0048, 28H0060, 280X036, 280X042

Upflow,

Downflow,

Horizontal

28TQ042

28TO048, 28T0060

ELECTRIC HEATER*

(Blow-Thru Airflow)

Upflow, Downflow, Horizontal

208V

40FS920300EH 7.5 40FS920300EH 7.5

40FS916300 6 - 18.8 8-25 40FS916320 40FS916500

40FO916

38HQ9000**

40FS920300 40FS916320 40FS916500

3.75-15

7.5-22.5 6-18.8

6-15

7.5-22.5

3.75-15

7.5-22.5

40FQ920 7.5-22.5 10-30

38HQ9001**

7.5-18.8

fHorizontal application not recommended for Weathermaster IV system. iModel 40FS220 not for use with 28QX coil.

**For use with 38HQ227 and 234 only.

Heating

240 V

10.0

10.0 Fig. 2, 3

Unit

Fig. 2, 3

5-20

10-30

8-25

8-20

10-30

Fig. 2, 3

5-20

10-30

10-25

UNIT ASSEMBLY

POSITION

Cooling

Unit

Fig. 4

except dow

Heating and

Cooling Unit

iflow —

Fig. 4 Fig. 5

Fig. 5

Models 28VQ,HQ coils and 40FS heaters are for use in cooling-only and/or cooling and electric

heating systems. The 28VQ and HQ coils are also for use in heat pump systems with 38HQ or 40FQ electric heaters. Model 28TQ coil is for installation in 38TQ 2-speed heat pump systems. The 28QX coil is for solar-assisted heat pump systems. The 28VH coil application is with Model 40FS075 only.

Fan section, coil and electric heater are tested

and approved for installation in unconditioned

space per ARI Standard (80 F db, 75 F wb indoor temperature; 80 F db outdoor temperature). Insu

late supply and return air ductwork in uncondi tioned space. If conditions exceed the ARI Stand ard, additional insulation with vapor barrier may

be required for the unit.

Fan Sections 40FS can be positioned to discharge

air upward (upflow), horizontally, or downward

^(downflow), except for sizes 075, 120 which cannot

be used in downflow applications, and are suitable for “Attic-Type” installations.

The 28 Series Coils are approved as draw-thru

(airflow) units only with the 40FS fan section. Install

coils in draw-thru position; heater in blow-thru position. Therefore, coil must be attached to air inlet end of fan section. As indicated in Table 3, per missible coil airflow position(s) in system are: 28TQ — upflow, downflow or horizontal; 28VQ — upflow or downflow; 28HQ — horizontal; 28QX — upflow or horizontal; 28VH002 — horizontal or

^upflow with 40FS075 only, upflow with 40FS120

only.

Assembly of coils to 40FS fan section, electric heater and filter section is described in this booklet. For further coil information, see 28 Series installa tion data.

COIL CONDENSATE DRAINAGE (for any unit assembly installed above an occupied or usable space) — In addition to normal condensate drain line connection, install an auxiliary condensate pan under entire unit assembly. Route drain line to any drain that is visible to occupant. In 28 VH coil appli cations, only the drain pan needed should be used. See 28VH Installation Instructions.

Under prolonged high humidity conditions, elimi

nator plates may be required on downflow applica

tions. Horizontal coil installation may also require

special condensate removal methods. See Coil In stallation Data.

Accessory Electric Heater is used with 40FS,

208/230-volt fan section. See Electrical Data and Wiring table for fan section/electric heater usage.

Use electric heater as a blow-thru unit only by

attaching heater to air discharge end of 40FS fan section in any of the 3 positions. Electric heater has both heating and cooling controls including a 40-va or 60-va control circuit transformer, indoor fan relay and low-voltage terminal strip.

MODELS 40FS916320 AND 40FS916500EH,

GM AND HV — These heaters are approved for downflow usage but require the use of adapters (downflow support angles) to support fan section weight. See Installation, Heating Unit Assembly.

Filter Section is shipped taped to air inlet end of

fan section. Filter section includes a reversible filter rack with 5/8-in. duct connection flanges. On

most unit assemblies the filter section can be attached to unit with flanges exposed or turned over

so flanges are inside unit. The permanent one-in. filter media pulls out (Fig. 1) for easy removal and cleaning.

Cooling Control Kit is an accessory for 40FS,

208/230-volt fan sections used in cooling-only in stallations. The kit contains a 40-va transformer, fan deck filler panels, indoor fan relay and low-voltage terminal strip. See Fig. 11, and cooling control kit installation on page 9. Because accessory electric heaters come equipped with cooling controls listed above (plus required heating controls), a cooling control kit is not required when electric heater is used. An accessory humidity control kit is required for use in 28TQ 2-speed installations. See Step 7

and Fig. 12.

INSTALLATION

Step 1 — Inspect Equipment — File claim with

shipping company if shipment is damaged or incomplete.

Step 2 — Determine Position of Unit by Air

flow Direction — See Table 3 and Fig. 2, 3, 4 and

5. Ensure access panels on all units face front before

and after unit assembly.

Step 3 — Assemble Required Unit — Follow

assembly procedure below for required unit. On downflow unit assemblies, loosen or remove fan

motor mounting bolts and rotate fan motor so

oiling holes are a minimum of 45° above horizontal center line of motor.

Fasteners for assembling units are shipped in a bag inside of fan section or inside electric heater enclosure. Use the no. 10 serrated hex head sheet metal screws (or equivalent) provided, where indi cated in unit assembly instructions below, to ensure proper electrical ground continuity.

( .\l NON: \ll coil'« iiiii'l be applied draw-ihru

and l1e:ller.^ blow-ihiii v\heii eombining

HEATING UNIT ASSEMBLY (Fig. 2)

Electric Heater Models except 40FS916320. 40FS916500EH. GM and HV. and 40FS916500LW and PA when used with fan sections 40FS075.

-»40FS120. 40FS200 and 40FS220 — Position fan section for upflow air direction. (Accessory flange deck40FS900391 or40FS900401 required.) Setelectric heater on air discharge end of fan section. Attach heater to fan section with 5 no. 8-32 self threading screws provided. Clearance holes for screws are provided on each side (2) and hack (1) of fan section and engagement holes on heater.

Electric Heater Models 40FS916320. 40FS916330

and 40FS9165Q0EH. GM and HV — Position fan section for upflow air direction. Mount heater on fan section supply air duct connection flanges, and attach with 4 sheet metal screws. Four clearance holes for screws, provided on heater cabinet, can be used as template for drilling engagement holes in duct flanges as required. See Fig. 3. Assembly may be aided by first removing top flange deck from fan section (2 screws hold flange deck in place). Assembled heater and flange deck can then be resecured to fan section. Reposition plug buttons

and rubber grommet positions in top flange deck to accommodate heater fan leads. Install door air seal strip on fan deck along front edge of heater.

Electric Heater Models 40FS916500LW. and PA used with Fan Sections 40FS200 and 40FS220 — Position fan section for upflow air direction. Assemble flange deck according to instructions shipped with accessory. Mount heater on fan section supply air duct connection flanges; attach with 3 no. 8-32 self-threading screws and bracket provided as shown in Fig. 3.

On all heating unit assemblies, attach filter section to air inlet (return) end of fan section. The filter section can be mounted with its 5/8-in. duct connection flanges inside or outside of fan section. Filter section is held in place with 4 screws and speed nuts provided. See Fig. 6. Clearance holes for screws are provided on each side of filter section. Speed nuts provide engagement holes on each side of fan section.

To position heating unit for horizontal airflow, simply place assembled unit on either left or right side with access panels at front. Position Model

40FS075 horizontally only with the motor above the scroll as shown in Fig. 4.

For a downflow heating unit, turn assembled unit

over so fan discharges downward thru electric heater. Remove fan section access panel. Turn access panel so Carrier nameplate is in upright position and replace panel on fan section.

CAU’IION: The electric heater modeK 4ii! II. (I\l. Il\ and 401

are appro\ed for downflow but w ill not support fan section weight. When assembled unit is used in downlliiw piisilmn. iiiNtall aCi.eNMii\ i|h\m;- llow Niippuri ;ingle' li)l b‘J0l).14l tiisiippoii Ian weight as describeil in Downllow Support .Angles below.

Downflow Support Angles

1. Position fan-heater combination for upflow

arrangement (Fig. 3). Remove screws (4) secur ing fan cover; remove and set aside cover.

2. Remove tie angle. Save screws “A” (2).

3. Install accessory fan deck filler panels as de scribed in instructions shipped with accessory. Assembly is similar to filler panels on accessory cooling control kit. See Step 6 and Fig. 11.

4. Position support angles on fan section as shown in Fig. 11. Reinstall screws “A” securing support angles and flange deck to fan wrapper.

5. Using screws “B” supplied, attach each angle to corresponding fan side flange. Holes in side flanges are clearance holes.

6. Using remaining hole in each angle as a guide drill a .128 in. diameter hole in front flange of flange deck. Install screws “C” (supplied) in these holes to attach angles to front flange.

NOTE: All 3 screws are required in each angle for proper unit stability.

7. Using the 4 screws removed in step 1, reattach fan cover so that Carrier nameplate is upside down. Fan-heater assembly is now ready to be

inverted so that when installed in final loca tion, nameplate will be right-side up.

The electric heater is equipped with heating controls as described in Modular System Intro duction. See Electrical Data and Wiring for wiring details.

COOLING UNIT ASSEMBLY — Be sure 28 Series coil is assembledin recommended airflow position;

DRAW-THRU AIRFLOW

Upflow

28TQ.28VQ, 28QX.28VH 28TQ,28VH

Coil casing on most models has sheet metal screw engagement holes for assembly to fan section. When engagement holes are not provided, carefully drill holes where required.

Upflow and Horizontal Cooling Unit — Position fan section for upflow air direction and coil in upright position as shown in Fig. 4, page 6. Set fan section on top of cooling coil casing. Attach fan section to coil casing with 5 no. 10 hex head sheet metal screws provided. Clearance holes for screws

are provided on each side (2) and back (1) of fan section and engagement holes in sides and back of coil casing. (Drill engagement holes as required).

Before attaching filter section to air inlet (return)

end of coil casing, remove return air duct flange from coil casing. Be sure to install secondary con densate tray with lip over edge of condensate pan (28HQ only). The filter section can be mounted with its 5/ 8-in. duct connection flanges inside or outside of coil casing. Filter section is held in place with 4 screws and speed nuts provided (Fig. 6). Engage ment holes for screws are provided by speed nuts on each side of coil casing. Drill engagement holes in each side of coil casing as required.

Use cooling unit as assembled above for hori

zontal airflow. To position unit for horizontal airflow, place unit on its right side by turning it clockwise 90°.

Downflow Cooling Unit — Install as accessory downflow base under fan section to provide a “firebreak” in accordance with UL requirements. This base, which is a heater enclosure with no heating components in it, is shown in Fig. 4. Install base in the same manner as the heater as described previously in Heating Unit Assembly. Also see Fig. 2. The bases are used as follows;

FAN SECTION

40FS160300 40FS900220 40FS200300 40FS900230 40FS220300

Turn fan section (only) over so fan discharges downward. Remove return air duct flange from coil casing. Place coil, in an upright position, on air inlet end (top) of fan section. Attach coil casing to fan section with 4 no. 10 hex head sheet metal

screws provided. Clearance holes for screws are provided in each side of fan section and engage ment holes on sides of coil casing. (Drill engage ment holes as required).

Downflow

28TQ.28VQ

Horizontal

28HQ,28QX,

USES BASE

40FS900230

Set filter section on top of coil section with filter flanges overlapping coil flanges. Drill 1/8-in. holes thru coil and filter flanges, and fasten together with sheet metal screws provided. Do not drill into filter support rack. See Fig. 6.

Remove fan section access panel. Turn access panel so Carrier nameplate is in upright position and replace panel on fan section.

An accessory cooling control kit is required for 208-230-volt upflow, horizontal or downflow cooling units described above. See cooling control kit installation. An accessory humidity control package is required for use with the 28TQ coil in 2-speed applications. See 28TQ installation data.

HEATING AND COOLING UNIT ASSEMBLY — Attach electric heater to fan section as described

under Heating Unit Assembly. However, before attaching filter section, proceed as follows:

Upflow and Horizontal Heating/Cooling Units — Position heating unit assembly (Fig. 2, 3) for

upflow air direction and coil in upright position as shown in Fig. 5 and 7. Set heating unit assembly on top of cooling coil casing. Attach heating unit assembly to coil casing with 5 no. 10 hex head sheet metal screws provided. Clearance holes for screws

are provided on each side (2) and back (1) of fan

section, and engagement holes in side and back of

coil casing. (Drill engagement holes as required).

Before attaching filter section to air inlet (return) end of coil casing: remove return air duct flange from coil casing. Be sure to install secondary con

densate tray with lip over edge of condensate pan (28HQ only). The filter section can be mounted with its 5/8-in. duct connection flanges inside or

outside of coil casing. Filter section is held in place with 4 screws and speed nuts provided (Fig. 6).

Engagement holes for screws are provided by speed nuts on each side of coil casing. Drill engagement holes in each side of coil casing as required.

Use cooling and heating unit as assembled above for horizontal airflow. To position unit for hori zontal airflow, place unit on its right side by turning it clockwise 90°.

Downflow, Heating/Cooling Unit —^ When 40FS916320, or 40FS916500EH, GM, or HV heaters are used in this assembly, install accessory downflow support angles 40FS900241 to support fan section/coil weight as described on page 3. Turn fan section/electric heater assembly (Fig. 2, 3) over

so fan discharges downward thru electric heater.

Remove return air duct flange from coil casing.

UPFLOW

airflow direction

HORIZONTAL DOWNFLOW

*ALL HEATER MODELS EXCEPT 40FS9I6320,40FS9I6330 AND 40FS9I6500 LW AND PA. SEE FIG. 3

Fig. 2 — Heating Unit Assembly

Fig. 4 — Cooling Unit Assembly

AIRFLOW DIRECTION

♦ heater 40FS9I6320 AND 40FS9I6500 EH,GM AND HV SHOWN INFIG.3

Fig. 5 — Heating and Cooling Unit Assembly

Place coil, in an upright position, on air inlet end (top) of fan section. Attach coil casing to fan section with no. 10 hex head sheet metal screws provided. Clearance holes for screws are provided on each side of fan section and engagement holes on sides of coil casing. (Drill engagement holes as required).

Set filter section on top of coil section with filter flanges overlapping coil flanges. Drill 1/8-in. holes thru coil and filter flanges and fasten together with sheet metal screws provided. Do not drill into filter support rack. See Fig. 6 and 8,

Remove fan section access panel. Turn access panel so Carrier nameplate is in upright position and replace panel on fan section.

The electric heater is equipped with heating controls and cooling system controls as described in Modular System Introduction. See Electrical Data and Wiring, page 9, for wiring details.

Ductwork — Air Ducts should be installed in

accordance with the Standards of the National Fire Protection Association, NFPA numbers 90A and 90B in compliance with paragraph 46.1-E of the UL Standard 1096.

All 40FS units with accessory electric heaters

are suitable for installation with 0-in. clearance

from heater cabinet, discharge plenum and duct

work to combustible materials with the following exceptions: When using 40FS920300PA (30 kw).

+ 12 hidden pages

Carrier 40FS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY CONSIDERATIONS

MODULAR SYSTEM INTRODUCTION

INSTALLATION