Carrier FV4BNB006000, FV4BNF005000, FV4BNF003000, FV4BNF002000 Installation Guide

Installation Instructions

Fan Coil for Puron® Refrigerant

002,003, 005, 006

FV4B

A98023

Fig. l--Model FV4B

NOTE: Read the entire instruction manual before starting the installation. This symbol -_ indicates a change since the last issue.

SAFETY CONSIDERATIONS

hnproper 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 fi_ctolT-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 and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instrnctions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and National Electrical Code

(NEC) for special requirements. Recognize safety information. This is the safety-alert symbol z_ • When you see this symbol on the unit and in instructions manuals, be alert to

the potential for personal inju W.

Understand the signal words DANGER, WARNING, CAUTION, and NOTE. 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

Form: IM-FV4B-02 Cancels: IM-FV4B-01 Printed in U.S.A. 6-03 Catalog No. 63FV-4B1

injury or death. CAUTION is used to identi_ unsafe practices which would 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.

z_x WARNING: Before installing or servicing unit, 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.

INTRODUCTION

Model FV4B Fan Coil units are designed for flexibility and can be used for upflow, horizontal, or downflow (kits required and manufactured and mobile home) applications. These units are designed specifically for Puron (R-410A) and must be used only with Puron air conditioners and heat

pumps as shipped.

These units are designed to meet the low air leak requirements currently in effect. Because of this, the units need special attention in the condensate

pan and drain connection area and when brazing tubing. These units are available lbr application in systems of 24,000 through 60,000 Btuh nominal cooling capacities. Factory-authorized, field-installed

electric heater packages are available in 5 through 30 kw. See Product Data for available accessory kits.

INSTALLATION

PROCEDURE 1--CHECK EQUIPMENT

Unpack unit and move to final location. Remove carton taking care not to damage unit.

Inspect equipment for damage prior to installation. File claim with shipping company if shipment is damaged or incomplete. Locate unit rating

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

PROCEDURE 2--MOUNT FAN COIL

Unit can stand o1" lie on floor, o1"hang from ceiling o1"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 the alterative of running 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.

FV4B Fan Coils can be installed lbr upflow and horizontal-left applications as _actory shipped. (See Fig. 2, 4 and 8.) Units can be installed for horizontal-right applications with field modifications. Units may be converted for downflow applications using _actory-authorized accessory kits.

NOTE: To ensure proper drainage for horizontal installations, unit must be installed so it is within i/8 in. level of the length and width of unit.

A. Upflow Installation

It"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 nmst pass through the coil. (See Fig. 2.)

B. Modular Units

The FV4B Fan ('oil 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. 3.)

To disassemble unit, remove rear comer brackets by removing 2 screws which secure brackets. (See Fig. 3.) Remove either 2 screws in each fi'ont corner of coil box, or 2 screws in blower box. Do not remove all 4 screws in each corner. (See Fig. 3.) 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.

C. Horizontal Installations

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

i. Arrange support for unit by setting it in or above secondary condensate pan.

2. When suspending unit t'rom ceiling dimples in casing indicate proper location of screws for mounting metal support straps. (See Fig. 4.)

D. Horizontal-Right Conversion of Units with Slope Coils

NOTE: Gasket kit number KFAHD0101SLP is required for horizontal slope coil conversion to maintain low air leakdow sweat pertbrmance.

i. Remove blower and coil access panels and fitting panel. (See Fig. 5.)

2. Remove screw securing coil assembly to right side casing flange.

3. Remove coil assembly.

4. Lay _an coil on its right side and reinstall coil assembly with condensate pan down. (See Fig. 5.)

5. Attach coil to casing flange using previously removed coil mounting screw.

6. Make sure the pan cap in the fitting door is properly seated on the fitting door to retain the low air leak rating of the unit.

7. Add gaskets from kit KFAHD per kit instructions.

8. 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.

002-005 21-IN.

006 24-1N. FRONT SERVICE

UPFLOW/_

POWER ENTRY --&

OPTIONS

CLEARANCE

__(S FIELD SUPPLIED

SUPPLYDUCT

.....

UNIT A I

003 19 In.

PRIMA_

UPFLOW/DOWNFLOW

SECONDARY DRAIN

UPFLOW/DOWNFLOW

PRIMARY DRAIN

Fig. 2--Slope Coil Unit in Upflow Application

[

EWS

FIELD MODIFIED

A SIDE RETURN

LOCATION FOR SLOPE COIL UNITS ONLY

FIELD SUPPLIED

RETURN PLENUM

A00091

BRACKET

Fig. 3--Modular Unit Assembly

E. Horizontal Right Conversion of Units With A-Coil

To convert units for horizontal right installations:

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

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.

5. Remove horizontal &ain pan support bracket from coil support rail on left side of unit and reinstall on coil support rail on right side of unit.

A95293

LOW VOLT ENTRY

OPTIONS

POWER ENTRY OPTIONS

FIELD

FRONT SERVICE 002-005 21-IN.

CLEARANCE (FULL FACE

I I OF UNIT)

FILTER ACCESS CLEARANCE

PRIMARY

SECONDARY

DRAIN

Fig. 4---Slope Coil in Horizontal-Left Application (Factory Ready)

006 24qN

1 3/4 IN

RIMARY

DRAIN

A00096

COIL MOUNTING BLOWER

ASSEMBLY

COIL

SUPPORT

RAIL

SLOPE COIL

SKI

DRAINPAN

REFRIGERANT CONNECTIONS

SECONDARY DRAIN

Fig. 5--Slope Coil in Horizontal Right Application

6. Convert air-seal assembly for horizontal right. a. Remove air-seal assembly from coil by removing 4 screws. (See Fig. 6.)

b. Remove air splitter (B) from coil seal assembly by removing 3 screws. (See Fig. 6-_actory-shipped inset.)

c. Remove filler plate (A) and install air splitter (B) in place of filler plate. d. Install filler plate (A) as shown in horizontal right application. e. Remove condensate troughs ((7) and install on opposite tube sheets. f. Install hose onto plastic spout.

7. Install horizontal pan on right side of coil assembly.

A03001

SUPPORT

RAIL

BRACKET

DRAIN

SUPPORT

BRACKET

SUPPORT

RAiL

BRACKET

PRIMARY

HORIZONTAL RIGHT

SECONDARY DRAIN HORIZONTAL RIGHT

CONNECTIONS

DRAIN PAN

*_ HORIZONTAL

RIGHT

APPLICATION

Fig. 6--A-Coil in Horizontal-Right Application

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 con'ectly position and secure coil assembly in unit. Be sure clip with large of I;et is used on right side of unit

to secure horizontal pan.

i0. Remove two oval fitting caps from left side of the coil, access panel, and fitting panel.

11. Remove insulation knockouts on right side of coil access panel

12. Remove 2 oval coil access panel plugs and reinstall into holes on left side of coil access panel and fitting panel.

13. Install condensate pan fitting caps (from Step 10) in the right side of the coil door making sure that the cap snaps and seats cleanly on the back side of the coil door. Make sure no insulation interferes with seating of the cap.

14. 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.

F. Downflow Installations

A00071

z_ CAUTION: The conversion of the fan coil to downflow requires special procedures for the condensate drains on both

A coil and Slope units. The vertical drains have an overflow hole between the primary and secondary drain holes. This hole is plugged for all applications except downflow, but must be used for downflow. During the conversion process, remove the

plastic cap covering the vertical drains only and discard. Remove the plug from the overflow hole and discard. At completion of the downflow installation, caulk around the vertical pan fitting to door joint to retain the low air leak performance of the

unit. Failure to follow this CAUTION could result in personal injury or product and property damage.

In this application, field conversion of the evaporator is required using accessory downflow kit along with an accessory base kit. Use fireproof resilient gasket, 1/8- to 1/4-in. thick, between duct, unit, and floor.

NOTE: To convert units lbr downflow applications, refer to Installation Instructions supplied with kit for proper installation. For slope fan coils, use kit Part No. KFADC0201SLP. For A fan coils use kit Part No. KFADC0401ACL. Use fireproof resilient gasket, 1/8- to ii4-in, thick, between

duct, unit, and floor. NOTE: Gasket kit number KFAHD0101SLP is also required for all downflow applications to maintain low air leak.low sweat performance.

G. Manufactured and Mobile Home Housing Applications

l. Fan coil unit must be secured to the structure using field-supplied hardware.

2. Allow a minimum of 24" clearance from access panels.

3. Recommended method of securing lbr typical applications a. If fan coil is away from wall, attach pipe strap to top of_an coil using No. 10 self tapping screws. Angle strap down and away from back

of fan coil, remove all slack, and _asten to wall stud of structure using 5/16-in. lag screws. Typical both sides of _an coil.

b. If _an coil is against wall, secure fan coil to wall stud using 1/8-in. thick right-angle brackets. Attach brackets to Pan coil using No. i0

self tapping screws and to wall stud using 5/16-in. lag screws. (See Fig. 7.)

4" MAX

SECURE FAN COIL TO STRUCTURE

UNIT AWAY FROM WALL PIPE STRAP

(TYPICAL BOTH SIDES)

"'x OR

UNIT AGAINSTWALL 1/8-1NTHICK ANGLE

MOUNTING BRACKET

(TYPICAL BOTH SIDES)

_ i DOWN FLOW

PROCEDURE 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 seal duct-to-unit joint. Duct connection flanges are provided on unit air discharge connection. When using FV4B units with 20-, 24-, and 30-kw electric heaters, maintain a 1-in. clearance from combustible materials to discharge plenum and

ductwork for a distance of 36 in. from 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 nmst be insulated and

covered with vapor ban'ier. Ductwork Acoustical Treatment

Metal duct systems that do not have a 90 ° elbow and 10 ft of main duct to first branch takeoff may reqnire interual acoustical insulation lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of 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.

PROCEDURE 4--ELECTRICAL CONNECTIONS

On units with a factory installed disconnect with pull-out removed, service and maintenance can be safely performed on only the load side of the

control package.

z_ WARNING: Field wires on the line side of the disconnect found in the fan coil unit remain live, even when the pull-out

is removed. Service and maintenance to incoming wiring can not be performed until the main disconnect switch (remote to the unit) is turned off. Failure to do so will result in electrical shock causing personal injury or death.

4" MAX Fig. 7--A-Coil

-- BASE KIT (KFACB)

_._ SECURE UNITTO FLOOR

ANGLE BRACKETOR PIPESTRAP

A02003

A. Line-Voltage Connections

If unit contains an 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.)

For units without electric heat:

i. Connect 208/230v power leads from field disconnect to yellow and black stripped leads.

2. Connect ground wire to unit ground lug.

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

z_x WARNING: 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.

z_ WARNING: 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 nmst have a separate branch electric circuit with a field-supplied disconnect switch located within sight from,

and readily accessible from the unit.

FACTORY SHIPPED -- BRACKET

HORIZONTAL LEFT

APPLICATION 4_.

HORIZONTAL

DRAIN PAN

AIR SEAL HORIZONTAL LEFT ASSEMBLY SECONDARY DRAIN

REFRIGERANT

CONNECTIONS

COIL

SUPPORT

RAIL

DRAIN PAN

SUPPORT

BRACKET

COIL

BRACKET

PRIMARY DRAIN

HORIZONTAL LEFT

Fig. 8---A-Coil in Horizontal Left Application (Factory Ready)

B. 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 mininmm) 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 color-coded, insulated (35°C minimum) wires. PCB is circuited for single-stage heater operation. When additional heater staging is desired using outdoor thermostats or Intelligent Heat Staging, remove Jnmper J2 on PCB to enable staging.

Connect low-voltage leads to thermostat and outdoor unit. (See Fig. 9, 10, 11, or 12.)

C. Intelligent Heat Staging Option

Intelligent Heat staging of the electric heat package is possible when the FV4B is installed as a part of a single-speed heat pump system using a corporate 2-speed programmable thermostat (model TSTATXXP2S01-B), Thermidistat TM Control, or capable zoning control and any 1 of the

following electric heat packages: Relay heaters KF(TEH 1401N09, KFCEH 1501F 15, KFCEH 1701C 15, KFCEH 1801 F20, KFCEH 1901 C20, KFCEH2101 F24, OR KFCEH2201F 30.

Complete system low-voltage wiring as shown in Fig. 9, 10, 11, or 12. NOTE: Where local codes require thermostat wiring be routed through conduit or raceways, splices can be made inside the tim coil unit. All

wiring must be NEC Class 1 and must be separated l}om incoming power leads. A _actory-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 fi_ctory wired for 230-v operation. For 208-v applications, disconnect black wire l}om 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 Staging.

--_ D. Manufactured Housing

In manufactured housing applications, the Code of Federal Regulations, Title 24, Chapter XX, Part 3280.714 requires that supplemental electric heat be locked out at outdoor temperatures above 40 deg. F. except for a heat pump defrost cycle. A corporate thermostat in conjunction with an

outdoor sensor can be used to lock out supplemental heat above 40 deg. F. Refer to thermostat instructions for details. Ifa non-corporate thermostat is used, an outdoor thermostat may be reqnired.

E. Ground Connections

A00072

z_ WARNING: The cabinet must have an uninterrupted or unbroken ground according to NEC, ANSI/NFPA 70 and local

codes to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes. (See Ground/Conduit Note below.) Failure to follow this

warning could result in an electrical shock, fire, or death.

NOTE: Use UL listed conduit and conduit connector to connect supply wire(s) to unit and obtain proper grounding. If conduit connection uses reducing washers, a separate ground wire must be used. Grounding may also be accomplished by using grounding lug provided in control box.

Use of dual or multiple supply circuits will reqnire grounding of each circuit to ground lugs provided on unit and heaters.

PROCEDURE 5--REFRIGERANT TUBING CONNECTION AND EVACUATION

Use accessory tubing package or field-supplied tubing of refrigerant grade. Insulate entire suction tube if field-supplied tubing is used. Tubing package has an insulated suction tube. Do not use damaged, dirty, or contaminated tubing because it may plug refrigerant flow control device. When tubing package is used and sweat connections are made within 60 sec, coil and tubing system does not require evacuation. Ahvays evacuate

coil and field-supplied tubing to 500 microns before opening outdoor unit service valves.

INDOOR CONTROL

HEAT STAGE 2 F_-

N/A

HEAT STAGE 1 _.

COOL STAGE 1 D"

FAN

24 VAC HOT

DEHUMIDIFY F_"

FAN COiL 1-SPEED

.... 4r_ REMOVE J2 JUMPER

D # FOR HEAT STAGING

.... 4i'_'_1 .B--

.... i"E_ "-"i REMOVE

AIR CONDITIONER

L J1 JUMPER

] _" FOR

_r DEHUMIDIFY

.... FTI JM°DES

24 VAC COMM

HUMIDIFY F_-

.....

-----q4HUM'D'F'ERJ

/ (24VAC)/

N/A

OUTDOOR _I_"

SENSOR _

CONNECTIONLI _z I"

Fig. 9--FV4B Fan Coil Wiring with 1-Speed Air Conditioner

INDOOR CONTROL FAN COIL 2-SPEED

HEAT STAGE 2 F_

HEAT STAGE 1

COOL STAGE 1

COOL STAGE 2 F'_"

FAN

24 VAC HOT

DEHUMIDIFY E_

__4OUTDOORli_

"-- SENSOR I

............. J

AIR CONDITIONER

.... ''_ _ REIk!OVEJ2JU!PER

.... ,.E_]_ _b_ FOR HEAT STAGING

....°

REMOVE

] "J1 JUMPER FOR

_r'DEHUMIDIFY

.... I '-_ _1 MODES

A98477

24 VAC COMM

HUMIDIFY I-_'_-I..

N/A

OUTDOORI--I q

SENSOR _

CONNECTIONLI _z f"

Fig. 10--FV4B Fan Coil Wiring with 2-Speed Air Conditioner

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

damage to the unit surface and condensate pan fitting caps. Failure to follow this CAUTION could result in minor personal

injury or product and property damage.

Units have sweat suction and liquid robe connections. Make suction tube connection first.

i. Cut tubing to correct length.

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

3. Braze connection using silver bearing or non-silver bearing brazing materials. Do not use solder (materials which melt below 800°F). Consult local code requirements.

__--q4HUMtDtF'ERJ

| (24VAC) |

._,_4OUTDOORli_

"-- SENSOR I

............. J

A98478

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