ICP FCV2400C2, FCV3600C2, FCV4800C2, FCV6000C2 Installation Instructions And Owner's Manual

INSTALLATION
INSTRUCTIONS

Models

FCV2400C2
FCV3600C2

FCV4800C2

FCV6000C2

Requires

AMF001NHA

Accessory No Heat Kit

Use ONLY factory listed electric heaters.

General Information / Installation ............ 2

Upflow Installations ........................ 3

Horizontal Installations ..................... 3

Ductwork Connections ..................... 3

Filter Installation ........................... 4

Condensate Drain .......................... 5

Refrigerant Lines ........................... 5

Electrical Connections ...................... 6

Motor Speeds and Airflow ................... 7

Blower Performance ........................ 9

Checks and Maintenance ................... 10

Wiring Diagram ............................ 11

Replacement Parts ......................... 12

Variable Speed Fan Coils

SafetyLabelingand SignalWords

Danger,Warning and Caution

The signal words DANGER, WARNING and CAUTION

are used to identify levels of hazard seriousness. The
signal word DANGER is only used on product labels to

signify an immediate hazard. The signal words WARN-
ING and CAUTION will be used on product labels and

throughout this manual and other manuals that may ap-

ply to the product.
DANGER - immediate hazards which WILL result in se-

vere personal injury or death.
WARNING - Hazards or unsafe practices which

COULD result in severe personal injury or death.
CAUTION - Hazards or unsafe practices which COULD

result in minor personal injury or product or property
damage.

Signal Words in Manuals

The signal word WARNING is used throughout this

manual in the following manner:

The signal word CAUTION is used throughout this

manual in the following manner:

CAUTION

Product Labeling

Signal words are used in combination with colors and/or
pictures on product labels.

PrintedinU.S.A. 496 01 4109 02

June 2002

_ Installation Instructions

FigUre Dimensions and Clearances

14-3/8" (2 Ton)
17-7/8" (3 Ton)

/8" (4 / 5 Ton)

Fan Coils ]

Filter Door

42"

(2&3 Ton)

52"

(4-5 Ton)

_F 21 1/2"

./ W

16-3/8 (2 Ton)_

19-7/8 '' (3 Ton) BottomReturnAirOpening

27-1/8 '' (4 / 5 Ton) 141/2X20 2Ton

18X20 3Ton

251/4X20 4-5 Ton

8 1/2"

38-20-17

GeneralInformation

Installation or repairs made by unqualified persons can
result in hazards to you and others. Installation MUST

conform with local building codes and with the
National Electrical Code NFPA70 current edition.

The information contained in this manual is intended
for use by a qualified service technician familiar with

safety procedures and equipped with the proper tools
and test instruments.

Failure to carefully read and follow all instructions in
this manual can result in equipment malfunction,
property damage, personal injury and/or death.

The blower cabinet may be used for cooling or heat pump opera-
tion with or without electric heat. Installations without electric

heat, require a No Heat Kit.The cabinet can be installed in an up-
flow or horizontal position (Figure 2, 3). Horizontal installations

CLEARANCES

NO HEATERS

All Sides .................................. 0"

From Supply Duct .......................... 0"

Recommended Service From Front .......... 20"

(Service for blower, filter if installed)

WITH HEATERS

All Sides .................................. 0"

From First Three

Feet of Supply Duct to Combustibles ........ 1"

From Duct after Three Feet ................. 0"

Recommended Service From Front .......... 20"

(Service for blower, filter, heaters if installed)

Fire Hazard

When heaters are installed maintain clear-
ances from combustible materials as speci-

fied on unit rating plate. Do not use plastic
lined or combustible flexible ducting within 36

inches of the supply end of the air handler.

Failure to do so can result in fire, property
damage, personal injury and/or death.

require a horizontal kit. Some models are shipped with the hori-
zontal kit already installed .These units are not shipped with air fil-

ters installed. Filter must be field supplied, either washable or
disposal type. Washable filters are available as an accessory.

Location

Select the best position which suits the installation site conditions.
The location should provide adequate structural support, space in

the front of the unit for service access, clearance for return air and
supply duct connections, space for refrigerant piping connections

and condensate drain line connections. If heaters are being
installed make sure adequate clearance is maintained from sup-
ply ductwork, See Clearances and Warning in Figure 1.

NOTE: Internal filter can be accessed from separate filter door. If
the filter can NOT be easily accessed, a remote filter is recom-

mended. Refer to ACCA Manual D for remote filter sizing.

Ifthe unit is located in an area of high humidity, nuisance sweating
of casing may occur. On these installations a wrap of 2" fiberglass
insulation with a vapor barrier should be used.

_J 496 01 4109 02

Fan Coils

UpflowInstallations

The unit is ready to install in the upflow position without modifica-
tions.

The unit MUST be supported on the bottom ONLY and set on a
supporting frame or shelf. Use screws through the bottom to an-

chor to supporting frame.

Figule 2 I

Airflow Positions

UPFLOW POSITION

HEAll_R

o O_

RLTER 38-20-19

Non-DuctedReturn Air Closet Installation

The cabinet can be installed in a closet with a false bottom to form
a return air plenum, or mounted on an open platform inside the

closet. Platform should be high enough to provide a free (open)
area for adequate return airflow into the bottom of the cabinet.

The open area can be on the front side or a combination of front
and sides, providing there is clearance on the sides between cabi-

net and closet. Refer to ACCA Manual D for sizing and free

area recommendations.

NOTE: Local codes may limit application of systems without a

ducted return to single story dwellings.

Horizontal Leftand RightInstallations

Units that are shipped with the horizontal drain pan installed are

set up for horizontal left hand airflow. They must have the drain
pan repositioned for right hand airflow. All other units must have

the horizontal drain pan kit installed for either left or right hand ap-
plications. For installation of the drain pan, refer to the installation

instructions included with the horizontal drain pan kit, and the fo!-
lowing.

CAUTION

Afield-fabricated auxiliary drain pan, with a seperate drain is

REQUIRED for all installations over a finished living space or
in any area that may be damaged by overflow from the main

drain pan. In some localities, local codes require an auxiliary
drain pan for ANY horizontal installation.

Drain Pan Installation / Conversion for Right Hand Airflow

See Figure 4

1. Remove coil access panel and carefully pull Coil/Horizon-
tal Drain Pan Assembly out.

2. Separate horizontal drain pan from coil drain pan. The coil
drain pan fits snuggly inside the horizontal pan.

Installation Instructions ]

Figure 3

Airflow Positions

HORIZONTAL LEFT POSITION

,,=,

HORIZONTAL RIGHT POSITION

,,=,

m

38-20-19

3. Position side of coil drain pan into horizontal drain pan
trough on deep end of pan on right side of coil.

4 Remove coil drip flanges from A-coil and reinstall on right

side of coil (same side as horizontal drain pan).

5. Remove the coil support bracket from the left side of the
cabinet and reinstall bracket on the right side of the cabinet.

6. Install drain plugs as required in back side of horizontal
drain pan. Install plugs in A col! drain pan to prevent air

leaks.

7. Slide coil assembly into cabinet being careful not to tear in-
sulation.

NOTE: Be sure A coil pan fits into the support bracket on the back
side of the cabinet and that pan is under the flange of the bracket

on the right side. The brackets fit over the top edge of the A coil
drain pan to hold it when it's put into the horizontal position.

8. Refer to Restrictor Orifice Selection and change restrictor if
necessary, then install coil access panel.

Cabinet can now be placed on it's side for horizontal airflow.

SuspendedCabinetInstallation

1. The cabinet may be supported on a frame or shelf, or it may
be suspended.

2. Use metal strapping or threaded rod with angle iron sup-
ports under the auxiliary drain pan to suspend cabinet.

These supports MUST run parallel with the length of the
cabinet (Figure 5 ).

3. Ensure that there is adequate room to remove service and
access panels after installing supporting brackets.

4. Place Styrofoam blocks in auxiliary drain pan to support
cabinet.

DuctConnections

SupplyDuct

Supply duct must be attached to the outside of flange on outlet
end of unit. Flexible connectors may be used if desired. Maintain

clearances from supply duct to combustibles when heaters are
installed. See Figure 1 and unit rating plate.

ReturnDuct

Return duct should be attached to bottom of unit using sheet met-

al screws or other fasteners.

496 01 4109 02 3L_

_ Installation Instructions

FigUre 4 Horizontal Drain Pan

Fan Coils I

Drip Flange mounts to
top two holes in coil plate

Coil Access Panel

Horizontal Drain Pan
(Left Hand Airflow)

Coil Support Bracket

(Right Hand Airflow)

\

Filter Door

Drip Flanges
(Left Hand Airflow)

Drip Flanges
(Right Hand Airflow)

il Support Bracket

Coil Support Bracket

(Left Hand Airflow)

--_ Plug drains

on back side

Horizontal Drain Pan
(Right Hand Airflow)

38-20-06

FilterInstallation

Filters must be field supplied. The blower cabinet is set up for an
internal filter or a remote filter grille or other means may be pro-

vided. Refer to ACCA Manual D for remote filter sizing.
To install an internal filter, remove screw securing filter door and

slide filter into unit. Some filters are marked for airflow direction,
make sure arrow points towards blower if marked. Washable fil-

ters are offered as an accessory. Disposable filter sizes are listed

in Filter Static Pressure Drop Table.

Figure 5 Horizontal Installation

S MUST II I h Field'FabricatedDrainPan

upports runpara e wit blowercabinet =_-o=

_J 496 01 4109 02

I Fan Coils Installation Instructions

CondensateDrainConnections

The unit is provided with 3/4" National Pipe Thread (NPT) con-
densate drains. (Figure 1). Any drain can be used as a primary or

secondary drain depending on the fitting used. Condensate drain

lines should be installed in a manner that does not obstruct ac-

cess to the filter.
There is a secondary drain fitting supplied with the unit that will

convert any of the primary condensate drain connections into a
secondary drain connection. This fitting should be installed in any

of the primary drain connections to convert itto a secondary drain.

Figule 6 Condensate Drain Fittings

Secondary
Drain Fitting Primary Drain

(small hole) Fitting

1. Connect the drain lines to the appropriate drain fittings. 3/4"
PVC or other type of drain line may be used. The drain line

must not be smaller than the drain fitting.

2. Install a trap in the drain line below the bottom of the drain
pan and pitch the drain lines down from the coil at least I/4"

per foot of run. Horizontal runs over 15 feet long must also
have an anti-siphon air vent (stand pipe), installed ahead

of the horizontal run. An extremely long horizontal run may

require an oversized drain line to eliminate air trapping.

3. Routetotheoutsideor toafloor drain, laundrytrayorwaste
line (sewer). Check local codes before connecting to a

sewer line.

4. Insulate drain lines where sweating could cause water

damage.

5. If a gravity drain cannot be used, install a condensate

pump. Install the pump as close to the indoor section as
possible.

Waste Line Connection

If the condensate line is to be connected to a waste line, an open

trap must be installed ahead of the waste line to prevent escape of
sewer gases. NEVER CONNECT THE DRAIN LINE DIRECTLY

TO A WASTE LINE. ALWAYS INCLUDE AN AIR GAP AND
TRAP, (Figure 7). Be sure to keep the trap filled with water during

the winter or off season.

,oureJ

Condensate Drain to Waste Line

Air Gap Above

uid Level

Condensate

Line

Trap

Sewer Li_

RefrigerantLineConnections

Size refrigerant lines according to information provided with out-
door condensing unit. Route the refrigerant lines to the coil in a

manner that wil! not obstruct service access to the unit or removal
of the filter.

1. Remove rubber plugs from refrigerant connections using a
pulling and twisting motion. Hold refrigerant lines to avoid

bending or distorting.

2. Remove the coil door before brazing refrigerant connec-

tions to prevent damage to paint finish.

3. Fit refrigerant lines into coil connections and remove the
tubing plate and slide plate over the refrigerant lines to as-

sure sufficient room for brazing.

4. Reinstall tubing plate and door and install the gasket, pro-
vided with the unit, over the suction and liquid lines into the

tubing plate recess to ensure an air seal around the coil.

See Figure 8.

Figule8 I Refrigerant Lines

Gasket ,,_

Refrigerant k_ne_s__ "

.%

j Tubing Plate

Recessed

Area

For Gasket

496 01 4109 02 5[_