Carrier FA4ANF Service Manual
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Carrier FA4ANF Service Manual

Residential fan coil units
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TABLE OF CONTENTS

SAFETY CONSIDERATIONS...................................................2
INTRODUCTION ........................................................................2
UNIT IDENTIFICATION...........................................................2
PRODUCT OFFERING ..............................................................4
FAN MOTOR SPEED TAPS .....................................................4
- CES013003-00 and -01 PCB...............................................2-7
• Unit Functions ............................................................................2
• Troubleshooting PCB ..................................................................4
- HK61GA001 and HK61GA003 PCB .........................6-19
• PCB Component Functions.........................................................7
• Troubleshooting PCB ................................................................11
AND TROUBLESHOOTING..............................................18
• Description of Electric Heater Components.............................19
Electric Heaters.......................................................................20
TROUBLESHOOTING - FK4B .................................20-27
• Integrated Controls and Motor (ICM2) ....................................20
• PCB Layout and Description ....................................................20
• Sequence of Operation ..............................................................21
• Easy Select Configuration Taps................................................22
• Troubleshooting PCB ................................................................25
• Troubleshooting ICM2 ..............................................................25
and Controls ...............................................................................27
• Accessories ................................................................................27
• Integrated Controls and Motor (ICM2) ..................................28
• PCB Layout and Description ..................................................29
• Sequence of Operation ............................................................29
• Easy Select Configuration Taps..............................................32
• Troubleshooting PCB ..............................................................33
• Troubleshooting ICM2 ............................................................33
FK4C, FV4A, 40FKA Motor and Controls.........................33
• Accessories ..............................................................................35
• Problems Affecting TXV ........................................................36
LIQUID TUBE STRAINER ...................................................37
REMOVAL AND REPLACEMENT ..........................37-38
• A-Coil Units ............................................................................37
• Slope Coil Units ......................................................................37
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 03FA-4A3
Tab 3d 2e
Residential Fan Coil Units
Service Manual
Page
FX, FV, 40FKA COIL/CONDENSATE PAN REMOVAL
AND REPLACEMENT ................................................38-40
CARE AND MAINTENANCE...............................................39
• Filter Assembly .......................................................................39
• Blower Motor and Wheel .......................................................40
• Fan Motor ................................................................................40
• Electric Heater Service............................................................40
• Liquid Tube Strainer ...............................................................42
• Sequence of Operation ............................................................42
• Care and Maintenance.............................................................42
• Fan Motor ..................................................................................43
• Electric Heater Service..............................................................43
• Liquid Tube Strainer .................................................................45
• Care and Maintenance...............................................................45
FG3A SERVICE AND TROUBLESHOOTING ....................46
• Service .......................................................................................46
• Maintenance...............................................................................46
• Unit Functions ...........................................................................47
• Smart Heat Operation................................................................48
Printed in U.S.A.
Form F-5SM
Fig. 1-Typical Fan Coil
Pg 1
6-99
A98023
Replaces: F-4SM

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  • Page 1: Table Of Contents

    Residential Fan Coil Units Visit www.carrier.com Service Manual TABLE OF CONTENTS Page SAFETY CONSIDERATIONS...........2 INTRODUCTION ................2 UNIT IDENTIFICATION............2 PRODUCT OFFERING ..............4 FAN MOTOR SPEED TAPS .............4 FA4A, FB4A, FC4B, FF1D, FH4A, AND FX4A CIRCUIT BOARD FUNCTION AND TROUBLESHOOTING — CES013003-00 and -01 PCB..........2-7 •...

  • Page 2: Safety Considerations

    This symbol → indicates a change since the last issue. 2. A 5-amp fuse is used to protect the low-voltage transformer secondary. SAFETY CONSIDERATIONS 3. The fan relay is controlled by thermostat and turns fan on and Improper installation, adjustment, alteration, service, maintenance, off.

  • Page 4: Product Offering

    Table 1—Product Offering MODEL UNIT SIZE DESCRIPTION CABINET FA4ANF 018-060 Multipoise Single Piece FB4ANB 042-070 Multipoise Modular FB4ANF 018-060 Multipoise Single Piece Multipoise FB4ASB 042-060 Modular 50 Hz Multipoise FB4ASF 018-060 Single Piece 50 Hz FC4BNB 042-070 Multipoise Modular FC4BNF...
  • Page 5 VOLTAGE PCB BLOCK WIRING FUSE TIME DELAY FUSE LR40061 FAN RELAY A97020 Fig. 3A—Fan Coil Printed-Circuit Board 3. Check field power leads L1 and L2. If these are not receiving 2. Check sequencer/relay number 1 and plug wiring. Yellow power, system cannot function. wire should be connected to pin number 9 of plug and to limit switch.

  • Page 6: Circuit Board Function And Troubleshooting

    CAUTION: SCHEMATIC DIAGRAM NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND SEE RATING PLATE FOR VOLTS & HERTZ ATTENTION: FIELD POWER WIRING NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE COOLING CONTROLS COMPONENT ARRANGEMENT ELECTRIC HEAT SEE NOTE #1 DISCONNECT PER NEC...

  • Page 7: Pcb Component Functions

    WARNING ELECTRIC SHOCK HAZARD DISCONNECT REMOTE POWER SUPPLY BEFORE OPENING PANEL. PULL TO OPEN RELAY 322861-101 REV. A FF1D CONTROL BOX WARNING ELECTRIC SHOCK HAZARD DISCONNECT REMOTE POWER SUPPLY BEFORE OPENING PANEL. PULL TO OPEN 322861-101 REV. A FF1A/FF1B/FF1C CONTROL BOX A98184 Fig.
  • Page 8 CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING BLOWER MOTOR 150V TO GROUND ATTENTION: ROTATION LEGEND 30KW 1PH SCHEMATIC DIAGRAM CAPACITOR LIMIT SWITCH DISCONNECT PER NEC FIELD POWER WIRING COMMON MARKED TERMINAL SEE RATING PLATE LOW VOLTAGE FUSE PLUG AND RECEPTACLE...
  • Page 9 CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND BLOWER MOTOR ATTENTION: ROTATION NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE SCHEMATIC DIAGRAM COMPONENT ARRANGEMENT FIELD POWER WIRING DISCONNECT PER NEC SEE RATING PLATE...
  • Page 10 HK61GA001 LOW VOLTAGE TERMINAL BOARD 2ND STAGE ELECTRIC HEAT BREAKOFF TABS FOR STAGING 3RD STAGE NOT USED 2FC-1 HK61GA001A FUSE (LOW VOLTAGE) INTERLOCK DIODES PLUG CONNECTIONS AUX1 FOR VARIOUS 24VDC ACCESSORIES AUX2 RELAY TRANSFORMER TRANSFORMER FAN CONNECTIONS CONNECTIONS AC LINE DUMMY DUMMY EAC2...

  • Page 11: Troubleshooting Pcb

    HK61GA003 LOW VOLTAGE TERMINAL BOARD 2ND STAGE ELECTRIC HEAT BREAKOFF TABS FOR STAGING FAN INTERLOCK DIODES AND FAN 3RD STAGE TIME DELAY OFF CIRCUIT FUSE (LOW VOLTAGE) PLUG HK61GA003 CONNECTIONS AUX1 FOR VARIOUS 24VDC ACCESSORIES AUX2 RELAY FAN CONNECTIONS DUMMY TRANSFORMER CONNECTIONS DUMMY...
  • Page 12 LS 6 HTR6 SEQ 3 LS 5 HTR5 LS 4 HTR4 SEQ 2 LS 5 HTR5 LS 2 HTR2 LOW VOLTAGE TERMINAL BOARD SEQ 1 LS 1 HTR1 INDOOR THERMOSTAT 2FC-1 CONNECT E TO E C TO C ETC. GRAY HK61GA001A SEQ1 GRAY...
  • Page 17 LS 4 HTR4 SEQ 2 LS 3 HTR3 LS 2 HTR2 SEQ 1 LS 1 HTR1 TERM BOARD 5 AMP FUSE SEQ1 SEQ2 AUX1 RELAY 240 VDC AUX2 PLUG DUMMY DUMMY AC LINE EAC2 EAC1 COMMON DUMMY 240 VAC 240 VAC COMMON YEL-COMMON RED-LO...

  • Page 18: Electric Heater Function And Troubleshooting

    3. Check power leads L1 and L2. If these are not receiving If the PCB has high-voltage applied to it: power, the system cannot function. 1. Check the low-voltage transformer leads, R and C. Make sure If the PCB has high voltage applied to it: they are wired to the correct location.

  • Page 19: Description Of Electric Heater Components

    BLOWN 2FC-1 DIODE BLOWN DIODE HK61GA001A BLOWN DIODE AUX1 24VDC AUX2 RELAY TRANSFORMER AC LINE DUMMY DUMMY EAC2 COMMON DUMMY COMMON EAC1 240 VAC 240 VAC A97033 Fig. 14—Control Board Noting Diodes Step 1—Description of Electric Heater If a limit switch has been determined to be defective, NEVER Components BYPASS THE LIMIT SWITCH.

  • Page 20: Troubleshooting Kfa, Kfb, Kfc, And Kfd Series Electric Heaters

    The time required for PTC to heat to a sufficient point controls ON NUISANCE TRIPS timing of device. The time required for disc to cool down when 1. Check for low airflow due to dirty filters, blocked registers, or power is removed controls OFF time of device. The PTC can be undersized duct.

  • Page 21: Sequence Of Operation

    DO NOT REMOVE OPTIONAL SAFETY GROUND POWER CONNECTOR 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 CONTROL CONNECTOR OPTIONAL SAFETY GROUND DRAIN HOLE A94079 Fig. 15—FK4B, FK4C and FV4A ICM2 Motor Connection to heater panel is made through 12-circuit connector COOLING MODE—SINGLE SPEED OR 2-SPEED HIGH P1.

  • Page 22: Easy Select Configuration Taps

    LOW VOLTAGE TERMINAL BLOCK EASY SELECT 5 AMP HEAT RANGE 0-30 0-20 0-10 1200 1000 AC/HP SIZE PRINTED CIRCUIT BOARD TYPE HP-COMFORT HP-EFF Y/Y2 AC/HP ADJUST DELAY AC/HP TIME W2-E JUMPER 3RD STAGE MOLEX 7-PIN CONNECTOR (1) MOTOR W2-W3 JUMPER 2ND STAGE GROUND 24VDC...
  • Page 23 HIGH VOLTAGE SEC1 1K 2W AUX1 HUM1 SEC2 AUX2 HUM2 W/W1 1K 2W Y/Y2 QC19 Y/Y2 1K 2W 5 – 30 5 – 20 5 – 10 0 – 5 1200 1000 AUX. HEAT RANGE AC/HP SIZE HP–COM. HP–EFF. AC/HP QC10 QC11 TYPE...
  • Page 24 Table 3—Male/Female Quick-Connect Terminals (FK4B) SIZE FEMALE SIZE MALE DESCRIPTION Motor line voltage connection (230 vac 60 Hz) Transformer line voltage connection (230 vac 60 Hz) Transformer tap storage terminal for 208-vac lead Secondary connection from transformer (24 vac) SEC1 This connection is common to chassis ground through eyelet marked GROUND SCREW REQUIRED.

  • Page 25: Troubleshooting Pcb

    airflow. This profile will minimize cold blow in heat pump If There Are Blown Diodes: operation and could enhance system efficiency. If diodes are blown, it is probable that electric heater plug is 4. ENH, enhanced selection provides a 30 sec on/180 sec off miswired.
  • Page 26 CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND BLOWER MOTOR ATTENTION: ROTATION NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE SCHEMATIC DIAGRAM 30KW 1PH SCHEMATIC DIAGRAM FIELD POWER WIRING DISCONNECT PER NEC DISCONNECT PER NEC...

  • Page 27: Condensed Version Of Troubleshooting Fk4B Motor And Controls

    Table 6—FK4B Motor Control Test Values (With 16-pin connector at motor unplugged) ** VOLTAGES—7-PIN PLUG P2 SCREW TERMINALS OPERATING MODE Y/Y2 HAVING 24 VAC Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Electric Heating 24 vdc 24 vac 1-Speed A/C...

  • Page 28: Fan Coil Description And Troubleshooting - Fk4C, Fv4A, 40Fka

    HUMIDISTAT RED WIRE FROM ICM2 TO PCB TERMINAL MOTOR MARKED 'RED' HUMIDISTAT WIRING FOR DE-HUMIDIFY MODE A93215 Fig. 22—Humidistat Wiring for De-Humidify Mode 22 illustrates the wiring connections to activate de-humidify mode. Carefully consult product airflow data for cooling and dehumidi- fying mode.

  • Page 29: Pcb Layout And Description

    OPTIONAL SAFETY GROUND DRAIN HOLE POWER CONNECTOR 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 DRAIN HOLE CONTROL CONNECTOR OPTIONAL SAFETY GROUND CONTROL POWER ENDSHIELD DRAIN HOLE A98201 Fig. 23—FK4C, FV4A, and 40FKA ICM2.3 Motor Step 10—PCB Layout and Description AC/HP CFM Adjust—(Black Wire) AC/HP Time Delay—(Grey Wire)
  • Page 30 ® YYWWX 5 AMP. SEC1 SEC2 MAX. EASY SELECT AUX/HEAT KW/CFM 0-30 0-20 0-10 1075 AC/HP SIZE SYSTEM TYPE HP-COMFORT HP-EFF AC/HP CFM ADJUST ON/OFF DELAY CONTINUOUS FAN AUX1 HUM1 AUX2 HUM2 24VAC HEATER/MOTOR A96430 Fig. 24—Easy Select Board minutes. If super dehumidification call continues, lower CFM and HEAT PUMP HEATING MODE—COMFORT HEAT WITH outdoor section operation will again resume for another 10 40FKA...
  • Page 31 SYSTEM DIAGRAM HEATER/MOTOR SEC1 SEC2 5 AMP AUX1 " HUM1 " AUX2 " HUM2 " " DIODE LOGIC AUX HEAT AC/HP SYSTEM AC/HP CFM ON/OFF CONTINUOUS KW/CFM SIZE TYPE ADJUST DELAY A96431 Fig. 25—Easy Select Board Schematic Table 7—Connections on Single Barrier Strip Mounted, Cross Slotted, Captive Binding Head SCREW DESCRIPTION TERMINAL...

  • Page 32: Easy Select Configuration Taps

    Table 8—Connections and Connector (FK4C) TYPE TYPE PIN NO. DESCRIPTION CONNECTION CONNECTOR Pin 1 Common to screw terminal G Pin 2 Common to screw terminal Y/Y2 through diode D3 Pin 3 Common to Y1 through diode D2 Pin 4 Common to W2 screw terminal Pin 5 Common to W2 screw terminal Pin 6...

  • Page 33: Troubleshooting Pcb

    NOTE: If applied to two-speed unit, do not select continuous fan more va than transformer rating allows. When fuse blows because as high since LO speed cooling will also run at HIGH airflow and of high voltage, the system has mixed high- and low-voltage insufficient dehumidification may result.
  • Page 34 CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND BLOWER MOTOR ATTENTION: ROTATION NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE LEGEND 20KW 1PH SCHEMATIC DIAGRAM COMMON LIMIT SWITCH FIELD POWER WIRING...

  • Page 35: Accessories

    Table 9—FK4C Motor Control Test Values (With 16-pin connector at motor unplugged) ** VOLTAGES—12-PIN PLUG PL1 SCREW TERMINALS OPERATING MODE Y/Y2 HAVING 24 VAC Pin 7 Pin 1 Pin 9 Pin 10 Pin 8 Pin 2 Pin 3 Electric Heating 24 vac 24 vac 1-Speed A/C...

  • Page 36: Thermostatic Expansion Valves (Txv)

    TEFLON SEAL PISTON 3. The needle valve on pin carrier is spring-loaded, which also exerts pressure on underside of diaphragm via push rods, which closes valve. Therefore, bulb pressure equals evapora- tor pressure at outlet of coil plus spring pressure.

  • Page 37: Liquid Tube Strainer

    7. Replace seal ring on retainer. e. Turn off electrical supply to outdoor unit. 8. Reconnect refrigerant tube to piston body. f. Front seat vapor service valve. 9. Pressurize tubing and coil, then leak check. g. Recover any remaining refrigerant. NOTE: All outdoor unit coils will hold only factory-supplied 10.

  • Page 38: And Replacement

    c. Start unit in cooling mode. 14. Install new coil/pan assembly into unit. Secure with 2 screws previously removed from unit casing. d. Run unit until low pressure switch opens at 27 psig or vapor pressure reaches 5 psig (35kPa). Do not allow 15.

  • Page 39: Care And Maintenance

    14. Horizontal Applications only—Place horizontal condensate 13. Install new coil into condensate pan using 2 original screws pan into position on coil/pan assembly. and 2 support columns. NOTE: Correct coil position in condensate pan is essential to NOTE: Installation of horizontal condensate pan is not necessary reliable operation.

  • Page 40: Blower Motor And Wheel

    clean cooling coil, remove coil access panel. If coil is coated with centered in inlet opening. If not, loosen setscrew and align as dirt or lint, vacuum it with a soft brush attachment. necessary. Be careful not to bend coil fins. If coil is coated with oil or grease, 5.
  • Page 41 SCHEMATIC DIAGRAM FOR 2, 3, & 5 KW HEATERS COMPONENT ARRANGEMENT IFR (TDR OPTIONAL) MOTOR SEE RATING PLATE TRANS FOR VOLTS & HZ DISCONNECT FIELD POWER DISCONNECT SUPPLY HTR1 HTR2 CHASSIS GROUND TRANS TRANS WHEN EQUIPPED WHEN EQUIPPED IFR/TD CHASSIS BRN 5 CHASSIS GROUND...

  • Page 42: Cleaning Or Replacing Refrigerant Flow-Control Device

    Step 3—Cleaning or Replacing Refrigerant Flow-Control Device As with any mechanical equipment, personal injury can result Refer to Fig. 30 and instructions given in Piston Body Cleaning or from sharp metal edges. Be careful when removing parts. Replacement section above. Step 4—Liquid Tube Strainer AIR FILTER The refrigerant flow-control device is protected by a wire mesh...

  • Page 43: Fd3A Service And Troubleshooting

    BLOWER WHEEL INLET RING ″ ⁄ GROMMET MOTOR A86006 Fig. 34—FF1A/FF1B/FF1C Motor, Inlet Ring, and Blower Wheel Assembly weights (clips) on blower wheel vanes. Do not drop or bend The motor is turned on through 2 different routes. The first occurs wheel as balance will be affected.
  • Page 44 SCHEMATIC DIAGRAM SEE NOTE #4 LS-1 LS-2 FIELD POWER SUPPLY (OPTIONAL) HTR-2 LS-2 FL-2 FC QT (OPTIONAL) HTR-1 LS-1 FL-1 NOTE #2 LS-2 TRANS TRANS NOTE #1 FC QT TRANS TRANS COMPONENT ARRANGEMENT SEE NOTE #4 FIELD POWER WIRING EQUIP. GND. DISCONNECT N.E.C.

  • Page 45: Liquid Tube Strainer

    6. Pull strainer out of coil liquid refrigerant tube and replace with new strainer. Damage may occur to the scroll compressor if operated at a Step 5—Care and Maintenance negative suction pressure during a system pumpdown. 2. Bleed and (if possible) recover remaining refrigerant from tubing and coil through gage port on vapor-tube service valve.

  • Page 46: Fg3A Service And Troubleshooting

    hot water and detergent. Be careful not to disturb balance weights CLEANING OR REPLACING REFRIGERANT (clips) on blower wheel vanes. Do not drop or bend wheel as FLOW-CONTROL DEVICE balance will be affected. Refer to Fig. 36 and instructions given in FD3A Service and Troubleshooting section above.

  • Page 47: Unit Functions

    CEPL130121-01 MOV1 SEC2 LOW VOLTAGE SEC1 TERMINAL BOARD W 2T (CUT WHEN OUTDOOR THERMOSTAT IS USED) AUX– AUX+ (HIGH FAN ONLY WHEN CUT) RECEPTACLE XFORM DUMMY 240 VAC COMMON DUMMY A94127 Fig. 39—Smart Heat Printed-Circuit Board (PCB) d. G terminal provides input signal from thermostat signaling 5.

  • Page 48: Smart Heat Operation

    Table 10—Electric Heater Stage Limiting STAGES (KW OPERATING) HEATER PART NO. W2T Only (JW1 cut) W2T and W3 Heater Stage KFAEH2201H10 or 10 kw Non-Fused KFCEH0101H10 KFAEH2301H15 or 15 kw Fused KFCEH0201H15 KFAEH2401H20 or 20 kw Fused KFCEH0301H20 5. When both W3 and W2T are energized without JW1 being cut Table 11—LED Codes for Smart Heat PCB or with outdoor thermostat closed, system operation stages FLASH CONDITION...
  • Page 49 Table 12—Troubleshooting Voltage Readings and Test Points Input Voltages LOCATION NORMAL READING PURPOSE L1 and L2 208/230 vac Main power supply input to fan coil L3 and L4 208/230 vac Power to electric heaters 9-pin connector 208/230 vac Power to smart control 7 and 9 T1 and T3 208/230 vac...
  • Page 50 HEATING (COMPRESSOR AND ELECTRIC HEAT) • Is limit switch LS3 open? If so, check fan coil air filter or air distribution system for blocking or restriction that might reduce If heat pump alone cannot satisfy heat requirements of structure, airflow and cause limit switch to open. room thermostat calls for additional heat by way of an input to W2 Operation of heaters can be confirmed further by using a clamp-on terminal of control.

  • Page 51: Puron® (R-410A) Quick Reference Guide

    → PURON® (R-410A) QUICK REFERENCE GUIDE • Do not use liquid-line filter driers with rated working pressures FOR INSTALLERS AND TECHNICIANS less than 600 psig. • Puron (R-410A) refrigerant operates at 50-70 percent higher • Do not install a suction-line filter drier in liquid line. pressures than R-22.
  • Page 52 Fig. 40—Smart Heat Typical Wiring Diagram (Motor Speed at 20kw Shown) Copyright 1999 CARRIER Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 f5sm Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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