Bryant SM03-4 Service Manual
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Bryant SM03-4 Service Manual

Bryant SM03-4 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 ..................................................................5
- HK61GA001 and HK61GA003 PCB .........................8-19
• PCB Component Functions.........................................................9
• Troubleshooting PCB ................................................................11
AND TROUBLESHOOTING..............................................19
• Description of Electric Heater Components.............................19
Electric Heaters.......................................................................20
AND 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 ................................................................24
• Troubleshooting ICM2 ..............................................................26
and Controls ...............................................................................26
• Accessories ................................................................................27
• Integrated Controls and Motor (ICM2) ....................................28
• PCB Layout and Description ....................................................28
• Sequence of Operation ..............................................................28
• Easy Select Configuration Taps................................................30
• Troubleshooting PCB ................................................................32
• Troubleshooting ICM2 ..............................................................34
FK4C, FV4A Motor and Controls .........................................34
• Accessories ................................................................................34
• Problems Affecting TXV ..........................................................36
LIQUID TUBE STRAINER .....................................................36
REMOVAL AND REPLACEMENT..................................36
• A-Coil Units ..............................................................................36
• Slope Coil Units ........................................................................37
FX, FV COIL/CONDENSATE PAN REMOVAL
AND REPLACEMENT........................................................38
Service Manual
RESIDENTIAL FAN COIL UNITS
Page
-1-
Cancels: SM03-4
Fig. 1-Typical Fan Coil
CARE AND MAINTENANCE.................................................39
• Filter Assembly .........................................................................39
• Blower Motor and Wheel .........................................................39
TROUBLESHOOTING ..................................................40-42
• Fan Motor ..................................................................................40
• Electric Heater Service..............................................................40
• Liquid Tube Strainer .................................................................40
• Sequence of Operation ..............................................................40
• Care and Maintenance...............................................................40
• Fan Motor ..................................................................................44
• Electric Heater Service..............................................................44
• Liquid Tube Strainer .................................................................44
• Care and Maintenance...............................................................45
• Service .......................................................................................45
• Maintenance...............................................................................46
• Unit Functions ...........................................................................46
• Smart Heat Operation................................................................47
SM03-5
6-99
A98023

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  • Page 1: Table Of Contents

    Service Manual RESIDENTIAL FAN COIL UNITS Cancels: SM03-4 SM03-5 6-99 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 —...

  • 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 Improper installation, adjustment, alteration, service, maintenance, and off.
  • Page 3 —3—...

  • 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 024-060 Multipoise Single Piece...

  • Page 5: Troubleshooting Pcb

    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 6 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 7 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 DISCONNECT PER NEC CAPACITOR LIMIT SWITCH FIELD POWER WIRING COMMON MARKED TERMINAL SEE RATING PLATE LOW VOLTAGE FUSE PLUG AND RECEPTACLE...

  • Page 8: Circuit Board Function And Troubleshooting

    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 9: Pcb Component Functions

    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 10 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 11: Troubleshooting Pcb

    6. W2 is used to turn on the first stage of electric heat which 2. W3--When a signal is sent to W3, 2 control signals are sent is interlocked with the fan through the normally closed fan out to the sequencers; a 24-v dc signal to sequencer number relay.
  • 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 13 —13—...
  • Page 14 —14—...
  • Page 15 —15—...
  • Page 16 —16—...
  • 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 A. If the fan will not turn on from the thermostat: 2. Check sequencer number 1 and the plug wiring. The yellow wire should be connected to pin number 9 of the plug and IF THERE IS NO HIGH VOLTAGE TO THE PCB: the limit switch.

  • Page 19: Electric Heater Function And Troubleshooting

    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 ELECTRIC HEATER FUNCTION AND The device itself consists of a bimetallic disc, which when TROUBLESHOOTING overheated "snaps through"...

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

    In simplistic terms, the sequencers which we use are nothing more E. Nuisance Trips than normally-open limit switches which sit on top of a small 1. Check for low airflow due to dirty filters, blocked registers, resistive heater. When voltage is applied to this heater, a positive or 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 Fuse Data: 5-amp automotive-type ATC/ATO (tan) D.

  • 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: Troubleshooting Pcb

    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 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 26: Troubleshooting Icm2

    3. Check power leads L1 and L2. If these are not receiving 1. Check transformer and thermostat wiring. (See Fig. 16 and power, system cannot function. 18.) Be sure transformer is not shorting out because thermostat wires are miswired. IF PCB HAS HIGH VOLTAGE APPLIED TO IT: 2.

  • Page 27: Accessories

    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

    torque from speed and airflow numbers. If calculation does not 230 VAC OR FAN COIL 115 VAC BRANCH CKT match stored blower characteristics, torque is adjusted until AUX1 AUX2 GND HOT NEUT agreement is reached. This calculation and adjustment is per- formed every 0.8 sec while motor is in operation.
  • Page 29 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 and FV4A ICM2.3 Motor circuit from R to G.

  • Page 30: Easy Select Configuration Taps

    ® 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 K. Low-Voltage Circuit Fusing and Reference XII.
  • 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: Troubleshooting Pcb

    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 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 LIMIT SWITCH COMMON FIELD POWER WIRING...

  • Page 34: Troubleshooting Icm2

    → 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...

  • Page 35: Accessories

    - Check for 24v between pin-1 and pin-12 on the 16-pin plug. percent of nominal cooling mode airflow. This reduction will (See Fig. 27.) If no voltage is present, replace wiring harness. If increase the system latent capacity until the humidity falls to a voltage is present, jumper screw terminal R-Y/Y2 on circuit board level which causes the humidistat to close its contacts.

  • Page 36: Problems Affecting Txv

    I. PROBLEMS AFFECTING TXV 8. Reconnect refrigerant tube to piston body. 9. Pressurize tubing and coil, then leak check. A. Low Suction Pressure 10. Evacuate tubing and coil as necessary. 1. Restriction in TXV 2. Low refrigerant charge CAUTION: Use a backup wrench and do not over tighten, as deformation of the piston body will occur, 3.

  • Page 37: Slope Coil Units

    e. Turn off electrical supply to outdoor unit. a. Attach manifold/gage set to service valves. f. Front seat vapor service valve. b. Front seat (close) liquid tube service valve. g. Recover any remaining refrigerant. c. Start unit in cooling mode. NOTE: All outdoor unit coils will hold only factory-supplied d.

  • Page 38: And Replacement

    13. Install new coil into condensate pan using 2 original screws 12. Place coil assembly in plastic condensate pan and secure and 2 support columns. using 4 screws through delta plate. (See Fig. 31.) NOTE: Correct coil position in condensate pan is essential to 13.

  • Page 39: Care And Maintenance

    10. Remove remaining 2 screws securing coil to condensate water and mild detergent. Rinse and allow filter to dry. No oiling pan. or coating of filter is required. New filters are available from your local distributor. Place filter in slot with cross-mesh binding up or 11.

  • Page 40: Ff1A/Ff1B/Ff1C Service And Troubleshooting

    2. Reassemble cutoff plate to housing using identified holes NOTE: Transformer is fused. Do not short circuit. from disassembly procedure. D. Fan Relay 3. Position motor and mount in same position as when blower Relay coil is 24 volts. Check for proper control voltage. Replace housing was in unit.
  • 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 BLOWER WHEEL INLET RING ″ ⁄ GROMMET MOTOR A86006 Fig. 34—FF1A/FF1B/FF1C Motor, Inlet Ring, and Blower Wheel Assembly WARNING: As with any mechanical equipment, per- CAUTION: Do not use caustic household drain cleaners sonal injury can result from sharp metal edges. Be careful in condensate pan or near coil.
  • Page 43 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 44: Fd3A Service And Troubleshooting

    III. CLEANING OR REPLACING REFRIGERANT 3. Slide blower wheel onto motor shaft with setscrew upward FLOW-CONTROL DEVICE and aligned with shaft flat portion. Vertically position wheel along shaft to position marked during disassembly. 1. Pump down outdoor unit. Close service valves at outdoor NOTE: If previous shaft was not marked or if replacing previous unit.

  • Page 45: Care And Maintenance

    3. Remove sheet metal screw holding bracket clip in place. Blower motor and wheel may be cleaned using a vacuum with a Screw is located between coil and refrigerant flow-control soft brush attachment. Remove grease with a mild solvent such as device.

  • Page 46: Maintenance

    II. MAINTENANCE f. W2D terminal provides input from outdoor unit (heat pump) signaling control board that heat pump is in WARNING: Disconnect electrical power to all circuits defrost. before servicing unit. Failure to do so may result in g. W2T terminal provides input from thermostat signaling personal injury from electrical shock or moving parts.

  • Page 47: Smart Heat Operation

    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) TABLE 10—ELECTRIC HEATER STAGE LIMITING STAGES (KW OPERATING) HEATER PART NO.

  • Page 48: Electrical Operating Sequences And Troubleshooting

    D. Troubleshooting Printed-Circuit Board • Are line voltage fuses FU1 and FU2 good? (Diagnostic LED) If 208/230v is available across terminals F1 and HI and fan does The PCB of Smart Heat option heater package contains a micro- not operate, check the following: processor which controls fan operation, fan speed, outdoor unit, •...
  • 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: Puron® (R-410A) Quick Reference Guide

    → PURON® (R-410A) QUICK REFERENCE GUIDE Eventually, the total number of heaters is cycled on. In emergency FOR INSTALLERS AND TECHNICIANS heat mode, LED indicator signals 7 flashes. • Puron (R-410A) refrigerant operates at 50-70 percent higher The amount of emergency heat available depends on whether pressures than R-22.
  • Page 51 CAUTION: THIS COMPARTMENT MUST BE CLOSED EXCEPT FOR SERVICING NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING BLOWER MOTOR 150V TO GROUND ATTENTION: ROTATION NE CONVIENT PAS AUX INSTALLATIONS DE PLUS DE 150 V A LA TERRE SCHEMATIC DIAGRAM COMPONENT ARRANGEMENT DISCONNECT PER NEC FIELD POWER WIRING HTR1...
  • Page 52 Course descriptions and schedules are in our catalog. CALL FOR FREE CATALOG 1-800-962-9212 [ ] Packaged Service Training [ ] Classroom Service Training A94328 © 1999 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231 —52— Printed in U.S.A. sm035 Catalog No. 13FA-4A1...

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