Carrier FG4 Service And Maintenance Instructions

FB4, FE4, FF1E, FFM, FG4, FH4, FJ4, FT4, FV4, FX4, FZ4, PF4, FMA, F54, FY5
Residential Fan Coil Units
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fan Coil Description and Troubleshooting. . . . . . . . . . . . . . . . . . . . . 2
FY5, FH4, PF4 (even sizes) and FF1E (even sizes) . . . . . . . . . . . 2
Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electric Heater Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cleaning or Replacing Refrigerant Flow-Control Device . . . . . 2
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CES013003-00, 01 (HK61EA002, HK61EA006) Control Boards3
Printed Circuit Board (PCB) Component . . . . . . . . . . . . . . . . . . 3
Unit Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Troubleshooting the Printed Circuit Board (CES013000-00, 01 /
HK61EA002 / HK61EA006) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FB4C, FJ4, FX4D, F54, PF4, FF1E, and FZ (odd sizes). . . . . . . . 5
Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FV, FT4, FG4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Constant Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Integrated Controls and Motor ECM2.3/5.0 . . . . . . . . . . . . . . . . 7
PCB Layout and Description (FT4, FV4). . . . . . . . . . . . . . . . . . 7
Sequence of Operation (FT4, FV4) . . . . . . . . . . . . . . . . . . . . . . 7
Easy Select Configuration Taps . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
InteliSense™ Technology (FT4) . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connected Portal and Service Tech App . . . . . . . . . . . . . . . . . 14
Power On LED/Board States . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How to Troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How Does the Service Tech Know when the System is Functioning
Properly? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FE4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electronically Commutated Motor ECM 3.0 . . . . . . . . . . . . . . 15
Troubleshooting (FE4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Vefify Motor Winding Section . . . . . . . . . . . . . . . . . . . . . . . . . 16
Motor Turns Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 18
ADVANCED TROUBLESHOOTING: . . . . . . . . . . . . . . . . . . 18
Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cooling Coil, Drain Pan, and Condensate Drain . . . . . . . . . . . 19
FFM and FMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electric Heater Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning or Replacing Refrigerant Flow-Control Device . . . . 21
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electric Heater Function and Troubleshooting . . . . . . . . . . . . . . . . . 25
FB4, FE4, FF1E, FH4, FJ4, FV4, FX4, FZ and PF4 . . . . . . . . . . 25
Description of Electric Heater Components . . . . . . . . . . . . . . . . 25
Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
KFC and KFD Electric Heat Relay. . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting KFC and KFD Series Electric Heaters . . . . . . . 25
Discolored Wire Insulation at Terminal . . . . . . . . . . . . . . . . . . 25
Fuse Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
No Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Heater Will Not Turn Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Nuisance Trips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FFM, FMA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Description of Electric Heater Components . . . . . . . . . . . . . . . . 25
Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FB4, FE4, FE4A/B, FH4, FJ4, FT4, FV4, FX4, FZ4, F54 and PF426
Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cooling Coil, Drain Pan, and Condensate Drain . . . . . . . . . . . 26
Blower Motor and Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FF1E, FFMA, FMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cooling Coil, Drain Pan, and Condensate Drain . . . . . . . . . . . 27
Blower Motor and Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Refrigerant Flow-Control Devices. . . . . . . . . . . . . . . . . . . . . . . . 28
Thermostatic Expansion Valves (TXV) . . . . . . . . . . . . . . . . . . 28
Problems Affecting TXV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Aluminum Coil Unit TXV's. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Piston Body Cleaning and Replacement . . . . . . . . . . . . . . . . . . . 29
Liquid Tube Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Aluminum Coil Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Old Copper or Tin-Plated Coils with TXV. . . . . . . . . . . . . . . . 30
Old All-Aluminum Coils with TXV. . . . . . . . . . . . . . . . . . . . . 30
Installation – A-Coil Units Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation – Slope Coil Units Only. . . . . . . . . . . . . . . . . . . . . . . . . 32
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, maintenance, or
use can cause explosion, fire, electrical shock, or other conditions which
may cause death, 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
factory-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, protective clothing and
work gloves. Have a fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in literature and
attached to the unit. Consult local building codes and the current editions
of the National Electrical Code (NEC) NFPA 70.
In Canada, refer to the current editions of the Canadian Electrical Code
CSA C22.1.
Recognize safety information. This is the safety-alert symbol
you see this symbol on the unit and in instruction manuals, be alert to the
potential for personal injury.
Understand the signal words DANGER, WARNING, and CAUTION.
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
injury or death. CAUTION is used to identify unsafe practices which
may 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.
. When