Carrier FED004815 - User Manual

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Installation Instructions & Homeowner’s Information

Approved for use in manufactured homes.

NOTE: Read the entire instruction manual before starting the

installation.

Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

POSITION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Line Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Thermostat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Thermostat Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Transformer Information

(applicable to on-site HVAC contractor) . . . . . . . . . . . . . . . . . . . . 4

Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Filtered Grille Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Minimum CFM and Motor Speed Selection

(applicable to on-site HVAC contractor) . . . . . . . . . . . . . . . . . . . . 5

Sequence of operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Continuous Fan (Whole House Ventilation) . . . . . . . . . . . . . . . . . 5

Electric Heat or Emergency Heat Mode . . . . . . . . . . . . . . . . . . . . 5

HOMEOWNER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 11

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Heating Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cooling Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fan Control (Whole House Ventilation) . . . . . . . . . . . . . . . . . . . 11

WHAT TO DO IF YOUR SYSTEM DOES NOT WORK . . . . . . . 11

Before Requesting a Service Call: . . . . . . . . . . . . . . . . . . . . . . . . 11

REGULAR MAINTENANCE REQUIREMENTS . . . . . . . . . . . . . 11

Indoor Unit Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Condensate Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Outdoor Unit Coils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Painted Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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 the kits or accessories

when installing.

Follow all safety codes. Wear safety glasses, protective clothing and

work gloves. Use quenching cloths for brazing operations. Have fire

extinguisher available. Read these instructions thoroughly and follow all

warnings or cautions attached to the unit. Consult local building codes

and the applicable editions of the National Electrical Codes (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 . When

you see this symbol on the unit and in instructions or 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.

INTRODUCTION

Model FED has been designed for downflow applications. Models are

available for electric heat sizes 10 kW – 20 kW. All models use an ECM

motor.

FED models contain a factory supplied replaceable air filter.

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.

NOTE: Internal filter can be accessed from a separate filter door.

FED “B” Series

Downflow Electric Furnace

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Before installing, modifying or servicing system, always turn off main

power to system. There may be more than one disconnect switch. Lock

out and tag switch with a suitable warning label.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear

appropriate protective clothing and gloves when handling parts.

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Summary

Safety Considerations

General Safety Precautions

Covers electrical shock, cut hazards, and general safety warnings for installation and operation.

Introduction and Location

Product Overview

Brief introduction to the FED Series downflow electric furnace.

Installation Site Selection

Guidance on choosing the optimal location for unit installation.

Unit Positioning and Hazards

Positioning and Structural Requirements

Instructions for unit placement, floor base, and clearances.

Operational Hazards and Warnings

Warnings on property damage from filter use and fire hazards from clearances.

Electrical Connections

Electrical Safety and Wiring Procedures

Details on electrical shock hazards, line voltage, and thermostat wiring.

Wiring and Grounding Details

Thermostat, Transformer, and Grounding

Instructions and diagrams for wiring thermostat, transformer, and ensuring proper grounding.

Airflow Configuration and Operation

Airflow Setup and Speed Selection

Guidance on filtered grilles, minimum CFM, and motor speed tap selection.

Unit Operation Sequences

Explanation of unit operation in continuous fan and electric heat modes.

Homeowner Information

Thermostat Settings and Modes

Instructions for setting thermostat for heating, cooling, and fan control.

System Troubleshooting and Maintenance

Troubleshooting and Service Calls

Steps to resolve issues before contacting a service technician.

Routine Maintenance and Safety

Guidance on regular maintenance tasks and associated safety precautions.

Summary

Safety Considerations

General Safety Precautions

Covers electrical shock, cut hazards, and general safety warnings for installation and operation.

Introduction and Location

Product Overview

Brief introduction to the FED Series downflow electric furnace.

Installation Site Selection

Guidance on choosing the optimal location for unit installation.

Unit Positioning and Hazards

Positioning and Structural Requirements

Instructions for unit placement, floor base, and clearances.

Operational Hazards and Warnings

Warnings on property damage from filter use and fire hazards from clearances.

Electrical Connections

Electrical Safety and Wiring Procedures

Details on electrical shock hazards, line voltage, and thermostat wiring.

Wiring and Grounding Details

Thermostat, Transformer, and Grounding

Instructions and diagrams for wiring thermostat, transformer, and ensuring proper grounding.

Airflow Configuration and Operation

Airflow Setup and Speed Selection

Guidance on filtered grilles, minimum CFM, and motor speed tap selection.

Unit Operation Sequences

Explanation of unit operation in continuous fan and electric heat modes.

Homeowner Information

Thermostat Settings and Modes

Instructions for setting thermostat for heating, cooling, and fan control.

System Troubleshooting and Maintenance

Troubleshooting and Service Calls

Steps to resolve issues before contacting a service technician.

Routine Maintenance and Safety

Guidance on regular maintenance tasks and associated safety precautions.

The FED "B" Series Downflow Electric Furnace is designed for downflow applications, suitable for use in manufactured homes. It provides electric heating and can be integrated with add-on cooling or heat pump systems.

Function Description

The furnace's primary function is to provide electric heating for residential spaces. It utilizes an ECM (Electronically Commutated Motor) for efficient airflow management. The unit is controlled by a wall-mounted thermostat, allowing users to set desired temperatures for heating and, if a cooling system is installed, for cooling. The fan can operate continuously for whole-house ventilation or cycle automatically with the heating or cooling system.

Important Technical Specifications

Heating Capacity: Available in electric heat sizes ranging from 10 kW to 20 kW.
Motor Type: All models use an ECM motor.
Airflow Performance: Detailed airflow performance tables (Table 3 and Table 4) are provided for various models (FED002410*, FED003610*, FED003612*, FED003615*, FED004815*, FED006020*) across different blower speeds (Tap 1 to Tap 5) and total static pressures (0.10 to 0.60 inches water column), both with and without an accessory cooling coil.
- For example, a FED002410* at Tap 5 without a cooling coil can deliver 1123 CFM at 0.10 static pressure, while with a cooling coil, it delivers 976 CFM at the same settings.
- Airflow values are calculated at 230V with a dry coil, factory-approved filter, and electric heater. Airflow at 208V is approximately the same due to the constant torque ECM motor.
- Return static pressure must be less than 0.40 in. wc to avoid condensate blowing out of the drain pan.
- Airflow above 400 cfm/ton on 4800 - 6000 size units could lead to condensate blowing off the coil or splashing out of the drain pan.
Electrical Data (Fan Coil Only, with Electric Heat): (Table 5)
- Voltage: All values are calculated at 230 volts. The transformer is factory wired for 230V operation but can be reconfigured for 208V by disconnecting the black wire from the 230V terminal and connecting it to the 208V terminal.
- Circuit Breakers: Series B units have circuit breakers mounted horizontally and factory-supplied in the OFF position. For downflow installation, the circuit breaker switch should be slid to the right to power the unit.
- Wiring: Requires copper wire (75°C min.) only. Wire size must comply with NEC and local codes. Low voltage fuse should not exceed 5 amps.
- Examples:
  - FED002410* (10 KW): Single circuit, 2.8 Motor Amps, 40 Heater Amps, 53.6 Min Circuit Amps, 60 Breaker Size.
  - FED003612* (12 KW): Dual circuit (A and B), 4.1 Motor Amps, 31.7 (A) and 15.8 (B) Heater Amps, 44.8 (A) and 19.8 (B) Min Circuit Amps, 50 (A) and 20 (B) Breaker Size.
  - FED006020* (20 KW): Dual circuit (A and B), 6 Motor Amps, 40 (A) and 40 (B) Heater Amps, 57.5 (A) and 50 (B) Min Circuit Amps, 60 (A) and 50 (B) Breaker Size.
Thermostat Wiring: Uses minimum 22 AWG color-coded, insulated (35°C minimum) wire for low-voltage connections. If the thermostat is over 100 feet from the unit, 18 AWG wire is recommended.
Clearances: Maintain 0" clearance for back and sides, 0" for ducts. For front access, 6" in a closet (to closet door) and 24" in an alcove.
Floor Cutout Dimensions:
- FED002410* thru FED004815*: 14.5" x 14.5"
- FED006020*: 17.5" x 17.5"
Safety: Designed with safety-alert symbols (DANGER, WARNING, CAUTION) to indicate potential hazards. Electrical shock hazard warnings emphasize turning off main power before servicing. Cut hazard warnings advise wearing protective clothing and gloves when handling sheet metal parts.

Usage Features

Installation: The unit is shipped with the supply air side UP. Installation involves cutting a hole in the floor, applying UL 181 rated caulk or duct mastic, installing the plenum and floor base, and then inverting the unit onto the base. Electrical knockouts must be removed, and the filter and its access door removed before inversion. The unit flanges fit into the base opening, and it slides to the back, ensuring tabs engage with casing slots.
Thermostat Control:
- Heating Mode: Set system selector to HEAT and temperature above current room temperature.
- Cooling Mode (if installed): Set system selector to COOL and temperature below current room temperature.
- Fan Control (Whole House Ventilation): Selector switch can be set to ON for continuous operation or AUTO for automatic cycling with heating/cooling. Continuous fan operation is recommended for maximum comfort.
Motor Speed Selection: Fan speed is selected at the fan motor by repositioning wires at terminals labeled 1-2-3. Speed taps 1, 2, and 3 have a 90-second blower off time delay. Tap 2 (WHITE wire) is used for electric heat only. Tap 5 is NOT used for electric heating.
Filtered Grille Applications: If the unit is in a closet, a filtered return air grille can be used as a door or through an adjacent wall. In this case, the internal filter must be removed.
Sequence of Operations:
- Continuous Fan: Thermostat closes R to G, signaling the motor for continuous indoor blower operation. A 90-second off delay occurs after G is de-energized.
- Electric Heat/Emergency Heat: Thermostat closes R to W, energizing electric heat relay(s) and the indoor blower motor. When W is de-energized, relays open, and the motor stops.

Maintenance Features

Regular Inspections: The system should be regularly inspected by a qualified service technician.
Indoor Unit Air Filter: Inspect monthly and replace disposable filters or clean reusable filters as required. Dirty filters are a common cause of poor performance and compressor failures. Filters should be installed with arrows pointing in the direction of airflow.
Condensate Drain: If a cooling system is installed, check the condensate drain at least monthly during the cooling season for free flow and clean if necessary.
Outdoor Unit Coils: Clean debris (grass clippings, leaves, dirt, dust, lint) from outdoor coils to maintain efficiency and prevent compressor damage. Use a soft bristle brush with light pressure to avoid damaging coil fins.
Painted Surfaces: In areas with high mineral concentrations in water, avoid spraying the unit with lawn sprinklers to prevent premature deterioration of paint and metal components.
Troubleshooting (Before Service Call):
1. Check thermostat settings (HEAT/COOL, desired temperature).
2. Inspect and replace/clean the return air filter.
3. Check and reset circuit breakers or replace fuses.
4. Inspect outdoor unit coils and fins for obstructions and debris. Ensure the fan blade is not obstructed.
Access: The internal filter can be accessed from a separate filter door. The control box provides grounding lugs. The wiring protection plate should be connected to the downflow base after wiring is complete and before attaching the front base of the cabinet to the floor.