Comfortaire FCA SEries Service manual

UNIVERSAL MOUNTED FAN COIL UNIT
FCA SERIES
OWNER’S AND INSTALLATION MANUAL
Version
20111021BL

2
INDEX
PAGE
I
INTRODUCTION OF FCA SERIES
3-5
REFERENCE CARD
4
READING INSTRUCTION
5
INSTALLATION ACCESSORIES PROVIDED
5
INSTALLATION REQUIRED TOOLS
5
II
SAFETY PRECAUTIONS
6-8
INSTALLATION PRECAUTIONS
7
OPERATION PRECAUTIONS
7-8
III
INSTALLATION START-UP AND SERVICE
INSTRUCTIONS
9-14
SAFETY CONSIDERATIONS
9
INSTALLATION INITIAL CHECK
9
SELECTION OF INSTALLATION LOCATION
9-10
MOUNTING
11-12
IV
REFRIGERANT PIPING
13-15
V
CONDENSATE DRAIN
15
VI
ELECTRICAL WIRING
16
VII
REMOTE CONTROL HANDSET
17-19
VIII
WIRED WALLPAD (OPTIONAL)
20-21
IX
ONBOARD CONTROL AND LED LIGHTS
22
X
MAINTENANCE
23
XI
FILTER REMOVAL FOR CLEANING
24
XII
OPERATION TIPS
24
XIII
TROUBLESHOOTING
25

3
INTRODUCTION OF FCA SERIES
FLOOR / CEILING SUSPENDED DUAL TYPE
FLEXIBLE TWO-WAY INSTALLATION
The rounded design of the FCA unit allows either under ceiling or floor-level installation. Under
ceiling installation frees up wall and floor space, while floor-level installation helps prevent the loss
of warm air.
SLIM AND ATTRACTIVE DESIGN
New fashionable appearance and light weight structure.
LOW NOISE OPERATION
The unit not only does it has ultra quiet multi-speed motor and a tangential blower wheel for
optimum sound.
3D SWING FUNCTION FOR BETTER COMFORT
The horizontal and vertical air sweep combination allows three-dimensional control of the air
direction.
LED ERROR DISPLAY FOR TROUBLESHOOTING
Easy to read LED display for 6 error diagnostics.
IR REMOTE HANDSET OPERATION
User friendly control platform with functions in Cooling, Dehumidifying, Heating, Fan, Auto, auto
control sleep mode, 24hrs ON/OFF timer, etc.

4
REFERENCE CARD
Write the model and serial numbers here which you can find them on a
label on the side of each unit:
Model Number: _______________________________
Serial Number: _______________________________
Dealer’s Name: _______________________________
Dealer’s Tel: _______________________________
Date Purchased: _______________________________
Staple your receipt to this page in the event you need it to prove date
of purchase or for warranty issues.

5
READ THIS MANUAL
Inside you will find many helpful hints on how to install and use your air
conditioner properly. Just a little preventive care on your part can save
you a great deal of time and money over the life of your air conditioner.
You will find many answers to common problems in the troubleshooting
table. If you review our chart of TROUBLESHOOTING first, you may not
need to call for service at all.
Warning
1. Disconnect from the main before servicing this appliance.
2. Do not repair by yourself. In case of malfunction of this appliance, do
not repair by yourself. Contact the sales dealer or service dealer for a
repair.
3. Turn off the power (isolation from main power supply). Switch off the
breaker, or switch off the power disconnecting means to isolate the
equipment from the main power supply in case of an emergency.
INSTALLATION ACCESSORIES PROVIDED
Manual x 1
Spring washer x 4
High pressure
Insulated hose x 1
Remote Control x 1
Washer x 4
Low pressure
Insulated hose x 1
AAA battery x 2
Bolt x 4
Grille x 1
INSTALLATION REQUIRED TOOLS
Electric drill
Adjustable wrench
Level gauge
Refrigerant gas leak detector
Screw driver
vacuum pump
Torque wrench
Gauge manifold

6
SAFETY PRECAUTIONS
Before operating, please read the following “Safety Precautions”
carefully.
To prevent personal injury, injury to others and property damage, the
following instructions must be followed.
Incorrect operation due to failure to follow instructions will cause harm
or damage, the seriousness of which is classified as follow:
Warning This sign indicates the possibility of death or serious injury.
Caution This sign indicates the possibility of injury or damage to property.
The instructions to be followed are classified by the following symbols:
This symbol denotes an action that is PROHIBITED.
This symbol denotes actions that are COMPULSORY.

7
INSTALLATION PRECAUTIONS
Warning
Do not install, remove and reinstall the unit by yourself.
Improper installation will cause leakage, electric shock or fire. Please engage an authorized
Dealer or specialist for the installation work.
Caution
This room air conditioner must be earthed.
Improper grounding could cause electric shock.
Ensure that the drainage piping is connected properly.
Otherwise, water will leak out.
Do not install the unit in a potentially explosive atmosphere.
Gas leak near the unit could cause fire.
OPERATION PRECAUTIONS
Warning
Do not operate with wet hands.
This may cause an electric shock.
Do not insert finger or other objects into the indoor unit.
Since the fan rotates at high speed, this may cause an injury.
Do not expose directly to cold air for a long period of time.
This could damage your health.
Do not turn the breaker off/on during operation.
This may cause a fire due to spark, etc.
Be sure to turn off the breaker absolutely after switching the indoor unit off with the
remote controller.

8
Use specified power cord.
If abnormal condition (burnt smell, etc) occurs, switch off the
power supply.
Caution
Do not wash the unit with water.
Do not put a vase or glass on the indoor unit.
Do not use for other purpose such as preservation.
Do not use any combustible equipment at airflow direction.
Do not stop the operating unit by pulling out the power supply
line.
Do not operate the unit for a long time in high humidity, e.g.
leaving a door or window open.
In the cooling mode, if the unit is operated in a room with high humidity (80%RH or
more) for a long time, water condensed in the air conditioner may drop and wet or
damage furniture, etc.
Do not charge or disassemble the batteries and do not throw
them into a fire.
This may result in leakage, fire or an explosion.
Switch off the power supply before cleaning.
Ventilate the room regularly.
Pay attention as to whether the installation rack is damaged
after a long period of usage.
Switch off the power supply if the unit is not used for a long
period.
Replace the 2 batteries with new ones of same type.
Using an old battery together with a new one may result in heat generation, leakage
or an explosion.
If liquid from the alkaline batteries gets onto your skin or
clothes, wash it well with clean water.
If liquid from the alkaline batteries gets into your eyes, wash them well with clean
water and consult a doctor at once.

9
INSTALLATION, START-UP AND SERVICE
INSTRUCTIONS FOR FCA INDOOR UNIT
SAFETY CONSIDERATIONS
1. Installation and servicing of air conditioning equipment can be hazardous due to system
pressure and electrical components. Only trained and qualified personnel should service
equipment.
2. When working on air conditioning equipment observe precautions in the literature and
labels attached to the unit and other safety precautions that may apply. Follow all safety
codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations.
Have a fire extinguisher available for all brazing operations.
WARNING!
Before performing service or maintenance operations on the system, turn off the
main power switches to the unit. Electrical shock could cause personal injury.
INSTALLATION INITIAL CHECK
1. The carton should not be removed from unit until reaching final location to avoid damage.
2. Inspect unit for shipping damage and file a claim with the transport agency if necessary.
3. Check field electrical works:
a. Proper size of fuses and wire, correct wiring connections and grounding as specified
by the local electrical codes.
b. Also check supply voltage. This must be within the limits shown on the rating plate.
4. Check for a proper condensate flow.
5. Be sure piping insulation is adequate.
6. Confirm there are no obstructions to air flow for the unit. Also check for sufficient
clearances for servicing of the unit.
SELECTION OF THE INSTALLATION LOCATION
1. Unit should be installed in a proper location to avoid blind sector, as shown in Fig. 1.
2. There should not be any heat source of steam near the unit.
3. There should not be any obstacles to prevent the air circulation.
4. A place where air circulation in the room will be good.
5. A place where noise prevention is taken into consideration.
6. Ensure the spaces indicated by arrow from the wall, ceiling, fence, or other obstacles.
7. Do not install the unit near the door way.
8. Do not install the unit near a fire alarm.
9. Do not install the unit in a machinery shop or kitchen where oil vapour flows into the unit.
The oil will deposit on the heat exchanger, thereby reducing the unit performance. In the
worse case it may deform or break the plastic parts of the units. It is recommended that the
standard filter be replaced with a special filter if necessary.

10
10.Pay attention to the following points when the unit is installed in a hospital or other facilities
where electromagnetic radiation is radiated from equipment.
a. Do not install the unit where the electromagnetic waves are directly radiated at the
electrical box, remote control cable or remote control switch.
b. Install the unit and components as far away as is practical (at least 16ft/5m) from the
electromagnetic wave source.
c. Install a noise filter if any harmful electrical noise exists in the power supply.
Fig. 1

11
MOUNTING THE UNITS
1. The unit comes equipped with two bracket hangers for mounting the unit under ceiling as
well as a packet for mounting the remote control handset.
2. Prepare the mounting bolt (M10) at the distance specified in Fig. 2 and in the dimensional
drawing.
3. Carry out the pipeline operation in the ceiling after finishing the installation of the main
body. While choosing where to start the operation, determine the direction of the pipes to
be drawn out. Especially in case of there is a ceiling, position the refrigerant pipes drain
pipes, indoor and outdoor lines to the connection places before hanging up the machine.
WALL MOUNTING INSTALLATION
1. Fix the hook with tapping screw onto the wall as shown in Fig. 2.
2. Hang the unit on the hook.
Fig. 2

12
CEILING INSTALLATION
1. Remove the side board as shown in Fig. 3.
2. Locate the handing arm on the hanging screw bolt.
3. Prepare the mounting bolts on the unit as shown in Fig. 4.
4. Hang the unit on the hanging arm by sliding backward. Securely tighten the mounting bolts
on both sides as shown in Fig. 5
Fig. 3
Fig.4
Fig. 5

13
REFRIGERANT PIPING
1. The liquid line and suction line should be run according to piping design as shown in Fig.6.
2. Brazing should be performed with a constant purge of nitrogen through the piping. This is to
keep the inside of tubing clean.
3. Insulate suction and liquid lines separately to prevent sweating.
Fig.6
4. Connections to the indoor unit are flared as shown in Fig. 7.
4.1. Make flared joints for both suction and liquid lines.
4.2. Ensure tube and fitting are in line with one another before tightening nut to provide
concentric seating of tube on fitting to prevent leakage.
5. Tighten the flare nut with two torque wrenches until the wrench clicks. See Fig.8. When
tightening the flare nut with torque wrench, ensure the direction for tightening flows the
wrench.
THE DIMENSION OF THE UNIT
Table 1
Model
A
B
C
D
E
F
G
H
FCA24-1A
1245
680
244
760
450
1119
200
240
FCA36-1A
1245
680
244
760
450
1119
200
240
FCA54-1A
1670
680
244
1070
450
1542
200
240
Please refer to Fig. 2 and Fig. 6.
Remark: All units in mm.

14
IMPORTANT
A. Be sure to apply a sealing cap or waterproof tape to prevent dust or water from getting into
the tubes before they are used.
B. Be sure to apply refrigerant lubricant to the matching surfaces of the flare and union before
connecting them together. This is effective for reducing gas leaks.
Fig.7
Fig.8
Piping Size
Torque
1/4"
1.4~1.7kg.m
3/8"
1.4~1.7kg.m
1/2"
4.8~6.2kg.m
5/8"
4.8~6.2kg.m
3/4"
6.9~9.9kg.m

15
6. Permissible piping for recommended combinations.
6.1. Limit the number of bends in piping to less than 3.
6.2. Table 2 –Maximal distance of pipeline
Table 2
Model
FCA24-1A
FCA36-1A
FCA54-1A
Max length (ft/m)
39/12
49/15
49/15
Max height (ft/m)
26/8
26/8
26/8
Max elbow (pcs)
10
10
10
6.3. Use vacuum pump to exhaust air in pipeline.
6.4. When the piping is longer than 26in/8m, add refrigerant as shown in Table 3.
Table 3
Liquid line diameter (in or mm)
Charged weight (oz/in or g/m)
Ф0.3 / Ф6.3
0.34 or 30.0
Ф0.4 / Ф9.5
0.70 or 65.0
Ф0.5 / Ф12.7
1.28 or 120.0
CONDENSATE DRAIN
1. Be sure the unit is reasonably level and pitched toward the drain to ensure proper drainage.
2. Connect the condensate drain pipe to the coupling, see Fig.9.
3. The indoor unit uses gravity to drain; therefore the piping outside the unit should slope
downward.
4. “Important”, avoid draining as shown in Fig.10, A, B, C. Follow proper draining as shown in
Fig.10D.
Fig.9 Fig.10

16
ELECTRICAL WIRING
1. Be sure to supply power from a dedicated power outlet.
2. Wiring should be made in accordance with the applicable local codes.
3. Connect the cable to the indoor unit by connecting the wires to the terminals on the control
board individually according to the outdoor unit connection. (Ensure that the color of the
wires of the outdoor unit and the terminal No. are the same as those of the indoor unit).
4. Ground both indoor and outdoor units, and the ground wire should be longer than the
common wires.
5. Connect power wires and signal wires to the corresponding ports according to the wiring
diagram.
6. Close control board cover.
IMPORTANT
A. Secure the cables with a cable clamp after connecting them to the terminal block.
B. Connect the wires according to color codes by referring to the wiring diagram.
C. Power cabling can be executed by authorized electricians only.
D. The power and signal connecting cables connected to the indoor and outdoor unit should
be comply with the following specifications in Table 4.
Table 4
Model
Indoor power wires
Signal wires of indoor and outdoor unit
FCA24-1A
3x1.0mm2
4x0.75mm2
FCA36-1A
3x1.0mm2
4x0.75mm2
FCA54-1A
3x1.0mm2
4x0.75mm2

22
APPENDIX II: CONNECTING INDOOR & OUTDOOR UNITS DEMONSTRATION
SAFETY CONSIDERATIONS
1. Installation and servicing of air conditioning equipment can be hazardous due to system pressure and
electrical components. Only trained and qualified personnel should service equipment.
2. When working on air conditioning equipment observe precautions in the literature and labels attached to the
unit and other safety precautions that may apply. Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for brazing operations. Have a fire extinguisher available for all brazing operations.
INDOOR UNIT TERMINALS
Connect each wire to the proper terminals.(Pic.7 and Table 1)
Pic.7
ICONS
NAMES
DETAILS
C
COM terminal
Use to connect the 24V AC neutral wire to the outdoor unit
Y 24V AC signal terminal Use to connect the 24V AC signal wire to the outdoor unit which to
control the ON/OFF signals of the compressor and fan motor.
Ground line terminal Use to connect ground wire to the outdoor unit.
N
Neutral line terminal
Use to connect the neutral line to the outdoor unit.
L
Hot line terminal
Use to connect the hot line to the outdoor unit.
Table 1
To outdoor unit wires

17
REMOTE CONTROL HANDSET
Note: The TURBO, LAMP, AIR FLOW and CLEAN functions are applicable for special latest
develop new models instead of normal ones.
AIR FLOW
button
HOLD button
SLEEP button
CLEAN button
LAMP button
SWING button
MODE button
POWER button
FAN SPEED
button
TIMER button
TURBO button
SETTING
TEMPERATURE
buttons

18
REMOTE CONTROL HANDSET
1. TRANSMISSION SOURCE
Infrared transmission source.
2. POWER BUTTON
Press to turn the air conditioner ON or OFF.
3. MODE BUTTON
Press to select desired operation modes in the order: Auto > Cooling > Dehumidifying >
Heating > Fan > Auto.
4. SETTING TEMPERATURE BUTTONS
Press to increase set temperature.
Press to decrease set temperature.
Temperature range: 61°F-90°F (16°C-32°C) in display.
Note: In Dehumidifying mode and Automatic mode, setting temperature selecting function is
disabled.
5. FAN SPEED BUTTON
Press to select desired fan speed. Press from one to another as shown below.
When the previous fan speed was AUTO FAN, HIGH fan speed will be selected when
switching to FAN mode.
Note: In Dehumidifying mode, fan speed fixed in LOW speed.

19
6. SWING BUTTON
Press the swing button to evenly distribute air in the room or to adjust the louver to preferred
opening.
7. AIRFLOW BUTTON
Press to select swing in left/right direction. The airflow mode sequence is Swing > Stop >
Swing.
8. TIMER BUTTON
The timer function is not activated in the default mode. To set timer on/off, press the timer
button once to activate the timer on/off mode. Each press after will move by 1 hour. The switch
order is: >1hr>2hr>…>24hr>off>1hr….
Note: The timer will continue to activate unless it is cancelled by press the timer button once
again. If turn on/off the unit before the timer set time, the timer on/off function will be cancelled.
9. SLEEP BUTTON
Press for sleep mode ON or OFF.
Setting sleep function in FAN mode, the fan speed will automatically switch to LOW. Press the
FAN SPEED button to adjust the speed.
Setting sleep function in dehumidifying mode, the fan speed will automatically switch to LOW
and is not adjustable.
10. HOLD BUTTON
Press to lock or unlock the remote control keyboard.
11. TURBO BUTTON
Press for turbo mode ON or OFF in COOL mode. The fan speed will switch to HIGH. Turbo
function does not work in auto, dehumidifying, and fan mode.