92-24161-94 rev. 01 rhwb series hydronic air handler
TRANSCRIPT
92-24161-94-01SUPERSEDES 92-24161-94-00
INSTALLATION INSTRUCTIONSHYDRONIC AIR HANDLERRHWB-
DO NOT DESTROY THIS MANUAL. PLEASE READ CAREFULLY AND KEEPIN A SAFE PLACE FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.
ISO 9001:2008
2
IMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCE WITH THEUNDERWRITERS LABORATORY(UL) CERTIFICATION OR THESEINSTRUCTIONS, CAN RESULT INUNSATISFACTORY OPERATIONAND/OR DANGEROUS CONDI-TIONS AND ARE NOT COVEREDBY THE UNIT WARRANTY.
DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM ANDDRAW POLLUTANTS SUCH ASDIRT, DUST, FUMES AND ODORSINTO THE HOME CAUSINGPROPERTY DAMAGE. FUMESAND ODORS FROM TOXIC,VOLATILE OR FLAMMABLECHEMICALS, AS WELL AS AUTO-MOBILE EXHAUST AND CARBONMONOXIDE (CO), CAN BE DRAWNINTO THE LIVING SPACETHROUGH LEAKING DUCTS ANDUNBALANCED DUCT SYSTEMSCAUSING PERSONAL INJURY ORDEATH (SEE FIGURE 2).• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUSTBE SEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDING CAR-BON MONOXIDE FROMMIGRATING INTO THE LIVINGSPACE.
• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCHAS WATER HEATERS ORBOILERS - ALL JOINTS, SEAMS,AND OPENINGS IN THE EQUIP-MENT AND DUCT MUST ALSOBE SEALED TO PREVENTDEPRESSURIZATION OF THESPACE AND POSSIBLEMIGRATION OF COMBUSTIONBYPRODUCTS INCLUDINGCARBON MONOXIDE INTO THELIVING SPACE.
IN COMPLIANCE WITHRECOGNIZED CODES, IT ISRECOMMENDED THAT ANAUXILIARY DRAIN PAN BEINSTALLED UNDER ALLEVAPORATOR COILS AND UNITSCONTAINING EVAPORATORCOILS AND AIR HANDLERS USEDWITH EVAPORATOR COILS THATARE LOCATED IN ANY AREA OF ASTRUCTURE WHERE DAMAGE TOTHE BUILDING OR BUILDINGCONTENTS MAY OCCUR AS ARESULT OF AN OVERFLOW OFTHE COIL DRAIN PAN, ASTOPPAGE IN THE PRIMARYCONDENSATE DRAIN PIPING ORANY WATER LEAK POTENTIALFROM THE AIR HANDLER.
! WARNING
NOTICE
APPLICATION OF THIS HYDRONICAIR HANDLER SHOULD BEINDOORS. SPECIAL ATTENTIONSHOULD BE GIVEN TO UNITSIZING AND PIPING, FILLING, ANDPURGING.
NOTICE
FAILURE TO FOLLOW THISCAUTION MAY RESULT INPERSONAL INJURY. SHEETMETAL PARTS MAY HAVESHARP EDGES OR BURRS. USECARE AND WEAR APPROPRIATEPROTECTIVE CLOTHING.
CAUTION
NOTICE
SAFETY INFORMATION
WHEN AN AIR HANDLER ISINSTALLED SO THAT SUPPLYDUCTS CARRY AIR CIRCULATEDBY THE AIR HANDLER TO AREASOUTSIDE THE SPACECONTAINING THE AIR HANDLER,THE RETURN AIR SHALL ALSO BEHANDLED BY DUCT(S) SEALEDTO THE AIR HANDLER CASINGAND TERMINATING OUTSIDE THESPACE CONTAINING THE AIRHANDLER.
INSTALLATION MUST COMPLYWITH ALL INSTALLATIONINSTRUCTIONS INCLUDING:• AIR HANDLER OPERATINGUNDER THERMOSTATICCONTROL;
• RETURN AIR DUCT SEALED TOTHE AIR HANDLER;
• AIR FILTERS IN PLACE;• RETURN AIR TEMPERATUREMAINTAINED BETWEEN 55°F(13°C) AND 80°F (27°C); AND
• CLEAN AIR HANDLER, DUCTWORK AND COMPONENTSUPON SUBSTANTIALCOMPLETION OF THECONSTRUCTION PROCESS,AND VERIFY AIR HANDLEROPERATING CONDITIONSINCLUDING FLOW RATE ANDTEMPERATURE RISE,ACCORDING TO THEINSTRUCTIONS.
! WARNING
! WARNING
! WARNINGDO NOT OPERATE THE SYSTEMFOR EXTENDED PERIODSWITHOUT FILTERS. A PORTIONOF THE DUST ENTRAINED IN THEAIR MAY TEMPORARILY LODGEIN THE AIR DUCT RUNS AND ATTHE SUPPLY REGISTERS. SOOTDAMAGE MAY RESULT WITH, ORWITHOUT, FILTERS IN PLACE,WHEN CERTAIN TYPES OFCANDLES ARE BURNED, ORCANDLEWICKS ARE LEFTUNTRIMMED.
HORIZONTAL UNITS MUST BECONFIGURED FOR RIGHT HANDAIR SUPPLY OR LEFT HAND AIRSUPPLY. HORIZONTAL DRAINPAN MUST BE LOCATED UNDERINDOOR COIL. FAILURE TO USETHE DRAIN PAN CAN RESULT INPROPERTY DAMAGE.
! CAUTION
WHEN USED IN COOLINGAPPLICATIONS, EXCESSIVESWEATING MAY OCCUR WHENUNIT IS INSTALLED IN ANUNCONDITIONED SPACE. THISCAN RESULT IN PROPERTYDAMAGE.
! CAUTION
CODES AND STANDARDS:IT IS THE RESPONSIBILITY OFTHE INSTALLER TO FOLLOW ALLNATIONAL CODES, STANDARDSAND LOCAL ORDINANCES, INADDITION TO INSTRUCTIONSLAID OUT IN THIS MANUAL. THEINSTALLATION MUST COMPLYWITH REGULATIONS OF THELOCAL BUILDING, HEATING,PLUMBING, AND OTHER CODES.WHERE LOCAL CODES ARE NOTAPPLICABLE, THE INSTALLATIONMUST COMPLY WITH THENATIONAL CODES AND ANY ANDALL AUTHORITIES HAVINGJURISDICTION.
! NOTICE
! WARNINGDO NOT OPERATE THE SYSTEMWITHOUT FILTERS. A PORTIONOF THE DUST ENTRAINED IN THEAIR MAY TEMPORARILY LODGEIN THE DUCT RUNS AND AT THESUPPLY REGISTERS. THISRESIDUE COULD SOIL CEILINGS,WALLS, DRAPES, CARPETS ANDOTHER ARTICLES IN THE HOUSE.SOOT DAMAGE MAY OCCURWITH FILTERS IN PLACE, WHENCERTAIN TYPES OF CANDLES,OIL LAMPS OR STANDING PILOTSARE BURNED.
33
IMPORTANT: TO ENSURE PROPER INSTALLATION AND OPERATION OFTHIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TOATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIRTHIS PRODUCT. UPON UNPACKING OF THE AIR HANDLER, INSPECT ALLPARTS FOR DAMAGE PRIOR TO INSTALLATION AND START-UP.
PROHIBITED APPLICATIONSRHWB HYDRONIC AIR HANDLERS WITH OPTION CODE 414 AREREQUIRED FOR INSTALLATION IN CALIFORNIA PER AB1953. OPTIONCODE 414 IS ALSO REQUIRED IN VERMONT, PER SB152 FOR USE OF THISAIR HANDLER IN AN OPEN SYSTEM WITH POTABLE WATER.
IMPORTANT: THE HYDRONIC AIR HANDLER CAN ONLY BE USED WHENPROPERLY MATCHED WITH A TANKLESS WATER HEATER FROM THEMANUFACTURER, AS SPECIFIED BY THE MANUFACTURER.
CONTENTS
Safety Precautions ...................................................................................................1
Safety Information ....................................................................................................2
General Information..................................................................................................4
Location Requirements and Considerations ............................................................6
Selection Procedure .................................................................................................8
Ducting ...................................................................................................................10
Installation ..............................................................................................................12
Plumbing.................................................................................................................13
Electrical Wiring......................................................................................................16
Accessories ............................................................................................................16
Sequence of Operation ..........................................................................................20
Maintenance...........................................................................................................22
Troubleshooting......................................................................................................24
Wiring Diagram.......................................................................................................25
IMPORTANT: All manufacturerproducts meet current Federal OSHAGuidelines for safety. CaliforniaProposition 65 warnings are requiredfor certain products, which are notcovered by the OSHA standards.
California's Proposition 65 requireswarnings for products sold in Californiathat contain, or produce, any of over600 listed chemicals known to the Stateof California to cause cancer or birthdefects such as fiberglass insulation,lead in brass, and combustion productsfrom natural gas.
All “new equipment” shipped for sale inCalifornia will have labels stating thatthe product contains and/or producesProposition 65 chemicals. Although wehave not changed our processes,having the same label on all ourproducts facilitates manufacturing andshipping. We cannot always know“when, or if” products will be sold in theCalifornia market.
You may receive inquiries fromcustomers about chemicals found in, orproduced by, some of our heating andair-conditioning equipment, or found innatural gas used with some of ourproducts. Listed below are thosechemicals and substances commonlyassociated with similar equipment inour industry and other manufacturers.
• Glass Wool (Fiberglass) Insulation• Carbon Monoxide (CO)• Formaldehyde• Benzene
More details are available at theWebsites for OSHA (OccupationalSafety and Health Administration), atwww.osha.gov and the State ofCalifornia's OEHHA (Office ofEnvironmental Health HazardAssessment), at www.oehha.org.Consumer education is important sincethe chemicals and substances on thelist are found in our daily lives. Mostconsumers are aware that productspresent safety and health risks, whenimproperly used, handled andmaintained.
! WARNING
4
GENERAL INFORMATION
FIGURE 1UPFLOW AIR HANDLERTHE RWHB SERIES HYDRONIC AIR HANDLERS ARE DESIGN-CERTIFIED BY UL
9 8
7
3
2
1
5
4
10
6
ITEM ITEMNO. PART NAME NO. PART NAME
1 DOOR SWITCH 6 BLOWER2 JUNCTION BOX 7 PUMP3 TRANSFORMER 8 WATER INLET4 CAPACITOR 9 WATER OUTLET5 LOW VOLTAGE (THERMOSTAT) TERMINAL 10 BLOWER MOTOR
4
Association, Inc., BatterymarchPark, Quincy, MA 02269.” Thesepublications are:
• ANSI/NFPA No. 70-(Latest Edition)National Electrical Code.
• NFPA90A Installation of AirConditioning and VentilatingSystems.
• NFPA90B Installation of Warm AirHeating and Air ConditioningSystems.
• The equipment has beenevaluated in accordance with theCode of Federal Regulations,Chapter XX, Part 3280.
IMPORTANTINFORMATION ABOUTEFFICIENCY AND INDOORAIR QUALITYCentral cooling and heatingequipment is only as efficient as theduct system that carries the cooled orheated air. To maintain efficiency,comfort and good indoor air quality, itis important to have the properbalance between the air beingsupplied to each room and the airreturning to the cooling and heatingequipment.Proper balance and sealing of theduct system improves the efficiencyof the heating and air conditioningsystem and improves the indoor airquality of the home by reducing theamount of airborne pollutants thatenter homes from spaces where theductwork and/or equipment islocated. The manufacturer and theU.S. Environmental ProtectionAgency’s ENERGY STAR Programrecommend that central duct systemsbe checked by a qualified contractorfor proper balance and sealing.
DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM ANDDRAW POLLUTANTS SUCH ASDIRT, DUST, FUMES AND ODORSINTO THE HOME CAUSINGPROPERTY DAMAGE. FUMESAND ODORS FROM TOXIC,VOLATILE OR FLAMMABLECHEMICALS, AS WELL ASAUTOMOBILE EXHAUST ANDCARBON MONOXIDE (CO), CANBE DRAWN INTO THE LIVINGSPACE THROUGH LEAKINGDUCTS AND UNBALANCED DUCTSYSTEMS CAUSING PERSONALINJURY OR DEATH (SEE FIGURE2).• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUSTBE SEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDINGCARBON MONOXIDE FROMMIGRATING INTO THE LIVINGSPACE.
• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCHAS WATER HEATERS ORBOILERS - ALL JOINTS, SEAMS,AND OPENINGS IN THEEQUIPMENT AND DUCT MUSTALSO BE SEALED TO PREVENTDEPRESSURIZATION OF THESPACE AND POSSIBLEMIGRATION OF COMBUSTIONBYPRODUCTS INCLUDINGCARBON MONOXIDE INTO THELIVING SPACE.
IMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCE WITH THE ULCERTIFICATION OR THESEINSTRUCTIONS, CAN RESULT INUNSATISFACTORY OPERATIONAND/OR DANGEROUS CONDI-TIONS AND ARE NOT COVERED BYTHE UNIT WARRANTY.
IN COMPLIANCE WITHRECOGNIZED CODES, IT ISRECOMMENDED THAT ANAUXILIARY DRAIN PAN BEINSTALLED UNDER ALLEVAPORATOR COILS OR UNITSCONTAINING EVAPORATOR COILSOR AIR HANDLERS USED WITHEVAPORATOR COILS THAT ARELOCATED IN ANY AREA OF ASTRUCTURE DAMAGE TO THEBUILDING OR BUILDING CONTENTSMAY OCCUR AS A RESULT OF ANOVERFLOW OF THE COIL DRAINPAN OR A STOPPAGE IN THEPRIMARY CONDENSATE DRAINPIPING.
required for the job specification.• Read the entire instructions beforestarting the installation.
• Some building codes require extracabinet insulation and gasketingwhen unit is installed in atticapplications.
• If installed in an unconditionedspace, apply caulking around thepower wires, control wires,refrigerant tubing and condensateline where they enter the cabinet.Seal the power wires on the insidewhere they exit conduit opening.Caulking is required to prevent airleakage into and condensate fromforming inside the unit, control box,and on electrical controls.
• Install the unit in such a way as toallow necessary access to thecoil/pump and blower/controlcompartment.
• Install the unit in a level position toensure proper condensatedrainage. Make sure unit is level inboth directions within 1/8”.
• Install the unit in accordance withany local code which may applyand the national codes. Latesteditions are available from:“National Fire Protection
RECEIVINGImmediately upon receipt, all cartonsand contents should be inspected fortransit damage. Units with damagedcartons should be openedimmediately. If damage is found, itshould be noted on the deliverypapers, and a damage claim filedwith the last carrier.• After unit has been delivered to jobsite, remove carton, taking carenot to damage unit.
• Check the unit rating plate for unitsize, voltage, phase, etc. to besure equipment matches what is
NOTICE
NOTICE
! WARNING
FIGURE 2MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES
5
6
GENERAL INFORMATION1. IMPORTANT: If installing the
unit over a finished ceiling orliving area, be certain to install anauxiliary condensate drain panunder the entire unit. Thisauxiliary drain pan should extendunder any evaporator coilinstalled with the air handler andthe open portion of thecondensate drain assembly.
2. IMPORTANT: If using a coolingevaporator coil with this airhandler:
Be sure the air passes over thecoil/pump before passing overthe cooling coil.
IMPORTANT: Support this unitwhen installed. Since this airhandler is suitable for attic orcrawl space installations, it maybe installed on combustible woodflooring or by using supportbrackets. See Figure 5.
5. IMPORTANT: If installing in autility room, be sure the dooris wide enough to:
a. allow the largest part of the airhandler to pass; or
b. allow any other appliance(such as a water heater)to pass.
6. IMPORTANT: This air handler isnot approved or recommendedfor installation on its back, withaccess doors facing upwards(see Figure 3).
CLEARANCE -ACCESSIBILITYThe design of air handlers with inputratings as listed in the tables underFigure 4 are certified by UL for theclearances to combustible materialsshown in inches.
See name/rating plate and clearancelabel for specific model number andclearance information.
Service clearance of at least 24” isrecommended in front ofall air handlers.
NOTE: Use recommended 24”clearance if accessibility clearancesare greater than fire protectionclearances.
Air handlers are shipped with abottom closure panel installed.When bottom return air is used,remove the panel by removing thetwo screws attaching the panel tothe front base angle.
SITE SELECTION1. Select a site in the building near
the center of the proposed, orexisting, duct system.
2. Locate the air handler to maintainproper clearance to combustiblesas shown in the following tables.
LOCATION REQUIREMENTS AND CONSIDERATIONS
PROHIBITED INSTALLATIONS
The air inlet is not allowed to be atthe front or back of the air handler.
Do not position the air handler on its backor with it face down. Do not cut sides of
horizontal application.
NOTE:Multiple air handlers configured for installation witha single Tankless Water Heater is prohibited.
6
Front
Back
FIGURE 3
FIGURE 4CLEARANCE TO COMBUSTIBLES, UPFLOW, HORIZONTAL LEFT OR RIGHT,NO DOWNFLOW
I392
SUPPLY
AIR WATER
INLE
T
WATER
OUTLE
T
RETURN
AIR
AIRFL
OW
27
3⁄8
26
7⁄16
IMPORTANT: Support this unit when installed. Since this airhandler is suitable for attic or crawl space installation, it may beinstalled on combustible wood flooring or by using supportbrackets.
MINIM
UM
CLEA
RAN
CE(IN.)
LEFT
RIGHT
SHIP
MODEL
AB
CD
EF
SIDE
SIDE
BACK
TOP
FRONT
WGT
S
0617
1 ⁄216
11⁄32
155 ⁄8
3 ⁄4ID
1513
25⁄32
00
01
0*118
0824
1 ⁄223
11⁄32
225 ⁄8
3 ⁄4ID
2220
25⁄32
00
01
0*137
1024
1 ⁄223
11⁄32
225 ⁄8
3 ⁄4ID
2220
25⁄32
00
01
0*145
*Aserviceclearanceof
atleast2
4inches
isrecommendedin
fronto
fallairh
andlers.
7
8
SELECTION PROCEDURE(WITH EXAMPLE)I. Define hot water load for the totalrequired domestic hot waterusage.
As an example, let’s assume that theselected Tankless Water Heater for yourwhole house solution is the RTG-74 andyour calculated heat gain and heat lossvalues are as stated in section II.
II. Determine cooling and heatingrequirements at design conditions:
The ACCA’s Manual J Residential LoadCalculation method is the establishedtrade standard, approved by ANSI, forthe correct siziing and selection ofHeating, Ventilation, Air-Conditioningand Refrigeration (HVACR) equipment inresidential homes. The most recentrevision is the eight edition, an all-inclusive new approach to ensuring thatIndoor Air Quality (IAQ) systems are asefficient, safe, and healthy as possible.Refer to the Air Conditioning Contractorsof America website at:http://www.acca.org/tech/manualj/ or aqualified HVACR contractor for furtherassistance.
Assumptions:
Required Cooling Capacity . 48,000 BTU/HR(Total Capacity)
Required Heating Capacity . 60,000 BTU/HR
Evaporator Air Quantity. . . . . . . . . 1600 CFM
External Static Pressure . . . . . . . 0.2 in. W.C.
Electrical Characteristics . . . . . . . . . 115-1-60
III. Determine total external staticpressure (ESP) at designconditions:
Before using the Airflow PerformanceTable calculate the total static pressurerequired. From the given example, notethe Wet Coil Pressure Drop (selectedfrom the field supplied EvaporativeCased Coil Installation Instructions), andthe Filter Pressure Drop. Determine bothstatic pressures at 1600 CFM:
Wet Coil Pressure Drop . . . .0.3 in. W.C.(From Coil Manufacturer’s Installation Instructions)
External Static Pressure . . . 0.2 in. W.C.(Ductwork, etc.)
Filter Pressure Drop . . . .08 in. W.C.(.08 inches if the included filter is used; refer tothe filter’s manufacturer’s instructions if another
filter is used.)
Total Static Pressure. . . 0.58 in. W.C.
IV. Select unit based on requiredcooling capacity airflow:
For an initial selection, choose a unitsize that will provide the requiredairflow. Refer to Airflow PerformanceTable. Note that at 0.6 ESP (externalstatic pressure) the RHWB-06WMP48A unit will deliver 1560CFM when configured for HIGHspeed.
V. Select heating capacity of unitto provide the requisite designcondition:
From the Hydronic Air Handler/Tankless Water Heater, note that theunit RHWB-06WMP48A, (as selectedabove) when matched with the RTG-95 Tankless Water Heater, willprovide 59.2 MBH (59,200 BTU/HR)at an input water temperature (to AirHandler) of 150°F.
Model Number Nomenclature RHWB 06W M P 36 A
Rheem
Air HandlerWater
Denotes a major design change in theproduct line (i.e. capacity)
Nominal Heating Capacity (BTU/HR)06W 60,00008W 80,00010W 100,000
RevisionA = Rev 0
Blower SizeM = 11x7R = 11x10
VariationsP = PSC Motor
48 = 15-1700 CFM60 = 1900-2100 CFMDesign Series
R
Brand Application Type DesignSeries
Heating Output Designation@ Inlet Water Temp 150°F
(Output BTU/HR)
BlowerSize Variations Heat/Cool
Designation Revision
H W B -06W M P 36 A
R = Rheem H = Air handler W = Water B = 2nd Series 06W (60,000) M = 11x7 P = PSC 48 = 1500-1700 CFM A = Rev 008W (80,000) R = 11x10 60 = 1900-2100 CFM10W (90,000)
RTG-53 32600 39500 47500 N/A N/ARTG-64 40900 47100 51000 N/A N/ARTG-66 40200 46400 54700 63500 71300
RHWB-06WMP48A RTG-74 High 0.5 1622 37800 46200 54000 62700 71300RTG-84 40000 47800 52100 60300 68100RTG-95 37200 45200 50900 59200 66400
RTG-53 35000 41300 50600 N/A N/ARTG-64 42000 50900 53400 N/A N/ARTG-66 40400 50500 56500 65500 73600
RHWB-08WRP60A RTG-74 Med-High 0.5 1586 40300 49700 58800 71600 81600RTG-84 45800 53300 56900 66900 76000RTG-95 45300 53100 60000 70500 80700
RTG-53 35500 44500 53300 N/A N/ARTG-64 40800 48000 53200 N/A N/ARTG-66 48300 57800 62100 71800 83000
RHWB-10WRP60A RTG-74 Med-High 0.5 1620 49300 59600 69500 79100 89700RTG-84 43200 51800 56900 65100 75400RTG-95 48300 58200 61000 71000 79800
9
HYDRONIC AIR HANDLERTANKLESSWATER HEATER PERFORMANCETABLE 1Entering Water Temperature (°F)
Air Handler Model Tankless Model Blower Speed ESP (in. w.c.) Heating Air Delivery(CFM)
120 130 140 150 160
Performance is based on the following assumptions:1) an estimated 100 ft. equivalent length of 0.75-inch piping.2) 0.80” w.c. of external air static.
10
DUCTINGProper air flow is required for thecorrect operation of this air handler.Too little air flow can cause erraticoperation and can damage the heatexchanger. The duct system mustcarry the correct amount of air forheating and cooling if summer airconditioning is used.Size the ducts according toacceptable industry standards andmethods. The total static pressuredrop of the air distribution systemshould not exceed 0.8" w.c.
NOTE: Return air grilles and warm airregisters must not be obstructed
IMPORTANT: Some high efficiencyfilters have a greater than normalresistance to air flow. This canadversely affect air handler operation.BE SURE TO CHECK AIR FLOW.IMPORTANT:When using outsideair, design and adjust the system tomaintain a return air temperatureABOVE 50° F during the heatingseason.
UPFLOW UNITS1. Position the unit to minimize long
runs of duct or runs of duct withmany turns and elbows.
2. Open the return air compartment.
a. Cut an opening in the side.The opening shouldbe cut the full width of theknockouts on the unit. SeeFigure 4.
NOTE:Where the maximum air flowis 1800 CFM or more, both sides orthe bottom must be used for returnair.
3. Connect the return duct or returnair cabinet to the unit. Make theconnection air tight to prevententraining combustion gasesfrom an adjacent fuel-burningappliance.
4. Be sure to have adequatespace for the unit filter.
NOTE: DO NOT take return airfrom bathrooms, kitchens, airhandler rooms, garages, utility orlaundry rooms, or cold areas.
NOTE: DO NOT use a rear airreturn.
5. If summer air conditioning (heatpump) is desired, position theindoor coil on the top of the unit.Insure that no air can bypass thiscoil.
6. Connect the supply air plenum tothe air handler plenum opening.
HORIZONTAL UNIT1. Position the unit to minimize long
runs or runs with many turns andelbows.
2. If summer air conditioning or heatpump is desired, position theindoor coil on the supply air endof the unit. Insure that no air canbypass this coil.
3. Connect the air handler to thesupply air plenum.
4. Connect the return air ducting tothe return air opening of the unit.Make the connection air tight toprevent pulling combustion gasesfrom an adjacent fuel-burningappliance.
5. Be sure to have adequatespace for the unit filter.NOTE: DO NOT take return airfrom bathrooms, kitchens, airhandler rooms, garages, utility orlaundry rooms, or cold areas.
FIGURE 5CUTOUT AND DRILL INFORMATIONUPFLOW ONLY JACKET
DRILL (2)3/16" DIA.HOLES
8.000”
4.875”
1.531”
*Solid metal bottom required if side duct penetration is used.
11
Blower located to the right of coil section. Conditioned air is discharged to the left.
Blower located below coil section. Conditioned air is discharged upward.
Blower located to the left of coil section. Conditioned air is discharged to the right.
Blower located above coil section. Conditioned air is discharged downward.
F
FIGURE 6POSITION ORIENTATION UPFLOW
PROHIBITED
SUSPENDED CABINETINSTALLATIONIf the cabinet cannot be supported on aframe or supported from the wall, it maybe suspended.
Use metal strapping or threaded rod withangle iron supports under cabinet forsupport. These supports MUST runparallel with the length of the cabinet.
Ensure that there is adequate room toremove service and access panels afterinstalling supporting brackets.
If an auxiliary drain pan is required, thesupport is to be placed under a drainpan.
IT IS THE INSTALLER’SRESPONSIBILITY TO USE ANAPPROPRIATE HANGING METHODCAPABLE OF SUPPORTING THEUNIT’S WEIGHT. REFER TO THESPECIFICATION SECTION OF THISDOCUMENT FOR THE RESPECTIVEUNIT’S INSTALLED WEIGHTS.
FOR SEISMIC HANGINGREQUIREMENTS, REFER TO LOCALCODES.
Attachment Methods Using Straps
Method 1
Use (4) #8 x 3/4 sheet metal screwsfor each strap. The straps should bevertical against the air handler sidesand not pull away from the air handlersides.
Method 2
Fold all straps under the air handlerand secure with (4) #8 x 3/4 sheetmetal screws (2 screws at the sideand 2 screws at the bottom. (Caremust be taken not to drive the screwthrough the coil.)
INSTALLATION
! WARNING
NOTICE
FIGURE 7HORIZONTAL UNIT SUSPENSION
DOORASSEMBLY
8” MIN FORDOOR REMOVAL
(2) HEX NUTS, (2) WASHERS & (2)LOCK WASHERS REQ. PER ROD
USE 1” SQUARE, 1-1/4 x 1-1/4 x 1/4ANGLE IRON OR EQUIVALENT
SECURE ANGLEIRON TO BOTTOMOF AIR HANDLERWITH 3 #8 x 3/4”SCREWS TYPCIALFOR 2 SUPPORTS
1/4” THREADED ROD(4 REQUIRED)
F
FIGURE 8HORIZONTAL UNIT SUSPENSION WITH STRAPS
DOORS
1 INCH x 22 GAUGEGALVANIZED STRAPSTYPICAL FOR 4 STRAPS
RETURN AIROPENING
SUPPLY AIR OPENING
BACK
12
PLUMBINGCodes:Observe all local sanitary codes wheninstalling water lines. The water supplymating connection to the Hydronic AirHandler is made via the two (3/4 in. dia.X 2-1/2 in. long) copper stubs to thefront-left of the unit labeled “WATER IN”and “WATER OUT” (see Figure 1).Mating connectors to be two field-supplied, 3/4 in., FNPT-sweat ends orequivalent.
All associated hydronic piping MUSTcomply with ICC, UPC and any otherlocal codes or ordinances havingjurisdiction. USE POTABLE GRADECOPPER PIPING AND BRASSAPPURTENANCES ONLY.
Flow Switch Installation:(Recommended for Open-LoopSystems)
Care must be taken to ensure that theflow switch is not damaged due toexcessive tightening. The torque mustnot exceed the maximum limit statedbelow. The installation should bechecked to ensure that no leaking isevident.
Mating connectors to be (2) 3/4” FNPTfittings (field supplied).
Pipe-work/connector alignment isimperative (avoid bending stress).
Polytetrafluoroethylene (PTFE) threadseal tape (teflo tape), or equivalent, isrecommended.
Tighten fittings to maximum torque of15lb/ft (20Nm).
Soldering Copper Tubing:The common method of joining coppertubing in hydronic heating systems issoft soldering. Plumbing codes do notallow solders containing lead to be usedfor domestic water service. USE ONLY95/5 tin/antimony solder for all pipingsystems that incorporate a domesticwater supply.
NOTE: Precautions must be takenduring soldering to avoid debris orsolder from lodging in piping system.
Tubing Insulation:Any tube-conveying fluid at atemperature greater than that of thesurrounding air releases heat.
Insulate all accessible hot water linesand associated valves with material,such as expanded neoprene orpolyurethane 3/8-in. to 1⁄2-in. thick.
Match the pipe sleeve’s inside diameterto the pipe’s outside diameter for a snugfit. Place the pipe sleeve so the seamwill be face down on the pipe. Tape,wire, or clamp insulation every foot ortwo to secure it to the pipe. If taping isdesired, use acrylic tape instead of ducttape.
Copper Tubing Support:Copper tubing must be properlysupported to prevent sagging orbuckling. On horizontal runs with hardtemper tubing, the following maximumsupport spacing is suggested:
• 1/2 in. to 3/4 in. tube: 5 feet maximumspacing
• 1 in. to 1-1/4 in. tube: 6 feet maximumspacing
The above suggested spacing does notaccount for extra weight of pipingcomponents such as an expansion tank,etc. When such components arepresent, the piping should be supportedimmediately adjacent to the component.
On vertical runs, copper tubing shouldbe supported at each floor level or at amaximum of every 10 feet.
Thermal Expansion of Piping:In all hydronic systems, pipingundergoes temperature swings as thesystem operates. This causes changesin the length of the piping due to thermalexpansion.
If the piping is rigidly mounted, thisexpansion can cause annoying poppingor squeaking sounds and, in extremecases, the piping can even buckle.
To counter expansion movement,design piping circuits with sufficientelbows, tees or expansion loops (onlyused in large systems) or pipingsupports that allow the tubing to expandand contract freely.
Another alternative is to install anexpansion compensator fitting capableof absorbing the movement.
Hydraulic Resistance ofFittings, Valves, and OtherDevices:Before the total hydraulic resistanceof a piping circuit can be found, theindividual hydraulic resistances of allfittings, valves, or other suchcomponents must be determined.One approach is to consider eachfitting, valve, or other device as anequivalent length of copper tube ofthe same pipe size (see Table 2).
By using the equivalent length ofpiping for all components in thecircuit, the circuit can be treated as ifit were a single piece of pipe havinga length equal to the sum of theactual pipe length, the totalequivalent lengths of all fittings,valves, or other devices. Refer toFigure 9 and the calculation ofequivalent lengths.
Pipe Sizing Considerations:When selecting a pipe size for agiven flow rate, the resulting averageflow velocity should be between 2and 4 feet per second.
At water flow velocities ofapproximately 2 feet per second,flowing water will carry air bubblesalong a vertical pipe. Average flowvelocities of 2 feet per second orhigher can draw along air bubbles ina downward flow. At the abovestated velocities air bubbles shall berouted to an air separator where theycan be collected and discharged fromthe system. Use Taco 4900 seriesair separator, Model 49-075, orequivalent (field supplied).
Average flow velocities higher than 4feet per second could cause flownoise and should be avoided.
Expansion Tanks:All liquids used in hydronic heatingsystems expand when heated. Forall practical purposes, liquids areincompressible. Any containercompletely filled with a liquid andsealed from the atmosphere willexperience a rapid increase inpressure as the liquid is heated.
To prevent this from occurring, allclosed-loop hydronic systems MUSTbe equipped with an expansion tank.Refer to expansion tankmanufacturer’s instructions for propersizing and installation.
13
14
PROCEDURE FORCALCULATING THE TOTALEQUIVALENT LENGTH OF PIPE
Given piping assembly as shown inFigure 9 below, what is the totalequivalent length of the system?
First determine the total straight pipelengths; next refer to Table 2 todetermine the equivalent straight pipelength for each fitting shown. Addtogether the equivalent lengths of pipingand fittings.
(3/4”) Tubing 24 ft.
7 (3/4”) 90 deg. Elbows 7 (1.9) = 13.3 ft.
5 (3/4”) Side Port Tees 5 (3.8) = 19.0 ft.
1 (3/4”) Taco air separator = .3 ft.2 (3/4”) Ball Valve 2 (.2) = .4 ft.
Total Equivalent Length . . . . . = 57 ft.
WHERE POSSIBLE THE LENGTH OFPIPE SHOULD NOT EXCEED 100FEET TOTAL EQUIVALENT LENGTH.
ANY PIPING RUNNING THROUGHUNCONDITIONED SPACE MUST BEINSULATED TO PREVENT HEATLOSS, AND POSSIBLE FREEZING OFTHE LINE.
STICKERS INDICATING DIRECTIONOF FLOW (WATER IN AND WATEROUT) ARE LABELED ON THEOUTSIDE OF THE CABINET. DO NOTREVERSE THESE LINES, AS THISWILL CAUSE THE UNIT TOMALFUNCTION.
Piping ConfigurationWhen employing a Tankless WaterHeater in a hydronic system, thesystem is considered an open-loopsystem when configured tosimultaneously deliver both domestichot water and space heating. Bydefinition, if the circuit is sealed offfrom the atmosphere at all locations(as is true for most modern hydronicsystems), it is called a closed-loopsystem. If the circuit is open to theatmosphere at any point, it is calledan open-loop system.
NOTICE
FIGURE 9EQUIVALENT LENGTH CALCULATION
COLDHOTT3T1
1-1/2 FT
BV1
1 FT
T4
EV2
COLDWATERSUPPLY
T2
T5
EL7
2 FT1-1/2 FT
TEMPEREDWATER
AS
EL5
1 FT
EL6 2 FT
1 FT
4 FTEL4
4 FT
3 FT
EL3FS
3 FT
IN
1/2 FT
EL2
EL1
1 FT
OUT
AIRHANDLER
Table 2 – Equivalent Length of Straight Pipe for Valves and Fittings (ft)
Diameter (in.)
0.375 0.5 0.75 1 1.25 1.5
Globe Valve 14.1 18.8 28.1 37.5 46.9 56.3
Angle Valve 6.3 8.3 12.5 16.7 20.8 25.0
Gate Valve 0.5 0.7 1.1 1.4 1.8 2.1
Ball Valve (BV) 0.1 0.1 0.2 0.3 0.3 0.4
90 Degree Standard Elbow 0.9 1.3 1.9 2.5 3.1 3.8
45 Degree Standard Elbow 0.5 0.7 1.0 1.3 1.7 2.0
Standard Tee with flow through run 0.6 0.8 1.3 1.7 2.1 2.5
Standard Tee with flow through branch 1.9 2.5 3.8 5.0 6.3 7.5
Rheem TanklessWater Heater
COLDWATERSUPPLY
TEMPEREDWATER
AIRHANDLER
15
FIGURE 10TYPICAL PIPING ARRANGEMENT FOR DIRECT SPACE HEATING AND DOMESTIC WATER SUPPLY WITH TANKLESS
All piping to be 3/4 inch.
(BV)
(DV)
Evaporator Coil
Air Separator
Flow Switch
Open-Loop SystemIf piping is done in accordance with therecommended schematic diagramshown in Figure 10, the following purgeand priming procedure applies.
PURGING AND PRIMING THESYSTEM:The following procedure describes howthe system may be piped to eliminatethe need for a “purge cart” to fill thesystem and remove entrapped airbubbles.
STEP 1: CLOSE the air separatorventing valve.
STEP 2: CLOSE ball valve 3 (BV3);
STEP 3: OPEN drain valve 3 (DV3) towhich a hose MUST be connected anddraining to a sink, drain or outdoors.
STEP 4: CLOSE drain valves 1 & 2(DV1 and DV2) and OPEN ball valve 2(BV2).
STEP 5: OPEN cold water supply mainvalve (ball valve 1 - BV1). The systemwill begin the prime/purge process usingthe street pressure. Entrapped airbubbles being pushed out of the systemwill be evident by a slight vibration of thedischarge hose connected to drain valve3 (DV3). The hose will stop vibratingwhen laminar flow is achieved.
STEP 6: CLOSE drain valve 3 (DV3);
STEP 7: OPEN ball valve 3 (BV3).The system is now purged, primedand ready to go.
STEP 8: OPEN the air separatorventing valve.
NOTE: For an open-loop system, useexpansion tank approved for potablewater use only.
16
jurisdiction. USE COPPER WIREONLY. Provide separate branch electriccircuit with field supplied disconnectswitch.Location of disconnect switch to be inclear site, accessible and in closeproximity to the unit.Correct polarity MUST be maintained for115 V wiring. If polarity is incorrect, unitwill NOT operate.Use a separate fused branch electricalcircuit containing a properly sized fuseor circuit breaker. Run this circuit directlyfrom the main switch box to an electricaldisconnect that is readily accessible andlocated near the air handler. Connectfrom the electrical disconnect to thejunction box on the left side of the airhandler, inside the blower compartment.For the proper connection, refer to theappropriate wiring diagram located onthe inside cover of the air handlercontrol box and in these instructions.The electrical junction box may bemoved to the right side if necessary. Aknockout is provided. Seal the oppositehole with plug provided.Make all electrical connections inaccordance with the latest edition of theNational Electrical Code, ANSI/NFPA70and local codes having jurisdiction.These may be obtained from:National Fire ProtectionAssociation, Inc.
Batterymarch ParkQuincy, MA 02269
CSA - International178 Rexdale Blvd.Etobicoke (Toronto), OntarioCanada M9W, 1R3
ELECTRICAL WIRING
TURN OFF ELECTRIC POWER ATFUSE BOX OR SERVICE PANELBEFORE MAKING ANYELECTRICAL CONNECTIONS.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTINGIN PERSONAL INJURY OR DEATH.
THE CABINET MUST HAVE ANUNINTERRUPTED GROUNDACCORDING TO THE LATESTEDITION OF THE NATIONALELECTRICAL CODE (NEC), ANSI/NFPA70- OR IN CANADA, THECANADIAN ELECTRICAL CODE,CSA-C221 OR LOCAL CODESTHAT APPLY. DO NOT USE GASPIPING AS AN ELECTRICALGROUND. A GROUND SCREW ISPROVIDED IN THE JUNCTIONBOX. FAILURE TO DO SO CANCAUSE ELECTRICAL SHOCK,RESULTING IN PERSONALINJURY OR DEATH.
THIS AIR HANDLER IS EQUIPPEDWITH A BLOWER DOOR SAFETYSWITCH. DO NOT DISABLE THISSWITCH. FAILURE TO FOLLOWTHIS WARNING CAN RESULT INELECTRICAL SHOCK, PERSONALINJURY OR DEATH.IMPORTANT: The air handler mustbe installed so that the electricalcomponents are protected from water(condensate).Before proceeding with the electricalconnections, be certain that thevoltage, frequency and phasecorresponds to that specified on theair handler rating plate. For single airhandler application, maximum over-current protection is 15 amperes.
IF A DISCONNECT SWITCH IS TOBE MOUNTED ON THE UNIT,SELECT A LOCATION WHERE ADRILL OR FASTENER WILL NOTCONTACT ELECTRICAL ORHYDRONIC COMPONENTS.ELECTRICAL SHOCK CAN CAUSEPERSONAL INJURY OR DEATH.NOTE: Prior to making any electricalconnections, ensure that supplyvoltage, frequency, and phase are asspecified on unit rating plate.Check to ensure that the existingelectrical service is adequate tohandle the additional load imposed bythe Hydronic Air Handler. Refer tounit wiring diagram for properelectrical connections.All electrical connections MUSTcomply with NEC and any other localcodes or ordinances having
! WARNING
! WARNING
! WARNING
! CAUTION
THERMOSTATThe room thermostat must be com-patible with the integrated air handlercontrol on the air handler. Generally,all thermostats that are not of the“current robbing” type are compatiblewith the integrated air handler control.The low voltage wiring should besized as shown (see Figures 12 and13).NOTE: Do not use 24 volt controlwiring smaller than No. 18 AWG.Install the room thermostat inaccordance with the instruction sheetpacked in the box with the thermostat.Run the thermostat lead wires insidethe blower compartment and connectto low voltage terminals as shown onthe wiring diagram. Never install thethermostat on an outside wall orwhere it will be influenced by drafts,concealed hot or cold water pipes orducts, lighting fixtures, radiation fromfireplace, sun rays, lamps, televisions,radios or air streams from registers.Refer to instructions packed with thethermostat for “heater” selection oradjustment.
ACCESSORIESFIELD-INSTALLEDOPTION ACCESSORIESELECTRONIC AIR CLEANERLine voltage power can be suppliedfrom the screw terminal “EAC” and aline voltage neutral screw terminal onthe control board. This will power theelectronic air cleaner whenever thecirculating air blower is in operation.
Expansion tank for closed systemsair separator – TACO Model 49-075.
17
FIGURE 11FIELD WIRING DIAGRAM
W G R C Y1
Y1
Y2
W
G
B
R
CP3
FS
BLK
WHT
AIR HANDLER
Flow Sensor(Packaged with Unit)
5 Wire
3 Wire Heating Only
Single StageThermostat
24 Volt FS / WH Connector
24 Volt Terminal Block
Control Box
PCB
Condensing Unit
Field 115, 208 / 230 Volt Wiring
Field 24 Volt Wiring
Factory 24 Volt Wiring
Factory 115 Volt Wiring
Junction Box
L1
L2
FIGURE 12THERMOSTAT WIRING DIAGRAMSSINGLE STAGE AIR HANDLER W/SINGLE STAGE A/C
FIRST STAGE HEAT/COOL
AUX HEATING
FAN
24VAC HOT
24 VAC COMMON
SINGLE STAGEAIR-HANDLER
SINGLE SPEEDCONDENSING
UNIT
HEAT/COOL & COOL ONLYTHERMOSTATS
Y1
W
G
R
C
Y1
Y2
W
G
B
R
C
Y1
C
FIGURE 13THERMOSTAT WIRING DIAGRAMSSINGLE STAGE AIR HANDLER W/SINGLE STAGE HEAT PUMP*
FIRST STAGE HEAT/COOL
AUX HEATING
FAN
RVS COOLING
24VAC HOT
24 VAC COMMON
HEAT PUMP THERMOSTATSSINGLE STAGEAIR-HANDLER
SINGLE STAGEHEAT PUMP
Y1
W
G
B
R
C
Y1
W
G
B
R
C
Y1
B
R
C
Y2
F
*Requires Fossil Fuel KitRefer to Kit for further wiring instructions.
TABLE 3
System Low Voltage WiringDiagramsNOTE: Local codes may requirethermostat wiring to be routed throughconduit or raceways. In such instancessplices can be made inside the HydronicAir Handler. All wiring must be NEC ClassI and must be separated from incomingpower leads.
Provide field-supplied disconnect formaximum fuse or circuit breaker sizes, asrequired by code.
Transformer is factory wired for 115Voperation.
The secondary circuit of the transformeris protected by a 3-amp fuse mounted onthe printed circuit board.
FIGURE 14HYDRONIC AIR-HANDLER CONTROL BOARD
FLOW SENSORCONNECTIONS
SW1 SET-UP SWITCHAND HEATING BLOWOFF DELAY
24 V THERMOSTATTERMINALS
TRANSFORMER 24 VCONNECTIONS
P3
P4
P1
3 AMP FUSE
OPERATING MODEJUMPER (SHUNT)
STATUS LED LIGHT
115 VAC (L2)NEUTRALCONNECTIONS
PUMPCONNECTIONS
115 VAC (L1) LINEVOLTAGECONNECTION
FANPARK
FANCONNECTIONHEATING
FANCONNECTIONCOOLING
HUMIDIFIER CONNECTIONS(DRY CONTACT) 24 VAC OR115 VAC
FLASH UPGRADECONNECTION(FACTORY ONLY)
u1
AN
1
P7
BG
WY2
Y1R
C
NOTES:1. For proper operation of an open loop system (refer to Figures 11 and 16), the jumper (shunt) position on PCB point “P7” should be inthe FS position.
2. When changing shunt position ensure that unit power is turned off.
Wire Gauge Maximum Distance (feet)
18 gauge 60
16 gauge 100
14 gauge 160
12 gauge 250
Dip Switch Options:
Refer to the appropriate diagram for theproper dip switch setting to be used withthe designed application (Figure 15).
THERMOSTAT INSTALLATION:
Thermostat should be mounted:
• approximately 5 ft. (1.5 m) from floor
• close to or in a frequently usedroom, preferably on an inside,partitioning wall
• on a section of wall without pipesor duct work.
Thermostat should NOT be mounted:
• close to a window, on an outsidewall, or next to a door leading tothe outside.
18
• exposed to direct light and heat froma lamp, sun, fireplace, or other heat-radiating object which may cause afalse reading.
• close to or in direct airflow fromsupply registers and return-air grilles
• In areas with poor air circulation,such as behind a door or in an alcove
Refer to thermostat wiring diagram andthermostat installation instructions forfurther details.
START-UP PROCEDURE(HEATING ONLY):The following conditions must be metprior to unit start-up.
Debris from soldering and/or otherinstallation activities can causeequipment failure. Ensure that allassociated lines and appurtenancesare free of debris.
Check to ensure that unit is secure.
Check that blower wheel rotates freelywithin the scroll housing.
Check all wiring to ensure thatconnections are tight.
Check all ductwork and pipeconnections to ensure proper seal.
Check to ensure that all packagingwraps are removed from equipment.
Ensure that front access doors areproperly installed.
Check to ensure proper connection(s)to the appropriate blower speed tap(Heat /Cool – High and Low). Refer toDry Air Delivery Table and/or theappropriate wiring diagram(s) in thismanual.
Perform all safety and start-up checksfor Tankless Water Heater as permanufacturer’s instructions.
Having verified all preceding checks,the Air Handler’s Start-Up Procedure isas follows:
STEP 1: Purge and fill system; followappropriate purging procedure as laidout in this manual in section titled“Purging and Priming the System”.
STEP 2: Turn on power supply to airhandler. Caution: blower and/orcirculator may start to operate ifthermostat is on and a call is present.
STEP 3: Turn thermostat ON andswitch system to the heating mode.The thermostat shall be set higher thanthe actual room temperature; this willcause the circulator to energize andinitiate the heating cycle. (If the pumpdoes not start, or the Air Handler is notproducing heat, refer to theTroubleshooting Section, in thismanual).
STEP 4: Program room thermostat asdesired by homeowner.
START-UP PROCEDURE(COOLING SYSTEM)Refer to field-supplied evaporator coiland outdoor unit manufacturer’sInstallation Instructions for systemhook-up, start-up instructions andrefrigerant-charging method details.
TROUBLESHOOTING BLOWERAND/OR PUMP MOTOR ANDCONTROLSIf blower and/or pump motor doesnot run:
Turn OFF power and check thefollowing:
1. Check that door switch is in theCLOSED position.
2. Check 3 amp fuse on PrintedCircuit Board (PCB).
3. Check for 24 VAC between COMand 24 VAC on IAC. If no voltageis present, check transformer.
4. Check all connections for kinkswhich could cause looseconnections. Ensure connectionsare secure.
5. Verify that approximately 120VAC is present across L1 and L2.
FIGURE 15DIP SWITCH POSITIONS
30 SECONDS OFFDELAY (DEFAULT)
60 SECONDS OFFDELAY
1 ON
234 1 ON
234
90 SECONDS OFFDELAY
120 SECONDS OFFDELAY
1 ON
234 1 ON
234
1 ON
Key:
Switch is in the ON position.
Switch does not affect this setting.
1 ONSwitch is in the OFF position.
SINGLE-STAGE A/CCONFIGURATION
(DEFAULT)T
1 ON
234
SINGLE-STAGE HPCONFIGURATION
1 ON
234
19
20
• If the room temperature shouldcontinue to fall, circuit R and W iscompleted by the second-stage heatroom thermostat. Circuit R-Wenergizes a pump. The completedcircuit will energize supplementalheat. The heat pump will de-energizewhen the auxiliary heat is activated. Adual fuel thermostat or fossil fuel kitwill be required.
BLOWER TIME DELAY (HEATINGOR COOLING)All models are equipped with a blowertime delay (BTD) in lieu of a blower relay(BR) (see Figure 21). The blower will runfor 30 seconds after the blower timedelay (BTD) is de-energized.
DEFROST (DEFROST HEATCONTROL)• For sequence of operation of defrostcontrols, see outdoor heat pumpinstallation instructions.
• Supplemental heat during defrost canbe provided by connecting the purple(PU) pigtail in the outdoor unit to theW on the thermostat. This willcomplete the circuit between R and Wthrough a set of contacts in the defrostrelay (DR) when the outdoor heatpump is in defrost. This circuit, ifconnected, will help prevent cold airfrom being discharged from the indoorunit during defrost.
• For most economical operation, if coldair is not of concern during defrost, thepurple wire can be left disconnected.Supplemental heat will then come ononly when called for by second stageroom thermostat.
EMERGENCY HEAT (HEATINGHEAT PUMP)• If selector switch on thermostat is setto the emergency heat positioin, theheat pump will be locked out of theheating circuit, and all heating will behydronic heat. Jumper should beplaced between W and E on thethermostat sub-base so that the
SEQUENCE OF OPERATIONCOOLING (COOLING ONLY ORHEAT PUMP)• When the thermostat “calls forcooling,” the circuit between R and Gis completed, causing the blowerrelay (BR) to energize. The N.O.contacts will close, causing the indoorblower motor (IBM) to operate. Thecircuit between R and Y is alsocompleted: This circuit closes thecontactor (CC) in the outdoor unitstarting the compressor (COMP) andoutdoor fan motor (OFM).
HEATING (HYDRONIC)• When the thermostat “calls for heat,”the circuit between R and W iscompleted. The control monitors theFS input and energizes the circulatingpump if the FS signal is present. Theindoor blower will then be activated.
If the FS signal is NOT present, thecontrol will energize the circulatingpump for 60 seconds in an attempt toactivate the Flow Switch (FS). If theFS signal does not become activeduring this time, the control will de-energize the pump wait 60 secondsand then retry the sequence until theFS signal is present. During this timethe Status LED will rapidly flash,indicating that a heat demand ispresent, but not being satisfiedbecause of the state of the FS inputsignal.
HEATING (HEAT PUMP)• When the thermostat “calls for heat,”the circuits between R and B, R andY and R and G are completed. CircuitR and B energizes the reversingvalve (RV) switching it to the heatingposition (remains energized as longas selector switch is in “heat”position. Circuit R and Y energizesthe contractor (CC) stating theoutdoor fan motor (OFM) andcompressor (COMP). Circuit R and Yenergizes the blower relay (BR)starting the indoor blower motor(IBM).
electric heat control will transfer tothe first stage heat on thethermostat. This will allow theindoor blower to cycle on and offwith the electric heat when the fanswitch is in the auto position.
ROOM THERMOSTAT(ANTICIPATOR SETTING)See instructions with outdoor section,condensing unit or heat pump forrecommended room thermostats.
• On units with one electric heatsequencer (HR1) (see wiringdiagram on unit), heat anticipatorsetting should be .16.
• On units with two electric heatsequencers (HR1 & HR2) (seewiring diagram on unit), heatanticipator setting should be .32 ifboth are connected to same stageon thermostat. Setting should be.16 if (HR1 & HR2) are connected toseparate stages.
NOTE: Some thermostats contain afixed, non-adjustable heatanticipator. Adjustment is notpermitted.
• The thermostat should be mounted4 to 5 feet above the floor on aninside wall of the living room or ahallway that has a good aircirculation from the other roomsbeing controlled by the thermostat.It is essential that there be free aircirculation at the location of thesame average temperature as otherrooms being controlled. Movementof air should not be obstructed byfurniture, doors, draperies, etc. Thethermostat should not be mountedwhere it will be affected by drafts,hot or cold water pipes or air ductsin walls, radiant heat fromfireplaces, lamps, the sun, T.V. oran outside wall. See instructionssheet packaged with thermostat formounting and installationinstructions.
21
! WARNING
SETTING BLOWERTIMINGSThe IAC (Integrated Air HandlerControls) has four quick connectterminals for connecting the motorspeed leads. These are:
1. FAN SPEED — motor runs onthis speed when the thermostatis in the “FAN ON” position.
2. COOL — connect desiredcooling speed.
3. HEAT — connect desiredheating speed.
If cooling speed and fan speed aredesired to be the same, this may beaccomplished by not connecting “Y”to the IAC.
If desired for cool, fan and heat to allbe the same speed, then “piggyback”jumper “H/C” to “FAN” and do notconnect “Y” to the IAC. Do notconnect other motor leads to “H” or“C.”
DIRECT DRIVEINSTRUCTIONS FORCHANGING BLOWERSPEED
DISCONNECT THE ELECTRICALSUPPLY TO THE AIR HANDLERBEFORE ATTEMPTING TOCHANGE THE BLOWER SPEED.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTINGIN PERSONAL INJURY OR DEATH.
The blower motor must be wired forblower speeds required for normaloperation.
If additional blower speed taps areavailable (leads connected to “M1”and “M2” on the electronic control),speeds may be changed if necessaryto fit requirements of the particularinstallation. Reconnect the unusedmotor leads to “M1” or “M2.” Checkmotor lead color for speeddesignation.
Heating speeds should not bereduced where it could cause the airhandler air temperature rise toexceed the maximum outlet airtemperature specified for the unit.
IMPORTANT: Always check airtemperature rise after changing theheating speed for any reason.
CFM @ ESP
Model Blower / Motor HP Speed 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Low 921 915 886 876 855 841 817 780 734 690
M-Lo 1189 1180 1179 1137 1131 1102 1072 1030 985 915RHWB-06WMP48A 11x7, 3/4
M-Hi 1335 1315 1306 1307 1277 1246 1210 1161 1090 1019
High 1841 1795 1747 1681 1622 1560 1500 1420 1358 1288
Low 1319 1307 1300 1240 1236 1210 1177 1149 1100 1032
M-Lo 1484 1480 1471 1463 1418 1385 1359 1314 1246 1166RHWB-08WRP60A 11x10, 3/4
M-Hi 1687 1676 1671 1611 1586 1553 1513 1453 1389 1284
High 1971 1974 1948 1929 1871 1806 1751 1699 1610 1511
Low 1299 1294 1308 1279 1257 1231 1205 1165 1122 1053
M-Lo 1515 1519 1499 1487 1415 1418 1394 1348 1296 1221RHWB-10WRP60A 11x10, 3/4
M-Hi 1684 1695 1693 1663 1620 1586 1569 1514 1451 1365
High 1954 1971 1974 1982 1973 1944 1917 1818 1775 1700
HYDRONIC AIR HANDLER AIR FLOW PERFORMANCE - RHWB MODELSTABLE 4
Note: Units tested without filters in place.
THESE INSTRUCTIONS AREINTENDED AS AN AID TOQUALIFIED SERVICEPERSONNEL FOR PROPERINSTALLATION, ADJUSTMENTAND OPERATION OF THIS UNIT.READ THESE INSTRUCTIONSTHOROUGHLY BEFOREATTEMPTING INSTALLATIONOR OPERATION. FAILURE TOFOLLOW THESE INSTRUCTIONSMAY RESULT IN IMPROPERINSTALLATION, ADJUSTMENT,SERVICE OR MAINTENANCE,POSSIBLY RESULTING IN FIRE,ELECTRICAL SHOCK, CARBONMONOXIDE POISONING,EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.
DISCONNECT MAIN ELECTRICALPOWER TO THE UNIT BEFOREATTEMPTING ANY MAINTE-NANCE. FAILURE TO DO SO CANCAUSE ELECTRICAL SHOCKRESULTING IN PERSONALINJURY OR DEATH.
! WARNING
FILTERSKeep the filters clean at all times.Vacuum dirt from filter, wash withdetergent and water, air drythoroughly and reinstall.
NOTE: Some filters must be resizedto fit certain units and applications.See Table 5 and Figures 16 and 17.
• 24.5” - 80,000 and 100,000BTU/HR unit requires removal of a7" segment of filter and frame toget the proper width for a side filter.
DO NOT OPERATE THE SYSTEMFOR EXTENDED PERIODSWITHOUT FILTERS.A PORTION OF THE DUSTENTRAINED IN THE AIR MAYTEMPORARILY LODGE IN THE AIRDUCT RUNS AND AT THE SUPPLYREGISTERS. THIS RESIDUE CANSOIL CEILINGS, WALLS, DRAPES,CARPETS AND OTHERHOUSEHOLD ARTICLES.
TABLE 5FILTER SIZES
UPFLOW FILTER SIZES
AIR HANDLER INPUT BOTTOM SIDE QUANTITYWIDTH MBTU/HR SIZE SIZE
171/2" 60 153/4" X 25" 153/4" X 25" 1241/2" 80, 100 223/4" X 25" 153/4" X 25" 1
MAINTENANCE
FIGURE 16
JACKET ASSEMBLY
SOLID BOTTOM
NOTE:BACK FLANGE OF SOLID BOTTOM FITSUNDERNEATH JACKET. SIDES AND FRONTFLANGES FIT OVER FLANGES ON JACKET.SCREW
(2) REQ’D.
JACKET ASSEMBLY
FILTER FILTERROD
SOLID BOTTOM REMOVAL
FILTER & ROD LOCATION
! CAUTION
22
FIGURE 17FILTER LOCATIONS
JACKET
DRILL (2)3/16" DIA.HOLES
8.000
4.875
1.531
JACKET
JACKET
ANGLE
FILTER RODSUPPORTANGLE
FILTER SUPPORTANGLE(SEE ANGLE DETAIL)
ATTACH WITHSHEET METALSCREWS (2 REQÕD)
ANGLE DETAIL
CUT-OUT AND DRILL DETAILROD & FILTER SUPPORT ANGLE ASSEMBLY
F
UPFLOW
I
FILTER RODSUPPORTANGLE
FILTER SUPPORTANGLE(SEE ANGLE DETAIL)
the flue passageways, the ventsystem and the main burners forcontinued safe operation. Payparticular attention to deteriorationfrom corrosion or other sources.
• IMPORTANT: It is recommendedthat at the beginning and atapproximately half way through theheating season, a visual inspectionbe made of the main burner flamesfor the desired flame appearance bya qualified installer, service agencyor the gas supplier. If the flames aredistorted and/or there is evidence ofback pressure, check the vent andinlet air system for blockage. If thereis carbon and scale in the heatexchanger tubes, the heatexchanger assembly should bereplaced.
REPLACEMENT PARTSSee sheet enclosed with air handlerfor replacement part information.
TROUBLESHOOTINGRefer to Figure 20 for determiningcause of unit problems.
WIRING DIAGRAMSFigure 21 are complete wiringdiagrams for the air handler andpower sources.
LUBRICATIONIMPORTANT: DO NOT attempt tolubricate the bearings on the blowermotor or the induced draft blowermotor. Addition of lubricants canreduce the motor life and void thewarranty.
The blower motor and induced draftblower motor are permanentlylubricated by the manufacturer and donot require further attention.
The blower motor and induced draftblower motor must be cleanedperiodically by a qualified installer,service agency, or the gas supplier toprevent the possibility of overheatingdue to an accumulation of dust anddirt on the windings or on the motorexterior. And, as suggestedelsewhere in these instructions, theair filters should be kept clean. Dirtyfilters can restrict airflow. The motordepends upon sufficient air flowingacross and through it to keep fromoverheating.
SYSTEM OPERATIONINFORMATIONAdvise The Customer
1. Keep the air filters clean. Theheating system will operatebetter, more efficiently and moreeconomically.
2. Arrange the furniture and drapesso that the supply air registersand the return air grilles areunobstructed.
3. Close doors and windows. Thiswill reduce the heating load onthe system.
4. Avoid excessive use of kitchenexhaust fans.
5. Do not permit the heat generatedby television, lamps or radios toinfluence the thermostatoperation.
6. Except for the mounting platform,keep all combustible articles 3feet from the air handler and ventsystem.
7. IMPORTANT: Replace all blowerdoors and compartment coversafter servicing the air handler. Donot operate the unit without allpanels and doors securely inplace.
8. Explain proper operation of thesystem with constant aircirculation.
ANNUAL INSPECTION• The air handler should operate formany years without excessive scalebuild-up in the flue passageways.However, it is recommended that aqualified installer, service agency, orthe gas supplier annually inspect
UPFLOWONLY
23
FIGURE 20GENERAL TROUBLESHOOTING CHART
ydemeResuaCelbissoPmotpmyS
lortnoctaegatlovtcerrocrofkcehCnoitcennoclacirtceleensoolrofforewoPlortnoctaegatlovtcerrocrofkcehChgihoottes-noitarbilacfotuotatsomrehT
Call for domes�c hot water - air handler disabled un�l call ends. Unitis opera�ng as designed. Unit is opera�ng as designed
rekaerbteser/sesufecalpeRrekaerbdeppirt/sesufnwolBremrofsnartecalperg–niriwkcehCevitcefedremrofsnarT
daoletaluclaceRretaehretawroreldnahriadezisylreporpmIgnittespatdeepsrotomkcehCwolfriaroodnireporpmI
Call for domes�c hot water–air handler disabled un�l call ends. Unitis opera�ng as designed. Unit is opera�ng as designed
Check line voltage at pumpCheck wires and connectorsCheck pump capacitor
Call for domes�c hot water - air handler disabled un�l call ends. Unitis opera�ng as designed. Unit is opera�ng as designed
Check line voltage at blower motorCheck wires and connectorsCheck blower motor capacitor
General Trouble Shoo�ng Chart
Power off or loosen electrical connec�onPump does not run
Power off or loosen electrical connec�onBlower does not run
Warning: Disconnect all power to unit before servicing. Failure to shut off power can cause electrical shock resul�ng in personal injury or death.
Unit will not run
Insufficient hea�ng
24
General Troubleshooting Chart
FIGURE 21ELECTRICAL WIRING DIAGRAM
25
26
27
28 CM 0910