2
H2 / V
Horizontal / Vertical
Air Handlers
Installation and Operation Manual
800 – 10,000 CFM
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE
VICINITY OF THIS OR ANY OTHER APPLIANCE.
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury, or loss of life.
WARNING
Owner should pay particular attention to the words:
NOTE, CAUTION, and WARNING. NOTES are
intended to clarify or make the installation easier.
CAUTIONS are given to prevent equipment
damage. WARNINGS are given to alert owner that
personal injury and/or equipment damage may
result if installation is not handled properly.
Feature Overview
1
Fully Insulated 1”
Double-Wall Construction
2
Painted
Galvanized Steel
Construction
3
Duct or
Accessory Flange
4
Filter Access
Double-wall construction for reduced cabinet
1
loss, better air quality, and easier cleaning.
Attractive pre-painted powder coat finish on a
2
cabinet that is built to last.
1” flange allows connection to accessory boxes,
3
fiberglass or metal ductwork.
4
Easy slide out filter access for 2” or 4” pleated
filters. Add a special filtration section for more
air cleaning capability.
Panel removes easily to clean or service the
5
coils, and other internal components.
Duct or Accessory
10
Flange
9
Plenum Fan Access
8
Cast Half-Turn Handles
7
Control Panel Access
& More Coil Access
6
Drain Connection
on Either Side
5
Coil Access
Stainless steel or galvanized sloped drain pan
6
can be selected for left or right hand connection.
Remove door for access to fully enclosed
7
control box and more access to coils.
Half-turn cast handles pull door firmly against
8
automotive style gasketing for tight air seal.
Full access to fan wheel, motor, and drive
9
components for quick servicing.
2” flange allows connection to accessory boxes,
10
fiberglass, or metal ductwork.
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Contents
1. Description……………….....………... 4 4. Start-Up…...……………….....………... 15
Important Safety Information 4
Unit Data 5
Unit Orientation (Left or Right Hand) 7
Model Number Nomenclature 8
Base Model Number
Feature Number
2. Delivery…...……………….....………... 11
Receipt & Inspection 11
Storage 11
3. Installation……..………….....………... 12
General 12
Certification 12
Codes & Ordinances 12
Handling 12
Service & Installation Clearance 12
Mounting & Suspension 13
Sealing 13
Cooling Equipment 13
Heating Equipment 14
Condensate Piping
Electrical
Thermostat
Filters
14
14
14
14
Tables: Figures:
5.1
5.2
6.1
6.2
18.1
20.1
21.1
H2 General Data
V2 General Data
Water Coil Connection Sizes
DX Coil Connection Sizes
Bearing Setscrew Torques
Bearing Lubrication Schedule
Troubleshooting
General 15
Check Out 15
Procedures 15
Commissioning 16
5. Operation & Maintenance....………... 18
General 18
Maintenance Schedule 18
Blower Assembly 18
Indoor Coils 19
Heating 19
Cleaning 20
Chilled Water 20
Lubrication 20
Service 20
Filters 20
6. Troubleshooting…………….………... 21
Common Problems 21
7. Factory Start-Up Form.…….………... 22
7a
Unit Orientation
8a
Model Number Structure
12a
Service Clearance
13a
Air Handler Suspension
19a
Angular Misalignment
19b
Parallel Misalignment
19c
Belt Deflection
3
1. Description
Important Safety Information
ONLY QUALIFIED PERSONNEL SHOULD
PERFORM INSTALLATION, OPERATION, AND
MAINTENANCE OF EQUIPMENT DESCRIBED IN
THIS MANUAL.
H2/V2 Air Handlers are designed for safe operation
when installed, operated, and maintained within
design specifications and the instructions set forth
in this manual. It is necessary to follow these
instructions to avoid personal injury or damage to
equipment or property during equipment
installation, operation, start-up, and maintenance.
The information in this manual should be followed
exactly to prevent property damage or personal
injury.
WARNING
WARNING
Installation and service must be performed by a
qualified installer or service agency.
NOTE
This equipment is protected by a standard limited
warranty under the condition that initial installation,
service, start-up, and maintenance is performed
according to the instructions set forth in this
manual. This manual should be read in its entirety
prior to installation and before performing any
service or maintenance work.
Equipment described in this manual is available
with many optional accessories. If you have
questions after reading this manual in its entirety,
consult other factory documentation or contact
your Sales Representative to obtain further
information before manipulating this equipment or
its optional accessories.
IMPORTANT!
WARNING
RISK OF DAMAGE, INJURY, AND LOSS OF LIFE
– Improper installation, adjustment, alteration,
service, or maintenance can cause property
damage, personal injury, or loss of life. A qualified
installer or service agency must perform
installation and service.
RISK OF ELECTRICAL SHOCK – Unit may have
multiple power supplies. Turn the electrical power
to the unit OFF at disconnect switch(es) before
attempting to perform any service or maintenance.
WARNING
RISK OF INJURY FROM HOT PARTS –
Disconnect all power before servicing electric
resistance heating elements to prevent serious
injury resulting from automatic starts. Unit may
have multiple power supplies.
WARNING
RISK OF INJURY FROM HOT PARTS –
Disconnect all power, close all isolation valves,
and allow equipment to cool before servicing
equipment with hot water and steam heating coils.
Hot water will circulate even after power is off.
Equipment may have multiple power supplies.
WARNING
RISK OF INJURY FROM MOVING PARTS Disconnect all power before servicing motor or
blower to prevent serious injury resulting from
automatic starts. Motor and blower may have
multiple power supplies.
WARNING
WARNING
These units must not be used as a “construction
heater” at any time during any phase of
construction. Very low return air temperatures,
harmful vapors, and misplacement of the filters will
damage the unit and its efficiency.
NOTE
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4
Unit Data
Table 5.1
Coil Face Area Designation
*Note: 1/2 HP motors are direct drive. All other motors are belt drive with adjustable motor sheave.
** 2 HP motor not available in 265/1/60.
Electric Heating KW 7, 14 7, 14, 21 14, 21, 28, 35, 42 14, 28, 42, 56, 70
Quantity / Wheel Dia. / Type
Blower Motor
Maximum HP
FPT Drain Connection Size
Pleated Filter Size
Cabinet Size
CFM Range
Blower
Double Oversize 3 5 7.5
Triple Oversize 5 7.5 10
(Quantity)
H2 General Data
A B C C+ D
1 1 1 2 3 4 1 2
800 - 1200 800 - 2000 1800 - 3000 1800 - 4000 2000 - 4800 2500 - 6000 3000 - 6000 4300 - 10000
1 / 10” / FC 1 / 15” / BI 1 / 18.5” / BI 1 / 18.5” / BI 1 / 27” / BI
Standard 1/2* 1 1 2 3
Oversize 2** 2 3 5
3/4”
16”x20”x2
(1)
16”x20”x2
(2)
24”x24”x2”
(2)
Table 5.2
Coil Face Area Designation
Electric Heating KW 7, 14 7, 14, 21 14, 21, 28, 35, 42 14, 28, 42, 56, 70
Quantity / Wheel Dia. / Type
Blower Motor
Maximum HP
FPT Drain Connection Size
Pleated Filter Size
Cabinet Size
CFM Range
Blower
Double Oversize 3 5 7.5
Triple Oversize 5 7.5 10
(Quantity)
V2 General Data
A B C C+ D
1 1 1 2 3 4 1 2
800 - 1200 800 - 2000 1800 - 3000 1800 - 4000 2000 - 4800 2500 - 6000 3000 – 6000 4300 - 10000
1 / 10” / FC 1 / 15” / BI 1 / 18.5” / BI 1 / 18.5” / BI 1 / 27” / BI
Standard 1/2* 1 1 2 3
Oversize 2** 2 3 5
3/4”
16”x20”x2
(1)
24”x24”x2”
(1)
16”x 20”x2”
(4)
*Note: 1/2 HP motors are direct drive. All other motors are belt drive with adjustable motor sheave.
** 2 HP motor not available in 265/1/60.
24”x24”x2”
(3)
16”x20”x2”
(6)
16”x20”x2”
(10)
16”x20”x2”
(9)
5
Table 6.1
Water Coil Connection Sizes
GPM
1.5 – 2.5 5/8 1/2
2.6 – 7 7/8 1/2
7.1 – 14 1 1/8 1
14.1 – 24 1 3/8 1 1/4
24.1 – 40 1 5/8 1 1/2
40.1 – 80 2 1/8 2
80.1 – 150 2 5/8 2 1/2
150.1 – 250 3 1/8 3
Sweat Conn.
Size (In.)
MPT Conn.
Size (In.)
Table 6.2
Coil Face Area Designation 1 1 1 2 3 4 1 2
Single Circuit
Double Circuit
Cabinet Size A B C C+ D
Coil Selection Stub Out Size (Suction - Liquid)
Standard
Oversized
Standard
Oversized
DX Coil Stub Out Connection Sizes
7/8” – 1/2 ” 7/8” – 1/2 ” 1 1/8” – 5/8” 1 1/8” – 5/8” 1 3/8” – 5/8”
1 1/8” – 5/8”
7/8” – 1/2 ” 1 1/8” – 5/8” 1 1/8” – 5/8” 1 3/8” – 5/8”
1 1/8” – 5/8” 1 1/8” – 5/8” 1 3/8” – 5/8”
1 1/8” – 5/8”
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6
Unit Orientation
Determine left hand or right hand piping connections:
Figure 7a, Unit Orientation
Horizontal Air Handler
Left Hand Side
Return Air Supply Air
AIRFLOW
Connections & service
access on right side for
right hand orientation
Right Hand Side
Remember: Consider the air to be “hitting the
back of your head” as you face the return air inlet.
Vertical Air Handler
Left Hand Side
Return Air
AIRFLOW
Supply Air
Top View
Top View
Right Hand Side
Connections and service
access on right side for
right hand orientation
7
Model Number Nomenclature
The base model number identifies main unit features. The feature number identifies optional features ordered with
the equipment. Together, they comprise the complete model number.
Figure 8a, Model Number Structure
Base Model Number
Feature Number
H2 – C1 – 2 – 10 – 3B1
:
A 0 0 0 D 0 A 0 0 0
Complete Model Number
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8
Base Model Number
TYPE
2
H =
V =
TYPE
Horizontal
Vertical
CABINET SIZE
B
C+
Coil Face Area
1 = Standard Only
A
1 = Standard Only
1 = Standard
C
2 = Oversize
3 = Double Oversize
4 = Triple Oversize
1 = Standard
D
2 = Oversize
MAIN FEATURES
CABINET
SIZE
- - - -
VOLTAGE
COOLING
HEATING
VOLTAGE
1 =
208-230V/1Ø/60HZ
2 =
208-230V/3Ø/60HZ
3 =
460V/3Ø/60HZ
4 =
575V/3Ø/60HZ
5 =
115V/1Ø/60HZ
6 =
380-415V/3Ø/50HZ
7 =
265V/1Ø/60HZ
8 =
115V/1Ø/60HZ
COOLING
00 =
10 =
16 =
50 =
56 =
20 =
30 =
40 =
99 =
No Cooling
Evaporator / Single Circuit
Evaporator / Single Circuit – Six Row
Evaporator / Double Circuit
Evaporator / Double Circuit – Six Row
Chilled Water / Standard Coil
Chilled Water / Optional Coil
Chilled Water / Optional Coil – Six Row
Special Coil Selection
kW*
A =
B =
C =
D =
H =
E =
F =
G =
000 =
100 =
200 =
3 =
7 (5.3)
14 (10.5)
21 (15.8)
28 (21.0)
35 (26.3)
42 (31.5)
56 (42.0)
70 (52.5)
HEATING
No Heating
Steam Coil
Hot Water Coil
Electric Heat
STAGING
1 =
1 Stage
2 =
2 Stage
3 =
3 Stage
4 =
4 Stage
*kW in parentheses is 208V
9
Feature Number
MOTOR
0 =
Standard
A =
Oversize
B =
Double Oversize
C =
Triple Oversize
E =
Standard High Efficiency
F =
Oversize High Efficiency
G =
Double Oversize
High Efficiency
H =
Triple Oversize
High Efficiency
FILTERS
1 2 3 4 5 6
0 =
Standard – 2” Pleated
A =
4” Pleated
B =
No Filters (For Use w/ Mixing Box)
ORIENTATION*
0 =
Standard – Right Hand – Front or Top Discharge
B =
Left Hand – Front or Top Discharge
*Front Discharge Available on Horizontals ONLY.
Top Discharge Available on Verticals ONLY.
CONTROLS
0 =
Standard
A =
B =
C =
Electric Heat Units
All
Phase and Brown Out Control
Electric Heat Unit w/ Phase and Brown Out Control
REFRIGERATION
0 =
Standard
A =
External Hot Gas Bypass – Single Circuit Evaporator
B =
External Hot Gas Bypass – Double Circuit Evaporator
C =
Heat Pump
Modulating Hot Gas Reheat w/ External Hot Gas Bypass
D =
ELECTRICAL
0 =
A =
Standard
Auxiliary Module
FEATURE OPTIONS
FILTERS MOTOR
ORIEN.
CTRLS.
REFRIG
.
ELECT
.
PULLEY
PULLEYS
0 =
A =
B =
UNIT SIZE
OPEN
7 8
0 =
Standard – Combination 1
Combination 2
Combination 3
A 0 = Direct Drive - B
C
D
The above selections are for general guidelines only.
Refer to fan curves and software for best selection.
CABINET SPECIAL
9
SPECIAL
0 =
X =
CABINET
0 =
Standard
Stainless Steel Drain Pan
A =
OPEN
Standard
COMBINATION
0 = Combination 1 1000 1400
A = Combination 2 1400 1800
B = Combination 3 1800 2200
0 = Combination 1 900 1300
A = Combination 2 1300 1700
B = Combination 3 1700 2100
0 = Combination 1 800 1100
A = Combination 2 1100 1300
B = Combination 3 1300 1600
10
Standard
(Lt. Beige Textured Paint)
Special
(SPA Req’d)
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10
2. Delivery
ALL SHIPMENTS ARE FOB THE FACTORY. IT IS
THE RESPONSIBILITY OF THE RECEIVING PARTY
TO INSPECT THE EQUIPMENT UPON ARRIVAL.
Receipt & Inspection
Units should be inspected for damage that may have
occurred in transit. Please do not refuse shipments!
Do the following upon receipt:
1. Assure that freight carrier is in compliance with
Bill of Lading instructions.
2. Inspect delivery before signing Bill of Lading.
If damage is found or if items are missing:
1. Note on Bill of Lading immediately.
− Photograph damage if possible
− Do not move or discard damaged
freight packaging materials
2. Call carrier immediately to file a freight claim
and to schedule an inspection.
3. After losses have been acknowledged by the
freight carrier, call the factory for a repair or
replacement part quote: 1-903-236-4403
4. With permission of freight carrier, order parts
and/or make repairs.
5. Stay in contact with freight carrier to ensure
payment of your claim.
If repairs must be made to damaged goods, then the
factory should be notified before any repair action is
taken in order to protect the warranty. Certain
equipment alteration, repair, and manipulation of
equipment without the manufacturer’s consent may
void the product warranty. Contact the Warranty
Department for assistance with handling damaged
goods, repairs, and freight claims: 1-903-236-4403.
LOOSE SHIPMENT ITEMS – Upon receipt check
shipment for items that ship loose such as
thermostats and other controls. Consult order and
shipment documentation to identify potential looseshipped items. Loose-shipped items may have
been placed inside unit cabinet for security.
NOTE
NOTICE OF PILFERING – Check packing list
against delivered goods. Ensure that equipment
and loose-shipped items have not been pilfered or
misplaced during staging or trans it. The factory
not responsible for missing items after shipment.
NOTE
is
Storage
This equipment is not suitable for outdoor use or
storage. Never place this equipment where it may be
subjected to outdoor conditions such as rain, snow,
humidity, extreme temperatures, or corrosive
chemicals.
If installation will not occur immediately following
delivery, then store equipment in a dry, protected area
away from construction traffic, and in the proper
orientation as marked on the packaging with all
internal packaging in place. Secure all loose-shipped
items.
WARNING
This unit must be stored indoors if installation is
not to occur immediately following delivery.
Damage resulting from improper storage will not
be covered by the limited warranty.
11
3. Installation
General
H2/V2 air handling units are designed as a selfcontained heating, cooling, or combination unit for
indoor installation only. The use of refrigerant, chilled
water, electric resistance, steam, or hot water as
operating mediums will be dictated by design of the
heating and cooling coils installed in the unit. Flexible
connectors are required on all duct connections and
installed to minimize air leaks.
Certification
Cooling Models
a) Certified for use with a commercial
condensing or chilled water remote unit (with
or without compressor(s))
b) Certified for indoor installation only.
Steam or Hot Water Heat Models
a) Certified for indoor installation only.
Electric Heat Models
a) Certified as an electric warm air furnace with
or without cooling coil.
b) Certified for indoor installation only.
Codes & Ordinances
System should be sized in accordance with National
Warm Air Heating and Air Conditioning Association
Literature, or the Guide of American Society of
Heating, Refrigeration and Air Conditioning Engineers.
The installation must conform with local building
codes, or in the absence of local codes, with (United
States) “ANSI / UL 1995”, (Canada) current, C.S.A.
Standard C22.2, No. 236, Canadian Electrical Code
Part 1, and C.S.A. Standard B52 Mechanical
Refrigeration Code, and Local Plumbing or Waste
Water Codes.
It is the responsibility of the installing contractor to
comply with codes, ordinances, local and
municipal building laws, and manufacturer’s
instructions. Personal injury and/or equipment
damage may result if proper procedures are not
followed.
WARNING
Handling
Be aware of what is contained in the equipment!
Dependent upon the optional accessories that were
ordered, this equipment may contain fragile
components and delicate electronics. Although the
unit is constructed of sturdy materials, avoid impacts
and handling methods that may damage internal
apparatus and structure, or the exterior painted
surfaces of the unit. Take care not to apply destructive
force to coils, coil and drain stub-outs, or other parts
protruding beyond the extents of the unit casing.
Always handle the unit by its exterior casing, and
never by any of the protruding parts.
Keep equipment free from debris, and construction
waste during installation. Foreign materials may
adversely affect unit operation resulting in premature
failures that will not be covered by the manufacturer’s
warranty. Attach all service panels, and cover all
exposed equipment when work is not being performed.
Leave unit protected from other construction until startup is to occur.
Always wear hand and eye protection when
handling, installing, servicing, or maintaining
equipment. Sharp or pointed edges, moving parts,
and flying debris may cause personal injury.
WARNING
Service & Installation Clearance
Before setting the air handler into place, caution must
be taken to provide clearance for unit panels/doors
that must be accessible for periodic service. These
areas contain the controls, safety devices, refrigerant
or water piping, shut-off valves and filter access.
H2/V2 air handlers require a minimum of 36 inches of
service clearance on the access panel side of the
unit in order to ensure room for removal, r eplacem ent,
or service of coils and other components if necessary.
Figure 12a, Service Clearance
V2 Top View
36”
Service
Clearance
Return Air
Collar
Discharge Air
Collar
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12
Mounting & Suspension
An auxiliary (emergency) drain pan is
recommended for all applications where there is a
risk of water damage to surrounding structure or
furnishings. Refer to local codes.
NOTE
Floor Mounted
Make sure the unit is level, and mounted on a fieldsupplied platform with a minimum height of 6” to allow
for proper fall on the condensate line. Other installation
provisions may be necessary according to job
specifications. V2 air handlers are designed for upflow
applications only.
Suspended
The H2 horizontal air handler is equipped for
suspended installations. The air handler should be
lifted into position by supporting the unit with the skid
used for shipping. Suspend the air handler from its
four corners with field supplied 3/8”-16 NC “all-thread”
rods. Screw the rods into the threaded steel retainer
wells built into the air handler top and secure with nuts.
The air handler must be installed level and care should
be taken to prevent damage to the cabinet. Other
installation provisions may be necessary according to
job specifications.
Figure 13a, Suspended Horizontal Air Handler
Field Supplied
All-thread Rod
Ceiling
Support
Wells for
Threaded Rod –
All Corners
Sealing
It is very important to keep outside air from infiltrating
the unit cabinet. Seal all piping penetrations with
Armaflex, Permagum, or other suitable sealant. Also
seal around drain connections, electrical connections,
and all other inlets where air may enter the cabinet.
This is especially important when the unit is installed in
an unconditioned area.
Cooling Equipment
Air Handler Equipped with Refrigerant Coil (DX)
This section is not intended to provide all the
information required by the designer or installer of the
refrigerant piping between the condensing units and
the air handler. The appropriate sections of the
ASHRAE Guide and the ASME standards should be
used for final information. Acceptable system design
and installation will include consideration as follows:
− Piping from the condensing unit to the indoor air
handler is the responsibility of the installing
contractor.
− Only clean “ACR” tubing should be used.
− Piping should conform to generally accepted
practices and codes.
− Care must be taken not to cross the circuits on
multiple circuit systems.
− Once piped, the interconnecting piping and air
handler MUST BE evacuated to 50 microns or
less; leak checked and charged with refrigerant as
indicated on the unit name plate.
− Make sure air handler thermal expansion valve
bulb is mounted with good thermal contact on the
correct suction line on a horizontal section, close
to the evaporator in the 4 or 8 o’clock position and
well insulated. Care must be taken to ensure the
bulb is mounted on the correct suction line on
multiple circuit systems.
− The suction line (and hot gas bypass line if
present) should be insulated for its entire length
Lines should be fastened and supported according to
local codes.
Air Handler Equipped with Chilled Water Coil
Water supply lines must be insulated with closed cell
type pipe insulation or insulation that includes a vapor
barrier. Lines should be properly fastened, drained
and supported according to local code requirements.
13
Heating Equipment
When heat is called for, the cooling section is
inoperable except for the indoor blower motor. Actual
heating is accomplished by the air handling unit with
hot water, steam or electric heating capabilities.
Air Handler Equipped with Hot Water Coil
Water supply lines must be insulated, properly
fastened, drained and supported according to local
code requirements.
Air Handler Equipped with Steam Coils
The air handling unit MUST BE installed high enough
to allow for a minimum of one foot (1’) condensate
drop leg off of the steam coil (or as recommended by
the steam trap manufacturer). Lines should be
insulated with approved insulation and be properly
fastened, sloped and supported according to local
code requirements.
Air Handler Equipped with Electric Heating
INSTALLATION IS TO BE ADJUSTED TO OBTAIN
AN AIR TEMPERATURE RISE WITHIN THE RANGE
SPECIFIED ON THE RATING PLATE.
Heating is accomplished by passing electrical current
through a specified amount of resistance heaters
which will produce the required heat. The indoor
blower motor will energize at the same time as the
heaters. Wiring to the air handler must be done in
accordance with local electrical codes and/or
standards. Check specified electrical rating and install
with proper wire size.
Condensate Piping
If the air handler is equipped with cooling, a drain trap
must be connected to the drain pan at the unit. A
condensate connection is provided on each side of the
unit. Condensate piping should be installed according
to local codes. The line should be the same pipe size
as the drain nipple and should pitch downward toward
the building drain.
All cooling coils must have drain pans equipped with
“P” traps to avoid pulling air from outside the unit back
through the drain line. A plug is provided for the
unused condensate connection. The trap should be
located in warm ambient spaces. An additional drain
pan may be installed under the air handler, and should
include a separate drain line for overflow from the
primary drain. An air break should be used with long
runs of condensate lines.
Drain pans in any air conditioning equipment, even
when they have a built-in slope to the drain, will have
moisture present and will require periodic cleaning to
prevent any build-up of algae or bacteria. Cleaning of
the drain pans will also prevent any possible plugging
of the drain lines, and overflow of the pan itself. Some
means to clean out the “P” trap should be provided.
Only qualified personnel should clean drain pans,
drain lines, or the insides of equipment.
Electrical
Check the unit data plate to make sure it agrees with
the power supply. Connect power to the unit
according to the wiring diagram provided with the unit.
The power and control wiring may be brought in
through the holes provided on the unit. Protect the
branch circuit in accordance with code requirements.
If the control wires are to run inside the same conduit,
use 600-volt wire or as required by applicable codes.
The units must be electrically grounded in accordance
with the National Electric Code, ANSI / UL 1995 when
installed if an external source is utilized; in Canada
use current C.S.A. Standard C22.2, No. 236,
Canadian Electric Code Part 1.
Power wiring is to the unit terminal block. The
manufacturer has done all wiring beyond this point.
Power can be applied to the unit after the control
wiring is connected, and start up checks are complete.
Thermostat
The low voltage room thermostat should be located on
an inside wall 4 to 5 feet a above the floor where it will
not be subjected to drafts, sun exposure or heat from
electrical fixtures or appliances. Control wire size
must be large enough to prevent excess voltage drop
that may cause improper operation of the equipment.
Follow manufacturer’s instructions enclosed with
thermostat for general installation procedure.
Filters
Open filter access door and slide correct filter in with
arrow pointing towards the blower in the direction of
airflow.
For filter sizes see back cover.
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14
4. Start-Up
p
General
Equipment power should be on at least 24 hours
before start-up to allow the crankcase heater to
boil off refrigerant that may have accumulated in
the com
ONLY QUALIFIED, AUTHORIZED PERSONNEL
SHOULD POWER ON, OR START-UP THIS
EQUIPMENT.
The use of common sense, and good practice in the
installation, and start-up of equipment will prevent
many potential problems with the system in the future.
Before starting up the equipment, building construction
should be complete, and start-up personnel should:
− Have a working knowledge of general HVAC
− Be familiar with unit functions, features,
− Have appropriate literature on hand for
Equipment operation during construction is not
recommended. Construction site pollution can
affect unit operation, and seriously degrade
performance. Operation during construction will
void all manufacturer’s warranties.
Before the structure is occupied, the installation,
and/or start-up personnel must take three essential
steps:
1. Check Out
2. Start-Up
3. Commissioning
Check Out
Equipment should be thoroughly checked for loose
wiring, a free spinning blower wheel, and well fitting
access panels. Air handlers should not be operated
ressor oil.
and mechanical commissioning procedures
and practices;
optional unit accessories, and all control
sequences;
consultation.
CAUTION
CAUTION
without proper ductwork and access panels installed,
except as required during start-up and air balancing.
1. Check all electrical connections to be sure
they are tight.
2. Open all access panels, and remove all
shipping screws, or restraints.
3. Clean out any debris that may have been left.
4. Check belt alignment, and tightness of fan
drives.
5. Check bearing locking collars, and fan wheel
set screws for tightness.
6. Turn fan wheels to assure free rotation.
7. Ensure electrical supply matches the unit
nameplate.
8. Ensure condensate lines are connected, and
glued.
9. Check local codes for any special provisions.
10. Replace, and/or close all access panels.
11. Ensure that return, and/or supply dampers in
ductwork are open.
12. Check electrical phasing to ensure fan rotates
in proper direction.
Procedures
Failure to adhere to the following start-up
procedures will void all manufacturer’s warranties.
Install gauges, voltmeter, and ammeter before startup. Observe refrigerant pressures during initial
operation. Note, and determine the cause of any
excessive sound, or vibration. Follow start-up
procedures outlined below to start each piece of
equipment.
NOTE
Completed factory test sheets are in the equipment
literature packet shipped inside the unit. Factory
run-test readings recorded on the test sheets for
may be helpful to reference during start-up.
Electric Heating Section Procedures
1. Perform final visual inspection. Check all
equipment, ductwork, and piping to verify that
all work is complete, and equipment is
properly installed and mounted. Improperly
installed equipment, or ductwork can affect
readings.
NOTE
15
2. Ensure there is no construction debris in the
unit.
3. Check the unit for external damage.
4. Note all accessories installed.
5. Install a filter of the proper size and type.
6. Check all terminal blocks, fuses, fuse blocks,
and contactors for correctness.
7. Check all high and low voltage wiring
connections for correctness, and tightness.
8. Check unit for correct incoming voltage per the
data plate.
9. Check the security of the locking system on all
blower bearings
10. Turn the unit power on.
11. Turn the unit blower on, and check for correct
rotation.
12. If correct, take blower amp readings, and
compare to see if the amp draw is within the
safety factor area of the motor. Once correct,
turn blower off.
13. Turn on the first stage of heating
− Check amp draw of each element of
each stage
− Ensure blower started w/ electric heat
− Check for temperature rise across
heating section while all stages are on
− If temperature rise is within range, turn
all heating calls off
− Check to see that blower stops
Refrigerant (DX) Cooling Section:
1. Perform final visual inspection. Check all
equipment, ductwork, and piping to verify that
all work is complete, and equipment is
properly installed and mounted. Improperly
installed equipment, or ductwork can affect
readings.
2. Perform condensing unit start-up checks in
addition to these air handler checks according
to the unit manufacturer’s instructions.
3. Ensure there is no construction debris in the
unit.
4. Check the unit for external damage.
5. Note all accessories installed.
6. Install filter of the proper size and type.
7. Ensure that drain P-trap is installed.
8. Check all terminal blocks, fuses, fuse blocks,
and contactors for correctness.
9. Check all high, and low voltage wiring
connections for tightness. Check unit for
correct incoming voltage per the data plate.
10. Check the security of the locking system on all
blower bearings
11. Turn the unit power on.
12. Turn the unit blower on, and check for correct
rotation.
13. If correct, take blower amp readings, and
compare to see if the amp draw is within the
safety factor area of the motor.
14. Check, and record ambient temperature.
15. Check for Guaranteed Off Timers (GOT),
and/or Time Delay Relays (TDR).
16. Start the first stage cooling circuit, and blower
circuit.
17. After all stages of cooling have been on for at
least five minutes, record the return air
temperature, and supply air temperature.
Optional Equipment
Operation of each of the following, if equipped in the
unit, must be checked according to that item’s
manufacturer’s specifications:
− Phase and brownout monitor
− Hot gas reheat
− Hot gas bypass
Commissioning
The commissioning of an air conditioning system is the
process of achieving, verifying, and documenting the
performance of that system to meet the operational
needs of the building. This may not be a formal
process in smaller structures, such as a normal
residence, but some form of owner acceptance will
occur. Adjustments made during the commissioning
phase may include air, or water balancing, or
configuration of controls, and operational sequences.
Air Balancing
High performance systems commonly have complex
air distribution and fan systems. Unqualified personnel
should not attempt to adjust fan operation, or air
circulation, as all systems have unique operating
characteristics. Professional air balance specialists
should be employed to establish actual operating
conditions, and to configure the air delivery system for
optimal performance.
Water Balancing
A hydronic specialist with a complete working
knowledge of water systems, controls, and operation
must be employed to properly balance the entire
system. Unqualified personnel should not attempt to
manipulate temperatures, pressures, or flow rates, as
all systems have unique operating characteristics, and
improper balancing can result in undesirable noises
and operation.
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16
Controls
A variety of controls and electrical accessories may be
provided with the equipment.
Identify the controls on each unit by consulting
appropriate submittal, or order documents, and
operate according to the control manufacturer’s
instructions. If you cannot locate installation,
operation, or maintenance information for the specific
controls, then contact your sales
control manufacturer for assistance.
Do not alter factory wiring. Deviation from the
supplied wiring diagram will void all warranties,
and may result in equipment damage or personal
injury. Contact the factory with wiring
discrepancies.
WARNING
representative, or the
17
5. Operation & Maintenance
General
Immediately following building occupancy, the air
conditioning system requires a maintenance schedule
to assure continued successful operation. A
maintenance program similar to the example given
below should be scheduled for routine maintenance of
this equipment in order to provide continued efficient,
and reliable operation for the owner.
Maintenance Schedule
One week after start-up:
− Check refrigerant charge. Evacuate and repair
coil if leaking.
− Adjust belt tension on all fan drives.
− Check filters for cleanliness. Measure pressure
loss if applicable. Replace if necessary.
− Check cycling of compressors, fans, and valves.
Correct unusual cycling.
Monthly:
− Lubricate bearings if operating continuously at
1500 rpm, or higher, or in other extreme
conditions.
− Check cleanliness of filters, and replace if
necessary.
− Check cooling coil drain pan to assure proper
drainage.
− Inspect evaporator, and condenser coils. Clean if
dirty, or obstructed in any way.
Quarterly:
− Lubricate bearings if operating at 1000 rpm, or
less, and in temperatures less than 150°F, or other
extreme conditions.
− Check damper operation for freedom of
movement. Correct any binding that may occur.
− Check belts, and pulleys on all fan drives for
tension, and unusual wear.
− Check operation of heating, and cooling section if
seasonal.
− Check inlet, and outlet air temperatures.
Determine cause for abnormal changes.
Annually:
− Clean the condenser, and evaporator coils with
steam, or a non-corrosive coil cleaner.
− Clean the drain line, “P” trap, and condensate pan.
− Check refrigerant pressures, and temperatures
every Spring, and correct unusual operation.
− Check heating section every Fall. Check all
electrical connections for tightness, and check
heater elements for indications of overheating.
Determine cause and replace elements if
necessary.
Blower Assembly
H2/V2 air handlers use backward inclined airfoil blower
wheels* that are non-overloading, very efficient, and
very easy to clean. Clean blower wheels are
necessary to reduce electrical use, maintain capacity
and reduce stress on the unit. The blower wheel, and
blower section need to be inspected periodically, and
cleaned of dust, or debris.
To inspect and clean the blower; set thermostat to the
“OFF” position; turn the electrical power to the unit to
the “OFF” position at the disconnect switch. Clean the
assembly, check the bearings for looseness, inspect
the belt condition and tightness, check screws for
tightness, rotate blower wheel while listening close to
each bearing to check for noise or roughness in the
bearing, which indicates a failing bearing.
Bearings
AAON uses pre-lubricated bearings, and bearings that
have been sized for an average failure rate of 50%
after 200,000 hours, or 22.8 years, of operation (see
heading “Lubrication” in this section for more
information). The bearing sizing tables below are
based on rotational speeds, and radial loading.
However, the alignment of the bearing to the shaft,
and the security of the bearing inner race to the shaft
will greatly affect bearing life. Even though the
manufacturer is responsible for bearing tolerances,
and mounting design, the installer or start-up
technician is advised to check the security of the
bearing locking system before start-up
.
Table 18.1, Bearing Setscrew Torque Recommendations
Size
(In.)
1 1/4 - 28 66 - 85 8 - 32 63 - 70
1 3/16 1/4 - 28 66 - 85 8 - 32 63 - 70
1 7/16 5/16 - 24 126 - 164 10 - 24 81 - 90
1 7/8 3/8 - 24 228 - 296 1/4 - 20 162 - 180
Setscrew Locking Skewzloc Locking Shaft
Thread Torque (In-Lbs) Thread Torque (In-Lbs)
*Exception – Size A1 H2/V2 uses 10” forward curved fan
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18
Belts
Belt drive misalignment is one of the most common
causes of premature belt failure. A belt can be
destroyed in a matter of days if the drives have been
aligned incorrectly.
The most common tool for measuring misalignment is
a straightedge. Hold the straightedge flush across one
pulley to gauge the degree of misalignment of the two
sheaves. The maximum allowed misalignment is one
half degree of angular misalignment, and 1/10
inch per foot between sheave centers for parallel
misalignment.
Figure 19a, Angular Misalignment
Pulley Pulley
Straightedge
Belt
Corrected by moving the position of the motor.
Figure 19b, Parallel Misalignment
Pulley
Straightedge
Pulley
Belt
Corrected by adjusting sheaves on one, or both shafts.
Frequent belt tensioning is highly recommended. Most
belt manufacturers would suggest a retensioning after
as little as 8 hours of operation. A simplified method of
adjusting tension is to gauge the amount of force
required to deflect the belt by 1/64
th
of an inch per inch
of distance between sheave centers. For example, if
the sheaves are 20 inches apart, then the amount of
deflection with the forces listed below is 20/64
of an inch.
Deflections required for:
“A” belts: 4 to 6 lbs.
“B” belts: 6 to 10 lbs.
“C” belts: 10 to 18 lbs.
th
of an
th
(5/16th)
Figure 19c, Belt Deflection
Sheave Centers
Force
Deflection = 1/64th in.
per inch of length
Indoor Coils
Coils should be inspected and cleaned annually to
ensure there is no obstruction to airflow. Dirty
evaporator coils will eventually freeze up, and often
result in a time consuming, and expensive service call.
Clean filters will help to prevent dirt from accumulating
on the evaporator, however the evaporator should be
cleaned annually with a soft bristled brush, and/or a
non-corrosive coil cleaning solution.
Heating
Electric
Set thermostat in the heat mode; call for heat to
engage all electric heat strips. Check blower for
proper rotation and voltage. Measure the amperage
and voltage. Compare them to the nameplate data.
If applicable, check remote heat pump condensing unit
as per the manufacturer’s recommendations.
Steam or Hot Water
Set thermostat in the heat mode. Observe supply
blower for proper rotation and voltage. Check boiler or
hot water operation according to the manufacturer’s
instructions. Check control flow valves for correct
operation and settings per the manufacturer’s
instructions.
19
Cleaning
(
)
Inspect and clean unit interior at the beginning of each
heating and cooling season and as operating
conditions require
.
Chilled Water
Check remote chiller operations as per the
manufacturer’s instructions. Check coolant flow valves
for correct operation and settings.
Lubrication
Most motors and bearings are permanently lubricated.
Some applications, however, will require that bearings
be re-lubricated periodically. The schedule will
depend on the operating duty, temperature variations
or other atmospheric conditions.
For bearings equipped with lubrication fittings the
lubrication schedule is dependent on operating
temperatures, and rotational speeds as shown in table
24.1 below. Lithium based grease conforming to an
NLGI grade No. 2 consistency is recommended. This
medium viscosity, low torque grease is rust inhibiting,
and water-resistant. It is satisfactory for operating
temperatures in the range of –10°F to 250°F.
Bearings should only be re-lubricated when at normal
operating temperatures, and not running. Rotate the
fan shaft by hand, adding only enough grease to purge
the seals. A one-inch bearing has a total grease
capacity of only .25 ounces. Added grease should be
limited to .09 ounces.
Recommended greases are:
− SHELL OIL – DOLIUM R
− CHEVRON OIL – SRI No. 2
− TEXACO INC. – PREMIUM RB
DO NOT OVER
LUBRICATE!
Table 20.1, Fan Bearing Lubrication Schedule
Fan Speed Temperature Environment Greasing Interval
500 rpm
1000 rpm
1500 rpm
Any Speed
Any Speed
Up to 150 °F
Up to 210 °F
Up to 210 °F
Up to 150 °F
210 - 250 °F
Clean 2 to 6 months
Clean 2 weeks to 2 months
Clean Monthly
Dirty 1 week to 1 month
Dirty Weekly
Service
In the event the unit is not functioning correctly and a
service company is required, only a company with
service technicians qualified and experienced in both
heating and air conditioning should be permitted to
service the systems in order to keep warranties in
effect. The service tech may call the factory if
assistance is required.
BEFORE CALLING, THE MODEL AND SERIAL
NUMBER OF THE UNIT WILL BE NEEDED FOR THE
WARRANTY SERVICE DEPARTMENT TO HELP
ANSWER QUESTIONS REGARDING THE UNIT.
AAON Coil Products
Phone: 1-903-247-9242
Fax: 903-236-4463
Warranty Department
Filters
for filter sizes see back cover
Open filter access door. Slide filters towards you and
inspect. Replace old filters with the size indicated on
each filter or as shown in the table on the back cover
of this manual. Be sure arrow points toward the
blower. Filters should be checked every 30 days and
replaced or cleaned as necessary.
IT IS IMPORTANT TO KEEP COILS, BLOWERS,
AND FILTERS CLEAN!
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20
6. Troubleshooting
Common Problems
Table 21.1, Problems, Causes, & Solutions
Problem Possible Cause Solutions
Frosted evaporator coil, low
suction pressure
Unit runs, but supplies warm air Loss of refrigerant
Compressor starts, but opens
high pressure control
High suction pressure, but low
superheat
Unit operates continuously Low refrigerant charge
Restricted air flow
Low fan speed
Reversed blower rotation
Low refrigerant charge
Faulty expansion valve element
Plugged filter-drier
Refrigerant over-charged
Air in condenser coil
Condenser fan faulty
Condenser coil dirty
Oversized expansion valve
Poor sensing bulb location
Low superheat adjustment
Unit undersized
Clean, or replace filters
Check fan drives
Correct wiring
Add refrigerant
Check leaks, add refrigerant
Replace valve element
Replace filter-drier
Remove some refrigerant
Evacuate and recharge refrigerant
Replace fan motor
Clean condenser coil
Replace with correct expansion valve
Relocate sensing bulb, secure to suction line
Adjust expansion valve
Check and recharge to nameplate
Decrease load or resize unit
Thermostat set too low, increase temperature setting
21
7. Factory Start-Up Form
The factory start-up form is provided for the customer’s convenience only. It is not required to be returned to the
factory. However, it is advisable to complete a start-up form to file with permanent unit records. Additionally, the form
opposite this page may be completed and sent to the factory to be kept in the customer’s order file.
You may complete and return the form to:
AAON Coil Products, Inc.
Warranty Department
203 Gum Springs Road
Longview, Texas 75602
Fax: 903-247-9219 (please use fax cover sheet)
Additional Start-Up Notes:
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22
,
You may complete this form at start-up and fax to
903-247-9219
or mail to:
23
www.aaon.com
24
25
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Pressure – Temperature Chart, R-410A & R-22
PSIG PSIG PSIG PSIG PSIG
R-410A R-22
(°F)
20 78.3 43.1 50 142.2 84.1 80 234.9 143.6 110 364.1 226.4 140 540.1 337.4
21 80.0 44.2 51 144.8 85.7 81 238.6 146.0 111 369.1 229.6 141 547.0 341.6
22 81.8 45.3 52 147.4 87.4 82 242.3 148.4 112 374.2 232.8 142 553.9 345.9
23 83.6 46.5 53 150.1 89.1 83 246.0 150.8 113 379.4 236.1 143 560.9 350.3
24 85.4 47.6 54 152.8 90.8 84 249.8 153.2 114 384.6 239.4 144 567.9 354.6
25 87.2 48.8 55 155.5 92.6 85 253.7 155.7 115 389.9 242.8 145 575.1 359.0
26 89.1 50.0 56 158.2 94.4 86 257.5 158.2 116 395.2 246.1 146 582.3 363.5
27 91.0 51.2 57 161.0 96.1 87 261.4 160.7 117 400.5 249.5 147 589.6 368.0
28 92.9 52.4 58 163.8 98.0 88 265.4 163.2 118 405.9 253.0 148 596.9 372.5
29 94.9 53.7 59 166.7 99.8 89 269.4 165.8 119 411.4 256.5 149 604.4 377.1
30 96.8 55.0 60 169.6 101.6 90 273.5 168.4 120 416.9 260.0 150 611.9 381.7
31 98.8 56.2 61 172.5 103.5 91 277.6 171.0 121 422.5 263.5
32 100.9 57.5 62 175.4 105.4 92 281.7 173.7 122 428.2 267.1
33 102.9 58.8 63 178.4 107.3 93 285.9 176.4 123 433.9 270.7
34 105.0 60.2 64 181.5 109.3 94 290.1 179.1 124 439.6 274.3
35 107.1 61.5 65 184.5 111.2 95 294.4 181.8 125 445.4 278.0
R-410A R-22
(°F)
R-410A R-22
(°F)
R-410A R-22
(°F)
R-410A R-22
(°F)
36 109.2 62.9 66 187.6 113.2 96 298.7 184.6 126 451.3 281.7
37 111.4 64.3 67 190.7 115.3 97 303.0 187.4 127 457.3 285.4
38 113.6 65.7 68 193.9 117.3 98 307.5 190.2 128 463.2 289.2
39 115.8 67.1 69 197.1 119.4 99 311.9 193.0 129 469.3 293.0
40 118.1 68.6 70 200.4 121.4 100 316.4 195.9 130 475.4 296.9
41 120.3 70.0 71 203.6 123.5 101 321.0 198.8 131 481.6 300.8
42 122.7 71.5 72 207.0 125.7 102 325.6 201.8 132 487.8 304.7
43 125.0 73.0 73 210.3 127.8 103 330.2 204.7 133 494.1 308.7
44 127.4 74.5 74 213.7 130.0 104 334.9 207.7 134 500.5 312.6
45 129.8 76.1 75 217.1 132.2 105 339.6 210.8 135 506.9 316.7
46 132.2 77.6 76 220.6 134.5 106 344.4 213.8 136 513.4 320.7
47 134.7 79.2 77 224.1 136.7 107 349.3 216.9 137 520.0 324.8
48 137.2 80.8 78 227.7 139.0 108 354.2 220.0 138 526.6 329.0
49 139.7 82.4 79 231.3 141.3 109 359.1 223.2 139 533.3 333.2
27
Table 28.1, Pleated Filter Sizes
Cabinet Size (CFM Range)
Horizontal (H2) Units
16” x 20” x 2”
Pleated Qty.
24” x 24” x 2”
Pleated Qty.
Vertical (H2) Units
16” x 20” x 2”
Pleated Qty.
24” x 24” x 2”
Pleated Qty.
AAON
2425 S. Yukon Ave.
Tulsa, OK 74107-2728
Phone: 918-583-2266
Fax 918-583-6094
Download this manual
and others from:
www.aaon.com
It is the intent of AAON to provide accurate and current product information. However, in the
interest of product improvement, AAON, Inc. reserves the right to change pricing,
specifications, and/or design of its products without notice, obligation, or liability.
®
AAON
is a registered trademark of AAON, Inc.
Effective October 2007
Supersedes February 2006
Typical Filter Sizes
A
(800 – 1,200)
1 2 10
2 3
A
(800 – 1,200)
1 4 6 9
1
B
(1,200 – 2,000)
B
(1,200 – 2,000)
Optional 4”
C
(2,000 – 4,000)
C
(2,000 – 4,000)
C+
(3,000 – 6,000)
C+
(3,000 – 6,000)
D
(6,000 – 10,000)
D
(6,000 – 10,000)
P87860 02-06 (ACP 27294)
H2V2 IOM 071019
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