INSTALLATION GUIDE
AFW & ABW Series - Vertical Wall Mount Air
Handler (Hydronic Heat)
1. Safety Instruction
Potential safety hazards are alerted using the following symbols. The symbol is used in conjunction with terms
that indicate the intensity of the hazard.
`
WARNING
!
This symbol indicates a potentially hazardous situation, which if not avoided,
could result in serious injury, property damage, product damage or death.
CAUTION
!
Certied technicians or those individuals
WARNING
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and product damage or personal injury hazard may occur
without such background.
WARNING
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WARNING
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installer’s responsibility to ensure that product is installed
in strict compliance with national and local codes. Manufacturer takes no responsibility for damage (personal, product
or property) caused due to installations violating regulations. In absence of local/state codes, refer to National Electric Code: NFPA 90A & 90B Uniform Mechanical Code.
WARNING
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(i.e. automobile, space heater, water heater etc.) ensure that
the enclosed area is properly ventilated.
meeting the requirements specied by
NATE may use this information. Property
All power sources should be disconnected prior to servicing. Failure to do so may
cause personal injury or property damage.
Product designed and manufactured to
permit installation in accordance with local and national building codes. It is the
When this unit is installed in an enclosed
area, such as a garage or utility room with
any Carbon Monoxide producing devices
This symbol indicates a potentially hazardous situation, which if not avoided,
may result in moderate injury or property damage.
2. Ensure These Steps are Completed to Reduce
Chances of a Frozen Hydronic Coil
• Ensure the air handler motor and control board are receiving
proper power input per the wiring diagram.
• Ensure the hydronic coil has access to a constant water supply as
loss of water movement can lead to a frozen coil.
• Prime the water circulator pump using the purge valve per the
“Start-Up” section of this installation guide.
• Run the pump for ve minutes after priming to ensure no air is in
the system.
• If any interruption to the water supply occurs, prime the water
circulator pump again.
• Insulate the water piping in unconditioned spaces or within
structures that may be unoccupied during freezing conditions.
• If the air handler does not have an internal pump and/or relies on
an external boiler system for hot water, the installer may need to
rewire the system to ensure that it maintains access to a constant
water supply.
Only factory authorized kits and acces-
CAUTION
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these instructions. Some localities may require a licensed
installer/service personnel.
WARNING
!
WARNING
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damages caused due to modication of the unit to operate
with alternative power sources.
sories should be used when installing or
modifying this unit unless it is so noted in
Unit is not approved for outdoor installations.
The unit is designed for operation with
108/120 V, single phase, 60 Hz power
supply. Aspen will not be responsible for
1
3. Inspection
ü On receiving the product, visually inspect it for any major shipping
related damages. Shipping damages are the carrier’s responsibility.
Inspect the product labels to verify the model number and options
are in accordance with your order. Manufacturer will not accept damage claims for incorrectly shipped product.
4. Installation Preparation
Read all the instructions in this guideline carefully while paying special attention to the WARNING and CAUTION alerts. If any of the
instructions are unclear; clarify with certied technicians. Gather all
the tools needed for successful installation of the unit prior to beginning the installation.
4A. Clearances
This unit is designed for zero clearance installation on three sides
and adequate clearance to provide access for service in the front.
A minimum of 2.5 – 3.5 feet clearance is recommended on the front
end (Fig 4A-1).
4C. Condensate Drain
Drain lines from the auxiliary drain pan
CAUTION
!
The drain lines must be installed with ¼” per foot pitch to provide free
drainage. A condensate trap MUST be installed on the primary drain
line to ensure proper drainage of the condensate. The trap must be
installed in the drain line below the bottom of the drain pan (Fig.
4C-1)
CAUTION
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from the drain pan. Aspen will NOT be responsible for any
damages resulting from failure to follow these instructions.
should NOT be connected to the primary
drain line of the coil.
Fig 4C-1. Condensate Drain Trap
Since coil is upstream of the blower, all
drains MUST be trapped or sealed. Failure
to do so will result in condensate overow
Fig 4A-1. Minimum Clearance for Air Handler
4B. Recess Mounting or Wall Mounting Option
These units are designed to be installed in a small room where they
can be mounted above a water heater or recessed into a wall. The
unit should be installed in Vertical Upow position ONLY.
If installing the air handler into a recessed wall, the unit must leave
clearance to allow the removal of the front panels. The bottom of the
unit should also rest on a sturdy platform or oor. The unit must be
level to allow condensate drainage.
These air handlers come with an offset mounting bracket that at-
taches the air handler to the wall when the unit is ush mounted to
the wall.
If the drain pan is constructed of nylon
CAUTION
!
DO NOT USE SOLVENT BASED PIPE DOPE. THIS WILL REDUCE THE LIFE OF THE PAN.
The drain pan has primary (red) and secondary (white) drain connections. If a secondary drain line is required, it should be run separately
from the primary and should terminate in a highly visible location.
Condensate disposal through the secondary drain line indicates that
the primary drain line is plugged and needs cleaning. If a secondary drain line will not be provided, plug the secondary drain. Drain
plugs are NOT to be reused without plumbers tape or putty. Drain
line connection should be nger tightened, then turned no more than
one complete turn as needed to ensure a rm connection. DO NOT
overtighten connection or damage may occur.
or plastic; use Teon tape to connect the
drain lines to the threads in the drain pan.
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4D. Ductwork
Duct systems should be installed in accordance with standards for
air-conditioning systems, National Fire Protection Association Pamphlet No. 90A or 90B. They should be sized in accordance with National Environmental
System Contractors
Association Manual K,
or whichever is applicable.
On any job, non-ammable exible collars
should be used for
the return air and discharge connections to
prevent transmission
of vibration (Fig 4D-1).
Although these units
have been specially
designed for quiet vibration-free operation, air ducts can act as soundboards, and if poorly installed, amplify the slightest vibration to the annoyance level.
All main supply and return air drops should be properly sized as
determined by the designer of the duct system and should not nec-
essarily be the size of the duct ange openings of the unit. (The
duct size should never be smaller than the ange openings of the air
handler supply and return air openings.)
These models have a bottom or front return. Discard the drain access panel in the bottom of the unit if this is a bottom return application (Fig 4D-2). In case of a front return application, the front access
panel should be removed and discarded.
Fig 4D-1.
Fig 4D-4.
It is recommended that wherever supply and return air sheet metal
ducts pass through unconditioned areas, they be insulated to prevent excessive heat loss during heating operation. When applied in
conjunction with summer air conditioning, sheet metal duct routed
through unconditioned areas should be insulated and have an outside vapor barrier to prevent formation of condensation.
5. Installation
Ensure that the unit is adequately sized.
CAUTION
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WARNING
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to installation. If holding pressure is not present, return coil
to distributor for exchange.
CAUTION
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present) are protected from heat during brazing and installation to prevent leakage. Use a core removal tool to temporarily remove the core when brazing. Replace the core once
brazing is completed.
The tonnage of the outdoor unit should
never exceed the tonnage of this unit.
The coil was manufactured with a dry nitrogen pre-charge. Release the pressure
through the Schrader valve test port prior
Some Aspen coils may include a Schrader
valve on the suction manifold. Ensure that
the Schrader valve and valve core (where
Fig 4D-2.
If an accessory grill is being used, the front access panel should be
removed and discarded (Fig 3D-3).
Fig 4D-3.
A lter rack is provided for a 1”X20”X20” nominal size lter (Fig 4D-
4). Inspect and clean or replace lter every month. A blocked lter
can reduce air ow to the coil and hinder the performance of the
system.
Only lead free solder should be used to
CAUTION
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WARNING
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be extremely hot and might result in burns and other personal injury along with equipment damage. Ensure that proper
safety gear is being used prior to making connections.
ü Clean coil ns with degreasing agent or mild detergent and rinse
ns clean prior to installation.
ü The refrigerant line sizes should be selected according to the recommendations of the outdoor unit manufacturer.
ü Care must be taken to ensure all connection joints are burr-free
and clean. Failure to do so may increase chances of a leak. It is
recommended to use a pipe cutter to remove the spun closed end of
the suction line.
ü To reduce air leakage, rubber grommets may be present where the
lines pass through the coil case. To avoid damage, remove grommets prior to brazing by sliding over the lines. Use a quenching cloth
or allow the lines to cool before reinstalling the grommets.
ü Use of wet rags/quenching cloth is highly recommended to prevent
weld-related damages to the casing and Schrader valve (if present).
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connect water (hydronic) coil to the hot
water source.
Prior to connecting the water (hydronic)
coil, make sure that the hot water supply
is turned off. Water from the heater could
6. Mounting Air Handler To Wall
1. Install the air handler in a level position side to side and front to
back. If this step is not followed, condensate water damage may oc-
cur. (Both ush mount and recess mount congurations.)
2. Determine where the air handler is to be placed on the wall.
Place the hanging bracket on
the wall and align the holes of
the bracket with the wall studs.
Level the hanging bracket and
mark the holes to drill pilot holes
for the screws.
8A. Flowrator Coils
Fig 8A-1. Flowrator assembly components
CAUTION
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ing to the capacity of the outdoor unit.
Use Piston sizes recommended by the
outdoor unit manufacturer whenever possible. The piston should be sized accord-
3. Drill the pilot holes.
4. Secure the bracket with
screws sufcient to hold 4X the
weight of the air handler.
5. Position the air handler on the
wall with the bracket on the air
handler slightly higher than the
bracket secured on the wall.
Lower the air handler so that the
brackets engage. Check the unit
for level, both side to side and
front to back.
WARNING
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Failure to install the proper piston can
lead to poor system performance and
possible compressor damage.
I. Installation
Note: Photos are for basic illustration purposes only. Actual equip-
ment conguration may differ from that shown.
I-1. Disassemble owrator body
using two wrenches and unscrewing with a counterclockwise
motion.
O-ring
I-2. Replace the Teon O-ring
(located between the halves).
Discard Schrader if present.
7. Connecting Ducting
1. Secure supply air ducting to the top of the air handler. Canvas connectors are recommended for reducing potential noise transmission.
2. If the bottom return air opening is
being used, remove the bottom panel.
If a front return is being used, this panel will remain in place.
3. Secure the return air ducting to the air handler cabinet.
8. Metering Devices/Liquid Line Connection
Aspen coils are available with two kinds of metering devices a) owrator or b) TXV. The following instructions are separated into sec-
tions by metering device.
!
CAUTION
Be aware of the Teon O-ring. Be sure to
replace the O-ring to attain a proper
seal. (The Teon O-ring is located between
the two halves of the owrator)
I-3. Slide the attachment nut onto
the liquid line stub out.
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I-4. Braze the stub-out portion to the liquid line and let cool.
O-ring
I-6. Tighten the nut to a torque of approximately 10-30 ft-lbs. Do NOT
overtighten the nut. Overtightening will impede the piston movement
during operation.
I-5. Taking care that the white
Teon seal is still in place inside
the owrater body, rmly seat the
stub and screw the attachment
nut to owrater body.
II. Piston Replacement
Note: Photos are for basic illustration purposes only. Actual equip-
ment conguration may differ from that shown.
During some installations, a piston change may
be required. If so, the installer MUST change the
piston. Use piston sizes recommended by the
outdoor unit manufacturer. If a sizing chart is not
available, use the piston size chart provided below to size the required piston. The size of the
Fig 8A-2
piston is stamped on the piston body (Fig 8A-2).
II-5. Pull the piston out using a
small wire or pick. Verify the piston size (size is typically stamped
on the body of the piston - Fig
8A-2). If a different piston size
is required by the outdoor unit
manufacturer, replace the piston
using the small wire provided with
the piston kit.
II-6. Replace the piston with one
of the correct size. Do not force
the new piston into the body.
Make sure the piston moves
freely in body.
CAUTION
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coil. Failure to ensure this orientation will cause the piston
to be bypassed during operation which might damage the
outdoor unit.
Pay close attention to the piston orientation. The pointed end of the piston MUST
go into the distributor body, towards the
Use the chart below when matching coil with an outdoor unit with a
different nominal capacity than the coil.
II-1. Evacuate the system as per manufacturer guidelines and recommendations
II-2. Turn the 13/16” nut once to release any residual pressure in the
coil.
II-3. After ensuring that the coil
is free of any residual pressure,
disassemble the owrator body
completely using two wrenches.
Take great care not to distort the
feeder tubes. The wrench used
to clasp the nut should be turned
in counter-clockwise direction to
unscrew the nut.
II-7. Assemble the two halves correctly and ensure that the white
Teon O-ring is present between the two halves (See I-5). Slide the
13/16” nut onto the distributor body.
CAUTION
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II-8. Tighten the nut to a torque of approximately 10-30 ft-lbs. Do NOT
overtighten the nut. Overtightening will impede the piston movement
during operation.
II-9. If present, slide the rubber grommet back to position to prevent
air leakage.
Be aware of the Teon O-ring. Be sure to
replace the O-ring to attain a proper
seal. (The Teon O-ring is located between
the two halves of the owrator)
8B. TXV Coils
II-4. Slide the 13/16” nut over
the lineset and separate the two
halves of the owrator.
Fig 8B-1. Components of a typical TXV assembly
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The sensing bulb and TXV body MUST be
WARNING
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be covered using a quench cloth or wet cloth when brazing.
Pointing the brazing ame away from the valve and sensing
bulb provide partial protection only.
CAUTION
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painted green for R22 or pink for R410A. In absence of color, the caps will be marked with the compatible refrigerant.
CAUTION
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formance and possible compressor damage.
protected from overheating during brazing. The sensing bulb and TXV body must
Ensure that the TXV selected is compatible with the refrigerant used in the outdoor system (R22 or R410A). TXV caps are
The valves should be sized according to
the capacity of the outdoor unit. Failure to
install the right valve can lead to poor per-
I. TXV Bulb Horizontal Mounting
The orientation and location of the TXV bulb has a major inuence
on the system performance.
Ensure that the TXV bulb is in direct con-
CAUTION
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ed. Failure to do so will impair the proper functioning of the
TXV valve.
It is recommended that the TXV bulb be installed parallel to the
ground (on a horizontal plane). The bulb position should be at
2 o’clock or 10 o’clock. Fig. 7B-2 shows the recommended position
for the TXV bulb installation in the horizontal plane.
tact with the suction/vapor line. Gap between the bulb and tube should be avoid-
II. TXV Bulb Vertical Mounting
As recommended in Section
8B-I, the TXV sensing bulb
should be mounted in a horizontal plane in relation to the
suction/vapor line. However,
some installation congurations may require that the
sensing bulb be mounted vertically. In this instance, place
the bulb opposite the piping
wall being hit by refrigerant
and oil leaving the distributor
tubes, and with capillary tubes
directed upwards as shown in
Fig. 8B-3.
Fig 8B-3. Recommended location
for vertical TXV bulb mount
If the TXV sensing bulb is mounted verti-
CAUTION
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wall opposite to that being directly hit by the refrigerant and
oil leaving the distributor tubes.
cally; the capillary MUST be directed upwards. The bulb must be mounted on the
III. Field-Installed TXV Retrot
Note: Photos are for basic illustration purposes only. Actual equip-
ment conguration may differ from that shown.
When installing an expansion valve, it is not necessary to slide the
coil out of the housing.
Bulb position at
2 o’clock or
10 o’clock
Fig 7B-2. Recommended location for horizontal TXV bulb mount
The TXV sensing bulb SHOULD be mounted on the suction line approximately 6” from the TXV or coil housing using the metal clamp
provided. In order to obtain a good temperature reading and correct
superheat control, the TXV sensing bulb must conform to ALL of the
following criteria:
1. The sensing bulb MUST be in direct and continuous
contact with the suction line.
2. The sensing bulb should be mounted horizontally on
the suction line.
3. The sensing bulb MUST be mounted at the 2 o’clock or
10 o’clock position on the circumference of the suction line.
4. The sensing bulb MUST be insulated from outside air.
A properly mounted sensing bulb will prevent false readings caused
by liquid refrigerant that may have formed inside the suction/vapor
line. Insulation will protect the sensing bulb from false readings due
to contact with warm air.
III-1. Disassemble the owrator
body using two wrenches. Unscrew the body with a counterclockwise motion.
III-2. Remove the existing ow-
rator piston using a small wire
or pick.
III-3. Replace the Teon O-ring
seal in place (located between
the halves).
O-ring
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III-4. Inspect the TXV box to conrm that the valve is compatible
with the refrigerant in the system.
Male
(Inlet)
Female
(Outlet)
III-5. Remove the valve from
the box and note the location of the inlet side (threaded
male port) and the outlet side
(female swivel nut port).
III-6. After ensuring that the
Teon O-ring seal is still in place
inside the owrator body, screw
the female swivel nut onto the
owrator body.
O-ring
III-7. Slide attachment the nut onto the liquid line stub out
(See 8A, I-3)
III-8. Braze the stub-out portion to the liquid line and let cool.
WARNING
!
Do not attempt to touch brazed joints
while hot. Severe burns may result.
B. Screw are nut on TXV equal-
ization tube on to the Schrader
valve stem.
III-12b. In some cases, a suction line schrader port may not be
present. If a Schrader port is NOT present:
A. Install a eld-supplied braze-on schrader
valve like that shown on the suction line near the
intended sensing bulb mounting location. Follow valve manufacturer instructions and recommendations for installation.
B. Attach equalizer tube to valve as described in
section III-12a above.
III-13. Mount the sensing bulb as described in section 8B-I or 8B-II.
When handling or manipulating the equal-
!
CAUTION
izer tube, take great care not to kink or
make extreme bends in the tubing.
O-ring
III-10. Tighten all connections taking care to use proper back up.
III-11. Remove the valve identication sticker from the valve and
place it adjacent to the Aspen model number on unit name plate.
III-12a. Some Aspen coils come with a Schrader valve on the suction line. If a Schrader port is present:
III-9. Remove the additional Teflon O-ring seal from the box and
place on the shoulder just inside
the TXV inlet port. Screw the nut
attached to the stub-out portion of
the owrator body onto the inlet
port of the TXV.
A. Remove the valve stem from
the Schrader port mounted on the
suction line.
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9. Connecting Refrigerant Lines
1. Release nitrogen holding charge by depressing the
Shrader Valve at the liquid line
connection on the air handler.
If no gas releases from the air
handler, contact distributor regarding potential leak.
2. Cut off Shrader Valve tting at
the liquid line connection. Use a
tubing cutter for this step. Clean
the burr from the cut tubing to
reduce the chance of future
leaks. Connect the liquid line to
the tubing at the indoor unit.
7. Flow nitrogen through the piping when brazing.
8. Braze both refrigerant line connections using proper brazing procedures.
9. When all line connections are brazed, perform a proper system
evacuation procedure per the outdoor unit manufacturer instructions.
10. Seal the penetration openings where the lineset piping enters the air handler cabinet.
10. Leak Check
1. Following outdoor unit manufacturer instructions and recommendations, charge the system with dry nitrogen to a maximum pressure
of 150 PSIG.
3. Use a tubing cutter to remove
the spun end from the suction
line connection at the air handler. Clean the burr from the cut
tubing to reduce the chance of
future leaks.
4. To avoid heat damage to grommets where present, remove these
prior to brazing by sliding them over the refrigerant lines and out of
the way.
5. Check to determine if the
evaporator coil has a Shrader
tting on the suction manifold.
If yes, remove the valve core
to prevent heat damage during
brazing. Replace the valve core
once the piping has cooled.
2. Check all brazed and screwon line connections by applying a
soap solution to the joint. A leak
will produce bubbles in the soap
solution.
3. If any leaks or are discovered, relieve system pressure and repair
leaks. Repeat steps 1-3.
4. With no leaks or weak connections present, evacuate the system
and charge as per the outdoor unit manufacturer instructions and
specications.
11. Electrical Installation
These units are designed for single phase 120 volts, 60 Hz power
supply. Wire selection and wiring must be in accordance with the National Electric Code and/or local codes. Unit terminals are designed
to accommodate copper or aluminum wiring. If aluminum wiring is
used, please observe special precautions relative to sizing, wire connections and corrosion protection.
Fig.11-1 shows the typical electrical connections required for A/C
only and heat pump applications.
6. If the air handler has a TXV
metering device, remove the
sensing bulb from the suction
line prior to brazing to prevent
heat damage from occurring.
Replace the sensing bulb once
the piping has cooled.
Fig 11-1.
8
Line voltage wiring should be
routed through the access holes
at the top of the air handler.
Proper electrical conduit con-
nection ttings should be used.
Connect the power wiring to the
line side connections on the air
handler. The electrical ground
wire should be connected to the
grounding lug. Ensure both the
eld supplied ground wire and air
handler GREEN ground wire are
both secured to the grounding
lug of the air handler (Fig 11B-2).
Fig 11B-2.
11A. Single Stage Cooling
Fig 11A-2.
During cooling mode operation, indoor blower wire “G” will energize
a time delay relay located on the control board inside the air handler.
After a short time delay period, the time delay relay will send out a 24
volt signal to the low voltage terminal on the motor. (See Schematic
Fig 22-1.) Fan time delay periods are 30 seconds ON delay and 120
seconds OFF delay. The Y wire from the thermostat is not connected
at the air handler. This wire goes directly to the outdoor unit 24 volt
wiring to turn on the outdoor condensing unit when a call for cooling
takes place. The 24 volt common for the outdoor unit circuitry is connected at the air handler brown wire. (See Fig11-1.)
The hydronic heater low voltage wiring terminal “W” is wired directly
from the thermostat to the air handler. The indoor blower, on a call for
heat, will ON delay for a period of 5 seconds. When the call for heat
has been satised, the indoor blower will have an OFF delay time
period of 60 seconds.
Operating CFM based upon each speed tap number is shown on
the electrical wiring diagram of the unit. Final air volume adjustments
should be made by referencing total external static pressure (Table
11B-1).
Table 11B-1.
11C. Jumper Placement
The unit ships with a micro-processor based board which controls
the electrical functioning of the unit. An inspection of the controls is
recommended prior to startup.
Fig.11C-2 provides a schematic of the control board present in the
unit. The units ship from the factory with the aquastat jumper in the
OFF position (right two pins) and the heating selector in the HW
position (right two pins). If an aquastat is used in the application, the
jumper should be changed to the ON position (left two pins).
Note: Terminals T and N located on the top right side of the board
are not intended for eld use and should be left disconnected.
11B. Two Stage Condensing Units
If the outdoor condensing unit is a two stage model, a eld provided
Y2 wire can be connected to the motor using an electrical spade con-
nector. The number 4 and 5 terminals on the motor are speed taps
that will increase the blower speed for second stage cooling opera-
tion. Both the G and Y2 terminals will be energized at the same time
during a call for second stage blower speed operation. The motor will
run at the speed where the Y2 wire is connected (Fig 11B-1).
Fig 11B-1.
Fig 11C-2.
The aquastat (AQ) jumper must be in the
CAUTION
!
to the ON position without installing an aquastat, the blower
will not be energized.
OFF position at all times, except for when
an aquastat is used. If the jumper is moved
11D. Pump/Valve/Boiler Wiring
On units shipped from the factory with a pump installed (Fig 11D-3),
the pump will be energized on a call for heat.
9
Fig 11D-3.
On units that were shipped without factory installed pumps, two
black wires should be connected to the terminals marked “BOILER”
T T (see Fig 11C-2). In applications where a boiler provides the hot
water supply, these wires should be connected to the boiler control
wiring. Terminals “BOILER” T T are normally open dry contacts.
In applications where a valve is used to regulate the hot water supply,
the two black wires located on the “BOILER” T T terminals should be
removed and placed on the two terminals marked “VALVE”. These
wires should be connected to a 24V valve according to local requirements and instructions of the valve manufacturer.
On a call for heat, 24V will be sent to the eld-installed valve or pump
relay, the valve will open or pump relay will close contacts allowing
the pump to run. Water will circulate through the water (hydronic) coil
for 60 seconds prior to energizing the blower. After the thermostat is
satised, the blower will continue to stay energized for a minimum of
30 seconds. The additional blower run time helps maximize heating
efciency.
11E. Freeze Protection Sensor Wiring
The freeze protection sensor is connected to the “FP” and “R“ terminals. This sensor is normally open and will close when the sensor
detects a temperature of less than 40ºF. The pump will operate and
stay ON for a minimum of 30 seconds.
The board has a built-in timer which circulates hot water 6 times a
day for 60 seconds to prevent the hydronic coil from freezing.
Table 13-1.
Use a Magnehelic Gauge with a 1” scale and two static pressure
tips to measure the static pressure during the air volume adjustment
procedure (Fig. 13-1). The high port static pressure tip should be
placed in the supply duct near the outlet of the air handler. The low
port static pressure tip should be placed in the return air duct near
the entrance to the air handler. The factory provided air lter should
be in place inside of the air handler.
Fig. 13-1
1. Select a starting speed tap from the CFM table.
12. Condensate Drain
1. Condensate drain is located at front as shown in picture with primary and secondary drain port.
2. Pipe condensate system using proper PVC ttings.
3. Ensure a minimum 2” trap
is installed in the condensate
drain. Locate the trap near to
the connection opening on
the air handler. See illustration.
13. Air Volume Adjustment
Air volume needs to be set to the level recommended by the outdoor
unit equipment manufacturer. Most systems will require around 400
CFM of indoor air for every 1 ton of system cooling capacity. The air
volume must be set prior to attempting system charge.
This air handler uses a constant torque ECM motor. This motor
will try to maintain proper motor torque to achieve programmed air
volume levels at varying levels of external static pressure. The air
volume level produced by the air handlers at varying external static
pressure levels is shown in Table 12-1.
The blower motor has selectable speed taps labeled 1 thru 5 (Fig.
13-2). The speed taps are energized by 24 volts received from the
time delay relay. When two stage cooling units are used, both the
rst and second stage fan speed taps will be energized at the same
time. The motor will run at the speed generated at the highest motor
speed tap.
Fig. 13-2
2. Call for fan only operation at the thermostat. .
3. Read the external static pressure level on the Magnehelic gauge.
4. Make speed tap selection changes to get the air vol-
ume as close as possible to the required level. .
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5. If the static pressure is above .5” wc, excessive turbulence or duct friction needs to be reduced. (Obstructions in
the duct system can also cause excessive static pressure.)
16. Start-Up
Ensure that motor is pre-loaded with program from factory.
6. When proper air volume is established, move on to the charging
procedure.
14. System Charging
An improperly charged system may cause
CAUTION
!
of the coil, refer to the outdoor unit manufacturer for charging
techniques and amount of charge. If outdoor unit manufacturers
charging instructions are unavailable; then refer to instructions
below to charge the system.
1. Bring airow up to the maximum CFM possible according to Table
13-1.
2. Evacuate refrigeration system to micron level required by outdoor
unit manufacturer.
3. Release system charge from outdoor unit and call for cooling.
4. Use outdoor unit equipment manufacturer specic charging charts
if available and make proper charge adjustment based upon outdoor
unit instructions.
5. If outdoor unit instructions and charts are not available, use Aspen
provided charts. Make certain indoor air temperature is near comfort
level setpoint 75F, prior to establishing superheat and subcooling
levels.
14A . Flowrator Coils
Add refrigerant until the superheat measured at the outdoor unit suction/vapor line matches the superheat from the chart below.
Outdoor
Temp
°F D.B. Min Nom Max
65 30 35 40
70 26 30 34
75 21 25 29
80 17 20 23
85 12 15 18
90 8 10 12
95
100
degradation in system performance and
damage the compressor. After installation
Superheat
4 5 7
The hot water (hydronic) coil and all wa-
WARNING
!
result in pump damage. Aspen will not be responsible for
any property or personnel damage caused by failure to follow this instruction.
WARNING
!
burns. Use of proper safety gear while installing or servicing
the equipment is strongly recommended as is installation
of a water-tempering valve (for water temperatures of above
140ºF) to supply lower temperature water to xtures in the
house. N170L series or equivalent should be used.
WARNING
!
are no leaks in the coils, connections, and/or water piping.
Failure to do so could result in water leaks and property damage. Aspen will not be responsible for any damage caused
by failure to follow this instruction.
Connect the hydronic coil to the water heater system as shown in Fig
16-1 and 16-2. Use exible piping and insulate all pipes. Plumbing
must be in compliance with state or local codes (Code CMR248 in
Massachusetts). The units for hydronic heat have different top and
heater box congurations. This conguration is not suitable for electric heat. DO NOT try to install hydronic heater in a unit not equipped
for it. Verify connections: hot water to “in” and cold water to “out”.
7/8” ODstubs are provided for plumbing connections (Fig 16-3 and
16-4. Bleed the air ow system through the bleeder port (Fig 16-5)
or optional valve.
ter lines MUST be purged of air prior to
starting the pump. Failure to do so could
Hot water owing to the coil should be in
the range of 120º - 180º F. Water at these
temperatures can cause rst-degree
Installer MUST open water lines and run
system to a.) ensure pump is primed and
waterow is constant and b.) ensure there
Table 15B-1.
14B . Expansion Valve Coils
Add refrigerant until the subcooling measured at the outdoor unit
liquid line matches the subcooling recommendation of the outdoor
manufacturer. If chart is unavailable charge the unit to a subcooling
value of 8ºF +/- 1ºF.
15. Adjustment Of Heat Anticipator
After all connections are made, start-up and checkout must be performed before proper evaluation of the entire system can be made.
Make sure that heat anticipator is properly set as noted on thermo-
stat instructions. Load requirements can vary in each residence and
it may be necessary for the installer or homeowner to make slight adjustments to the heat anticipator setting for longer or shorter cycles.
It is recommended to change the setting no more than plus or minus
0.05 amps at a time. Greater changes can cause the unit to rapid
cycle or remain on excessively. Measure anticipator circuit current
with electric heaters energized and set anticipator to proper level.
Fig 16-1.
Fig 16-2.
11
OUTPUT BTUH
TEMP RISE
•
()
..
Fig 16-3. Water In
Fig 16-4. - Water Out
formed before proper evaluation of the entire system can be made.
Make sure that heat anticipator is properly set as noted on thermostat instructions.
Load requirements can vary in each residence and it may be necessary for the installer or homeowner to make slight adjustments to the
heat anticipator setting for longer or shorter cycles. It is recommended to change the setting no more than plus or minus 0.05 amps at
a time. Greater changes can cause the unit to rapid cycle or remain
on excessively. To properly check the unit’s operation, the installer
should have an electrical current measuring device (0-10 amp Amprobe, Fluke), air pressure measuring device (0-1.0 in slope gauge),
and a temperature-measuring device (0-200ºF thermometer).
Install the Amprobe to measure blower current, the slope gauge to
measure static air pressure at the units and the temperature device
to measure unit supply and return air temperature. Before taking
measurements, be sure that all registers, grilles and dampers are
open or are set to their proper positions. Be sure that clean lters are
in place. Temperature measuring device must be installed to obtain
average temperature at both inlet and outlet. For outlet, measure
temperature of each main trunk at a location far enough away to
avoid heater radiation and read the average temperatures. Table
16-1 below shows the CFM that should be achieved at various external static pressures.
Fig 16-5.
Purging The System
1. Open air vent and allow water heater to ll with water. Close air
vent when water heater is full and all air has been purged.
2. Ignite water heater. Set thermostat on water heater to 140 degrees.
3. Close the valve on the hot water supply from the water heater (“A”)
and open the valve on the cold water return to the water heater (“B”).
Then open the air vent in the fan coil. Use bucket or hose to discard
water during purging process at air bleed valve. Purge air completely
from line.
4. Once air is purged, close return valve (“B”) and open supply valve
(“A”). Purge the coil and lines of air completely.
5. After air is purged from the system and lled with water, open the
return valve (“B”). Then close the air vent in the fan coil.
6. Apply power to the fan coil and set the room thermostat on heat.
Raise the temperature setting to activate the circulating pump
7. Check the pump to ensure proper operation. The water inlet of the
unit should be hot if the water temperature in the water heater has
reached the set point. If water is not being circulated through the coil
but the pump is running, then open the air bleed valve in the unit and
purge any air left in the system.
Table 16-1. - CFM Delivered at Various External Statics
17. Electric Heat Controls
Turn on power supply. Set thermostat fan switch to on. Set the cooling indicator to maximum, heating to minimum. System switch may
be on heat or cool. Check slope gauge measurement against appro-
priate air ow chart. Make damper, register and motor speed adjustments to obtain required airow.
Set thermostat fan switch to auto, system to heat and thermostat
heating indicator to maximum heat. Blower should start and all heat
be energized.
Check air ow using temperature rise method.
CFM
=
108
Note: BTUH output should be computed by 500 x Gallons Per Minutes x System Temperature Change = BTUH OUTPUT.
8. Adjust the water heater thermostat so that the water temperature
entering the hot water coils is 120 – 180ºF depending on the amount
of heat required by the structure. This is done with the unit energized
and operating long enough for all temperatures to stabilize.
After all connections are made, start-up and check-up must be per-
12
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