Heatcontroller AFM42-60 User Manual

INSTALLATION, OPERATION
& MAINTENANCE MANUAL
Multi-Position Air Handler with
Hyrdonic Heat with X13 Motor
HWCGxxX0A
Heat Controller • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
Multi-Position Air Handler with Hydronic Heat with X13 Motor HWCGxxX0A Heat Controller
REQUI RE D
Safety Instruction
Potential safety hazards are alerted using symbol. 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
This symbol indicates a potentially hazardous situation which if not avoided, may result in moderate injury or property damage.
WARNING
individuals meeting the requirements specified by NATE may use this information. Property and product damage or personal injury hazard may occur without such background.
WARNING
disconnected prior to servicing. Failure to do so may cause personal injury or property damage.
WARNING
ured to permit installation in accordance with local and national building codes. It is the 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 (CEC or CSA for Canadian Installation).
WARNING
enclosed area, such as a garage or utility room with any Carbon Monoxide producing devices (i.e. automobile, space heater, water heater etc.) ensure that the enclosed area is properly ventilated.
CAUTION
accessories should be used when installing or modifying this unit unless it is so noted in these instructions. Some localities may require a licensed installer/service personnel.
WARNING
installations.
Certified technicians or those
All power sources should be
Product designed and manufact-
When this unit is installed in an
Only factory authorized kits and
Unit is not approved for outdoor
WARNING
The unit is designed for operation with 108/120 V, single phase, 60 Hz power supply. manufacturer will not be reponsible for damages caused due to modification of the unit to operate with alternative power sources.
Inspection
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 that the model number and options are in accordance with your order. Manufacturer will not accept damage claims for incorrectly shipped product.
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 certified technicians. Gather all the tools needed for successful installation of the unit prior to beginning the installation.
This unit is designed for zero clearance installation on three sides and adequate clearance to provide access for serivce in the front. A min of 2.5 – 3.5 feet clearance is recommended on the front end.
If the unit is to be installed in garages, warehouses or other areas where they may be subjected to physical damage, adequate protective barriers must be installed. Unit MUST be installed 18” away from source of ignition.
If the unit is located in high humidity areas like attics or unconditioned garage; the air handler casing might experience nuisance sweating. In such installation scenarios, wrapping the casing with a 2” fiberglass insulation with vapor barrier SHOULD be used.
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. Figure 1 illustrates the typical drain trap installation
DRAI N CONNECTI ON
2" MINI MUM
FLEXIBLE
TUBI NG- HOSE
OR PIPE
A POSITIVE
LIQUID SEAL IS
Figure.1. Typical drain line trap set up
3" MINI MU
2
Heat Controller Multi-Position Air Handler with Hydronic Heat with X13 Motor HWCGxxX0A
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-flammable flexible collars should be used for the return air and discharge connections to prevent transmission of vibration. Although these units have been specially designed for quiet vibration-free operation, air ducts can act as soundboards can, 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 necessarily be the size of the duct flange openings of the unit.
When installing a central air return grille in or near the living space, it is advisable to design the ductwork so that the grille is not in direct line with the opening in the unit. One or two elbows and acoustical duct liner will also assure a quieter installation and system.
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.
Installation
CAUTION
sized. The tonnage of the outdoor unit should never exceed the tonnage of this unit.
WARNING
dry nitrogen pre-charge. Release the pressure through the Schrader valve test port prior to installation. If holding pressure is not present, return coil to distributor for exchange.
Clean coil fins with degreasing agent or mild detergent and rinse fins clean prior to installation.
All connection joints should be burr-free and clean. Not removing the burr and cleaning may increase the chance of a leak. It is recommended to use a pipe cutter to remove any spun closed ends.
To avoid damage to grommets (where present), remove these prior to brazing by sliding over the lines. Use a quenching cloth or allow the lines to cool before reinstalling the grommets.
Ensure that the unit is adequately
The coil was manufactured with a
WARNING
Prior to connecting the water (hydronic) coil, make sure that the hot water supply is turned off. Water from the heater could be extremely hot and may result in burns and other personal injury along with equipment damage. Ensure that proper safety gear is being used prior to making connections.
CAUTION
Only lead free solder should be used to connect water (hydronic) coil to the hot water source.
CAUTION
Some coils may include a Schrader valve on the suction manifold. Ensure that the Schrader valve and valve core (where present) are protected from heat to prevent leakage.
Metering Device
Coils use a TXV metering device. Instructions below are for the metering device. Ensure that the instructions are thoroughly read and understood.
TXV Coils:
WARNING
MUST be protected from overheating during brazing. The sensing bulb and TXV body must be covered using a quench cloth or wet cloth when brazing. Pointing the brazing flame away from the valve and sensing bulb provide partial protection only.
CAUTION
compatible with the refrigerant used in the outdoor system (R22 or R410A). TXV caps are painted green for R22 or pink for R410A. In absence of color, the caps will be marked with the compatible refrigerant.
CAUTION
according to the capacity of the outdoor unit. Failure to install the right valve can lead to poor performance and possible compressor damage.
TXV Bulb Mounting
The orientation and location of the TXV bulb has a major influence on the system performance.
CAUTION
direct contact with the suction/vapor line. Gaps between the bulb and tube should be avoided. Failure to eliminate gaps will impair the proper functioning of the valve.
It is recommended that the TXV bulb be installed parallel to the ground (in a horizontal plane). The bulb position should be above and between 4 o’clock and 8 o’clock.
3
The sensing bulb and TXV body
Ensure that the TXV selected is
The valves should be sized
Ensure that the TXV bulb is in
Multi-Position Air Handler with Hydronic Heat with X13 Motor HWCGxxX0A Heat Controller
Fig. 2 shows the recommended position for the TXV bulb installation in the horizontal plane.
The TXV sensing bulb SHOULD be mounted 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 continous contact with the suction line
2) The sensing bulb should be mounted horizontally on the suction line.
3) The sensing bulb must be mounted above and between the 4 and 8 o’clock position on the circumference of the suction line.
4) The sensing bulb must be insulated from outside air.
SUCTION/VAPOR LINE
METAL STRAP
TXV BULB POSI TION 4 O'CLOCK OR 8 O'CLOCK
Fig.2. Recommended location of the TXV bulb in a horizontal orientation
The mounting location and insulation guards the sensing bulb from false reading due to hot outside air or liquid refrigerant formed inside the suction/vapor line.
As recommended earlier, the TXV sensing bulb should be mounted in a horizontal plane in relation to the suction/vapor line. However, in case such a mounting is not feasible and the sensing bulb has to be mounted vertically; then place the bulb as shown in Fig.3.
Fig.3. Sensing bulb mounted in a vertical orientation
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CAUTION
If the TXV sensing bulb is mounted vertically; the capillary MUST be directed upwards. The bulb must be mounted on the wall opposite to that being directly hit by the refrigerant and oil leaving the distributor tubes.
Field – Installed Expansion Valve Coils
Remove the valve identification sticker from the valve and place it adjacent to the model number on unit name plate.
When installing an expansion valve, it is not necessary to remove all the access panels and slide the coil out of the housing.
1) Disassemble the flowrator body using two wrenches. Unscrew the body with a counter­clockwise motion.
2) Replace the white Teflon seal in place (located between the halves).
3) Remove the existing flowrator piston using a small wire or pick.
4) Inspect the TXV box to confirm that the valve is compatible with the refrigerant in the system.
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).
6) After ensuring that the white Teflon seal is still in place inside the flowrator body, screw the female swivel nut onto the flowrator body.
7) Place the attachment nut on the liquid line.
8) Braze the stub-out portion to the liquid line and
let cool.
WARNING
joint while hot. Touching it may cause sever burns.
9) Remove the additional white Teflon seal ring from the box and place on the shoulder just inside the inlet port. Screw the nut attached to the stub-out portion of the flowrator body onto the inlet port of the TXV.
10) Tighten all connections taking care to use proper
Some coils come with a Schrader valve on the suction line. If a Schrader port is present
back up.
11) Remove valve stem from the Schrader port mounted on the suction line
12) Screw flare nut on TXV equalization tube in to the Schrader valve stem
Coils without Schrader Ports
11) Locate a convenient spot on the suction line and punch a ¼” hole with a pick or other suitable tool.
Do not attempt to touch the braze
Heat Controller Multi-Position Air Handler with Hydronic Heat with X13 Motor HWCGxxX0A
CAUTION
enter suction manifold.
12) Insert TXV equalizer tube approximately 3/8” into the hole and apply solder to seal.
Fig.4 shows the components of a typical TXV assembly
TXV BULB
Fig.4. Components of a typical TXV assembly
CAUTION
valve may require the use of a hard-start kit. Follow the outdoor unit manufacturer’s guidelines.
Do NOT drill a hole as chips will
DISTRIBUTOR
TEFLON O- RINGS
TAIL PIECE
Using a non-bleed expansion
Air handler orientation
This unit can be installed in vertical or right horizontal position without modifications. In case of a counterflow application, the horizontal drain pan MUST be removed. Fig. 5 shows the various orientations this air handler can be installed in.
CAUTION
horizontal orientation; an auxiliary drain pan MUST be provided by the installer and placed under the entire unit with a separate drain line that is properly sloped and terminated in an area visible to the home owner. The auxiliary pans provide extra protection to the area under the unit should the primary and secondary drain plug up and overflow. As expressed in our product warranty;
failure to follow this installation requirment will void the product warranty. The drains from the auxiliary
drain pan must be installed according to the local building codes.
When the unit is used in an
Fig.5. Various airflow orientation
Horizontal Left-hand Installation
With Air Handler in vertical position remove all access panels.
Remove horizontal drain pan from right hand side. Disconnect any drain connections.
Relocate the removed horizontal drain pan on to the left side and reconnect the drain connections.
“P” traps must be installed on primary and secondary drains of the horizontal drain pan.
Reinstall all access panels to the unit.
Fig.6. Air flow direction in Horizontal Left application
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