Installation, Operation and
Maintenance Manual
A. Introduction
1
Heat Controller, Inc., air handlers come in a variety
of models and sizes for upflow or horizontal use and
when combined with cooling coils, are ready for air
conditioning and heat pump applications.
These instructions are primarily to assist qualified
individuals in the proper installation of this equipment
Refer to local codes
and regulations for additional guidance.
B. Rules for Safe Installation and Operation
1. Read these rules and the instructions carefully.
Failure to follow the rules and the instructions
could cause a malfunction of the unit and a
possible safety hazard. Keep these instructions
nearby the unit for future reference.
2. This unit has been designed and manufactured to
comply with national codes; however, it is the
installer’s responsibility to install this unit to
comply with prevai
ling codes and regulations.
Heat Controller, Inc., assumes no responsibility
fo
r units installed in violation of any code or
regulation.
3. Before servicing, ALWAYS SHUT OFF
ELECTRICITY TO THE UNIT. This will
prevent any electrical shocks.
4. Ground the unit to prevent electric shock. All
electrical wiring should be in accordance with
the National Electrical Code.
5. Ductwork must be installed in accordance with
the standards of the National Fire Protection
Association (NFPA) for the installation of Air
Conditioning, Warm Air Heating and Ventilating
Systems (NFPA 90A and 90B). The air
ibution duct system should be sized for 0.2
distr
hes of static pressure. See National
inc
Environmental Systems Contractors Association
Manual K for duct sizing recommendations.
Ductwork in non-conditioned spaces must be
insulated to prevent formation of condensate and
for maximum operating efficiency.
6. The safety testing agency label appearing on the
unit covers the unit and factory installed coil(s)
only. It does not cover any other equipment.
7. Exterior surface of cabinet may sweat when unit
is
installed in non-conditioned space such as attic
or garage. Installer must provide protection such
as full size auxiliary drain pan on all units
installed in non-conditioned space such as attic
or garage type installations to prevent damage
from condensation It is recommended that units
installed in
non-conditioned space be insulated
on the outside with 1” thick fiberglass with the
vapor barrier on the outside.
8. While
designed to operate quietly when properly
installed, several steps should be taken to insure
this: Use of isolation pads when mounting unit,
flexible duct collars for discharge, and use of
acoustical duct liners are all good installation
practices that promote quiet operation
.
9. Cabinet insulation is rated for R=4.2 (standard).
Some jurisdictions require R=6.0 on installations in
non-conditioned space. Add insulation 1” thick to
terior of air handler to comply in these
ex
jurisdictions, putting the vapor barrier on the outside.
HOT WATER CAN SCALD: WATER HEATED
TO A TEMPERATURE WHICH WILL SATISFY
SPACE HEATING, CLOTHES WASHING, DISH
WASHING, AND OTHER SANITIZING NEED
S
CAN SCALD AND PERMANENTLY INJURE A
PERSON UPON CONTACT.
10. Some people are more likely to be permanently
injured by hot water. These include the elderly,
children, the infirm, or physically handicapped. If
yone using hot water in a home fits into one of
an
these groups, or if there is a local code or state law
requiring certain maximum temperature water at the
hot water tap, then special precautio
ns must be taken
in addition to using the lowest possible temperature
setting that satisfies hot water needs, some type of
tempering device, such as a mixing valve, must be
used to ensure that people who might be adversely
fected are not subjected to harmful water
af
temperatures..
C. UNPACKING THE UNIT
The unit should be unpacked on receipt and if damage is
found, a claim should be made immediately to the shipping
carrier. This is the responsibility of the shipping carrier. This
is the responsibility of the entity receiving the equipment. The
air handler is completely assembled, as received. Electric
power, thermostat wiring, water piping, refrigerant piping and
duct connections are needed to c
omplete an installation.
Additionally, drain connections will be needed.
Ch
eck the rating plate for unit size, voltage, phase etc. to
make sure unit meets your requirements.
D. PHYSICAL INSTALLATION
MINIMUM CLEARANCES
These units have a 0” minimum clearance to combustible
materials rating from all cabinet surfaces. The unit should be
installed with serviceability clearance of 30” from the front of
the unit. The unit can be serviced entirely from the front,
including replacing the filter. Be sure to route primary and
secondary drain connections so as not to obstruct filter
replacement.
ARRANGEMENT
2
Unit is shipped from the factory arranged to be installed
in a vertical upflow or horizontal right to left airflow
position (standard) or field convertible to a horizontal left
to right airflow position.
Upflow Application
In an upflow application the discharge outlet is at the top.
Care should be taken to ensure unit is level to permit
proper condensate drainage. Normal upflow instal
lation
will be in a basement or closet. If installed in a closet, the
clos
et should have a platform framed in, with an opening
on top of the platform centered in the closet. Connect the
supply air outlet to a warm air plenum. Install return air
grilles from outside the closet to space below the
platform. Platform must be at least 10” above the floor.
Run all supply and return ductwork in accordanc
e with
local codes.
A “P” TRAP MUST BE INSTALLED IN THE COIL
N LINE! CAP ALL UNUSED DRAIN FITTINGS.
DRAI
Horizontal Application
Horizontal application will normally be used in an attic
or crawl space. This type of installation requires a return air
duct be attached to the air handler inlet. The opposite end
of the return air duct is attached to a return air filter grille
through the ceiling or wall
. Remove filter from unit if
filter grill is used. The unit is shipped in right to left
configuration.
IT IS MANDATORY TO USE AN EMERGENCY
AUXILIARY DRAIN PAN WITH ANY COIL OR AIR
HANDLER INSTALLED IN AN ATTIC OR ABOVE
A FINISHED CEILING!
A. PIPING
Do not exceed 70 feet of piping between the air handler and
water heater. The water heater must be installed in
accordance with its installation instructions and local codes
and should be as close to the unit as practical, with the piping
system for the air handler as short as possible. The air
handler and water heater must be located indoors and
not subject to freezing temperature. If wate
r lines pass
through an unconditioned space, they must be protected so as
revent freezing. See section on Low Temperature
to p
Protection for Operational Coil Protection.
AIR HANDLER MUST BE LOCATED SO THAT IF ANY
CONNECTIONS SHOULD LEAK, WATER WILL NOT
CAUSE DAMAGE TO THE ADJACENT AREA. IF
DAMAGE MAY BE POSSIBLE, A SUITABLE DRAIN
PAN MUST BE INSTALLED UNDER THE AIR
HANDLER, NOT OVER 1 1/2 INCHES
MINIMUM LENGTH AND WIDTH AT LEAST TWO
INCHES GREATER THAN THE AIR HANDLER
DIMENSIONS AND CONNECTED TO AN ADEQUATE
N. THE MANUFACTURER ASSUMES NO
DRAI
RESPONSIBILITY FOR ANY WATER DAMAGE IN
DEEP, WITH
.RELDNAH RIA SIHT HTIW NOITCENNOC
TO ENSURE UNIT WILL NOT INTERFERE WITH
DRAI
NS AND REFRIGERANT LINES
MODIFICATION MUST BE MADE PRIOR TO
INSTALLING THESE LINES.
:snoitacilppa thgir ot tfel roF
1. Remove and set aside front panels.
2. Remove the coil support bracket (4-screws).
3. Remove horizontal drain pan retraining clip (1.
screw)
4. Carefully remove coil assembly and bottom
drain pan.
5. Move horizontal drain pan from left hand side of
coil to right side.
6. Install modified coil assembly back into unit.
einstall coil support bracket and horizontal
7. R
drain pan retraining clip
8. Determine drain holes being used and reposition
knockout caps.
9. Reinstall doors.
HOT TO
HOUSE
H C
WATER HEATER
COLD TO W.H.
TUO NI
H02 AIR HANDLER
Typical water heater application.
(Circulating pump to air handler not shown.)
Total piping footage should not exceed 140 feet. All piping
should be ¾” copper or approved plastic. It is recommended
that a water shut off valve for the water heater
be located
close to the water heater. Isolation valves are additionally
recommended. See diagram above. Isolation and shutoff valves
are not included with air handler.
It is
recommended that any installed devices, which could
create a closed system, have a bypass and/or the system have
an expansion tank to relieve the pressure built by thermal
expansion in the water system. Contact the local water
r and/or plumbing contractor for assistance.
supplie
This air handler is designed to be used with a potable water
system.
TOXIC CHEMICALS SUCH AS USED FOR FREEZE
3
PROTECTION, BOILER TREATMENT OR
NONPOTALE WATER HEATING APPLIANNCES
MUST NEVER BE INTRODUCED INTO A POTABLE
WATER/SPACE HEATING SYSTEM.
IF THE SYSTEM REQUIRES WATER AT
TEMPERATURES HIGHER THAN REQUIRED FOR
OTHER USES, A TEMPERING MEANS, SUCH AS A
MIXING VALVE, MUST BE INSTALLED TO
TEMPER THE WATER FOR THOSE OTHER USES
IN ORDER TO REDUCE SCALD HAZARD
POTENT
AT PLUMB
FOLLOW MANUFACTURER’S INSTURCTIONS
After piping has been installed, fill the system with water
and check connections for leaks. To ensure complete
filling of the system follow start-up procedure section.
E. POWER WIRING
Refer to the unit’s nameplate for specific electrical data.
IAL. MIXING VALVES ARE AVAILABLE
ING SUPPLY OR HARDWARE STORES.
FOR INSTALLATION OF THESE VALVES.
G. BLOWER MOTOR
Units are equipped with a three-speed blower motor.
Two factory-selected motor speed leads are connected to
the fan relay (FR) to provide automatic speed change for
heating and cooling airflow volumes. The pre-selected motor
speeds would normally not have to be changed in the field.
All AHG models contain a blower “ON” time delay (BDR) as
well as a post purge timer (TDR) that delays the blower
rning off at the end of the cooling cycle, this improves
tu
ergy efficiency. Terminal number 4 on the fan relay (FR) is
en
the cooling blower speed and terminal number 6 on the fan
relay (FR) is the heating blower speed.
H. REFRIGERANT PIPING
All air handlers have DX refrigerant cooling coils installed;
liquid and suction piping should be sized in accordance with
condensing unit manufacturer’s recommendations. An
adapter may be required to make the transition between the
line set and the coil connector. The evaporator coil has sweat
copper connections. The suction line is a swaged solder cup
connection. The liquid line connection is m
portion of the TXV. Remove the nut on the inlet to the
pansion valve and place it on the tail piece prior to brazing
ex
the liquid line. DO NOT connect the tail piece to the TXV
until the liquid line has been brazed to the tail piece.
Refrigerant lines should be soldered with silver solder or
another high temperature brazing alloy. Dry nitrogen must
flow through the refrigerant
to prevent oxidation.
lines during the brazing operation
ade to a tail piece
DISCONNECT POWER AT MAIN FUSE OR
CIRCUIT BREAKER DISTRIBUTION PANEL
BEFORE WIRING UNIT TO PREVENT SHOCK OR
FIRE HAZARD.
Use copper conductors only
Tighten all wire connectors
minimum circuit ampacity. For correct wire size, refer to
the National Electrical Code. Use 75C minimum wire in
unit wiring compartment.
.
. Refer to unit nameplate for
NOTE:
SEE UNIT FOR COMPLETE WIRING DIAGRAM
LOCATED ON BLOWER HOUSING.
F. CONTROL WIRING
Field connections are made to the low voltage terminal
strip. Consult installation instructions provided with
accessory items for specific information on control
wiring. Use 18 AWG control conductors are
recommended for lengths up to 100 feet. Class 2 wiring
is acceptable. Do not short control leads. Transformer
burn-out will result. Set thermostat heat anticipator at
0.15 amps for air handler.
I. REFRIGERANT FLOW CONTROL
As shipped, the TXV installed on the A-coil is for the
nominal capacity of a 13 SEER matched with Heat
Controller, Inc., condensing units. The TXV is for use on an
R-22 system. For other refrigerants, contact the factory. TXV
has a built-in check valve for reverse flow and is suitable for
heat pump operation. All are externally equalized with nonadjustable superheat and have 15% bleed. Hard star
capability for outdoor units is not normally required when a
% bleed valve is used. The external equalizer line attached
15
to the TXV has a female flare nut and is attached to the
suction line at the coil. Install the attached to the suction line
at the coil. Install the TXV bulb to the suction line using the
bulb clamp furnished with the kit. The bulb should be
installed on a horizontal run of
On a line less than 7/8” OD or over, the bulb should be
ins
talled in a position of about 4 or 8 o’clock. If the bulb
installation is made on a vertical run, the bulb should be
located at least 6 inches from any bend and on the tubing side
opposite the plane of the bend. On vertical bulb installations,
the bulbs should be positioned with the bulb capillary tube at
top. The bulb must be insulated using thermal
the
insulation to protect it from the effects of the surrounding
ambient temperature.
the suction line of possible.
t
J. CONDENSATE DRAIN
4
The air handler drain pan has ¾” FPT primary and
secondary connections whether used in an upflow or
horizontal configuration. Piping from each stub is to have
a 1 ½” minimum trap and each run pitched so as to
provide for adequate drainage and secondary fittings
together into a common drain when an air handler is
installed above a finished ceiling, an auxiliary drain pan
must be provided under the
g codes. The secondary drain must be piped to a
buildin
unit as required by most local
location that would provide the occupant a warning if the
primary drain is blocked.
K. AIR FILTER
Air handlers are factory equipped with an air filter. If the
return grille has its own filter, the filter installed in the air
handler should be removed. Air filter should be inspected
and cleaned or replaced as often as is necessary to
prevent restriction of air flow (minimum every three
months for normal installations). Always replace the
filter with the same type as originally furnished.
HECK TEST AND START UP
L. C
The unit should be tested after the system has been
completely installed to determine proper operation.
M. SYSTEM SHUTDOWN
For short periods of time during freezing temperatures if the
system is to be left unused, to prevent freezing of the air
handler and piping, do the following: Do not turn the system
off. Leave the air handler’s thermostat on heat setting. If the
water and air handler must be shut down for extended
periods, a qualified service technician needs to be contacted
to ensure the air handler and piping
to
prevent freeze damage.
are drained of all water as
N. PERIODIC MAINTENANCE
Inspect and clean or replace filters at least every three months
to ensure good airflow and optimum system capacity,
efficiency and life. This equipment should NEVER BE RUN
WITHOUT AN AIR FILTER IN PLACE (See AIR FILTER
Section). The blower motor is permanently lubricated.
ALWAYS disconnect power before removing access doors!
O. LOW TEMPERATURE PROTECTION – HOT
WATER COIL
The unit is equipped with two low temperature protection
thermostats located on the discharge face of the hot water
coil; these thermostats provide protection as follows:
CFP – Stops the outdoor unit (condensing unit of AC system)
if the discharge air becomes sufficiently low to cause possible
freezing of the water in the hot water coil. Cycling of this
thermostat is an indication of a problem. P
ossible causes are
inadequate air flow, blocked filter, or blocked air system.
– Provides power to the heating terminal (W) of the unit
HFP
terminal strip to start the heating equipment in the event the
air temperature above the coil becomes sufficiently low to
cause possible freezing of the water in the hot water coil.
NOTE:
HEATING SYSTEM SHOULD NOT BE SWITCHED
ON UNTIL SYSTEM IS FILLED AND HOT WATER
COIL IN THE AIR HANDLER AND SUPPLY AND
RETURN LINES ARE VENTED.
1. Fill and pressurize the water heater and air
handler.
2. Vent air from the water tank by opening a hot
water spigot.
Energize the unit by swi
source and the thermostat. Depending on how the
AH
G was interfaced with the heat supply, hot water
should start flowing through the water to air coil and
30 – 45 seconds after a call for heat the blower will
energize.
UNITS ARE RATED AT TEMPERATURES OF 130–
180°F. SET ENTERING WATER TEMPERATURE AT
DESIGN TEMPERATURE AND TAKE PROPER
SAFEGUARDS FOR WATER USAGE AT SUPPLY
POINTS, AS PER LOCAL CODES AND SAFETY
CONSIDERATIONS.
tching on the line voltage
IF THE HEATING EQUIPMENT IS TURNED OFF, SOME
PART OF THE HEATING EQUIPMENT HAS FAILED,
OR DURING POWER OUTAGES THIS THERMOSTAT
CANNOT PROVIDE NECESSARY PROTECTION AND
EEZE DAMAGE COULD OCCUR. IF THESE
FR
CIRCUMSTANCES COULD OCCUR, SEPARATE
FREEZE PROTECTION MUST BE PROVIDED.
ANTIFREEZE SOLUTION IS RECOMMENDED EXCEPT
ON POTABLE WATER SYSTEMS. ON POTABLE
WATER SYSTEMS, BACKUP HEAT MAY BE
REQUIRED TO AVOID FREEZE DAMAGE.
CFP and HFP – Thermostats are located on the discharge
of the unit. Access to these thermostats for service
replacement will require an opening in the discharge duct
with suitable replaceable cover or the discharge duct
must be removed temporarily.
UNDER NO CIRCUMSTANCES WILL THE CFP
AND /OR HFP DEVICES PROVIDE FREEZE
PROTECTION TO ANY EQUIPMENT EXTERIOR TO
THE AHG UNIT AND PROTECTION OF THE AHG
UNIT IS SUBJECT TO THE LIMITATIONS
CI
THAT MIGHT RESULT FROM FAILURE OF THESE
DESCRIBED ABOVE. UNDER NO
RCUMSTANCES WILL HEAT CONTROLLER,
INC., BE RESPONSIBLE FOR ANY DAMAGE
DEVICES OR OTHER COMPONENTS.
DIMENSIONS
AHG - 36, 48, 60AHG - 24, 30
Design, specifications, performance data and materials subject to change without notice.
06/2009
Rev. 121908
1900 Wellworth Ave., Jackson, Michigan 49203 • Ph. 517-787-2100 • Fax 517-787-9341
www.heatcontroller.com
THE QUALITY LEADER IN CONDITIONING AIR
AHGIOM122208
Loading...