Heat Controller HCG''V1E, HMG''X1E, HMG''F1E User Manual

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AIR HANDLER

Installation Instructions

HMG**F1E, HMG**X1E & HCG**V1E Series

IMPORTANT

Please read all information in this manual thoroughly and become familiar with the capabilities and use of your appliance before attempting to operate or maintain this unit.These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Improper installation, service, adjustment, or maintenance may cause explosion, fire, electrical shock or other hazardous conditions which may result in personal injury or property damage.

Unless otherwise noted in these instructions, only factory authorized kits or accessories may be used with this product. Keep this manual where you have easy access to it in the future. If a problem occurs,check the instructions and follow recommendations given.If these suggestions don’t eliminate your problem, call your servicing contractor.

DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

TABLE OF CONTENTS

Important Safety Information........................

3

Requirements & Codes........................................

3

General Information...........................................

4

Before You Install this Unit.........................................

4

Locating the Air Handler............................................

4

Minimum Clearances.................................................

4

Operation of Air Handler During Construction...........

4

Installation in a Garage..............................................

5

Plenums & Air Ducts..................................................

5

Unconditioned Spaces............................................

5

Air Filters................................................................

5

Acoustical Duct Work..............................................

5

Air Handler Installation...................................

6

Packaging Removal...................................................

6

Mounting Applications................................................

6

Upflow Installations....................................................

6

Downflow Installations...............................................

6

Horizontal Installations...............................................

7

Horizontal Left Installations....................................

7

Horizontal Right Installations..................................

7

Circuit Breaker Cover Installation...............................

8

Refrigerant Line Connections....................................

8

Orifice removal & Installation..................................

9

Connecting the Linsets...........................................

9

Condensate Drainage .............................................

10

Electrical Connections..................................

11

Pre-Electrical Checklist............................................

11

Line Voltage.............................................................

11

Grounding................................................................

11

Thermostat Connections..........................................

11

Control Board...........................................................

12

Twinning................................................................

12

Heater Kits...............................................................

13

Electronic Air Cleaner..............................................

13

Humidifier.................................................................

13

Optional Humidistat..................................................

13

Startup & Adjustments....................................

13

Before You Start the Unit..........................................

13

Refrigerant Charging................................................

14

Air Circulation...........................................................

14

Running the Blower Continuously.........................

14

Selecting Continuous Low Spd Fan Operation.....

14

Turning the Blower Off..........................................

14

System Cooling....................................................

14

System Heating....................................................

14

Selecting minimum Electric Heat Airflow..............

14

Blower Configurations..............................................

14

Determining Nominal System Capacity................

14

3-Speed Units.......................................................

14

High Efficiency Units (Var. & Fixed Speed)...........

15

Selecting Basic Heating Airflow............................

15

Selecting Basic Cooling / Heat Pump Airflow.......

15

Dehumidification Options.........................................

15

Unit Maintenance................................................

16

Troubleshooting................................................

16

Figures & Tables..................................................

17

Figure 12. HMG**F1E, HMG**X1E &

 

HCG**V1E Physical Dimensions.........

17

Figure 13. Air Handler Components.....................

18

Airflow Data..............................................................

19

Table 5. HMG**F1E Air Handlers..........................

19

Table 6. HMG**X1E Air Handlers..........................

20

Table 7. HMG**X1E Air Handlers (Heat Only)......

21

Table 8. HCG**V1E Air Handlers (Cool Only).......

21

Table 9. HCG**V1E Airflow Settings.....................

22

Electrical Diagrams & Data......................................

23

Figure 14. Single Stage Control Board.................

23

Figure 15. Two-Stage Control Board.....................

23

Figure 16. Fixed Speed Control Board.................

24

Figure 17. Variable Speed Control Board.............

24

Figure 18. HMG**F1E Wiring Diagram.................

25

Figure 19. HMG**X1E Wiring Diagram.................

26

Figure 20. HCG**V1E Wiring Diagram.................

27

Table 10. HMG**F1E MCA & MOP Data..............

28

Table 11. HMG**X1E & HCG**V1E

 

MCA & MOP Data.................................

29

Table 12. Control Board Operation.......................

30

Installation / Performance Checklist......

32

2

Important SAFETY INFORMATION

INSTALLER: Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING indicates a potentially hazardous situation that if not avoided, could result in personal injury or death. CAUTION indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury or property damage.

Improper servicing could result in dangerous operation, serious injury, death or property damage.

Beforeservicing,disconnectallelectricalpower to air handler.

When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

Verify proper operation after servicing.

WARNING:

NITROGEN

 

 

 

 

 

 

 

HEALTH

1

 

 

 

 

 

 

 

 

 

 

 

 

 

FLAMMABILITY

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REACTIVITY

0

 

 

 

 

 

 

0 Minimal Hazard 1 Slight Hazard

HMG**F1E,HMG**X1E & HCG**V1E air handlers leave the factory with a nitrogen holding charge. Use caution when preparing coils for field connections. If repairs make it necessary for evacuation and charging, it should only be attempted by qualified, trained personnel thoroughly familiar with this equipment. Some local codes require licensed installation service personnel to service this type of equipment. Under no circumstances should the equipment owner attempt to install and/or service this equipment. Failure to comply with this warning could result in equipment damage, personal injury, or death.

WARNING:

PROPOSITION 65 WARNING: This product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

Requirements & Codes

WARNING:

This unit must be installed in accordance with instructions outlined in this manual during the installation, service, and operation of this unit. Unqualified individuals should not attempt to interpret these instructions or install this equipment. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death.

The installer must comply with all local codes and regulations which govern the installation of this type of equipment. Local codes and regulations take precedence over any recommendations contained in these instructions. Consult local building codes for special installation requirements.

This equipment contains nitrogen gas. Installation or servicing should only be performed by qualified trained personnel thoroughly familiar with this type equipment.

All electrical wiring must be completed in accordance with local, state and national codes and regulations and with the National Electric Code (ANSI/NFPA 70) or in Canada the Canadian Electric Code Part 1 CSA C.22.1.

Installationofequipmentmayrequirebrazingoperations.

Installer must comply with safety codes and wear appropriate safety equipment (safety glasses, work gloves, fire extinguisher, etc.) when performing brazing operations.

Installthisunitonlyinalocationandpositionasspecified on pages 4 & 5. This unit is designed only for Indoor installations and should be located with consideration of minimizing the length of the supply and return ducts. See Tables 5 - 9 (pages 19 - 22) and the rating plate for proper circulating airflow data.

Follow all precautions in the literature, on tags, and on labels provided with the equipment. Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment.

This air handler may be used for temporary heating of buildings or structures under construction. See the guidelines listed on page 4.

Air handler installations in a residential garage must be installed as specified on page 5.

3

GENERAL INFORMATION

This appliance has been tested for capacity and efficiency in accordance with AHRI Standards and will provide many years of safe and dependable comfort, providing it is properly installed and maintained. Abuse, improper use, and/or improper maintenance can shorten the life of the appliance and create unsafe hazards. Please read all instructions before installing the unit.

Before You Install this Unit

This equipment is securely packaged at the time of shipment and upon arrival should be carefully inspected for damage prior to installing the equipment at the job site.Claims for damage (apparent or concealed) should be filed immediately with the carrier.

it is recommended that the cooling load of the area to be conditioned should be calculated and a system of the proper capacity selected.

Check the electrical supply and verify the power supply is adequate for unit operation.The system must be wired and provided with circuit protection in accordance with local building codes. If there is any question concerning the power supply, contact the local power company.

Verify the duct system is appropriate for the air handler being installed. Please note that when replacing an existing system with lower air-flow, the duct system may require modification.

Locating the Air Handler

Survey the job site to determine the best location for mounting the unit. Consideration should be given to availability of electric power, service access, and noise.

The dimensions of the room or alcove must be able to accommodate the overall size of the unit and the installation clearances listed in Table 1. Physical dimensions for this air handler are also shown in Figure 12 (page 17).

Theairhandlershouldbesetintopositionbeforerouting the refrigerant tubing.

Minimum Clearances

This appliance must be installed in accordance with clearances listed in Table 1. The air handler must be installed with ample clearance for easy access to the air filter, blower assembly, heater assembly, controls, and vent connections. Applicable building codes may require additional clearance to equipment. Refer to applicable building codes for details.

Static pressure drop through louvered openings and through return air plenums should be considered in the overall duct design in the determination of the total external static pressure.

Operation of Air Handler During Construction

CAUTION:

Failure to follow these instructions will void the factory warranty and may significantly reduce the life or the performance of the air handler, and/or result in other unsafe conditions. It is the responsibility of the installing contractor to insure these provisions are met.

Operating an air handler in a construction environment can cause the appliance a variety of problems. Proper use of commercial portable space heating equipment during construction is recommended. This air handler may be used during construction if it is not in violation of any applicable codes and the following criteria are met:

The installation must meet all applicable codes and be permanently installed according to the instructions supplied with the air handler including electrical supply and duct work.

Theairhandlermustbecontrolledbyaproperlyinstalled thermostat that complies with the current provisions of the NEC (ANSI/NFPA 70) and all applicable codes having jurisdiction. Thermostat connections must be made in accordance with instructions supplied with the air handler and thermostat. See pages 11 - 12.

The installation must include a properly installed filter in the return air system with no by-pass air.The filter must be inspected frequently and replaced when necessary.

Return air must be supplied unrestricted and located such that dust and gases from construction activity are not introduced into the circulating air system.

Before occupying the structure: The filter must be replaced or cleaned, the duct work must be inspected and cleaned of any construction debris, and the air

INSTALLATION CLEARANCES

Left Side

......... 0 Inches

Right Side

....... 0 Inches

Back................

0 Inches

Front...........

See Notes

 

REAR

 

 

LEFT

RIGHT

 

 

SIDE

SIDE

 

FRONT

NOTES:

Alcove Installations - Allow 24 in. minimum clearance from front of unit to nearest wall or partition for servicing. Recommended clearance is 36 in.

Table 1. Minimum Unit Clearances

4

handler must be cleaned and/or repaired if found to be dirty, damaged, or malfunctioning in any way by a qualified HVAC technician. The air handler shall be inspected and approved by applicable local authority even if this requires redundant inspections.

The serial number for the air handler used during construction must be submitted in writing (fax and email also acceptable). This information will be used to track the long-term affects of air handler usage during construction.Proof of this submittal shall be available for the final inspection of the air handler prior to occupancy.

Installation in a Garage

WARNING:

Donotplacecombustiblematerialsonoragainst the cabinet. Do not place flammable materials, (gasoline, paint thinners, etc.) or any other flammable vapors and liquids, in the vicinity of the air handler.

The HMG**F1E, HMG**X1E & HCG**V1E series air handler may be installed in a residential garage with the provision that the unit must be located or protected to prevent physical damage by vehicles.

Plenums & Air Ducts

Plenums and air ducts should be installed in accordance with the standards of the National Fire Protection Association Standard for Installation of Air Conditioning Systems (NFPA 90A), Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems (NFPA 90B), and all applicable local codes. NFPA publications are available by writing to: National Fire Protection Association, Batterymarch Park, Quincy, ME 02269 or visit www.NFPA.org online.

WARNING:

All return ducts must be secured to the air handler using appropriate methods. All return ducts must be adequately sealed.When return air is provided through the bottom of the unit, the joint between the air handler and the return air plenum must be air tight.

Return air and circulating air ducts must not be connected to any other heat producing device such as a fireplace insert, stove, etc. This may result in fire, explosion, carbon monoxide poisoning,personal injury,or property damage.

Design the duct work according to methods described by the Air Conditioning Contractors of America (ACCA).

Thisunitisdesignedonlyforusewithareturnandsupply duct. The return air duct must have the same free area

as the opening provided on the air handler. The ducts should be appropriately sized to the capacity of the air handler to ensure its proper airflow rating.

Use transition fittings if the supply and/or return air openings of the unit do not match the duct openings. These transitions should be dimensioned in accordance with standard practice as specified in the ASHRAE recommendations for duct transitions.

Flexible connectors may be used between the unit and the ductwork to prevent transmission of vibration from the unit to the structure. If electric heater kits are installed, heat resistant material must be used for the flexible connector at the supply air end of the unit.

It is good practice to seal all connections and joints with industrial grade sealing tape or liquid sealant. Requirements for sealing ducts vary from region to region.Consult with local codes for requirements specific to your area.

Unconditioned Spaces

All duct work passing through unconditioned space must be properly insulated to minimize duct losses and prevent condensation. Use insulation with an outer vapor barrier. Refer to local codes for insulation material requirements.

Air Filters

HMG**F1E, HMG**X1E & HCG**V1E series air handlers are not supplied with an air filter when shipped from the factory. The installer must provide a high velocity filter that is appropriately sized to the return air duct opening or filter rack located in the bottom of the unit. Accessing the filter does not require tools and can be removed from the front of the unit by removing the filter door. See Unit Maintenance (page 16) for filter sizes and installation information.

WARNING:

Never operate the air handler without a filter or with doors removed. Dust and lint can build up on internal components, resulting in loss of efficiency,equipmentdamage,andpossiblefire.

Acoustical Duct Work

Certain installations may require the use of acoustical lining inside the supply duct work. Acoustical insulation must be in accordance with the current revision of the Sheet Metal and Air Conditioning Contractors National Association (SMACNA) application standard for duct liners.Duct lining must be UL classified batts or blankets with a fire hazard classification of FHC-25/50 or less.

Fiber duct work may be used in place of internal duct liners if the fiber duct work is in accordance with the current revision of the SMACNA construction standard on fibrous glass ducts. Fibrous duct work and internal acoustical lining must be NFPA Class 1 air ducts when tested per UL Standard 181 for Class 1 ducts.

Damping ducts, flexible vibration isolators, or pleated media-style filters on the return air inlet of the air handler may be used to reduce the transmission of

5

equipment noise eminating from the air handler.These treatmentscanproduceaquieterinstallation,particularly in the heated space. However, they can increase the pressure drop in the duct system. Care must be taken to maintain the proper maximum pressure rise across the air handler, temperature rise and flow rate. This may mean increasing the duct size and/or reducing the blower speed. These treatments must be constructed and installed in accordance with NFPA and SMACNA construction standards. Consult with local codes for special requirements. For best sound performance, be sure to install all the needed gaskets and grommets around penetrations into the air handler, such as for electrical wiring.

Air handler INSTALLATION

The HMG**F1E, HMG**X1E & HCG**V1E Series Air Handler is shipped ready for vertical upflow installation and isapprovedforattic,basement,alcove/closetorcrawlspace installation with zero clearance to combustibles. See Table 1 (page 4) for required installation clearances. This appliance is approved only for indoor use.

The unit must be leveled at installation and attached to a properly installed duct system.

The surface that the air handler is mounted on must provide sound physical support of the unit.

The air handler must be installed so that all electrical components are protected from water.

If a louvered door is installed across the front of this unit, the appliance must be mounted flush or behind front edge of finished wall.

Always reinstall the doors on the air handler after servicingorcleaning/changingthefilters.Donotoperate the air handler without all doors and covers in place.

Packaging Removal

Remove the shipping crate and User’s Manual from the equipment. When removing the crate, use extra care so tubing connectios are not damaged. Do not pull on the coils upper tubes.

Mounting Applications

Vertical only air handlers are factory ready for upflow applications. These units may be applied in downflow applications when applied with the appropriate field kit.

Factory ready horizontal air handlers may be applied in upflow or horizontal-left and -right discharge applications. These units may also be applied in downflow discharge when applied with the appropriate field kit as specified in the units Technical Specifications.

Through-the-floor installations require a 1/4” thick noncombustible resilient gasket to be used whenever the supply or return air ducts pass through the floor.The gasket should be positioned between the duct, unit, and floor.

Horizontal

Drain Pan

Retur

Air

Figure 1. Upflow Installation

Upflow Installations

All air handlers are factory shipped, ready for upflow installation. The horizontal drain pan may be removed from the air handler when installing the unit in an upflow configuration. All return air must enter from the bottom of the unit. A typical upflow unit is shown in Figure 1.

Downflow Installations

The downflow accessory kit (SeeTechnical Specifications) is required for downflow applications. Instructions for installing the downflow accessory kit are included with the kit.It is recommended that the accessory be installed prior to installing the unit.All return air in downflow applications must enter through the top of the unit.A typical installation of the unit in a downflow application is shown in Figure 2.

Cabinet

Tube

Close-off

Plate

Adaptor Kit

Coil

Figure 2. Downflow Installation

6

Horizontal Installations

These air handlers can be installed horizontally in an attic, basement, crawl space or alcove.It can also be suspended from a ceiling in a basement or utility room in either a right to left airflow or left to right airflow as shown in Figure 3. Air handlers may or may not be shipped from the factory with all the parts required for horizontal left applications and horizontal right applications.If your unit does not have parts for a horizontal application, a kit may be available.

NOTE: In all horizontal applications in which the unit is installed above a finished ceiling and/or living space, a secondary drain pan must be installed under the entire unit to avoid damage to the ceiling in the event of condensate overflow.Additionally, it is recommended that an approved water level indicator or float switch device be used to shut down the unit in the event water is detected in the auxiliary drain pan.

If suspending the air handler from the ceiling, assemble a support frame (Figure 4) using slotted iron channel and full threaded rod. Fasten the frame together with nuts, washers, and lockwashers. Secure the support frame to the rafters with lag bolts. The air handler can also be

HORIZONTAL RIGHT

RETURN

AIR

HORIZONTAL LEFT

RETURN

AIR

Figure 3. Horizontal Configurations

 

Nuts (x2)

 

Lag

 

Bolt

Threaded

Washer

and

Rod

Lockwasher

 

 

Nuts (x2)

Figure 4. Unit Horizontally Suspended

suspended using steel straps around each end of the unit.The straps should be attached to the air handler with sheet metal screws and to the rafters with bolts.

Horizontal Left Installations:

1.Remove the coil access door.

2.Remove the plug from one of the threaded holes in the horizontal drain pan. Completely remove the webbing located in the threaded holes of the horizontal drain pan. IMPORTANT: If the webbing is not removed, the condensate will not drain properly and ceiling damage may occur.

3.Insert the plug (from horizontal drain pan) into the open and unused drain hole in the drain pan at the bottom of the unit to block bypass air.

4.Remove the corresponding drain line knockout from the coil access door to allow access to the horizontal drain.

5.Replace the door and attach the drain line.

Horizontal Right Installations:

1.Remove the coil access door.Unscrew the line-set tube close-off plate from the front left cabinet rail.

2.Slide the coil and drain pan assembly out of the unit.

3.Remove the sheet metal hairpin covers (if supplied) from the back of the coil and discard.

4.Place the horizontal drain pan on the opposite side of the coil. On units with 2 sets of knockouts, remove the other set of knockouts in the coil spacing plates and insert support rod.

5.Slide the coil and the horizontal drain pan assembly back into the unit. Re-attach the tube close off plate.

NOTE: For 24K & 30K BTUH applications, it may be preferrable to remove the blower assembly prior to installing the coil & drainpan. In this case follow instructions 1-4 as listed above but also remove the blower access door and blower assembly. The blower assembly is secured with two screws on either side near the front.With these removed the blower assembly can slide out of the front of the unit. Install the coil and drain pan as described in step 5 and then replace the blower assembly. Take care to ensure that the flanges on the sides of the blower assembly are captured by the pockets in the blower deck. It may be necessary to lift the blower assembly during insertion to allow the lower blower leg to clear the side of the drain pan. The blower will stop against the back of the blower deck. Replace the two screws and the blower access door and procede with steps 6-9.

6.Remove the plug from one of the threaded holes in the horizontal drain pan. Completely remove the webbing located in the threaded holes of the drain pan.

IMPORTANT: If the webbing is not removed, the condensate will not drain properly and ceiling damage may occur.

NOTE: It is recommended that the suction line be insulated up to the coil inside of the cabinet.

7

7.Insert the plug (from horizontal drain pan) into the open and unused drain hole in the drain pan at the bottom of the unit to block bypass air.

8.Remove the corresponding drain line knockout from the coil access door to allow access to the horizontal drain.

9.Replace the door and attach the drain line

Circuit Breaker Cover Installation

The air handler circuit breaker cover is designed to protect the breakers of an installed heater kit from debris and condensation.The cover attaches to the breaker recess of the air handler upper access door using a double-sided adhesive gasket. See Figure 5. The heater kit circuit breaker toggles are still accessible and can be switched with the cover in place.

There are 2 different circuit breaker cover sizes:

2-breaker cover for 2, 2.5, 3, 3.5, & 4 ton air handlers.

3-breaker cover for 5 ton air handlers.

After the heater kit is properly installed, remove the appropriate knockouts in the upper air handler access door and follow these instructions to install the breaker cover:

1.Clean any oil, dirt, or insulation fibers from the recess area of the air handler access door.This step is important for ensuring the gasket adheres properly to the sheet metal door.

2.Remove release paper from one side of the gasket and attach to back side of the breaker cover. NOTE:For proper alignment, It is recommended to leave the center section of the gasket in place when attaching the gasket to the breaker cover. Remove the center section after the gasket is applied to the breaker cover.

Circuit

 

Breakers

 

Recess

 

Circuit

 

Breaker

 

Cover

 

Air

 

Handler A

 

ccess

 

Door

Figure 5. Circuit Breaker Cover

3.Remove the release paper from the other side of the gasket and attach to the circuit breaker recess area.

4.Press firmly along all four sides of the cover to ensure gasket and cover are securely attached to the access door.

Refrigerant Line Connections

WARNING:

NITROGEN

 

 

 

 

 

 

 

HEALTH

1

 

 

 

 

 

 

 

 

 

 

 

 

 

FLAMMABILITY

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REACTIVITY

0

 

 

 

 

 

 

0 Minimal Hazard 1 Slight Hazard

The coil in the air handler is factory shipped with a nitrogen charge. Avoid direct face exposure or contact with valve when gas is escaping. Always ensure adequate ventilation is present during the depressurization process. Address any uncertainties before proceeding. Failure to comply with this warning could result in equipment damage, personal injury, or death.

The installer should make every effort to ensure the field installed refrigerant containing components of the system have been installed in accordance with these instructions and sound installation practices for reliable system operation and longevity.

Theairhandlercoildoesnotcontainarefrigerantcharge.

Refer to the installation instructions supplied with the outdoor unit for refrigerant charge information.

Alwaysrefertotheinstallationinstructionssuppliedwith the outdoor unit for piping requirements. The suction and liquid lines must be sized in accordance with the condensing unit specifications. See Figure 12 (page 17) for liquid and suction line locations.

When connecting refrigerant linesets together, it is recommended that dry nitrogen be flowing through the joints during brazing.This will prevent internal oxidation and scaling from occurring.

Refrigerant tubing should be routed in a manner that minimizes the length of tubing and the number of bends in the tubing. It should be supported in a manner that prevents it from vibrating or abrading during system operation.Tubing should be kept clean of foreign debris during installation.

Ifpreciseformingofrefrigerantlinesisrequired,acopper tubing bender is recommended.Avoid sharp bends and contact of the refrigerant lines with metal surfaces.

Refrigerant lines should be wrapped with pressure sensitive neoprene or other suitable material where they pass against sharp sheet metal edges.

HMG**F1E,HMG**X1E&HCG**V1ESeriesairhandlers are charged through service valves on the end of the liquid tube for each circuit. These must be removed before brazing the line sets.

8

Orifice Removal & Installation

The orifice installed in the air handler has been sized for use with the most popularly matched outdoor units. The orifice size as shipped from the factory is listed on the air handler rating plate. Perform steps 1 - 9 to confirm that the orifice size meets the requirements outlined in the outdoor unit installation manual.

1.Remove the cap from the end of the liquid line.

2.Verify pressurization by depressing the Schrader valve on the end of the liquid line.Listen for any escaping gas.

If there is no pressure, test the coil for leakage.

If leakage is found, clearly mark the location of the leak and return the coil to the distributor for processing.

If no leaks are found, the coil may be installed.

3.Depress the valve to relieve all pressure from the coil.

4.Remove and discard the valve core.

CAUTION:

To prevent damage to the unit or internal components, it is recommended that two wrenchesbeusedwhenlooseningortightening nuts. Do not over tighten!

5.Using two wrenches, loosen the nut and distributor body as shown in Figure 6. Turn the assembly nut counter- clock-wise until the orifice body halves are seperated.

6.Insert a light-gauge wire hook between the distributor body and the restrictor orifice while being careful not to scratch either part. Carefully remove the restrictor orifice from the distributor body. See Figure 7.

7.Check the actual size of the new orifice. NOTE: The size is stamped on its side. Do not use pin gauges to measure the orifice diameter.

8.Insert the new orifice into the distributor body, rounded end down. See Figure 8.

CAUTION:

To prevent damage to the unit or internal components, it is recommended that two wrenchesbeusedwhenlooseningortightening nuts. Do not over tighten!

9.Realign the assembly nut on the distributor body and hand tighten both components. Mark a line on both bodies and then tighten an additional 1/4 turn using two wrenches.The movement of the two lines will show how much the nut is tightened. If a torque wrench is used, tighten to 10-12 ft. lbs. or 14-16 Nm.

Figure 7. Removal of Orifice

Figure 8. Restrictor Insertion into Distributor Body

Connecting the Linesets

IMPORTANT NOTES FOR HORIZONTAL OR DOWNFLOW INSTALLATIONS WITH TXV VALVE:

The sensing bulb must be located flush against the suction line for optimum heat transfer.

Avoidattachingthesensingbulbtothelowestpartof the suction line where condensate may accumulate.

Do not locate the sensing bulb on vertical sections of the lineset.

For horizontal lines, the bulb should not be located at 12 or 6 o’clock position of the suction line. The best location is at 4 or 8 o’clock.

For additional information on proper sensing bulb locations, please refer to the valve manufacturer’s instructions.

IMPORTANT: The steps in the Orifice Removal & Installation section must be performed before the linesets are connected.

Figure 6. Loosening of Nut & Distributor Body

9

1. Remove grommets from line set holes.

CAUTION:

It is recommended that a wet rag be wrapped around the suction line in front of the close off plate or the sensing bulb (if TXV is installed) before applying heat. Failure to keep components cool during brazing may result in structural damage, premature equipment failure, or possible personal injury.

2.Unbraze and remove the cap on the suction line.

3.Route and cut both lineset tubes to proper length in accordance with the outdoor unit specifications. Verify the ends are round, clean, and free of any burrs.

4.Positiongrommetonlinesetwithsufficientdistanceaway from brazing area.Brazing processes can permanently damage grommets.

5.Connect the suction and liquid lineset tubes.

CAUTION:

It is recommended that a wet rag be wrapped around the suction line in front of the close off plate or the sensing bulb (if TXV is installed) before applying heat. Failure to keep components cool during brazing may result in structural damage, premature equipment failure, or possible personal injury.

UPFLOW

HORIZONTAL

3/4” Adapter w/ 3/4” dia. hose barb

DOWNFLOW

3/4” minimum dia. PVC or flexible tubing

NOTES:

1.The drain lines must maintain a downward slope to ensure proper condensate drainage.

2.Each condensate drain must be trapped separately using a J-Trap or field supplied loop.

Figure 9. Condensate Drainage Example

6.Braze the individual connections with dry nitrogen flowing through the joints. NOTE: This will prevent internal oxidation and scaling from occurring.

7.Wrap the refrigerant lines with pressure sensitive neoprene or other suitable material especially where the lines enter the opening in the sheet metal.

8.Evacuate the system of moisture and non-condensables to prevent low efficiency operation or damage to the unit. The suggested range of evacuation is 350 - 500 microns.

9.Charge the system with refrigerant. Refer to the outdoor unit installation manual for additional charging instructions.

10.Check the system for leaks, including the lineset and the brazed joints.

11.Replace all grommets and properly dispose of all removed parts.

Condensate Drainage

CAUTION:

The air handler must be level to ensure proper condensate drainage. An unlevel installation may result in structural damage, premature equipment failure, or possible personal injury.

Methods for disposing of condensate vary according to local codes. Refer to local codes or authority having jurisidiction for restrictions and proper condensate disposal requirements.

The drain pan that is supplied with this air handler contains a primary and secondary drain fitting. The condensate is drained from the unit through two 3/4” female pipe fittings located on the front side of the unit as shown in Figure 9.

Thedrainpanmustbedrainedwithfieldsuppliedtubing or pvc pipe and adequately trapped. Both drain tubes must have a minimum diameter of 3/4” and be trapped separately.

IMPORTANT: Failure to install a trap may result in condensation overflowing the drain pan, resulting in substantial water damage to surrounding area.

Routebothlinestoasuitabledrain,avoidingsharpbends and pinching of the lines. The drain should maintain a minimum horizontal slope in the direction of discharge of not less than 1” vertical for every 10 ft of horizontal run.

If the air handler is located in or above a living space where damage may result from condensate overflow, an auxiliary drain pan shall be installed under the unit. A separate drain line should extend from the pan to a conspicuous point and serve as an alarm indicating that the primary drain is restricted. As an alternative to a separate drain line, an approved water level indicator or float switch device may be used to shut down the unit in the event water is detected in the auxiliary pan.

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