Rheem RHWB-08WRP60A, RHWB-06WMP48A, RHWB-10WRP60A, RHWB-04WMX36A, RHWB-06WMXP48A Installation Instructions Manual

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Page 1

INSTALLATION INSTRUCTIONS

DO NOT DESTROY THIS MANUAL. PLEASE READ CAREFULLY AND KEEP

IN A SAFE PLACE FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.

ISO 9001:2008

HYDRONIC AIR HANDLER

RHWB-

SUPERSEDES 92-24161-94-04

92-24161-94-05

Page 2

SAFETY INFORMATION

WARNING

WHEN AN AIR HANDLER IS INSTALLED SO THAT SUPPLY DUCTS CARRY AIR CIRCULATED BY THE AIR HANDLER TO AREAS OUTSIDE THE SPACE CONTAINING THE AIR HANDLER, THE RETURN AIR SHALL ALSO BE HANDLED BY DUCT(S) SEALED TO THE AIR HANDLER CASING AND TERMINATING OUTSIDE THE SPACE CONTAINING THE AIR HANDLER.

WARNING

INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:

• AIR HANDLER OPERATING UNDER THERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TO THE AIR HANDLER;

• AIR FILTERS IN PLACE;

• RETURN AIR TEMPERATURE MAINTAINED BETWEEN 55°F (13°C) AND 80°F (27°C); AND

• CLEAN AIR HANDLER, DUCT WORK AND COMPONENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY AIR HANDLER OPERATING CONDITIONS INCLUDING FLOW RATE AND TEMPERATURE RISE, ACCORDING TO THE INSTRUCTIONS.

NOTICE

IMPROPER INSTALLATION, OR INSTALLATION NOT MADE IN ACCORDANCE WITH THE UNDERWRITERS LABORATORY (UL) CERTIFICATION OR THESE INSTRUCTIONS, CAN RESULT IN UNSATISFACTORY OPERATION AND/OR DANGEROUS CONDITIONS AND ARE NOT COVERED BY THE UNIT WARRANTY.

WARNING

DUCT LEAKS CAN CREATE AN UNBALANCED SYSTEM AND DRAW POLLUTANTS SUCH AS DIRT, DUST, FUMES AND ODORS INTO THE HOME CAUSING PROPERTY DAMAGE. FUMES AND ODORS FROM TOXIC, VOLATILE OR FLAMMABLE CHEM I CALS, AS WELL AS AUTOMOBILE EXHAUST AND CARBON MONOXIDE (CO), CAN BE DRAWN INTO THE LIVING SPACE THROUGH LEAKING DUCTS AND UNBALANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH (SEE FIGURE 2).

• IF AIR-MOVING EQUIPMENT OR DUCTWORK IS LOCATED IN GARAGES OR OFF-GARAGE STORAGE AREAS - ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIPMENT AND DUCT MUST BE SEALED TO LIMIT THE MIGRATION OF TOXIC FUMES AND ODORS INCLUDING CAR BON MONOXIDE FROM MIGRATING INTO THE LIVING SPACE.

• IF AIR-MOVING EQUIPMENT OR DUCTWORK IS LOCATED IN SPACES CONTAINING FUEL BURNING APPLIANCES SUCH AS WATER HEATERS OR BOILERS - ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIP MENT AND DUCT MUST ALSO BE SEALED TO PREVENT DEPRESSURIZATION OF THE SPACE AND POSSIBLE MIGRATION OF COMBUSTION BYPRODUCTS INCLUDING CARBON MONOXIDE INTO THE LIVING SPACE.

NOTICE

APPLICATION OF THIS HYDRONIC AIR HANDLER SHOULD BE INDOORS. SPECIAL ATTENTION SHOULD BE GIVEN TO UNIT SIZING AND PIPING, FILLING, AND PURGING.

CAUTION

FAILURE TO FOLLOW THIS CAUTION MAY RESULT IN PERSONAL INJURY. SHEET METAL PARTS MAY HAVE SHARP EDGES OR BURRS. USE CARE AND WEAR APPROPRIATE PROTECTIVE CLOTHING.

CAUTION

WHEN USED IN COOLING APPLICATIONS, EXCESSIVE SWEATING MAY OCCUR WHEN UNIT IS INSTALLED IN AN UNCONDITIONED SPACE. THIS CAN RESULT IN PROPERTY DAMAGE.

NOTICE

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER ALL EVAPORATOR COILS AND UNITS CONTAINING EVAPORATOR COILS AND AIR HANDLERS USED WITH EVAPORATOR COILS THAT ARE LOCATED IN ANY AREA OF A STRUCTURE WHERE DAMAGE TO THE BUILDING OR BUILDING CONTENTS MAY OCCUR AS A RESULT OF AN OVERFLOW OF THE COIL DRAIN PAN, A STOPPAGE IN THE PRIMARY CONDENSATE DRAIN PIPING OR ANY WATER LEAK POTENTIAL FROM THE AIR HANDLER.

WARNING

DO NOT OPERATE THE SYSTEM WITHOUT FILTERS. A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE DUCT RUNS AND AT THE SUPPLY REGISTERS. THIS RESIDUE COULD SOIL CEILINGS, WALLS, DRAPES, CARPETS AND OTHER ARTICLES IN THE HOUSE.

SOOT DAMAGE MAY OCCUR WITH FILTERS IN PLACE, WHEN CERTAIN TYPES OF CANDLES, OIL LAMPS OR STANDING PILOTS ARE BURNED.

CAUTION

HORIZONTAL UNITS MUST BE CONFIGURED FOR RIGHT HAND AIR SUPPLY OR LEFT HAND AIR SUPPLY. HORIZONTAL DRAIN PAN MUST BE LOCATED UNDER INDOOR COIL. FAILURE TO USE THE DRAIN PAN CAN RESULT IN PROPERTY DAMAGE.

NOTICE

CODES AND STANDARDS: IT IS THE RESPONSIBILITY OF THE INSTALLER TO FOLLOW ALL NATIONAL CODES, STANDARDS AND LOCAL ORDINANCES, IN ADDITION TO INSTRUCTIONS LAID OUT IN THIS MANUAL. THE INSTALLATION MUST COMPLY WITH REGULATIONS OF THE LOCAL BUILDING, HEATING, PLUMBING, AND OTHER CODES. WHERE LOCAL CODES ARE NOT APPLICABLE, THE INSTALLATION MUST COMPLY WITH THE NATIONAL CODES AND ANY AND ALL AUTHORITIES HAVING JURISDICTION.

Page 3

WARNING

IMPORTANT: All manufacturer products meet current Federal OSHA Guidelines for safety. California Proposition 65 warnings are required for certain products, which are not covered by the OSHA standards.

California's Proposition 65 requires warnings for products sold in California that contain, or produce, any of over 600 listed chemicals known to the State of California to cause cancer or birth defects such as fiberglass insulation, lead in brass, and combustion products from natural gas.

All “new equipment” shipped for sale in California will have labels stating that the product contains and/or produces Proposition 65 chemicals. Although we have not changed our processes, having the same label on all our products facilitates manufacturing and shipping. We cannot always know “when, or if” products will be sold in the California market.

You may receive inquiries from customers about chemicals found in, or produced by, some of our heating and air-conditioning equipment, or found in natural gas used with some of our products. Listed below are those chemicals and substances commonly associated with similar equipment in our industry and other manufacturers.

• Glass Wool (Fiberglass) Insulation

• Carbon Monoxide (CO)

• Formaldehyde

• Benzene More details are available at the

Websites for OSHA (Occupational Safety and Health Administration), at www.osha.gov California's OEHHA (Office of Environmental Health Hazard Assessment), at www.oehha.org. Consumer education is important since the chemicals and substances on the list are found in our daily lives. Most consumers are aware that products present safety and health risks, when improperly used, handled and maintained.

and the State of

CONTENTS

Safety Precautions...................................................................................................1

Safety Information....................................................................................................2

General Information..................................................................................................4

Location Requirements and Considerations............................................................6

Selection Procedure.................................................................................................8

Ducting...................................................................................................................12

Installation..............................................................................................................14

Plumbing.................................................................................................................15

Electrical Wiring......................................................................................................18

Accessories............................................................................................................18

Sequence of Operation..........................................................................................22

Maintenance...........................................................................................................24

Troubleshooting......................................................................................................26

Wiring Diagrams................................................................................................27-28

PROHIBITED APPLICATIONS

RHWB HYDRONIC AIR HANDLERS ARE EQUIPPED STANDARD WITH STAINLESS STEEL PUMPS AND COMPLY WITH CALIFORNIA PER AB1953 AND VERMONT PER SB152 FOR USE IN AIR HANDLER AND IN AN OPEN SYSTEM WITH POTABLE WATER.

IMPORTANT: TO ENSURE PROPER INSTALLATION AND OPERATION OF THIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TO ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIR THIS PRODUCT. UPON UNPACKING OF THE AIR HANDLER, INSPECT ALL PARTS FOR DAMAGE PRIOR TO INSTALLATION AND START-UP.

Page 4

GENERAL INFORMATION

FIGURE 1

UPFLOW AIR HANDLER THE RWHB SERIES HYDRONIC AIR HANDLERS ARE DESIGN-CERTIFIED BY UL

ITEM ITEM NO. PART NAME NO. PART NAME

1 DOOR SWITCH 7 PUMP 2 JUNCTION BOX 8 WATER INLET 3 TRANSFORMER 9 WATER OUTLET 4 CAPACITOR 10 BLOWER MOTOR 5 LOW VOLTAGE (THERMOSTAT) TERMINAL 11 HYDRONIC COIL ASSEMBLY 6 BLOWER

Page 5

IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY

Central cooling and heating equipment is only as efficient as the duct system that carries the cooled or heated air. To maintain efficiency, comfort and good indoor air quality, it is important to have the proper balance between the air being supplied to each room and the air returning to the cooling and heating equipment.

Proper balance and sealing of the duct system improves the efficiency of the heating and air conditioning system and improves the indoor air quality of the home by reducing the amount of airborne pollutants that enter homes from spaces where the ductwork and/or equipment is located. The manufacturer and the U.S. Environmental Protection Agency’s ENERGY STAR Program recommend that central duct systems be checked by a qualified contractor for proper balance and sealing.

WARNING

DUCT LEAKS CAN CREATE AN UNBALANCED SYSTEM AND DRAW POLLUTANTS SUCH AS DIRT, DUST, FUMES AND ODORS INTO THE HOME CAUSING PROPERTY DAMAGE. FUMES AND ODORS FROM TOXIC, VOLATILE OR FLAMMABLE CHEMICALS, AS WELL AS AUTOMOBILE EXHAUST AND CARBON MONOXIDE (CO), CAN BE DRAWN INTO THE LIVING SPACE THROUGH LEAKING DUCTS AND UNBALANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH (SEE FIGURE

2).

• IF AIR-MOVING EQUIPMENT OR DUCTWORK IS LOCATED IN SPACES CONTAINING FUEL BURNING APPLIANCES SUCH AS WATER HEATERS OR BOILERS - ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIPMENT AND DUCT MUST ALSO BE SEALED TO PREVENT DEPRESSURIZATION OF THE SPACE AND POSSIBLE MIGRATION OF COMBUSTION BYPRODUCTS INCLUDING CARBON MONOXIDE INTO THE LIVING SPACE.

NOTICE

IMPROPER INSTALLATION, OR INSTALLATION NOT MADE IN ACCORDANCE WITH THE UL CERTIFICATION OR THESE INSTRUCTIONS, CAN RESULT IN UNSATISFACTORY OPERATION AND/OR DANGEROUS CONDITIONS AND ARE NOT COVERED BY THE UNIT WARRANTY.

NOTICE

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER ALL EVAPORATOR COILS OR UNITS CONTAINING EVAPORATOR COILS OR AIR HANDLERS USED WITH EVAPORATOR COILS THAT ARE LOCATED IN ANY AREA OF A STRUCTURE DAMAGE TO THE BUILDING OR BUILDING CONTENTS MAY OCCUR AS A RESULT OF AN OVERFLOW OF THE COIL DRAIN PAN OR A STOPPAGE IN THE PRIMARY CONDENSATE DRAIN PIPING.

FIGURE 2

MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES

RECEIVING

Immediately upon receipt, all cartons and contents should be inspected for transit damage. Units with damaged cartons should be opened immediately. If damage is found, it should be noted on the delivery papers, and a damage claim filed with the last carrier.

• After unit has been delivered to job site, remove carton, taking care not to damage unit.

• Check the unit rating plate for unit size, voltage, phase, etc. to be sure equipment matches what is

required for the job specification.

• Read the entire instructions before starting the installation.

• Some building codes require extra cabinet insulation and gasketing when unit is installed in attic applications.

• If installed in an unconditioned space, apply caulking around the power wires, control wires, refrigerant tubing and condensate line where they enter the cabinet. Seal the power wires on the inside where they exit conduit opening. Caulking is required to prevent air leakage into and condensate from forming inside the unit, control box, and on electrical controls.

• Install the unit in such a way as to allow necessary access to the coil/pump and blower/control compartment.

• Install the unit in a level position to ensure proper condensate drainage. Make sure unit is level in both directions within 1/8”.

• Install the unit in accordance with any local code which may apply and the national codes. Latest editions are available from: “National Fire Protection

Association, Inc., Batterymarch Park, Quincy, MA 02269.” These publications are:

• ANSI/NFPA No. 70-(Latest Edition) National Electrical Code.

• NFPA90A Installation of Air Conditioning and Ventilating Systems.

• NFPA90B Installation of Warm Air Heating and Air Conditioning Systems.

• The equipment has been evaluated in accordance with the Code of Federal Regulations, Chapter XX, Part 3280.

Page 6

LOCATION REQUIREMENTS AND CONSIDERATIONS

Front

Back

GENERAL INFORMATION

1. IMPORTANT: If installing the unit over a finished ceiling or living area, be certain to install an auxiliary condensate drain pan under the entire unit. This auxiliary drain pan should extend under any evaporator coil installed with the air handler and the open portion of the condensate drain assembly.

2. IMPORTANT: If using a cooling evaporator coil with this air handler:

Be sure the air passes over the coil/pump before passing over the cooling coil.

FIGURE 3

PROHIBITED INSTALLATIONS

IMPORTANT: Support this unit

when installed. Since this air handler is suitable for attic or crawl space installations, it may be installed on combustible wood flooring or by using support brackets. See Figure 5.

5. IMPORTANT: If installing in a

utility room, be sure the door is wide enough to:

a. allow the largest part of the air

handler to pass; or

b. allow any other appliance

(such as a water heater) to pass.

6. IMPORTANT: This air handler is not approved or recommended for installation on its back, with access doors facing upwards (see Figure 3).

CLEARANCE ACCESSIBILITY

The design of air handlers with input ratings as listed in the tables under Figure 4 are certified by UL for the clearances to combustible materials shown in inches.

See name/rating plate and clearance label for specific model number and clearance information.

Service clearance of at least 24” is recommended in front of all air handlers.

NOTE: Use recommended 24” clearance if accessibility clearances are greater than fire protection clearances.

Air handlers are shipped with a bottom closure panel installed. When bottom return air is used, remove the panel by removing the two screws attaching the panel to the front base angle.

SITE SELECTION

1. Select a site in the building near the center of the proposed, or existing, duct system.

2. Locate the air handler to maintain proper clearance to combustibles as shown in the following tables.

The air inlet is not allowed to be at the front or back of the air handler.

Do not position the air handler on its back

or with it face down. Do not cut sides of

horizontal application.

NOTE: Multiple air handlers configured for installation with a single Tankless Water Heater is prohibited.

Page 7

FIGURE 4

CLEARANCE TO COMBUSTIBLES, UPFLOW, HORIZONTAL LEFT OR RIGHT, NO DOWNFLOW

BACK TOP FRONT

MINIMUM CLEARANCE (IN.)

SIDE SIDE

LEFT RIGHT

⁄32 0 0 0 1 0*

⁄4 ID 15 13

⁄8

⁄32 15

⁄32 0 0 0 1 0*

⁄4 ID 15 13

⁄4 ID 22 20

⁄8

⁄32 15

⁄32 22

IMPORTANT: Support this unit when installed. Since this air handler is suitable for attic or crawl space installation, it may be installed on combustible wood flooring or by using support brackets.

⁄2 16

⁄2 23

04 17

MODEL A B C D E F

⁄2 23

06 17

08 24

10 24

*A service clearance of at least 24 inches is recommended in front of all air handlers.

AIRFLOW

AIR

⁄8

RETURN

INLET

WATER

OUTLET

WATER

⁄16

AIR

SUPPLY

I392

Page 8

SELECTION PROCEDURE

Model Number Nomenclature

(WITH EXAMPLE)

I. Define hot water load for the total

required domestic hot water usage.

As an example, let’s assume that the selected Tankless Water Heater for your whole house solution is the RTG-74 and your calculated heat gain and heat loss values are as stated in section II.

II. Determine cooling and heating

requirements at design conditions:

The ACCA’s Manual J Residential Load Calculation method is the established trade standard, approved by ANSI, for the correct siziing and selection of Heating, Ventilation, Air-Conditioning and Refrigeration (HVACR) equipment in residential homes. The most recent revision is the eight edition, an allinclusive new approach to ensuring that Indoor Air Quality (IAQ) systems are as efficient, safe, and healthy as possible. Refer to the Air Conditioning Contractors of America website at:

http://www.acca.org/tech/manualj/

qualified HVACR contractor for further assistance.

or a

Assumptions: Required Cooling Capacity . 48,000 BTU/HR

(Total Capacity) Required Heating Capacity . 60,000 BTU/HR

Evaporator Air Quantity. . . . . . . . . 1600 CFM

External Static Pressure . . . . . . . 0.2 in. W.C.

Electrical Characteristics . . . . . . . . . 115-1-60

III. Determine total external static

pressure (ESP) at design conditions:

Before using the Airflow Performance Table calculate the total static pressure required. From the given example, note the Wet Coil Pressure Drop (selected from the field supplied Evaporative Cased Coil Installation Instructions), and the Filter Pressure Drop. Determine both static pressures at 1600 CFM:

Wet Coil Pressure Drop . . . .0.3 in. W.C.

(From Coil Manufacturer’s Installation Instructions)

External Static Pressure . . . 0.2 in. W.C.

(Ductwork, etc.)

Filter Pressure Drop . . . .08 in. W.C.

(.08 inches if the included filter is used; refer to

the filter’s manufacturer’s instructions if another

filter is used.)

Total Static Pressure. . . 0.58 in. W.C.

IV. Select unit based on required

cooling capacity airflow:

For an initial selection, choose a unit size that will provide the required airflow. Refer to Airflow Performance Table. Note that at 0.6 ESP (external static pressure) the RHWB06WMP48A unit will deliver 1560 CFM when configured for HIGH speed.

V. Select heating capacity of unit

to provide the requisite design condition:

From the Hydronic Air Handler/ Tankless Water Heater, note that the unit RHWB-06WMP48A, (as selected above) when matched with the RTG95 Tankless Water Heater, will provide 59.2 MBH (59,200 BTU/HR) at an input water temperature (to Air Handler) of 150°F.

Rheem

Air Handler

Water

Design Series

Denotes a major design change in the product line (i.e. capacity)

Nominal Heating Capacity (BTU/HR)

04W 40,000 06W 60,000 08W 80,000 10W 100,000

HYDRONIC AIR HANDLER MODEL IDENTIFICATION

HWB -06W MP 36 A

Brand Application Type

R = Rheem H = Air handler W = Water B = 2nd Series

RHWB 04W MP36 A

Variations

P = PSC Motor X = ECO Tech

Blower Size

M = 11x7 R = 11x10

Heating Output Designation

Design

Series

Inlet Water

Temp = 150°F

[66°C]

04W 40,000 [11.7 kW]

06W 60,000 [17.6 kW]

08W 80,000 [23.5 kW]

10W 90,000 [28.3 kW]

Output

BTU/HR [kW]

Blower

Size

M = 11x7

R = 11x10

Revision

A = Rev 0

Variations

36 = 1100-1300 CFM 48 = 1500-1700 CFM 60 = 1900-2100 CFM

[279 x 178 mm]

[279 x 254 mm]

P = PSC X = ECO

TECH™

Heat/Cool

Designation

36 = 1100-1300 CFM

36 = [519-613.5 L/s]

48 = 1500-1700 CFM

48 = [707.9-802.3 L/s]

60 = 1900-2100 CFM

60 = [896.7-991.1 L/s]

Revision

A - Rev 0

Page 9

HYDRONIC AIR HANDLER ELECTRICAL PHYSICAL SPECIFICATIONS - PSC MODELS

U.S. and Canadian Models

MODEL NUMBERS

Nominal Heating Capacity BTU/hr [W] 40000 60000 80000 100000

Air Side Temperature Rise* °F [°C] 45-75 [25-41.7] 40-70 [22.2-38.9] 35-65 [19.4-36.1] 35-65 [19.4-36.1] Heating CFM [L/s] @ .8 WC [.19 kPa] 590 [278] 1000 [471] 1453 [685] 1818 [858] Cooling CFM [L/s] @ .5 WC [.12 kPa] 1235 [582] 1622 [765] 1871 [883] 1973 [931]

Power Supply (V - HZ - PH) 115 - 60 - 1

Minimum Circuit Ampacity - Amps 9.6 10.9 13.6 13.6

Max Rating of Over Current Protective Device - Amps 15.8 18.2 23 23

Maximum Fuse or Circuit Breaker Size 15 15 20 20

Motor HP [W] 1/2 [373] 3/4 [559] 3/4 [559] 3/4 [559]

Blower (D x W) in [mm] 11 x 7 [279 x 178] 11 x 7 [279 x 178] 11 x 10 [279 x 254] 11 x 10 [279 x 254]

Blower Motor Type PSC

Pump Type Wet Rotor

Pump Power Supply (V - HZ - PH) 115 - 60 - 1

Pump Motor RLA/LRA - Amps 1.8

Pump HP [W] 1/8

Pump Maximum Working Pressure psi [kPa] 125 [861]

Min/Max Working Temperature °F [°C] 160 [71]

Water Connection Type Copper Studs

Inlet Water Connection Diameter in [mm] 3/4 [19]

Out Water Connection Diameter in [mm] 3/4 [19]

Return Air Filter Size in [mm] 12 x 16 [305 x 406] 16 x 24 [406 x 609]

Standard High Velocity Filter Size (L x W x H) in [mm] 15 3/4 x 25 x 1 [400 x 635 x 25] 22 3/4 x 25 x 1 [578 x 635 x 25]

Shipping Weight LBS [kg] 107 [48.5] 118 [53.5] 137 [62.1] 145 [65.7]

RHWB-04WMP36A RHWB-06WMP48A RHWB-08WRP60A RHWB-10WRP60A

HYDRONIC AIR HANDLER ELECTRICAL PHYSICAL SPECIFICATIONS - ECO-TECH™ MODELS

U.S. and Canadian Models

MODEL NUMBERS

Nominal Heating Capacity BTU/hr [W] 40000 60000 80000 100000

Air Side Temperature Rise* °F [°C] 45-75 [25-41.7] 40-70 [22.2-38.9] 35-65 [19.4-36.1] 35-65 [19.4-36.1] Heating CFM [L/s] @ .8 WC [.19 kPa] 578 [272] 1030 [485] 1502 [707] 1847 [870] Cooling CFM [L/s] @ .5 WC [.12 kPa] 1180 [556] 1300 [612] 1645 [775] 1707 [804]

Power Supply (V - HZ - PH) 115 - 60 - 1

Minimum Circuit Ampacity - Amps 9.6 12.4 12.4 12.4

Max Rating of Over Current Protective Device - Amps 15.8 20.9 20.9 20.9

Maximum Fuse or Circuit Breaker Size 15 20 20 20

Motor HP [W] 1/2 [373] 3/4 [559] 3/4 [559] 3/4 [559]

Blower (D x W) in [mm] 11 x 7 [279 x 178] 11 x 7 [279 x 178] 11 x 10 [279 x 254] 11 x 10 [279 x 254]

Blower Motor Type EcoTech / ECM Type

Pump Type Wet Rotor

Pump Power Supply (V - HZ - PH) 115 - 60 - 1

Pump Motor RLA/LRA - Amps 1.8

Pump HP [W] 1/8

Pump Maximum Working Pressure psi [kPa] 125 [861]

Min/Max Working Temperature °F [°C] 160 [71]

Water Connection Type Copper Studs

Inlet Water Connection Diameter in [mm] 3/4 [19]

Out Water Connection Diameter in [mm] 3/4 [19]

Return Air Filter Size in [mm] 12 x 16 [305 x 406] 16 x 24 [406 x 609]

Standard High Velocity Filter Size (L x W x H) in [mm] 15 3/4 x 25 x 1 [400 x 635 x 25] 22 3/4 x 25 x 1 [578 x 635 x 25]

Shipping Weight LBS [kg] 116 [52.6] 126 [57.2] 146 [66.2] 153 [69.3]

RHWB-04WMX36A RHWB-06WMXP48A RHWB-08WRX60A RHWB-10WRX60A

Page 10

SAMPLE HYDRONIC AIR HANDLER PERFORMANCE

WATER FLOW

LB/HR

[kg/hr]

2000/

[907]

2000/

[907]

2000/

[907]

2000/

[907]

GPM

AIR INLET

TEMP (°F) [°C]

68 [20]

AIR OUTLET

TEMP (°F) [°C]

RHWB-04WMP36A RHWB-04WMX36A

RHWB-06WMP48A RHWB-06WMX48A

RHWB-08WRP60A RHWB-08WRX60A

RHWB-10WRP60A RHWB-10WRX60A

WATER INLET

TEMP (°F) [°C]

120 [49] 110 [43] 106 [41] 20900 [6.13] 30 [17]

130 [54] 117 [47] 113 [45] 25800 [7.56] 37 [21]

140 [60] 125 [52] 122 [50] 29800 [8.73] 43 [24]

150* [66] 132 [56] 130 [54] 35000 [10.26] 50 [28]

160 [71] 140 [60] 137 [58] 40000 [11.72] 57 [32]

120 [49] 100 [38] 105 [41] 38200 [11.20] 31 [17]

130 [54] 108 [42] 109 [43] 44900 [13.16] 37 [21]

140 [60] 115 [46] 116 [47] 50600 [14.83] 42 [23]

150 [66] 120 [49] 126 [52] 60000 [17.58] 49 [27]

160 [71] 126 [52] 129 [54] 67100 [19.67] 55 [31]

120 [49] 106 [36] 103 [39] 45500 [13.33] 26 [14]

130 [54] 113 [39] 108 [42] 53700 [15.74] 31 [17]

140 [60] 121 [43] 113 [45] 62500 [18.32] 36 [20]

150 [66] 128 [46] 120 [49] 71800 [21.04] 42 [23]

160 [71] 135 [49] 123 [51] 80500 [23.59] 47 [26]

120 [49] 96 [36] 100 [38] 47200 [13.83] 27 [15]

130 [54] 101 [38] 110 [43] 57800 [16.94] 33 [18]

140 [60] 106 [41] 112 [44] 66900 [19.61] 38 [21]

150 [66] 111 [44] 119 [48] 77000 [22.57] 44 [24]

160 [71] 106 [46] 124 [51] 86800 [25.44] 50 [28]

WATER OUTLET

TEMP (°F) [°C]

CFM - Cubic Feet Per Minute Performance is based on the following assumptions:

1) an estimated 100 ft. [30m] equivalent length of 0.75-inch piping

2) 0.50” [13] w.c. of external air static.

AIR CFM

[L/s]

646 [305]

1000 [462]

1450 [684]

1800 [850]

CAPACITY

(BTU/HR) [kW]

AIR TEMP

RISE (°F) [°C]

Page 11

HYDRONIC AIR HANDLER TANKLESS WATER HEATER PERFORMANCE

Capacity (BTU/HR) [kW]

Entering Water Temperature (°F) )°C)

Air Handler Model

RHWB-04WMP36A RHWB-04WMX36A

RHWB-06WMP48A RHWB-06WMX48A

RHWB-08WRP60A RHWB-08WRX60A

RHWB-10WRP60A RHWB-10WRX60A

CFM = Cubic Feet Per Minute ESP = External Static Pressure *Recommended Operating Point Inlet Air at 72°F [22°C] Capacities are based on a piping arrangement with a total equivalent length of 100 ft [30m]. Entering water temperatures must not exceed 160°F [71°C]

Tankless

Model

RTG-64

RTG-95 RTGH-84 RTGH-95

RTG-53

RTG-64

RTG-66

RTG-74

RTG-84

RTG-95 RTGH-84 RTGH-95

RTG-53

RTG-64

RTG-66

RTG-74

RTG-84

RTG-95 RTGH-84 RTGH-95

RTG-53

RTG-64

RTG-66

RTG-74

RTG-84

RTG-95 RTGH-84 RTGH-95

Blower Speed

High

Med-High

ESP

(In. W.C.)

0.5

[124.5]

0.5

[124.5]

0.5

[124.5]

0.5

[124.5]

Heating Air

Delivery

(CFM) [L/s]

1235 [583]

1622 [765]

1586 [749]

1620 [765]

120 [49] 130 [54] 140 [60] 150* [65] 160 [71]

26400 [7.74] 31800 [9.32] 35500 [10.40] N/A N/A 25700 [7.53] 30900 [9.06] 33900 [9.94] 39600 [11.61] 44800 [13.13]RTG-84 25600 [7.50] 31500 [9.23] 34600 [10.14] 40000 [11.72] 45400 [13.31] 27700 [8.12] 30100 [8.82] 35400 [10.37] 40600 [11.90] 46000 [13.48] 25400 [7.44] 30200 [8.85] 32700 [9.58] 40200 [11.78] 45400 [13.31]

32600 [9.55] 39500 [11.58] 47500 [13.92] N/A N/A 40900 [11.99] 47100 [13.80] 51000 [14.95] N/A N/A 40200 [11.78] 46400 [13.60] 54700 [16.03] 63500 [18.61] 71300 [20.90] 37700 [11.05] 46200 [13.54] 54000 [15.83] 62700 [18.38] 71300 [20.90] 40000 [11.72] 47800 [14.01] 52100 [15.27] 60300 [17.67] 68100 [19.96] 37200 [10.90] 45200 [13.25] 50900 [14.92] 59200 [17.35] 66400 [19.46] 38600 [11.31] 44300 [12.98] 49000 [14.36] 55300 [16.21] 62000 [18.17]

33900 [9.94] 43300 [12.69] 53800 [15.77] 60600 [17.76] 69500 [20.37]

35000 [10.26] 41300 [12.10] 50600 [14.83] N/A N/A 42000 [12.31] 50900 [14.92] 53400 [15.65] N/A N/A 40400 [11.84] 50500 [14.80] 56500 [16.56] 65500 [19.20] 73600 [21.57] 40300 [11.81] 49700 [14.57] 58800 [17.23] 71600 [20.98] 81600 [23.91] 45800 [13.42] 53300 [15.62] 56900 [16.68] 66900 [19.61] 76000 [22.27] 45300 [13.28] 53100 [15.56] 60000 [17.58] 70500 [20.66] 80700 [23.65] 45900 [13.45] 54900 [16.09] 59000 [17.29] 67500 [19.78] 75900 [22.24] 44900 [13.16] 52700 [15.44] 58300 [17.09] 65200 [19.11] 73100 [21.42]

35500 [10.40] 44500 [13.04] 53300 [15.62] N/A N/A 40800 [11.96] 48000 [14.07] 53200 [15.59] N/A N/A 48300 [14.16] 57800 [16.94] 62100 [18.20] 71800 [21.04] 83000 [24.32] 49300 [14.45] 59600 [17.47] 69500 [20.37] 79100 [23.18] 89700 [26.29] 43200 [12.66] 51800 [15.18] 56900 [16.68] 65100 [19.08] 75400 [22.10] 48300 [14.16] 58200 [17.06] 61000 [17.88] 71000 [20.81] 79800 [23.39] 44600 [13.07] 53000 [15.53] 56000 [16.41] 65400 [19.17] 74400 [21.80] 44600 [13.07] 52000 [15.24] 56500 [16.56] 65400 [19.17] 75500 [22.12]

Page 12

DUCTING

JACKET

DRILL (2) 3/16" DIA. HOLES

8.000”

4.875”

1.531”

Proper air flow is required for the correct operation of this air handler. Too little air flow can cause erratic operation and can damage the heat exchanger. The duct system must carry the correct amount of air for heating and cooling if summer air conditioning is used.

Size the ducts according to acceptable industry standards and methods. The total static pressure drop of the air distribution system should not exceed 0.8" w.c.

NOTE: Return air grilles and warm air registers must not be obstructed

IMPORTANT: Some high efficiency filters have a greater than normal resistance to air flow. This can adversely affect air handler operation. BE SURE TO CHECK AIR FLOW.

IMPORTANT: When using outside air, design and adjust the system to maintain a return air temperature ABOVE 50° F during the heating season.

UPFLOW UNITS

1. Position the unit to minimize long runs of duct or runs of duct with many turns and elbows.

2. Open the return air compartment. a. Cut an opening in the side.

The opening should be cut the full width of the knockouts on the unit. See Figure 5.

FIGURE 5

CUTOUT AND DRILL INFORMATION UPFLOW ONLY

NOTE: Where the maximum air flow

is 1800 CFM or more, both sides or the bottom must be used for return air.

3. Connect the return duct or return air cabinet to the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

4. Be sure to have adequate

space for the unit filter. NOTE: DO NOT take return air

from bathrooms, kitchens, air handler rooms, garages, utility or laundry rooms, or cold areas.

NOTE: DO NOT use a rear air return.

5. If summer air conditioning (heat pump) is desired, position the indoor coil on the top of the unit. Insure that no air can bypass this coil.

6. Connect the supply air plenum to the air handler plenum opening.

HORIZONTAL UNIT

1. Position the unit to minimize long runs or runs with many turns and elbows.

2. If summer air conditioning or heat pump is desired, position the indoor coil on the supply air end of the unit. Insure that no air can bypass this coil.

3. Connect the air handler to the supply air plenum.

4. Connect the return air ducting to the return air opening of the unit. Make the connection air tight to prevent pulling combustion gases from an adjacent fuel-burning appliance.

5. Be sure to have adequate

space for the unit filter. NOTE: DO NOT take return air

from bathrooms, kitchens, air handler rooms, garages, utility or laundry rooms, or cold areas.

DOWNFLOW UNITS

1. Position the unit to minimize long runs of duct or runs of duct with many turns and elbows.

2. If summer air conditioning is desired, position the indoor coil on the supply air side of the unit. Insure that no air can bypass this coil.

3. Connect the furnace to the supply air plenum.

4. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

5. Be sure to have adequate space for the unit filter.

NOTE: DO NOT take return air from bathrooms, kitchens, furnace rooms, garages, utility or laundry rooms, or cold areas.

*Solid metal bottom required if side duct penetration is used.

Page 13

Blower located to the right of coil section. Conditioned air is discharged to the left.

Blower located below coil section. Conditioned air is discharged upward.

Blower located to the left of coil section. Conditioned air is discharged to the right.

Blower located above coil section. Conditioned air is discharged downward.

FIGURE 6

POSITION ORIENTATION

UPFLOW

HORIZONTAL LEFT

HORIZONTAL RIGHT

DOWNFLOW

Page 14

INSTALLATION

Refer to the specification section of this

DOOR ASSEMBLY

8” MIN FOR DOOR REMOVAL

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS REQ. PER ROD

USE 1” SQUARE, 1-1/4 x 1-1/4 x 1/4 ANGLE IRON OR EQUIVALENT

SECURE ANGLE IRON TO BOTTOM OF AIR HANDLER WITH 3 #8 x 3/4” SCREWS TYPCIAL FOR 2 SUPPORTS

1/4” THREADED ROD (4 REQUIRED)

DOORS

1 INCH x 22 GAUGE GALVANIZED STRAPS TYPICAL FOR 4 STRAPS

RETURN AIR OPENING

SUPPLYAIR OPENING

BACK

SUSPENDED CABINET INSTALLATION

If the cabinet cannot be supported on a frame or supported from the wall, it may be suspended.

Use metal strapping or threaded rod with angle iron supports under cabinet for support. These supports MUST run parallel with the length of the cabinet.

Ensure that there is adequate room to remove service and access panels after installing supporting brackets.

If an auxiliary drain pan is required, the support is to be placed under a drain pan.

FIGURE 7

HORIZONTAL UNIT SUSPENSION

WARNING

IT IS THE INSTALLER’S RESPONSIBILITY TO USE AN APPROPRIATE HANGING METHOD CAPABLE OF SUPPORTING THE UNIT’S WEIGHT. REFER TO THE SPECIFICATION SECTION OF THIS DOCUMENT FOR THE RESPECTIVE UNIT’S INSTALLED WEIGHTS.

NOTICE

FOR SEISMIC HANGING REQUIREMENTS, REFER TO LOCAL CODES.

Attachment Methods Using Straps

Method 1 Use (4) #8 x 3/4 sheet metal screws

for each strap. The straps should be vertical against the air handler sides and not pull away from the air handler sides.

Method 2 Fold all straps under the air handler

and secure with (4) #8 x 3/4 sheet metal screws (2 screws at the side and 2 screws at the bottom. (Care must be taken not to drive the screw through the coil.)

FIGURE 8

HORIZONTAL UNIT SUSPENSION WITH STRAPS

Page 15

PLUMBING

Codes:

The RHWB air handler is used in potable water systems. Therefore, it is important to observe all local sanitary codes when installing water lines. The water supply mating connection to the Hydronic Air Handler is made via the two (3/4 in. dia. X 2-1/2 in. long) copper stubs to the front-left of the unit labeled “WATER IN” and “WATER OUT” (see Figure 1). Mating connectors to be two field-supplied, 3/4 in., FNPT-sweat ends or equivalent.

All associated hydronic piping MUST comply with ICC, UPC and any other local codes or ordinances having jurisdiction. USE POTABLE GRADE COPPER PIPING AND BRASS APPURTENANCES ONLY.

Flow Switch Installation:

(Recommended for Open-Loop Systems)

Care must be taken to ensure that the flow switch is not damaged due to excessive tightening. The torque must not exceed the maximum limit stated below. The installation should be checked to ensure that no leaking is evident.

Mating connectors to be (2) 3/4” FNPT fittings (field supplied).

Pipe-work/connector alignment is imperative (avoid bending stress).

Polytetrafluoroethylene (PTFE) thread seal tape (teflo tape), or equivalent, is recommended.

Tighten fittings to maximum torque of 15lb/ft (20Nm).

The pressure flow switch should be installed in a straight horizontal section of pipe at least 4” from elbows.

Soldering Copper Tubing:

The common method of joining copper tubing in hydronic heating systems is soft soldering. Plumbing codes do not allow solders containing lead to be used for domestic water service. USE ONLY 95/5 tin/antimony solder for all piping systems that incorporate a domestic water supply.

NOTE: Precautions must be taken during soldering to avoid debris or solder from lodging in piping system.

Water Storage Tank:

When connecting directly to a water storage tank it is necessary to ensure the water flow rate does not become excessive. Excessive water flow can result in increased system noise and potential system damage. In order to regulate the flow it is required that an adjustable valve be placed between the air handler outlet and the storage tank.

Furthermore, two pressure taps will need to be installed, the first located between the air handler outlet and the adjustable valve as near as possible to the outlet, and the second on the inlet water attached as near as possible to the inlet. While the water pump is engaged the adjustable valve will be closed until the pressure difference between the outlet and the inlet is greater than 13.5 PSID.

Tubing Insulation:

Any tube-conveying fluid at a temperature greater than that of the surrounding air releases heat.

Insulate all accessible hot water lines and associated valves with material, such as expanded neoprene or polyurethane 3/8-in. to 1⁄2-in. thick.

Match the pipe sleeve’s inside diameter to the pipe’s outside diameter for a snug fit. Place the pipe sleeve so the seam will be face down on the pipe. Tape, wire, or clamp insulation every foot or two to secure it to the pipe. If taping is desired, use acrylic tape instead of duct tape.

Copper Tubing Support:

Copper tubing must be properly supported to prevent sagging or buckling. On horizontal runs with hard temper tubing, the following maximum support spacing is suggested:

• 1/2 in. to 3/4 in. tube: 5 feet maximum spacing

• 1 in. to 1-1/4 in. tube: 6 feet maximum spacing

The above suggested spacing does not account for extra weight of piping components such as an expansion tank, etc. When such components are present, the piping should be supported immediately adjacent to the component.

On vertical runs, copper tubing should be supported at each floor level or at a maximum of every 10 feet.

Thermal Expansion of Piping:

In all hydronic systems, piping undergoes temperature swings as the system operates. This causes changes in the length of the piping due to thermal expansion.

If the piping is rigidly mounted, this expansion can cause annoying popping or squeaking sounds and, in extreme cases, the piping can even buckle.

To counter expansion movement, design piping circuits with sufficient elbows, tees or expansion loops (only used in large systems) or piping supports that allow the tubing to expand and contract freely.

Another alternative is to install an expansion compensator fitting capable of absorbing the movement.

Hydronic Resistance of Fittings, Valves, and Other Devices:

Before the total hydronic resistance of a piping circuit can be found, the individual hydronic resistances of all fittings, valves, or other such components must be determined. One approach is to consider each fitting, valve, or other device as an equivalent length of copper tube of the same pipe size (see Table 2).

By using the equivalent length of piping for all components in the circuit, the circuit can be treated as if it were a single piece of pipe having a length equal to the sum of the actual pipe length, the total equivalent lengths of all fittings, valves, or other devices. Refer to Figure 9 and the calculation of equivalent lengths.

Pipe Sizing Considerations:

When selecting a pipe size for a given flow rate, the resulting average flow velocity should be between 2 and 4 feet per second.

At water flow velocities of approximately 2 feet per second, flowing water will carry air bubbles along a vertical pipe. Average flow velocities of 2 feet per second or higher can draw along air bubbles in a downward flow. At the above stated velocities air bubbles shall be routed to an air separator where they can be collected and discharged from the system. Use Taco 4900 series air separator, Model 49-075, or equivalent (field supplied).

Average flow velocities higher than 4 feet per second could cause flow noise and should be avoided.

Expansion Tank:

All liquids used in hydronic heating systems expand when heated. For all practical purposes, liquids are incompressible. Any container completely filled with a liquid and sealed from the atmosphere will experience a rapid increase in pressure as the liquid is heated.

To prevent this from occurring, all closed-loop hydronic systems MUST be equipped with an expansion tank. Refer to expansion tank man u fac turer’s instructions for proper sizing and installation.

Water circulation:

The hydronic air handler has a strict in press cycle which will circulate the water in the coil for 6 minutes per day to prevent water stagnation.

Page 16

PROCEDURE FOR

COLDHOT

1-1/2 FT

1 FT

EV2

COLD WATER SUPPLY

EL7

2 FT

1-1/2 FT

TEMPERED WATER

1 FT

2 FT

1 FT

4 FT

3 FT

1/2 FT

EL1

1 FT

OUT

AIR HANDLER

CALCULATING THE TOTAL EQUIVALENT LENGTH OF PIPE

Given piping assembly as shown in Figure 9 below, what is the total equivalent length of the system?

First determine the total straight pipe lengths; next refer to Table 4 to determine the equivalent straight pipe length for each fitting shown. Add together the equivalent lengths of piping and fittings.

(3/4”) Tubing 24 ft. 7 (3/4”) 90 deg. Elbows 7 (1.9) = 13.3 ft. 5 (3/4”) Side Port Tees 5 (3.8) = 19.0 ft. 1 (3/4”) Taco air separator = .3 ft.

2 (3/4”) Ball Valve 2 (.2) = .4 ft.

Total Equivalent Length . . . . . = 57 ft.

FIGURE 9

EQUIVALENT LENGTH CALCULATION

NOTICE

WHERE POSSIBLE THE LENGTH OF PIPE SHOULD NOT EXCEED 100 FEET TOTAL EQUIVALENT LENGTH.

ANY PIPING RUNNING THROUGH UNCONDITIONED SPACE MUST BE INSULATED TO PREVENT HEAT LOSS, AND POSSIBLE FREEZING OF THE LINE.

STICKERS INDICATING DIRECTION OF FLOW (WATER IN AND WATER OUT) ARE LABELED ON THE OUTSIDE OF THE CABINET. DO NOT REVERSE THESE LINES, AS THIS WILL CAUSE THE UNIT TO MALFUNCTION.

Piping Configuration

When employing a Tankless Water Heater in a hydronic system, the system is considered an open-loop system when configured to simultaneously deliver both domestic hot water and space heating. By definition, if the circuit is sealed off from the atmosphere at all locations (as is true for most modern hydronic systems), it is called a closed-loop system. If the circuit is open to the atmosphere at any point, it is called an open-loop system.

Rheem Tankless Water Heater

COLD WATER SUPPLY

AIR HANDLER

TEMPERED WATER

Globe Valve 14.1 18.8 28.1 37.5 46.9 56.3 Angle Valve 6.3 8.3 12.5 16.7 20.8 25.0 Gate Valve 0.5 0.7 1.1 1.4 1.8 2.1 Ball Valve (BV) 0.1 0.1 0.2 0.3 0.3 0.4 90 Degree Standard Elbow 0.9 1.3 1.9 2.5 3.1 3.8 45 Degree Standard Elbow 0.5 0.7 1.0 1.3 1.7 2.0

Table 4 – Equivalent Length of Straight Pipe for Valves and Fittings (ft)

0.375 0.5 0.75 1 1.25 1.5

Diameter (in.)

Standard Tee with flow through run 0.6 0.8 1.3 1.7 2.1 2.5 Standard Tee with flow through branch 1.9 2.5 3.8 5.0 6.3 7.5

Page 17

All piping to be 3/4 inch.

(BV)

(DV)

Evaporator Coil

AirSeparator

Flow Switch

Open-Loop System

If piping is done in accordance with the recommended schematic diagram shown in Figure 10, the following purge and priming procedure applies.

PURGING AND PRIMING THE SYSTEM:

The following procedure describes how the system may be piped to eliminate the need for a “purge cart” to fill the system and remove entrapped air bubbles.

STEP 1: CLOSE the air separator venting valve.

STEP 2: CLOSE ball valve 3 (BV

FIGURE 10

TYPICAL PIPING ARRANGEMENT FOR DIRECT SPACE HEATING AND DOMESTIC WATER SUPPLY WITH TANKLESS

3);

STEP 3: OPEN drain valve 3 (DV which a hose MUST be connected and draining to a sink, drain or outdoors.

STEP 4: CLOSE drain valves 1 & 2

1 and DV2) and OPEN ball valve 2

(DV (BV

2).

STEP 5: OPEN cold water supply main valve (ball valve 1 - BV

1). The system

will begin the prime/purge process using the street pressure. Entrapped air bubbles being pushed out of the system will be evident by a slight vibration of the discharge hose connected to drain valve 3 (DV

3). The hose will stop vibrating

when laminar flow is achieved.

3) to

STEP 6: CLOSE drain valve 3 (DV STEP 7: OPEN ball valve 3 (BV

The system is now purged, primed and ready to go.

STEP 8: OPEN the air separator venting valve.

NOTE: For an open-loop system, use expansion tank approved for potable water use only.

3);

3).

Page 18

ELECTRICAL WIRING

WARNING

TURN OFF ELECTRIC POWER AT FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

THE CABINET MUST HAVE AN UNINTERRUPTED GROUND ACCORDING TO THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE (NEC), ANSI/ NFPA70- OR IN CANADA, THE CANADIAN ELECTRICAL CODE, CSA-C221 OR LOCAL CODES THAT APPLY. DO NOT USE GAS PIPING AS AN ELECTRICAL GROUND. A GROUND SCREW IS PROVIDED IN THE JUNCTION BOX. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK, RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

THIS AIR HANDLER IS EQUIPPED WITH A BLOWER DOOR SAFETY SWITCH. DO NOT DISABLE THIS SWITCH. FAILURE TO FOLLOW THIS WARNING CAN RESULT IN ELECTRICAL SHOCK, PERSONAL INJURY OR DEATH.

IMPORTANT: The air handler must

be installed so that the electrical components are protected from water (condensate).

Before proceeding with the electrical connections, be certain that the voltage, frequency and phase corresponds to that specified on the air handler rating plate. For single air handler application, maximum overcurrent protection is 15 amperes.

CAUTION

IF A DISCONNECT SWITCH IS TO BE MOUNTED ON THE UNIT, SELECT A LOCATION WHERE A DRILL OR FASTENER WILL NOT CONTACT ELECTRICAL OR HYDRONIC COMPONENTS. ELECTRICAL SHOCK CAN CAUSE PERSONAL INJURY OR DEATH.

NOTE: Prior to making any electrical

connections, ensure that supply voltage, frequency, and phase are as specified on unit rating plate.

Check to ensure that the existing electrical service is adequate to handle the additional load imposed by the Hydronic Air Handler. Refer to unit wiring diagram for proper electrical connections.

All electrical connections MUST comply with NEC and any other local codes or ordinances having

jurisdiction. USE COPPER WIRE ONLY. Provide separate branch electric circuit with field supplied disconnect switch.

Location of disconnect switch to be in clear site, accessible and in close proximity to the unit.

Correct polarity MUST be maintained for 115 V wiring. If polarity is incorrect, unit will NOT operate.

Use a separate fused branch electrical circuit containing a properly sized fuse or circuit breaker. Run this circuit directly from the main switch box to an electrical disconnect that is readily accessible and located near the air handler. Connect from the electrical disconnect to the junction box on the left side of the air handler, inside the blower compartment. For the proper connection, refer to the appropriate wiring diagram located on the inside cover of the air handler control box and in these instructions.

The electrical junction box may be moved to the right side if necessary. A knockout is provided. Seal the opposite hole with plug provided.

Make all electrical connections in accordance with the latest edition of the National Electrical Code, ANSI/NFPA70 and local codes having jurisdiction.

These may be obtained from: National Fire Protection

Association, Inc. Batterymarch Park Quincy, MA 02269

CSA - International 178 Rexdale Blvd. Etobicoke (Toronto), Ontario Canada M9W, 1R3

THERMOSTAT

The room thermostat must be compatible with the integrated air handler control on the air handler. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated air handler control. The low voltage wiring should be sized as shown (see Figures 12 and

13). NOTE: Do not use 24 volt control

wiring smaller than No. 18 AWG. Install the room thermostat in

accordance with the instruction sheet packed in the box with the thermostat. Run the thermostat lead wires inside the blower compartment and connect to low voltage terminals as shown on the wiring diagram. Never install the thermostat on an outside wall or where it will be influenced by drafts, concealed hot or cold water pipes or ducts, lighting fixtures, radiation from fireplace, sun rays, lamps, televisions, radios or air streams from registers. Refer to instructions packed with the thermostat for “heater” selection or adjustment.

ACCESSORIES

FIELD-INSTALLED OPTION ACCESSORIES

ELECTRONIC AIR CLEANER

Line voltage power can be supplied from the screw terminal “EAC” and a line voltage neutral screw terminal on the control board. This will power the electronic air cleaner whenever the circulating air blower is in operation.

Expansion Tank:

Expansion tank for closed systems air separator – TACO Model 49-075.

Page 19

FIGURE 11

R C

Y1 Y2

W G

R C

BLK

WHT

AIR HANDLER

Flow Sensor (Packaged with Unit)

5 Wire

3 Wire Heating Only

Single Stage Thermostat

24Volt FS / WH Connector

24 VoltTerminal Block

Control Box

PCB

Condensing Unit

Field115, 208 / 230Volt Wiring Field 24 Volt Wiring Factory 24 Volt Wiring Factory115Volt Wiring

Junction Box

FIRST STAGE HEAT/COOL

AUX HEATING

FAN

24VAC HOT

24 VAC COMMON

SINGLE STAGE AIR-HA NDLER

SINGLE SPEED

CONDENSING

UNIT

HEAT/COOL & COOL ONLY

THERMOSTATS

FIRST STAGE HEAT/COOL

AUX HEATING

FAN

RVS HEATING

24VAC HOT

24 VAC COMMON

HEAT PUMP T HERMOSTATS

SINGLE STAGE AIR-HANDLER

SINGLE STAGE

HEAT PUMP

FIELD WIRING DIAGRAM

FIGURE 12

THERMOSTAT WIRING DIAGRAMS SINGLE STAGE AIR HANDLER W/SINGLE STAGE A/C

FIGURE 13

THERMOSTAT WIRING DIAGRAMS SINGLE STAGE AIR HANDLER W/SINGLE STAGE HEAT PUMP*

*Requires Fossil Fuel Kit Refer to Kit for further wiring instructions.

Page 20

System Low Voltage Wiring

FLOW SENSOR CONNECTIONS

SW1 SET-UP SWITCH AND HEATING BLOW OFF DELAY

24 V THERMOSTAT TERMINALS

TRANSFORMER 24 V CONNECTIONS

3AMP FUSE

OPERATING MODE JUMPER (SHUNT)

STATUS LED LIGHT

115 VAC (L2) NEUTRAL CONNECTIONS

PUMP CONNECTIONS

115 VAC (L1) LINE VOLTAGE CONNECTION

FAN PARK

FAN CONNECTION HEATING

FAN CONNECTION COOLING

HUMIDIFIER CONNECTIONS (DRY CONTACT) 24 VAC OR 115 VAC

FLASH UPGRADE CONNECTION (FACTORY ONLY)

AN1

Diagrams

NOTE: Local codes may require

thermostat wiring to be routed through conduit or raceways. In such instances splices can be made inside the Hydronic Air Handler. All wiring must be NEC Class I and must be separated from incoming power leads.

Provide field-supplied disconnect for maximum fuse or circuit breaker sizes, as required by code.

Transformer is factory wired for 115V operation.

The secondary circuit of the transformer is protected by a 3-amp fuse mounted on the printed circuit board.

FIGURE 14

HYDRONIC AIR-HANDLER CONTROL BOARD

Dip Switch Options:

Refer to the appropriate diagram for the proper dip switch setting to be used with the designed application (Figure 17).

THERMOSTAT INSTALLATION:

Thermostat should be mounted:

• approximately 5 ft. (1.5 m) from floor

TABLE 5

Wire Gauge Maximum Distance (feet)

18 gauge 60 16 gauge 100 14 gauge 160 12 gauge 250

• close to or in a frequently used room, preferably on an inside, partitioning wall

• on a section of wall without pipes or duct work.

Thermostat should NOT be mounted:

• close to a window, on an outside wall, or next to a door leading to the outside.

NOTES:

1. For proper operation of an open loop system (refer to Figures 11 and 17), the jumper (shunt) position on PCB point “P7” should be in the FS position.

2. When changing shunt position ensure that unit power is turned off.

Page 21

SINGLE-STAGE A/C

CONFIGURATION

(DEFAULT)

SINGLE-STAGE HP

CONFIGURATION

2 3 41

2 3 4

30 SECONDS OFF DELAY (DEFAULT)

60 SECONDS OFF

DELAY

2 3 41

2 3 4

90 SECONDS OFF

DELAY

120 SECONDS OFF

DELAY

2 3 41

2 3 4

Key:

Switch is in the ON position.

Switch does not affect this setting.

Switch is in the OFF position.

TWO-STAGEA/C CONFIGURAT

ION

TWO-STAGEHP

CONFIGURATION

2 3 41

2 3 4

• exposed to direct light and heat from a lamp, sun, fireplace, or other heatradiating object which may cause a false reading.

• close to or in direct airflow from supply registers and return-air grilles

• In areas with poor air circulation, such as behind a door or in an alcove

Refer to thermostat wiring diagram and thermostat installation instructions for further details.

FIGURE 15

DIP SWITCH POSITIONS

START-UP PROCEDURE (HEATING ONLY):

The following conditions must be met prior to unit start-up.

Debris from soldering and/or other installation activities can cause equipment failure. Ensure that all associated lines and appurtenances are free of debris.

Check to ensure that unit is secure. Check that blower wheel rotates freely

within the scroll housing. Check all wiring to ensure that

connections are tight. Check all ductwork and pipe

connections to ensure proper seal. Check to ensure that all packaging

wraps are removed from equipment. Ensure that front access doors are

properly installed. Check to ensure proper connection(s)

to the appropriate blower speed tap (Heat /Cool – High and Low). Refer to Dry Air Delivery Table and/or the appropriate wiring diagram(s) in this manual.

Perform all safety and start-up checks for Tankless Water Heater as per manufacturer’s instructions.

Having verified all preceding checks, the Air Handler’s Start-Up Procedure is as follows:

STEP 1: Purge and fill system; follow appropriate purging procedure as laid out in this manual in section titled “Purging and Priming the System”.

STEP 2: Turn on power supply to air handler. Caution: blower and/or circulator may start to operate if thermostat is on and a call is present.

STEP 3: Turn thermostat ON and switch system to the heating mode. The thermostat shall be set higher than the actual room temperature; this will cause the circulator to energize and initiate the heating cycle. (If the pump does not start, or the Air Handler is not producing heat, refer to the Troubleshooting Section, in this manual).

STEP 4: Program room thermostat as desired by homeowner.

START-UP PROCEDURE (COOLING SYSTEM)

Refer to field-supplied evaporator coil and outdoor unit manufacturer’s Installation Instructions for system hook-up, start-up instructions and refrigerant-charging method details.

TROUBLESHOOTING BLOWER AND/OR PUMP MOTOR AND CONTROLS

If blower and/or pump motor does not run:

Turn OFF power and check the following:

1. Check that door switch is in the CLOSED position.

2. Check 3 amp fuse on Printed Circuit Board (PCB).

3. Check for 24 VAC between COM and 24 VAC on IAC. If no voltage is present, check transformer.

4. Check all connections for kinks which could cause loose connections. Ensure connections are secure.

5. Verify that approximately 120 VAC is present across L1 and L2.

Page 22

SEQUENCE OF OPERATION

COOLING

Single Stage Cooling

• When the thermostat calls for cooling (Y), there is a 1 second delay then the control energizes the high blower tap (COOL_HI).

• When the thermostat ends the call for cooling (Y), there is a 30 second cooling off delay then the control deenergizes the high blower tap (COOL_HI).

• A call for cooling has priority over continuous fan.

HEATING (HYDRONIC)

• When the thermostat “calls for heat,” the circuit between R and W is completed. The control monitors the FS input and energizes the circulating pump if the FS signal is present. The indoor blower will then be activated.

If the FS signal is NOT present, the control will energize the circulating pump for 60 seconds in an attempt to activate the Flow Switch (FS). If the FS signal does not become active during this time, the control will deenergize the pump wait 60 seconds and then retry the sequence until the FS signal is present. During this time the Status LED will rapidly flash, indicating that a heat demand is present, but not being satisfied because of the state of the FS input signal.

HEATING (Heat pump is the primary source of heat)

Single Stage Heating

• The thermostat calls for heating (Y, R, and B), there is a 1 second delay then the control energizes the high blower tap (COOL_HI).

• When the thermostat ends the call for cooling (Y), there is a 30 second cooling off delay then the control deenergizes the high blower tap (COOL_HI).

• When the thermostat calls for emergency heat (W), the hydronic heating mode is activated.

BLOWER TIME DELAY (HEATING OR COOLING)

All models are equipped with a blower time delay (BTD) in lieu of a blower relay (BR) (see Figure 19). The blower will run for 30 seconds after the blower time delay (BTD) is de-energized.

DEFROST (DEFROST HEAT CONTROL)

• For sequence of operation of defrost controls, see outdoor heat pump installation instructions.

• Supplemental heat during defrost can be provided by connecting the purple (PU) pigtail in the outdoor unit to the W on the thermostat. This will complete the circuit between R and W through a set of contacts in the defrost relay (DR) when the outdoor heat pump is in defrost. This circuit, if connected, will help prevent cold air from being discharged from the indoor unit during defrost.

• For most economical operation, if cold air is not of concern during defrost, the purple wire can be left disconnected. Supplemental heat will then come on only when called for by second stage room thermostat.

EMERGENCY HEAT (HEATING HEAT PUMP)

• If selector switch on thermostat is set to the emergency heat positioin, the heat pump will be locked out of the heating circuit, and all heating will be hydronic heat. Jumper should be placed between W and E on the thermostat sub-base so that the electric heat control will transfer to the first stage heat on the thermostat. This will allow the indoor blower to cycle on and off with the electric heat when the fan switch is in the auto position.

ROOM THERMOSTAT (ANTICIPATOR SETTING)

See instructions with outdoor section, condensing unit or heat pump for recommended room thermostats.

• The thermostat should be mounted 4 to 5 feet above the floor on an inside wall of the living room or a hallway that has a good air circulation from the other rooms being controlled by the thermostat. It is essential that there be free air circulation at the location of the same average temperature as other rooms being controlled. Movement of air should not be obstructed by furniture, doors, draperies, etc. The thermostat should not be mounted where it will be affected by drafts, hot or cold water pipes or air ducts in walls, radiant heat from fireplaces, lamps, the sun, T.V. or an outside wall. See instructions sheet packaged with thermostat for mounting and installation instructions.

Page 23

HYDRONIC AIR HANDLER AIR FLOW PERFORMANCE - RHWBTABLE 6

Model

RHWB04WMP36A

RHWB06WMP48A

RHWB08WRP60A

RHWB10WRP60A

RHWB04WMX36A

RHWB06WMX48A

RHWB08WRX60A

RHWB10WRX60A

Note: When selecting a motor speed tap, use the lowest speed tap possible to achieve the rated cooling air-flow at the external static pressure for the application (including cooling coil).

Blower / Motor HP

Inches [mm]

11 x 7

[279 x 178] /

1/2 [373]

11 x 7

[279 x 178] /

3/4 [559]

11 x 10

[279 x 254

3/4 [559]

11 x 10

[279 x 254] /

3/4 [559]

11 x 7

[279 x 178] /

1/2 [343]

11 x 7

[279 x 178] /

3/4 [559]

11 x 10

[279 x 254] /

3/4 [559]

11 x 10

[279 x 254] /

3/4 [559]

Speed 0.1 [.02] 0.2 [.05] 0.3 [.07] 0.4 [.10] 0.5 [.12] 0.6 [.15] 0.7 [.17] 0.8 [.19] 0.9 [.22] 1.0 [.24]

Low 794 [375] 775 [366] 749 [353] 719 [339] 686 [324] 655 [309] 621 [293] 590 [278] 534 [252] 473 [223]

M-Lo 1036 [489] 1024 [483] 1002 [473] 977 [461] 922 [435] 895 [423] 865 [408] 826 [390] 761 [359] 689 [325]

M-Hi 1202 [567] 1176 [555] 1160 [547] 1100 [519] 1073 [506] 1047 [494] 1008 [476] 969 [457] 926 [437] 890 [420] High 1356 [640] 1336 [631] 1301 [614] 1266 [597] 1235 [583] 1202 [567] 1156 [546] 1093 [516] 1030 [486] 959 [453]

Low 921 [435] 915 [432] 886 [418] 876 [413] 855 [404] 841 [397] 817 [386] 780 [368] 734 [346] 690 [326]

M-Lo 1189 [561] 1180 [557] 1179 [556] 1137 [537] 1131 [534] 1102 [520] 1072 [506] 1030 [486] 985 [465] 915 [432]

M-Hi 1335 [630] 1315 [621] 1306 [616] 1307 [617] 1277 [603] 1246 [588] 1210 [571] 1161 [548] 1090 [514] 1019 [481] High 1841 [869] 1795 [847] 1747 [824] 1681 [793] 1622 [765] 1560 [736] 1500 [708] 1420 [670] 1358 [641] 1288 [608]

Low 1319 [623] 1307 [617] 1300 [614] 1240 [585] 1236 [583] 1210 [571] 1177 [555] 1149 [542] 1100 [519] 1032 [487]

M-Lo 1484 [700] 1480 [698] 1471 [694] 1463 [690] 1418 [669] 1385 [654] 1359 [641] 1314 [620] 1246 [588] 1166 [550]

M-Hi 1687 [796] 1676 [791] 1671 [789] 1611 [760] 1586 [749] 1553 [733] 1513 [714] 1453 [686] 1389 [656] 1284 [606] High 1971 [930] 1974 [932] 1948 [919] 1929 [910] 1871 [883] 1806 [852] 1751 [826] 1699 [802] 1610 [760] 1511 [713]

Low 1299 [613] 1294 [611] 1308 [617] 1279 [604] 1257 [593] 1231 [581] 1205 [569] 1165 [550] 1122 [530] 1053 [497]

M-Lo 1515 [715] 1519 [717] 1499 [707] 1487 [702] 1415 [668] 1418 [669] 1394 [658] 1348 [636] 1296 [612] 1221 [576]

M-Hi 1684 [795] 1695 [800] 1693 [799] 1663 [785] 1620 [765] 1586 [749] 1569 [740] 1514 [715] 1451 [685] 1365 [644] High 1954 [922] 1971 [930] 1974 [932] 1982 [935] 1973 [931] 1944 [917] 1917 [905] 1818 [858] 1775 [838] 1700 [802]

Low 960 [453] 891 [420] 836 [394] 781 [368] 731 [344] 682 [322] 630 [297] 578 [273] 540 [255] 460 [217]

Med-low 1178 [555] 1118 [527] 1068 [504] 1017 [479] 973 [459] 922 [435] 877 [414] 833 [393] 781 [369] 730 [345]

Med-high 1323 [624] 1269 [598] 1222 [576] 1180 [556] 1130 [533] 1089 [514] 1051 [496] 1006 [475] 958 [452] 914 [431]

High 1481 [698] 1431 [675] 1381 [651] 1333 [629] 1291 [609] 1250 [590] 1209 [571] 1168 [551] 1122 [530] 1085 [512]

Low 1092 [515] 1037 [489] 992 [468] 938 [442] 896 [422] 849 [401] 790 [373] 739 [349] 689 [325] 633 [299]

Med-low 1360 [641] 1308 [617] 1264 [596] 1222 [576] 1174 [554] 1138 [537] 1095 [517] 1027 [485] 988 [466] 945 [446]

Med-high 1462 [689] 1424 [672] 1378 [650] 1340 [632] 1300 [614] 1263 [596] 1223 [577] 1185 [559] 1147 [541] 1111 [524]

High 1779 [839] 1743 [822] 1716 [809] 1674 [790] 1698 [801] 1662 [784] 1624 [776] 1588 [749] 1525 [720] 1427 [673]

Low 1533 [723] 1475 [696] 1412 [666] 1357 [640] 1287 [607] 1239 [585] 1185 [559] 1129 [533] 1069 [505] 1002 [473]

Med-low 1658 [782] 1604 [757] 1551 [731] 1500 [707] 1438 [679] 1392 [657] 1336 [631] 1277 [603] 1231 [581] 1174 [554]

Med-high 1842 [869] 1782 [841] 1747 [824] 1701 [802] 1645 [776] 1601 [756] 1547 [730] 1502 [709] 1456 [687] 1401 [661]

High 2131 [1005] 2074 [978] 2030 [958] 1969 [929] 1929 [910] 1885 [890] 1833 [865] 1786 [843] 1744 [823] 1688 [797]

Low 1598 [754] 1533 [723] 1471 [694] 1401 [661] 1344 [634] 1286 [607] 1221 [576] 1162 [548] 1099 [519] 1020 [481]

Med-low 1731 [816] 1674 [790] 1605 [757] 1546 [729] 1488 [702] 1435 [607] 1377 [650] 1320 [623] 1264 [597] 1206 [569]

Med-high 1943 [916] 1877 [885] 1822 [859] 1762 [831] 1707 [806] 1651 [779] 1609 [759] 1552 [732] 1498 [707] 1446 [682]

High 2197 [1036]2151 [1015] 2095 [988] 2047 [966] 1995 [942] 1949 [920] 1896 [895] 1847 [872] 1800 [850] 1745 [824]

CFM [L/s] Air Delivery External Static Pressure Inches Water Column [kPa]

DIRECT DRIVE INSTRUCTIONS FOR CHANGING BLOWER SPEED

WARNING

DISCONNECT THE ELECTRICAL SUPPLY TO THE AIR HANDLER BEFORE ATTEMPTING TO CHANGE THE BLOWER SPEED. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

The blower motor must be wired for blower speeds required for normal operation.

If additional blower speed taps are available (leads connected to “M1” and “M2” on the electronic control), speeds may be changed if necessary to fit requirements of the particular installation. Reconnect the unused motor leads to “M1” or “M2.” Check motor lead color for speed designation.

Heating speeds should not be reduced where it could cause the air handler air temperature rise to exceed the maximum outlet air temperature specified for the unit.

IMPORTANT: Always check air temperature rise after changing the heating speed for any reason.

Page 24

MAINTENANCE

TABLE 7

FILTER SIZES

WARNING

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

UPFLOW FILTER SIZES

AIR HANDLER INPUT BOTTOM SIDE

WIDTH MBTU/HR SIZE SIZE

/2" 45, 60 153/4" X 25" 153/4" X 25" 1

/2" 80, 100 223/4" X 25" 153/4" X 25" 1

FILTERS

Keep the filters clean at all times. Vacuum dirt from filter, wash with detergent and water, air dry thoroughly and reinstall.

NOTE: Some filters must be resized to fit certain units and applications. See Table 7 and Figures 18 and 19.

• 24.5” - 80,000 and 100,000 BTU/HR unit requires removal of a 7" segment of filter and frame to get the proper width for a side filter.

QUANTITY

CAUTION

DO NOT OPERATE THE SYSTEM FOR EXTENDED PERIODS WITHOUT FILTERS. A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE SUPPLY REGISTERS. THIS RESIDUE CAN SOIL CEILINGS, WALLS, DRAPES, CARPETS AND OTHER HOUSEHOLD ARTICLES.

FIGURE 16

SOLID BOTTOM

SCREW (2) REQ’D.

JACKET ASSEMBLY

NOTE: BACK FLANGE OF SOLID BOTTOM FITS UNDERNEATH JACKET. SIDES AND FRONT FLANGES FIT OVER FLANGES ON JACKET.

SOLID BOTTOM REMOVAL

JACKET ASSEMBLY

FILTER

FILTER & ROD LOCATION

FILTER ROD

Page 25

FIGURE 17

JACKET

DRILL (2) 3/16" DIA. HOLES

8.000

4.875

1.531

JACKET

ANGLE

FILTER ROD SUPPORT ANGLE

FILTER SUPPORT ANGLE (SEE ANGLE DETAIL)

ATTACH WITH SHEET METAL SCREWS (2 REQÕD)

ANGLE DETAIL

CUT-OUT AND DRILL DETAIL

ROD & FILTER SUPPORT ANGLE ASSEMBLY

UPFLOW

FILTER LOCATIONS

UPFLOW

ONLY

FILTER ROD SUPPORT ANGLE

FILTER SUPPORT ANGLE (SEE ANGLE DETAIL)

LUBRICATION

IMPORTANT: DO NOT attempt to lubricate the bearings on the blower motor or the induced draft blower motor. Addition of lubricants can reduce the motor life and void the warranty.

The blower motor and induced draft blower motor are permanently lubricated by the manufacturer and do not require further attention.

The blower motor and induced draft blower motor must be cleaned periodically by a qualified installer, service agency, or the gas supplier to prevent the possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor exterior. And, as suggested elsewhere in these instructions, the air filters should be kept clean. Dirty filters can restrict airflow. The motor depends upon sufficient air flowing across and through it to keep from overheating.

SYSTEM OPERATION INFORMATION

Advise The Customer

1. Keep the air filters clean. The heating system will operate better, more efficiently and more economically.

2. Arrange the furniture and drapes so that the supply air registers and the return air grilles are unobstructed.

3. Close doors and windows. This will reduce the heating load on the system.

4. Avoid excessive use of kitchen exhaust fans.

5. Do not permit the heat generated by television, lamps or radios to influence the thermostat operation.

6. Except for the mounting platform, keep all combustible articles 3 feet from the air handler and vent system.

7. IMPORTANT: Replace all blower doors and compartment covers after servicing the air handler. Do not operate the unit without all panels and doors securely in place.

8. Explain proper operation of the system with constant air circulation.

ANNUAL INSPECTION

• The air handler should operate for many years without excessive scale build-up in the flue passageways. However, it is recommended that a qualified installer, service agency, or the gas supplier annually inspect

the flue passageways, the vent system and the main burners for continued safe operation. Pay particular attention to deterioration from corrosion or other sources.

• IMPORTANT: It is recommended that at the beginning and at approximately half way through the heating season, a visual inspection be made of the main burner flames for the desired flame appearance by a qualified installer, service agency or the gas supplier. If the flames are distorted and/or there is evidence of back pressure, check the vent and inlet air system for blockage. If there is carbon and scale in the heat exchanger tubes, the heat exchanger assembly should be replaced.

REPLACEMENT PARTS

See sheet enclosed with air handler for replacement part information.

TROUBLESHOOTING

Refer to Figure 18 for determining cause of unit problems.

WIRING DIAGRAMS

Figure 19 are complete wiring diagrams for the air handler and power sources.

Page 26

FIGURE 18

ydemeResuaC elbissoPmotpmyS

lortnoc ta egatlov tcerroc rof kcehCnoitcennoc lacirtcele ensool ro ffo rewoP lortnoc ta egatlov tcerroc rof kcehChgih oot tes - noitarbilac fo tuo tatsomrehT

Call for domesc hot water - air handler disabled unl call ends. Unit is operang as designed.

Unit is operang as designed

rekaerb teser / sesuf ecalpeRrekaerb deppirt / sesuf nwolB

remrofsnart ecalperg–niriw kcehCevitcefed remrofsnarT

daol etaluclaceRretaeh retaw ro reldnah ria dezis ylreporpmI

gnittes pat deeps rotom kcehCwolf ria roodni reporpmI

Call for domesc hot water–air handler disabled unl call ends. Unit is operang as designed.

Unit is operang as designed

Check line voltage at pump Check wires and connectors Check pump capacitor

Call for domesc hot water - air handler disabled unl call ends. Unit is operang as designed.

Unit is operang as designed

Check line voltage at blower motor Check wires and connectors Check blower motor capacitor

General Trouble Shoong Chart

Power oﬀ or loosen electrical connecon

Pump does not run

Power oﬀ or loosen electrical connecon

Blower does not run

Warning: Disconnect all power to unit before servicing. Failure to shut oﬀ power can cause electrical shock resulng in personal injury or death.

Unit will not run

Insuﬃcient heang

Water does not ﬂow

Water lines are air locked

Purge air from lines

GENERAL TROUBLESHOOTING CHART

General Troubleshooting Chart

Page 27

FIGURE 19

ELECTRICAL WIRING DIAGRAM – PSC MODELS

Page 28

FIGURE 20

ELECTRICAL WIRING DIAGRAM – ECO TECH™ MODELS

CM 0313