Rheem RW1T Installation Manual

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

RWIT-

SUPERSEDES 92-24161-150-00

92-24161-150-01

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.

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...................................................................................................................10

Installation..............................................................................................................12

Plumbing.................................................................................................................13

Electrical Wiring......................................................................................................16

Accessories............................................................................................................16

Sequence of Operation..........................................................................................20

Maintenance...........................................................................................................22

Troubleshooting......................................................................................................24

Wiring Diagrams................................................................................................25-26

PROHIBITED APPLICATIONS

RWI(-) 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.

GENERAL INFORMATION

FIGURE 1

THE RWI(-) 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 (OUTLET FOR 14” HAH) 3 TRANSFORMERS 9 WATER OUTLET (INLET FOR 14” HAH) 4 CAPACITORS 10 BLOWER MOTOR 5 LOW VOLTAGE (THERMOSTAT) TERMINAL 11 HYDRONIC COIL ASSEMBLY 6 BLOWER

ST-A1242-01-X0

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.

LOCATION REQUIREMENTS AND CONSIDERATIONS

FRONT

BACK

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.

PROHIBITED INSTALLATIONS

NOTE: MULTIPLE AIR HANDLERS CONFIGURED FOR INSTALLATION WITH A SINGLE TANKLESS WATER IS PROHIBITED.

ST-A1242-02-X0

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

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.

ST-A1242-02-X0

FIGURE 4

RETURN AIRSUPPLY AIR

TOP

BOTTOM

LEFT

RIGHT

FRONT

OPTIONAL RETURN AIR CUTOUT

(EITHER SIDE)

OPTIONAL RETURN AIR CUTOUT

(EITHER SIDE)

REF

CLEARANCE TO COMBUSTIBLES, UPFLOW, HORIZONTAL LEFT OR RIGHT, DOWNFLOW

⁄8

⁄16

⁄16 19 3

⁄16

⁄8 5

⁄16 19 4

⁄16 19

⁄2 16

⁄2 17

⁄2 16

⁄2 23

⁄2 16

⁄2 23

ST-A1242-03-X0

Model A B C D E F

RW1T06A3617 17

RW1T08A4821 21 20 20 16

RW1T04A2414 14 13 13 16

RW1T10A6024 24

Note: Service clearance of 24” is recommended in front of air handler.

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 RW1T06A3617NAA 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 RW1T06A3617NAA, (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.

TRADE BRAND

R = RHEEM

PRODUCT CATEGORY

W = HYDRONIC AIR HANDLER

STAGE OF AIR FLOW

1 = SINGLE 2 = TWO STAGE M = MODULATING

MOTOR TYPE

T = CONSTANT TORQUE V = VARIABLE SPEED P = PSC

NOMINAL CAPACITY

04 = 40,000 BTU/H 06 = 60,000 BTU/H 08 = 80,000 BTU/H 10 = 100,000 BTU/H

MAJOR SERIES

A = FIRST

RW 1 T 04 A 24 14 NAA***

CONTROLS

C = COMMUNICATING N = NON-COMMUNICATING

WIDTH

14 = 14” 17 = 17.5” 21 = 21” 24 = 24.5”

MAX COOLING AIRFLOW TONNAGE

24 = UP TO 2 TON 36 = UP TO 3 TON 48 = 2.5 TO 4 TON 60 = 3 TO 5 TON

OPTION CODE (SEE ADS-3803) BLANK = NONE

MINOR SERIES

A = FIRST

VOLTAGE

A = 115/1/60

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

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Model Numbers

RW1T04A2414NAA RW1T06A3617NAA RW1T08A4821NAA RW1T10A6024NAA

Nominal Heating Capacity BTU/hr [kw] 40000 [11.7] 60000 [17.6] 80000 [23.4] 100000 [29.3]

Air Side Temperature Rise* °F [°C] 32-53 [17.6-29.2] 24-43 [13.2-23.7] 25-49 [13.8-27.0] 25-46 [13.8-25.3]

Rated Heating CFM [L/s] 800 [378] 1200 [566] 1625 [767] 1800 [850]

Cooling Range CFM [L/s] 600-800 [283-556] 800-1200 [283-612] 1000-1625 [472-775] 1200-1800 [612-804]

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

Minimum Circuit Ampacity - Amps 8 10 12.9 12.9

Max Rating of Over Current Protective Device - Amps 11.7 18 23.2 23.2

Maximum Fuse or Circuit Breaker Size - Amps 10 15 20 20

Motor HP [W] 1/3 [248] 1/2 [373] 3/4 [559] 3/4 [559]

Blower (D x W) in [mm] 10 x 6 [254 x 152] 10 x 8 [254 x 203] 10 x 10 [254 x 254] 11 x 11 [279 x 279]

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 [.86]

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

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]

Shipping Weight LBS [kg] 91 [41] 100 [45] 122 [55] 129 [58]

HYDRONIC AIR HANDLER HEATING PERFORMANCE

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