Thermo Pride AH2436E1, AH4260E1 Installation And Service Manual

13 & 14 SEER

AIR HANDLER

INSTALLATION & SERVICE MANUAL

MODELS: AH2436E1, AH4260E1

PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION AND BEFORE
PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST
BE LEFT WITH THE USER AND SHOULD BE RETAINED FOR FUTURE
REFERENCE BY QUALIFIED SERVICE PERSONNEL.

: Improper installation, adjustment, alteration, service, or maintenance can
cause injury or property damage. Refer to this manual. For assistance or additional
information consult a qualified installer, service agency, or manufacturer listed below.

MAC-183

ECN 4849-MA

THERMO PRODUCTS, LLC.
BOX 217
NORTH JUDSON, IN 46366
PHONE: [phone] MADE IN USA

TABLE OF CONTENTS

SECTION BEGINNING PAGE

SAFETY SECTION 1

KNOCKDOWN OF AIR HANDLER 2

REASSEMBLY OF AIR HANDLER 3

SETTING UP THE A-COIL FOR AIR CONDITIONING 3

INSTALLATION OF HOT WATER COIL 4

BLOWER AIR ADJUSTMENT 6

DUCT SYSTEM 9

DUCT SIZING CHART 10

INDOOR EVAPORATOR COIL 10

TUBING LINE SETS 10

HOW TO MEASURE LIQUID SUB-COOLING 14

MEASURING TEMPERATURE DROP ACROSS THE “A” COIL 15

ELECTRICAL 15

UA ADAPTER CABINET 16

RECOMMENDED SUSPENSION PROCEDURE FOR AH AIR HANDLER 16

ECM TROUBLE SHOOTING 17

TROUBLE SHOOTING CHARTS 20

SEQUENCE OF OPERATION 21

REPLACEMENT PARTS LIST 23

All installations and services must be performed by qualified personnel.

SAFETY SECTION

This page contains various warnings and cautions found throughout this Service and Installation Manual.
Please read and comply with the statements on the cover and the statements below.

: Improper installation, adjustment, alteration, service, or maintenance can cause injury
or property damage. Refer to this manual. For assistance or additional information consult a
qualified installer, service agency, or manufacturer listed below.

: If drilling or screwing into panel or plate is necessary, make certain drill or screw does not

penetrate into any part of evaporator coil or hot water coil and cause damage. Personal injury and/or
property damage may result.

: Do not use this system if any part has been under water. Immediately call a qualified
service agency to inspect the system and to replace any part of the electrical or control system which has
been under water.

: The cooling and heating coils must be cleaned by a qualified service person.

: This air handler is not to be used to condition during construction.

: When testing electrical equipment, always follow standard electrical procedures and

precautions.

: DO NOT wet electronic components during hydronic testing. Wetting electronic

components may damage circuitry and cause a hazardous situation. Dry moisture from all leads and
terminals if wetting occurs. Wait at least 24 hours for the circuit to fully dry before energizing the
system.

: Personal injury or property damage could result from major repair or service of this
system by anyone other than a qualified contractor.

: If you do not follow these instructions exactly an unsafe condition may result causing
personal injury, loss of life or property damage.
Installation and service personnel are required by some states to be licensed. Persons not qualified shall
not install this equipment nor interpret these instructions.

All local codes and regulations take precedence over the instructions in this manual and should be
followed accordingly. In the absence of local codes, installation must conform with these instructions,
regulations of the National Fire Protection Association and provisions of the National Electric Code.

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All installations and services must be performed by qualified personnel.

AIR HANDLER

Each air handler is shipped with an evaporator preinstalled. The AH2435E1 is shipped with a
12U2430AG15 evaporator coil for 2 to 3 ton operation. The AH4260E1is shipped with a 12U3648AG17
evaporator coil for 3 to 5 ton operation.

The construction of the air handler permits easy knockdown and reassembly. See Figure A.

FOLLOW THESE STEPS FOR KNOCKDOWN OF AIR HANDLER:

1. Start with unit setting in a vertical position(Figure A).

2. Remove middle door.

3. Remove screws from bottom door, top door, and top front panel. Remove doors and top panel of air

handler.

4. Remove the retention clip from in front of the A-coil drain pan and the horizontal drain pan shipping

screw(s) from the right side casing.

5. Remove the A-coil assembly.

6. Disconnect power leads and unplug circulation pump connector from the blower control board.

Figure A.

2

All installations and services must be performed by qualified personnel.

7. Remove the screws that secure the blower assembly to the blower pan and pull blower sub-assembly

out the front of the unit.

8. Remove screws that secure the blower pan to the side & back casings.

9. Push the front edges of the side casings slightly apart and remove the blower pan.

10. Remove screws from the bottom and the casing back.

11. Remove casing back and side casings from the bottom.

REASSEMBLY OF AIR HANDLER

To reassemble the air handler, reverse steps above starting with number 10.

SETTING UP THE A-COIL FOR AIR CONDITIONING

The AH2436E1 & AH4260E1 come with the A-coil pre-installed for vertical and left to right horizontal
airflow.

IMPORTANT: When air handler is installed in attic above a finished ceiling, it is recommended that
a safety overflow pan with its own separate drain be installed under the entire unit.

For a right to left horizontal air flow the following steps 1-8 must be followed.
Otherwise skip to step 9.

Reversing the horizontal orientation

1. Remove the middle door of the air handler.

2. Remove the bottom door of the air handler.

3. Remove the retention clip from in front of the A-coil drain pan.

4. Remove the horizontal drain pan shipping screw(s) from the right side casing.

5. Remove the A-coil assembly and slip the horizontal drain pan assembly off of the right side of the A­coil.
5a. Remove the bottom right side support L-bracket and remount in the left hand position using the pre­punched holes for a guide.

6. Slip the horizontal drain pan assembly onto the left side of the A-coil.

7. Replace the A-coil assembly into the air handler. The A-coil drain pan should slide under the rear
retention clip. The horizontal drain pan assemble should rest against the right panel insulation and the
bottom side support.

8. Replace the retention clip for the front of the evaporator drain pan.

For all orientations

9. Cut open the appropriate drain pan drain access hole in the bottom door.

10. Slip the Suction line grommet panel over the suction line up to the bottom door surface.

3

All installations and services must be performed by qualified personnel.

Figure B

11. Make appropriate liquid and suction line connections to coil and braze connections.
NOTE: A wet rag makes an excellent heat sink for tubing and grommets.

: If drilling or screwing into panel of plate is necessary, make certain drill does not penetrate

into any part of evaporator coil or hot water coil to avoid personal injury and/or property damage.

13. Position grommet panel on bottom door surface and secure in place with screws. Refer to Figure B.

14. Make appropriate condensate drain connections and seal the access opening.

INSTALLATION OF THE HOT WATER COIL:

1. Remove top door of air handler.

2. Slide hot water coil's side hanger brackets into coil channel(retaining channel) in the air handler. See

Figure C.

3. Push coil into unit until the coil is stopped by the back casing.

4. Cut out appropriate holes in insulation, realign top door and secure into place.

5. Make appropriate hydronic connections to inlet(blower side) and outlet(duct side) of coil and braze

into place.

6. Seal connections through panel with duct sealer or equivalent.

4

All installations and services must be performed by qualified personnel.

Figure C

: If drilling or screwing into panel or plate is necessary, make certain drill does not

penetrate into any part of evaporator coil or hot water coil. Personal injury and/or property damage may
result.

NOTE: Drain lines must be pitched no less than 1/4" per foot away from the air handler.

Figure D

5

All installations and services must be performed by qualified personnel.

BLOWER AIR ADJUSTMENT

The ECM blower control must be set in order to
establish proper air movement. Use the following
steps to do this:

1. Identify to tonnage of the condensing unit that will
be used.

2. If Hydronic heat is to be used, identify your BTU
heat requirements, preferred supply air temperature,
water temperature and water flow through the coil in
gallons per minute.

3. Locate the blower control board mounted to the
front of the blower assembly.

4. Locate the red switch block labeled SW1 for
adjusting the Heating and Cooling blower speed.

5. Locate SW2, just below SW1, for adjusting Blower
delays.

Figure E

BLOWER COOLING SPEEDS
Refer Table C1 for setting switches 4, 5 & 6 for the A/C sizing.

Table C1 COOLING SWITCH SETTINGS

A/C

TONS

2

2-1/2

3

3-1/2

4

5

Shaded cells represent the factory settings

CFM

800 OFF OFF OFF
1000
1200
1400
1600
1800
2000
2200

AH2436E1 COOL

Settings (SW1)

4 5 6 4 5 6

ON

OFF

OFF OFF

ON

ON ON ON

OFF OFF

AH4260E1 COOL

Settings (SW1)

ON

ON ON

OFF OFF

ON

OFF

OFF

ON ON

OFF
OFF

ON
ON

BLOWER HEATING SPEEDS

In the next two pages:

1. Locate the page that refers to the Air Handler to be set up.

2. Find the line(s) on the chart that best represents the water temperature and gallons per minute available.

3. Find the point along the curve that best fits the BTU and Supply Air temperature desired.

4. Read the letter associated with that point and use it to find the switch settings in the table below the
chart.

(The table below the switch settings represent the actual numbers represented by the chart.)

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