Thermo Pride Air Handler Modular MV User Manual
MODULAR
INSTALLATION MANUAL
MAC-226
ECN 5287-MA 121005
VARIABLE SPEED AIR HANDLERS
MODELS: MV
LIST OF SECTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRIC HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5
LOW VOLTAGE CONTROL CONNECTIONS . . . . . . . . . . . . . . . . . . 5
REQUIRED CONTROL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
LIST OF FIGURES
Typical Installation with MC or FC Evaporator Coil . . . . . . . . . . . . . . .3
Coil and Air Handler Attachment Details . . . . . . . . . . . . . . . . . . . . . . .3
Gasket Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Dimensions & Duct Connection Dimensions . . . . . . . . . . . . . . . . . . . . 4
Typical Horizontal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air Handler Control Board – Communications Connections . . . . . . . .6
LIST OF TABLES
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Heat Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Comfort Setting Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Physical and Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . 11
Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . 11
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Data - 1 Ø - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Data - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ISO 9001
Certified Quality
Management System
LINE POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AIRFLOW AND COMFORT SETTING SELECTION . . . . . . . . . . . . 10
UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cooling Models with and without Electric Heat Wiring . . . . . . . . . . . . 7
Two-Stage Heat Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air Handler with Communicating AC or HP . . . . . . . . . . . . . . . . . . . . 8
Line Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical Data - (For Single Source Power Supply) -
Copper Wire 1 Ø - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Data - (For Single Source Power Supply) -
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Data - (For Multi-Source Power Supply) -
Copper Wire 1 Ø - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Data - (For Multi-Source Power Supply) -
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Handler Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION I: GENERAL
This modular air handler provides the flexibility for installation in any
upflow, downflow, or horizontal application. These versatile models may
be used for cooling or heat pump operation with or without electric heat.
A BRAND LABEL (available from Distribution) may be applied to the
center of the blower access panel.
The unit can be positioned for bottom return air in the upflow position,
top return air in the downflow position, and right or left return in the horizontal position.
Top and side power wiring and control wiring, accessible screw terminals for control wiring and easy to install electric heaters all combine to
make the installation easy, and minimize installation cost.
SECTION II: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WAR NIN G, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury
WAR NIN G indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury.
alert against unsafe practices and hazards involving only property damage.
.
.
It is also used to
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified contractor, installer or service agency.
This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
FIRE OR ELECTRICAL HAZARD
Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
A fire or electrical hazard may result causing property damage, personal injury or loss of life.
1. Install this air handler only in a location and position as specified in
SECTION III of these instructions.
2. Always install the air handler to operate within the air handler’s
intended maximum outlet air temperature. Only connect the air
handler to a duct system which has an external static pressure
within the allowable range, as specified on the air handler rating
plate.
3. 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.
4. The air handler is not to be used for temporary heating of buildings
or structures under construction.
5. The size of the unit should be based on an acceptable heat loss or
gain calculation for the structure. ACCA, Manual J or other
approved methods may be used.
SAFETY REQUIREMENTS
1. This air handler should be installed in accordance with all national
and local building/safety codes and requirements, local plumbing
or wastewater codes, and other applicable codes.
2. Refer to the unit rating plate for the air handler model number, and
then see the dimensions page of this instruction for supply air plenum dimensions in Figure 3. The plenum must be installed according to the instructions.
3. Provide clearances from combustible materials as listed under
Clearances to Combustibles.
4. Provide clearances for servicing ensuring that service access is
allowed for electric heaters and blower.
5. Failure to carefully read and follow all instructions in this manual
can result in air handler malfunction, death, personal injury and/or
property damage.
6. Check the rating plate and power supply to be sure that the electrical characteristics match.
7. Air handler shall be installed so the electrical components are protected from water.
8. Installing and servicing heating/cooling equipment can be hazardous due to the electrical components. Only trained and qualified
personnel should install, repair, or service heating/cooling equipment. Untrained service personnel can perform basic maintenance
functions such as cleaning and replacing the air filters. When
working on heating/cooling equipment, observe precautions in the
manuals and on the labels attached to the unit and other safety
precautions that may apply.
9. These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances
these instructions exceed certain local codes and ordinances,
especially those who have not kept up with changing residential
and non-HUD modular home construction practices. These
instructions are required as a minimum for a safe installation.
INSPECTION
As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage
should be noted on the carrier’s freight bill. A separate request for
inspection by the carrier’s agent should be made in writing. Also, before
installation the unit should be checked for screws or bolts, which may
have loosened in transit. There are no shipping or spacer brackets
which need to be removed.
Also check to be sure all accessories such as heater kits, suspension
kits, and coils are available. Installation of these accessories or field
conversion of the unit should be accomplished before setting the unit in
place or connecting any wiring, electric heat, ducts or piping.
LIMITATIONS
These units must be wired and installed in accordance with all national
and local safety codes.
Voltage limits are as follows:
Air Handler Voltage Voltage code
208/230-1-60 21 187-253
1. Rated in accordance with ARI Standard 110, utilization range “A”.
Airflow must be within the minimum and maximum limits approved for
electric heat, evaporator coils and outdoor units.
Entering Air Temperature Limits
Wet Bulb Temp.°F Dry Bulb Temp. °F
Min. Max. Min. Max.
57 72 65 95
Normal Operating
Voltage Range
1
SECTION III: UNIT INSTALLATION
CLEARANCES
Clearances must be taken into consideration, and provided for as follows:
1. Refrigerant piping and connections - minimum 12” recommended.
2. Maintenance and servicing access - minimum 36” from front of unit
recommended for blower motor / coil replacement.
3. Condensate drain lines routed to clear filter and panel access.
4. Filter removal - minimum 36” recommended.
5. A combustible floor base accessory is available for downflow
applications of this unit, if required by local code.
LOCATION
Location is usually predetermined. Check with owner’s or dealer’s
installation plans. If location has not been decided, consider the following in choosing a suitable location:
1. Select a location with adequate structural support, space for service access, clearance for air return and supply duct connections.
2. Use hanging brackets to wall mount unit as shown.
3. Normal operating sound levels may be objectionable if the air handler is placed directly over some rooms such as bedrooms, study,
etc.
4. Select a location that will permit installation of condensate line to
an open drain or outdoors allowing condensate to drain away from
structure.
5. When an evaporator coil is installed in an attic or above a finished
ceiling, an auxiliary drain pan should be provided under the air
handler as is specified by most local building codes.
6. Proper electrical supply must be available.
NOTICE
In severe high humidity, high temperature indoor unit environments,
seal completely with adequate fiberglass insulation using vapor
barrier on the outside.
2
FIGURE 1: Typical Installation with MC or FC Evaporator Coil (MC required for horizontal applications)
UPFLOW
DOWNFLOW
HORIZONTAL RIGHT
HORIZONTAL LEFT
DOWNFLOW AND HORIZONTAL CONVERSION
These air handler units are supplied ready to be installed in a upflow,
downflow and left or right hand horizontal position.
If the unit is to be installed with an evaporator coil, refer to Figure 1 for
unit positioning information.
TIE PLATE
AIR HANDLER
COIL
COIL
UPFLOW & HORIZONTAL
APPLICATIONS
DOWNFLOW
APPLICATION
TOP PLATE
AIR HANDLER
FIGURE 2: Coil and Air Handler Attachment Details
AIR HANDLER AND COIL UPFLOW AND
HORIZONTAL
1. Apply neoprene gasket to top of coil casing.
2. Position blower casing over coil opening.
3. Attach tie plate to casings of air handler and coil using screws.
4. Remove blower access panel and coil filter door.
5. Disconnect wiring to blower motor. *Note location of wires as these
will be reconnected in a later step.
6. Remove blower motor and housing.
7. Fasten duct flanges of coil to duct flanges of air handler with
screws. See Figure 1.
8. Secure base of air handler to top of coil using screws.
9. Locate 2” wide foam gasket.
10. On the interior of the air handler/coil attachment point, apply foam
gasket over duct flanges on the sides and back.
11. Reinstall blower motor and housing by reversing the process in
Steps 3 and 4.
12. Complete electrical and blower speed connections as outlined in
other sections of this document.
13. Reposition and replace blower access panel.
AIR HANDLER AND COIL DOWNFLOW
1. Position blower casing over duct connection and secure such that
the supply air end of the blower is down.
2. Apply neoprene gasket to return-air side of air handler.
3. Place coil casing over blower return opening.
4. Attach tie plate to casings of air handler and coil using screws.
5. Remove blower access panel and coil filter door.
6. Disconnect wiring to blower motor.
*Note location of wires as these will be reconnected in a later step.
7. Remove blower motor and housing.
8. Fasten duct flanges of coil to base of air handler with screws. See
Figure 1.
9. Secure base of air handler to base of coil using screws.
10. Locate 2” wide foam gasket.
11. On the interior of the air handler/coil attachment point, apply foam
gasket over duct flanges on the sides and back.
12. Reinstall blower motor and housing by reversing the process in
Steps 3 and 4.
13. Complete electrical and blower speed connections as outlined in
other sections of this document.
14. Reposition and replace blower access panel.
3
FIGURE 3: Gasket Location
J
K
B
FIGURE 4: Dimensions & Duct Connection Dimensions
TABLE 1:
Dimensions
Models
MV
ABDE JK
Height Width Power Control
12B
12D 24-1/2 23-1/2 21-19/32
16C 21 20 18-3/32
25
20D 24-1/2 23-1/2 21-19/32
1. Actual size (Conduit size).
10-3/8”
A
CIRCUIT BREAKER
PANEL
21-1/2”
20-1/2”
Dimensions
17-1/2 16-1/2 14-19/32
E
TOP OUTLET
DIMENSIONS
D
BOTTOM INLET
DIMENSIONS
Wiring Knockouts
1
7/8” (1/2”)
1 3/8” (1”)
7/8” (1/2”)
1 23/32” (1 1/4”)
DUCT CONNECTORS
Use 1/2" screws to connect ductwork to bottom of unit. Longer
screws will pierce the drain pan and cause leakage. If pilot holes
are drilled, drill only though field duct and unit bottom flange.
Air supply and return may be handled in one of several ways best
suited to the installation. See Figure 3 for dimensions for duct inlet and
outlet connections.
The vast majority of problems encountered with combination heating
and cooling systems can be linked to improperly designed or installed
duct systems. It is therefore highly important to the success of an installation that the duct system be properly designed and installed.
Use flexible duct collars to minimize the transmission of vibration/noise
into the conditioned space. If electric heat is used, non-flammable
material must be used.
4
Where return air duct is short, or where sound may be a problem,
sound absorbing glass fiber should be used inside the duct. Insulation
of duct work is a must where it runs through an unheated space during
the heating season or through an uncooled space during the cooling
season. The use of a vapor barrier is recommended to prevent absorption of moisture from the surrounding air into the insulation.
The supply air duct should be properly sized by use of a transition to
match unit opening. All ducts should be suspended using flexible hangers and never fastened directly to the structure. This unit is not
designed for non-ducted (freeblow) applications. Size outlet plenum or
transition to discharge opening sizes shown in Figure 3.
Duct work should be fabricated and installed in accordance with local
and/or national codes. This includes the standards of the National Fire
Protection Association for Installation of Air-Conditioning and Ventilating Systems, NFPA No. 90B.
AIR FILTERS
Air filters and filter racks must be field supplied.
.
Equipment should never be operated without filters.
SUSPENSION KITS
A suspension kit is available. Models 1BH0601 (unit size 018-060) is
designed specifically for the units contained in this instruction (upflow
application only). For installation of these accessory kits, see the
instructions packed with the kit.
HORIZONTAL SUSPENSION
For suspension of these units in horizontal applications, it is recommended to use angle steel support brackets with threaded rods, supporting the units from the bottom, at the locations shown in Figure 4.
SUSPENSION SUPPORT LOCATIONS FOR HORIZONTALAPPLICATIONS
MIN. 3/8”
THREADED ROD
MIN. 1-1/2” x 1-1/2” Angle
Recommended length
26” minimum
with 2” clearance on
both sides of Air Handler
2
WW
Units
(Nominal Tons)
1-1/2 - 3 Ton 16” 48” 22”
3-1/2 - 5 Ton 24” 53” - 58” 22”
FIGURE 5: Typical Horizontal Installation
XX
Dimension
WW XX YY
1-1/2
YY
SECTION IV: ELECTRIC HEATER
INSTALLATION
If the air handler requires electric heat, install the electric heat kit
according to the installation instructions included with the kit. After
installing the kit, mark the air handler nameplate to designate the heater
kit that was installed. If no heater is installed, mark the name plate
appropriately to indicate that no heat kit is installed.
The HEAT ENABLE jumper (See Figure 5) must be moved to the HEAT
position to enable operation of the heater
Use only 4HK heater kits, as listed on Air Handler name plate and in
these Instructions. Use data from Tables 9 and 12 for information on
required minimum motor speed tap to be used for heating operation,
maximum over-current protection device required and minimum electrical supply wiring size required for listed combination of Air Handler and
Heater Kit.
For Upflow, Downflow and Horizontal right hand applications the kits
can be installed without modification.
Field modification is required for Horizontal left-hand airflow application
only. Follow instructions with heater for modification.
NOTICE
If a heat kit with a circuit breaker is installed in the air handler, the
circuit breaker cover cladding must be removed to gain access to
the sheet metal cover plate. Some local codes may require that the
circuit breaker remain visible. If so, do not re-install circuit breaker
cover cladding.
SECTION V: LOW VOLTAGE CONTROL
CONNECTIONS
This air handler can be connected to the wall thermostat and outdoor A/
C or heat pump using either conventional low voltage (24 VAC) thermostat wiring OR using four-wire digital communications wiring. To use
conventional low voltage wiring, see the section below entitled “Conventional Low Voltage Control Wiring”. To use four-wire communications control wiring, see the section below entitled “Control Wiring using
Communicating Controls”.
The Communicating System consists of several intelligent communicating components including the Communicating Thermostat Control
(touch-screen wall thermostat), variable speed air handler, air conditioner (15 and 18 SEER premium air conditioners) or heat pump (13, 15
and 18 SEER premium heat pumps), which continually communicate
with each other via a four-wire connection called the A-R-C-B. Commands, operating conditions, and other data are passed continually
between components over the A-R-C-B bus. See Figure 8. The result is
a new level of comfort, versatility, and simplicity.
In order to use this air handler in full communications (COMM) mode, it
MUST be installed with the matching touch-screen Communicating
Control (wall thermostat) and an outdoor air conditioner or heat pump
with a fully communicating control.
This air handler may also be used along with the Communicating Thermostat Control and a non-communicating outdoor air conditioner
through the addition of a communicating Outdoor Aux Control board to
the outdoor unit. This system allows full communication between the air
handler and thermostat and limited communication to the outdoor unit.
5
Loading...