Thermo Pride Air Handlers ECM Blower 13-14 SEER User Manual
13 & 14 SEER
AIR HANDLER
INSTALLATION & SERVICE MANUAL
MODELS: AH2436AE1, AH4260AE1,
AH2436BE1, AH4260BE1
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.
THERMO PRODUCTS, LLC.
BOX 217
NORTH JUDSON, IN 46366
PHONE: (574) 896-2133 MADE IN USA
MAC-202
ECN 5320-MA 130307
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 4
COUNTERFLOW ORIENTATION 6
INSTALLATION OF HOT WATER COIL 8
BLOWER AIR ADJUSTMENT 9
DUCT SYSTEM 13
DUCT SIZING CHART 14
INDOOR EVAPORATOR COIL 14
TUBING LINE SETS 14
HOW TO MEASURE LIQUID SUB-COOLING 18
MEASURING TEMPERATURE DROP ACROSS THE “A” COIL 19
ELECTRICAL 19
UA ADAPTER CABINET 22
RECOMMENDED SUSPENSION PROCEDURE FOR AH AIR HANDLER 22
ECM TROUBLE SHOOTING 23
TROUBLE SHOOTING CHARTS 26
SEQUENCE OF OPERATION 28
REPLACEMENT PARTS LIST 29
1
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.
2
AIR HANDLER
Each air handler is shipped with an evaporator coil preinstalled. The AH2436A(B)E1 is shipped with a
13U2436AB14 evaporator coil for 2 to 3 ton operation. The AH4260A(B)E1is shipped with a
13U4848AH20 evaporator coil for 3 to 5 ton operation.
The construction of the air handler permits easy knockdown and reassembly. See Figure A & B.
Figure A.
FOLLOW THESE STEPS FOR KNOCKDOWN OF AH2436:
1. Start with unit setting in a vertical position (Figure A).
2. Remove blower access door.
3. Remove screws from front a-coil access panel, front heating option access panel, front middle panel
and supply air end casing.
4. Remove the front A-coil drain pan retainer and the horizontal drain pan support shipping screw(s)
from the right side casing.
5. Remove the evaporator a-coil assembly.
6. Remove the side support drain pan angles and A-coil bottom front and rear supports.
7. Disconnect power leads and unplug circulation pump connector from the blower control board.
8. Remove the screws that secure the blower assembly to the blower pan and pull blower sub-assembly
out the front of the unit.
3
9. Remove screws that secure the blower pan to the side & rear casings.
10. Push the front edges of the side casings slightly apart and remove the blower pan.
11. Remove screws from the return air end panel and side & rear casings.
12. Remove side & rear casings from the return air end panel.
REASSEMBLY OF AH2436
To reassemble the air handler, reverse steps above starting with number 12.
Figure B.
FOLLOW THESE STEPS FOR KNOCKDOWN OF AH4260
1. Start with unit setting in a vertical position (Figure B).
2. Remove the blower access door and front A-coil access panel.
3. Remove front tie panel (four screws).
4. Remove four screws between left/right side blower module casings and left/right side coil module
casings.
5. Remove two screws between rear blower module casing and rear coil module casing.
6. Top blower section is now disengaged from bottom coil section. Lift top off of bottom section.
7. If the Air Handler needs to be completely knocked down, follow steps in procedure for the
knockdown of the AH2436.
4
REASSEMBLY OF AH4260
To reassemble the air handler, reverse steps above starting with number 7.
SETTING UP THE A-COIL FOR AIR CONDITIONING
The AH2436 & AH4260 come with the A-coil pre-installed for vertical and left to right horizontal airflow. The A-coil can also be re-positioned for counterflow operation.
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 1-7 must be followed.
Otherwise skip to step 8.
Reversing the horizontal orientation
1. Remove the front a-coil access panel of the air handler.
2. Remove the front a-coil drain pan retainer.
3. Remove the horizontal drain pan support shipping screw(s) from the right side casing.
4. Remove the A-coil assembly and slip the horizontal drain pan assembly off of the right side of the
A-coil.
5. Slip the horizontal drain pan assembly onto the left side of the A-coil.
6. Re-install the A-coil assembly into the air handler. The A-coil drain pan should slide under the rear
retention clip. The horizontal drain pan assembly should rest against the left side casing insulation
and the side support angle.
7. Re-install the front a-coil drain pan retainer in front of the a-coil drain pan.
For all orientations
8. Cut open the appropriate drain pan drain access hole in the front A-coil access panel.
9. Slip the Suction line grommet panel over the suction line up to the access panel surface.
5
Figure C
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 C.
14. Make appropriate condensate drain connections and seal the access opening.
6
For counterflow orientations:
Figure D
To convert AH2436 to counterflow:
1. Remove front A-coil access panel
2. Remove front a-coil drain pan retainer and the horizontal drain pan support shipping screws from
the right side casing.
3. Remove the A-coil assembly. Slide the horizontal drain pan assembly off of the right side of the
A-coil and discard.
4. Remove A-coil bottom front, side, rear supports, side support drain pan angles and rear a-coil
drain pan retainer.
5. Turn air handler over.
6. Re-install supports, angles and retainer removed in step 4 in the counterflow configuration using
pre punched holes located in the center of the casings.
7. Re-install A-coil and front a-coil drain pan retainer.
8. Re-install front A-coil access panel.
7
Figure E
To convert AH4260 to counterflow:
1. Remove the blower access door and front a-coil access panel.
2. Remove front tie panel (four screws).
3. Remove four screws between left/right side blower module casings and left/right side coil module
casings.
4. Remove two screws between rear blower module casing and rear coil module casing.
5. Top blower section is now disengaged from bottom coil section.
6. Lift blower module off of coil module.
7. Turn blower module over.
8. Remove return air end casing from coil module.
9. Place coil module on top of inverted blower module.
10. Re-install return air end casing on top of coil module and secure with screws.
11. Re-install all screws which secure blower module to coil module.
12. Re-install front tie panel.
13. Re-install blower access door and front a-coil access panel.
8
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 F.
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.
Figure F
: 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.
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