B6BX air handler
Contents
1. 11 Control Boalda oiie aaa i 12 aN sess ie ase ete e coer ede eee eer 12 Heater KSE 12 Electronic Air 12 cii 12 Startup amp Adjustments 13 Before You Start the 13 Refrigerant 14 Air Girc lati a Rm 14 Running the Blower Continuously 14 Selecting Continuous Low Spd Fan Operation 14 Turning the Blower 14 System Cooling sese 14 System 14 Blower Configurations 14 3 Speed Units 14 p Speed Units eren PER e tute 14 Unit Maintenance eere 15 Troubleshooting eere 15 Figures amp Tables eee 16 Figure 12 B6BX Physical Dimensions 16 Figure 13 BEBX Components 17 Data cmt t n inertes 18 Table BeBX Blower Performance Data 18 Electrical Data amp Diagrams 19 Table 4 BeBX MCA MOP Data 192. eee 4 Operation of Air Handler During Construction 4 Installation in a Garage 5 Plenums amp Air Ducts cccccecesseeceeeceseeeseeeeeseassesees 5 Unconditioned 5 5 Acoustical Duct Work 5 Air Handler Installation 6 Packaging 6 Mounting 6 Upflow Installations 6 Downflow Installations ccce 6 Horizontal Installations 6 Horizontal Left Installations 7 Horizontal Right Installations 7 Refrigerant Line 8 Orifice removal amp Installation 8 Connecting the Linsets 9 Condensate Drainage 10 Electrical Connections 11 Pre Electrical 11 Line Voltage iet ed 11 Grounditigs iie reditus 11 Thermostat Connections
3. S310N 99 WVESVIC ith ECM Motor Handler w ies Air iagram for B6BX Ser Wiring D 15 Figure 22 23 INSTALLATION PERFORMANCE CHECK LIST ATTENTION INSTALLERS It is your responsibility to know this product better than your customer This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product Safety should always be the deciding factor when installing this product and using common sense plays an important role as well Pay attention to all safety warnings and any other special notes highlighted in the manual Improper installation of the air handler or failure to follow safety warnings could result in serious injury death or property damage These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance Some local codes require licensed installation service personnel for this type of equipment Please read all instructions carefully before starting the installation Return these instructions to the customer s package for future reference USA DESIGNED ASSEMBLED Intertek ELECTRICAL SYSTEM Supply Voltage V Has the thermostat been calibrated Is the thermostat level INSTALLER NAME CITY INSTALLATION ADDRESS CITY UNIT MODEL UNI
4. 1 9 cm 3 4 in dia hose barb x 1 9 cm 3 4 in minimum dia PVC or flexible tubing NOTES 1 The drain lines must maintain a downward slope to ensure proper condensate drainage 2 Each condensate drain must be trapped separately using a J Trap or field supplied loop Figure 9 Condensate Drainage Example ELECTRICAL CONNECTIONS A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Beforeservicing disconnectall electrical power to the air handler When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing Pre Electrical Checklist Y Verify the voltage frequency and phase of the supply source match the specifications on the unit rating plate Verify that the service provided by the utility is sufficient to handle the additional load imposed by this equipment See the unit wiring label or Table 4 page 19 for proper high and low voltage wiring Verify factory wiring is in accordance with the unit wiring diagram Figures 14 amp 15 pages 21 amp 22 Make sure the connections didn t loosen during shipping or installation Line Voltage Electrical connections must be in compliance with all applicable local codes
5. MCA MOP MCA MOP MOP MCA MOP MCA MOP MOP Table 4 B6BX Minimum Circuit Ampacity amp Maximum Overcurrent Protection 19 Control Signal 5 KW Stage 1 Heat on instantly Heat blower on after 3 second delay W ON Stage 1 Heat on instantly EHEAT 10 KW Heat blower on after 3 second delay Stage 2 Heat on after 5 seconds delay OFF Heat stages off instantly Blower off after 15 second delay 5 KW Stage 1 Heat on instantly Cool blower on after 3 second delay ON Stage 1 Heat on instantly W amp Y 10 KW Cool blower on after 3 second delay AUX HEAT Stage 2 Heat on after 5 seconds delay OFF Heat stages off instantly Heat blower turns off after 40 second delay ool blower on after 3 second delay gy C ew ae Cool blower off instantly Cool Blower on after 3 second delay Cool Blower off after 40 second delay Table 5 Control Board Operation E H P amp cO Table 6 Control Board Settings 20 yH 0S LC L LZ _ HO LO3NNOO 1 el NOILVOO1 m um ebneb aues oui TVNIINH3 L jo 5 501 K uo asn pe e dai si porem euJ91UI Y pesn Aj
6. The air handler should be set into position before routing the refrigerant tubing REAR LEFT SIDE 0cm in RIGHT SIDE 0 cm in T See Note TNOTE from front of unit to nearest wall or partition for servicing Recommended clearance is 91 cm 36 in Figure 1 Minimum Unit Clearances Minimum Clearances This appliance must be installed in accordance with clearances listed in Figure 1 The air handler must be installed with ample clearance for easy access to the air filter blower assembly heater assembly and controls Applicable building codes may require additional clearance to equipment Refer to applicable building codes for details Static pressure drop through louvered openings and through return air plenums should be considered in the overall duct design in the determination of the total external static pressure Operation of Air Handler During Construction A CAUTION Failure to follow these instructions will void the factory warranty and may significantly reduce the life or the performance of the air handler and or result in other unsafe conditions It is the responsibility of the installing contractor to insure these provisions are met Operating an air handler in a construction environment can cause the appliance a variety of problems Proper use of commercial portable space heating equipment during construction is recommended This air handler may be used
7. 712 1509 737 1562 757 1603 782 1657 803 1702 826 1749 846 1793 865 1832 048 060E C M2 785 1663 807 1709 826 1750 850 1801 872 1848 890 1885 913 1934 932 1974 M3 940 1992 963 2041 983 2082 1003 2126 1025 2172 M4 973 2062 910 1928 986 2088 923 1956 999 2117 1016 2153 1032 2187 1045 2214 1062 2251 1078 2284 M5 NOTES 894 1894 996 2110 1011 2143 1 Airflow is shown in liter s per second cfm 5 2 External static pressure is shown in cm inches W C 3 All airflows are measured with filter and with dry coil For wet coil subtract 1 external static pressure 4 See unit nameplate or installation instructions for maximum recommended external static pressure 18 1022 2165 1036 2194 1052 2229 Table B6BX Blower Performance Data 1068 2262 1085 2299 1100 2331 T T m m N e e d 220 50Hz Single Phase ELECTRICAL DATA amp DIAGRAMS 240 VAC 50Hz Single Phase Aux Heat Installed Nom KW Single Circuit Multiple Circuit Circuit A Circuit B Circuit C Single Circuit Multiple Circuit Circuit A Circuit B Circuit C
8. e track the long term affects of air handler usage during construction Proof of this submittal shall be available for the final inspection of the air handler prior to occupancy Installation in a Garage A WARNING Donot place combustible materials on or against the cabinet Do not place flammable materials gasoline paint thinners etc or any other flammable vapors and liquids in the vicinity of the air handler The B6 Series air handler may be installed in a residential garage with the provision that the unit must be located or protected to prevent physical damage by vehicles Plenums amp Air Ducts A WARNING All return ducts must be secured to the air handler using appropriate methods All return ducts must be adequately sealed When return air is provided through the bottom of the unit the joint between the air handler and the return air plenum must be air tight Return air and circulating air ducts must not be connected to any other heat producing device such as a fireplace insert stove etc This may result in fire explosion carbon monoxide poisoning personal injury or property damage e e Supply and return air must be delivered to the air handler by duct s secured to the air handler casing running full size and without interruption This unit is designed only for use with areturn and supply duct The return air duct must have the same free area as the opening provided on the air ha
9. 4 Allow the unit to remain under vacuum for at least 30 minutes 5 Weigh in the proper amount of new or reclaimed refrigerant Refer to the air conditioner or heat pump installation manual for the proper type and quantity of refrigerant Refrigerant Charging The system refrigerant charge can be checked and adjusted through the service ports provided at the front panel of the outdoor unit Use only gauge lines which have a Schrader depression device presentto actuate the valve Air Circulation Running the Blower Continuously Set the thermostat s system mode to OFF and the thermostat s fan mode to ON The blower motor should run continuously Check for air delivery at the register s Ensure that there are no obstructions at the registers or in the ducts Selecting continuous low speed fan operation Standard Blower The air handler is equipped with an option of continuous low speed fan operation When G is energized without Y Y2 the air handler will operate using the cooling speed With Y Y2 or Y Y2 energized the air handler will operate in the selected cooling speed including 40 sec blower off delay Turning the Blower Off Set thermostat s fan mode to AUTO the blower will shut down immediately System Cooling 1 Set the thermostat s system mode to COOL and fan mode to AUTO Lower the thermostat s temperature mode below room temperature and observe that the blower energizes Check the air being discharged at
10. Table 5 Control Board Operation 20 Table 6 Control Board Settings 20 Figure 14 W D with PSC 21 Figure 15 W D with ECM Motor 22 Installation Performance Checklist 24 IMPORTANT SAFETY INFORMATION INSTALLER Please read all instructions before servicing this equipment Pay attention to all safety warnings and any other special notes highlighted in the manual Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored WARNING indicates a potentially hazardous situation that if not avoided could result in personal injury or death CAUTION indicates a potentially hazardous situation that if not avoided may resultin minor or moderate injury or property damage A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage e Before servicing disconnect all electrical power to air handler When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing N WARNING NITROGEN HEALTH 1 FLAMMABILITY 0 REACTIVITY 0 0 Minimal Hazard 1 Slight Hazard
11. a refrigerant charge Refer to the installation instructions supplied with the outdoor unit for refrigerant charge information Always refer to the installation instructions supplied with the outdoor unit for piping requirements The suction and liquid lines must be sized in accordance with the condensing unit specifications See Figure 12 page 16 for liquid and suction line locations When connecting refrigerant linesets together it is recommended that dry nitrogen be flowing through the joints during brazing This will prevent internal oxidation and scaling from occurring Refrigerant tubing should be routed in a manner that minimizes the length of tubing and the number of bends in the tubing It should be supported in a manner that prevents it from vibrating or abrading during system operation Tubing should be kept clean of foreign debris during installation If precise forming of refrigerant lines is required a copper tubing bender is recommended Avoid sharp bends and contact of the refrigerant lines with metal surfaces Refrigerant lines should be wrapped with pressure sensitive neoprene or other suitable material where they pass against sharp sheet metal edges B6BX series air handlers are charged through service valves on the end of the liquid tube for each circuit These must be removed before brazing the line sets Orifice Removal amp Installation The orifice installed in the air handler has been sized for use with the
12. duct size and or reducing the blower speed These treatments must be constructed and installed in accordance with all national and local codes For best sound performance be sure to install all the needed gaskets and grommets around penetrations into the air handler such as for electrical wiring AIR HANDLER INSTALLATION The B6 Series Air Handler is shipped ready for vertical upflow installation and is approved for attic basement alcove closet or crawlspace installation with zero clearance to combustibles See Figure 1 page 4 for required installation clearances This appliance is only for indoor use The unit must be leveled at installation and attached to a properly installed duct system The surface that the air handler is mounted on must provide sound physical support of the unit The air handler must be installed so that all electrical components are protected from water If a louvered door is installed across the front of this unit the appliance must be mounted flush or behind front edge of finished wall e Packaging Removal Remove the shipping crate and User s Manual from the equipment When removing the crate use extra care so tubing connections are not damaged Do not pull on the coils upper tubes Mounting Applications Vertical only air handlers are factory ready for upflow applications These units may be applied in downflow discharge applications when applied with the appropriate field kit Factory rea
13. during construction if it is not in violation of any applicable codes and the following criteria are met The installation must meet all applicable codes and be permanently installed according to the instructions supplied with the air handler including electrical supply and duct work The air handler must be controlled by a properly installed thermostat that complies with the current provisions of national and local electrical codes Thermostat connections must be made in accordance with instructions supplied with the air handler and thermostat See page 11 The installation must include a properly installed filter in the return air system with no by pass air The filter must be inspected frequently and replaced when necessary Return air must be supplied unrestricted and located such that dust and gases from construction activity are not introduced into the circulating air system Before occupying the structure The filter must be replaced or cleaned the duct work must be inspected and cleaned of any construction debris and the air handler must be cleaned and or repaired if found to be dirty damaged or malfunctioning in any way by a qualified HVAC technician The air handler shall be inspected and approved by applicable local authority even if this requires redundant inspections The serial number for the air handler used during construction must be submitted in writing fax and email also acceptable This information will be used to
14. not use pin gauges to measure the orifice diameter 8 Insert the new orifice into the distributor body rounded end down See Figure 8 page 9 Connecting the Linesets IMPORTANT NOTES FOR HORIZONTAL OR DOWNFLOW INSTALLATIONS WITH TXV VALVE The sensing bulb must be located flush against the suction line for optimum heat transfer Avoid attaching the sensing bulb to the lowest part of the suction line where condensate may accumulate Do not locate the sensing bulb on vertical sections of the lineset For horizontal lines the bulb should not be located at 12 or 6 o clock position of the suction line The best location is at 4 or 8 o clock For additional information on proper sensing bulb locations please refer to the valve manufacturer s instructions IMPORTANT The steps in the Orifice Removal amp Installation section page 8 must be performed before the linesets are connected 1 Remove grommets from line set holes CAUTION It is recommended that a wet rag be wrapped Figure 8 Restrictor Insertion into Distributor Body around the suction line in front of the close off plate or the sensing bulb if TXV is AN CAUTION installed before applying heat Failure to keep components cool during brazing may result To prevent damage to the unit or internal structural damage premature equipment components it is recommended that two failure or possible personal
15. 0 8 cm x 2 5 12 in x 20 in x 1 in 45 7 cm x 50 8 cm x 2 5 cm 18x 20 x 1 50 8 cm x 50 8 cm x 2 5 cm 20x20x1 Table 1 Filter Sizes Blower Compartment Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life It is recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual inspection Blower Fan Wheel Inspect the blower wheel blades for accumulations of dirt and clean if necessary Inspect mounting nut for tightness when done Blower Motor amp Assembly Inspect the blower assembly and motor mounting brackets for tightness and corrosion Correct deficiencies if necessary The blower motor contains sealed bearings and under normal operating conditions no maintenance is necessary for the life of the equipment TROUBLESHOOTING If the air handler fails to operate check the following Is the electric turned on Is the thermostat operating properly Are the blower compartment door s in place Is the air handler disconnect closed Has the circuit breaker tripped or the control board fuse burned open Are any manual reset switches open Is the filter dirty or plugged Is the LED on the air handler control board constantly ON If not refer to Table 2 to determine fault condition RED LED AN2 DIAGNOSTIC Control
16. AC The unit has an output to power an electronic air cleaner when the blower is running This output is rated to 1 0 amp at 208 240V Humidifier The unit has an output to power a humidifier when the blower is running This output is rated to 1 0 amp at 208 240V Car CONTROL BOARD FOR C CABINET HEATER P1 Figure 10 B6BX Control Boards Air Hand Thermostat WYGR 0000 ler T A Air Conditioner aA M Y Typical Air Conditioner with Standard Air Handler Thermostat W20YGRCE 9999990 LO NOTE Jumper between W2 4 E is required when no OD T Stat is used Heat Pump Typical Heat Pump with Standard Air Handler Figure 11 Typical Thermostat Connections STARTUP amp ADJUSTMENTS A WARNING NITROGEN HEALTH FLAMMABILITY 0 REACTIVITY 0 Minimal Hazard 1 Slight Hazard The evaporator coil is shipped from the factory with a nitrogen charge Use caution when preparing coils for field connections If repairs make it necessary for evacuation and charging it should only be attempted by qualified trained personnel thoroughly familiar with this
17. B6 Series Air Handlers leave the factory with a nitrogen holding charge Use caution when preparing coils for field connections If repairs make it necessary for evacuation and charging it should only be attempted by qualified trained personnel thoroughly familiar with this equipment Some local codes require licensed installation service personnel to service this type of equipment Under no circumstances should the equipment owner attempt to install and or service this equipment Failure to comply with this warning could result in equipment damage personal injury or death REQUIREMENTS amp CODES A WARNING This unit must be installed in accordance with instructions outlined in this manual during the installation service and operation of this unit Unqualified individuals should not attempt to interpret these instructions or install this equipment Failure to follow safety recommendations could result in possible damage to the equipment serious personal injury or death The installer must comply with all local codes and regulations which govern the installation of this type of equipment Local codes and regulations take precedence over any recommendations contained in these instructions Consult local building codes for special installation requirements This equipment contains nitrogen gas Installation or servicing should only be performed by qualified trained personnel thoroughly familiar with this type equipment A
18. B6BX SERIES AIR HANDLER IMPORTANT Please read all information in this manual thoroughly and become familiar with the capabilities and use of your appliance before attempting to operate or maintain this unit These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance Some local codes require licensed installation service personnel for this type of equipment Improper installation service adjustment or maintenance may cause explosion fire electrical shock or other hazardous conditions which may result in personal injury or property damage Unless otherwise noted in these instructions only factory authorized kits or accessories may be used with this product Keep this manual where you have easy access to it in the future If a problem occurs check the instructions and follow recommendations given If these suggestions don t eliminate your problem call your servicing contractor DO NOT DESTROY PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE TABLE OF CONTENTS Important Safety Information 3 Requirements amp 3 General Information 4 Before You Install this Unit 4 Locating the Air 4 Minimum Clearances
19. Fault No Power e eee e Blower Fault Normal Operation Table 2 Air handler Control Board Fault Conditions FIGURES amp TABLES 19 34 _ Ln 2 addi 3 4 1 9 3 4 2 9 1 1 8 13 Knockout typ 3 2 1 1 4 NE pcm D 1 7 8 NI Knockout 7 1 1 5 8 e 78 l p 1 1 4 gt 8 3 3 1 4 6 7 2 5 8 22 9 1 1 8 Knockout typ eia 2 9 1 1 8 NIE J E qe 2 3 5 8 9 14 3 5 5 8 4 4 4 8 1 7 8 i 224 7 8 4 4 mm 1 3 4 DETAIL Knockout typ 38 7 15 1 4 J 8 3 3 1 4 5 7 2 1 4 CUM o LIQUID te Lt 3 05575 TEEN 3 esses Tall 126 49 5 16 50 19 11 16 46 4 18 1 4 651570 7 22718 NOTE All Dimensions shown as inches Figure 12 BeBX Physical Dimensions Upper Door Assembly Lower Door Assembly Breaker 60A J Circuit Heating Element Assembly amp Transformer p Motor Control A lt gt Blower Control B Wheel Board Capacitor Motor Mount Kit N e SA Motor Assembly Filter Horizontal Door Drain Pan Vertical Drain Pan Filter Tracks
20. Figure 13 B6BX Components Dry Coil ESP 25 0 1 AIRFLOW DATA 76 0 3 1 0 0 4 1 3 0 5 1 5 0 6 1 8 0 7 2 0 0 8 LOW 296 627 234 496 N A N A N A N A N A MED 348 737 293 620 247 523 215 456 N A N A N A HIGH Dry Coil ESP 434 920 25 0 1 5 0 2 365 774 76 0 3 328 694 1 0 0 4 261 554 1 3 0 5 228 484 1 5 0 6 N A 1 8 0 7 N A 2 0 0 8 024 030E B LOW 531 1125 509 1079 480 1018 447 948 406 860 352 745 287 609 203 430 MED 610 1293 580 1228 546 1157 506 1072 463 980 406 861 336 712 248 526 HIGH Dry Coil ESP 692 1466 25 0 1 655 1387 5 0 2 615 1304 76 0 3 570 1207 1 0 0 4 521 1103 1 3 0 5 465 985 1 5 0 6 390 827 1 8 0 7 303 641 2 0 0 8 036 042E B LOW 695 1473 662 1403 626 1327 585 1240 541 1146 496 1051 434 919 346 733 MED 726 1539 691 1463 655 1387 611 1295 565 1196 517 1095 458 970 372 789 HIGH Dry Coil ESP 755 1599 25 0 1 721 1528 5 0 2 680 1441 76 0 3 639 1353 1 0 0 4 590 1249 1 3 0 5 536 1136 1 5 0 6 480 1018 1 8 0 7 392 830 2 0 0 8 M1
21. T SERIAL Minimum clearances per page 4 Is the unit properly installed and YES leveled Does condensate drain properly in both drain tubes Has the owner s information been reviewed with the home owner Has the literature package been YES NO left near the appliance NORDYNE COMPLETE COMFORT GENUINE VALUE Specifications amp illustrations subject to change without notice or incurring obligations O Fallon MO Printed in U S A 01 12 709333A Replaces 7093330
22. Variable speed air handlers cannot be twinned Heater Kits When electric heat packages with circuit breakers are field installed the circuit breaker may be used as a disconnecting means in most applications Reference the NEC and local codes for disconnect requirements 3A Fuse BLWDTC BLWDTC_R E CONTROL BOARD FOR A amp B CABINET ELE HEATER P1 If a heater kit is installed The B6BX air handler is shipped from the factory without an electric heater kit installed If Electric heat is desired the H6HK heater kit may be purchased separately and field installed Determine the correct size heater kit for your unit by referring to the list below or the units rating label A 15Kw 20Kw C senna 30Kw max 1 Connect the 2 wire plug of the air handler to the mating 2 wire plug of the heater kit 2 Connect the line voltage leads to the circuit breaker or terminal block provided 3 Connect the heater kit plug with the mating receptacle on the air handler control board If a heater kit is not installed 1 Remove the 2 wire plug of the air handler by cutting the wires and discarding the plug 2 Strip the ends of the 2 air handler wires and connect to the line voltage leads with the 2 wire nuts provided Electronic Air Cleaner E
23. a Route both lines to a suitable drain avoiding sharp bends and pinching of the lines The drain should maintain a minimum horizontal slope in the direction of discharge of not less than 2 5 cm 1 vertical for every 3 048 M 10 ft of horizontal run f the air handler is located in or above a living space where damage may result from condensate overflow an auxiliary drain pan shall be installed under the unit A separate drain line should extend from the pan to a conspicuous point and serve as an alarm indicating that the primary drain is restricted As an alternative to a separate drain line an approved water level indicator or float switch device may be used to shut down the unit in the event water is detected in the auxiliary pan Install a single 12 7 cm 5 inch trap in the condensate drain line as close to the coil as possible Make sure that the top of the trap is below the bottom of the drain pan to prevent the condensate from overflowing the drain pan NOTE There must be only one trap in the drain line Using more than one trap may prevent drainage Prime the trap with water Insulate the drain if itis located in an unconditioned space and test the condensate line for leaks Consult local codes for additional restrictions or precautions During system checkout inspect the drain line and connections to verify proper condensate drainage e e HORIZONTAI 190m 3 4 in Adapter N a
24. and ordinances Anelectrical disconnect mustbe located within sight of and readily accessible to the unit This switch shall be capable of electrically de energizing the outdoor unit See unit data label for proper incoming field wiring Any other wiring methods must be acceptable to authority having jurisdiction It is recommended that the line voltage to the unit be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the unit Overcurrent protection must be provided at the branch circuit distribution panel and sized as shown on the unit rating label and according to applicable local codes See the unit rating plate and Table 4 page 19 for minimum circuit ampacity and maximum overcurrent protection limits The installer should become familiar with the wiring diagram schematic before making any electrical connections to the unit See the unit wiring label or Figures 14 amp 15 pages 21 amp 22 Use only copper wire for the line voltage power supply to this unit Use proper code agency listed conduit and a conduit connector for connecting the supply wires to the unit Aluminum supply wire may be used if a heater kit is installed f replacing any of the original wires supplied with the unit the replacement wire mustbe copper wire consisting of the same gauge and temperature rating Provide power supply for the unit in accordance with the unit wiring diagram and the unit rating
25. ddns 94 uonisod H3NHOJSNVHL dei eui yden dey owe wo BL Nid S jenp e ILI lt 32euuo52siq z suon nasu uonej eisu out 995 G3ATIVLSNI LON H31V3H NAHM UMOUS se eq jou ONISNOH 3AOW3M OL SAYIM 12 uonpeuuo de peeds 1010UJ JAMO 941 1 E INVYSOVIG 1505 AGA VE 21 Figure 14 Wiring Diagram for B6BX Series Air Handler with PSC Motor 1180 0821114 N33H9 MOTI3A ALIHM MOTI3A SVE ONIYIM Gals aN3941 1566 3 nidis 1009 Ave YAWYOSASNVYEL JO 1eddoo 2601 Ajuo asn si Bum eui JI t Ajddns eui uonisod de ay dey 5 991 2 12euuoosiq 2 2 9 HOA 02 802 1v3H quvogd MOTI3A ALIHM 434 uoneordde peeds pue 10 SOYDUMS 195 0 YUM paplAojd suononajsur 5 S jou dej peads
26. dy horizontal air handlers may be applied in upflow or horizontal left and right discharge applications These units may also be applied in downflow discharge when applied with the appropriate field kit as specified in the units Technical Specifications Through the floor installations require a 1 4 thick noncombustible resilient gasket to be used whenever the supply or return air ducts pass through the floor The gasket should be positioned between the duct unit and floor Upflow Installations All air handlers are factory shipped ready for upflow installation The horizontal drain pan may be removed from the air handler when installing the unit in an upflow configuration All return air must enter from the bottom of the unit A typical upflow unit is shown in Figure 2 Downflow Installations downflow accessory kit See Technical Specifications is required for downflow applications Instructions for installing the downflow accessory kit are included with the kit It is recommended thatthe accessory be installed prior to installing the unit All return air in downflow applications must enter through the top of the unit A typical installation of the unit in a downflow application is shown in Figure 3 Horizontal Installations The B6 Series air handler can be installed horizontally in an attic basement crawl space or alcove It can also be suspended from a ceiling in a basement or utility room in either a right to lef
27. e sheet metal 9 Evacuate the system of moisture and non condensables to prevent low efficiency operation or damage to the unit The suggested range of evacuation is 350 500 microns 10 Charge the system with refrigerant Refer to the outdoor unitinstallation manualfor additional charging instructions 11 Check the system for leaks including the lineset and the brazed joints 12 Replace all grommets and properly dispose of all removed parts Condensate Drainage A CAUTION The air handler must be level to ensure proper condensate drainage An unlevel installation may result in structural damage premature equipment failure or possible personal injury Methods for disposing of condensate vary according to local codes Refer to local codes or authority having jurisidiction for restrictions and proper condensate disposal requirements The drain pan that is supplied with this air handler contains a primary and secondary drain fitting The condensate is drained from the unit through two 1 9 cm 3 4 female pipe fittings located on the front side of the unit as shown in Figure 9 The drain pan mustbe drained with field supplied tubing or pvc pipe and adequately trapped Both drain tubes must have a minimum diameter of 1 9 cm 3 4 and be trapped separately IMPORTANT Failure to install a trap result in condensation overflowing the drain pan resulting in substantial water damage to surrounding are
28. e tools and can be removed from the front of the unit by removing the filter door See Unit Maintenance page 15 for filter sizes and installation information A WARNING Never operate the air handler without a filter or with doors removed Dust and lint can build up on internal components resulting in loss of efficiency equipment damage and possible fire Acoustical Duct Work Certain installations may require the use of acoustical lining inside the supply duct work Acoustical insulation must be in accordance with all national and local codes for duct liners Duct lining must be UL classified batts or blankets with a fire hazard classification of FHC 25 50 or less Fiber duct work may be used in place of internal duct liners if the fiber duct work is in accordance with all national and local codes Fibrous duct work and internal acoustical lining must be NFPA Class 1 air ducts when tested per UL Standard 181 for Class 1 ducts Damping ducts flexible vibration isolators or pleated media style filters on the return air inlet of the air handler may be used to reduce the transmission of equipment noise eminating from the air handler These treatments can produce a quieter installation particularly in the heated space However they can increase the pressure drop in the duct system Care must be taken to maintain the proper maximum pressure rise across the air handler temperature rise and flow rate This may mean increasing the
29. equipment Some local codes require licensed installation service personnel to service this type of equipment Under no circumstances should the equipment owner attempt to install and or service this equipment Failure to comply with this warning could result in equipment damage personal injury or death Before You Start the Unit Prior to start up complete the following inspections y Verify the unitis level and properly located with adequate clearances for servicing the unit See Figure 1 pg 4 Check condensate drain line s for proper drainage Verify the surrounding area and top of the unit is free from obstructions and debris Check all duct connections Make sure the duct work is adequately sealed to prevent air leakage Check all coil connections for leaks Verify that the line voltage power leads are securely connected and the unitis properly grounded Make sure all doors are installed before restoring power to the unit y Verify the thermostat is wired correctly Make sure all low voltage wires are securely connected Verify the power supply branch circuit overcurrent protection is sized properly Verify filter is properly and securely installed IMPORTANT Before starting the unit install the initial charge on units that are factory shipped with a nitrogen holding charge 1 Read all installation instructions first 2 Purge the nitrogen holding charge 3 Evacuate the unit to 350 500 microns
30. es of the drain pan IMPORTANT If the webbing is not removed the condensate will not drain properly and ceiling damage may occur NOTE It is recommended that the suction line be insulated up to the coil inside of the cabinet 7 Insert the plug from horizontal drain pan into the open and unused drain hole in the drain pan at the bottom of the unit to block bypass air 8 Remove the corresponding drain line knockout from the coil access door to allow access to the horizontal drain 9 Replace the door and attach the drain line Washer Lockwasher Threaded Rod N Nuts x2 Figure 5 Unit Horizontally Suspended Refrigerant Line Connections A WARNING NITROGEN HEALTH FLAMMABILITY 0 REACTIVITY 0 0 Minimal Hazard 1 Slight Hazard The coilin the air handler is factory shipped with a nitrogen charge Avoid direct face exposure or contact with valve when gas is escaping Always ensure adequate ventilation is present during the depressurization process Address any uncertainties before proceeding Failure to comply with this warning could result in equipment damage personal injury or death The installer should make every effort to ensure the field installed refrigerant containing components of the system have been installed in accordance with these instructions and sound installation practices for reliable system operation and longevity The air handler coil does not contain
31. fe hazards Please read all instructions before installing the unit Before You Install this Unit This equipment is securely packaged at the time of shipment and upon arrival should be carefully inspected for damage prior to installing the equipment at the job site Claims for damage apparent or concealed should be filed immediately with the carrier The cooling load of the area to be conditioned must be calculated and a system of the proper capacity selected It is recommended that the area to be conditioned be completely insulated and vapor sealed Check the electrical supply and verify the power supply is adequate for unit operation The system must be wired and provided with circuit protection in accordance with local building codes If there is any question concerning the power supply contact the local power company Y Verify the duct system is appropriate for the air handler being installed Please note that when replacing an existing system with lower air flow the duct system may require modification Locating the Air Handler Survey the job site to determine the best location for mounting the unit Consideration should be given to availability of electric power service access and noise The dimensions of the room or alcove must be able to accommodate the overall size of the unit and the installation clearances listed in Figure 1 Physical dimensions for this air handler are also shown in Figure 12 page 16
32. formance and comfort it may be necessary to change the factory set speed See Table 3 page 18 for airflow data To change the blower speed 1 Disconnect all electrical power to the unit and remove the upper door 2 Remove the black and red wires from the blower motor jumping terminal Discard the blower motor jumping terminal 3 Connect the heating speed wire red and the cooling speed wire black to the desired blower speed marked on the terminal block of the blower motor Terminal 4 Hi speed Terminal 5 Med speed Terminal 6 Low speed 4 Replace the upper door and secure it to the unit 5 Restore power to the unit 5 Speed Units Blower speed can be selected by setting the switches on the control board See Table 6 page 20 UNIT MAINTENANCE Proper maintenance is most important achieve the best performance from a air handler Some of the components and their locations are shown in Figure 12 page 17 If any component of the air handler must be replaced use only factory authorized replacement parts specified in the Replacement Parts List provided online A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnectallelectrical power to air handler When servicing controls label a
33. injury wrenches be used when loosening or tightening nuts Do not over tighten 2 Remove the rubber plug from the suction line 3 Out the Schroeder housing from the end of the liquid line Verify the end is round clean and free of any burrs 4 Route and cut both lineset tubes to proper length in accordance with the outdoor unit specifications Verify 9 Realign the assembly nut on the distributor body and hand tighten both components Mark a line on both bodies and then tighten an additional 1 4 turn using two wrenches The movement of the two lines will show how 5 ends are Si AEE ro a of d burrs much the nut is tightened If a torque wrench is used Position grommeton line setwith sufficient distance away tighten to 14 16 Nm 10 12 ft Ibs usc mE processes can permanently 6 Connect the suction and liquid lineset tubes CAUTION It is recommended that a wet rag be wrapped around the suction line in front of the close off plate or the sensing bulb if TXV is installed before applying heat Failure to keep components cool during brazing may result in structural damage premature equipment failure or possible personal injury 7 the individual connections with dry nitrogen flowing through the joints NOTE This will prevent internal oxidation and scaling from occurring 8 Wrap the refrigerant lines with pressure sensitive neoprene or other suitable material especially where the lines enter the opening in th
34. ll electrical wiring must be completed in accordance with local state and international codes and regulations Installation of equipment may require brazing operations Installer must comply with safety codes and wear appropriate safety equipment safety glasses work gloves fire extinguisher etc when performing brazing operations Install this unit only in a location and position as specified on pages 4 amp 5 This unit is designed only for Indoor installations and should be located with consideration of minimizing the length of the supply and return ducts See Table 4 page 18 and the rating plate for proper circulating airflow data Follow all precautions in the literature on tags and on labels provided with the equipment Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment This air handler may be used for temporary heating of buildings or structures under construction See the guidelines listed on page 4 Air handler installations in a residential garage must be installed as specified on page 5 GENERAL INFORMATION This appliance has been tested for capacity and efficiency in accordance with AHRI 210 240 Standards and will provide many years of safe and dependable comfort providing it is properly installed and maintained Abuse improper use and or improper maintenance can shorten the life of the appliance and create unsa
35. ll wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing These maintenance instructions are primarily intended to assist qualified technicians experienced in the proper maintenance and operation of this appliance Always reinstall the doors on the air handler after servicing or cleaning changing the filters Do not operate the air handler without all doors and covers in place Verify that the thermostat is properly installed and is not being affected by drafts or heat from lamps or other appliances To achieve the best performance and minimize equipment failure it is recommended that a yearly maintenance checkup be performed At a minimum this check should include the following items Air Filter s B6 Series Air Handlers are not supplied with an air filter when shipped from the factory It is recommended that the filter be cleaned or replaced monthly Newly built or recently renovated homes may require more frequent changing until the construction dust has minimized Filter sizes shown Table 1 are available at most local retailers A WARNING Never operate the air handler without a filter in place Dust and lint in the return air can build up on internal components resulting in loss of e efficiency equipment damage and possible fire Filters designed to remove smaller particles such as pollen may require additional maintenance CABINET SIZE FILTER SIZE 30 5 cm x 5
36. most popularly matched outdoor units The orifice size as shipped from the factory is listed on the air handler rating plate Perform steps 1 9 to confirm that the orifice size meets the requirements outlined in the outdoor unit installation manual 1 Remove the cap from the end of the liquid line 2 Verify pressurization by depressing the Schrader valve on the end ofthe liquid line Listen for any escaping gas If there is no pressure test the coil for leakage leakage is found clearly mark the location of the leak and return the coil to the distributor for processing e f no leaks are found the coil may be installed 3 Depress the valve to relieve all pressure from the coil 4 Remove and discard the valve core A CAUTION To prevent damage to the unit or internal components it is recommended that two wrenches be used when loosening or tightening nuts Do not over tighten 5 Using two wrenches loosen the nut and distributor body as shown in Figure 6 Turn the assembly nut counter clock wise until the orifice body halves are seperated Figure 6 Loosening of Nut amp Distributor Body 6 Insert a light gauge wire hook between the distributor body and the restrictor orifice while being careful not to scratch either part Carefully remove the restrictor orifice from the distributor body See Figure 7 page 9 7 Check the actual size of the new orifice NOTE The size is stamped on its side Do
37. ndler The ducts should be appropriately sized to the capacity of the air handler to ensure its proper airflow rating Table 3 page 18 contains the maximum airflow data listed by model Use transition fittings if the supply and or return air openings of the unit do not match the duct openings These transitions should be dimensioned in accordance with standard practice as specified in the ASHRAE recommendations for duct transitions Flexible connectors may be used between the unit and the ductwork to prevent transmission of vibration from the unit to the structure If electric heater kits are installed heat resistant material must be used for the flexible connector at the supply air end of the unit Seal all connections and joints with industrial grade sealing tape or liquid sealant Requirements for sealing ductwork vary from region to region Consult with local codes for specific requirements Unconditioned Spaces All duct work passing through unconditioned space must be properly insulated to minimize duct losses and prevent condensation Use insulation with an outer vapor barrier Refer to local codes for insulation material requirements Air Filters B6 Series Air Handlers are not supplied with an air filter when shipped from the factory The installer must provide ahigh velocity filter that is appropriately sized to the return air duct opening or filter rack located in the bottom of the unit Accessing the filter does not requir
38. ng must be NEC Class 1 and must be separated from incoming power leads The thermostat should be mounted about 1 5 Meters 5 feet above the floor on an inside wall DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces sunlight or lighting fixtures and convective heat from warm air registers or electrical appliances Refer to the thermostat manufacturer s instruction sheet for detailed mounting and installation information Install the grommet which is packed with the unit in the hole for low voltage wires Properly connect the low voltage wiring between the thermostat outdoor unit and control board NOTE When the low voltage wires are positioned in this grommet the grommet will prevent chafing and or shorting of the low voltage leads Control Board The control board in the air handler controls the timing sequence of the elements The board is equipped with a 3 second blower on delay and a 15 second blower off delay in heating and a 40 second blower off delay in cooling See Figures 14 or 15 pages 21 22 and Table 5 pages 20 for control board operation Twinning B6BX air handlers are not supplied with a built in twinning capability To connect two air handlers to a common single stage AC condensing unit or heat pump a twinning kit is available for field installation Please follow the instructions supplied with the kit NOTE
39. ove the plug from one of the threaded holes in the horizontal drain pan Completely remove the webbing located in the threaded holes of the horizontal drain pan IMPORTANT If the webbing is not removed the condensate will not drain properly and ceiling damage may occur 3 Insert the plug from horizontal drain pan into the open and unused drain hole in the drain pan at the bottom of the unit to block bypass air 4 Remove the corresponding drain line knockout from the coil access door to allow access to the horizontal drain 5 Replace the door and attach the drain line RETURN AIR 3 RETURN Figure 4 Horizontal Configurations Horizontal Right Installations 1 Remove the coil access door Unscrew the line set tube close off plate from the front left cabinet rail 2 Slide the coil and drain pan assembly out of the unit 3 Remove the sheet metal hairpin covers if supplied from the back of the coil and discard 4 Place the horizontal drain pan on the opposite side of the coil On units with 2 sets of knockouts remove the other set of knockouts in the coil spacing plates and insert support rod 5 Slide the coil and the horizontal drain pan assembly back into the unit Re attach the tube close off plate 6 Remove the plug from one of the threaded holes in the horizontal drain pan Completely remove the webbing located in the threaded hol
40. plate Use UL listed conduitand conduit connectors for connecting the supply wires to the unit and for proper grounding Field supplied bushings for the power supply cables must be added to support and protect the power supply cables 208 230 Volt units are shipped from the factory wired for 240 volt operation For 208V operation remove the lead from the transformer terminal marked 240V and connect it to the terminal marked 208V Grounding A WARNING The unit cabinet must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur Do not use gas piping as an electrical ground This unit must be electrically grounded in accordance with local codes Use the grounding lug provided in the control box for grounding the unit Thermostat Connections Thermostat connections shall be in accordance with the instructions supplied with the thermostat The thermostat used with this equipment must operate in conjunction with any installed accessories Typical AC and air handler hookups are shown in Figure 11 page 13 A CAUTION Isolation must be maintained from the external Class 2 output of any transformer in a cooling circuit Use a thermostat with isolating contacts to prevent inter connection of Class 2 outputs Where local codes require that the thermostat wiring must be routed through a conduit or raceway splices can be made inside the unit however all wiri
41. t airflow or left to right airflow as shown in Figure 4 page 7 Air handlers may or may not be shipped from the factory with all the parts required for horizontal left applications and horizontal right applications If your unit does not have parts for a horizontal application a kit may be available NOTE In all horizontal applications in which the unit is installed above a finished ceiling and or living space a secondary drain pan mustbe installed under the entire unit to avoid damage to the ceiling in the event of condensate Horizontal Drain Pan Return Air Figure 2 Upflow Installation Cabinet f 1 Adaptor Kit Figure 3 Downflow Installation overflow Additionally it is recommended that an approved water level indicator or float switch device be used to shut down the unit in the event water is detected in the auxiliary drain pan If suspending the air handler from the ceiling assemble a support frame Figure 5 using slotted iron channel and full threaded rod Fasten the frame together with nuts washers and lockwashers Secure the support frame to the rafters with lag bolts The air handler can also be suspended using steel straps around each end of the unit The straps should be attached to the air handler with sheet metal screws and to the rafters with bolts Horizontal Left Installations 1 Remove the coil access door 2 Rem
42. the register is cooler than room temperature Verify unit refrigerant pressures are in order Blower should be turning in direction indicated by arrow NOTE DO NOT alter unit wiring Listen for any unusual noises Locate the source and correct as needed 2 Allow the unit to run for several minutes and then set the thermostat s temperature above room temperature Verify the blower cycles off with the thermostat System Heating 1 Set the thermostat s system mode to HEAT and the fan mode to AUTO Increase the thermostat s temperature above room temperature and observe that the blower energizes Checkthe air being discharged atthe register is warmer than room temperature 2 Allow the unit to run for several minutes and then set the thermostat s temperature below room temperature Verify the blower cycles off with the thermostat Blower Configurations 3 Speed Units The blower speed is preset at the factory for operation at the same speed for heating and cooling by using the jumping terminal on the blower motor and connecting it to the desired speed with both the red and black wires connected to the jumping terminal NOTE The control board is programmed with a 40 second off delay in the cooling mode for optimum system performance and efficiency A CAUTION To avoid personal injury or property damage make sure the motor leads do not come into contact with any uninsulated metal components of the unit For optimum system per
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