Air Handlers ECM Blower 13/14 SEER Manual
Contents
1. WD 595 1 N EN WI RI G D IAG RAM BLOWER SWITCH SETTING TABLES N ON F OFF AH A5 6A L 1 AH 42 6 OA Im 1 HEATING AH2438AE1 4260 1 is REM SW1 3 2 1 CFM 211 CFM PR LR 689 FOE Fs oar F F IN 754 FACTORY F 1102 F N JF 819 F N JF 1197 FACTORY F N N 897 F N IN 1311 LADDER DIAGRAM ELECTRICAL SCHEMATIC whe te 97s ET L2 N JF N 1066 JF N 1558 NJN JF 1170 NTN JF 1710 N JN JN 1300 N JN 1900 OPTIONAL 255 BLOWER DEHUMIDISTAT E AH4260AE1 MOTOR TT TEE rel ss ONLY Ld EN FF IN 25 Cele 4 Iie ets al APERIRI DUM FACTORY F N F 3 FACTORY N F 5 1 PWR pt ttt I ee Wa Cd N N N BLOWER DELAYS ON DELAY OFF DELAY ORMOC SW sw2 2 1 Sec 473 _MIN FACTORY F F 30 FACTORY F F 2 115v 60 FIN 4 NJF 120 6 CYY YN TEX N N 240 NIN 8 24v C E FAN TIMER CONTROL 350915 Ps B BK 3 BIE 24 VAC Te WE R GAS TO A C W 29 T STAT CONTACTOR HCC 4 G 1 G BLOWER 1202. 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 A CAUTION 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 For counterflow orientations REAR A COIL DRAIN PAN RETAINER EVAPORATOR A COIL A COIL BOTTOM REAR SUPPORT eas d PRE PUNCHED HOLES FOR SECURING A COIL SUPPORTS COUNTERFLOW CONFIGURATION 7 4 7 FRONT A COIL ACCESS PANEL FRONT A COIL DRAIN PAN A COIL BOTTOM RETAINER SIDE SUPPORT SIDE SUPPORT DRAIN PAN A COIL BOTTOM ANGLE FRONT SUPPORT Figure D To convert AH2436 to counterflow Remove front A coil access panel 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 dr
3. 1 To p zl W Wri 4 pg BL Sy TO PUMP BOLER ds HOKE 55 o C CONTACTOR T CONTROL E 0 a E Y baed HI lo ee Y BL 5251 nm 3X2X1 1115 VAC 6X54 X SX8X7 NEUTRAL 2 ot PUMP BOILER Jn 83 w pet CONTROL Tease Y Y B NOTES LEGEND 1 CONNECT HOT TO L1 AND COMMON TO L2 FIELD WIRING 2 REPLACEMENT WIRE MUST BE TYPE 105 C FACTORY WIRING OR EQUIVALENT 3 MAX FUSE SIZE 15A FOR AH2436AE1 AND 20A FOR AH4260AE1 19 WD 596 N ON F WO 886 TE WI R D LAG RA BLOW
4. 155 A Motor Speed A B C etc 145 ai 7gpm 180 4 5 135 4 e 3gpm 2 160 F Water H 7 160 c e 125 5gpm Pao 2 e 2 115 7 140 o 4gpm 105 e 3gpm 95 25 35 45 55 65 75 85 Heating Capacity KBTU H Heat Settings SW1 SPEED cM 1 2 3 PAT 689 OFF B 174 ON OFF 87 ON 0 OFF LE 95 166 ON LG 1170 ON ON 1300 ON ON Water Tubeside 42 Heat sam sos Gevare 05 Heat T Supply Air F 88 Heat 59 Feat Supply Air F 7 Feat Supply Te Heat 9343 712 Supply Air C 116 15 Heat 51611 67039 Supply Air F 132 130 127 125 122 120 117 114 Heat Supply Air Heat Supply Air F Heat accum e mmc c i c n c m P Ru ge c 9 es Nanc S 1 Supply Air F i Heat Kbtu H 38730 40806 42723 44842 46788 48872 51041 53484 Heat Kbtu H 37900 39865 41666 43651 45468 47406 49417 51672 Supply Air F Supply Air F 118 Heat Kbtu H Heat Kbtu H
5. 72 I3vaercHv LINA 29 AUHONS AYVA AWN ST3GON YIHLO NMOHS 13 092 L SALON 39 19 LINA 95805 WINNI 05805 026092 SS3NUVH dANd NOLLWINONID Hee 23 626092 SS3NNVH UIMOd 99 SEOSE secose SS3NUWH 13404 YOLOW 396 0 09 SS3NNVH TOMLNOD SOLON 296 6605 POSE YINYOISNYAL 09S 1505 516052 Wad TOALNOD 29 18 54 18 5907 HOLON C3NNYaDOud Bot 290076 ATQNSSY ONISNOH N3MOT8 voc 86075005 16995005 AlgW3ssv Sns amoda 9 202 9 Z0z ONW MTIQNVH av TWANYN S 8 G Sd0V 8 5 540 39V Ovd TINVH 4004 1 111819 1 244819 TINGOW 534078 305 LHOW 570 F 1 942819 1 911818 TINGON AIOI 3015 1 31 9NSYO zc 1 5 819 1 811818 TINGON 338OT8 AVIY ONISYO I SL 8L9 1 211819 55309 good 0 1211819 1 211819 55200 40 INONJ HNYd 62 1 142919 1 142819 3L1NOMJ 8 1 99 819 1 99 819 TINGON 102 AYAY ONISVO Ze 1 99 819 1 892819 FINGOW 102 3015 LHOW ONISYO 9 1 59 919 1 9 819 TINGON
6. 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 SWI for adjusting Blower delays BLOWER COOLING SPEEDS Refer Table C1 for setting switches 4 5 amp 6 for the A C sizing Table C1 COOLING SWITCH SETTINGS AH2436A BE1 COOL AH4260A BE1 COOL TONS CFM Settings SW1 Settings SW1 4 5 6 2 2 1 2 1000 ON OFF OFF 3 1200 OFF OW OFF OFF ON OFF 3 1 2 OFF 4 ON ON 5 ON ON Shaded cells represent the factory settings BLOWER HEATING SPEEDS WITH HYDRONIC COIL 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 10 HYDRONIC COIL MODEL AH2436 E1 Temperature amp Heat Values at 140 160 amp 180 F and 3 4 5 6 amp 7 gallons per minute at selected speeds
7. the replacement PSC motor to the neutral common terminal on the fan control board N 1 through 7 Connect the high speed replacement PSC motor lead typically black to the EAC terminal on the fan control board The EAC contact is energized with 115VAC any time the control board is calling for fan operation whether in heating or cooling mode This replacement should be only used in emergency situations and only until a replacement ECM motor can be obtained and reinstalled ECM PSC Replacement for 2436 1 or AH4260BE1 call Tech Service 28 REPLACEMENT PARTS AYA 513000 MULHONS AYVA 10 NMOHS L3y9erzuv 1 S3ION are i E oreoss oceoss SS3NuVH JAM dHNd NOLLV TOO Hee 62608 SS3NUVH JAM M30d IPE L 506 pus SSJNUVH H3MOd SOLON def L EEOSE EEOSE SSINYYH TOMLNOD HOLOW IE L 16605 97052 M3WUOJSNYUL Obf 05 518056 TOMLNGD 99 L 087 540 O8P SdO SOLON Q3AWwHDONd are 2195005 23145005 ATENSSSY ONISNOH 434018 16435005 06775005 ATBMGsSv 8nS 334018 E 1 20 9 200 209 UTIGNVH NIV TVANYNN MISNI 8
8. 102305 LAN 9NISV Sc 1 9 819 1 29 819 3 NYMLBY ONISYD vz 1 09 919 1 09 818 56302 102 BNvd S7 1 65 819 1 661818 QN3 14405 ONIS D zz 1 cecgla 1 255819 avd maL lz 1 109819 1 206818 Avd Wal oz x 8 ze bl 19288 19 82 TWINOZIIOH Nyd 91 9005 lt 9005 34R080 s z n i 090056 arouse TVS TANIA LINNON 810056 810062 8 6 09A3H ONIHSNG zl 68026 Y f680c 14 0 1195 71192 Nyd woa 6 v988l 9981 NYd TWLNOZINOH 1509915 8 79981 29981 3Ovssvd 553 JUM H3 3IVId e 02281 g 02481 Nvd 130905 3015 STONY 9 69 81 69 81 NYd 102 GNVISH S 99 81 89 81 NYd 1102 SENMISH v 19181 1918 109 eodivid g 99 81 z 85481 1909915 NOlLdO TANNYHO c 99 9005 59 85005 NOlvHOdVA3 O2 1 ALO AD ON Lad NOILdIJOS30 515 WALI 138092 8HY I3vascrHv 30
9. 5 540 L 8 54540 3OovoDvd 3IONVH 5000 ZE 1 608819 1 208819 5300 W34018 004 5 1 108819 L 1 108419 SS300 NOILdO 9NILY3H LNOHJ T3NYd 0g 1 008819 1 008819 ONG Aldd S ONISYO 6c 1 862819 1 86 819 TIGGIN LNOYS TANYd 80 L 1 682819 L 1 68 819 Zz B8 819 p 1 884819 305 LHI ONISYD 9 1 8 819 L 1 284819 1431 ONISVO Gc 1 984819 L 1 984819 Nunl38 QN3 1 58 819 L 1 984819 SS309Y 102 LNONJ IHNVd 1 1 969819 1 969819 3IVld vc 116819 1 185819 WL lc B 9 8 t KJ E al l 820 82209 TWINOZIMOH Nyd I 1 89 07005 07005 IGNHOND GL 81005 81005 09A3H vi 60005 L 800042 399 TANIA 3 039 EL gt s 16 87 16192 Nyd 334018 2988 2988 3ovssvd SS3NuvH 3114 8302 OL 2 66 81 z 66 81 1804415 NOLLdO ONILY3H TANNVHO 6 L 96 81 96 81 uv3u WOLLOS 102 71904415 8 66 81 4 S6 8l 3015 WOLLOG 102 18040018 L 76 81 6 91 LNOYS MOLLOS 109 7 1904475 9 6 8l 6 8l IWINOZIMOH 1404415 g 6181 2 26 81 NVAO 71804405 2015 TONY t 16191 16 81 NYd Nivel 102 18084 06281 06 81 Nyd NlvHO 102 ayaa H3NIVL3H 2 9 85005 79 85005 ATgN3SSV YOLYYOdYAJ 102 LO ON 19 AD ON La d NOlLdIH9S30 SLavd Wall 389
10. AS NECESSARY YES CHECK 120V or 240V SUPPLY IS THERE 120V or 240V NO CONNECTION FUSES SERVICE SWITCH AND SUPPLIED TO MOTOR YES DISCONNECT 16 PIN AVAE HARNESS FROM Kio OROS RA MOTOR IS THERE 12VDC CONTE NO CHECK 24VAC ACROSS PIN12 amp PIN1 gt gt TO INTEGRATED CONTROL AND PIN12 amp PIN3 INTEGRATED CONTROL AT THE HARNESS PLUG YES DISCONNECT 16PIN HARNESS FROM INTEGRATED CONTROL NO REPLACE IS THERE 12VDC ACROSS INTEGRATED PIN 6 amp PIN 1 CONTROL YES AT THE CONROL ES CHECK HARNESS CONNECTIONS AND WIRE TURN THERMOSTAT MANUAL SWITCH ON IF AVAILABLE OR JUMPER 9 CHECK CONNECTIONS AND WIRES BETWEEN R amp G ON INTEGRATED CONTROL gt gt AT INTEGRATED CONTROL IF OK IS THERE VOLTAGE GREATER THAN REPLACE INTEGRATED CONTROL 12VDC BETWEEN PIN15 amp PIN1 YES CHECK CONNECTION ON HARNESS AND MOTOR RECONNECT HARNESS TO MOTOR IF CONNECTIONS ARE GOOD AND MOTOR STILL DOES NOT RUN REPLACE MOTOR 26 TEE Sequence of Operation Delay Active Yes Yes On Delay Yes Yes Mode On Ended No N No No 1 BURNER Off BURNER On 2 HEAT mode Off 3 BLOWER Off Delay Started 4 Status LED Off Yes Yes DEHUM Active On Delay Ended BLOWER LOW
11. EHI08A 45A EH212A 70A EH216A 85A The following points must be checked by the installer and or electrician before the air conditioning system is started 1 Check every electrical connection of PUSH ON or SCREW ON terminals to ensure it is on tightly on its proper post 2 Review wiring diagram for proper routing 2 0 LOW VOLTAGE CONNECTION DIAGRAM FOR AIR HANDLER w AIR CONDITIONER amp HYDRONIC HEAT AIR AR HANDLER CONTHCTOR THERMOSTAT 9 Q 0 9 CC COM HYDRONIC CC PUMP BOILER CONTROL G 1 Le me LOW VOLTAGE CONNECTION DIAGRAM FOR LOW VOLTAGE CONNECTION DIAGRAM FOR AIR HANDLER w HEAT PUMP amp HYDRONIC HEAT AIR HANDLER w HEAT PUMP amp ELECTRIC HEAT HEAT PUMP HEAT PUMP HEAT PUMP HEAT PUMP THERMOSTAT CONTROL THERMOSTAT CONTROL AIR HANDLER AIR HANDLER CONTROL GIRONE OC e VOC Eee Oe eae 00000 CC COM ELECTRIC HEATER ce HYDRONIC CC SOLATIO PUMP BOILER BL RELAY CONTRO
12. brackets into coil channel retaining channel in the air handler See Figure Push coil into unit until the coil is stopped by the back casing Cut out appropriate holes in insulation realign top door and secure into place Make appropriate hydronic connections to inlet blower side and outlet duct side of coil and braze into place Seal connections through panel with duct sealer or equivalent TRIM PLATE SUPPORT COIL SIDE HANGER COIL SIDE BRACKET HANGER BRACKET HOT WATER COIL FRONT HEATING OPTION ACCESS DETAIL A PANEL Figure F A CAUTION 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 UNIT PRIMARY amp AUX z DRAIN s MIN A POSITIVE LIQUID FLEXIBLE TUBING SEAL 15 REQUIRED HOSE OR PIPE Figure G NOTE Drain lines must be pitched no less than 1 4 per foot away from the air handler BLOWER AIR ADJUSTMENT Figure H z S 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
13. us m f 10 21 5 94 7 1 8 ae 10 1 95 Supply Air F Heat Kbtu H 2607 7 5 Air F 2 1 19 e uh 140 H20 7 70 07 5 6 121 95 5 5 Supply Air F 8 1 25 12 19 ns 1 7 6s 6 72 Supply Air CF m no f 18 Heat Kotu H e 9 0 149 17 Supply Air F 1 7 Heat Kbtu H ce 6 e 72 12 BLOWER TIME DELAY In cases where the yellow wires are used to start and stop the hydronic pump SW2 may be used to delay when the blower is cycled on or off to increase comfort and efficiency Use Table D1 to set the switches appropriately Table D1 Delays before blower cycles ON or OFF SW2 Positions Delay SW Positions OFF Delay 1 2 Seconds 3 4 Minutes OFF OFF 30 OFF OFF 2 ON OFF 60 ON OFF 4 OFF ON 120 OFF ON 6 ON ON 480 ON ON 8 DUCT SYSTEM The duct system and load sizing calculation should follow the design standards of Air Conditioning Contractors of America ACCA manuals D amp J or the American Society of Heating Refrigeration and Air Conditioning Engineers Inc ASHRAE Latest Edition Fundamentals Volume To aid you in evaluating existing duct systems quickly review the chart on Page 14 which shows the CFM capacity for square inch areas based on 10 wc static pressure SP loss on the supply syst
14. 100 MODEL Suction Liquid Suction Liquid Suction Liquid HP14241A1 HP14301A1 s M AC14241E2 AC14301E2 T FE HP14361A1 HP14421A1 5 5 3 5 5 HP1448xA1 HP1460xA1 7 8 3 8 1 1 8 1 2 1 1 8 5 8 AC14361E2 AC14421E2 P T NOTES For line lengths over 25 adjust charge accordingly per foot of variation from chart 65 oz per foot for 3 8 and 3 4 line set 674 oz per foot for 3 8 and 7 8 line set 694 oz per foot for 1 2 and 7 8 line set 72 oz per foot for 1 2 and 1 line set 76 oz per foot for 5 8 and 1 1 8 line set These charges are to be used in conjunction with a liquid sub cooling measurement for best performance 15 TUBING INSTALLATION The compressor oil is constantly pumped through the refrigerant lines in normal operation of an air conditioning system To ensure proper lubrication of the compressor by avoiding oil accumulation at undesirable points in the system follow the guidelines listed below 1 No traps in the suction line are necessary if the outdoor condensing unit is level with the indoor evaporator coil or the indoor evaporator coil is 4 feet or less lower then the outdoor condensing unit Any horizontal runs of suction line should have minimum 1 2 pitch for every 10 feet of line towards the outdoor condensing unit See Figure I MIN 1 2 IN OF PITCH
15. 5 SO 700 259 17x16 20 14 22x12 28X10 58x2 58x6 500 8 2529 18x16 20x14 24x12 30x10 40x8 62x6 900 20 514 18 16 22x14 26 12 32x10 44x8 64 6 2000 20 514 20 16 22 14 26 12 54 10 46x8 22001 20 514 18x18 20x16 24x16 28 12 56x10 48x8 THE INDOOR EVAPORATOR COIL 1 EVAPORATOR COIL is a finned coil through which air in the home is circulated Heat from the air is transferred to the liquid refrigerant inside the evaporator coil The coils for use in AH air handlers are in an A shaped configuration A Models 2 CONDENSATE DRAIN PAN is attached to the bottom of the evaporator coil to collect water condensed out of the air Two drain fittings are provided for connection to a convenient drain point 3 HORIZONTAL CONDENSATE DRAIN PAN is attached to the right side of the first one for horizontal left to right air flow It may relocated to the left side as well A drain fitting is provided for connection to a convenient drain point TUBING LINE SETS 1 SUCTION LINE is an insulated large copper tube connecting the outlet of the A C evaporator to the suction inlet of the A C CONDENSER 14 2 LIQUID LINE is a single small tube connecting the outlet of the A C condenser to the expansion valve inlet on the A C evaporator coil TUBING SIZE REFERENCE CHART Tube Diameter for Total Line Length 0 50 50 75 75
16. ER SWITCH SETTING TABLES N ON F OFF HEATING 2436 1 AH4260BE1 AH2436BE1 amp AH4260BE1 ERIS Ue F F F 689 ELE TF 1007 eng F r N 7s4 F F N 1102 LADDER DIAGRAM ELECTRICAL SCHEMATIC 119 eip astien FACTORY F N 897 1311 2 L1 L2 G N F F 975 N F F 1425 MODELS b d N F N 1056 N F 1558 a WITH AR HANDLER N N F 1170 1710 R G OPTIONAL N 1300 N 1900 BLOWER Ww Y DEHUMIDISTAT EH2 4 USED WITH AIR HANDLER aes COOLING AH4260BE1 SWIJE 5 4 TONS 6 5 4 TONS NOTES PWR 5 PWR 4 i diag hres pike e ens hd Fir IF 2 FININ 3 5 1 MODEL 216 DEPICTED IN 28 SCHEMATIC BELOW BL F 3 FACTORY N F N 5 DRE NA ps ds 5 1 MODEL COMPONENTS WILL DIFFER FACTORY WIRED FOR TERMINAL BLOCK NIN IN gt POLOS BLOWER DELAYS DELAY OFF DELAY eHtoaa 1 SEQUENCER 240VAC SUPPLY COOCH ow sw2 2 1 sec X 3 MN 1 No BREU SRE as Y FACTORY F F 30 FACTORY F F 2 1 4W HEATER poses i 1 1 on E 5 amp EH20BA 2 SEQUENCER 1 NO CIRCUIT BREAKER amp 24 VAC E _ _ ol BOR NIN 8 1 HEATER 1 212 3 SEQUENCER FAN TIMER CONTROL 350574 LS 4 2 40 SP CIRCUIT BREAKER SW2 BK BR 2 204 SP CIRCUIT B
17. L row W NU e G Nor e 9 USED e iO USED OR k 5 2 NL 8 9 PIN CONNECTOR CONNECTOR 21 UA ADAPTER CABINET The UA adapter cabinet is designed to be used in conjunction with the AH AIR HANDLER to allow a free standing vertical discharge installation The UA cabinet is shipped completely assembled and ready for installation The return air opening can face either left or right by exchanging the front filter door and rear filter block off assemblies The AH AIR HANDLER is then placed on the UA adapter cabinet inlet side down The UA cabinet is equipped with a permanent washable air filter AH AIR HANDLER RECOMMENDED SUSPENSION PROCEDURE The detail below is the proper and safest way to suspend the AH These components should be easily found at your local hardware store 1 2 OR HEAVIER GASKET MATERIAL DOUBLE NUT 3 8 OR HEAVIER THREADED ROD 1 8 OR HEAVIER ANGLE IRON DOUBLE NUT FIG M 22 ECM TROUBLE SHOOTING DIAGNOSTC FEATURES The control board is equipped with 4 green Input Status LEDs and 1 red Board Status LED These are intended to provide a quick view into furnace performance without requiring a voltmeter The green Input Status LEDs are driven by Y W and DEHUM inputs and are located directly below those inputs They will light to indica
18. Next subtract the measured tube temperature from the converted suction temperature The end result is the liquid sub cooling EXAMPLE Measured Temp 95 F Measured Pressure 211PSI which equates to a 1059F saturation temperature Listed temperature for measured pressure according to R 22 temperature scale on manifold gauge or R 22 section of pressure temperature chart The difference equals the degrees superheat 10 F 18 A liquid sub cooling of about 10 F leaving the condenser is good over a wide range of operating conditions for a system with a in the evaporator like the 2436 amp AH4260A BE1 MEASURING TEMPERATURE DROP ACROSS THE A COIL The temperature drop across the coil should be around 18 F to 23 F difference between inlet and outlet air This should be measured as close to the air handler as possible to eliminate duct losses ELECTRICAL All wiring must conform to the provisions of local codes or in the absence of local codes with the provisions of the National Electrical Code ANSI NFPA No 70 Latest Edition and this instruction manual Equivalent type wire must be used if any of the original wire supplied with the unit needs to be replaced NOTE Condensing unit is not included in above amp rating
19. No 1 A C Off 2 COOL mode Off BLOWER COOL 3 BLOWER Off Delay Started 4 Status LED Off BLOWER LOW 1 BLOWER Off No Delay 2 Status LED Off 1 HEAT mode On 2 BLOWER HEAT 3 Status LED Flashes 1 HEAT mode On 2 Blower On Delay Started 3 Burner On 4 Status LED On continuous 1 COOL mode On 2 Blower On Delay Started 3 Condenser On 4 Status LED On continuous 1 FAN mode On 2 BLOWER LOW 3 Status LED On continuous 27 Sequence of Operation Glossary Inputs W Switched 24vac indicating a Heat call from the thermostat Y Switched 24vac indicating a Cool call from the thermostat G Switched 24vac indicating a call for blower operation from the thermostat DEHUM Switched 24vac indicating a call for Dehumidification from a de humidistat BLOWER Speeds HEAT The Heating Blower speed selected by positions 1 2 amp 3 of SWI CFM tables on page 11 12 COOL The Cooling Blower speed selected by positions 4 5 amp 6 of SW1 CFM tables on page 10 LOW The LOW Blower speed selected by positions 4 5 amp 6 of SW1 CFM tables on page 10 ECM PSC Replacement for AH2436AE1 or AH4260AE1 only In an emergency situation a defective ECM motor can be replace with a PSC motor to provide temporary circulating air flow for heating or cooling This is done by replacing the ECM motor in the motor mounting bracket with a PSC motor of similar Horsepower Wire the common lead typically white of
20. PER 10 FT SUCTION OUTDOOR CONDENSING LINE TOWARDS OUTDOOR UNIT UNIT LIQUID LINE i A SUCTION LINE MAX DISTANCE LOWER FOR NO TRAP IN SYSTE INDOOR EVAPORATOR COIL Y Figure I 2 trap is necessary in the suction line at the indoor evaporator coil if the indoor evaporator coil is more than 4 feet below the outdoor condensing unit OUTDOOR CONDENSING UNIT EUR LINE SUCTION LINE ADDITIONAL SUCTION LINE OIL TRAP FOR EACH 20 FOOT RISE OF PIPE MAINTAIN PITCH FOR THIS P uus ON OF TUBING 30 FT MAX SUCTION LINE OIL 4 TRAP WHEN INDOOR UNIT IS 4 FEET OR MORE BELOW OUTDOOR UNIT INDOOR EVAPORATOR COIL Figure J 16 NOTE Multiple suction line traps are recommended for longer or multiple suction lines See Figure J An inverted trap should be installed on the horizontal suction line near the evaporator coil to prevent liquid flood back to the compressor See Figure K if the indoor evaporator coil is located 10 or more above the condensin
21. PPORT CU eth J gt HORIZONTAL DRAN PAN p Dy 4 d amp 1 COIL is SIDE SUPPORT DRAIN PAN ANGLE FRONT MIDDLE PANEL 1 A COIL BOTTOM REAR SUPPORT FRONT A COIL ACCESS PANEL FRONT A COIL DRAIN PAN RETAINER A COIL BOTTOM FRONT SUPPORT RETURN AIR END PANEL Figure A FOLLOW THESE STEPS FOR KNOCKDOWN OF AH2436 Start with unit setting in a vertical position Figure A 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 Remove the front A coil drain pan retainer and the horizontal drain pan support shipping screw s from the right side casing Remove the evaporator a coil assembly Remove the side support drain pan angles and A coil bottom front and rear supports Disconnect power leads and unplug circulation pump connector from the blower control board Remove the screws that secure the blower assembly to the blower pan and pull blower sub assembly out the front of the unit roues zs 9o Ug UA 9 Remove screws that secure the blower pan to the side amp 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 amp rear casings 12 Remove side amp rear casings from the return
22. REAKER 7 Qo 1 1 8KW HEATER amp m BL jg E 1 1 HEATER 24 VAC rM 1 DE 216 T 4 SEQUENCER TO A C W 2 9 2 404 DP CIRCUIT BREAKER amp 5 CONTACIOR dCC n G ti i n 12 800 HEATER BK BK G 5 PS LOWE ILC E A W CIRCUIT 4 BREAKER p SY IMT HEATER BK Eje HI aot lav A 32 he R R t3 LMT HEATER TO o R R d 2 UUL PUMP BOILER th 22 yp ia Y CCL COMPRESSOR CONTROL 120 1 HEATER CONTACTOR p VAC pen gp 7 nes Ule M iod wc 5051 d4 orci BL TERMINAL c xa BKy ee Liab lock i CEL N NNN SEQUENCER SEQUENCER SEQUENCER SEQUENCER fs PUMP BOILER 5 3 6 H 13 10 0 w Get CONTROL 5 5 RHE Ply po Bled ed 2AVAC 3t208 240VAC Me 237 AL ST BK w W W LEGEND i 5 64 mcm FIELD WIRING EN ee ee ee ie eee ee oe uu E FACTORY WIRING ies R 2 R ELECTRIC HEAT OPTION 1 CONNECT 240VAC INCOMING POWER TO L1 AND L2 i FIELD CONNECTION WIRING 2 REPLACEMENT WIRE MUST BE TYPE 105 C OR EQUIVALENT Eo 22 SUPPLIED WITH KIT 3 MAX FUSE SIZE 10 FOR AH2436BE1 AND 15A FOR AH4260BE1 WITHOUT ELECTRIC HEAT Max fuse size for AH2436BEI EH104A 30A Max fuse size for AH4260BE1 w EH208A 50
23. Supply Air CF 113 111 109 102 105 103 101 99 Heat Kbtu H HYDRONIC COIL MODEL HC2 A AH4260 E1 Temperature amp Heat Values at 140 160 amp 180 F and 7 8 9 amp 10 gallons per minute at selected speeds 150 Motor Speed A B C etc 180 F Water 10gpm 180 9gpm 4 8gpm 140 4 7gpm 160 F Water K gt H 10gpm 160 5 9gpm A 8gpm 10gpm 140 9gpm 8gpm 7 130 120 Supply Air w 70 Return F 110 100 40 60 80 100 120 Heating Capacity KBTU H Heat Settings SW1 SPEED CFM 1 2 3 107 OFF B 1102 ON OFF D 131 ON ON OFF E 145 OFF ON Fr 1558 ON OrF GG 1710 OFF ON ON H 190 ON 0 ON Inlet Water Tubeside CFM 1007 1102 B 1197 C 1311 D 1425 E 1558 F 1710 G 1900 H Temperature PD m 130 1 eal Seno Air CF m Heat Kou vas Heat Ko 7 gom Supply Air Heat Kbtu H 114 Lia Aii A seis 1 c io 192 Supply Air CF Heat Kbtu H 9 Air CF 160 F eat Kot 8 8 8 8 4 6 7 4 L 1 4 1 1 2 1 9 101 20 2 9 Heat Kbtu H LCD a i
24. Thermo Pride 13 amp 14 SEER AIR HANDLER INSTALLATION amp SERVICE MANUAL MODELS 2436 1 4260 1 2436 1 4260 1 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 ANWARNING 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 LISTED NORTH JUDSON IN 46366 PHONE 574 896 2133 MADE IN USA MAC 202 ECN 5320 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 29 TROUBLE SHOOTING CHARTS 26 SEQUENCE OF OPERATION 28 REPLACEMENT PARTS LIST 29 SAFETY SECTION This page contains various warnin
25. ain 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 po RETURN AIR END CASING a COLL MODULE FRONT A COIL ACCESS PANEL n FRONT a BLOWER MODULE TIE PANEL BLOWER ACCESS DOOR Figure E To convert AH4260 to counterflow ae DOSE QN S e 12 Remove the blower access door and front a coil access panel Remove front tie panel four screws Remove four screws between left right side blower module casings and left right side coil module casings Remove two screws between rear blower module casing and rear coil module casing Top blower section is now disengaged from bottom coil section Lift blower module off of coil module Turn blower module over Remove return air end casing from coil module Place coil module on top of inverted blower module 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 Re install front tie panel 13 Re install blower access door and front a coil access panel INSTALLATION OF THE HOT WATER COIL 1 Remove top door of air handler 2 Slide hot water coil s side hanger
26. air end panel REASSEMBLY OF AH2436 To reassemble the air handler reverse steps above starting with number 12 REAR BLOWER MODULE CASING LEFT SIDE BLOWER MODULE CASING LEFT SIDE COIL MODULE CASING 7 Z won SIDE BLOWER MODULE CASING FRONT TIE PANEL REAR COIL MODULE CASING BLOWER ACCESS DOOR owe SIDE COIL MODULE CASING Q pu FRONT A COIL ACCESS PANEL Figure B FOLLOW THESE STEPS FOR KNOCKDOWN OF AH4260 Start with unit setting in a vertical position Figure B Remove the blower access door and front A coil access panel Remove front tie panel four screws Remove four screws between left right side blower module casings and left right side coil module casings Remove two screws between rear blower module casing and rear coil module casing 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 rues oa ee eus 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 amp 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 instal
27. ator coil must be evacuated to 29 96 Hg 1000 microns or lower when all joints and fittings are leak free The service valves on the condenser may then be opened to release the refrigerant to the system Verify proper system performance See condensing unit manual for additional performance data 17 HOW TO MEASURE LIQUID SUB COOLING NOTE A good electronic thermometer and accurate liquid pressure gauge with a check valve in the Schraeder fitting are necessary ACAUTION Failure to use a liquid side hose fitting with a built in check valve may result in personal injury and significant refrigerant loss Sub cooling is measured by taking a temperature and pressure reading See Figure L The pressure reading is gauged at the pressure port located on the liquid service valve The temperature reading is taken at the liquid line at the 3 00 o clock or 9 00 o clock position with the liquid line as the center of the clock PRESSURE PORT LIQUID SERVICE VALVE AT OUTDOOR mn CONDENSER UNIT N 2 9 00 O CLOCK 3 00 O CLOCK POSITION 7 POSITION of BR OUTDOOR CONDENSING UNIT fo LINE SUCTION Figure L Make sure the tube where the temperature is measured is not in direct sunlight Read the temperature at the liquid line Read the liquid pressure Then convert pressure into temperature
28. ccurred and moisture is present Replace motor and perform Moisture Check e Evidence of moisture present inside air mover Perform Moisture Check DO DON T e Check out motor controls wiring and connections thoroughly before replacing motor Automatically assume the motor is bad e Orient connectors down so water can t get in gt Install drip loops Locate connectors above 7 and 4 o clock positions Use authorized motor and control model s for replacement Replace one motor or control model with another unless an authorized replacement e Keep static pressure to a minimum gt Recommend high efficiency low static filters gt Recommend keeping filters clean gt Design ductwork for min static max comfort gt Look for and recommend ductwork improvement where necessary in replacement Use high pressure drop filters some have 1 2 H2O drop Use restricted returns e Size the equipment wisely Oversize system then compensate with low airflow Check orientation before inserting motor connectors Plug in power connector backwards Force plugs Moisture Check e Connectors are orientated down or as recommended by equipment manufacturer e Arrange harnesses with drip loop under motor e Is condensate drain plugged e Check for low airflow too much latent capacity e Check for undercharged condition e Check and plu
29. ems Each of the system s components trunk lines take offs runs and register and grill free areas must be properly sized and matched together to ensure you are obtaining the air handling capacity of the duct system A 12x8 duct with a 400 CFM capacity for example MAY NOT flow 400 CFM if the register s to which it connects can only flow a total of 200 CFM The air handling capacity MUST BE EQUAL TO the supply system at a minimum when sizing the return air duct system It is recommended to follow design parameters set down by ACCA or ASHRAE on the return air duct systems 13 DUCT SIZES FOR HOMES Velocity Approximately 800 Feet Per Minute CFM DIA SQ RECTANGULAR DUCT DIMENSIONS INCHES 45 4 65 19 6 100 6 28 9x4 150 Z 58 8x6 12 4 200 5 30 10x6 14x4 250 9 65 8x8 12x6 18x4 500 9 63 10x8 14x6 20x4 400 78 12x8 16x6 25x4 500 2 1145 0x10 14x8 19x6 30x4 600 2 113 2x10 16X8 22x06 38x4 700 2 113 4x10 18x8 26x6 500 4 154 2X12 VOR CRISP s MN Iac 900 4 154 4x12 TARTS 22 8 S286 000 6 20 5x12 18 10 24x8 34x6 100 6 20 4x14 16 12 20x10 26x8 40x6 200 6 20 sx 28x0 AE 2x6 500 6 20 12 22x10 GOx6 46 86 400 8 LIS 6x14 19x12 24x10 52x8 48x6 500 8 255 ARNE SAS 30x6 600 8 255 TexTe Tx 22X12 cox 265
30. g leaks in return ducts cabinet 24 Comfort Check e Check proper airflow settings e Low static pressure for lowest noise e Set low continuous fan CFM e T stat in bad location CONTROL CONNECTOR 39 PWB HERDER 770974 1 PIN DESCRIPTION DYT 5 M HEAT M Y Y2 ADJUST 2 16 SUGGESTED MATING CONHECTOR HOUSING AMP 770583 1 SONTACT AMP 770904 1 POWER CONNECTOR PWB HEADER amp MP 1 3550840 0 DESCRIPTION JUMPER PIN 1 TO PIN 2 FOR 120 4 LINE INPUT QNZY CHASSIS GROUND AC LINE 120 or 240V AC LINE 120V or 240V lt 9 Ap CONTACT AMP 350537 1 WARNING APPLYING 240VAC LINE INPUT WITH PIN 1 TO PIN 2 JUMPER IN PLACE WILL PERMANENTLY DAMAGE UNIT e 2 2 Figure ECM PIN CONNECTORS Troubleshooting table above and Figure N adapted from GE Industrial Systems publication GED 7161C Troubleshooting GE ECM Driven Systems 25 TROUBLESHOOTING CHARTS THIS GUIDE SHOULD BE USED IN THE CASE OF A STOPPED OR MANFUNCTIONED ECM BLOWER MOTOR THE FOLLOWING SHOULD HELP ESTABLISH THE TYPE OF MALFUNCTION OR DEVIATION FROM THE NORMAL BLOWER OPERATION TO USE THIS DIAGRAM YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES CONFIRM IF EITHER BLOWER NO WHEEL IS RUBBING AGAINST DOES BLOWER SPIN FREELY gt HOUSING OR MOTOR SHAFT IS SPINNING FREELY REPAIR OR REPLACE
31. g unit MAINTAIN PITCH SECTIO Bie ae MESE INDOOR EVAPORATOR COIL OUTDOOR 2 SUCTION LINE 50 FT MAX di Doe LINE TUBING e Figure K A gradual loop in the tubing can be constructed to take up the excess tubing if you find that too much tubing has been brought onto a job Such a loop MUST be kept in a horizontal flat plane to avoid trapping the oil Refrigerant lines should be inserted into a suitable conduit or raceway when the lines are to be buried between the building and the outdoor condensing unit The lines must be provided with sufficient protection and support to prevent damage when installed above ground When making on the job tubing a solder of 9596 tin 596 antimony or any of the silver solders such as SilFos Phos Copper Easy Flo 35 or 45 should be used No attempt will be made here to instruct proper soldering or brazing technique but it is necessary that the installer be properly instructed in accordance with good existing practices All joints and fittings must be properly leak tested as per EPA guidelines after on the job tubing has been made up The line set and the evapor
32. gs and cautions found throughout this Service and Installation Manual Please read and comply with the statements on the cover and the statements below AWWARNING 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 A CAUTION 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 AAWARNING 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 A WARNING The cooling and heating coils must be cleaned by a qualified service person A WARNING This air handler is not to be used to condition during construction ACAUTION When testing electrical equipment always follow standard electrical procedures and precautions A CAUTION 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 ANWARNING Personal injury
33. led 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 2 Remove the front a coil drain pan retainer 3 4 Remove the A coil assembly and slip the horizontal drain pan assembly off of the right side of the Mt 7 Remove the front a coil access panel of the air handler Remove the horizontal drain pan support shipping screw s from the right side casing A coil Slip the horizontal drain pan assembly onto the left side of the A coil 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 Re install the front a coil drain pan retainer in front of the a coil drain pan For all orientations 8 9 Cut open the appropriate drain pan drain access hole in the front A coil access panel Slip the Suction line grommet panel over the suction line up to the access panel surface A COIL ACCESS PANEL AIR HANDLER pE RIM PLATE GROMMET SUCTION LINE SCREW 4 PLACES SUCTION LINE TO EVAPORATOR COIL GROMMET LIQUID LINE LIQUID LINE TO EVAPORATOR COIL
34. n motor harness connectors Check for erratic CFM command in variable speed applications Check out system controls T stat Perform Moisture Check e Hunts or puffs at high CFM speed Does removing panel or filter reduce puffing Reduce restriction Reduce max airflow e Stays at low CFM despite system call for cool or heat CFM 23 Check low voltage T stat wires and connections Verify fan is not in delay mode wait until delay complete R missing not connected at motor Perform motor control replacement check e Stays at high R missing not connected at motor Is fan in delay mode wait until delay time complete Perform motor control replacement check e Blower won t shut off Current leakage from controls into G Y or W Check for Triac switched t stat or solid state relay Excessive noise Determine if it s air noise cabinet duct or motor noise interview customer if necessary e Noisy blower or cabinet Check for loose blower housing panels etc High static creating high blower speed Check for air whistling thru seams in ducts cabinets or panels gt Check for cabinet duct deformation e Hunts or puffs at high CFM speed Does removing panel or filter reduce puffing gt Reduce restriction gt Reduce max airflow Evidence of Moisture e Motor failure or malfunction has o
35. or property damage could result from major repair or service of this system by anyone other than a qualified contractor A WARNING 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 AIR HANDLER Each air handler is shipped with an evaporator coil preinstalled The AH2436A B EI is shipped with a 13U2436AB14 evaporator coil for 2 to 3 ton operation The AH4260A B Elis 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 amp B SUPPLY AIR END CASING LEFT SIDE CASING HEATING OPTION SUPPORT CHANNEL REAR CASING FRONT HEATING OPTION ACCESS PANEL BLOWER PAN BLOWER SUB ASSEMBLY REAR A COIL DRAIN PAN RETAINER BLOWER ACCESS DOOR 2 5 P wie 2 RS Vy Yo APE 7 o gt a 222 ae HORIZONTAL DRAIN SU
36. te the presence of these signals The red Board Status LED has two functions It will light when the board recognizes a valid input signal and will stay lit until all valid signals are removed This is intended to show that the board is functioning and able to respond to input signals GENERAL GUIDELINES TO TROUBLESHOOTING GE ECM DRIVEN SYSTEMS ACAUTION Disconnect power from unit before removing or replacing connectors or servicing motor Wait at least 5 minutes after disconnecting power before opening motor SYMPTOM CAUSE PROCEDURE Motor rocks slightly when starting Motor won t start e No movement This is normal start up for ECM Check power at motor Check low voltage 24 VAC R to C at motor Check low voltage connections G PWM W R C at motor Check for unseated pins in connectors on motor harness Test with a temporary jumper between Check motor for tight shaft Perform motor control replacement check Run Moisture Check e Motor rocks but won t start Check for loose or compliant motor mount Make sure blower wheel is tight on shaft Perform motor control replacement check Motor oscillates up amp down while being tested off of blower Motor starts but runs erratically Varies up and down or intermittent It is normal for motor to oscillate with no load on shaft Check line voltage for variation or sag Check low voltage connections G PWM W R C at motor unseated pins i
Download Pdf Manuals
Related Search