Thermo Products AH2-A User's Manual
Contents
1. OUTDOOR CONDENSINC UNI I y LIQUID LIN H 7 ic N P d A i ie 30 FT MAX INE Oll ito EN INDOOR S 4 FEET OR MORE BELOW NDC IL SUCTION LINE ADDITIONAL SUCTION NE OIL TRAP FOR ACH 20 FOOT RIS OF PIPE MAINTAIN PITC FOR THIS Ps CTION OF TUBING l Xu O a e VOR VAPORA 9 OK JOR EVAPORATOR CO An inverted trap should be installed on the horizontal suction line near the evaporator coil to prevent liquid flood back to the compressor See Fig G2 if the indoor evaporator coil is located 10 or more above the condensing unit 50 FT MAX MAINTAIN PITCH FOR THIS i l SECTION OF TUBING fl r4 d i qm see HW S All installations and services must be performed by qualified personnel 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 damage2. Set A coil in place on primary drain pan Secure coil installation strip with aluminum tape as indicated in Figure B2 inset 2 This makes a small ramp to slide the coil up and on the rear pocket brake Slide pan with coil into air handler making sure that the A coil plastic pan is properlv positioned in the primarv drain pan Insure the plastic coil pan on base of the A coil slides into rear clip See Figure B2 Secure front of plastic pan to bottom of unit with supplied pan clip See Figure B3 inset An extension for nut driver mav be of benefit Pan should rest on pocket brakes on each side of side casing when properly installed IMPORTANT When air handler is installed in attic above a finished ceiling it is recommended that a safetv overflow pan with its own separate drain be installed under the entire unit Remove trim plate from A coil connections Cut out appropriate holes in insulation remove appropriate knockouts and realign coil access panel and secure into place Make appropriate liquid and suction line connections to coil and braze connections NOTE A wet rag makes an excellent heat sink for tubing NCAUTION 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 All installations and services must be performed by qualified personnel 13 Position grommets in
3. coil access panel to allow installation of trim plate secure trim plate in place with screws and seal connections with duct sealer or equivalent NOTE The air handler is factory assembled for left to right horizontal and vertical applications If a right to left horizontal application is desired the fan center must be moved to the right side casing which will position it above the primary drain pan x fols Xi REAR A COIL CLIP 56 1 A 7 CC STRIP at ot INSTALLATION PA m PRIMARY DRA SNA A m PRIMARY DRAIN Mt rd PAN ut Figure B2 All installations and services must be performed by qualified personnel L TRIM PLATE Figure B3 INSTALLATION OF THE HOT WATER COIL 1 Remove top door of air handler 2 Slide hot water coil s side hanger brackets into coil channel retaining channel in the air handler See Figure B4 inset Figure B4 3 Push coil into unit until the coil is stopped by the back casing 4 Cut out appropriate holes in insulation realign top door and secure into place All installations and services must be performed by qualified personnel 5 Make appropriate hydronic connections to inlet blower side and outlet duct side of coil and braze into place 6 Seal connections through panel with duct sealer or equivalent A CAUTION If drilling or screwing into panel or plate is necessary make certain drill does not penetrate into any pa
4. when installed above ground When making on the job tubing a solder of 95 tin 5 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 evaporator 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 HOW TO MEASURE SUPERHEAT NOTE A good electric resistance thermometer and accurate suction pressure gauge are necessary Superheat is measured by taking a temperature and pressure reading See Figure I The pressure reading is gauged at the pressure port which is located on the suction service valve The temperature reading is taken at the evaporator coil on the header assembly in the 2 00 o clock or 10 00 o clock position with header assembly tube as the center of the clock HEADER ASSEMBLY Figure I 15 All installations and services must be performed by qualified personnel Read the temperature at header assemblv to
5. 18 1 350018 1 24 25 26 27 TRIM PLATE 14394 1 14394 1 28 TRIM PLATE 14395 1 14396 1 2 REQ D 19 All installations and services must be performed by qualified personnel AH2 A Air Handler with HC2 A Hydronic Coil Outlet Air Temerature vs Heating Capacity GPMPSI Coil Drop 14 LL l E 4 ANS Medium Low M c etm High 12 2 11 5 m l z 40 60 80 100 120 Heating Capacity Mbtuh 7 GPM 65 1 5 H20 8 GPM 95 2 2 H2O 4 9 GPM 1 17 2 7 H20 x 10 GPM 1 34 3 1 H20 180 F Inlet Water Terp pX Ow Peed AH1 A Air Handler with HC1 A Hydronic Coil Outlet Air Temperature vs Heating Capacity GPMPSI Coil Drop 160F Inlet ALCUN T 0X Medium Low Ax MedumHgh 3GPM A76 1 1 H2O x Ma e i u 4 GPM 823 1 9 H2O ES 4 5GPM1 25 29 H2O x 6GPM1 65 3 8 H2O do coa AX xe m AA A Q ka mA x l 4a E Heating Capacity Mbtuh 20
6. AFETV SECTION This page contains various warnings and cautions found throughout this Service and Installation Manual Please read and comply with the statements on the cover and the statements below AWARNING 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 AWARNING 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 AWARNING The cooling and heating coils must be cleaned by a qualified service person AWARNING This air handler is not to be used to condition during construction ACAUTION When testing electrical equipment always follow standard electrical procedures and precautions ACAUTION 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 energiz
7. AH AIR HANDLER is then placed on the UA adapter cabinet inlet side down The AH rests on the support angles of the UA adapter cabinet The UA cabinet is equipped with a permanent washable air filter When using the UA air handler the coil drain and coil drain pan must be utilized in place of the primary drain and primary drain pan found in the air handler 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 MATERIAI l N IEAVIER THREADED ROD OR HEAVIER ANGLE IRON 18 All installations and services must be performed by qualified personnel REPLACEMENT PARTS ie ae w AHT A AH2 A TEM PARTS ER n DESCRIPTION DS PART NO QTY PART NO QTY 1 2 3 DRAIN PAN 37149 1 37150 1 4 SIDE CASING LEFT 27128 1 27139 1 5 SIDE CASING RIGHT 27129 1 27140 1 6 CASING BACK 17130 1 17148 1 7 COIL CHANNEL 17135 2 17145 2 8 9 BLOWER SUB ASSEMBLY S00S4081 S00S4082 O PANEL FRONT TOP 17131 17141 1 DOOR TOP 17132 17142 2 DOOR MIDDLE 27133 27143 3 DOOR BOTTOM 17134 17144 4 BOTTOM 27138 27147 5 HARNESS SUB ASSEMBLY S0084351 S0084351 6 7 8 9 20 COIL SPACER 17160 1 17160 1 21 PAN CLIP 17161 1 17161 1 22 COIL INSTALLATION STRIP 17162 1 17162 1 23 BUSHING 3500
8. Thermo Pride UB 10 amp 12 SEER AIR HANDLER INSTALLATION amp SERVICE MANUAL MODELS AH1 A AH2 A 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 AWARNING 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 AM UNDERWRITERS BOX217 U L LABORATORIES NORTH JUDSON IN 46366 g l PHONE 574 896 2133 MADE IN USA MAC 165 ECN 4392 MA TABLE OF CONTENTS SECTION BEGINNING PAGE SAFETV SECTION 1 KNOCKDOWN OF AIR HANDLER 3 REASSEMBLY OF AIR HANDLER 3 INSTALLATION OF A COIL IN A VERTICAL APPLICATION 3 INSTALLATION OF A COIL IN A HORIZONTAL APPLICATION 4 INSTALLATION OF HOT WATER COIL 6 BLOWER AIR ADJUSTMENT 7 DUCT SYSTEM 9 CFM CAPACITY CHARTS 10 DUCT SIZING CHART 11 INDOOR EVAPORATOR COIL 11 TUBING LINE SETS 12 SUPERHEAT MEASUREMENT 15 MEASURING TEMPERATURE DROP 16 ELECTRICAL 17 UA ADAPTER CABINET 17 RECOMMENDED SUSPENSION PROCEDURE FOR AH AIR HANDLER 18 REPLACEMENT PARTS LIST 19 OUTLET AIR TEMPERATURE VS HEATING CAPACITY CHARTS 20 All installations and services must be performed by qualified personnel S
9. al load CFM CAPACITY The CFM at 2 static pressure takes into account the resistance of the internal A coil The CFM at a 5 static pressure accounts for the addition of an external hydronics coil which would typically add 3 to the static pressure 10 All installations and services must be performed by qualified personnel DUCT SIZES FOR HOMES Velocity Approximately 800 Feet Per Minute DIA SQ RECTANGULAR DUCI DIMENSIONS INCHES 4 6 Jx4 2x4 5 14x4 J 18x4 9 20x4 Q 25x4 12 Ox 30x4 12 2x 58x 12 Ay 4 54 JA IX 1C A 54 4x12 x1 C B 201 5x12 8x1C 6 201 4x14 6x12 20x10 6 201 5x14 7x12 22x10 6 201 6x14 3x12 22x 8 255 6x14 9x12 24x10 8 255 x14 20x12 26x10 8 255 16x16 8x14 22x12 26x10 36x8 54x6 8 255 17x16 20x14 22x12 28x10 38x8 58x6 8 255 18x16 20x14 24x12 50x10 40x8 62x6 314 16x16 22x14 26x12 52x10 44x8 64x6 514 20x16 22x14 26x12 54x10 46x8 14 18x18 20x16 24x16 28x12 56x 48x86 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 wate
10. calculate the superheat Then read the suction pressure and then add the line loss of 2 lbs for 25 of tubing Then convert pressure into temperature Next subtract the converted suction temperature from the measured coil header temperature and the end result is the superheat EXAMPLE Measured Temp 50 F Off header assembly at 10 00 or 2 00 position See Figure I Measured Pressure 71PSI 2PSI 73PSI which equates to a 439F saturation temperature Measured from pressure port 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 79F All 10 SEER models of Thermo Pride air conditioners should have a 3 F to 79F superheat at an 85 F to 95 F outdoor temperature and a 70 F to 80 F indoor temperature The superheat temperature will not be accurate if the indoor temperature is not within the 70 F to 80 F range Therefore an indoor temperature within the above range must be achieved before an accurate superheat can be measured MEASURING TEMPERATURE DROP ACROSS THE A COIL The temperature drop across the coil should be around 15 F to 20 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 pro
11. ing the system AWARNING Personal injury or property damage could result from major repair or service of this system by anyone other than a qualified contractor AWARNING If you do not follow these instructions exactly an unsafe condition may result causing personal injury loss of life or property damage All installations and services must be performed by qualified personnel 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 capable of operation within a range of evaporator coil sizes The evaporator size specified is shipped as a separate item and must be installed by the contractor Model AH2 A will accommodate the 1060 G1 1242 G1 1042E and 1048E The AH1 A will accommodate the 1024E 1030E 1036E 1224 G1 1230 G1 and 1236 G1 The construction of the air handler permits easy knockdown and reassembly See Figure A NOINI JACK UA ADIING DAUR ASING RIGHT J DOOR BOTTOM No Figure A All installations and services must be pe
12. r condensed out of the air A drain fitting is provided for connection to a convenient drain point 11 All installations and services must be performed by qualified personnel 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 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 0 50 TOTAL LINE LENGTH MODEL SUCTION LINE LIQUID LINE 1024 amp 1030 1036 amp 1042 1048 amp 1060 50 75 TOTAL LINE LENGTH MODEL SUCTION LINE LIQUID LINE 1024 amp 1030 1036 amp 1042 1048 amp 1060 75 100 TOTAL LINE LENGTH MODEL SUCTION LINE LIQUID LINE 1024 amp 1030 1036 amp 1042 1 1 8 1048 amp 1060 1 1 8 0 50 TOTAL LINE LENGTH MODEL SUCTION LINE LIQUID LINE 1224 amp 1230 1236 amp 1242 50 75 TOTAL LINE LENGTH MODEL SUCTION LINE LIQUID LINE 1224 amp 1230 1236 amp 1242 12 All installations and services must be performed by qualified personnel 75 100 TOTAL LINE LENGTH SUCTION LINE LIQUID LINE 1224 amp 1230 1236 amp 1242 1 1 8 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 se
13. rformed by qualified personnel FOLLOW THESE STEPS FOR KNOCKDOWN OF AIR HANDLER 1 2 Start with unit setting in a vertical position Figure A Remove screws from bottom door middle door top door and top front panel Remove doors and top panel of air handler Disconnect blower leads from blower terminal strip Remove screws that secure the blower pan to the side casings and the back casing Pull blower sub assembly up and out the front of the unit Remove screws from the bottom and the casing back Remove casing back and side casings from the bottom REASSEMBLY OF AIR HANDLER To reassemble the air handler reverse steps above starting with number 7 INSTALLATIONS OF A COIL IN VERTICAL APPLICATIONS A standard Thermo Pride A coil is used in all air handlers The coil and its attached drain pan are installed in the air handler See Figure B1 S Figure B1 All installations and services must be performed by qualified personnel INSTALLATIONS OF A COIL IN HORIZONTAL APPLICATION For the AH1 A in all A coil applications 1024E 1030E 1036E and 1224 30G1 except the 1236G1 the A coil spacer must be used For the AH2 A in all A coil applications the A coil spacer must be used 1 2 10 11 12 Remove bottom door of air handler Remove middle door of air handler Slide primary drain pan out of unit Set A coil spacer in primary drain pan if needed See Figure B2 1 inset
14. rt of evaporator coil or hot water coil Personal injury and or property damage may result UNIT ha TAN y s io ue i UWS 4 WA 2 MIN POSITIVE LIQUID FL i EXIBLE TUBING SEAL IS REQUIRED HOSE OR PIPE Figure C NOTE Drain lines must be pitched no less than 1 4 per foot away from the air handler TRIM PANEL INSTRUCTIONS Included as a loosely packed part in the condensate drain pan of both air handlers is two trim panels These panels are to be used in reducing the free area between both the hydronic coil lines and the evaporator coil lines The hydronic coil panel has two holes which the inlet and outlet lines fit through This panel is to be secured to the air handler via the prepunched holes and included screws The evaporator coil panel is a flat rectangular panel measuring 8 1 2 x 3 with a 1 2 brake on one edge The 1 2 brake is to fit into the pocket brake of the side casing and the larger part of the panel is to be attached to the bottom door via the prepunched holes and included screws This panel will close the gap that is created between the side of the air handler and the grommet panel that is installed on the evaporator coil BLOWER AIR ADJUSTMENT The direct drive blower must be set in order to establish proper air movement Use the following steps to do this For cooling only remove low speed connection to terminal block unless continuous fan is desired All installations and
15. s 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 WILL 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 All installations and services must be performed by qualified personnel CFM CAPACITY CHARTS AH1 A 2 Duct Static Pressure with heating coil And applicable Evaporator Coil Model CFM HI CFM M HI CFM M LOW CFM LOW 1024E and 1030E 1299 1123 992 821 1224 3061 1756 1202 1073 880 1036E 1435 1231 1055 861 1236G1 1438 1193 1036 860 2 Duct Static Pressure and applicable Air Conditioning Coil Only 1024E and 1030E 1224 30G1 1036E 1236G1 Heating coil 2 Duct Static Pressure 2 Duct Static Pressure 3 additional load AH2 A 2 Duct Static Pressure with heating coil And Applicable Evaporator Coil Model CFM HI CFM M HI CFM M LOW CFM LOW 1060G1 and 1242G1 2052 1632 1326 1034 1042bE 1915 1444 1296 1078 1048E 1568 1433 1251 1054 2 Duct Static Pressure and applicable Air conditioning coil only 1060G1 and 1242G1 1042bE 1048E Heating coil only 2 Duct Static Pressure 2 Duct Static Pressure 3 addition
16. services must be performed by qualified personnel 1 Determine the appropriate blower speed settings listed in tables below 2 Set the blower motor speed to match air conditioning requirement connect the red wire cooling tap to the appropriate fan speed on the terminal strip located on the blower see Figure D 3 Set the blower motor speed to match heating requirement connect the orange wire heating tap to the appropriate fan speed on the terminal strip located on the blower see Figure D FN M et RMINAL Figure D M E Terminal sip SER 40 000 btuh 60 000 btuh 80 000 btuh 100 000 btuh A Cooling Tap Locations gt LL a Red Red f Red _ ii ners All installations and services must be performed by qualified personnel Recommended Heating Capacitv Water Flow Rates for Heating 100 000 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 11 which shows the CFM capacity for square inch areas based on 10 we static pressure SP loss on the supply systems Each of the system s components trunk lines take offs run
17. t 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 superheat measurement for best performance 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 F below OUTDOOR MIN 1 2 IN OF PITCH PER 10 FT SUCTION CONDENSING LINE TOWARDS OUTDOOR UNIT LIQUID LINE INDOOR EVAPORATOR CO 13 All installations and services must be performed by qualified personnel Figure F 2 A 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 NOTE Multiple suction line traps are recommended for longer or multiple horizontal lines See Fig G1
18. visions 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 A 10 amp time delayed fuse or circuit breaker is recommended NOTE Condensing unit is not included in above amp rating 16 All installations and services must be performed by qualified personnel The following points must be checked bv the installer and or electrician before the air conditioning svstem 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 A loose terminal will cause poor flow of electrical power and result in very high current draw This can lead to blown fuses or burned wires 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 CAL SCHEMATIC LECTRIC O TIMER PACKAGE DIAGRAM W LADDER CKAGE PAC TIMER DER DIAGRAM WN AD 17 All installations and services must be performed by qualified personnel A return air opening can be cut in any of the four sides or the bottom of the UA cabinet The
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