Transcript
AIR HANDLER INSTALLATION INSTRUCTIONS Table of Contents AIR HANDLER SAFETY .................................................................1 INSTALLATION REQUIREMENTS ................................................2 Tools and Parts ............................................................................2 Outdoor System Requirements ...................................................2 Location Requirements................................................................2 Installation Configurations ...........................................................3 Airflow Conversion .......................................................................3 Drain Pan Connections ................................................................4 Electrical Requirements ...............................................................5 Duct Work Requirements.............................................................5
INSTALLATION INSTRUCTIONS ..................................................5 Inspect Shipment .........................................................................5 Install Condensate Drain Pan.......................................................6 Install Duct Work ..........................................................................7 Filter Specifications ......................................................................7 Verify Orifice Size .........................................................................7 Connect Refrigerant Lines ...........................................................7 Make Electrical Connections .......................................................8 Complete Installation..................................................................12 SEQUENCE OF OPERATION ......................................................14 AIR HANDLER MAINTENANCE ..................................................14 ASSISTANCE OR SERVICE .........................................................14 Accessories ................................................................................14
AIR HANDLER SAFETY Your safety and the safety of others are very important. We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety messages. This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow the safety alert symbol and either the word “DANGER” or “WARNING.” These words mean: You can be killed or seriously injured if you don't immediately follow instructions. You can be killed or seriously injured if you don't follow instructions. All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you what can happen if the instructions are not followed.
065682400
INSTALLATION REQUIREMENTS These instructions are intended as a general guide only and do not supersede any national or local codes in any way. Compliance with all local, state, or national codes pertaining to this type of equipment should be determined prior to installation. Read this entire instruction manual, as well as the instructions supplied in separate equipment, before starting the installation. All models are designed for indoor installation only. The installation of the air handler, field wiring, warm air ducts, etc. must conform to the requirements of the National Electrical Code, ANSI/NFPA No. 70 (latest edition) in the United States, and any state laws, and local ordinances (including plumbing or wastewater codes). Local authorities having jurisdiction should be consulted before installation is made. Such applicable regulations or requirements take precedence over the general instructions in this manual. Install the conditioned air plenum, ducts and air filters (not provided) in accordance with NFPA 90B Standard for the Installation of Warm Air Heating and Air-Conditioning Systems (latest edition). The air handler is provided with flanges for the connection of the plenum and ducts. Air Filters must be listed as Class 2 furnace air filters. The air handler is shipped from the factory completely assembled, configured for upflow or horizontal right-hand discharge. For downflow (counterflow) or horizontal left-hand discharge, some field modifications and/or kits may be required. See the “Accessories” section. Do not remove the cabinet knockouts until it has been determined which knockouts will need to be removed for the installation. Select the final installation position which best suits the site conditions. Consider required clearances, space, routing requirements for refrigerant line, condensate disposal, filters, duct work, wiring, and accessibility for service. Refer to the air handler rating plate on the air handler for specific information.
Tools and Parts Assemble the required tools and parts before starting installation. Read and follow the instructions provided with any tools listed here. Tools Needed: ■
¹⁄₄ in. Nut driver
■
Tape measure
■
Level
■
Hammer
■
Screwdriver
■
Sealant
■
Adjustable wrench
Parts Supplied: ■ Replacement orifice package Parts Needed: Check local codes, check existing electrical supply, and read “Duct Work Requirements,” and “Electrical Requirements,” before purchasing parts. ■
2
U.L. listed wire nuts
Outdoor System Requirements The air handler is designed to match, and must be used with, outdoor units as rated. The indoor sections are manufactured with an interchangeable refrigerant metering orifice to provide optimum refrigerant control and system performance with a variety of different capacities of outdoor units. In some cases, the outdoor unit may require a refrigerant metering orifice change to obtain rated performance.
Location Requirements
Explosion Hazard Keep flammable materials and vapors, such as gasoline, away from air handler. Place air handler so that heating elements are at least 18 inches (46 cm) above the floor for a garage installation. Failure to follow these instructions can result in death, explosion, or fire. NOTE: When used on cooling applications, excessive sweating may occur when the air handler is installed in a very humid space. ■ If installed in an unconditioned space, sealant should be applied around the electrical wires, refrigerant tubing, and condensate lines where they enter the cabinet. ■
Electrical wires should be sealed on the inside where they exit the conduit opening. Sealant is required to prevent air leakage into and condensate from forming inside the air handler, control box, and on electrical controls.
■
The air handler must be installed in such a way as to allow free access to the coil/filter compartment and blower/control compartment.
■
The air handler must be installed in a level position to ensure proper condensate drainage.
Suspended Cabinet Installation Installation Clearances Non-Ducted Return Closet Installation The air handler can be installed in a closet with a false bottom to form a return air plenum or be installed with a return air plenum under the air handler. Louvers or return air grilles are field supplied. Local codes may limit application of systems without a ducted return to singlestory buildings. ■ Install louvers in a closet. Use the “Filter Requirements Chart” to determine the opening size that will provide the amount of free air you will require. If using louvers or grilles, match the free area rating of the louver or grille to the Minimum Return Air Free Area you determined to be necessary by consulting the “Filter Requirements Chart.” ■
If the free area is not known, assume a 25% free area for wood or a 75% free area for metal louvers or grilles.
■
If the return air plenum is used, the return air grille should be immediately in front of the opening in the plenum to allow for the free flow of return air.
■
When not installed in front of the opening, there must be adequate clearance around the air handler to allow for the free flow of return air.
NOTE: Air handler cannot be installed horizontally lying on or suspended from either the front or back of the air handler. They must be positioned with one side parallel to the floor (the side closest to the floor) when in the horizontal position. The suspending means must be field fabricated, and should consist of two “cradles” made by attaching two rods to a length of angle iron or suitable gauge steel.
Installation Configuration Options Shading indicates proper line connections
Counterflow Field converted with kit (return in top)
4
Suction
1 2
Liquid
1 3
Either drain set may be used
1 2
Installation Configurations For ease in installation, it is best to make any necessary coil configuration changes before setting air handler in place. See “Installation Configuration Options.”
Suction Liquid
Either drain set may be used
1 3 4
1. Optional drain connections (for horizontal installations) 2. Left hand drain connections
Vertical Installations Upflow The air handler must be supported on the bottom only and set on solid floor or field supplied supporting frame. Securely attach the air handler to the floor or supporting frame.
Upflow As shipped from the factory (return in bottom)
3. Right hand drain connections 4.Bottom/Filter frame
. Horizontal Right Factory ready
Counterflow A vertical upflow air handler may be converted to vertical downflow (counterflow). A kit is required for this conversion. See “Airflow Conversion” section. Suction Liquid
Horizontal Installations Drains
Horizontal installations can be left-hand or right-hand air supply. Adequate support must be provided to insure cabinet integrity. Ensure that there is adequate room to remove service and access panels if installing in the horizontal position. For correct horizontal coil installation, see “Installation Configuration Options.” IMPORTANT: ■ When an evaporator coil is installed in an attic or above a finished ceiling, an auxiliary drain pan should be provided under the air handler as specified by most local building codes. This coil is provided with a secondary drain that should be trapped and piped to a location that will give the occupant a visual warning that the primary drain is clogged. See “Connect Condensate Drain.”
A . Horizontal Left Right to Left Airflow - Requires drain pan location change
Liquid Suction Drains
Conversion from Vertical to Horizontal A vertical upflow or vertical downflow air handler may be converted to horizontal by removing the indoor coil and installing a horizontal drain pan on the coil for right-hand or left-hand air supply.
B
Airflow Conversion Accessory kit ADKTM is required to convert this air handler to counterflow. See “Accessory “section. Refer to the instructions provided with the accessory kit for proper installation.
3
Before Conversion
Drain Pan Connections All models come from the factory with center refrigerant connections and left or right drain connections in the vertical position. See “Installation Configuration Options.” Horizontal Installations can be either “Right” as pictured, or “Left”. IMPORTANT: Counterflow Converted Air Handlers should not be installed horizontally. For Horizontal Right Installations, use drain connections marked “A”, as shown.
4 3 2 5
1
Horizontal Right Factory ready
1. Top cap 2. Blower 3. Support bracket
Suction Liquid
Drains
A For Horizontal Left Installations, a drain pan location change is required. Use drain pan connections “B” as shown. Horizontal Left Right to Left Airflow - Requires drain pan location change
Liquid Suction
4. Side drain pan 5. Bottom drain pan
1. Remove and set aside front panels. 2. Carefully remove coil assembly and bottom drain pan as one assembly from the air handler. 3. Remove the 4 screws that attach the top cap and support bracket. 4. Rotate the support bracket to other side. 5. Using the 4 screws removed in Step 3, reinstall the top cap. 6. Move side drain pan to the opposite side. 7. Install modified coil assembly back into air handler in the same orientation that it was in previously.
After Conversion 4
Drains
B Follow the steps below to modify your drain pan for Horizontal Left configuration.
3 2
5
1
1. Top cap 2. Blower 3. Support bracket
4. Side drain pan 5. Bottom drain pan
8. Determine knockouts required for drain line connections, knock out and install drain lines. 9. Replace the front panels.
4
Electrical Requirements
WARNING
INSTALLATION INSTRUCTIONS Inspect Shipment
Electrical Shock Hazard Electrically ground air handler. Connect ground wire to ground terminal marked “GND”. Failure to do so can result in death or electrical shock. NOTE: Use copper conductors only. ■ All field wiring must be done in accordance with National Electrical Code, applicable requirements of UL and local codes, where applicable. ■
Electrical wiring, disconnect means and over-current protection are to be supplied by the installer. Refer to the air handler rating plate for maximum over-current protection, minimum circuit ampacity, as well as operating voltage.
■
The power supply must be sized and protected according to the specifications supplied on the product.
■
This air handler is factory configured for 240 Volt, single phase, 60 cycles. For 208 Volt applications, see “208 Volt Conversion” in the “Make Electrical Connections” section.
■
For optional Electric Heater applications, see “Accessories.” Refer to the instructions provided with the accessory for proper installation.
WARNING Excessive Weight Hazard Use two or more people to move and install air handler. Failure to do so can result in back or other injury. These air handlers are completely factory assembled, and all components are performance tested. Each unit consists of a blower assembly, refrigerant coil, and controls, in an insulated galvanized factory finished enclosure. Knockouts are provided for electrical wiring entrance 1. Check the unit rating plate to confirm specifications are as ordered. 2. Upon receipt of equipment, carefully inspect it for possible shipping damage. Take special care to examine the unit inside the carton if the carton is damaged. If damage is found, it should be noted on the carrier’s freight bill. Damage claims should be filed with the carrier immediately. Claims of shortages should be filed with the seller within 5 days. NOTE: If any damages are discovered and reported to the carrier, do not install the unit as your claim may be denied.
Duct Work Requirements ■
Install the conditioned air plenum, ducts and air filters (not provided) in accordance with NFPA 90B Standard for the Installation of Warm Air Heating and Air-Conditioning Systems (latest edition).
■
The air handler is provided with flanges for the connection of the plenum and ducts.
■
Air Filters must be listed as Class 2 furnace air filters.
■
Supply and return duct work must be adequately sized to meet the system’s air requirements and static pressure capabilities. Duct work should be insulated with a minimum of 1 in. thick insulation with a vapor barrier in conditioned areas or 2 in. minimum in unconditioned areas.
■
Supply plenum should be the same size as the flanged opening provided around the blower outlet and should extend ideally at least 3 ft from the air handler before turning or branching off plenum into duct runs.The plenum forms an extension of the blower housing and minimizes air expansion losses from the blower.
5
Install Condensate Drain Pan The air handler is provided with ³⁄₄ in. NPT condensate drain connections. A field-fabricated auxiliary drain pan, with a drain pipe to the outside of the building, is required in all installations over a finished living space or in any area that may be damaged by overflow from the main drain pan. In some localities, local codes may require an auxiliary drain pan for any horizontal installation. Make sure unit is level so that the drain pan will empty completely without water standing in the pan. 1. Remove the appropriate drain knockouts. See “Drain Pan Connections” section. You may need to remove the indoor coil assembly from the cabinet. 2. Remove any web from inside any threaded drain pan hole to which a drain line is to be connected. Use care when removing the web so as not to damage the coil. 3. Connect primary drain line connection to the primary drain pan connection. The primary drain connection is flush with the bottom of the inside of the pan. Secondary connection is raised above the bottom of the inside of the pan. NOTE: When making drain fitting connections to the drain pan, hand tighten. Using a sealant is recommended. Overtightening the fittings can split connections on the drain pan. 4. Secondary drain connections, if used, should be connected to a separate drainage system. Run the auxiliary drain line to a place where the occupant would notice if water started coming from the auxiliary drain. 5. Install a 3 in. trap in both the primary and secondary drain lines as close to the unit as practical. Make sure the top of the trap is below the connection to the drain pan to allow complete drainage of the pan. NOTE: Horizontal runs over 15 ft long must also have an antisiphon air vent (stand pipe) installed ahead of the horizontal run. See “Typical Condensate Drain Connection.” An extremely long horizontal run may require an oversized drain line to eliminate air trapping.
6
Typical Condensate Drain Connection (secondary drain not shown)
2
1
3 4
1.00" Min. 12.00" Max.
3.00" Min. 5
1. Air Handler 2. Drain connection 3. Drain line
4. Anti-siphon air vent (for horizontal runs of 15’ or longer) 5. Drain trap
NOTE: Do not operate air handler without a drain trap. The condensate drain is on the negative pressure side of the blower; therefore, air being pulled through the condensate line will prevent positive drainage without a proper trap. 6. Route the drain line to the outside or to an appropriate drain. Drain lines must be installed so they do not block service access to the front of the air handler. A 24 in. clearance is required for filter, coil, or blower removal and service access. NOTE: Check local codes before connecting the drain line to an existing drainage system. 7. Insulate the drain lines where sweating could cause water damage. Test condensate drain pan and drain line after installation: 1. Pour several quarts of water into drain pan, enough to fill drain trap and line. 2. Check to make sure the drain pan is draining completely, no leaks are found in drain line fittings, and water is draining from the end of the primary drain line. 3. Correct any leaks found.
Install Duct Work
Verify Orifice Size
IMPORTANT: ■ Install duct work in accordance with NFPA 90B and any local codes.
IMPORTANT: The proper orifice size is dependent on indoor coil/ outdoor unit combination and application. 1. Consult the outdoor unit information to determine if the indoor unit has the correct orifice installed. 2. If a change of the orifice is required, loosen the retainer nut and separate the retainer tube assembly.
■
Connect supply air duct to the flange on top of the air handler. If an isolation connector is used, it must be nonflammable.
■
A return air duct system is recommended. If the unit is installed in a confined space or closet, a return connection must be run, full size, to a location outside the closet.
2 3
1
Filter Specifications 4
Minimum Filter Requirements Chart Nominal Tons Air Conditioning & Nominal Airflow
Square Inch Surface Area & Nominal Size Disposable Filters
Cleanable Filters
1.0.75 in. Brass hex fitting 2. Supplied gasket
Minimum Return Air Free Area
Up to 2 Tons 800 - 900 CFM
432 sq. in. 20 in. x 25 in.
260 sq. in. 15 in. x 20 in.
260 sq. in.
2¹⁄₂ Tons 900-1000 CFM
480 sq. in. 20 in. x 30 in.
288 sq. in. 14 in. x 25 in.
288 sq. in.
3 Tons 576 sq. in. 346 sq. in. 1300 - 1500 CFM *14 in. x 25 in. 16 in. x 25 in.
346 sq. in
3¹⁄₂ Tons 672 sq. in. 404 sq. in. 1300 - 1500 CFM *16 in. x 25 in. 20 in. x 25 in.
404 sq. in.
4 Tons 768 sq. in. 461 sq. in. 1500 - 1700 CFM *20 in. x 25 in. 20 in. x 25 in.
461 sq. in.
5 Tons 960 sq. in. 576 sq. in. 1900 - 2100 CFM *20 in. x 30 in. 24 in. x 25 in.
576 sq. in.
3. Piston with orifice 4. 0.812 in. Brass hex nut
3. Remove the orifice with an orifice extractor tool from the replacement orifice package provided. 4. Insert the proper orifice into the fitting, seal end first. Make sure the orifice is free to move in the fitting. 5. Replace the retainer nut. NOTE: Overtightening the retainer nut will crush the gasket and may result in a system leak or stuck piston. 6. Dispose of all packaging and unused parts.
Connect Refrigerant Lines IMPORTANT: Refrigerant lines must be connected by a licensed, EPA certified refrigerant technician in accordance with established procedures. ■ To avoid damaging the rubber grommets in the cabinet while brazing, slide the rubber grommets over the refrigerant lines until they are away from the heat source. ■
* 2 disposable filters required for these units
Use a braze compound suitable for refrigeration lines, such as an alloy of silver or copper and phosphorus with a melting point of not more than 1100°F. Braze the copper refrigerant lines to the copper stubs at the coil and at the condensing unit and let cool. NOTE: Do not use soft solder.
■
Reinstall the rubber grommets after brazing is finished.
7
Make Electrical Connections NOTE: The constant air terminal is to be connected to a low speed motor tap only. If a motor is wired for a higher speed, the increased amp draw could cause the board control to fail and void the warranty.
3
1 2
240 Volt Installations
WARNING 1. Connect black to black 2. Connect yellow to yellow 3. Connect ground wire to ground terminal marked “GND”
6. Replace the air handler access panels.
Electrical Shock Hazard Disconnect all power supplies before servicing.
208 Volt Conversion
Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. Disconnect all power supplies. 2. Remove the air handler access panels. 3. Route the field supply wires to the air handler electrical connection box. 4. Using UL listed wire nuts, connect the field supply wires to the furnace (black to black and yellow to yellow).
WARNING
Electrical Shock Hazard Disconnect all power supplies before servicing. Replace all parts and panels before operating. Failure to do so can result in death or electrical shock. 1. Disconnect all power supplies. 2. Remove the control compartment access panel. 3. Move the 2 connected black transformer leads from the 240 Volt terminal on the transformer to the 208 Volt terminal on the transformer. See “Wiring Diagram - Blower”.
WARNING
Electrical Shock Hazard Electrically ground air handler. Connect ground wire to ground terminal marked “GND”. Failure to do so can result in death or electrical shock. 5. Connect ground wire to ground terminal marked “GND.”
8
Low Voltage Connections
9
Wiring Diagram - Electric Heat
DWG .NO.
065463300
WIRING DIAGRAM -ELECTRIC HEA T SEQ3
3rdSTAGE
CB3 LS5
L1C 12 BK
5
4
3
1
12 BK
L2C
18 BLU
18 BLK
HE5
GND.
12 YEL
2nd STAGE
SEQ2 CB2
18 BLK LS3
L1B
12 BK
5
4
3
1
12 BK
HE3
12 YEL
HE4
18 BLU
L2B
LS4
12 YEL
GND.
SEQ1
1stSTAGE
CB1 L1A
12 BK
LS1
5
4
12 BK
3
1
12 BK
12 BK L2A
HE1
HE2
LS2
12 YEL 12 YEL
18 WHT
18 BLU
14 RED
14 GRN
14 YEL
14 BLK
GND
TO BLOWER
1
2
GROUND LUG
3
4
5
6
6-PIN PLUG
HEATERS USED 5 KW = HE1 7.5 & 10 KW = HE1 & HE2 12.5 & 15 KW = HE1,HE2 & HE3 17.5 & 20 KW = HE1,HE2,HE3 & HE4 22.5 & 25 KW = HE1,HE2,HE3,HE4 & HE5
TB = TERMINAL BLOCK PD = PULL DISCONNECT CB = CIRCUIT BREAKER SEQ = SEQUENCER GND = GROUND LUG LS = LIMIT SWITCH HE = HEATER ELEMENT
CONTROL CIRCUIT WIRING TO BE 24 VOLT, N.E.C. CLASS 2
10
(OPT.) (OPT.) (OPT.)
POWER (FACTORY WIRED) POWER (FIELD WIRED) CONTROL (FACTORY WIRED) CONTROL (FIELD WIRED)
PLUG PIN LOCATION
AMP 350781-1 6-PIN CAP
1
2
3
4
5
6
Wiring Diagram - Blower WIRING DIAGRAM: BLOWER DIAGRAM
5 4
6
**
TD = TIME DELAY (OPT.) GND
OPTIONAL TIME DELAY
4
TR = TRANSFORMER
18 BLK
18 WHT
18 BLU
14 RED
14 YEL L2
MTR = BLOWER MOTOR
TD
H
CAP = MOTOR CAPACITOR
H
18 GRN
W2 18 WHT
24V
18 RED
208V 240V
TR
W1
18 BLU
C
18 BLU
WHT
C
18 GRN
18 BLU
BLK
BLU
G
18 RED
GRN
R
18 RED 18 GRN
18 BLU
1 3
TO THERMOSTAT BY OTHERS
R
COM
18 BLU
DS = DOOR SWITCH (OPTIONAL)
FROM TRANS
GND = GROUND CONNECTION
18 BLK
DS
6
5
4
2
RED WIRING DIAGRAM: NO HEAT
14 BLK
** 1
3
GND
WIRE NUTS BY OTHERS
5
RED
3
14 YEL(COM)
MTR
BLK
2
YEL
1
L2 OR
BRN CAP
WHT (IF 120V)
1
NEUT.
15 AMP SUPPLY VOLTAGE
14 RED(LO) 14 BLK(HI)
14 GRN
2 BR
BRN/WHT
14 YEL(240V)
4
L1
BLU
4
14 WHT(120V)
14 BLU(MED)
14 BLK
6
2
6-PIN PLUG
TO BLOWER GROUND LUG
WIRING DIAGRAM: HOT WATER WITH BLOWER DELAY SEQUENCER, W/REMOTE PUMP WIRE NUTS
120/240 VOLT
SEQ
BY OTHERS 3
1
5
4
L1 14 BLK
14 BLK
SPLICE
14 YEL (240 V)
L2 OR NEUT.
AQUASTAT SUPPLIED BY OTHERS IF REQUIRED
14 WHT (120 V)
15 AMP SUPPLY VOLTAGE TO REMOTE PUMP OR PUMP RELAY BY OTHERS 10 AMPS AT 120 VOLTS OR 240 VOLTS AC. USE 14 AWG MIN. WIRE PER NEC AND LOCAL CODES.
18 WHT
18 BLU
GND.
14 RED
14 YEL
14 BLK
BY OTHERS
14 GRN
14 BLK L1
BR = BLOWER RELAY
120V OR 220V
FROM TRANS.
3
18 BLU
1 2
6-PIN PLUG
TO BLOWER 1
2
GROUND LUG
3
4
GND = GROUND SEQ = SEQUENCER
5
11
Check Airflow
Complete Installation NOTE: Refer to outdoor unit installation instructions for system start-up instructions and refrigerant charging instructions.
Cooling blower speed ■
For proper cooling operation, the airflow through the indoor coil should be between 350 – 450 CFM per ton of cooling capacity (or 350 -450 CFM per 12,000 BTU/HR) based on the rating of the outdoor unit.
■
The cooling blower speed is factory configured to provide correct airflow for an outdoor unit that matches the maximum cooling capacity rating of the air handler.
■
If the outdoor unit is smaller than the maximum cooling capacity rating for the air handler, the cooling blower speed may need to be changed. Refer to “Blower Performance Chart.”
Pre-Start Check ■
Is unit properly located, level, secure, and serviceable?
■
Has an auxiliary pan been provided under the unit with separate drain for units installed above a finished ceiling or in any installation where condensate overflow could cause damage?
■
Have all webs been carefully removed from the drain connections that are being used? Have all drain pan plugs not used been properly plugged?
■
Has the condensate line been properly sized, run, trapped, pitched, and tested?
■
Is the duct work correctly sized, run, taped, and insulated?
■
Have all cabinet openings and wiring been sealed?
■
Is the indoor coil orifice size correct?
■
Have all unused orifice replacement parts and packaging been disposed of?
■
Is the filter clean, in place, and of adequate size?
■
Is the wiring neat, correct, and in accordance with the wiring diagram?
■
Is the unit properly grounded and protected (fused)?
■
Is the thermostat correctly wired and in a good location?
■
Are all access panels in place and secure?
Check Blower Operation
IMPORTANT: The cooling blower speed must be set to provide a minimum of 350 CFM airflow per ton (12,000 BTU/HR) of outdoor cooling capacity.
Heating blower speed (If Electric Heat or Hydronic Heat is installed) ■
The heating blower speed is factory configured for the same setting as the cooling blower speed.
■
It may be necessary to change the heating blower speed to obtain optimum comfort and performance.
WARNING
Electrical Shock Hazard Disconnect all power supplies before servicing.
1. Set thermostat to FAN ON. 2. The indoor blower should come on.
Replace all parts and panels before operating. Failure to do so can result in death or electrical shock.
Check Electric Heater (if used) 1. Set thermostat to call for auxiliary heat (approximately 5°F above ambient temperature).The indoor blower and auxiliary heat should come on together. Allow a minimum of 3 minutes for all sequencers to cycle on. 2. Set the thermostat so it does not call for heat. Allow up to 5 minutes for all sequencers to cycle off.
Check Hydronic Coil Heat (if used) 1. Set thermostat to call for heat (approximately 5°F above ambient temperature). The hydronic heat pump or valve will come on followed by the indoor blower. 2. Set the thermostat so it does not call for heat. Allow up to 5 minutes for the pump or valve and the blower to cycle off.
To change cooling blower speed: (Refer to “Wiring Diagram - Blower”) 1. Disconnect all power supplies. 2. Remove the control compartment access panel. 3. Remove the factory installed motor lead (Blue or Red) from pin #2 on the blower relay. 4. Remove the insulator from the desired motor speed tap. 5. Install the new motor speed tap onto pin #2 of the motor relay. 6. Install the insulator you removed unto the unused motor speed tap. 7. Replace all panels.
To change heating blower speed: (Refer to “Wiring Diagram – Blower”) 1. Disconnect all power supplies. 2. Remove the control compartment access panel. 3. Remove and discard the black jumper wire between pin #2 and pin #5 of the blower relay. 4. Remove and discard the insulator from the desired motor speed tap. 5. Install the new motor speed tap onto pin #5 of the motor relay. 6. Replace all panels.
12
Blower Performance Chart External Static Pressure in W.C. Air Handler Model
24
36
42
48
60
With Electric Heat
Blower Speed
With Hydronic Coil
.10
.20
.30
.40
.50
.10
.20
.30
.40
.50
Low (Red)
664
641
623
605
574
638
602
564
551
538
Medium (Blue)*
906
855
802
783
764
816
769
721
705
688
High (Black)
940
927
914
884
854
846
834
823
796
769
Low (Red)
1226
1156
1086
1061
1036
1092
1030
928
907
886
Medium (Blue)*
1465
1382
1245
1217
1188
1319
1244
1121
1096
1070
High (Black)
1467
1447
1427
1381
1334
1320
1302
1284
1243
1201
Low (Red)
1410
1329
1248
1219
1189
1287
1214
1137
1112
1086
Medium (Blue)*
1726
1628
1526
1491
1456
1554
1466
1374
1343
1312
High (Black)
1733
1709
1685
1630
1574
1560
1538
1517
1467
1417
Low (Red)*
1745
1645
1545
1509
1473
1570
1481
1381
1358
1326
Medium (Blue)
2107
2078
2048
1981
1913
1896
1870
1844
1783
1722
High (Black)
2163
2133
2103
2034
1964
1947
1920
1893
1831
1768
Low (Red)
1745
1645
1545
1509
1473
1570
1481
1381
1358
1326
Medium (Blue)*
2107
2078
2048
1981
1913
1896
1870
1844
1783
1722
High (Black)
2163
2133
2103
2034
1964
1947
1920
1893
1831
1768
* Factory setting for both heating and cooling. All data given while air handler is operating with a wet DX coil and air filter installed. When no heat accessory is installed, use the airflow from Electric Heat section.
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SEQUENCE OF OPERATION Cooling (cooling only or heat pump) When the thermostat calls for cooling, the circuit between R and G is completed, and the blower relay is energized. The Normally Open contacts close, causing the indoor blower motor to operate. The circuit between R and Y is also completed; this circuit closes the contactor in the outdoor unit starting the compressor and outdoor fan motor. Circuit R and O energizes the reversing valve, switching it to the cooling position. (The reversing valve remains energized as long as selector switch is in the COOL position.) Heating (electric heat only) When the thermostat calls for heat, the circuit between R and W is completed, and the heater sequencer is energized. A time delay follows before the heating elements and the indoor blower motor come on. Units with a second heat sequencer can be connected with the first sequencer to W on the thermostat subbase or connected to a second stage on the sub-base. Heating (heat pump) When the thermostat calls for heat, the circuits between R and Y and R and G are completed. Circuit R-Y energizes the contactor starting the outdoor fan motor and the compressor. Circuit R and G energizes the blower relay starting the indoor blower motor. If the room temperature should continue to fall, the circuit between R and W 1 is completed by the second stage heat room thermostat. Circuit R-W 1 energizes a heat sequencer. The completed circuit will energize supplemental electric heat (if applicable). Units with a second heater sequencer can be connected with the first sequencer to W 1 on the thermostat or connected to a second heating stage W 2 on the thermostat subbase. Emergency Heat (heating heat pump) If selector switch on thermostat is set to the emergency heat position, the heat pump will be locked out of the heating circuit, and all heating will be electric heat (if applicable). A jumper should be placed between W 2 and E on the thermostat subbase so that the electric heat control will transfer to the first stage heat on the thermostat. This will allow the indoor blower to cycle on and off with the electric heat when the fan switch is in the AUTO position. Heating (hydronic heat) When the thermostat calls for heat, the circuit between R and W is completed, and the heater sequencer is energized. The external circulating pump or control valve to supply hot water to the hydronic coil comes on, then a second set of contacts close which are used to bring on the indoor blower.
AIR HANDLER MAINTENANCE IMPORTANT: Do not operate system without a filter. A filter is required to protect the coil, blower, and internal parts from excessive dirt and dust. See “Installation Configurations” for the location of the filter in the unit cabinet and the service panel giving access to unit filter. The filter is placed in the supply air return duct by the installer. ■ Inspect air filters at least once a month and replace or clean as required. Dirty filters are the most common cause of inadequate heating or cooling performance. ■
Replace disposable filters. Cleanable filters can be cleaned by soaking in mild detergent and rinsing with cold water.
■
Install new/clean filters with the arrows on the side pointing in the direction of airflow.
■
Never replace a cleanable (high velocity) filter with a disposable (low velocity) filter unless return air system is properly sized for it.
■
If water should start coming from the auxiliary drain line, a problem exists which should be investigated and corrected. Contact a qualified person.
ASSISTANCE OR SERVICE If you need further assistance, you can write to the below address with any questions or concerns: Whirlpool® Home Cooling and Heating 7901 S.W. 6th Court Plantation, Florida 33324 Please include a daytime phone number in your correspondence.
Accessories To order accessories ask for the appropriate part number listed below or contact your Whirlpool® Home Cooling and Heating dealer. ADKT2-3 ADKT3-3 ADKTM-2 ADKTL-2
Downflow Adapter Model WM024 Downflow Adapter Model WM036 Downflow Adapter Model WM042 Downflow Adapter Model WM048, WM060
Electric Heat Kits and Hydronic Heater Coil Accessories Refer to the Accessory Kit Label on the front panel of the air handler for electric heat kit and hydronic heater coil accessory options and applications.
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Keep this book and your sales slip together for future reference. You must provide proof of purchase or installation date for in-warranty service. Write down the following information about your furnace to better help you obtain assistance or service if you ever need it. You will need to know the complete model and serial number. You can find this information on the front panel.
Dealer name____________________________________________________ Address ________________________________________________________ Phone number __________________________________________________ Model number __________________________________________________ Serial number __________________________________________________ Installation date ________________________________________________
065682400 © 2003. All rights reserved.
®/TM Whirlpool and all other trademarks are owned by Whirlpool, U.S.A., used under license by Tradewinds Distributing Company, LLC.
2/03 Printed in U.S.A.
