Installation & Operation Manual Air Handler Models: 13 SEER 2 Ton HB2400VD1M20 HB2400VD1V20 WARNING WHEN THIS APPLIANCE IS INSTALLED IN AN ENCLOSED AREA, SUCH AS A GARAGE OR UTILITY ROOM, WITH ANY CARBON MONOXIDE PRODUCING DEVICES (i.e. AUTOMOBILE, SPACE HEATER, WATER HEATER,ETC.) INSURE THAT THE ENCLOSED AREA IS PROPERLY VENTILATED. WARNING CARBON MONOXIDE (REFERED TO AS CO) CAN CAUSE PERSONAL INJURY OR DEATH WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS, LOCAL CODES OR NATIONAL CODES MAY CAUSE FIRE, EXPLOSION, ELECTRICAL SHOCK, PERSONAL INJURY OR PROPERTY DAMAGE. FOLLOW ALL LOCAL CODES. IN THE ABSENCE OF LOCAL CODES REFER TO : NATIONAL ELECTRICAL CODE NFPA 70 NFPA 90A & 90B UNIFORM MECHANICAL CODE READ THESE INSTRUCTIONS COMPLETELY BEFORE ATTEMPTING TO INSTALL OR SERVICE THIS APPLIANCE. ONLY FACTORY AUTHORIZED KITS OR ACCESSORIES SHOULD BE USED WHEN INSTALLING OR MODIFYING THIS APPLIANCE, UNLESS OTHERWISE NOTED IN THESE INSTRUCTIONS. SOME LOCALITIES MAY REQUIRE THE INSTALLER/SERVICER TO BE LICENSED. IF IN DOUBT CONTACT YOUR LOCAL AUTHORITIES. These instructions should be retained and kept adjacent to the unit for future reference. MODEL # HB 00VD1M20 MODEL # HB 00VD1V20 INSTALLATION DATE The information contained in this booklet is subject to change without notice. No. 0010572323 F INDEX TOPIC General Physical dimensions Replacement Parts Source Installation Requirements Air Flow Orientation Horizontal Left-Hand Instructions Refrigerant Tubing Condensate Removal Electrical Connections Thermostat Wiring Orifice Change Circulating Air Duct Blower Performance Start-up Regular Maintenance Model Number Explanation PAGE 2 3 4 4 5 6 7 8 8 9 10 12 12 13 13 14 The United States Environmental Protection Agency (EPA) has issued various regulations regarding the introduction and disposal of refrigerants introduced into this unit.Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines. These regulations may vary due to the passage of new laws, it is recommended that any work on this unit be done so by a certified technician. Should questions arise contact the local EPA office. THIS APPLIANCE IS NOT APPROVED FOR OUTDOOR INSTALLATION THIS APPLIANCE IS NOT TO BE USED AS A CONSTRUCTION HEATER GENERAL This appliance was designed certified and must be installed in accordance with published codes.In the absence of local codes please refer to the following codes: NFPA 90A NFPA 90B National Electrical Code NFPA 70 Uniform Mechanical Code Prior to shipment, this appliance was tested and inspected for damage at the factory.Unpack carefully and if damage is found, report it immediately to the transportation company. This appliance is approved for installation in alcoves, basements, attics or crawlway, and is designed for connection to air distribution ductwork. 2 PHYSICAL DIMENSIONS D 1" [2.54 cm] C PLASTIC BREAKER COVER E B 11" [29 cm] SUCTION LINE 3.3" [8.3 cm] PRIMARY & SECONDARY CONDENSATE DRAINSHORIZONTAL 3/4" NPT LIQUID LINE 2" [5.1 cm] F K G 1.1" [2.9 cm] 2" [5.1 cm] TYPICAL A 2.4" [ 6 cm] 1.2" [3 cm] H INLET FRONT VIEW 5" [12.7 cm] 1" [2.54 cm] J INLET RIGHT SIDE VIEW PRIMARY & SECONDARY CONDENSATE DRAINSUPFLOW 3/4" NPT-FEMALE A B C D E F G H J K 46.7 22 18.3 19.7 10 14.5 11.9 17.1 19.8 3.4 [118.7cm] [55.9cm] [46.4cm] [50.0cm] [25.4cm] [36.8cm] [30.3cm] [43.5cm] [50.3cm] [8.6cm] 3 REPLACEMENT PARTS SOURCE Replacement parts are available through local distributors.When ordering replacement parts, give the COMPLETE model and serial numbers shown on the rating plate. INSTALLATION REQUIREMENTS Before installing this appliance insure that it is properly sized and adequate power is available. This appliance can be installed in the vertical or right horizontal position without modification. The horizontal left and downflow positions require product modification. This product is designed for zero inch (0") clearance; however, adequate access for service or replacement must be considered without removing permanent structure. This unit can be installed on a platform when deemed necessary. In an attic installation a secondary drain pan must be provided by the installer and placed under the entire unit with a separate drain line properly sloped and terminated in an area visible to the owner. This secondary drain pan is required in the event that there is a leak or main drain blockage. Closed cell insulation should be applied to the drain lines in unconditioned spaces where sweating may occur. Appliances installed in garages, ware houses or other areas where they may be subjected to mechanical damage must be suitably guarded against such damage by installing behind protective barriers, being elevated or located out of the normal path of vehicles. When installed on a base, the base must also be protected by similar means. Heating and cooling equipment located in garages, which may generate a glow, spark or flame capable of igniting flammable vapors, must be installed with the ignition source at least 18" above the floor level. When more than one appliance is installed in a building, permanently identify the unit as to the area or space serviced by that applice. 4 AIR FLOW ORIENTATION *Horizontal Right Discharge Tube and Drain conn. front Horizontal Left Discharge Tube and Drain conn. front (see page 6) Important: Remove the horizontal pan when unit is installed in unconditioned i.e. (Garage, Attic ) application, or downflow applications, and install insulation kit on vertical ( donut shape ) drain pan. *Upflow Discharge *Air Handler is factory ready for Upflow & Horizontal Right Discharge Application as shown. 5 HORIZONTAL LEFT-HAND INSTRUCTIONS Important: Read instructions below carefully. Plastic Drain cover oval gasket Fig.1 WARNING: If incorrect knockouts are removed, flooding will occur. 5) Reinstall in the Airhandler, the "A" coil pan assembly with the horizontal drain pan on the left-hand side. Note: Push the assembly completely to the rear of the cavity and assure it slips into channel bracket at the rear of the cavity. 6) Replace the J-shape metal bracket or brackets on the vertical drain pan and place the plastic oval gasket on horizontal drain pan. Reinstall access panels and flowrator making sure not to over torque screws. Snap in the drain cover on the right lower service panel. 7) The Airhandler can now be placed in its left horizontal position as shown in Fig.2. The Airhandler must be leveled and then pitched 1/4" toward drain side. Important: Drain pan must be tested for proper drainage by pouring water into the pan. Traps must be installed on the primary drain and on the secondary drain if used. 8) In all cooling applications, a secondary drain pan must be provided by the installer and placed under the entire unit with a separate drain line properly sloped and terminated in an area visible to the user. 9) WARNING: The "A" coil contains 150 p.s.i.g. of air pressure. Before setting up flowrator assembly for field brazing see page 12 or read the Warning label on the lower access panel. 10) Failure to follow this installation requirements will cancel product warranty. Air flow Secondary Knockout Primary Knockout Fig.2 6 REFRIGERANT TUBING Refrigerant tubing should be installed as to avoid undue stress. They must be supported or routed to avoid strain or vibration. To avoid damage that can be caused by condensate, insulate the suction tube with a closed cell insulation with the seams sealed. The insulation should terminate at the tubing entrance to the air handler. Do not reduce the recommended tubing size. CONDENSATE REMOVAL THIS APPLIANCE EMPLOYS A DRAW-THROUGH COIL, THEREFORE A TRAP MUST BE INSTALLED IN THE DRAIN LINE(S) TO ALLOW FOR PROPER CONDENSATE DISPOSAL. The condensate trap must not be the "running" type, or "R" type. A "P " trap is required. The total workable height of this trap, in inches, must exceed the total negative pressure, in inches of water, as measured in the return duct. DRAIN CONNECTION UNIT 2" MINIMUM FLEXIBLE TUBING-HOSE OR PIPE A POSITIVE LIQUID SEAL IS REQUIRED 3" MINIMUM The condensate drain line must be at least 3/4 NPT, for each unit. Precautions must be used not to over tighten the adapter at the drain pan connection, this precaution will prevent damage to the plastic drain pan. A joint compound should be used to prevent leakage and act as a lubricant. When using copper tubing as a condensate line adequate caution muat be taken to prevent damage to the plastic drain pan during the soldering process. All condensate drain lines and drain traps should be adequately insulated. The unit and the auxiliary drain pan must be adequately elevated to insure proper drainage. Use of a condensate removal pump is permitted when necessary.This condensate pump should have provisions for shutting off the control voltage should a blocked drain occur. A trap must be installed between the unit and the condensate pump. Important: The evaporator coil is coated with oils that will dissolve Styrofoam and certain types of plastics. Therefore a removal pump or float switch must not contain any of these materials. NOTE: AFTER INSTALLATION AND POSITIONING THE UNIT , THE DRAIN PAN BEING USED SHOULD BE TESTED BY FILLING IT WITH WATER TO ENSURE PROPER DRAINAGE AND CHECK FOR LEAKS. 7 ELECTRICAL CONNECTIONS The required electrical power supply information is located on the series and rating plate on the exterior of the unit. Wiring selection must be in accordance with local codes, or in absence of local code, the National Electrical Code. A disconnect means should be installed within sight of the unit, when required by code. Copper wire is recommended for all electrical connections. When an optional heat kit is installed refer to the electrical requirements in that kit. The wiring diagram included in the heat kit must be placed over the wiring diagram on the air handler. All pertinent information, such as the rating plate, included in the optional heat kit must be applied to the Air Handler as indicated. The use of copper connections are recommended inside the control box (see UL 1995, section 37.9). Model No. Min. Blower Max. running Over-current Motor Ampacity 208/230 FLA 208/230 15/15 15/15 0.9 0.9 Blower Motor H.P. 1/8 1/8 HB2400VD1M20 -------HB2400VD1V20 -------- WARNING A MEANS OF STRAIN RELIEF MUST BE INSTALLED TO THIS APPLIANCE AT THE ELECTRICAL SERVICE ENTRANCE. When an optional electric heat kit is installed refer to the electrical requirements for that kit. The ampacity and overcurrent protection shown above is only for "HB" air handlers installed without a heat kit. 8 THERMOSTAT WIRING For Thermostat Control Environment-temperature and Air Conditioning open/stop, the wiring diagram as shown diagram 1. Thermostat can be mechanical type or programmable type. Note: Thermostat C : COM. TERMOSTAT R : AC24V C O Y G R Y : COMPRESSOR G : FAN O : 4 -WAY VALUE TO INDOOR For detailed Thermostat, please connect FAN RELAY OR YL RD BL CONTROL corresponding terminal according to above BL 24V COM control specification. O YCR TO OUTDOOR UNIT R,C,Y,O TRANSFORMER For Thermostat only control Air Conditioning open/stop, hot control Environment temperature, can adopt different power switch show diagram 2. This mode is control the indoor unit & heat pump outdoor unit at the same time no air supply mode. If need select the air supply mode, switch can adopt multi-connect switch or select switch. The detailed infor see the following diagram 3. Above diagram: Outdoor Unit Connection Left: Indoor and Outdoor unit power supply Respectively Right: Indoor unit power supply. Diagram 1 RUN SWITCH MODE SWITCH Open for heating Close for cooling TO INDOOR FAN RELAY CONTROL RD BL RD BL COM 24V O YCR TO OUTDOOR UNIT R,C,Y,O Diagram 2 TRANSFORMER 1 2 3 4 5 6 OFF FAN ONLY E. HEAT HEAT PUMP COOLING SELECT SWITCH TO FAN RELAY CONTROL YL BL OY C R TO OUTDOOR UNIT R,C,Y,O RD 24V BL COM TRANSFORMER Diagram 3 9 For Thermostat Control Environment-temperature and Air Conditioning open/stop, the wiring diagram as shown diagram 4. Thermostat can be mechanical type or programmable type. Note: Thermostat C: COM. TERMOSTAT R : AC24V C Y G R Y : COMPRESSOR G : FAN TO FAN For detailed Thermostat, please connect RELAY RD RD corresponding terminal according to above BL CONTROL BL control specification. 24V CY TO OUTDOOR UNIT C,Y Diagram 4 SWITCH COM TRANSFORMER For Thermostat only control Air Conditioning open/stop, hot control Environment temperature, can adopt different power switch show diagram 5. This mode is control the indoor unit & cooling only outdoor unit at the same time no air supply mode. If need select the air supply mode, switch can adopt multi-connect switch or select switch. The detailed infor see the following diagram 6. Above diagram: Outdoor Unit Connection Left: Indoor and Outdoor unit power supply Respectively Right: Indoor unit power supply. TO FAN RELAY CONTROL BL RD RD B ...