air handle
TRANSCRIPT
MANUFACTUREDWITH
AIRCOM ELECTRONICS
Operation, Sizing and Installation Manual
* LEAVE FOR HOMEOWNERNOTE: Due to ongoing research and product development, specifications,
ratings and dimensions are subject to change without notice.
69-AH0910
Installing Contractor
Telephone / Contact
Serial Number
Installation Date Model
TO BE COMPLETED BY CONTRACTOR AFTER INSTALLATION
AIR HANDLER
Models
AH-U-S4A-24-P16 (E16)AH-U-L4A-36-P16 (E16)AH-U-S2A-30-P16 (E16)AH-U-L2A-36-P16 (E16)AH-U-L2B-48-P16 (E16)
2
Introduction.......................................................................3
Overview of the AH..........................................................3
Description and Purpose ..................................................4
Operation Heating/Cooling...............................................4
Combo System Basic Principles .......................................5
Plumbing......................................................................6-11
Installation ......................................................................12
Function and Controls ...............................................13-14
Aircom Relays ................................................................15
Start-Up Procedure .........................................................15
Troubleshooting ..............................................................16
Model Number Nomenclature Breakdown.....................17
Specifications ............................................................18-22
Work Sheets...............................................................23-28
Wiring Diagrams .......................................................29-30
Table of Contents
Air Condition coil freezing can damage thehydronic coil of the Air Handler.Install a Freeze Thermostat Kit to your airconditioning coil to prevent coil freeze up. Checkwith your air conditioner distributor to obtain aFreeze Thermostat Kit.
ATTENTION
The Air Handler hydronic coil is not to be used forchilled water applications where condensation isexpected.
ATTENTION
3
You will notice that the heated air in your home feels morecomfortable than air heated by a conventional furnace. Onereason for this is that LIFEBREATH's hydronically heatedair is uniform and temperate... no short blasts of hot air orhot and cold temperature spikes. In this regard, the air flow-ing from your hot air vents will not feel as hot to the touchas air from a conventional furnace.With a high efficiency, adequately sized natural gas,propane or oil hot water heater/boiler, you will always haveplenty of hot water for showers and baths, washing dishesand clothes, and all other normal domestic hot water needs.If there is an unusually high demand for hot water, such asfilling a large hot tub, than all you need to do is allow moretime for the task so the water heater/boiler can keep up toits job of providing hot water for the heating system as wellas other household uses.
Once it is correctly installed, safety will never be an issuewith your LIFEBREATH air handler. No flames, fumes orflue gases to be concerned about. Your domestic hot waterheater/boiler now provides the heat source for your furnace.This Operating and Installation Guide will help you learnabout your LIFEBREATH Air Handler quickly and easily.The table of contents will show you where to find informa-tion on every feature of this unit along with easy tounderstand operating instructions. If, however, you doencounter a question that is not covered in this Guide youshould call the LIFEBREATH dealer who installed yourfurnace. Chances are that he will be able to give you a satis-factory answer but if he is unable to do so then we inviteyou to contact us directly.
Airia Brands Inc.
Introduction
Overview of the Air Handler
Hydronic Coiland PumpCompartment
AircomElectronicsand FanCompartment
4
IMPORTANT NOTEThe purpose of this manual is to act as an installation guideonly for the LIFEBREATH Air Handler. Manufacturers'instructions for other components, such as the water-heater/boiler, must be followed.All national and local code requirements must be met wheninstalling a LIFEBREATH Air Handler. Be sure to consultthe proper authorities.�ote: Temperatures greater than 130°F (54°C) pose a seri-
ous risk of scalding individuals running domestichot water for potable use.
This appliance complies with IAS Canada Inc. RequirementCR95-003, Additional Requirements for Fan Coil Units foruse with Potable Water Heaters.All piping and components connected to this appliance shallbe suitable for use with potable water.Toxic chemicals, such as used for boiler treatment, shall notbe introduced into the potable water heater system.When using this system, and water for space heating is
required to be at a higher temperature than for other uses, ananti-scald valve shall be used to ensure water for other usesis reduced in temperature to minimize a scald hazard poten-tial.Combining two or more end uses such as space heating andthe heating of domestic hot water in a single system has thepotential to increase efficiency and reduce overall capitalcosts. However, the proper design, installation, and com-missioning of these systems are critical if these advantagesare to be realized.This manual provides a guideline of good engineering prac-tice in the design, installation and commissioning ofIntegrated Combo Systems. The guidelines in the manualare designed for residential forced warm air IntegratedCombo Systems which utilize domestic water heaters orboilers and the LIFEBREATH furnace. Heating and coolingloads shall be calculated in accordance with recognizedResidential Heat Loss and Heat Gain Calculation methods.Duct design shall comply with recognized Residential AirSystem Design methods.
Description and Purpose
Operation Heating/Cooling
When the room thermostat calls for heat, it activates a cir-culation pump located inside the Air Handler. This pumpdelivers hot water from the water heater, through the fur-nace coil and back to the water tank. Simultaneously, thefurnace blower switches on to high speed and will start cir-culating air across the coil, which picks up heat and deliversit to the rest of your home.Once the thermostat's temperature is reached the pump willshut off, and the blower will return to its pre-set speed oroff.�ote: When the furnace blower is left running on lowspeed the air in the home circulates continuously. Whenthe heat is called for the blower will automatically switchto a higher speed. After the required hot air has beendelivered the blower will switch back to low speed.
When the thermostat calls for cooling (evaporator coil andcondensing unit required), the furnace blower activates tohigh speed and the outdoor condenser unit is energized.After the thermostat temperature is reached, the condensingunit will shut off and the blower will return to its presetspeed or off.
Off Season Circulation TimerAll models are equipped with a circulation timer. It is nor-mal operation for these models to automatically run thecirculation pump for a short period of time intermittently.
Closed Loop SystemA system becomes closed when a Check Valve or a back-flow prevention valve is installed in the cold water pipingupstream of the water heater.A check valve will prevent water being relieved into thecold water system due to pressure created whenwater is heated in the water heater.
5
WATER HEATER
DOMESTIC HOT WATER
SUPPLY AIR
BLOWER
HEATING COIL
CHECKVALVE
RETURN AIR
COLD WATER INLET
ANTI-SCALD VALVE (WHEN REQUIRED)
VALVE (shut off)
VALVE (shut off)
VALVE (shut off)
VALVE (balancing)
COOLING COIL (OPTIONAL)
DRAINVALVE
EXPANSION TANK OR OTHER MEANS
(WHEN REQUIRED)
CHECKVALVE
Combo System Basic Principles
Open and Closed SystemsOpen and Closed systems both deliver hot water and spaceheating.Water systems that incorporate a pressure tank (i.e. wellsystems) are normally Open Systems and most municipalwater systems are Closed Systems.
Drain ValveA drain valve is required to allow the heating loop to bedrained for service or repair and to remove air from theheating loop when commissioning a system. The drainvalve should be near the low point of the return piping sys-tem to be near the water heater. Ball, Globe or Gate Valvesare suitable for drain valves.
Check valves should always be installed in a vertical rise with the flow of water shown.
ATTENTION IMPORTANT
Refer to local codes, local bylaws and installationmanuals supplied with water heater before startingany installation work.
This Check Valveminimizes Thermo-Siphoning. ThermoSiphoning is the coldwater backflowingthrough the heatingloop when domestichot water is calledfor.
ConventionalCooling Coil(Not availablethrough Airia)
6
Plumbing
In order to improve serviceability of our products, thecheck valve is included with our manual kit for field instal-lation between the air-handler and hot water source.The check valve should be installed in a vertical run ofpipe with the flow of water in an upward direction.An arrow on the check valve indicates its correct orienta-tion and must match the direction of water flow.This will allow for ease of service to remove any installa-tion debris or service required due to extended hard waterconditions.
Note: Take care during soldering to avoid debris orsolder from lodging in the check valve.Note: It is critical to follow the piping configurationshown. Maintain a minimum distance of 12” abovethe CAF/AH. This will minimize thermal siphoning inthe combo system.
* It should be noted that problems have been observed when using the sidetappings on certain water heaters; therefore, it is strongly recommended to use the topwater tappings as indicated in Figure 1 to minimize thermal siphoning and relatedissues.
WaterHeater
CheckValve
ToHouse
CAForAH
Min. 12" (305 mm) above top of
CAF / AH12"
WaterHeater
CAForAH
CheckValve
Min. 12" (305 mm)above top of
CAF / AH
ToHouse
12"
Figure 1
Figure 2
7
Expansion TanksExpansion tanks are required in addition to a Check Valvefor Closed Systems because pressure is created when wateris heated in the water heater.The expansion tank has an air bladder which will contract torelieve pressure in the system. The tank should always beconnected to the cold water piping between the water heatershut off valve and the cold water inlet to the water heater.
Anti-Scald ValveAn anti-scald valve is required when the water heater ther-mostat is set above 140°F (60°C). Also, an anti-scald valvemay be required for all installations by the “authority hav-ing jurisdiction”. The valve is placed in the hot water supplypiping from the water heater downstream of the heatingloop connection and upstream of any domestic hot waterconnection.The purpose of the valve is to limit the maximum tempera-ture available for domestic hot water by mixing hot waterfrom the water heater with cold water from the municipalsupply.The Anti-Scald valve must be thermostatically controlledand approved to the ASSE standard No. 1016 and 1017 foruse as an anti-scald device.
Plumbing
WATER HEATER
DOMESTIC HOT WATER
SUPPLY AIR
BLOWER
HEATING COIL
CHECKVALVE
RETURN AIR
COLD WATER INLET
ANTI-SCALD VALVE (WHEN REQUIRED)
VALVE (shut off)
VALVE (shut off)
VALVE (shut off)
VALVE (balancing)
COOLING COIL(OPTIONAL)
DRAINVALVE
EXPANSION TANK OR OTHER MEANS
(WHEN REQUIRED)
CHECKVALVE
Closed Loop System
Time to Scald(1st degree burns)
Temperature Time
120°F (49°C) 8 min.
130°F (54°C) 20 sec.
140°F (60°C) 3 sec.
160°F (71°C) <1 sec.
ConventionalCooling Coil(Not availablethrough Airia)
Valves(a) Located on the cold water side of the Heater.
This valve has the ability to isolate the hot water(domestic and space heating) from the household coldwater supply. Every water heater requires this valveregardless of space heating use.
(b) Located on the hot water supply side of the heatingloop, downstream of its connection to the domesticwater.
(c) Located on the return side of the heating loop upstreamof its connection to the domestic cold water.
8
(a)
H C
(b)
(c)
Supply
Return
Plumbing
Ball Valve
The Ball Valve can be used as a shut off or drain valve.When in the open position, a full bore ball valve has verylittle resistance to flow, and these valves tend to be both theleast expensive and the least susceptible to seizing overtime. Do not use reduced bore ball valves as they are veryrestrictive to water flow.
Gate Valve
The Gate Valve can be used as a shut off or drain valve.When in the open position, there is very little resistance toflow. Gate valves tend to be less expensive than other typesof valves but are susceptible to chatter (noise) and malfunc-tion with age.
Globe Valve
The Globe valve can be used as a shut off, drain or throt-tling valve. Even in the open position, the valve is fairlyrestrictive to flow. It has a much greater equivalent length(resistance.) than the other types of valves.
Balancing (Throttling) Valve
The Balancing (Throttling) Valve is used to reduce thewater flow rate and thereby increase the water temperaturedrop. This is done to ensure proper activation of the waterheater thermostat.A Globe Valve could also be used for Balancing (Throttling)but has more resistance than the Balancing Valve.
These twovalves isolatethe heatingloop forservice orrepair.
9
Call for Space HeatingThere are two thermostats controlling every combo system,the water heater thermostat (controlling the hot water tem-perature) and the room thermostat (controlling the room airtemperature).
When the room thermostat calls for heat, the circulationpump is activated. Hot water is then drawn from the top ofthe water heater through the air handler, and then returnedto the water heater.
Plumbing
WATER HEATER
DOMESTIC HOT WATER
SUPPLY AIR
BLOWER
CHECKVALVE
RETURN AIR
COLD WATER INLET
ANTI-SCALD VALVE (WHEN REQUIRED)
VALVE (shut off)
VALVE (shut off)
VALVE (shut off)
VALVE (balancing)
COOLING COIL(OPTIONAL)
DRAINVALVE
HEATING COIL
Open Loop System
HotWater Temperature DropThe water heater thermostat will initiate the water heater asrequired as long as there is a 20°F (11°C) temperature dropbetween the hot water supplied to the air handler and thereturning water.A temperature drop less than 20°F (11°C) can cause thewater heater thermostat not to initiate. This will result in alower hot water supply temperature or poor space heatingperformance with fluctuating domestic water temperatures.
Call for Domestic HotWater and Space HeatingWhen both return water from the space heating loop andnew cold water (replacing domestic water being used)enters the water heater, the mixed entering water is coolenough to activate the thermostat quickly. In this situation,the water heater must be capable of satisfying the combinedneed for domestic hot water and space heating at the sametime.
Plumbing components and systemconfiguration may vary from diagramsportrayed.
ATTENTIONChemicals (such as boiler systemadditives) cannot be added to a domestic hot water system.
ATTENTION
10
Plumbing
Air SystemA circulation fan draws cool house air at approx. 70°F(21°C) from the return ductwork, forces it through the watercoil where it is heated, and then distributes it to the variousrooms of the house through the supply ductwork.
Water System PressuresWithin the water system of an Integrated Combo system,there are three terms that the designer/installer must under-stand. These are:• Head pressure• Water flow rate• Pressure drop
Head PressureHead pressure is the pressure created by the circulationpump to push water through the piping system. It is thispressure which is used to overcome the resistance to waterflow (friction) caused by the water pipe and fittings. It issimilar in concept to the external static pressure in an airduct system. Head pressure is measured in feet of water(millimeters of water).
Water Flow RateWater flow rate is the amount of water flowing in the sys-tem. It is directly related to the head pressure and theresistance to flow. Flow rate is measured in gallons perminute (liters per minute).
The circulation pump is factory installed within the air han-dler. The water flow rate will vary depending on the pumpsperformance and the head pressure (resistance) of the com-plete heating loop system.The piping and fittings used to connect the water heater andair handler must be sized to handle the volume of hot waterrequired by the air handler within the pressure limitations ofthe circulation pump. All piping, fittings solders, and fluxesmust be acceptable for use with domestic hot water.
Pressure Drop (PD)Pressure drop (PD) is the reduction in total pressure causedby components added to a piping system such as coils,valves, and fittings. The measurement of pressure drop isthe difference in pressure on the inlet side of the componentand the outlet side. Pressure drop is measured in feet ofwater (millimeters of water).When connecting the water lines for heating loop (air han-dler) to the domestic water system, the pipes should beconnected with a “tee” to the side of a vertical domesticwater pipe or the bottom of a horizontal domestic waterpipe. This is to help prevent air from entering the heatingloop. The connections should be as near as practical to thewater heater.
Water Pump Performance Specifications
NOTE
The vertical height of the heating loop does notimpact on the head pressure as the pressurerequired to push the water up the vertical height isoffset by the weight of the water in the vertical dropon the other side of the heating loop.
16
14
12
10
8
6
4
2
0
Capacity on U.S. gpm
S2 and S4 Models
1 2 4 6 8 10 12
Tota
lHea
din
Fee
t
L2 and L4 Models
1 2 4 6 8 10 12 14 16 18 20
16
14
12
10
8
6
4
2
0
Capacity on U.S. gpm
Tota
lHea
din
Fee
t
11
Air Handler Output CapacityThere are four factors that will significantly affect the heat-ing output of the air handler.They are:• Hot water supply temperature (EWT)• Hot water flow rate (GPM)• Air Handler return air temperature• Air Handler air flow rate (CFM)HotWater Supply TemperatureThe hot water supply temperature is controlled by the waterheater thermostat. This is set by the installing contractor toprovide the required temperature at the hot water outlet ofthe water heater.The hot water supply temperature is typically 140°F (60°C).If this temperature must be increased to achieve higher out-puts from the furnace an anti-scald valve must be used toprevent domestic hot water temperatures above 140°F(60°C). The manufacturer of the Hot water Tank should beconsulted for temperatures higher than 140°F (60°C).It is important that a warning label be placed near the waterheater thermostat telling the homeowner not to change thethermostat setting. The label is included with the furnace.
HotWater Flow RateThe hot water entering the water coil is the source of heat tothe air handler. The effect of changing the amount of waterentering the coil is the same as changing the water tempera-ture. As water flow is reduced, the output of the air handlerand the air temperature rise will both be lowered.
Air Handler Return Air TemperatureThe return air temperature entering the air handler isapprox. 60°F (33°C) below the hot water inlet temperature.If the return air temperature entering the air handler isreduced, more heat transfer will occur and the output of theair handler will increase.
Air Handler Air Flow RateThe air entering the air handler can only be warmed by thetemperature difference between the hot water and the coolair. As the volume (CFM (L/s)) of air is reduced, the amountof heat which can be transferred is also reduced.
Air Handler Temperature RiseIn a fuel fired furnace, the combustion gases can be 1000°F(538°C) above the return air temperature. These units typi-cally have a temperature rise from 50°F (10°C) to 90°F(32°C) and therefore delivers air at the diffuser at 120°F(49°C) to 160°F (71°C).
With an Integrated Combo System, the hot water tempera-ture is approx. 130°F (54°C) which is 60°F (15.5°C) abovethe return air temperature. These units typically have a tem-perature rise of 35°F (2°C) to 40°F (4°C) and thereforewould deliver air at the diffuser at approximately 105°F(40.5°C) to 110°F (43°C).
RoomThermostatThe room thermostat controls both the watercirculation pump and the air circulation fan. It should be ona centrally located, inside wall away from any source ofheat such as diffusers, appliances and direct sunlight.
Energy Saving RoomThermostatA set back thermostat or “smart stat” can be used with acombo system, but care must be taken in the timing of thetemperature changes. The timing of morning warm upshould be early enough that the desired air temperature hasbeen reached before the people begin to use domestic hotwater. The highest demand for space heating is during themorning warm up and the highest demand for domestic hotwater is during morning showers. Even if the water heateris properly sized, it may not be able to meet this combinedload. Therefore, large set backs should be avoided.
Design vs. Field ConditionsThe factors discussed between design parameters and actualfield conditions can impact greatly on output capacity.Therefore, it is important to do a thorough and completecommissioning of the integrated combo system to ensurethe design parameters are met.
PipingThe hot water piping between the hot water tank and the AirHandler should be new copper type, and should not be treat-ed with chemicals, sealant or anything else, that willinterfere with the purity of the potable water. Only non-lead,low temperature solder is permitted for sealing copperjoints.Where possible the length of pipe should not exceed 200'total equivalent length. Any piping running through uncon-ditioned space must be insulated to prevent heat loss, andpossible freezing of the line.Look inside the furnace and locate the pump. Attach the"Hot Water In" (Supply) to the pipe running to the pump.Attach the "Hot Water Out" (Return) to the pipe running tothe coil. Do not reverse these lines, as this will cause theunit to malfunction.For piping conventional water heaters, connections to andfrom the Air Handler to the water tank should be made atthe point where the pipes leave the tank vertically. A "T" fit-ting used in each vertical line, with the Air Handler pipingconnected to the horizontal side of this fitting, will workbest in avoiding air locks in the circulation pump of the fur-nace.*�ote: Remove shipping block from underneath pump anddiscard.
Plumbing
NOTEAlthough the water in the combo system is pressurized bythe domestic water system the pump is required to createwater flow in the heating loop. The domestic water systemapplies the same pressure to the supply and return sidesof heating loop.
This manual gives the contractor guidelines for installingthe LIFEBREATH Air Handler. All national and localcodes relating to this type of equipment must be followed.
Locating The UnitThe Air Handler is designed to be installed vertically, in aconditioned space, where the surrounding temperaturedoes not fall below 50°F (10°C). Attic installations are notrecommended. Typically the unit is installed in a mechani-cal area of the basement, or other partitioned mechanicalroom, elsewhere in the home.A location close to an outside wall is recommended, as theventilation supply and exhaust portion will need to be duct-ed to the outside air. Sufficient clearance around the unit isrequired for service of the filter, heat recovery core andcomponents. As a rule this unit should be installed adjacentto the hot water heater. If this is not possible, or if the pip-ing layout is complex, the total head pressure on the pumpshould be calculated.
DuctingThe duct sizing for the furnace section can be determinedusing HRAI Residential Air System Design Manual,SMACNA, or any other industry-recognized manuals.�ote: "Combo units" normally deliver air at approx.110°F (43°C), and therefore may require larger than nor-mal ductwork. When installing the Air Handler as areplacement unit on a retrofit application, always calcu-late the size of duct that is there.Any ductwork running through unconditioned space mustbe sealed properly and insulated to prevent heat loss. Alllocal codes must be followed in determining the amount ofinsulation needed.
Duct ConnectionsPenetrations from sheet metal screws used to fasten theductwork to the cabinet of the unit should only be placedinto the duct flange provided. This is to avoid contact anddamage of the heating/air conditioning coils and internalwiring.
12
Installation
13
R W Y G
A/C Unit
Thermostat
To “Y”
To “C”
T30
SW1
T29T28REDOGYWRCT25
T17
K3 K4 K5
COM
N.O.
K6
COM
N.O.
COM
N.O.
COM
N.O.
T18 T19
T20
RELAYFEED
T43
SPARE
T26 T27 GRNYEL
P2 P3
R 24Vac12Vac Com Thermostat DETC
Defrost
Freeze
Fan Hi Fan Med Fan Low
ON
P1
C4 C3
K7 K1 K2K8
8 7 6 5 4 3 2 1
C2 C1
T31
T32
T33
T34
T35
T36
T37
T38
T39
T40
T41
T42
Contact 1
N.0. COM N.C. N.0. COM N.C. N.0. COM N.C. N.0 . COM
Contact 2 Contact 3 Contact 4
Digital Controls
DIP SWITCHES TO BEADJUSTED BY QUALIFIEDTECHNICIANS ONLY. N.C
SEUL UN TECHNICIENQUALIFIÉ PEUT AJUSTÉ LESCOMMUTATEURS DIP.
CHASSIST44
T21 T22 T23 T24
AUX 1 AUX 2
T3 T4 T5 T6
Line/Ligne
T1 T2 T13 T14 T15 T16
Neutral/NeutreT11 T12
2 AMPS
Standard 24 VoltThermostatConnection(Thermostats are not avail-able through Airia)
Thermostat Heat Anticipator SettingsMechanical Thermostats - start at .5 amp and may need tobe increased depending upon the residual heat left in thehydronic coil and duct work.Electronic Thermostats - to be set on electric style heat.
Off Season Circulation TimerWater is periodically circulated through the space heatingloop during the summer and other periods of infrequent use.The concern is that water which remains stationary in theheating loop during the summer may be less than desirableas domestic hot water when it is returned to the water heaterat system startup in the fall.
Basic FunctionsC - CommonR - 24 volt SupplyW - Medium or High Fan Relay with Circulation Pump
(The speed depends on Dip Switch # 6 setting)Y&G- Medium or High Fan Relay
(The speed depends on Dip Switch # 7 setting)G - Low Speed Fan RelayO - High Speed Fan Relay with Circulation Pump
Function and Controls Standard Motor
Standard Motor DIP Switch Settings(DIP #1-8 OFF is Factory Setting)
ON
87
65
43
21
DIP #2 to ON will disable theOff Season Circulation Timer
DIP #6 to ON will selectMedium Speed for heating(Factory setting is OFF for HighSpeed)
DIP #7 to ON will selectMedium Speed for coolingswitch (Factory setting is OFFfor High Speed)
Do not adjust any other DIP switches thanindicated above.
WARNING
Do not energize the Air Handler until theplumbing is connected and commissioned.Failure to do so will damage the pump.
WARNING
14
Switch Setting
Adjust Switches
Both OFF
5 0N - 6 OFF
5 OFF - 6 ON
5 ON - 6 ON
Heat
Normal
Increase 15%
Decrease 15%
Normal
Cool
Normal
Increase 15%
Decrease 15%
Normal
Fan Speeds
Switch Setting
Heat Switches
Both OFF
3 0N - 4 OFF
3 OFF - 4 ON
3 ON - 4 ON
Fan Speeds
Heat
High
Med High
Med Low
Low
Switch Setting
Cool Switches
Both OFF
1 0N - 2 OFF
1 OFF - 2 ON
1 ON - 2 ON
Fan Speeds
Cool
High
Med High
Med Low
Low
Delay Switches are for future use - no function at this time
Note: Refer to individual specification pages for AirflowPerformance specifications. Above settings correspond
to DIP switch settings on the ECM circuit board only.Do not adjust DIP switches on MAIN Circuit Board.
T31
Conta
N.0. COMDigital Controls
R W Y GA/C Unit
Thermostat
To “Y”
To “C”
T30T29T28REDOGYWRCT25
T17
K3
COM
N.
K6
COM
N.O.
T26 T27 GRNYEL
P2 P3
R 24Vac12Vac Com Thermostat DETC
Defrost
Freeze
Fan Hi
P1
C4 C3
K8
T31
Cont
N.0. CODigital Controls
DIP SWITCHES TO BEADJUSTED BY QUALIFIEDTECHNICIANS ONLY.
SEUL UN TECHNICIENQUALIFIÉ PEUT AJUSTÉ LESCOMMUTATEURS DIP.
CHASSIS
T44
T3 T4 T5 T6
Line/Ligne
T1 T2 T13 T14 T15 T16
Neutral/NeutreT11 T12
2 AMPS
SW1
ON
8 7 6 5 4 3 2 1
T21 T22 T23 T24
AUX 1 AUX 2
Standard 24 VoltThermostatConnection(Thermostats are not avail-able through Airia)
Basic Functions• Thermostat fan switch will control low speed fanoperation
• Call for heating - high speed• Call for cooling - high speed
Function and Controls ECM Motor
ECM Motor DIP Switch Settings
Do not energize the Air Handler until theplumbing is connected and commissioned.Failure to do so will damage the pump.
WARNING
DIP switches #6 & #7 must be ON for the ECM motor to function (factory setting).
ATTENTION
ECM Motor DIP Switch Settings(DIP 6&7 ON is Factory Setting)
ON
87
65
43
21
DIP #2 to ON will disable theOff Season Circulation Timer
Factory Setting
Do not adjust any other DIP switches thanindicated above.
WARNING
COOL
1 2 3 4 5 6 7 8
HEAT ADJUST DELAY
COOL HEAT ADJUST DELAY
SW
1
off
on
T2
T1
Thermostat Heat Anticipator SettingsMechanical Thermostats - start at .5 amp and may need to beincreased depending upon the residual heat left in the hydroniccoil and duct work.Electronic Thermostats - to be set on electric style heat.
15
Aircom Relays
The Aircom circuit board has three available “dry contact”relays. Contact 3 is not available.
Contact 1This relay is a dry contact (no power supplied from board).The relay switches upon a call for heat.This relay can be used to switch the heat demand signal forboiler operation.Power (if required) must be supplied to common from anexternal source.Max. Voltage - 120 voltsMax. Amperage - 10 ampsMaximum 115V 10 amp resistive load.
T30T29T28
T43
SPARE
P2 P3
F2 MAX 2 amp
R 24Vac
Defrost
Freeze
K7 K1 K2K8
T31
T32
T33
T34
T35
T36
T37
T38
T39
T40
T41
T42
Contact 1
N.0. COM N.C. N.0. COM N.C. N.0. COM N.C. N.0 . COM
Contact 2 Contact 3 Contact 4
N.C
BoilerContact
T30T29T28
T43
SPARE
P3
MAX 2 amp
R 24Vac
Defrost
K7 K1 K2K8
T31
T32
T33
T34
T35
T36
T37
T38
T39
T40
T41
T42
Contact 1
N.0. COM N.C. N.0. COM N.C. N.0. COM N.C. N.0 . COM
Contact 2 Contact 3 Contact 4
N.C
HumidifierContact
Contact 2 and 4These relays are dry contacts (no power supplied fromboard). The relays switch whenever the CAF blower motoris operating.These relays can be used to interlock Humidifiers, AirCleaning Equipment, etc.Power (if required) must be supplied to common from anexternal source.Max. Voltage - 120 voltsMax. Amperage - 10 amps
In order for any appliance to work properly it must be setup and tested by a knowledgeable technician.The following conditions must be met prior tostart-up1. Ensure that connecting water lines are purged and free ofdebris.Caution: solder or other debris may cause the furnacepump or check valve to malfunction.
2. Blower wheel rotates freely inside its housing.3. Wiring connections are tight.4. All duct and pipe connections are sealed.5. Check that styrene block is removed from under pump.6. Front access door is on tight.7. Fan speed selection:a) Heating/Cooling - factory setting is at high speed andcan be changed in the electrical box to medium-high ormedium if required.
Once the necessary connections have been made,follow the Air Handler Start-Up Procedure:1. Close shut-off valves separating the Air Handler from thewater heater.
2. Set up water heater according to manufacturer's instruc-tions.
3. Purge air from unit. To do so, open the supply shut-offvalve to the furnace. Attach a garden hose to drain valve,and drain water until you get a continuous flow. Closethe drain valve and purge the pump. To purge the airfrom the pump, turn the large screw on the face of thepump counterclockwise until water leaks out, then tight-en. Open the supply shut-off valve.
4. Turn on power supply to Air Handler. Caution: blowermay start to operate at low speed.
5. Switch the room thermostat to heat. The thermostatshould be set higher than the current room temperature inorder to energize the pump and commence the heatingcycle. (If the pump does not start, or the Air Handler isnot producing heat, refer to the Troubleshooting Sectionin this manual.
6. Set room thermostat at desired temperature setting.
Start-Up Procedure
16
Lack of heat1. Check that the room thermostat is set to the desiredtemperature.
2. Confirm the units have power and the shut-off valvesare open.
3. Ensure there is power to the unit and that the pump isworking. If the pump is not working properly it may bestuck. Disconnect power and remove screw in center faceof the pump. Using a screwdriver, turn the pump shaftseveral times to free it from sticking. Replace center-screw and re-connect power. If pump still fails to start, itmay require replacement.
4. Confirm that the hot water heater is working and that hotwater is entering the Air Handler.
5. Make sure your water heater is sized large enough forheat load of house and for domestic hot water use.
6. Air may still be in the water lines. If so, re-purge thesystem according to the start up procedure.
7. Confirm that the inlet and outlet pipe connections are notreversed.
8. Ensure that there are no other restrictions in the waterlines, such as faulty valves, or debris.
Pump is noisyPumps can become noisy when air remaining in the linesinterfere with their operation. If this occurs re-purge thesystem as indicated in the Start-Up Procedure.
During cooling cycle, hot water circulates throughthe coilIf the check valve inside the cabinet is stuck in the openposition, hot water may infiltrate the heating coil. Thisoccurs when the hot pipes are not capped-off duringinstallation or service and foreign debris enters the piping.This debris can settle under the check valve seat and permithot water to flow into the coil. The problem can becorrected by repeatedly flushing the heating loop until it isclean.
Troubleshooting
17
ConfigurationU - Upflow - Return Air off Left or Right sideD - Downflow models are unavailable for Air Handlers
Hydronic Coil Size
S2A - Small Coil - 2 Row CoilS4A - Small Coil - 4 Row Coil L2A - Large Coil - 2 Row CoilL4A - Large Coil - 4 Row CoilL2B - Large Coil - 2 Row Coil
24 - 2 tons30 - 2.5 tons36 - 3.0 tons48 - 4.0 tons*Cooling coils not available from Airia
Motor ConfigurationP16 - Standard PSC Motor 120V/60HzE16 - Upgrade ECM Motor 120V/60Hz
Example Model Number AH - U - S2A - 24 - P16
* CFM (High Speed)Cooling Capacity
Model ConfigurationAH - Airhandler (No HRV)Refer to CAF (Clean Air Furnace) specifications ifa built-in HRV is required.
Available Air Handler Models
AH-U-S2A-30-P16(E16)AH-U-S4A-24-P16(E16)AH-U-L2A-36-P16(E16)AH-U-L4A-36-P16(E16)AH-U-L2B-48-P16(E16)
Refer to individual specifications pages forHydronic Coil and Blower outputs andconfigurations.
Model Number Nomenclature Breakdown
Refer to individual specification pages for Hydronic Coil and Blower outputs andconfigurations.
ATTENTION
Model AH-U-S4A-24-P16
WarrantyUnits carry a five year replacement parts warranty on allcomponents.
Side Front
29.5"(749 mm)
19"(483 mm)
32.5"(826 mm)
14"(356 mm)
Top
29.5"(749 mm)
19"
16"(406mm)
Supply Air17.25"(438 mm)
22"(559 mm)
Return AirBlower Section
SERVICE CLEARANCE 1'(305 mm)
SERVICE CLEARANCE 3'(914 mm)
(483 mm)
Filters 1" (25 mm) pleated in return plenum side.Case Prepainted galvanized steel for superior corrosion resistance.
Dimensions & Clearances
�ote: Return plenum openingavailable off either side ofcabinet. All units conformto CSA and UL Standards
18
Model AH-U-S4A-24-P16
Voltage 120 VAC 60 Hz
Hp 1/3
Amps (total) 8
Water 1/2" (13 mm) CopperConnections Soldered Connection
Airflow (High).25 in wg 1030 CFM.5 in. wg 890 CFM
Net Weight 111 lbs. (50.3 kg)
Shipping 130 lbs. (59 kg)Weight
Date: ___________________________________________
Tag: _____________________Qty:___________________
Project: _________________________________________
Engineer: _______________________________________
Contractor: ______________________________________
Supplier: ________________________________________
Quote#: _________________________________________
Submitted by: ____________________________________
19
WarrantyUnits carry a five year replacement parts warranty on allcomponents.
Top
29.5”(749 mm)
19"(483 mm)
22.25"(565 mm)
Supply Air17.25"
(438 mm)
Side Front
29.5"(749 mm)
19"(483 mm)
32.5"(826 mm)
14"(356 mm)
22"(559 mm)
Return AirBlower Section
SERVICE CLEARANCE 1' (305 mm)
SERVICE CLEARANCE 3' (914 mm)
Filters 1" (25 mm) pleated in return plenum side.Case Prepainted galvanized steel for superior corrosion resistance.
Dimensions & Clearances
Model AH-U-L4A-36-PI6
Voltage 120 VAC 60 Hz
Hp 1/2
Amps (total) 10.6
Water 3/4" (19 mm) CopperConnections Soldered Connection
Airflow (High).25 in wg 1350 CFM.5 in. wg 1180 CFM
Net Weight 121 lbs. (54.9 kg)
Shipping 140 lbs. (63.6 kg)Weight
Note: Return plenum opening
available off either side of
cabinet. All units conform
to CSA and UL Standards
Date: ___________________________________________
Tag: _____________________Qty:___________________
Project: _________________________________________
Engineer: _______________________________________
Contractor: ______________________________________
Supplier: ________________________________________
Quote#: _________________________________________
Submitted by: ____________________________________
Model AH-U-L4A-36-P16
WarrantyUnits carry a five year replacement parts warranty on allcomponents.
Side Front
29.5"(749 mm)
19"(483 mm)
32.5"(826 mm)
14"(356 mm)
Top
29.5"(749 mm)
19"
16"(406mm)
Supply Air17.25"(438 mm)
22"(559 mm)
Return AirBlower Section
SERVICE CLEARANCE 1'(305 mm)
SERVICE CLEARANCE 3'(914 mm)
(483 mm)
Filters 1" (25 mm) pleated in return plenum side.Case Prepainted galvanized steel for superior corrosion resistance.
Dimensions & Clearances
1280120010001020
3 GPM
130 140 150 160 170 180Water Temp.
29.828.926.526.8
35.033.931.131.4
40.038.835.636.2
45.143.840.240.7
CFM
@.2
5"W
G 50.348.944.845.3
55.853.949.450.0
4 GPM
130 140 150 160 170 180
31.830.928.228.3
37.336.133.033.1
42.841.437.837.9
48.346.842.642.9
53.952.147.447.8
59.457.452.352.8
5 GPM
130 140 150 160 170 180
33.432.229.229.4
38.937.734.234.6
44.843.239.239.6
50.648.744.244.7
56.254.249.249.8
62.259.854.254.9
10751040975880
27.527.326.325.0
32.331.930.829.2
37.036.435.333.5
41.641.039.838.0C
FM@
.5"W
G
46.645.844.142.2
51.150.448.846.5
S2A-30 Coil Output Chart (1000's of BTUH)
29.028.727.726.4
34.133.632.831.0
39.138.437.335.4
44.243.442.039.9
49.348.546.944.5
54.253.351.649.1
30.529.828.827.4
35.435.033.832.0
40.840.138.436.6
45.945.143.541.3
51.150.248.345.9
56.555.253.350.5
Note: Return plenum opening
available off either side of
cabinet. All units conform
to CSA and UL Standards
Model AH-U-S2A-30-P16Voltage 120 VAC 60 Hz
Hp 1/3
Amps (total) 8
Water 1/2" (13 mm) CopperConnections Soldered Connection
Airflow (High).25 in wg 1280 CFM.5 in. wg 1075 CFM
Net Weight 111 lbs. (54.9 kg)
Shipping 130 lbs. (59 kg)Weight
20
Date: ___________________________________________
Tag: _____________________Qty:___________________
Project: _________________________________________
Engineer: _______________________________________
Contractor: ______________________________________
Supplier: ________________________________________
Quote#: _________________________________________
Submitted by: ____________________________________
Model AH-U-S2A-30-P16
21
WarrantyUnits carry a five year replacement parts warranty on allcomponents.
Top
29.5”(749 mm)
19"(483 mm)
22.25"(565 mm)
Supply Air17.25"
(438 mm)
Side Front
29.5"(749 mm)
19"(483 mm)
32.5"(826 mm)
14"(356 mm)
22"(559 mm)
Return AirBlower Section
SERVICE CLEARANCE 1' (305 mm)
SERVICE CLEARANCE 3' (914 mm)
Filters 1" (25 mm) pleated in return plenum side.Case Prepainted galvanized steel for superior corrosion resistance.
Dimensions & Clearances
140213571090731
3 GPM
130 140 150 160 170 180Water Temp.
35.134.631.225.5
41.040.436.529.5
47.046.441.833.8
53.152.347.138.1
CFM
@.2
5"W
G 59.158.252.442.4
65.164.257.846.7
4 GPM
130 140 150 160 170 180
37.737.133.226.4
44.143.438.830.9
50.649.844.435.4
57.056.150.139.9
63.562.555.844.4
70.068.961.448.9
5 GPM
130 140 150 160 170 180
39.538.834.527.2
46.245.440.331.8
52.952.046.236.4
59.758.752.041.0
66.465.357.945.6
73.271.963.850.2
122011751022705
32.932.830.224.7
38.537.835.328.9
44.243.340.433.1
49.848.945.637.3C
FM@
.5"W
G
55.454.450.841.5
61.160.055.945.7
L2A-36 Coil Output Chart (1000's of BTUH)35.234.532.025.9
41.240.437.530.2
47.246.242.934.6
53.252.148.439.0
59.258.053.843.4
65.363.959.347.8
36.736.033.326.6
43.042.038.931.1
49.248.144.535.6
55.454.350.240.1
61.760.455.844.6
68.066.561.549.1
Model AH-U-L2A-36-P16Voltage 120 VAC 60 Hz
Hp 1/2
Amps (total) 10.6
Water 1/2" (13 mm) CopperConnections Soldered Connection
Airflow (High).25 in wg 1402 CFM.5 in. wg 1220 CFM
Net Weight 121 lbs. (50.3 kg)
Shipping 140 lbs. (59 kg)Weight
Note: Return plenum opening
available off either side of
cabinet. All units conform
to CSA and UL Standards
Date: ___________________________________________
Tag: _____________________Qty:___________________
Project: _________________________________________
Engineer: _______________________________________
Contractor: ______________________________________
Supplier: ________________________________________
Quote#: _________________________________________
Submitted by: ____________________________________
Model AH-U-L2A-36-P16
22
WarrantyUnits carry a five year replacement parts warranty on allcomponents.
Top
29.5"(749 mm)
19"(483 mm)
22.25"(565 mm)
Supply Air17.25"(438 mm)
Side Front
29.5"(749 mm)
19"(483 mm)
36.5”(927 mm)
18"(457 mm)
22"(559 mm)
Return Air Blower Section
SERVICE CLEARANCE 1' (305 mm)
SERVICE CLEARANCE 3' (914 mm)
Filters 1" (25 mm) pleated in return plenum side.Case Prepainted galvanized steel for superior corrosion resistance.
Dimensions & Clearances
196718681728
3 GPM
130 140 150 160 170 180Water Temp.
39.638.3
46.344.9
53.151.4
59.958.1
CFM
@.2
5"W
G
66.764.7
73.671.3
4 GPM
130 140 150 160 170 180
43.141.6
50.548.7
55.855.9
65.263.0
72.770.2
80.177.3
5 GPM
130 140 150 160 170 180
45.543.9
53.351.3
61.158.8
68.866.3
76.773.8
84.581.4
163916181575
37.537.336.940.4
43.943.743.247.3
50.350.049.554.2
56.856.555.861.1
CFM
@.5
"WG
63.362.962.268.1
69.769.368.675.1
L2B-48 Coil Output Chart (1000's of BTUH)40.740.439.944.1
47.647.246.751.6
54.554.253.559.2
61.561.160.366.7
68.568.067.274.3
75.575.074.081.9
42.842.541.946.7
50.049.749.054.6
57.356.956.162.5
64.664.263.370.5
71.971.570.578.5
79.378.777.786.6
Model AH-U-L2B-48-P16Voltage 120 VAC 60 Hz
Hp 3/4
Amps (total) 12.2
Water 1/2" (13 mm) CopperConnections Soldered Connection
Airflow (High).25 in wg 1967 CFM.5 in. wg 1639 CFM
Net Weight 135 lbs. (61.2 kg)
Shipping 155 lbs. (70.3 kg)Weight
Note: Return plenum opening
available off either side of
cabinet. All units conform
to CSA and UL Standards
Date: ___________________________________________
Tag: _____________________Qty:___________________
Project: _________________________________________
Engineer: _______________________________________
Contractor: ______________________________________
Supplier: ________________________________________
Quote#: _________________________________________
Submitted by: ____________________________________
Model AH-U-L2B-48-P16
23
24
25
26
27
28
29
Tran
sfo
rmer
12/2
4Vac
Tran
sfo
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T40
T41T42
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T11
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T21
T22
T23
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S
Standard MotorWiring Diagram
Do not initiate power before plumbing iscommissioned.
WARNING
30
Tran
sfor
mer
Tran
s-fo
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12/2
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EC
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Rela
is
F#Fu
seFu
sibl
e
SW#
Switc
hCo
mm
utat
eur
Ele
ctri
cal
con
tro
lp
ane
lse
rvic
eb
yel
ectr
icia
no
nly
.D
isco
nn
ect
elec
tric
al
sup
ply
pri
or
tose
rvic
ing
.Im
pro
per
wir
ing
may
resu
ltin
dam
age
toth
isu
nit
.U
seco
pp
ersu
pp
lyw
ires
.
CA
UT
ION
En
tret
ien
du
pan
nea
ud
eco
ntr
ôle
élec
triq
ue
par
un
élec
tric
ien
seu
lem
ent.
Co
up
ez
l’alim
enta
tio
nél
ectr
iqu
eav
ant
de
pro
céd
er
àl’e
ntr
etie
n.
Un
câb
lag
ein
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ua
tp
ou
rrai
ten
do
mm
ager
cet
app
arei
l.U
tilis
ezd
escâ
ble
sd
ecu
ivre
.
AT
TE
NT
ION
Bla
ck=
no
ir
Wh
ite
=b
lan
c
Red
=ro
ug
e
Blu
e=
ble
u
Yello
w=
jau
ne
Tan
=h
avan
e
Pu
rple
=p
ou
rpre
Bro
wn
=b
run
Alim
en-
tatio
nà
rela
is
CO
OL
FRO
IDH
EAT
CH
ALE
UR
ADJU
STRÉ
GLA
GE
DELA
YDÉ
LAI
Terr
e
DIP
SW
ITC
HE
ST
OB
EA
DJU
ST
ED
BY
QU
AL
IFIE
DT
EC
HN
ICIA
NS
ON
LY.
SE
UL
UN
TE
CH
NIC
IEN
QU
AL
IFIÉ
PE
UT
AJU
ST
ÉL
ES
CO
MM
UTA
TE
UR
SD
IP.
SW
1
ON
87
65
43
21
CH
AS
SIS
T44
T21
T22
T23
T24
AU
X1
AU
X2
T13
T14
T15
T16
Neu
tral
/Neu
tre
T11
T12
The
rmos
tat
2A
MP
S
T3T4
T5T6
Line
/Lig
ne
T1T2
C3
ECMWiring Diagram
Do not initiate power before plumbing iscommissioned.
WARNING
31