Installation Instructions

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1 HC2 HC3 HOT WATER COILS MULTIPOISE Installation Instructions NOTE: Read the entire installation instructions before starting the installation. SAFETY CONSIDERATIONS Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory -authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing. Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes and the current editions of the National Electrical Code (NEC) NFPA 70. In Canada, refer to the current editions of the Canadian Electrical Code CSA C22.1. Recognize safety information. This is the safety -alert symbol. When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and CAUTION. These words are used with the safety -alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestionswhich will result in enhanced installation, reliability, or operation. INTRODUCTION NOTE: Hot water coils are not suitable for use in potable water systems. Coil water circuit must be plumbed separately from residential hot water supply. These instructions cover the installation of listed coils with upflow, downflow, or horizontal air distribution systems. Installation of this equipment should be performed by a qualified technician.! CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in property damage. Installations subject to freezing ambient temperatures must have provision for freeze protection to avoid damage to this appliance and the dwelling. The safest method of freeze protection is to provide drains for the hot water coil and water lines. LOCATION! WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in property damage, personal injury or death. Installation or repairs made by unqualified persons can result in hazards to you and others. Installation must conform with local building codes or, in the absence of local codes, with the current edition of National Electrical Code NFPA 70. The information contained in this manual is intended for use by a qualified service technician familiar with safety procedures and equipped with the proper tools and test instruments. Shut OFF electric power at unit disconnect and/or service panel before beginning the following procedures. The hot water coil mounts directly over the discharge end of the air handler and aligns with the back and sides of air handler. The coil tubing is facing the same direction as the access door on the air handler. Coil may be used for horizontal, upflow or downflow configurations. It is best if the air handler is located in the conditioned space to minimize the possibility of freezing ambient temperatures. Location reasonably close proximity to the hydronic equipment is also preferred. INSTALLATION Before starting the installation, verify that the air handler has been properly installed. If the low voltage connections were brought into the cabinet on the top (left side), they may have to be moved so they come into the cabinet from the side. Whether or not they have to be moved depends on several things, type of wire and connectors used and fittings to be used on coil (See Fig. 1). 1. Disconnect primary power to the air handler before performing the installation. 2. If the duct work is already connected to the air handler, it will be necessary to remove approximately 21 in. (533 mm) where it connects to the discharge plenum. A transition will be required to connect plenum to coil. The 21 in. (533 mm) allows 3 in. (76 mm) for transition. 3. Apply the foam sealing tape around the bottom of the coil cabinet, then position the coil over the air handler discharge. Secure the coil case to the sides of the air handler with sheet metal screws to secure to fan coil. 4. Connect the discharge plenum to the discharge opening on the coil. Fasten to the flange using sheet metal screws.

2 Low Voltage (May have to move to side entrance) Fasten with Strap Both sides and back Fig. 1 - Installing the Hot Water Coil WATER LINE INSTALLATION Foam Tape Line Voltage A07321 NOTE: Shut-off electrical power or gas to the hot water supply. Shut-off the water supply and drain the hot water supply before starting the water line installation. All plumbing connections should be made with an appropriate lead -free solder. The hot water coil may be used in conjunction with a broad variety of hydronic equipments or boilers, including gas-fired, oil fired and electrically heated. Do not exceed _F (82_C) water temperature. If possible, select a hydronic equipment equipped with extra openings for a circulation loop. They may be side connections or a pair of additional connections on top of the hydronic equipment. Standard hydronic equipment may also be used, although some variation in hydronic equipment performance may be noticed. Plan the water lines to minimize run lengths and the number of elbows. Use a least 3/4 inch (nominal) water tube. Both supply and return run should be insulated separately with closed cell foam pipe insulation. A typical installation using a hot hydronic equipment is showninfig.2. Check Valve Hot Water Inlet to Coil Optional Check Valve Recirculating Pump (optional) 1. The supply run from the hot water supply to the coil should be connected to the hot water opening on top of the hydronic equipment or the upper side opening if the hydronic equipment is equipped for a recirculating loop. 2. The return run may be connected to the hydronic equipment in several different locations. If the hydronic equipment is equipped for a recirculating loop, use the lower side opening. 3. A Check valve is recommended to minimize thermo -syphoning of hot water through the coil during cooling season, unless the coil is operated as a separate zone in a multizone system, which is normally found only in boiler driven applications. Swing -check valves are recommended to minimize pressure drop. They should be mounted in a vertical section of pipe to be the most effective. 4. A circulating pump may be installed anywhere in the recirculating loop, either supply or return side, but it is usually more convenient to install immediately next to the coil because of the wiring connections. ELECTRICAL CONNECTIONS 1. Pump and/or zone valves must be activated from a 24 volt circuit from the room thermostat through a 24VAC SPST Coil. Use Kit No. KFAIF0101HWC. See Fig. 3. Any enclosed type fan relay meeting voltage and amp ratings will work, but it must be enclosed in an acceptable junction box. 2. Make all line voltage wiring connections inside the fan coil or in a junction box. GROUNDING Permanently ground in accordance with local codes and ordinances and in the United States with the current edition of the National Electrical Code NFPA70. Use a copper conductor of the appropriate size from the junction box, to a grounding lug on the circuit breaker panel or grounding prong of 115 Volt receptacle, when a plug connection is used.! CAUTION UNIT CORROSION HAZARD Failure to follow this caution may result in property or unit damage. Copper supply and return piping must NOT be installed directly into aluminum boiler section castings due to galvanic corrosion between dissimilar metals. Iron or steel bushings or pipe nipples should be used between copper system piping and boiler to make final connection to boiler. Also, the use of dielectric unions is acceptable. The packaged boiler is furnished with iron piping in the front boiler section for the supply and return connections. 4x4 or 2x4 Junction box for relay Fig. 2 - Typical Water Lines Installation A

3 RELAY RED RED Hydronic Equipment Control (ie; hydronic pump, zone valve or other hydronic control) (Refer to load ratings) OC2 OC1 12-pin wiring harness plug 240 VAC Fan Coil Supply VIO ORN 24 VOLT YEL BLK RED RED ID START -UP PROCEDURES SYSTEM FILL 1. Verify pump on hydronic system is off. 2. Fill system with water, purging air as the system fills. 3. Restore electrical power to the blower and set thermostat so heat should come on. This will energize the circulating pump to start flow through the coil. Allow it to run for several minutes to make sure air is flushed from system, then close faucet. 4. Turn thermostat off, so circulating pump is not running. 5. Restore electrical power or gas to the hydronic equipment. The system is now ready for start-up. 6. Refer to hydronic equipment installation instructions for additional information regarding filling the boiler or water heater. Allow sufficient time for the hydronic equipment to reach normal operating temperature. Check the thermostat setting. The hot water coil is designed to operate on any hot water source between _F (60_C)and _F (82_C). WATER TREATMENT AND FREEZE PROTECTION 1. When filling the hydronic system, water treatment is generally not required or desired. For localities where the water is unusually hard (above 7 grains hardness) or for low ph water conditions (below 7.0), consult a local water treatment specialist. a. This coil is designed for use in a closed hydronic heating system ONLY! b. Excessive feeding of fresh make-up water to the hydronic system may lead to premature failure of the hydronic equipment. 2. Use clean fresh tap water for initial fill and make -up of hydronic system. a. A sand filter must be used if fill and make -up water from a well is to be used. b. Consideration should be given to cleaning the heating system, particularly in retrofit situations, where a new hydronic equipment is being installed in an older piping system. c. In older systems, obviously discolored, murky, or dirty water, or a ph reading below 7, are indications that the system should be cleaned. d.aphreadingbetween7and8ispreferred. Fig. 3 - Typical Low Voltage Control Wiring A Antifreeze if needed, must be of a type specifically designed for use in closed hydronic heating systems and with aluminum. a. Choice and use of antifreeze must be in accordance with local plumbing codes. b. Only INTERCOOL NFP -50 is approved for use. INTERCOOL NFP -50 is available from Interstate Chemical Company. (1.) Use of any antifreeze other than INTERCOOL NFP -50 will void warranty. (2.) Antifreeze must be maintained per manufacturer s specifications. Failure to do so will result in the warranty being voided. c. Do not use automotive antifreeze as the type of corrosion inhibitors used will coat the boiler s heat transfer surfaces and greatly reduce capacity and efficiency. d. Consult antifreeze manufacturer s literature for compatibility of antifreeze with aluminum boiler. Some brands have corrosion inhibitors that break down more rapidly or become ineffective at higher operating temperatures when used with aluminum. Follow the antifreeze manufacturers instructions on determining the proper ratio of antifreeze to water for the expected low temperature conditions, and for maintaining the quality of the antifreeze solution from year to year. e. Use of antifreeze in any boiler will reduce capacity by as much as 10 to 20 percent, due to differing heat transfer and pumping characteristics. This must be taken into consideration when sizing the heating system, pump(s), and expansion tank. Consult antifreeze manufacturer s literature for specific information on reduced capacity. Follow all instructions for your hydronic system regarding system fill-up, purging, and start up. 3

4 Table 1 Heating Capacity - Hot Water Coils - HC2AXX TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT

5 Table 2 Heating Capacity - Hot Water Coils - HC2AXX TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT

6 Table 3 Heating Capacity - Hot Water Coils - HC2AXX TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT

7 Table 4 Heating Capacity - Hot Water Coils - HC3AXX TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT

8 Table 5 Heating Capacity - Hot Water Coils - HC3AXX TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT

9 Table 6 Heating Capacity - Hot Water Coils - HC3AXX TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT TC LDB LWT

10 UNIT HC 017 HC 021 HC 024 All values are in inches of water. Pressure drop includes standard fiberglass filters. All pressure drops are with dry coil. Table 7 HC Airside Pressure Drop (in. wc) HOT WATER 2ROW 3ROW Copyright 2008 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN Printed in U.S.A. Edition Date: 09/08 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Catalog No: IM --- HC2A Replaces: IM --- HC2A

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