Model Series AHCA and AHDA Indoor or Outdoor Cooling and Cooling/ Dehumidifying Split System Air Handlers (Hydronic and/or Gas Heating Optional)

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1 Model Series AHCA and AHDA Indoor or Outdoor Cooling and Cooling/ Dehumidifying Split System Air Handlers (Hydronic and/or Gas Heating Optional) INSTALLATION FORM RZ-NA 416 APPLIES TO: Installation/Operation/Maintenance Table of Contents Page Page Page GENERAL... 1 INSTALLATION & OPERATION Approval and Installation Codes Warranty Warnings Uncrating and Preparation... 3 Shipped-Separate Parts... 3 Storage Technical Data Dimensions Clearances Mounting/Rigging and Lifting Location and Weights... 6 Curb Cap Base... Mounting on Field Supplied Supports... Mounting on a Roof Curb... 9 Bottom Openings Indoor Installation Rigging and Lifting Condensate Drains Drain Trap Screened Inlet Air Hoods and Barometric Relief Hood Hood with Louvers (Option AS2) Hood with Filters (Option AS16) Barometric Relief Hood (Option ASB1) Duct Connections Electrical Supply and Controls Disconnect Switch Through-the-Base Access Voltage (ModelAHDA) Supply Wiring Size/Requirements Typical Wiring Diagrams Control Locations Controls and Sequence of Operation Optional Controls Blower Motor Cooling Coils Stock DX Coils Custom DX Coils Chilled Water Coils Dehumidifying System - AHDA Blowers, Belts and Drives Adjusting Blower Speed Blower Rotation Airflows and Pressure Drops OPTIONAL EQUIPMENT AND ACCESSORIES Gas Furnace... use Form 415/416-GF (found in Owner's Envelope) 18. Optional Dampers Damper Option Identification Discharge Outside and Return Inlet Air Hydronic Heat Module Hot Water Heat Coil Steam Heat Coil Evaporative Cooling Module - AHCA only Energy Recovery Preconditioner (Model ERSA) CHECK-TEST-STARTUP Summary of Control Settings...40 MAINTENANCE & SERVICE Gas Furnace... use Form 415/416-GF (NOTE: Booklet is in the Owner's Envelope.) 24. Maintenance Requirements Maintenance Schedule Filters Drive Components Coil Maintenance Refrigerant Circuit - AHDA Compressor Maintenance and Replacement - AHDA Handling Replacement P/N's Oil Charge Crankcase Heaters Voltage Utilization Range Compressor Protection Thermal Expansion Valves Troubleshooting General Air Handler Dehumidifier Refrigerant Circuit - AHDA Optional Gas-Fired Furnace Optional Evaporative Cooling Module INDEX BY PAGE NO RECORD OF JOB GENERAL The instructions in this manual apply to a split system cooling air handler Model AHCA and a split system cooling/dehumidifying air handler Model AHDA. The air handler system could also include a heat option; see heat options listed below. Configuration by Model AHCA AHDA includes DX or Chilled Water Coil X X with Dehumidifying Heat Pump N/A X Heat Options for above Cooling Models: Heating Coil Module (hot water or steam coil either factory or field supplied) Indoor Gas-Fired Furnace Outdoor Gas-Fired Furnace Heating Coil Module (hot water or steam coil either factory or field supplied) and Indoor Gas-Fired Furnace Heating Coil Module (hot water or steam coil either factory or field supplied) and Outdoor Gas-Fired Furnace All configurations are available for indoor or outdoor installation. Before beginning installation, know the application. This booklet includes air handler installation, startup, operation, and maintenance information. It also includes all optional component in- formation except the gas furnace. If the system being installed includes an optional gas furnace, use Form RZ-NA 415/416-GF with this manual. Both manuals are in the owner's envelope. If the system includes installation of a Model ERSA energy recovery preconditioner, follow instructions in Form 480 shipped with the energy recovery unit. If any applicable manual is missing, contact your distributor before beginning installation. Before beginning a procedure, carefully review the information, paying particular attention to cautions and warnings. Installation should be done by a qualified contractor in accordance with the instructions in this manual and in compliance with all codes and requirements of authorities having jurisdiction. For units with a DX coil, a field supplied condenser is required. Procedures requiring the handling of refrigerant should only be performed by a qualified HVAC technician and in compliance with all codes and requirements of authorities having jurisdiction. Form RZ-NA 416, Mfg No , Page 1

2 1. Approval and Installation Codes Model AHCA and Model AHDA systems are certified by ETL to Heating Cooling Equipment (latest edition), UL 1995 / CAN/CSA C22.2 No Electrical characteristics are shown on the system rating plate. The dehumidifier/heat pump circuit in Model AHDA is factory-charged with R-22 refrigerant. If a gas-fired furnace option is ordered, the system includes either an outdoor power-vented duct furnace(s) equivalent to a Reznor Series Model RP or an indoor separated-combustion, power-vented furnace equivalent to a Reznor Series Model SC. Both furnaces are designcertified to ANSI Standard Z83.8a by the Canadian Standards Association (CSA). Both indoor and outdoor furnaces are approved for use with either natural or propane gas. The furnace is factory equipped for the type of gas ordered. Check the furnace section rating plate (See Figure 1, Item 21) for type of gas and the correct firing rate. If a heating coil module is ordered, the system either includes a factory-installed hot water or steam heat coil or is designed for a field supplied coil. A field supplied boiler system is required. These systems must be installed in accordance with local building codes. Consult local authorities having jurisdiction before installation to verify local codes and installation procedure requirements. Figure 1 - General Layout and Label Locations 2. Warranty Refer to limited warranty information on the warranty form in the "Owner's Envelope" shipped with this system. If an optional extended warranty applies, keep the extended warranty card for future reference and verification of warranty. 3. Warnings There are warning labels on the unit (See Figure 1) and throughout this manual. For your safety, comply with all warnings during installation, operation, and service of this system. See Warning below and Hazard Intensity Levels in Figure 1. WARNING Model AHDA dehumidifying system refrigerant circuit contains chlorodifluoromethane (HCFC- 22), a substance that is believed to harm the public health and environment by destroying ozone in the upper atmosphere. Do not release HCFC-22 to the atmosphere. The U. S. Clean Air Act requires the recovery of any residual refrigerant. Flue Gas Exit(s) (outdoor gas furnace only) 6 Outside Air Inlet Air Section Evaporator Coil Section *16 15 Blower Section 1 *2 1 Discharge Plenum Section (horizontal or vertical) *4 Optional Return Air Filter Section 1 20 * *2 8 9 Blower (in blower section) 23 Combustion Air Inlet(s) (outdoor gas furnace only) Internal Ductwork Cabinet (cooling only) or Optional Heat Section (hot water coil, steam coil, or gas furnace) NOTE: Two cabinets are illustrated; only systems with two gas furnaces or one gas furnace and a heat coil module require two cabinets.) Label Location Key: 1 = Grounding Warning Label *2 = Close Compartment Warning Label 3 = Safety/Storage/Exposure Warning Label 4 = Moving Parts Warning Label 6 = Air Direction Label = Blower Motor Replacement Label 8 = Blower Rotation Label 9 = Voltage Identification Label 10 = Line Voltage Label *11 = Service Warning Label 12 = General Warning Label 13 = Wiring Notice Label 15 = Electrical Connection Label Two Electrical Compartment Covers in the Blower Section *16 = Replacement Filter Instructions 1 = Seal Holes Warning 18 = Terminal Strip Connection Identification 19 = System Rating Plate 20 = ETL Label 21 = Heater Rating Plate Location (with gas furnace only) 22 = Service Clearance (with heat section only) 23 = Gas Connection (with gas furnace only) 24 = Green Ground Label * Label on both sides of the unit If there is an optional gas furnace, remove this control panel to see the heater rating plate and additional warning labels. HAZARD INTENSITY LEVELS 1. DANGER: Failure to comply will result in severe personal injury or death and/or property damage. 2. WARNING: Failure to comply could result in severe personal injury or death and/or property damage. 3. CAUTION: Failure to comply could result in minor personal injury and/ or property damage. Form RZ-NA 416, Mfg No , Page 2

3 4. Uncrating and Preparation This system was test operated and inspected at the factory prior to crating and was in operating condition. If the equipment has incurred any damage in shipment, document the damage with the carrier and immediately contact your Reznor distributor. Check the entire unit for damage paying particular attention to the structural integrity of the points of attachment of the lifting rings. Check the rating plate found in the blower section for the specifications and electrical characteristics to be sure that they are compatible with the electric supply at the installation site. If the system includes an optional gas-fired furnace, check the rating plate on the furnace section to be sure that it is compatible with the gas supply at the installation site. The furnace rating plate is located on the electrical box in the heater control compartment (See Figure 1, Item 21). Read this booklet and become familiar with the installation requirements of your particular model. If you do not have knowledge of local requirements, check with the local agencies who might have requirements concerning this installation. Before beginning, make preparations for necessary supplies, tools, and manpower. Shipped-Separate Parts Check for shipped separate or shipped loose parts. Optional cooling or dehumidification controls, room relative humidity sensor, outside air temperature override, remote console, and/or disconnect switch are shipped separately for field installation. Other shipped separate options could include a roof curb, a screened outside air hood, a barometric relief hood, or a fill and drain kit for an optional evaporative cooling module. If the system includes an optional gas furnace, refer to the furnace manual for additional control parts that are shipped separately. Storage If the system is going to be stored outdoors (either on the ground or on the roof), take precautions to prevent condensate formation inside the electrical compartments and motor. 5. Technical Data Model AHCA Cooling Air Handler and Model AHDA Cooling/Dehumidifying Air Handler Size - Model AHCA or AHDA Model AHCA CFM Range Model AHDA Blower Motor (HP Range) 1/2-3 1/2-5 1/2-10 1/2-10 Evaporator Coil DX or Chilled Water Maximum Face Area (sq ft) Model AHDA Dehumidifier Circuit Size - Model AHDA Size - Model AHDA Evaporator Coil (Dehumidifier Circuit) Dehumidifier Compressor Tube Size (inches) 3/8 3/8 3/8 3/8 Voltage Rows Cooling Capacity 105/50 F (mbh) Fin Spacing (fpi) - 208V or 230V Hot Gas Connection (inches) 1 1-1/4 1-1/4 1-1/4 Fin Spacing (fpi) - 460V Suction Connection (inches) 1-1/4 1-3/4 1-3/4 1-3/4 Face Area (sq ft) Oil Charge (cc) Suction Connection (inches) 3/4 3/4 3/4 /8 RLA Liquid Connection (inches) 1/2 1/2 1/2 /8 Condenser Coil (Dehumidifier Circuit) Tube Size (inches) 5/16 5/16 5/16 3/8 Rows Fin Spacing (fpi) Face Area (sq ft) Hot Gas Connection (inches) 1/2 1/2 1/2 5/8 Form RZ-NA 416, Mfg No , Page 3

4 6. Dimensions Figure 2A - Dimensions (inches/mm) of Models AHCA and AHDA Sizes 30 and 40 in the configurations listed Model AHCA or AHDA Sizes 30 and 40 Cabinet A with one of the following configurations: No Heat Options Heating Coil Module (steam or hot water coil) Indoor or Outdoor Gas-Fired Furnace Size 100, 125, 150, 15, 200, or 225 OUTSIDE AIR OPTIONAL BOTTOM RETURN AIR OPENING 28-3/8 (21 mm) 28-3/8 (21 mm) OPTIONAL DOWNTURN SUPPLY AIR OPENING 36-9/16 (929 mm) - inside curb cap (for setting on roof curb or rails) 39-5/8 (1006 mm) - cabinet width 44 (1118 mm) - overall width of curb cap 12-1/8 (308 mm) Top View 19-1/2 (495 mm) 143-1/2 (3,645 mm) Side View 19-1/2 (495 mm) INLET AIR OPENING 28-3/8 (21 mm) 43-13/16 (1,113 mm) OPTIONAL SCREENED OUTSIDE AIR HOOD (OR EVAPORATIVE COOLING MODULE) 33-/8 (860 mm) OPTIONAL HORIZONTAL RETURN AIR OPENING FILTER SECTION COOLING COIL MODULE BLOWER MODULE INTERNAL DUCT (blank section); GAS-FIRED FURNACE; OR STEAM OR HOT WATER HEAT COIL MODULE HORIZONTAL OR DOWNTURN PLENUM 19-1/2 (495 mm) 39-5/16 (999 mm) OPTIONAL HORIZONTAL SUPPLY AIR OPENING (to use horizontal opening, move cover to vertical opening) Rear (Air Inlet) View INLET AIR MIXING SECTION 15-1/2 (394 mm) 3-3/16 (945 mm) DRAIN - BOTH SIDES (1 PVC) GAS CONNECTION LOCATION (with optional gas furnace only) 148-3/8 (3,94 mm) - Curb Cap Overall Length (Inside curb cap length for setting on roof curb or rails is 142-/8 (3,629 mm) 29 (3 mm) MOUNTING SURFACE 28-3/8 (21 mm) Front (Discharge Air) View Coil Connection Dimensions: Cooling, see Figures 24-26; Heating, see Figures Figure 2B - Dimensions (inches/mm) of Models AHCA and AHDA Sizes 55 and 0 in the configurations listed Model AHCA or AHDA Sizes 55 and 0 Cabinet B with one of the following configurations: No Heat Options Heating Coil Module (steam or hot water coil) Indoor or Outdoor Gas-Fired Furnace Size 250 or 350 OUTSIDE AIR OPTIONAL BOTTOM RETURN AIR OPENING 42-1/8 (1,00 mm) 42-1/8 (100 mm) OPTIONAL DOWNTURN SUPPLY AIR OPENING 50-5/16 (128 mm) - inside curb cap (for setting on roof curb or rails) 53-3/8 (1356 mm) - cabinet width 5-3/4 (146 mm) - overall width of curb cap 12-1/8 (308 mm) Top View 19-1/2 (495 mm) 143-1/2 (3,645 mm) 19-1/2 (495 mm) INLET AIR OPENING 42-1/8 (1,00 mm) Rear (Air Inlet) View 53-13/16 (1,36 mm) OPTIONAL SCREENED OUTSIDE AIR HOOD (OR EVAPORATIVE COOLING MODULE) 43-/8 (1114mm) INLET AIR MIXING SECTION OPTIONAL HORIZONTAL RETURN AIR OPENING FILTER SECTION 15-1/2 (394mm) 3-3/16 (945 mm) COOLING COIL MODULE DRAIN - BOTH SIDES (1 PVC ) Side View BLOWER MODULE INTERNAL DUCT (blank section); GAS-FIRED FURNACE; OR STEAM OR HOT WATER HEAT COIL MODULE GAS CONNECTION LOCATION (with optional gas furnace only) HORIZONTAL OR DOWNTURN PLENUM 29 (3 mm) 148-3/8 (3,94 mm) - Curb Cap Overall Length (Inside curb cap length for setting on roof curb or rails is 142-/8 (3,629 mm) 19-1/2 39-5/16 (495 mm) (999 mm) MOUNTING SURFACE OPTIONAL HORIZONTAL SUPPLY AIR OPENING (to use horizontal opening, move cover to vertical opening) 42-1/8 (1,00 mm) Front (Discharge Air) View Coil Connection Dimensions: Cooling, see Figures 24-26; Heating, see Figures Form RZ-NA 416, Mfg No , Page 4

5 Figure 2C - Dimensions (inches/mm) of Models AHCA and AHDA Sizes 30 and 40 in the configurations listed Model Sizes Cabinet A with one of the followng configurations: AHCA or AHDA 30 and 40 Indoor or Outdoor Gas-Fired Furnace Size 300 or 400 Indoor or Outdoor Gas-Fired Furnace Size 200 or 225 and Heating Coil Module OUTSIDE AIR OPTIONAL BOTTOM RETURN AIR OPENING 28-3/8 (21 mm) 28-3/8 (21 mm) OPTIONAL DOWNTURN SUPPLY AIR OPENING 36-9/16 (929 mm) - inside curb cap (for setting on roof curb or rails) 39-5/8 (1006 mm) - cabinet width 44 (1118 mm) - overall width of curb cap 12-1/8 (308 mm) Top View 19-1/2 (495 mm) Side View 10 (4,318 mm) 19-1/2 (495 mm) INLET AIR OPENING 28-3/8 (21 mm) Rear (Air Inlet) View 43-13/16 (1,113 mm) OPTIONAL SCREENED OUTSIDE AIR HOOD (OR EVAPORATIVE COOLING MODULE) 33-/8 (860mm) INLET AIR MIXING SECTION OPTIONAL HORIZONTAL RETURN AIR OPENING 15-1/2 (394mm) FILTER SECTION 3-3/16 (945 mm) COOLING COIL MODULE DRAIN - BOTH SIDES (1 PVC) BLOWER MODULE Flue Outlet Combustion Air Inlet OPTIONAL GAS FURNACE MODULE (outdoor furnace illustrated) OPTIONAL GAS-FIRED FURNACE OR STEAM OR HOT WATER HEAT COIL MODULE 18-3/4 (3,8 mm) - Curb Cap Overall Length (Inside curb cap length for setting on roof curb or rails is 12 (3,59 mm) HORIZONTAL OR DOWNTURN PLENUM Gas connection is at curb cap height on the control side of the system, approximately 30 (62mm) from the discharge end of the curb cap. 19-1/2 (495 mm) 39-5/16 (999 mm) MOUNTING SURFACE OPTIONAL HORIZONTAL SUPPLY AIR OPENING (to use horizontal opening, move cover to vertical opening) 28-3/8 (21 mm) Front (Discharge Air) View Coil Connection Dimensions: Cooling, see Figures 24-26; Heating, see Figures Figure 2D - Dimensions (inches/mm) of Models AHCA and AHDA Sizes 55 and 0 in the configurations listed Model Sizes Cabinet B with the following configurations: AHCA or AHDA 55 and 0 Indoor or Outdoor Gas-Fired Furnace Size 500, 600, or 00 Indoor or Outdoor Gas-Fired Furnace Size 350 and Heating Coil Module OUTSIDE AIR OPTIONAL BOTTOM RETURN AIR OPENING 42-1/8 (1,00 mm) 42-1/8 (100 mm) OPTIONAL DOWNTURN SUPPLY AIR OPENING 50-5/16 (128 mm) - inside curb cap (for setting on roof curb or rails) 53-3/8 (1356 mm) - cabinet width 5-3/4 (146 mm) - overall width of curb cap 12-1/8 (308 mm) Top View 19-1/2 (495 mm) 10 (4,318 mm) 19-1/2 (495 mm) INLET AIR OPENING 42-1/8 (1,00 mm) 53-13/16 (1,36 mm) OPTIONAL SCREENED OUTSIDE AIR HOOD (OR EVAPORATIVE COOLING MODULE) 43-/8 (1114mm) OPTIONAL HORIZONTAL RETURN AIR OPENING FILTER SECTION COOLING COIL MODULE Side View BLOWER MODULE Flue Outlet Combustion Air Inlet OPTIONAL GAS FURNACE MODULE (outdoor furnace illustrated) OPTIONAL GAS-FIRED FURNACE OR STEAM OR HOT WATER HEAT COIL MODULE HORIZONTAL OR DOWNTURN PLENUM 19-1/2 (495 mm) 39-5/16 (999 mm) OPTIONAL HORIZONTAL SUPPLY AIR OPENING (to use horizontal opening, move cover to vertical opening) Rear (Air Inlet) View INLET AIR MIXING SECTION 15-1/2 (394mm) 3-3/16 (945 mm) DRAIN - BOTH SIDES (1 PVC ) 18-3/4 (3,8 mm) - Curb Cap Overall Length (Inside curb cap length for setting on roof curb or rails is 12 (3,59 mm) Gas connection is at curb cap height on the control side of the system, approximately 30 (62mm) from the discharge end of the curb cap. MOUNTING SURFACE 42-1/8 (1,00 mm) Front (Discharge Air) View Coil Connection Dimensions: Cooling, see Figures 24-26; Heating, see Figures Form RZ-NA 416, Mfg No , Page 5

6 . Clearances Provide minimum clearances as listed below. Minimum clearances are required to ensure proper operation and access for service. Models AHCA and AHDA 30 and and 0 Inlet Air End Discharge Air End Control Side 120" (3050mm) 36" (914mm) 50" (120 mm) 61" (1549mm) Non-Control Side 50" (120 mm) 61" (1549mm) Vent Pipe (applies only to system with indoor gas furnace) 6" (152mm) If optional gas-fired heating is included, clearances to combustibles are required. Clearance to combustibles is defined as the minimum distance from the heater to a surface or object that is necessary to ensure that a surface temperature of 90 F above the surrounding ambient temperature is not exceeded. IMPORTANT CLEARANCE NOTE: Avoid recirculation of exhaust air from any source to the outside air inlet. Check local codes for requirements on minimum distance from a flue to an outside air inlet. 8. Mounting Weights Approximate Net Weight of Cooling Only System Size lbs kg lbs kg lbs kg lbs kg AHCA AHDA Approximate Net Weight of System with Heating Coil Module (no gas furnace) Size lbs kg lbs kg lbs kg lbs kg AHCA with heating coil module (steam or hot water) AHDA with heating coil module (steam or hot water) Approximate Net Weight of System with Gas Furnace or Combination Gas Furnace and Heating Coil Module AHCA AHDA Furnace* lbs kg lbs kg lbs kg lbs kg Furnace* lbs kg lbs kg lbs kg lbs kg R R S125 & R S125 & R S150 & R S150 & R S15 & R S15 & R S200 & R S200 & R S225 & R S225 & R S250 & R S250 & R S350 & R S350 & R S300 & R S300 & R S400 & R S400 & R S500 & R S500 & R S600 & R S600 & R S00 & R S00 & R SH200 & RH SH200 & RH SH225 & RH SH225 & RH SH350 & RH SH350 & RH * Prefix S indicates indoor furnace; prefix R indicates outdoor furnace; prefix SH indicates indoor furnace and a heating coil module; prefix RH indicates outdoor furnace and a heating coil module Location Model AHCA and AHDA systems may be mounted on a roof or on a cement slab. When the unit is being placed on a roof, location depends on the roof structure. If installing more than one system, it is recommended to minimize structural span deflection to discourage sound transmission. Position the unit so that the air inlet will not be facing into the prevailing wind. Always comply with the clearances in Paragraph. For condensate drainage and proper operation, it is important that the installation be level. Form RZ-NA 416, Mfg No , Page 6

7 Curb Cap Base The system is equipped with a load bearing curb cap which forms an integral part of the unit. This curb cap has bolted seams and has a "skirt" which fits over a roof curb or support rails. The curb cap is not designed to be placed directly on a roof or slab surface. The system may be mounted on roof curb purchased with the unit, a field supplied roof curb, or field supplied support rails. On a roof, a roof curb is recommended to provide a weatherproof installation as well as additional clearance for ductwork. Figure 3 - Curb Cap Base Curb Cap Extension Curb Cap Skirt Cabinet 4 (102mm) Roof curb or support rail fits inside the curb cap skirt Mounting on Field Supplied Support Rails (without a roof curb) - Figures 4 and 5 Prior to installation, be sure that the method of support is in agreement with all local building codes and is suited to the climate. If considering this type of installation in snow areas, it is recommended that the 4x4 wooden rails under the system be on a cross supported structure (see Figure 5) at least 12" (305mm) higher than the roof surface. IMPOR- TANT NOTE: If setting rails or cross support on roof surface and not decking, be sure to have sufficient tread material under the rails or supports to adequately spread the load and prevent "sinking" into the roofing material. Whether the supports are being mounted directly on the roof or slab surface or being placed "up" on an additional structure, the horizontal length of the system should be supported by two 4x4 treated wooden rails. Cut the rails to the appropriate length (Dimension "A") in Figure 4. Space the 4x4 wooden rails (See "B" Dimension, Figure 4) so that the curb cap "skirt" (See detailed view, Figure 4) will fit over the edge of the boards with the rails setting inside the horizontal length of the curb cap. If the rails are being laid directly on the roof or slab, position them as shown in Figure 4. Secure the support rails. Set the system on the rails, leaving the "ends" under open for ventilation. If the treated wooden rails are not being placed directly on the surface, cross supports should be placed under the rails at the ends of the unit and at all cabinet "joints". See Figure 5. The field supplied, weather resistant, cross-support structure must be adequate for the weight of the system (Refer to weights on page 6.) and all cross-supports should extend beyond the width of the system supporting the 4x4 wooden rails at the recommended locations. Figure 4 - Mounting Support Dimensions A 4x4 Treated Lumber B Detailed View of Curb Cap on Wooden Rail Curb Cap Skirt Curb Cap Extension Cabinet 4 (102mm) 4 x 4 treated wood rail fits inside curb cap skirt If setting rails or cross supports on roof surface, use sufficient roofing tread material to adequately spread the load and to prevent rails or supports from sinking into the roofing material. AHCA & AHDA 30, 40 55, 0 Configuration Cooling or Cooling/Dehumidifying only (no heat option); with Heating Coil Module (steam or hot water coil); or with Indoor or Outdoor Gas Furnace Size 100, 125, 150, 15, 200, or 225 With Indoor or Outdoor Gas Furnace Size 300 or 400; or with both Indoor or Outdoor Gas Furnace Size 200 or 225 and Heating Coil Module (steam or hot water coil) Cooling or Cooling/Dehumidifying only (no heat option), with Heating Coil Module (steam or hot water coil); or with Indoor or Outdoor Gas Furnace Size 250 or 350 With Indoor or Outdoor Gas Furnace Size 500, 600, or 00; or with both Indoor or Outdoor Gas Furnace Size 350 and Heating Coil Module (steam or hot water coil) A B inches mm inches mm 141-5/ / / / / / Form RZ-NA 416, Mfg No , Page

8 8. Mounting (cont'd) Figure 5 - Cross Support Locations for Mounting on Field Supplied Supports - inches (mm) Airflow Direction Locations where Cross Supports are Required Under a System that is Mounted on Rails Raised above the Surface (Distances are measured from center of support location along the curb cap.) 22 (559) 59-1/8 (1502) 95-3/8 (2423) C * 29-1/2 (49) D *Support required only with two gas furnaces or one gas furnace and a heating coil module Coil Section Blower Section Internal Ductwork Cabinet or Optional Heat Module (gas fired furnace or steam or hot water heat coil) Optional Heat Module Curb Cap Discharge Plenum Cabinet Cross Supports at Ends and all Cabinet Joints See location dimensions above; a minimum height of 12 (305mm) is recommended in snow areas. 4x4 Treated Lumber Rails AHCA and C *D Configuration AHDA inches mm inches mm 30, 40, 55, 0 Cooling or Cooling/Dehumidifying Only (no heat options) 148-3/ , 40, 55, 0 with Optional Heating Coil M odule (steam or hot water coil) 148-3/ with Indoor or Outdoor Gas-Fired Furnace Size 100, 125, 150, 15, 200, or / , 40 with Indoor or Outdoor Gas-Fired Furnace Size 300 or 400; OR with both Indoor or Outdoor Gas-Fired Furnace Size 200 or 225 and Heating Coil M odule 14-3/ /8 140 (hot water or steam coil) with Indoor or Outdoor Gas-Fired Furnace Size 250 or / , 0 with Indoor or Outdoor Gas-Fired Furnace Size 500, 600, or 00; OR with both Indoor or Outdoor Gas-Fired Furnace Size 350 and Heating Coil M odule (hot water or steam coil) 14-3/ /8 140 Form RZ-NA 416, Mfg No , Page 8

9 Mounting on a Roof Curb - Figure 6A The optional curb is a 16" fully enclosed curb as illustrated in Figure 6A. If the application is sound sensitive, consider installing a field supplied vibration isolation curb or specialty sound attenuation curb. Whether using the optional roof curb available with the air handler system or a field supplied curb, the curb must be secure, square, and level. The top surface of the roof curb must be caulked with 1/4" x 1-1/4" sealant tape or two 1/4" beads of suitable sealant. The unit must be sealed to the curb to minimize sound transmission, prevent air leakage, and to prevent water leakage into the curb area due to wind blown rain and capillary action. Except for the dimensional details specific to each model, the information and requirements in these instructions apply to all curbs. For curb assembly and installation, see Figures 6A and 6B and follow the instructions. Figure 6A - Optional Roof Curb Dimensions (See Figure 6B, page 10, for installation details.) Coil Section Blower Section Cabinet for Optional Heat Module or Internal Ductwork (cooling only) Optional Heat Module (Size 300, 400, 500, 600, or 00 gas furnace or with both gas and hydronic heat Sizes RH200, RH225, or RH350) Discharge Plenum Cabinet Curb Cap IMPORTANT: To minimize sound transfer and prevent air and water leakage, the top surface of curb MUST be sealed. IMPORTANT: If the system has a furnace section, the area enclosed by the roof curb must comply with clearance to combustible materials. If roof is constructed of combustible materials, the area within the curb must be either ventilated, left open, or covered with non-combustible material which has an "R" value of at least 5.0. If the area within the curb is left open, higher radiated sound levels may result. Roof Curb Field-supplied return air duct (See return air duct opening dimensions in Figure 6C.) Field-supplied discharge duct at optional vertical supply air opening (See opening dimensions in Figure 6C.) A C B D Roof Curb Sizes 30, 40 55, 0 Configuration Cooling or Cooling/Dehumidifying only (no heat option); with a Heating Coil M odule (steam or hot water coil); or with Gas Furnace Size 100, 125, 150, 15, 200, or 225 with Gas-Fired Furnace Size 300 or 400; OR with both a Gas-Fired Furnace Size 200 or 225 and a Heating Coil M odule Cooling or Cooling/Dehumidifying only (no heat option), with a Heating Coil M odule(steam or hot water coil); or with Gas Furnace Size 250 or 350 With Gas Furnace Size 500, 600, or 00; or with both Gas Furnace Size 350 and a Heating Coil M odule (hot water or steam) A B C D inches mm inches mm inches mm inches mm 141-5/ / / / / / / / / / / / Form RZ-NA 416, Mfg No , Page 9

10 8. Mounting (cont'd) Mounting on a Roof Curb (cont'd) Roof Curb Assembly and Installation Instructions (Figures 6A and 6B) Curbs are shipped unassembled. Field assembly and mounting on the roof are the responsibility of the installer. All hardware necessary to assemble the curb is supplied. Additional hardware must be field supplied. Before installing roof curb, verify that the size is correct for the system being installed. 1. Position curb cross rails and curb side rails as illustrated in Figure 6A. Each side rail is made up of two pieces. Fasten the side pieces with splice plates and hardware as illustrated in the splicing detail drawing in Figure 6B. Join the corners as illustrated in the corner detail. 2. Check the assembly for squareness. Adjust the roof curb so that the diagonal measurements are equal within a tolerance of + or - 1/8" (3mm). 3. Level the roof curb. To ensure proper condensate drainage and a weathertight seal between the curb cap and the roof curb, the roof curb must be leveled in both directions with no twist end to end. Shim level as required and secure curb to roof deck before proceeding with flashing. 4. Install field supplied flashing. 5. Before placing the unit on the curb, apply furnished 1/4" x 1-1/4" foam sealant tape to top surface of curb, making good butt joint at corners. The unit must be sealed to the curb to prevent water leakage into the curb area due to blown rain and capillary action. Figure 6B - Roof Curb Assembly Curb and Curb Cap Detail Cabinet 4 (102mm) Curb Cap MUST be sealed between curb cap and roof curb Roof Curb Splicing Detail Curb Cap Skirt Counter Flashing (by installer) Cant Strip (by installer) Roofing Felts (by others) 2 x 6 Wood Nailer Insulation 16 (406 mm) Curb Height For two top holes (one on each side of the plate), from inside the curb insert (4) 5/16 x 1 lag screws and (4) 5/16 lockwashers. For bottom six holes (three on each side), from outside of the curb insert (12) 5/16-18 x 3/4 long cap screws. Attach with (12) 5/16 lockwashers and (12) 5/16-18 hex nuts. (Inside of Curb) Weld, bolt, or lag screw curb to deck structure. Curb Section 16 (406mm) 1-/8 (48mm) 4 (102mm) 2 x 6 Wood Nailer 1-1/2 x 3 lb Fiberglass Flashed by the installer (flashing must be under lip of curb) Lag Screw Cap Screws Corner Detail Form RZ-NA 416, Mfg No , Page 10

11 Figure 6C - Bottom Duct Opening Dimensions in Relation to Optional Roof Curb 1-5/8" (41mm) is the measurement from duct opening to inside edge of roof curb. Duct openings should be 1" (25mm) larger than the duct size for installation clearance. H 12-1/8 (308mm) 1-5/8 (41mm) G Optional Return Air Opening 1-5/8 (41mm) Airflow Direction F 1-5/8 (41mm) G 1-5/8 (41mm) Vertical Supply Air Opening 19-1/2 (495mm) E 30, 40 55, 0 Model AHCA and AHDA Size and Configuration Cooling or Cooling/Dehumidifying only (no heat options); with Cabinet for Heating Coil M odule (steam or hot water coil); or with Gas Furnace Size 100, 125, 150, 15, 200, or 225 with Gas-Fired Furnace Size 300 or 400; OR with a both Gas-Fired Furnace Size 200 or 225 and a Heating Coil M odule (steam or hot water coil) Cooling or Cooling/Dehumidifying only (no heat options), with a Heating Coil M odule (steam or hot water coil); or with Gas Furnace Size 250 or 350 With Gas Furnace Size 500, 600, or 00; or with both Gas Furnace Size 350 and a Heating Coil M odule (steam or hot water coil) E F G H inches mm inches mm inches mm inches mm 2-1/ / / / / / / / / / / / / / / /4 133 Indoor Installation Slab Mounting - Follow the guidelines outlined under "Mounting on Field Supplied Support Rails" (page) and reference Figure 4 and Figure 5. Suspension - If the unit is suspended, vertical and horizontal support locations must comply with Figure 5, page 8. In humid environments (typically above 65 F dewpoint), it may be necessary to provide a drip pan below the unit. Rigging and Lifting DANGER: If there is any visible damage or any question about the integrity of the lifting rings, do not lift the system. Consult the factory. See Hazard Intensity Levels, page 2. See approximate net weights on page 6. If the unit is being mounted on a roof curb, apply gasketing to the roof curb prior to lifting the unit to the roof and setting it on the curb. See Figure 6A and detailed drawing in Figure 6B. Lifting rings are provided for rigging. Inspect the rings and their attachment points. If there is any doubt about the integrity of the lifting rings or their attachment points, contact the factory. If the circumstances require a rigging height that is less than 12 feet (3.M), spreader bars are required. Test lift the unit to be sure that it is secure. Lift the unit slowly, following safe lifting procedures. Failure to lift by the manufacturer's instructions could cause damage to the equipment and/or personal injury or death. The equipment manufacturer is not responsible for unsafe rigging or lifting procedures. DANGER: To prevent injury, death, or equipment damage caused by inadequate or improper rigging, test-lift the unit before attempting to install it on the roof. See Hazard Intensity Levels, page Condensate Drains A 1" PVC drain connection is located on both sides of the cabinet section that houses the evaporator coil. The coil cabinet condensate pan is fabricated for drainage using both drain outlets. Using only one condensate drain outlet can cause ponding in the condensate pan. Ensure the system is level and install a trap in each drain (see Figure ). Pitch each drain line at least 1/2" (13mm) for every 10 feet (3M) of horizontal run. Drain lines must not interfere with access panel removal. If the system has an indoor gas furance module, there is a condensate collector located beneath the gas valve service panel. For high dewpoint or high outside air application, it is recommended the collector pan be drilled and a minimum 1/4" diameter condensate line be installed. If the installation or local code requires, run all drains into a waste water system. Drain Traps The design of the drain traps is important. Since the condensate drain pan is on the blower side, there is a negative pressure at the drain relative to the ambient. The trap height must account for this static pressure difference. Maximum negative static can be determined by read- Figure - Condensate Drain Trap Dimensions (Install drains on both sides; install trap in both drains.) A = 1" (25mm) for each 1" (25mm) of maximum static pressure plus 1" (25mm) B = A + A/2 B Form RZ-NA 416, Mfg No , Page 11 A A/2 CL CL CL

12 9. Condensate Drains (cont'd) Drain Traps (cont'd) ing the negative pressure at the blower inlet and adding.2 w.c. to allow for dirty filters. If dimension "B" is not tall enough, the water seal will not hold and air will be drawn through the drain pipe into the system. If the outlet leg of the trap is too tall, water will back up into the drain pan. As condensate forms during normal operation, the water level in the traps rises until there is a constant outflow. Figure illustrates the appropriate dimensions for trapping a negative pressure system. Condensate Drain Use While improper trap design accounts for some condensate drainage system failures, incorrect maintenance of condensate drain traps can also cause problems. The combination of airborne particles and moisture in the air handler can result in algae formation in the drain pan and trap. The traps must be cleaned regularly to avoid blockage that can slow or stop water flow, resulting in backup into the system. If the drains have a cleanout opening (Figure 8), be sure to close the opening after cleaning. Figure 8 - Drain trap with cleanout To prevent air from entering always close the cleanout. 10. Optional Screened Outside Air and Barometric Relief Hoods Outside Air Hoods - The outside air hood (either Option AS2 or AS16) is a weatherized, screened hood designed to be field assembled and installed around the horizontal inlet air opening of the cabinet. Option AS2 includes moisture eliminating louvers; Option AS16 includes permanent aluminum filters. Follow the instructions that apply to the type of hood being installed. Illustrated instructions are also included with the option package. CAUTION: It is recommended that the inlet to the outside air hood NOT be facing into the prevailing wind. Allow 14" minimum clearance from the bottom of the air hood to the mounting surface. Option AS2, Screened Outside Air Hood with Moisture Eliminating Louvers (U.S. Patent 4,999,03) Figure 9 - Dimensions of Option AS2, Screened Outside Air Hood 4-5/8 (11mm) 31-11/32 (96mm) 43-1/32 (1106mm) Option AS2 Screened Outside Air Hood with Louvers NOTE: Width of hood is the same as the cabinet. 14 (356mm) minimum If the condensate drains are directly connected to a sewer, additional protection against sewage gas entering the air handler may be required. Consult with local building or health department codes. Seasonal Usage - At the beginning of the cooling season, inspect and clean the entire cooling coil cabinet including the condensate drain pan. Thoroughly clean dirt, algae, grease, and other contaminates. Inspect condensate drain pans, traps, and piping; fill traps with water to ensure proper operation. During a winter time shutdown of the cooling system it may be desirable to disconnect and remove all water from the traps and drains to prevent freeze damage. If local building codes permit, traps may be filled with an antifreeze solution. Or, piping may be designed with freeze plugs or other freeze protection methods (such as heat tape). Year Round Usage - Climates or applications with cooling requirements year round require more frequent inspections of the cooling coil cabinet and condensate drains. Depending on climate, freeze protection of traps may be required during non-cooling hours. Option AS2 Installation Instructions (Figure 10) All screw ends except those across the bottom should be inside the air hood. To avoid possible damage, it is recommended that the outside air hood be installed after the system has been placed on the roof. The air hood should be installed before the blower is operated. Do not install the hood while the system is in operation. Figure 10 - Assembly Drawing of Option AS2 Outside Air Hood Top Panel (edge must be under cabinet top) Right Side Panel Factory-assembled Louver Assembly including Moisture Eliminating Louvers (U.S. Patent 4,999,03) and Screen Bottom Panel Left Side Panel Form RZ-NA 416, Mfg No , Page 12

13 1. Install Top Panel - On the air inlet of the cabinet, remove the row of factory-installed screws attaching the system top. Slide the hood top panel under the edge of the cabinet top. The edge of the air hood top panel must be between the cabinet top and the end panel. Reinsert all of the sheetmetal screws. 2. Install Side Panels - Slide the hood right side panel into the slot between the cabinet end panel and the corner leg. Be sure that the side panel is under and to the inside of the hood top panel. Attach to the cabinet and the hood top using the required number of sheetmetal screws. Repeat with the left side panel. 3. Install Bottom Panel - Position the hood bottom panel so that it is to the inside of the two side panels and above the factoryinstalled support angle. Attach to both side panels. If the bottom panel does not rest tightly against the support angle, follow these instructions to adjust the position of the support angle: a) Slightly loosen (do not remove the screws). b) Slide the support angle up so that it is against the bottom panel. c) Tighten the screws. Attach the support angle to the hood bottom panel. The bottom panel of the hood and the support angle should be tight together; do not draw with the sheetmetal screws. 4. Install the Louver Assembly - With the intake screen toward the inside of the hood, position the vertical louver assembly in the inlet opening of the hood. Using the remaining sheetmetal screws, attach the louver assembly to the hood side panels at the holes provided. Option ASB1, Barometric Relief Hood To balance building pressure, the optional barometric relief hood is designed to automatically open to relieve positive indoor pressure. Figure 11 - Option ASB1, Barometric Relief Hood with Damper Option ASB1 Installation Instructions The barometric relief hood is shipped factory assembled. To avoid possible damage, it is recommended that the hood be installed after the system has been placed on the roof. Install the barometric relief hood before installing the outside air hood or inlet air ductwork. The barometric relief hood may be used with outside air hood, Option AS16; do not install with outside air hood, Option AS2. Install the hood before the blower is operated. Do not install the hood while the system is in operation. Refer to Figure 12 for installation location. Use sheetmetal screws to attach the hood over the opening. Figure 12 - Dimensions of both Option AS16, Outside Air Hood with Permanent Filters, and Option ASB1, Barometric Relief Hood A Option AS16 Outside Air Hood with 1 Permanent Filters B C D Option ASB1 Barometric Relief Hood Size A B C D inches mm inches mm inches mm inches mm 30, / / / , 0 43-/ / / Outside Air Hood with 1" Permanent Aluminum Filters, Option AS16 This hood has 1" permanent filters to catch moisture and a lower pressure drop than the hood with moisture-eliminating louvers (Option AS2). See position and dimensions of hood in Figure 12. Option AS16 Installation Instructions (Figure 13) NOTE: If installing a barometric relief damper, install it before installing the screened outside air hood. To avoid possible damage, it is recommended that the outside air hood be installed after the system has been placed on the roof. The air hood should be installed before the blower is operated. Do not install the hood while the system is in operation. Option AS16 outside air hood is shipped for field assembly and installation. All screw ends should be inside the air hood. Refer to the illustrations in Figure 13, page 14 and follow the instructions below. 1. Install Top Panel - On the air inlet of the cabinet, remove the factory-installed screws attaching the system top. Slide the hood top panel underneath the edge of the cabinet top. The edge of the hood top panel must be between the cabinet top and the end panel. Reinsert all of the sheetmetal screws. 2. Install Top Panel Slope Section (applies to hood with two-piece top only) - Position the slope section under the edge of the top panel. Attach with sheetmetal screws. 3. Install Side Panels - Slide the hood right side panel into the slot between the system cabinet end panel and the corner leg. Be sure that the side panel is under and to the inside of the hood top panel including the slope section. Attach to the cabinet and the hood top using the required number of 1/2" sheetmetal screws. Repeat with the left side panel. 4. Install Bottom Panel - Position the hood bottom panel so that it is to the inside of the two side panels. Attach to both side panels. 5. Install the Filter Assembly - Install filter frame with filters in place. Position the filter frame assembly in the inlet opening of the hood. Attach with sheetmetal screws, using four 1/2" screws at the front and back holes and two 3/4" screws at the center hole on each side. Form RZ-NA 416, Mfg No , Page 13

14 10. Optional Screened Outside Air and Barometric Relief Hoods (cont'd) Option AS16 Installation Instructions (cont'd) Figure 16 - Installation of Outside Air Hood, Option AS16 1/2 Sheetmetal Screws (Qty 9) P/N Hood Top (edge must be under the cabinet top) NOTE: A cabinets have 1-piece top; B cabinets have 2-piece top. 1/2 Sheetmetal Screws (Qty 8, 4 per side) P/N /2 Sheetmetal Screws (Qty 2) P/N Top Panel Slope Section - applies to AHCA/AHDA Sizes 55 and 0 1/2 Sheetmetal Screws (Qty 10, 5 per side) P/N Left Side Panel 3/4 Sheetmetal Screws (Qty 2, 1 per side) P/N Right Side Panel 1/2 Sheetmetal Screws (Qty 4, 2 per side) P/N Hood Bottom NOTE: If filter tray is mistakenly installed without filters in place, see Maintenance Section, page 42, Figure 42, for instructions on installing filters. 1/2 Sheetmetal Screws (Qty 4, 2 per side) P/N Filter Frame Assembly - holds four permanent aluminum filters 11. Duct Connections Requirements and Suggestions for Connecting and Installing Ducts Type of Ductwork - The type of duct installation to be used depends in part on the type of construction of the roof (whether wood joist, steelbar joist, steel truss, pre-cast concrete) and the ceiling (whether hung, flush, etc.). Ductwork Material - Rectangular duct should be constructed of not lighter than No. 26 U.S. gauge galvanized iron or No. 24 B & S gauge aluminum. Ductwork Structure - All duct sections 24 inches or wider, and over 48 inches in length, should be cross broken on top and bottom and should have standing seams or angle-iron braces. Joints should be S and drive strip, or locked. Through Masonry Walls - No supply air duct should come in contact with masonry walls. Insulate around all air ducts through masonry walls with not less than 1/2" (1" is recommended) of insulation. Through Uncooled/Unheated Space - Insulate all exposed supply air ducts passing through an uncooled or unheated space with at least 1/2" (1" is recommended) of insulation. Duct Supports - Suspend all ducts securely from adjacent buildings members. Do not support ducts solely by the unit duct connections. Duct Sizing - Proper sizing of the supply air ductwork is necessary to ensure a satisfactory installation. The recognized authority for such information is the Air Conditioning Contractors Association, th Street N.W., Washington, D.C A manual covering duct sizing in detail may be purchased directly from them. CAUTION: An external duct system static pressure not within the limits shown on the rating plate, or improper motor pulley or belt adjustment, may overload the motor. See Hazard Levels, page 2. Form RZ-NA 416, Mfg No , Page 14 Bottom Duct Connections - To minimize sound and vibration transmission, always use flexible duct connections at the unit for all duct connections. Insert ducts from below roof deck through roof opening into the unit. Gain access to the unit by removing side panels from the cabinet sections. Attach and seal flexible duct connections and ducts to provide airtight connections. Installation NOTE: If bottom discharge duct connection is used, seal around the horizontal connection cover plate to avoid any air or water leaks. Supply Air Duct Optional Horizontal Connection - If a horizontal discharge is being used, it is necessary to remove the cover from the opening (save the screws). The cover must then be positioned over the vertical discharge opening. Use the same screws to attach the cover over the opening in the bottom of the discharge section. The seal between the unit and the duct must be mechanical. Make duct connection with "U" type flanges on the top and bottom of the connecting duct. Slide the duct over the flanges giving an airtight fit. Provide "U" type channels for the side flanges to ensure tight joints. Use sheetmetal screws to fasten ducts and "U" channels to the flanges. Return Air Duct/Grill Size - Make certain that return air ducting or grills have a free area equal to the return duct size connection. If application uses bottom return air, be sure to remove the return air cover. Or, if needed to further balance outside and return air, the cover can be modified to decrease the size of the bottom return air opening. When restricting return air, always block the side closest to the filter leaving the full width toward the outside air entrance open. If the application requires horizontal return air, the seal between the unit and the duct must be mechanical. Make duct connection with "U" type flanges on the top and bottom of the connecting duct. Slide the duct over the flanges giving an airtight fit. Provide "U" type channels for the side flanges to ensure tight joints. Use sheetmetal screws to fasten ducts and "U" channels to the flanges.

15 12. Electrical Supply and Controls All electrical wiring and connections, including electrical grounding MUST be made in accordance with the National Electric Code ANSI/NFPA No. 0 (latest edition). In addition, the installer should be aware of any local ordinances or electric company requirements that might apply. CAUTION: If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105 C. See Hazard Levels, page 2. Disconnect Switch A disconnect switch is a required part of this installation. Refer to the supply wiring tables on pages 16 and 1 for electrical requirements by Model and size. Disconnect switches are avail- able, as options or parts, or may be purchased locally. When ordered as an optional component, the disconnect switch is shipped separately. When installing, be careful that the conduit and switch housing are clear of furnace panels and inspection plates. Allow at least four feet (1.2M) of service room between the switch and removable panels. If the system is equipped with a through-the-base electrical supply (Figure 14), mount the disconnect in the building and run the wires through the base. When providing or replacing fuses in the fusible disconnect, use dual element time delay fuses and size according to the rating plate. WARNING: To prevent injury or death due to electrocution or contact with moving parts, lock field supplied disconnect switch open. See Hazard Levels, page 2. Figure 14 - Option AVC1, Through-the-Base Electrical Connection Exit for Through-the-Base Line Voltage - run conduit into the disconnect switch Approximate Location of Through-the-Base Line Voltage Entrance (see photo below) A removable cover is provided for easy access when pulling wires. If equipped with Option AVC1, there is an entrance for line voltage supply wiring through the "floor" of the blower section. WARNING: If an optional gas furnace is included, if you turn off the power supply, turn off the gas. See Hazard Levels, page 2. Supply Wiring Check the tables on pages 16 and 1 and the rating plate for the supply voltage and current requirements. Run a separate line voltage supply with fused disconnect switch directly from the main electrical panel, making connection in the junction box. Field Supplied Wiring Size from Disconnect to Electrical Box for Connection to Motor Contactor or Starter Voltage/Phase Motor HP Wire Gauge BX Cable /3 1/2 to /8" /8" -1/2 10 1/2" /2" 460/3 1/2 to -1/2 14 3/8" /8" 55/3 1/2 to -1/2 14 3/8" /2" All external wiring must be within approved conduit and have a minimum temperature rise rating of 60 C. Conduit to and from the disconnect switch must be run so as not to interfere with the service panels. Voltage (Model AHDA) The electric supply to the unit must meet stringent requirements for the system to operate properly. Voltage supply and voltage imbalance between phases should be within the tolerances listed below. If the power is not within these voltage tolerances, contact the power company prior to operating the system. Voltage Supply - See voltage use range on the rating plate. Measure (and record) each supply leg voltage at all line disconnect switches. Readings must fall within the allowable range on the rating plate. Voltage Imbalance - In a 3-phase system, excessive voltage imbalance between phases will cause motors to overheat and eventually fail. Maximum allowable imbalance is 2%. To determine voltage imbalance, use recorded voltage measurements in this formula. Key: V1, V2, V3 = line voltages as measured VA (average) = (V1 + V2 + V3) / 3 VD = Line voltage (V1, V2, or V3) that deviates farthest from average (VA) Formula: % Voltage Imbalance = [100 x (VA-VD)] / VA Form RZ-NA 416, Mfg No , Page 15

16 12. Electrical Supply and Controls (cont'd) Supply Wiring Requirements NOTE: Supply wiring requirements do not change with the addition of a heat section. Model AHCA - All Sizes (1 Phase) Blower System Requirements Motor 115 V / 1 PHAS E 208 V / 1 PHAS E 230 V / 1 PHAS E HP Max Fuse Max Fuse Max Fuse Max Max Max with Evap with Evap with Evap Fuse Fuse Fuse Cooler Cooler Cooler === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === === Type Open Dripproof Totally Enclosed Type FLA FLA MCA Model AHCA - All Sizes (3 Phase) Blower Motor FLA MCA System Requirements 208 V / 3 PHAS E 230 V / 3 PHAS E 460 V / 3 PHAS E HP Max Max Max Max Fuse Cooler Fuse Cooler Fuse Cooler Fuse === === === === === === === === Form RZ-NA 416, Mfg No , Page 16 Open Dripproof Totally Enclosed Premium Efficiency MCA Max Fuse with Evap FLA MCA Max Fuse with Evap FLA FLA MCA MCA Max Fuse with Evap FLA 55 V / 3 PHASE MCA Max Fuse with Evap Cooler

17 Model AHDA 30 Blower System Requirements Motor 208V/3 PHASE 230V/3 PHAS E 460V/3 PHAS E Type Open Dripproof Totally Enclosed Premium Efficiency HP FLA MCA Max Fuse FLA MCA Max Fuse FLA MCA Max Fuse Models AHDA 40 and 55 Blower System Requirements Motor 208V/3 PHASE 230V/3 PHAS E 460V/3 PHAS E Type Premium Efficiency Totally Enclosed Open Dripproof HP FLA MCA Max Fuse FLA MCA Max Fuse FLA MCA Max Fuse Model AHDA 0 Blower System Requirements Motor 208V/3 PHASE 230V/3 PHASE 460V/3 PHASE Type Totally Enclosed Open Dripproof HP FLA MCA Max Fuse FLA MCA Max Fuse FLA MCA Max Fuse Blower Motor Type HP Form RZ-NA 416, Mfg No , Page 1 Premium Efficiency System Requirements 208V/3 PHASE 230V/3 PHASE 460V/3 PHASE FLA MCA Max Fuse FLA MCA Max Fuse FLA MCA Max Fuse

18 12. Electrical Supply and Controls (cont'd) Typical Wiring Diagram - Model AHCA with Standard Controls Figure 15 - W. D DISCONNECT SWITCH (SEE NOTES) BLOWER MOTOR CONTACTOR CONTACTS L1 OVERLOAD RELAY T1 L1 R L3 T /3/60 L3 L2 T2 R BLOWER MOTOR 9 L2 R 10 G GRD L1 BK BLOWER RELAY CONTACTS 1 3 BK S BK O.L A2 CR A1 W L2 BLOWER MOTOR CONTACTOR COIL & O.L V BL L1 BK 8.0 AMP FUSE BK H1 H2 H3 X1 24V H4 X2 H5 200 VA CONTROL TRANSFORMER BR W W L2 BR 16 8 BL 8 10 R 10 R R 16 CR BR BLOWER RELAY COIL DP-ST ON-OFF CONTROL SWITCH CHANGEOVER CONTROLLER FACTORY 0 DEGREES (BULB IN OUTDOOR AIR) AIR PROVING SWITCH BK BK BK R B W BK BK 40 R R 39 R 3 19 CR 1 BR BR COOL PERMISSIVE RELAY COIL COOL PERMISSIVE RELAY CONTACTS 21 8 BL 2 BL V CUSTOMER'S SENSOR (MOUNTED IN DISCHARGE AIR PLENUM) CUSTOMER'S STAGED COOLING OUTPUTS F1 CUSTOMER'S #1 FROSTSTAT F CUSTOMER'S DISCHARGE AIR CONTROLLER F3 CUSTOMER'S #2 FROSTSTAT F WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W MIXING BOX FACTORY WIRING FIELD WIRING MAKE FIELD CONTROL CONNECTION HERE TERMINAL BLOCK LOCATION MIXING BOX 10 (R) 8 (BL) (BR) OPTIONAL FACTORY WIRING OPTIONAL FIELD WIRING FIELD CONTROL WIRING TOTAL WIRE MINIMUM RECOMMENDED LENGTH WIRE SIZE 150 FEET #18 GA. 250 FEET #16 GA. 350 FEET #14 GA. MAKE FIELD POWER CONNECTION HERE COOLING COMPARTMENT BLOWER COMPARTMENT 40 (BK) 36 (BK) L1 L2 L3 S 8 10 F1 F2 F3 F OPERATING SEQUENCE 1. SET CONTROL SWITCH AT "OFF" POSITION. (OPEN) 2. TURN ON POWER, MAIN AND PILOT MANUAL GAS VALVE. 3. SET CONTROL SWITCH AT "ON" POSITION. (CLOSED) (A) ENERGIZING THE BLOWER MOTOR. (B) AIR PROVING SWITCH CLOSES, ENERGIZING THE CHANGEOVER CONTROLLER. 1) ON TEMPERATURE RISE ABOVE SETTING OF THE CHANGEOVER CONTROLLER. (A) COOLING RATE CONTROLLED BY THE DISCHARGE AIR CONTROLLER. (B) ON CALL FOR COOLING THE CORRESPONDING COMPRESSOR AND CONDENSERS ARE ENERGIZED. (C) ON ABNORMAL GAS PRESSURE OR LOW TEMPERATURE, THE CORRESPONDING COOLING CIRCUIT IS DE-ENERGIZED. 2) ON TEMPERATURE DROP BELOW SETTING OF THE CHANGEOVER CONTROLLER THE COOLING CIRCUIT IS DE-ENERGIZED. 4. SET CONTROL SWITCH AT "OFF" POSITION (OPEN) FOR SHUTDOWN. AHCA: AK-AN10 DWG# Form RZ-NA 416, Mfg No , Page 18 NOTES 1. THE FOLLOWING CONTROLS ARE SUPPLIED BY REZNOR FOR FIELD INSTALLATION: CONTROL SWITCH 2. THE FOLLOWING CONTROLS ARE SUPPLIED AS OPTIONAL EQUIPMENT: NONE 3. DOTTED WIRING AND THE FOLLOWING CONTROLS ARE SUPPLIED AND INSTALLED BY OTHERS: D/A CONTROLLER AND FROSTSTATS 4. CAUTION: IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 DEGREES C., 5. LINE AND BLOWER MOTOR BRANCH CIRCUIT WIRE SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROP BEYOND FIVE PERCENT OF SUPPLY LINE VOLTAGE. 6. USE #14 GA. WIRE FOR LINE AND MOTOR WIRING ON UNIT ( 1/2 HP. OR LESS).. USE #12 GA. WIRE FOR LINE AND MOTOR WIRE ON UNIT (10 HP.). 8. USE #18 GA. WIRE FOR 24 VOLT CONTROL WIRING ON UNIT. 9. WHEN PROVIDING OR REPLACING FUSES IN THE FUSIBLE DISCONNECT SWITCH USE DUAL ELEMENTS TIME DELAY FUSES AND SIZE ACCORDING TO 1.25 TIMES THE MAXIMUM TOTAL INPUT AMPS. 10. DISCONNECT SWITCH IS FIELD FURNISHED OR AVAILABLE FROM FACTORY AS AN OPTION. 11. ALL MOTORS MARKED IOL HAVE INTERNAL LINE BREAK. DLE

19 Typical Wiring Diagram - Model AHDA with Standard Controls Figure 16A - W. D DE-HUMIDIFIER SUMP HEATER L1 L2 DE-HUMDIDFIER CONTACTOR CONTACTS L1 T1 L3 T3 L2 T2 IOL DE-HUMIDIFIER COMPRESSOR 5 L3 6 DISCONNECT SWITCH (SEE NOTES) BLOWER MOTOR CONTACTOR CONTACTS L1 OVERLOAD RELAY T1 8 9 WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W 460/3/60 L1 L2 L3 L3 L2 T3 T2 BLOWER MOTOR 10 G GRD L1 BK BLOWER RELAY CONTACTS 1 3 BK S BK O.L A2 CR A1 W L2 BLOWER MOTOR CONTACTOR COIL & O.L V BK BK H1 H2 H3 H4 H5 W W L1 200 VA L2 8.0 AMP CONTROL FUSE TRANSFORMER BL X1 X2 BR BR 8 24V BL 8 8 DP-ST ON-OFF CONTROL SWITCH 48 AIR PROVING SWITCH BK BK BK 36 CHANGEOVER CONTROLLER FACTORY 0 DEGREES (BULB IN OUTDOOR AIR) R 10 R 10 R B W BK 2 1 PR OPTIONAL HIGH INLET TEMPERATURE CONTROLLER (BULB IN OUTDOOR AIR) R R 40 R B PR 41 TIME DELAY RELAY FACTORY 5 MINUTES 1 TD PR PR FROSTSTAT BK R BK R PR C LPCO PR NO R R 44 3 PR 19 CR 16 CR 44 1 PR 18 CR BR BR BR BR BLOWER RELAY COIL 12 DE-HUMIDIFIER CONTACTOR COIL COOL PERMISSIVE RELAY COIL BK TR TR1 BR BR 21 ENTHALPHY CONTROLLER (MOUNTED IN MIXED AIR) SETTING "A" REQUIRED 22 COOL PERMISSIVE RELAY CONTACTS 23 8 BL 2 BL 4 3 CUSTOMER'S #1 FROSTSTAT 24 F1 F V CUSTOMER'S #2 FROSTSTAT 26 2 CUSTOMER'S SENSOR (MOUNTED IN DISCHARGE AIR PLENNUM) CUSTOMER'S STAGED COOLING OUTPUTS F3 F4 FACTORY WIRING 28 FIELD WIRING CUSTOMER'S DISCHARGE AIR CONTROLLER OPTIONAL FACTORY WIRING OPTIONAL FIELD WIRING FIELD CONTROL WIRING TOTAL WIRE MINIMUM RECOMMENDED LENGTH WIRE SIZE 150 FEET #18 GA. 250 FEET #16 GA. 350 FEET #14 GA. MIXING BOX 41 (PR) 40 (R) 36 (BK) (BR) S L1 L2 L (PR) 10 (R) 8 (BL) (BR) F1 F2 F3 F MIXING BOX MAKE FIELD CONTROL CONNECTION HERE MAKE FIELD POWER CONNECTION HERE TERMINAL BLOCK LOCATION COOLING COMPARTMENT BLOWER COMPARTMENT AHDA: AK-AN10 DWG# OPERATING SEQUENCE 1. SET CONTROL SWITCH AT "OFF" POSITION. (OPEN) 2. TURN ON POWER, MAIN AND PILOT MANUAL GAS VALVE. 3. SET CONTROL SWITCH AT "ON" POSITION. (CLOSED) (A) ENERGIZING THE BLOWER MOTOR. (B) AIR PROVING SWITCH CLOSES, ENERGIZING THE CHANGEOVER CONTROLLER. 1) ON TEMPERATURE RISE ABOVE SETTING OF THE CHANGEOVER CONTROLLER. (A) ENERGIZING THE DE-HUMIDIFIER CIRCUIT AFTER A MINIMUM TIME DELAY. (B) COOLING STAGING AND REHEAT ARE CONTROLLED BY THE FIELD SUPPIED DISCHARGE AIR CONTROLLER. (C) ON CALL FOR COOLING THE CORRESPONDING COMPRESSOR AND CONDENSORS ARE ENERGIZED TO PREVENT EXCESSIVE DE-HUMIDIFER REHEAT. (D) ON ABNORMAL TEMPERATURE OR LOW GAS PRESSURE THE DE-HUMIDIFIER IS DE-ENERGIZED. (E) ON ABNORMAL GAS PRESSURE, LOW HUMIDITY OR LOW TEMPERATURE, THE CORRESPONDING COOLING CIRCUIT IS DE-ENERGIZED. 2) ON TEMPERATURE DROP BELOW SETTING OF THE CHANGEOVER CONTROLLER THE COOLING CIRCUIT IS DE-ENERGIZED. 4. SET CONTROL SWITCH AT "OFF" POSITION (OPEN) FOR SHUTDOWN. NOTES 1. THE FOLLOWING CONTROLS ARE SUPPLIED BY REZNOR FOR FIELD INSTALLATION: CONTROL SWITCH 2. THE FOLLOWING CONTROLS ARE SUPPLIED AS OPTIONAL EQUIPMENT: HIGH INLET TEMPERATURE CONTROLLER 3. DOTTED WIRING AND THE FOLLOWING CONTROLS ARE SUPPLIED AND INSTALLED BY OTHERS: D/A CONTROLLER AND FROSTSTATS 4. CAUTION: IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 DEGREES C., 5. LINE AND BLOWER MOTOR BRANCH CIRCUIT WIRE SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROP BEYOND FIVE PERCENT OF SUPPLY LINE VOLTAGE. 6. USE #14 GA. WIRE FOR LINE AND MOTOR WIRING ON UNIT ( 1/2 HP. OR LESS).. USE #12 GA. WIRE FOR LINE AND MOTOR WIRE ON UNIT (10 HP.). 8. USE #18 GA. WIRE FOR 24 VOLT CONTROL WIRING ON UNIT. 9. WHEN PROVIDING OR REPLACING FUSES IN THE FUSIBLE DISCONNECT SWITCH USE DUAL ELEMENTS TIME DELAY FUSES AND SIZE ACCORDING TO 1.25 TIMES THE MAXIMUM TOTAL INPUT AMPS. 10. DISCONNECT SWITCH IS FIELD FURNISHED OR AVAILABLE FROM FACTORY AS AN OPTION. 11. ALL MOTORS MARKED IOL HAVE INTERNAL LINE BREAK. DLE Form RZ-NA 416, Mfg No , Page 19

20 12. Electrical Supply and Controls (cont'd) Typical Wiring Diagram - Model AHDA with Factory-Installed Discharge Air Controller (Option BN10, Johnson Controls Model MS4 Multi-Stage Electronic Temperature Control) Figure 16B - W.D DEHUMIDIFIER SUMP HEATER L1 L2 DEHUMIDIFIER CONTACTOR CONTACTS L1 L3 L2 T1 T3 T2 IOL DEHUMIDIFIER COMPRESSOR 5 L3 6 DISCONNECT SWITCH (SEE NOTES) BLOWER MOTOR CONTACTOR CONTACTS L1 OVERLOAD RELAY T1 L1 L3 T3 CUSTOMER'S #1 FROSTSTAT 8 460/3/60 L2 L2 T2 BLOWER MOTOR F1 F2 9 L3 CUSTOMER'S #2 FROSTSTAT 10 G GRD F3 F L1 BK BLOWER RELAY CONTACTS 1 3 BK S BK O.L. 12 W L A2 CR A1 BLOWER MOTOR CONTACTOR COIL & O.L V BK BK H1 H2 H3 H4 H5 W W L1 200 VA L2 8.0 AMP CONTROL FUSE TRANSFORMER BL X1 X2 BR BR 8 24V BL 8 8 DP-ST ON-OFF CONTROL SWITCH 48 AIR PROVING SWITCH BK BK BK 36 CHANGEOVER CONTROLLER FACTORY 0 DEGREES (BULB IN OUTDOOR AIR) R 10 R 10 R B W BK 2 1 PR OPTIONAL HIGH INLET TEMPERATURE CONTROLLER (BULB IN OUTDOOR AIR) R R 40 R B PR 41 TIME DELAY RELAY FACTORY 5 MINUTES 1 TD PR PR FROSTSTAT BK R BK R PR C LPCO PR NO R R 44 3 PR 19 CR 16 CR 44 1 PR 18 CR BR BR BR BR BLOWER RELAY COIL 12 DEHUMIDIFIER CONTACTOR COIL COOL PERMISSIVE RELAY COIL BK TR TR1 BR BR 21 ENTHALPY CONTROLLER (MOUNTED IN MIXED AIR) SETTING "A" REQUIRED 22 COOL PERMISSIVE RELAY CONTACTS 23 8 BL 2 BL 3 4 PR PR 24 BR BR BL BR V1 V2 POWER SUPPLY STAGE 1 C1 1 Y Y 1 2 CR CUSTOMER'S 1ST STAGE 24V CONTACTOR COIL PTC SILICON SENSOR S1 SC PROCESS SENSOR STAGE 2 C2 2 PR PR BK BK 6 29 CR CUSTOMER'S 2ND STAGE 24V CONTACTOR COIL WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W FACTORY WIRING FIELD WIRING OPTIONAL FACTORY WIRING OPTIONAL FIELD WIRING FIELD CONTROL WIRING TOTAL WIRE MINIMUM RECOMMENDED LENGTH WIRE SIZE 150 FEET #18 GA. 250 FEET #16 GA. 350 FEET #14 GA. D CD * MS4 TEMPERATURE CONTROLLER * STAGE 3 C3 3 INPUT TO DISABLE REHEAT MIXING BOX 41 (PR) 40 (R) 36 (BK) (BR) S L1 L2 L (PR) 10 (R) 8 (BL) (BR) BL 80 F1 F2 F3 F MIXING BOX MAKE FIELD CONTROL CONNECTION HERE MAKE FIELD POWER CONNECTION HERE CUSTOMER'S 32 3RD STAGE 24V CR CONTACTOR COIL TERMINAL BLOCK LOCATION COOLING COMPARTMENT BLOWER COMPARTMENT OPERATING SEQUENCE 1. SET CONTROL SWITCH AT "OFF" POSITION. (OPEN) 2. TURN ON POWER, MAIN AND PILOT MANUAL GAS VALVE. 3. SET CONTROL SWITCH AT "ON" POSITION. (CLOSED) (A) ENERGIZING THE BLOWER MOTOR. (B) AIR PROVING SWITCH CLOSES, ENERGIZING THE CHANGEOVER CONTROLLER. 1) ON TEMPERATURE RISE ABOVE SETTING OF THE CHANGEOVER CONTROLLER. (A) ENERGIZING THE DEHUMIDIFIER CIRCUIT AFTER A MINIMUM TIME DELAY. (B) COOLING STAGING AND REHEAT ARE CONTROLLED BY THE DISCHARGE AIR CONTROLLER. (C) ON CALL FOR COOLING THE CORRESPONDING COMPRESSOR AND CONDENSERS ARE ENERGIZED TO PREVENT EXCESSIVE DE-HUMIDIFIER REHEAT. (D) ON ABNORMAL TEMPERATURE OR LOW GAS PRESSURE THE DEHUMIDIFIER IS DE-ENERGIZED. (E) ON ABNORMAL GAS PRESSURE, LOW HUMIDITY OR LOW TEMPERATURE, THE CORRESPONDING COOLING CIRCUIT IS DE-ENERGIZED. 2) ON TEMPERATURE DROP BELOW SETTING OF THE CHANGEOVER CONTROLLER THE COOLING CIRCUIT IS DE-ENERGIZED. 4. SET CONTROL SWITCH AT "OFF" POSITION (OPEN) FOR SHUTDOWN. AHDA: AK-AN10 DWG# NOTES 1. THE FOLLOWING CONTROLS ARE SUPPLIED BY REZNOR FOR FIELD INSTALLATION: CONTROL SWITCH 2. THE FOLLOWING CONTROLS ARE SUPPLIED AS OPTIONAL EQUIPMENT: HIGH INLET TEMPERATURE CONTROLLER 3. DOTTED WIRING AND THE FOLLOWING CONTROLS ARE SUPPLIED AND INSTALLED BY OTHERS: FROSTSTATS AND #1 - #3 STAGE COOLING CONTACTORS 4. CAUTION: IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 DEGREES C., 5. LINE AND BLOWER MOTOR BRANCH CIRCUIT WIRE SHOULD BE OF A SIZE TO PREVENT VOLTAGE DROP BEYOND FIVE PERCENT OF SUPPLY LINE VOLTAGE. 6. USE #14 GA. WIRE FOR LINE AND MOTOR WIRING ON UNIT ( 1/2 HP. OR LESS).. USE #12 GA. WIRE FOR LINE AND MOTOR WIRE ON UNIT (10 HP.). 8. USE #18 GA. WIRE FOR 24 VOLT CONTROL WIRING ON UNIT. 9. WHEN PROVIDING OR REPLACING FUSES IN THE FUSIBLE DISCONNECT SWITCH USE DUAL ELEMENTS TIME DELAY FUSES AND SIZE ACCORDING TO 1.25 TIMES THE MAXIMUM TOTAL INPUT AMPS. 10. DISCONNECT SWITCH IS FIELD FURNISHED OR AVAILABLE FROM FACTORY AS AN OPTION. 11. ALL MOTORS MARKED IOL HAVE INTERNAL LINE BREAK. MLS Form RZ-NA 416, Mfg No , Page 20

21 Figure 1 - Locations of Standard and Optional Components Airflow * Inlet Air/ Filter Section Cooling Coil Section Blower Section Optional Gas Furnace (shown), Optional Heat Coil Module, or Ductwork Cabinet (no heat option) Optional Gas Furnace (shown) or Optional Heat Coil Module Supply Air Discharge Plenum (horizontal or vertical discharge) DESCRIPTION 1 Venter Assembly 2 Optional Low Discharge Temperature Limit (Auto Reset Freezestat) 3 Optional Discharge Air Firestat 4 Optional Maxitrol Discharge Air Sensor (Opt AG8 or AG9) 4*Optional Maxitrol Amplifier (Opt AG, AG8, AG9 or AG41 with two gas furnace sections) 5 Optional Two-Stage Gas Control (Opt AG3) or Maxitrol Amplifier (Opt AG, AG8, AG9 or AG39 with one gas furnace section) 6 Optional Pilot High Gas Pressure Switch Optional Main Low Gas pressure Switch 8 Optional Main High Gas Pressure Switch 9 Combustion Air Pressure Switch 10Ignition Control 11 Time Delay Relay (optional) 12Limit Control (disc type) 13Limit Control (capillary type) 14Optional Low Discharge Temperature Limit (Freezestat) Time Delay Relay 15Optional Low Discharge Temperature Limit (Freezestat) Relay 16Optional Dirty Filter Pressure Switch 1Line Voltage Terminal Block 18Low Voltage Terminal Block 19Control Transformer 20Optional Return Air Firestat 21Line Voltage Terminal Strip 22Optional Convenience Outlet 23Blower Motor Contactor or Starter 24Control Transformer (as required) 25Dehumidification Compressor Contactor (Model AHDA only) 26Dehumidification Compressor Contactor Relay (Model AHDA only) 2Optional Control Relays (gas furnace options only) 28Auto Reset Reverse Flow Limit 29Low Voltage Terminal Strip 30Low Voltage Terminal Strip 31Optional Control Relays (cooling options only) 33Optional Cooling Discharge Air Control (the sensor is factory installed either in the discharge air plenum) 34Optional Blower Motor Location 35Standard Blower Motor Location 36Air Proving Pressure Switch 38Dehumidification Compressor (Model AHDA only) 39Dehumidification Condenser Coil (Model AHDA only) 40Main Cooling Evaporator Coil 41Dehumidification Evaporator Coil (Model AHDA only) 42Optional Two-Position Damper Motor 43Enthalpy Control 44Heating/Cooling Changeover Control 45High Ambient Temperature Control 48Line Voltage Field Connection Terminal Block 49Terminal Blocks 52Optional Damper Motor Transformer 53Field Grounding Lug 54Filter Bank 55Control Transformer (as required) 56Optional Return Air Dampers 5 Optional Outside Air Dampers Form RZ-NA 416, Mfg No , Page 21

22 12. Electrical Supply and Controls (cont'd) Standard Sequence of Operation and Optional Controls The standard cooling/heating changeover control, disables the cooling circuit based on ambient temperature (See Figure 18). Cooling discharge air control is either a factory-installed option (Figure 1, Item 33) or field supplied. Figure 18 - Changeover Control and Outdoor Cooling Changeover Guidelines Outdoor Cooling Changeover Temperature Cooling/heating changeover control to disable cooling, P/N (Item 44, Figure 1) is factory set at 68 F/20 C but may be adjusted to suit the climate. Sequence of Operation - Model AHCA (for locations of controls refer to Figure 1, pg 21) 1. Review the equipment wiring diagram, the wiring diagram for the compressors, and any other field interface diagrams for optional devices, such as smoke detectors, firestat(s), return or supply air temperature limits, time clocks, unit phase protection or transformer fuses which could override this sequence of operations. Low gas pressure or low temperature heating safety devices may also override unit operation (including cooling operation). 2. If equipped with an outside air damper, the blower will become enabled when the outside air damper is fully open. NOTE: Supply motor overload protection (such as external fuses) may override this sequence of operation. 3. Enabling the blower will close the airflow proving switch (Figure 1, Item 36) providing power through the cooling/heating changeover control (Figure 1, Item 44). The changeover control will enable cooling or optional heating (but not both, simultaneously) based on outdoor dry bulb temperature (Factory default settings: Cooling Disabled at 68 F/20 C, Heating Enabled at 65 F/18 C, Cooling/heating differential is 3 F or 2 C). 4. If the outdoor temperature is above the cooling/heating changeover setpoint, the dedicated cooling discharge air control (either factory or field supplied) will enable the compressor stages as required. NOTE: Check the unit wiring diagram to see if the system has an optional enthalpy control, Option DT4. Based on the relative humidity the enthalpy control will override the cooling enabled setpoint, providing blower only operation. If the outdoor temperature is below the changeover setpoint and the system is equipped with an optional heating section, the heating controls will be enabled. Figure 19 - Option DT4, Enthalpy Control, P/N 1230 (standard on Model AHDA) AHCA 5 F/23 C 2 F/22 C 68 F/20 C 68 F/20 C AHDA N/A N/A 65 F/18 C 65 F/18 C N/A = Model AHDA typically not used in dry climates. 5. Cooling Operation - Equipped with either factory-installed programmable discharge air control or field supplied discharge air control. If equipped with optional cooling discharge air control Option BN10 or BN11, follow the control manufacturer's literature to program the settings. Option BN10 provides 1 to 3 stage cooling for systems with evenly split cooling circuits. Option BN11 is the same control but includes relays that allow for compressor sequencing of 1/3, 2/3, and full system capacity. This option provides 3-stage control for two mismatched condensers. If equipped with a field supplied cooling discharge air control, refer to the control manufacturer's literature. Sequence of Operation - Model AHDA (for locations of controls refer to Figure 1, pg 21) In general the Model AHDA control sequence is combined with the Model AHCA control strategy to include the operation of a dedicated dehumidification mode. Read the Model AHCA control sequence above prior to reading this section. Always refer to the unit wiring diagram for details of the control sequence. Although the Model AHCA and Model AHDA control hardware is very similar, the AHDA includes a dedicated dehumidification/reheat circuit. The Model AHDA standard control sequence is designed to provide neutral air (68-2 F and 40-60% Rh). The discharge air control setpoints are programmed to maintain discharge reheat temperatures (This is accomplished by cycling cooling compressor capacity). The Model AHDA condenser reheat coil provides a nominal F rise above the cooling coil discharge temperature. The following describes the general unit operation: 1. See Model AHCA sequence of operations (Sequence 1, 2, 3 and 4). 2. If the outdoor temperature is above the cooling changeover setpoint, mechanical cooling and dehumidification are allowed. However, Model AHDA includes an outside air enthalpy control (see Figure 19) which overrides the cooling changeover control to enable or disable mechanical cooling based on outside air humidity and temperature. The factory default control setting is position A (5 F - 40% relative humidity). Other possible control settings ("B", C and D ) are not recommended. 3. If outdoor conditions are above the enthalpy control setpoint, the dehumidification compressor is enabled. Devices such as low Form RZ-NA 416, Mfg No , Page 22

23 refrigerant charge cutouts, evaporator coil frost thermostats, internal compressor overloads and control options (high temperature limit option and room relative humidity option) may override the dehumidification mode. The discharge air sensor, located downstream of the condenser reheat coil, enables compressors to hold reheat setpoint (factory default is a nominal 68 F). If equipped with a field supplied discharge air control, refer to the control manufacturer's literature. NOTE: Dehumidification compressor is enabled when entering air conditions are above outside air changeover temperature AND enthalpy control setpoint. Control Identification and Application Enthalpy and thermostat options ordered with the system are identified on the unit wiring diagram by their option code. Refer to the wiring diagram shipped with the system to identify the controls that apply to the installation. The table below identifies the control by its option code and application. The paragraphs that follow the table further explain the functions of certain optional controls. If an optional control requires field installation, consult the manufacturer's instructions in the option package and the unit wiring diagram. Option Code Standard BN10 BN11 CL50 (requires BN10 or BN11) Description Model Control Application Field-Supplied Discharge Air Control Reheat Discharge Air Control, 1 to 3 Stages of Programmable Cooling 3-Stage Discharge Air Control for Two Step Mismatched Condensers AHCA and AHDA AHCA and AHDA AHCA and AHDA AHDA AHCA CL4 Room Humidistat AHDA CL51 (requires BN10 or BN11) CL48 DT4 CN1 RC Options 2-Stage Room Cooling/Heating Thermostat 2-Stage Room Cooling/Heating Thermostat with Humidity Override Outside Air Temperature Override Economizer Override Outside Air Enthalpy Control Heat/Vent/Cool Switch Remote Control and Indicator Console AHDA AHDA AHCA (Std on AHDA) Terminal interface for customer-supplied discharge air controller, includes factory-installed cooling and dehumidification controls for proper unit operation. Includes outdoor cooling/heating changeover thermostat. Model AHDA dehumidifier is enabled based on outdoor enthalpy control. Customer-supplied condensers are staged to provide desired supply air temperature. Same as BN10 with relays for compressor sequencing of 1/3, 2/3, and full system capacity. Controls cooling based on zone setpoint by enabling discharge air control mode. If space thermostat is satisfied, dehumidifier is enabled to continuously dehumidify and reheat space. Dehumidifier sequence is disabled for entering air conditions below a nominal 55 F mixed air dewpoint. Space heating is based on zone setpoint by enabling heating discharge air control. When installing this option, the discharge air control setpoints must be modified; see paragraph on following page. Controls cooling based on zone setpoint by enabling cooling discharge air control. (Cooling space control will be limited to the outside air cooling changeover temperature.) Space heating is controlled based on zone setpoint by enabling heating discharge air control. Sensor Location N/A Discharge Air Plenum Discharge Air Plenum Designed for Field Installation in Space Designed for Field Installation in Space Setpoint Control Locations Field Supplied Control Panel Section Control Panel Section Space and Control Panel Section Space and Control Panel Section Uses zone relative humidity input to enable or disable dehumidification/reheat sequence. Dehumidification and cooling are Field Installed in Field Installed disabled when entering mixed air dewpoint is below a nominal 55 F. Space in Space When installing this option, the discharge air control setpoints must be modified; see paragraph on the following page. Same as CL50 except CL4 option (humidistat) is combined with cooling 2-stage thermostat. 1st stage enables cooling and dehumidifier (only if humidity is above setpoint). If 2nd stage cooling is enabled, dehumidifier and reheat sequence is disabled to provide useful cooling. When installing this optional control, the discharge air control setpoints must be modified; see paragraph on following page. Disables dehumidifier operation at high ambient conditions to allow useful cooling. When installing this option, the discharge air control setpoints must be modified; see paragraph on following page. Disables mechanical cooling based on low enthalpy and dewpoint. (For further information, see paragraph on the following page.) Designed for Field Installation in Space Field Installed in Mixed Air Inlet Factory Installed in Mixed Air Inlet Space and Control Panel Section Mixed Air Inlet Mixed Air Inlet AHCA and AHDA Provides manual selection of operating modes (wall mount). N/A Field Installed in Space AHCA and AHDA Wall mounted 16 gauge console (plastic or stainless steel cover) which provides unit status (indicator lights), on/off control, and remote damper adjustments. N/A Field Installed in Space Form RZ-NA 416, Mfg No , Page 23

24 12. Electrical Supply and Controls (cont'd) Optional Controls (cont'd) Room Controls, Options CL50, CL4, and CL51; and Outside Air Control, Option CL48 - When these space control options are to be used on a Model AHDA, the setpoints of the discharge control in the unit must be modified. Programmable controllers should have built-in setback controls configured for a nominal F during the reheat mode. For periods of useful cooling, reset the cooling discharge air setpoint (typically 55 F). For dehumidification/reheat mode, reset the discharge air control setpoint to prevent overcooling of the space (typically 0 F). Enthalpy Control, Option DT4 (See Figure 19) - Optional factory-installed controls could include an enthalpy control. The enthalpy control monitors the outside air temperature and humidity to override the cooling circuit with blower only operation. The enthalpy control is factory set at 5 F - 40% relative humidity (position "A"). (Settings at positions "B", "C" and "D" are not recommended.) For control location, see Figure 1, Item 43. NOTE: Enthalpy control is standard on Model AHDA. Remote Console, Options RC9, RC26, RC2, RC28, RC29, Figure 20A - Optional Remote Console RC30, RC31, and RC32) A selection of remote consoles is available with certain appropriate combinations of factory-installed controls. All consoles include indicator lights for blower and cooling operation. An on/off swtich, burner indicator light, and dirty filter light are available. If ordered with a damper control option (Option AR18, AR2, AR55, or AR5), the potentiometer will be mounted on the console if Option RC30 or RC31 is ordered. If an optional gas furnace is ordered with a gas control option that includes a Maxitrol temperature selector, the temperature selector may be mounted on the console (Option RCM). Wall-Mounted Remote Console Dimensions RC Switch Lights Optional Dimension - inches (mm) (qty) (qty) Control Length Height Depth /4 (23) -3/8 (18) 2-5/8 (6) /4 (23) -3/8 (18) 2-5/8 (6) With or 15-3/4 (400) -3/8 (18) 2-5/8 (6) Without 10-3/4 (23) -3/8 (18) 2-5/8 (6) /4 (23) -3/8 (18) 2-5/8 (6) /4 (23) -3/8 (18) 2-5/8 (6) *With or 15-3/4 (400) -3/8 (18) 2-5/8 (6) Without 15-3/4 (400) -3/8 (18) 2-5/8 (6) *RC30 and RC31 include a potentiometer NOTE: For recessed console without mounting ring, subtract /8" (22mm) from length and height. Dirty Filter Switch - If there is a dirty filter indicator light (Options RC 26, 28, 29, 30, and 31) on the console, there is a dirty filter switch in the heat section. For location, see Figure 1, Item 16. (NOTE: If the system does not include optional heat, the dirty filter switch is in this same approximate location in the ductwork cabinet.) During startups, the dirty filter switch must be set. Instructions for Setting Dirty Filter Switch (Figure 20B) With clean filters in place; inlet air, filter, and blower section doors closed; and the blower operating, increase the pressure setting by adjusting the set screw on the switch clockwise until the filter light is energized or the screw is bottomed out. At that point, adjust the set screw three full turns counterclockwise or until the screw is topended. At that setpoint, the filter light will be activated at approximately 50% filter blockage. Form RZ-NA 416, Mfg No , Page 24 Figure 20B - Dirty Filter Switch Negative pressure connection is toward the"back or bottom" of the switch (senses blower side of filters) Figure 22 - Firestat (200 F) Discharge only (Option BD2) or both inlet (return air) and discharge (Option BD3) Location: Figure 1, Items 3 and 20 Set screw (on front of switch) must be manually adjusted after the system is in operation. Positive pressure connection is toward the"front or top" of the switch (senses air inlet side of filters) Miscellaneous Optional Controls (see dampers, heat, and evaporative cooling sections for additional controls) Other control options could include a discharge air freezestat, an inlet or discharge firestat, or a 115V convenience outlet. See Figures 21, 22, and 23 to identify each control and its option code. Consult the system wiring diagram for option identification. Figure 21 - Discharge Air Low Limit (Freezestat), Option BE2 Adjustable ( F), factory set at 40 F, automatic reset with time delay relay, P/N Location: Figure 1, Item 2 Figure V Convenience Outlet, Option BC2 115V duplex receptacle includes ground fault protection; requires field supplied 115 power supply (transformer is not included) Location: Figure 1, Item Blower Motor Check the unit rating plate or motor name plate (See Figure 1, Item 34 or 35) to verify voltage, HP and type. Use an amp meter to check actual motor amps. Amps may be adjusted downward by reducing blower RPM or increasing duct system static pressure. All 55 volt blower motors and 208, 230, and 460 volt blower motors over 3HP include a starter. 208, 230 and 460 volt 1/2-3HP motors have internal overload protection but may be equipped with an optional starter (Option AN10); check the wiring diagram. 14. Cooling Coils The system is factory equipped with one of the following: Stock DX coil that has factory-supplied thermal expansion valves and piping inside the cabinet for field connection at the cooling cabinet wall facing the blower cabinet. Custom or Special DX coil that requires field supplied thermal expansion valves and piping connections at the coil. Chilled water coil that requires field supplied piping connections at the coil. All piping for connection to condensers or chillers is field supplied. Refer to connection locations in Figures 24, 25, and 26.

25 Stock DX Evaporator Coil Size Coil Coil Connections (inch) Distributor Tonnage Coil Fin Header Refrigerant Coil Spacing Diameter Condenser A Liquid Suction Tu be Nozzle Pressure Drop Option (fins/inch) (inch) TXV Range / CKT Total Line Line Size Size CKT (psig) C at 95 F LV A 1 1/8 1/2 1 1/8 1/ LV A 1 1/8 1/2 1 1/8 3 1/ C 1 1/8 1/2 1 1/8 6 1/ A 1 1/8 1/2 1 1/8 1/ LV C 1 1/8 1/2 1 1/8 6 1/ LV A 1 1/8 1/2 1 1/8 1/ C 1 1/8 1/2 1 1/8 6 1/ LV A 1 1/8 1/2 1 1/8 1/ C 1 1/8 1/2 1 1/8 1/ LV A 1 3/8 5/8 1 1/8 14 1/ A 1 3/8 5/8 1 1/8 11 1/ LV C 1 3/8 5/8 1 1/8 10 1/ A 1 3/8 5/8 1 1/8 11 1/ LV C 1 3/8 5/8 1 1/8 6 1/ LV19 B 13 6 A - C (2) 1 3/8 (2) 5/8 (2) 1 1/8 (2) 9 1/ (2) B 1 3/8 5/8 1 1/8 9 1/ Shaded coil options have mismatched capacity requirements. A Add all circuits (A + C) for total unit capacity B Two stacked coils, CKT A-C are bottom coil. Reznor recommends CKT B be used as second cooling stage (preventing unconditioned bypass air) Rows CKTS C Rated at nominal air flow, 95/6 F EAT, 50 F SST Feeds Additional Notes: Ckt A is recommended first stage, includes 3/8" hot gas side port connection (distributor side port varies from 3/8" to 1/2") Field installed refrigerant line sizes may be greater or less than coil connection sizes. Connections to stock coils are made at the cabinet openings on the vertical panel of the cooling coil cabinet that extends above and faces the blower cabinet (See Figure 24B). Make suction and liquid line connections as indicated in Figure 24A. Refrigerant lines may be smaller or larger than the connections. Avoid using oversized suction lines due to possible oil pooling. Always run lines so that they do not interfere with any cabinet door panels. The condensing unit supplier should ensure that the DX coil has adequate frost protection. Terminal strips are available for field wiring coil frost thermostats; check the wiring diagram. Cooling Coil Cabinet Transition (Top View) AIRFLOW Figure 24A - Stock DX Coil Connection Codes CKT B - SUCTION CKT A - SUCTION CKT A - LIQUID CKT B - LIQUID CKT C - SUCTION CKT C - LIQUID Figure 24B - Connection Location and Dimensions for Stock DX Coil (Option LV) - inches (mm) All dimensions to holes are centerline. Sizes 55 and 0 Sizes 30 and 40 Mixing Box Filters Cooling Coil Cabinet 13-5/8 (346) 3 (6) 3 (6) 14-1/4 (362) 3 (6) 3 (6) 5-/8 (149) 9-/8 (251) Blower Cabinet 8-1/8 (206) 3-3/4 (95) 3-3/4 (95) 3-3/4 (95) 3-3/4 (95) 3-3/4 (95) 3-3/4 (95) Heat Module 2-5/8 (6) Heat Module Suction Lines are 1-1/8" Liquid Lines are either 1/2" or 5/8" (check coil) Other openings are for optional hot gas bypass and equalizer tubes. Plenum Form RZ-NA 416, Mfg No , Page 25

26 ACCESS PANEL 14. Cooling Coils (cont'd) Custom DX Evaporator Coil Custom coils are either uneven split dual circuit coils (ordered as Option LY) or even split dual circuit coils (ordered as Option LX). The field supplied condenser system must match the cooling coil. Be sure which type of coil is on the system being installed. All custom coils require field supplied thermal expansion valves and tubing installed inside the cabinet. Liquid line coil connections are 5/8" copper tubing. Suction line coil connections are 1-3/8" copper tubing. To protect the suction headers, always support refrigerant piping independently from the coil connections. Cabinet openings for line connections are in the side panel of the cooling coil cabinet (Figure 25). Always run lines so that they do not interfere with any cabinet door panels. The condensing unit supplier should ensure that the DX coil has adequate frost protection. Terminal strips are available for field wiring coil frost thermostats; check wiring diagram. The uneven split dual circuit coils (Option LY) have 1/3, 2/3 split capacity and require matching unequal condensing unit capacities. The even split dual circuit coils (Option LX) are available for all sizes with the rows and fins per inch listed. Equal condensing unit capacities are required. Legend: AHCA or AHDA Uneven Split Dual X = Available as custom coil option Rows fpi Circuit Custom Coils = Available as standard coil option 4 12 LY14 X X = Not available on this Model 6 12 LY19 X X AHCA or AHDA AHCA or AHDA Rows fpi Even Split Dual Even Split Dual Rows fpi Circuit Custom Coils Circuit Custom Coils 6 LX65 X X X X 6 LX5 X X X X 8 LX66 X X X X 8 LX6 X X X X 2 10 LX6 X X X X 4 10 LX X X X X 12 LX68 X X X X 12 LX8 X X X X 14 LX69 X X X X 14 LX9 X X X X 6 LX0 X X X X 6 LX80 X X X X 8 LX1 X X X X 8 LX81 X X X X 3 10 LX2 X X X X 6 10 LX82 X X X X 12 LX3 X X X X 12 LX83 X X X X 14 LX4 X X X X 14 LX84 X X X X Figure 25 - Connection Location and Dimensions for Custom DX Coils (Options LY and LX) Connections are through the side panel. Access coil through small access panel and the door panel on the opposite side of the cabinet. All dimensions to holes are centerline. Cooling Coil Module OPTIONAL Optional HOT GAS Hot Gas BY-PASS Bypass OPENING Opening 1/2 LIQUID or 5/8 Liquid LINES Line OPENINGS Openings Identification of Coil Connections by Circuit (applies to Custom DX Coils) CKT A - LIQUID M L K J H G F E AIR FLOW EQUALIZER TUBE OPENINGS SENSING BULB OPENING AIRFLOW CKT B - LIQUID CKT A - SUCTION CKT B - SUCTION A B C D DRAIN 1 PVC SUCTION LINES (FACTORY 1-1/8 INSTALLE Side Views Size A B C D E F G H J K L M 30 and /4 32-1/8 33-1/2 3-1/4 #### #### ##### /2 36-1/8 36-1/2 inches 55 and /4 32-1/8 33-1/2 3-1/4 #### #### ##### /2 46-1/8 46-1/2 30 and mm 55 and Form RZ-NA 416, Mfg No , Page 26

27 Charging the System For DX coils, the refrigeration system will have to be evacuated and charged. After all connections are made, follow the compressor manufacturer's instructions to charge the DX system with refrigerant. Handling of refrigerant should only be performed by a qualified HVAC technician and in compliance with all codes and requirements of authorities having jurisdiction. WARNING: DX refrigerant circuit contains chlorodifluoromethane (HCFC-22), a substance that is believed to harm the public health and environment by destroying ozone in the upper atmosphere. Do not release HCFC-22 to the atmosphere. The U. S. Clean Air Act requires the recovery of any residual refrigerant. Chilled Water Evaporator Coil A chilled water coil has 2" MPT supply and return connections and 1/2" MPT vent and drain connections. All connections are made through the side of the cabinet (Figure 26). Run field-installed lines so that they do not interfere with any door panels. Chilled water coils require field supplied freeze protection. Coil damage caused by freezing is not covered under warranty. Figure 26 - Connection Locations and Dimensions for Chilled Water Coils (Option LC) Size A B inches inches /4 43-3/ /4 43-3/ /4 53-3/ /2 53-3/4 mm mm B A 4 (102mm) 8-/8 (225mm) 35-1/8 (892mm) 30-/8 (84mm) Coil Vent 1/2 MPT 2 MPT Chilled Water Return 2 MPT Chilled Water Supply 1/2 MPT Drain 1/2 MPT 2 MPT 2 MPT 1/2 MPT 15. Dehumidifying Refrigerant System - Model AHDA only The dehumidifying refrigerant circuit is a closed system that includes the evaporator coil, the reheat condenser coil, and the compressor. The system is fully charged with R22 refrigerant before it leaves the factory. For charging table, see page 46. Both the condenser coil and the compressor are located inside the coil cabinet downstream of the cooling evaporator coil. In this location, they act to raise the temperature of the airstream (reheat) after it has passed through the main evaporator coil. Model AHDA Dehumidifier Performance The dehumidifier can be checked in a stand-alone mode or in conjunction with the primary refrigeration system. In general, suction line superheat should be in the 8 to 12 F range, and liquid line subcooling should be in the 15 to 25 F range. When compared to conventional refrigeration performance, the dehumidifier suction pressures will tend to be higher and discharge pressures lower. The first table (on the right) shows typical performance in a standalone mode (with primary cooling compressors disabled). The second table shows Model AHDA dehumidifier performance with a nominal 55 F/12 C supply air temperature entering the reheat condenser (primary cooling compressors enabled). Both tables are developed for nominal airflow rates. Field measurements of pressures should be within 10-12% of listed values. Typical Stand-Alone Dehumidifier Pressures (primary cooling disabled) (subtract 18 psig for liquid line pressure) Coil Outside Outside Relative Suction Discharge Condition Dry Bulb Humidity PSIG PSIG Dry 65 F 30% Dry 5 F 30% Dry 80 F 30% Wet 5 F 0% Wet 80 F 0% Wet 85 F 0% Typical Dehumidifier with 55 F Air Entering the Dehumidifier Reheat Condenser (primary cooling enabled) (subtract 18 psig for liquid line pressure) Coil Outside Outside Relative Suction Discharge Condition Dry Bulb Humidity PSIG PSIG Dry 65 F 30% Dry 5 F 30% Dry 80 F 30% Wet 5 F 0% 3 18 Wet 80 F 0% Wet 85 F 0% Wet 90 F 0% Form RZ-NA 416, Mfg No , Page 2

28 15. Dehumidifying Refrigerant System (cont'd) - Model AHDA only Figure 2A - Standalone Dehumidifier Performance at Part Load Conditions Outside Air Temperature 0 F DB/62 F WB Leaving Evaporator Temperature 63 F DB/58 F WB Leaving Reheat Condenser Temperature 5 F DB Supply Air (NOTE: The primary cooling coil located between the dehumidifier evaporator and dehumidifier condenser coils is not shown.) Dehumidifier Evaporator Coil Dehumidifier Condenser Coil Dehumidifier Compressor Figure 2B - Operating Head Pressure of Dehumidifying Compressor Applies to all sizes of Model AHDA - The dehumidifying compressor is located in the coil cabinet 16. Blowers, Belts, and Drives Check belt tension. Proper belt tension and alignment is important to the long life of the belt and blower motor. A loose belt will cause wear and slippage. Too much tension will cause excessive motor and blower bearing wear. Adjust the belt tension by turning the adjusting screw on the motor base until the belt can be depressed 3/4" (19mm). See Figure 28. After correct tension is achieved, re-tighten the locknut on the adjustment screw. Be sure that the belt is aligned in the pulleys. Adjusting Blower Speed The blower speed may be adjusted to achieve the desired outlet temperature. If the system includes a furnace, any adjustment must be within the temperature rise and the static pressure limits shown on the furnace rating plate. Motors are factory set between maximum and minimum blower speeds. If the duct resistance is low, the blower may deliver too high an air volume. If the resistance is very low, the blower may deliver excess air to overload the motor, causing the overload protector to cycle the motor. Reducing the blower speed will correct these conditions. If ductwork is added to an installation, it may be necessary to increase the blower speed. Decreasing blower speed will increase outlet temperature (heating) or decrease outlet temperature (cooling); increasing blower speed will decrease outlet temperature (heating) or increase outlet temperature (cooling). Form RZ-NA 416, Mfg No , Page 28 Discharge Psig /4 (19mm) Figure 28 - Check Belt Tension Typical Operating Pressure Curves F Entering Reheat Condenser (subtract 18 psig for liquid line pressure) Suction Psig Entering Reheat Condenser Temperature F At final adjustment, amperes should not exceed motor nameplate rating. If heating is included, the temperature rise must be within the range specified on the furnace rating plate. The belt drive on these units is equipped with an adjustable pulley which permits adjustment of the blower speed. Follow these instructions to adjust the blower speed. 1. Turn off the gas (if equipped with a furnace) and the electric power. 2. Loosen belt tension and remove the belt. 3. Loosen the set screw on the side of the pulley away from the motor. 4. To increase the blower speed, turn the adjustable half of the pulley inward. To decrease the blower speed, turn the adjustable half of the pulley outward. One turn of the pulley will change the speed 8-10%. 5. Tighten the set screw on the flat portion of the pulley shaft. 6. Replace the belt and adjust the belt tension. Adjust tension by turning the adjusting screw on the motor base until the belt can be depressed 3/4". (See Figure 28.) Re-tighten the lock nut on the adjusting screw. Be sure that the belts are aligned in the pulley grooves properly and are not angled from pulley to pulley.. Turn on the gas (if equipped with a furnace) and the electric. 8. Check the motor amps with an amp meter. The maximum motor amp rating on the motor nameplate must not be exceeded. When service is complete, check for proper operation. Blower Rotation Each blower housing is marked for proper rotation. When viewed from the drive side, that rotation is clockwise. If actual rotation is not correct, interchange the two wires on the 3-phase supply connections at the terminal block. Do not change load side wiring.

29 1. Airflows and Pressure Drops CFM Ranges of Cooling and Cooling/Dehumidifying Air Handler (also applies to systems with heating coil module; for gas furnace, see below) AHCA Blower CFM Range AHDA Blower CFM Range 30 (1) 9 x (1) 9 x (1) 10 x (1) 10 x (1) 12 x (1) 12 x (2) 12 x (2) 12 x (2) 12 x (2) 12 x CFM Ranges with Optional Gas Furnace Model Size - Gas Furnace Size Blower CFM Range Model Size - Gas Furnace Size Blower CFM Range AHCA -100 (1) 9x AHCA -250 (2) 10x or (1) 10x or -350 (2) 12x AHDA -125 (1) 9x AHDA -500 (2) 15x * (1) 10x ** -600 (2) 15x (1) 12x (2) 15x (1) 12x Model Size - Gas Furnace Size Blower CFM Range -200 (1) 12x AHCA -250 (2) 10x (1) 12x or -350 (2) 12x (1) 12x AHDA -500 (2) 15x (1) 12x (2) 15x Model Size - Gas Furnace Size Blower CFM Range -00 (2) 15x AHCA -100 (1) 10x or -125 (1) 10x * Airflow for Model Size 30 above 3150 CFM requires coil AHDA -150 (1) 12x bypass option (1) 12x **Airflow for Model Size 55 above 5800 CFM requires coil -200 (1) 12x bypass option (1) 12x (1) 12x (1) 12x Pressure Drop Table (" w.c.) AHCA and AHDA CFM Evaporator Coil (Wet) Dehumidifier Coils (AHDA only) Filters (2" clean) Aluminum Permanent Disposable Pleated Screened Outside Air Hood with either Moisture- Eliminating Louvers 1" Permanent Filter Each Damper Assembly (Inlet or Discharge) Optional Heating Coil (Steam or Hot Water) Optional Evaporative Cooling (AHCA only) 6" Media 12" Media Moisture Elimination Pad Use Reznor's Use Reznor's Selection Selection Software Software for for pressure pressure losses losses specific to specific to the coils the coils installed in installed in your model your model Form RZ-NA 416, Mfg No , Page 29 Total External Static Pressure Total Static Pressure

30 OPTIONAL EQUIPMENT AND ACCESSORIES The list below indicates where to find installation information for optional equipment. Some options are located in this Optional Equipment Section. Others are located throughout the system manual. A separate manual is provided for optional gas-fired furnace installation. Option/Accessory (alphabetically listed)... Where to Look Barometric Relief Hood, Option ASB1... Paragraph 10, page 13 Controls, Cooling and Cooling/Dehumidifying... Paragraph 12, pages Dampers (Inlet or Discharge), Options AQ & AR... Paragraph 18, pages Energy Recovery Preconditioner for Makeup Air, Model ERSA...Paragraph 21, pages 36 Evaporative Cooling Module, Option AS 3, 4, 5, or 8 (AHCA only)... Paragraph 20, pages Gas Furnace (including all furnace options)...form 415/416-GF Hot Water Coil, Option LH... Paragraph 19, page 31 Roof Curb, Opt CJ... Paragraph 8, pages 9-11 Screened Outside Air Inlet Air Hood with Moisture-Eliminating Louvers, Opt AS2... Paragraph 10, page Screened Outside Air Inlet Air Hood with Filter for Eliminating Moisture, Opt AS16... Paragraph 10, pages Steam Coil, Option LS...Paragraph 19, pages 32 Through-the-Base Electrical Supply Entrance, Opt AVC1... Paragraph 12, pages Optional Dampers and Controls The system may be equipped with an outside air damper, outside and return air dampers, a discharge damper, or both inlet and discharge dampers. Check the wiring diagram shipped with the unit to verify electric damper control; dampers with electric controls will be listed by AQ or AR option designation. Discharge Air Damper (Option AQ8) A discharge air damper applies only to vertical discharge systems. The two-position discharge damper motor is located inside the downturn plenum section and is mounted on the damper jack shaft. The discharge damper closes when the unit is not operating. Outside Air Damper and Return Air Damper Options Option Code AR2 AR5 AR23 AR56 AR18 AR55 AR1 AR54 AR8 Description Zone Pressurization Control, Fully Modulating Motorized Outside and Return Air Dampers with Minimum Outside Air Damper Position and Pressure Null Switch (Outside air is horizontal opening; return air is bottom opening) Same as AR2 but both outside air and return air openings are horizontal. Zone Pressurization Control, Fully Modulating Motorized Outside and Return Air Dampers and Pressure Null Switch (Outside air is horizontal opening; return air is bottom opening) Same as AR23 but both outside air and return air openings are horizontal. 100% Outside Air and 100% Return Air Dampers with Modulating Motor (0-100% Outside Air with Remote Position Adjustment) (Outside air is horizontal opening; return air is bottom opening) Same as AR18 but both outside air and return air openings are horizontal. 100% Outside Air and 100% Return Air with Dampers with 2- Position Motor (Outside air is horizontal opening; return air is bottom opening) Same as AR1 but both outside air and return air openings are horizontal. 100% Motorized Outside Air Damper - 2 Position Motor 100% Outside and Bottom Return Air Opening, both with AR11 Dampers (M anual Adjustment) Outside air is horizontal opening; return air is bottom opening) Same as AR11 but both outside air and return air openings are AR53 horizontal. Form RZ-NA 416, Mfg No , Page 30 Application Modulates return and outside air damper positions to maintain zone pressure (modulates from minimum outside air damper position to 100%) by regulating return and outside air quantities (constant volume air flow). On shutdown, the outside air damper closes. Modulates return and outside air damper positions to maintain zone pressure by regulating return and outside air quantities (constant volume air flow). On shutdown, the outside air damper closes. Modulating damper motor provides for mixture of return and outside air as controlled by a manually set potentiometer. On shutdown, the outside air damper closes. Motorized outside air dampers are driven 100% open and return air dampers are driven 100% closed when unit is enabled. If unit is disabled, outside air damper is closed (return air damper opened) by spring return. Field installed time clocks may provide for occupied and unoccupied control sequences. Motorized outside air damper is opened 100% during unit operation. If unit is disabled, outside air damper is closed by spring return. Provides manual adjustment of return and outside air dampers Sensor Location Space Space N/A N/A N/A N/A Control Locations Field Installed in Space Field Installed in Space Field Installed in Space or Mixed Air Inlet Mixed Air Inlet Mixed Air Inlet Mixed Air Inlet

31 Damper Linkage Damper linkage provides limited air balance of return and outside air quantities. Return duct and outside air hood pressure drop differentials may require field-installed balancing dampers. Pressure Null Switch in Damper Options AR23, AR2, AR56, and AR5 The pressure null switch used in Options AR 23, 2, 56 and 5 is a Dwyer # with a range of " w.c. It is shipped separately for field installation. Refer to the following paragraphs and the manufacturer's installation instructions included with the switch. Description and Application - The pressure null switch is a diaphragm operated differential pressure switch used in makeup air applications to sense building pressure. The accompanying combination actuator/ control maintains a selected positive or negative pressure setpoint by changing the amount of outside air being introduced to the building through the outside air dampers. As more pressure is required in the building, the actuator drives the outside air damper toward the open position and the recirculated air damper towards the closed position. Conversely, as less pressure is required, the dampers move in the opposite direction. Installation Instructions for Pressure Null Switch 1. Select an indoor location free from excessive vibration where oil or water will not drip onto the switch and where ambient temperature will be within a range of -30 F (dry air) to 110 F. 2. Mount the switch with the diaphragm in a vertical plane. The switch is position sensitive and is calibrated to operate properly when the diaphragm is vertical. Mount switch securely. 3. Connect the pressure taps on the top of the switch to sources of air pressure differential. Metal tubing with 1/ 4" O.D. is recommended, but any tubing system which will not unduly restrict the air flow may be used. To maintain a positive building pressure, vent the low pressure tap to the outdoors and allow the high pressure tap to monitor building pressure. To maintain a negative building pressure, reverse the functions of the high and low pressure taps. In either case, be sure that the outdoor vent is protected from the wind and screened from insects. 19. Optional Heat Coil Modules Span Adjust Screw Electric Box The heat coil module is available with a factory-installed hot water coil (Option LH), with a factory-installed steam coil (Option LS), or designed for installation of a field supplied hot water or steam coil. Boiler, accessories, controls and lines are field supplied. Hot Water Coil, Option LH If factory equipped with a hot water coil, run the return and supply connections through the base (See Figure 30). Supply and return connections are 2" MPT. Return connection is at the top of the coil; supply connection is at the bottom. Coil has 1/2" FPT vent and drain with plugs. Use swing joints or flexible fittings in piping connections located adjacent to the heating coil. A hot water coil may be used for a coil runaround loop recovery system. Figure 30 - Hot Water Heat Coil 4. Adjustment of the Switch - The "HIGH" actuation point of the null switch is indicated on a calibrated scale secured to the transparent range screw enclosure. Building pressure is set by turning the adjustment screw. The "Low" actuation point is set by adjusting the span of the null by turning the span adjustment screw. The span range is.01 to.03" w.c. IMPORTANT: To eliminate shipping damage to the switch contacts, the manufacturer reduced the span adjustment to zero before shipping. The span should be adjusted prior to using the switch. (If the switch has been installed, disconnect the vent tube so that the null switch is in a neutral position.) Remove the electrical box cover and while observing the contacts, turn the span adjustment screw slowly in a clockwise direction. Continue turning the adjustment screw until you are able to see gaps between the common and both the low and high contacts. A minimum gap provides the greatest sensitivity. The wider the gap the lower the sensitivity. 5. See the wiring diagram included with the furnace to make electrical connections. Low Pressure Taps High AIR FLOW Cut two (2) holes in bottom 4 Field-Provided for 2-1/2 pipes. Seal around Knockouts the openings. for Locate holes Hot as Water desired. (2 Holes) Mounting Plate Pressure Adjust Screw Span of floating contact Figure 29 - Pressure Null Switch (shipped separately for use with Options AR23 and AR2) Span Adjustment Decreasing Increasing Low Common High Linkage to Diaphragm Switching action in the pressure null switch Top View Horizontal or Downturn Plenum Form RZ-NA 416, Mfg No , Page 31

32 19. Optional Heat Coil Modules (cont'd) Steam Coil, Option LS If factory equipped with a steam coil, the return and supply connections are through the cabinet side (See Figure 31). Coil connections are 2" MPT. Service access to the coil is from the side opposite the connections. Figure 31 - Steam Coil Connections AIR FLOW Openings for 2 MPT Supply and Return Connections 33-11/16 (856mm) -13/16 (198mm) 19-15/16 (506mm) 20. Optional Evaporative Cooling Module - Model AHCA only Figure 32 - Optional Evaporative Cooling Module is factory-installed on the system cabinet Form RZ-NA 416, Mfg No , Page 32 To provide comfort cooling under dry ambient conditions, the optional evaporative cooling module will operate at lower cost than the cooling coil circuit. Direct evaporative cooling works solely by exchanging latent for sensible energy in an airstream. This evaporative cooling module uses wetted rigid cellulose or rigid glass fiber media to retain water in order to allow time for evaporation. The evaporative cooling module is equipped with high efficiency pad media of either 6" or 12" rigid cellulose (Option AS3 or AS4) or 6" or 12" rigid glass fiber (Option AS5 or AS8). 6" media provides 68% efficiency; 12" media provides 90% efficiency. Efficiency values are stated at maximum allowable CFM without the addition of a moisture elimination pad with an inlet dry bulb temperature of 95 F and inlet wet bulb temperature of 65 F. The evaporative cooling efficiency is a function of the difference between inlet dry and wet bulb temperatures and face velocity. The stated cooling efficiency will rise with decrease of CFM and increase of the difference between inlet dry bulb and wet bulb air temperatures. Moisture elimination pads (Option ASA1) may be used on all units but are required for airflows above 600 FPM. The standard water controls for the evaporative cooling module include the float valve, the float switch, and pump assembly illustrated in the following paragraphs. If the cooling module has an optional AquaSaver metering water system, it will not have these controls but will have a solenoid valve with a timer assembly for controlling water flow. CAUTION: Water reservoir must be drained and pump motor turned off when outside temperature falls below 32 F/0 C. Pump must never be operated without water in the reservoir. See Hazard Levels, page 3. Installation Instructions - Evaporative Cooling Module The evaporative cooling module is completely factory assembled, installed and wired. No additional roof mounting is necessary. Follow these instructions to field connect the water supply and make necessary checks and adjustments before operating the cooling module. Supply and Drain Water Connections Float Valve (Figure 33) - In a module with pump and float controls, a float valve maintains the appropriate water level in the reservoir. Figure 33 - Connect Fresh Water Supply to Inlet of Float Valve Float Valve Rod (Inside Cabinet) Simulates Side Panel Compression Nut and Tubing Ferrule Use 1/4" Tubing for Fresh Water Supply Use field supplied 1/4" diameter tubing with a compression nut and tubing ferrule to connect the fresh water supply to the inlet of the float valve. Place nut and ferrule over tubing and insert tubing into the float valve stem. Tighten nut securely. AquaSaver Timed Metering Control System - If the cooling module is equipped with an optional timed metering system, connect a 1/ 2" water line to the fitting on the side of the cooling module. Due to various water pressures and installation conditions, the water supply line may bang abruptly when the solenoid valve in the AquaSaver system closes. This banging can be minimized by installing an optional water hammer arrestor in the supply line. When installing an arrestor, select an indoor (above 32 F/0 C) location, either horizontal or vertical, in line with and as close to the solenoid valve as possible. Follow the manufacturer's instructions to install and maintain the water hammer arrestor.

33 All Cooling Modules - A manual water shutoff valve should be installed upstream of the cooling module inlet, at a convenient non-freezing location, to allow the water supply to be turned on and off. If necessary, install a bleed line between the manual valve and the cooling module to allow drainage of the line between the shutoff valve and the cooling module. All cooling modules are equipped with overflow and drain fittings. The fittings are in the cabinet bottom and come complete with a lock nuts and a sealing gaskets. Check these fittings for tightness before installing the overflow and drain piping. The drain and overflow fittings will accommodate a 3/4" garden hose thread and are tapped with a 1/2" female pipe thread for iron pipe. Instructions for Installing Optional Fill & Drain Kit NOTE: Follow instructions included in the valve packages for attaching valves to the water line only. The remainder of the installation instructions with the valves does not apply to this type of application. Water Line Connections (See Figure 34): Supply (3-Way Valve) Connections - Connect the water supply line to "B" (normally closed). Connect the water drain line to "A" (normally open). Connect the middle outlet to supply the water to the cooling module reservoir. Drain (2-Way Valve) Connections - Connect the drain pipe from the reservoir to the valve inlet. Connect the outlet side into the drain lines from the cooling reservoir and the supply valve. Electrical Connections (requires black and white 14- gauge wire) - Refer to Wiring Diagram provided with the furnace: WARNING: Disconnect the power. Risk of electrical shock. 1. Refer to the wiring diagram for terminal connections. (NOTE: If kit is not ordered with the air handler, connections will not be shown on the diagram. Terminal connections are specific to each unit. Contact the factory for terminal connections. Be prepared to provide all air handler model information.) An optional automatic fill and drain kit (Option CT) is available that will automatically release supply water to the cooling module when a call for cooling is made and drain all water from the reservoir when the cooling switch is deactivated or a cooling thermostat is satisfied. See Figure 34. If installing an optional fill and drain kit, follow the instructions with Figure 34. Consult wiring diagram for electrical connections. (NOTE: The Option CT5 kit for an evaporative cooling module with an AquaSaver timed water control system is for freeze protection. It includes one valve, a temperature controller, and required relays.) Figure 34 - Water Connections including Optional Drain and Fill Kit Overflow fitting - 3/4 garden hose thread tapped with 1/2 female NPT Drain fitting - 3/4 garden hose thread tapped with 1/2 female NPT 2-way solenoid valve (normally open) Evaporative Cooling Module = Field supplied = Field-installed water piping 2. Run field supplied black wire from the electrical compartment (terminal on the wiring diagram) of the evaporative cooling module and connect to the black wire on both the 3- way and the 2-way valve. To drain Float valve inlet water connection (1/4 compression) or inlet water connection to solenoid valve for metering system (1/2 male fitting) 3-way solenoid valve Roof Line A (N.O.) B (N.C.) Water inlet Pressure regulator (10 psi max) Service valve 3. Run field supplied white wire from the electrical compartment (terminal on the wiring diagram) of the evaporative cooling module and connect to the white wire on both the 3- way and the 2-way valve. Bleed Line Connection (Does not apply to module with optional timed metering system.) - Shipped in Figure 35 - Bleed Line Connection Install the hose barb and attach bleed line. the evaporative cooling module bottom pan, find a 1/4" I.D. x 1/2" N.P.T. nylon bleed line fitting (hose barb). Thread the fitting into the female adapter located opposite the pump/inlet side of the water distribution line. The hose barb will protrude from the side of the cabinet (See Figure 35). Attach a 1/4" I.D. hose to the barb and run the hose to the nearest drain. Discharging a quantity of water by "bleed off" will limit the concentration of undesirable minerals in the water being circulated through the cooling module. Minerals buildup because evaporation only releases "pure water vapor" causing the concentration of contaminants in the water to increase as the evaporation process continues to occur. The minerals accumulate on the media, in the water lines, on the pump, and in the reservoir. Adequate bleed off is impor- tant to maintaining an efficiently operating evaporative cooling system. Filling & Adjusting Reservoir Water Level Float and Pump Control System - Turn on the water supply. Check for good flow. When the float valve (Figure 33) shuts off the water supply, measure the water depth. The depth of the water should be approximately 3". It may be necessary to adjust the float valve to obtain the proper water level or to free the float valve from obstructions. To adjust the float valve, simply bend the rod upward to raise the water level or downward to decrease the water level. Adjusting Water Flow Over Pads Figure 36 - Disconnect the power and use the ball valve to adjust water flow Ball Valve Proper water flow over the evaporative cooling media is critical to extend the life and maintain the efficiency of the pads. Follow the instructions to adjust water flow. Form RZ-NA 416, Mfg No , Page 33

34 20. Optional Evaporative Cooling Module - Model AHCA only Adjusting Water Flow Over Pads (cont'd) CAUTION: Do not flood the media pads with extreme quantities of water for long periods as this will cause premature breakdown of the media. An even flow from top to bottom of the media with the least amount of water is all that is required to assure maximum efficiency and media life span. More water does not provide more evaporation or more cooling. WARNING: Adjust ball valve only when the power is disconnected from the system. Failure to do so can cause electrical shock, personal injury or death. Float and Pump Control System - Using the ball valve, located in the middle of the length of hose running from the pump to the distribution line inlet (Figure 36), adjust the valve handle to allow the flow to completely dampen the media pads from top to bottom. Operate the unit watching the water flow. After 15 minutes with the blower in operation, the water should have completely dampened the pads but should not be flowing off the entering side of the media. If water is flowing off the entering side of the media, turn the system off, disconnect the power, and reduce the entering water flow. AquaSaver Timed Metering Control System - NOTE: Water flow and pad wetting time should be adjusted at maximum air flow and wet bulb depression to assure complete wetting of the media at the extreme operating conditions. In addition to adjusting water flow, the timing of the water on/off cycle can be adjusted. Adjustments are correct when l) the water rises from the holes in the sprinkler pipe (See Figure 3A) consistently along the entire pipe length, 2) the media pads wet evenly after a few "ON" cycles (no dry spots or dry streaks), and 3) a slight amount of excess water collects at the drain at the completion of the "ON" cycle. 1) AquaSaver Water Flow Adjustment - Using the ball valve illustrated in Figure 36, adjust the water flow depending on the pad height. See Figure 3A. Figure 3A - Adjust Water Flow with the Ball Valve in Figure 36 Pad A = Water rise from Height PVC Sprinkler Pipe A 24" 1/8" to 1/2" 48" 1/4" to 1/2" Through the use of a bimetallic strip, the timer is temperature sensitive and automatically increases the ON time approximately one second for each 1 F rise above the 80 F factory setting. The ON time will equal the setting for 80 F plus a second for each degree above 80 F. Let the unit cycle a few times to verify that the water flow is correct and the soaker hose is operating properly to wet the media pads completely from top to bottom during the ON cycle. All Modules - Check the reservoir for any water leaks. The reservoir was water tested, but if any small leaks are present, drain the reservoir and apply a waterproof silicone sealer around corners and welds. Evaporative Cooling Module Maintenance Reference: Troubleshooting Guide for Evaporative Cooling Module is on page 51. WARNING: Disconnect all power to the unit before doing any maintenance. Failure to do so can cause electrical shock, personal injury or death. Media - Over time, excessive amounts of mineral deposits may begin to build up on the media. Annually, scale and dirt should be washed off the entering surface of the media. Remove the pad retainers and screen (See Steps 1-3 and 6-8 of Media Replacement Instructions). Clean the media using a garden hose, mild soap, and a soft bristled brush. When the media becomes too clogged with mineral deposits and dirt that it cannot be cleaned, the pads should be replaced. The average pad life expectancy is approximately three cooling seasons. Select the correct replacement part numbers and order replacement media pads from your distributor. Follow the instructions below and remove and replace pads as shown in Figures 38A and 38B. Media Pad Replacement Part No. (each) AHCA Sizes Cellulose Fiber Glass Fiber (inches) 6" 12" 6" 12" 24 x , x 1-3/ x , 0 24 x 2-/ Qty Figure 38A - Removal and Replacement of Evaporative Cooling Module Media 2) AquaSaver Timer Adjustment - At any given temperature, the media pads should completely wet from top to bottom during the ON cycle. If the ON time is less than 45 seconds or greater than 90 seconds at 80 F, adjust the timer. Remove the junction box cover to access the timer adjustment screw (See Figure 36B). Screen Pad Figure 3B - Junction Box with AquaSaver Controls To increase the ON time, turn the Timer adjustment screw clockwise; one Adjustment cycle by 12 to 14 seconds. complete turn will increase ON Screw To decrease the ON time, turn the adjustment screw counterclockwise; one complete turn will decrease ON cycle by 12 to 14 seconds. Form RZ-NA 416, Mfg No , Page 34 Pad Retainer Screw Instructions for Replacing Evaporative Cooling Media 1. Remove the three sheetmetal screws that hold the top pad retainer. Release the top pad retainer from the cooling module.

35 2. Remove the three screws that hold the bottom pad retainer. Release the bottom pad retainer from the cooling module. 3. Disengage the inlet screen from media pads and remove. 4. Slide all media pads horizontally away from the cooling module until clear of bottom reservoir pan. Dispose of properly. 5. Slide media pads over both support rails until back stop is encountered. Media must be placed as shown in Figure 38B. Figure 38B - Media must be installed with 45 angle sloping downward toward the incoming outside air. Outside Airflow IMPORTANT: The media is made up of two different sheets of cooling material. Each sheet has its own unique angle. When replacing the cooling media, BE CERTAIN that the 45 angle slopes downward toward the incoming outside air. If the media is not installed properly, water blowoff from the media pads will occur. 45 Airflow to Space 6. Center screen on the incoming air side of the media.. Replace the bottom pad retainer by securing the retainer between the pad and the reservoir pan. Fasten with the three sheetmetal screws removed in Step Replace the top pad retainer by securing the retainer between the pad and top of the cooling module. Fasten with the three sheetmetal screws removed in Step 1. Water Feed and Distribution Line - Annually, the water supply line and the water distribution line should be flushed of debris and contaminants. 1. Remove the media pads. (Follow media replacement instructions above.) 2. Remove the water feed line from the downstream side of the ball valve. Unscrew the water bleed line barbed hose fitting. 3. Force a fresh water supply through the water inlet hose and thoroughly flush the distribution line. 4. Reassemble being careful to install media with air flow direction as shown in Figure 38B. Water Pump and Inlet Basket Screen (Does not apply to module with optional timed metering system.) - Annually, the pump and inlet basket screen should be removed, disassembled, and cleaned. Follow the instructions in Figure 39. WARNING: Do not expose pump motor or any part of the electrical box to water. Evaporative cooling pump is NOT submersible. Pump Removal and Cleaning Instructions 1. Disconnect the power supply to the unit. 2. Remove the service panel and the junction box door. Inside the junction box, disconnect the two line voltage power supply wires. 3. Upstream of the ball valve, disconnect the water feed line hose. 4. Unscrew the four screws holding the junction box to the cooling module. Remove the junction box-pump-float switch assembly. 5. Dislodge the inlet basket screen from the pump and clean any buildup of debris and dirt. Carefully remove the base cover plate from the bottom of the pump. Using a mild soap solution, wash all deposits from the inside of the pump and remove all debris from the impeller. 6. Reassemble the pump. Replace the parts in exact reverse order, being careful that everything is returned to its proper position. Pump Float Switch Pump Motor Figure 39 - Remove Junction Box, Pump and Float Switch as an Assembly Junction Box (Note: Only 208V unit will have a transformer in the junction box.) Carefully remove basket and snap-on cover plate to clean pump Form RZ-NA 416, Mfg No , Page 35

36 21. Energy Recovery Preconditioner for Makeup Air, Model ERSA If a Reznor Model ERSA Preconditioner Heat Recovery Wheel is being installed with a Model AHCA or AHDA, follow the instructions in Installation Form 480 (shipped with Model ERSA). Refer to Figure 40 for connection and overall dimension information. Top of field supplied duct connection must be symmetrical with both openings. Recommended ductwork length is 50" (120mm). Ductwork connection must be sloped and tapered as illustrated. Figure 40 - Model AHCA or AHDA with a Model ERSA Preconditioner Energy Recovery Wheel for Makeup Air Application ERSA Exhaust Air ERSA Horizontal or Bottom Return Air A ERSA Inlet Air Energy Recovery Wheel Airflow Airflow B Symmetrical Duct Connection E D C 5-5/8 (143) Bottom return air opening in unit is covered. Airflow Downturn Plenum - Horizontal or Bottom Discharge Model ERSA Preconditioner Energy Recovery Wheel - TopView Model AHCA or AHDA - Top View Energy Recovery Wheel 24 (610) F 4 (102) H G Mounting Surface Mounting Surface 11-5/16 (2980) 50 (120) 143-1/2 (3645) cooling only or with one heat module; 10 (4318mm) with two heat modules 310-5/8 (890mm) cooling only or with one heat module; 33-1/8 (8562mm) with two heat modules Model ERSA Preconditioner Energy Recovery Wheel - Side View Model AHCA or AHDA - Side View Dimensions (inches) AHCA or with AHDA ERS A A B C D E F G H 30 or / /8 28-3/ /4 30 or /4 18-1/2 4-1/4 6-1/2 28-3/8 18-1/2 14-3/8 15-1/4 55 or /4 18-1/2 4-1/4 13-1/4 42-1/8 18-1/2 14-3/8 25-1/4 55 or /4 22-1/2 5-3/4 9-3/4 42-1/8 18-1/2 14-1/4 25-1/4 Dimensions (mm) AHCA or with AHDA ERS A A B C D E F G H 30 or or or or Form RZ-NA 416, Mfg No , Page 36

37 CHECK-TEST-STARTUP 22A. Prior to Startup - should be done 24 hours prior to actual startup IMPORTANT NOTE: These startup instructions apply to components of the Model AHCA or AHDA split system air handler only. Assumptions: All connections are made; actual startup is imminent. Site is clean; all excess supplies, scraps, and debris have been removed. Outside air hood (or factory-installed evaporative cooling module) and, if applicable, barometric relief damper are installed. Clean filters are in place. Doors are removed for checks. WARNING: To prevent injury or death due to electrocution or contact with moving parts, lock disconnect switch open when doing checks prior to startup. See Hazard Levels, page 3. Air Handler System: Check clearances. See Paragraph. Be certain the electrical supply matches voltage rating of the unit. (Refer to the rating plate.) Check the wiring for loose connections or damaged wire. Tighten connections. Replace damaged wiring. (See Paragraph 12 for replacement wiring requirements.) Check all field wiring against the wiring diagram. Be sure all field-installed controls are in place. Be sure that wire gauges are as required for the electrical load. If installed outdoors, be certain that the electrical entrances are sealed against the weather. Check that fuses or circuit breakers are in place and sized correctly. Be certain optional manual reset controls (firestat and high gas pressure switch) are reset. Check blower pulley and motor pulley to be sure they are secure to the shafts. Check blower and pulleys for free movement. Check belt tension and alignment. See Paragraph 16. Remove any compressor tiedowns (Model AHDA only) and all other shipping supports and restraints. Be sure that cooling coil condensate drains are properly trapped and open. See Paragraph 9. If there is a gas furnace (Refer to Form RZ-NA 415/416-GF): Check gas piping for leaks and proper gas line pressure. See Form RZ-NA 415/416-GF, Paragraph. Bleed gas lines of trapped air. a) Turn manual shutoff valve to off position. b) Turn gas supply on. c) Observe gas meter for movement, or d) Attach pressure gauge readable to 0.1" w.c. and after turning gas on for ten seconds, turn gas supply off. No change in pressure should occur over a three-minute period. e) If either c) or d) above indicates a leak, locate leak by brushing a soapy solution on all fittings. Bubbles will appear at the leak. Repair and repeat tests. Check to make sure that the combustion air inlet and flue discharge openings are free of obstructions. If equipped with gas control Option AG41 or AG42, set the heat stage controllers. See Form RZ-NA 415/416-GF, Paragraph 13C(c). All Systems: When all checks are completed satisfactorily, close and secure all doors. If actual startup is scheduled in 24 hours, unlock the disconnect switch and turn on the electric. Model AHDA - Allow the dehumidifier compressor to warm up for at least 24 hours prior to startup. 22B. Startup (ambient temperature above 68 F/20 C; if below 68 F/ 20 C, see Paragraph 22D) Assumptions: All prior to startup checks have been completed satisfactorily. Model AHDA - Dehumidifier compressor has been allowed to warm up for at least 24 hours. If there is a gas-fired furnace section, turn on the gas. Sequence of Cooling Operation: 1. Set control switch at ON position (closed). A) Energizing the blower motor. B) Air proving switch closes, energizing changeover controller. 1) On temperature rise above setting of changeover controller, a) Energizing the dehumidifier circuit after minimum time delay (AHDA only) b) Cooling rate controlled by factory or field supplied discharge air control c) On call for cooling, the corresponding compressors and condenser motors are energized d) On low humidity or abnormal temperature, the dehumidifier is de-energized (AHDA only) e) On abnormal temperature, the corresponding cooling circuit is de-energized 2) On temperature drop below setting of the changeover controller, the cooling circuit is deenergized. 2. Set control switch at OFF position (open) for shutdown. Verify that the blower is rotating in the proper direction. Important NOTE: All refrigeration checks must be made by a qualified refrigeration technician. Model AHDA only - Check the dehumidifying circuit refrigerant subcooling (temperature of the line on the leaving side of the condenser coil). Acceptable subcooling readings range from 15 to 25 F. Check the dehumidifying circuit superheat (temperature of the gaseous refrigerant in the suction line leaving the dehumidifying coil). Superheat should be in the 8 to 12 F range. Refer to Paragraph 15 and Maintenance Section. Check all circuits. If the system is equipped with an optional dirty filter switch, set the switch. Follow the instructions in Paragraph 12. If there is a gas furnace (Refer to Form RZ-NA 415/416-GF): Adjust the changeover controller so that a call for heat exists. Observe for changeover and complete sequencing. Form RZ-NA 416, Mfg No , Page 3

38 22B. Startup (ambient temperature above 68 F/20 C) (cont'd) Sequence of Gas Furnace Operation: 1. Set the discharge temperature heating control at its lowest setting. a) Firing rate is controlled by the discharge duct sensor. b) Blower motor operation is continuous. 2. On a call for heat a) The venter motor is energized after 15-second (approximate) time delay. b) Venter flow switches from N.C. to N.O. contacts, energizing the pilot gas valve and spark gap to produce a pilot flame on each operating cycle. The sensing probe proves the presence of the pilot flame and energizes the safety switch portion of the control. The switch action de-energizes the spark gap and energizes the main valve. The main gas ignites and the unit fires. 3. If the flame is extinguished during main burner operation, the safety switch closes the main valve and recycles the spark gap. On a furnace equipped with a G0NGC-4 controller which includes lockout control, if the pilot is not established within 120 seconds (approximately), the unit locks out and must be reset by interrupting the power to the control circuit (See Lighting Instructions on the furnace). With the unit in operation, measure manifold gas pressure. Manifold pressure for natural gas should be 3.5" w.c. or 10" w.c. for propane gas. See Form RZ-NA 415/416-GF, Paragraph, for instructions for checking manifold pressure. (NOTE: If equipped with Gas Control Option AG39, AG40, AG41, or AG42, manifold gas pressure requirements are different; see Form RZ-NA 415/416-GF, Paragraph 13C.) Turn the unit off and on, pausing two minutes between each cycle. Observe for smooth ignition. If ductstat controlled, manipulate ductstat temperature adjustment slowly up and down to see if control is sequencing or modulating properly. Raising temperature setting drives burner on or to full fire. If outside air controlled, manipulate controller slowly up and down to see if control is sequencing or modulating properly. Lowering outside air temperature setting drives burner on or to full fire. NOTE: Be sure that all controls are returned to proper settings. Observe burner flame at full fire. Natural gas flame should be about 1-1/2" in height with blue coloring. Propane gas flame should be approximately the same length with blue coloring. Yellow tipping may appear on propane gas. If yellow extends beyond 1/2 to 3/4", adjust air shutters. See Form RZ-NA 415/ 416-GF, Paragraph 16. Close all panels tightly. With the heater on, check limit control by completely blocking off distribution air. The limit control should open within a few minutes, shutting off the gas supply to the main burners. 22C. After startup: Assumptions: All checks have been successfully performed and system is operating properly. All covers are secure. The area has been cleared of any excess supplies, scraps, and debris. Form RZ-NA 416, Mfg No , Page 38 Place "Owner's Envelope" containing Limited Warranty Card, this booklet, and any information on optional controls in an accessible location near the heater. Comply with the instructions on the envelope. 22D. Special Startup (ambient temperature below 68 F/20 C) Assumptions: All checks in Section 22A have been completed satisfactorily. Model AHDA - Compressor has been allowed to warm up for at least 24 hours. If there is a furnace section, turn on the gas. Adjust the changeover control so that a call for cooling exists. Observe for complete sequencing. Sequence of Cooling Operation: 1. Set control switch at ON position (closed). A) Energizing the blower motor. B) Air proving switch closes, energizing changeover controller. 1) On temperature rise above setting of changeover controller, a) Energizing the dehumidifier circuit after minimum time delay (AHDA only) b) Cooling rate controlled by factory or field supplied discharge air control c) On call for cooling, the corresponding compressors and condenser motors are energized d) On low humidity or abnormal temperature, the dehumidifier is de-energized (AHDA only) e) On abnormal temperature, the corresponding cooling circuit is de-energized 2) On temperature drop below setting of the changeover controller, the cooling circuit is deenergized. 2. Set control switch at OFF position (open) for shutdown. Verify that the blower is rotating in the proper direction. Important NOTE: All refrigeration checks must be made by a qualified refrigeration technician. Model AHDA only - Check the dehumidifying circuit refrigerant subcooling (temperature of the line on the leaving side of the condenser coil). Acceptable subcooling readings range from 15 to 25 F. Check the dehumidifying circuit superheat (temperature of the gaseous refrigerant in the suction line leaving the dehumidifying coil). Superheat should be in the 8 to 12 F range. Refer to Paragraph 15 and Maintenance Section, Paragraph 28. Check all circuits. If there is a gas furnace (Refer to Form RZ-NA 415/416-GF): Adjust the changeover controller so that a call for heat exists. Observe for changeover and complete sequencing. Sequence of Gas Furnace Operation: 1. Set the discharge temperature heating control at its lowest setting. a) Firing rate is controlled by the discharge duct sensor. b) Blower motor operation is continuous. 2. On a call for heat a) The venter motor is energized after 15-second (approximate) time delay.

39 b) Venter flow switches from N.C. to N.O. contacts, energizing the pilot gas valve and spark gap to produce a pilot flame on each operating cycle. The sensing probe proves the presence of the pilot flame and energizes the safety switch portion of the control. The switch action de-energizes the spark gap and energizes the main valve. The main gas ignites and the unit fires. 3. If the flame is extinguished during main burner operation, the safety switch closes the main valve and recycles the spark gap. On a furnace equipped with a G0NGC-4 controller which includes lockout control, if the pilot is not established within 120 seconds (approximately), the unit locks out and must be reset by interrupting the power to the control circuit (See Lighting Instructions on the furnace). With the unit in operation, measure manifold gas pressure. Manifold pressure for natural gas should be 3.5" w.c. or 10" w.c. for propane gas. See Form RZ-NA 415/416-GF, Paragraph, for instructions for checking manifold pressure. (NOTE: If equipped with Gas Control Option AG39, AG40, AG41, or AG42, manifold gas pressure requirements are different; see Form RZ-NA 415/416-GF, Paragraph 13C.) Turn the unit off and on, pausing two minutes between each cycle. Observe for smooth ignition. If ductstat controlled, manipulate ductstat temperature adjustment slowly up and down to see if control is sequencing or modulating properly. Raising temperature setting drives burner on or to full fire. If outside air controlled, manipulate controller slowly up and down to see if control is sequencing or modulating properly. Lowering temperature setting drives burner on or to full fire. NOTE: Be sure that all controls are returned to proper settings. Observe burner flame at full fire. Natural gas flame should be about 1-1/2" in height with blue coloring. Propane gas flame should be approximately the same length with blue coloring. Yellow tipping may appear on propane gas. If yellow extends beyond 1/2 to 3/4", adjust air shutters. See Form RZ-NA 415/ 416-GF, Paragraph 16. If the system is equipped with an optional dirty filter switch, set the switch. Follow the instructions in Paragraph 12. Close all panels tightly. With the heater on, check limit control by completely blocking off distribution air. The limit control should open within a few minutes, shutting off the gas supply to the main burners. 22E. After Special Startup: Assumptions: All checks have been successfully performed and system is operating properly. All covers are secure. The area has been cleared of any excess supplies, scraps, and debris. Place "Owner's Envelope" containing the system wiring diagram, this booklet, a Limited Warranty Form, and any optional information in an accessible location near the heater. If an optional extended warranty applies, be sure to keep the extended warranty form for future reference and verification of warranty. Comply with the instructions on the owner's envelope. If the system includes an optional heat section, it may be operated at temperatures below 68 F/20 C to provide heated makeup air to the building. When cooling season begins, redo the cooling startup procedures to verify proper cooling operation. If the system does not include an optional heat section, redo the cooling startup procedures when the cooling season begins. Form RZ-NA 416, Mfg No , Page 39

40 23. Summary of Factory Settings System Controls Changeover Control, P/N Cooling Discharge Air Control, P/N Cooling Discharge Air Control, P/N , with relay for sequencing Enthalpy Control, P/N 1230 (standard on Model AHDA) Outside Air Temperature Override, P/N Discharge Temperature Low Limit (Freezestat), P/N Firestat, P/N 4282 Dehumidifier Controls Compressor High Pressure Cutoff Gas Furnace Controls Ductstat, P/N 4100 Maxitrol Discharge Sensor, P/N High Temperature Limit Switches Auto Reset with Linear Sensor, P/N Auto Reset Disc Type Sensor, P/N 5041 Auto Reset Disc Type Sensor, P/N Auto Reset Disc Type Sensor, P/N 5953 High Gas Pressure Switch, P/N Low Gas Pressure Switch, P/N Heat Stage Controls with AG41 and AG42 Std or Opt Settings Adjustable Std Disables cooling (and enables Yes - Minimum cooling disable setpoint for optional heating) at 68 F/20 C Model AHDA is 65 F/18 C and for Model AHCA is 68 F/20 C. BN10 BN11 Cooling OFF Setpoint, 1 or 2 stage is 52 F: 3 stage is 51 F. Reheat setpoint is automatically 15 higher. Yes - Programmable; follow control manufacturer's instructions and instructions in Form CP48 for adjusting cooling OFF setpoint. DT4 on Position "A" - 5 F/23 C - Positions "B", "C", and "D" are not AHCA 40% Relative Humidity recommended CL F/40 C Yes, Range 25 to 225 F / -3 to 10 C BE2 40 F / 4 C Yes, Range 25 to 225 F / -3 to 10 C BD2 and 200 F / 93 C No; Manual Reset BD3 Std or Opt Settings Type Std Opens on psig between high and low side Internal Pressure Relief (IPR) - Applies to Model AHDA dehumidifier circuit compressor Std or Opt Setting Adjustable Std 0 F / 21 C Yes, Range F / C Opt N/A Yes, Range F / C Std Opens 20 F/132 C No - one installed in all furnace sections Opens 125 F/51 C No - in furnace section of units with one furnace Opens 145 F/62 C No - in first furnace section of units with two furnaces Opens 10 F/6 C No - in second furnace section of units with two furnaces Opt Natural Manual Reset, Adjustable 2-16" w.c. Propane Manual Reset, Adjustable 2-16" w.c. Opt Natural Automatic Reset, Adjustable 1-6" w.c. Opt Field set required; see Form Yes 415/416-GF Form RZ-NA 416, Mfg No , Page 40

41 MAINTENANCE AND SERVICE IMPORTANT: Do not release refrigerant to the atmosphere! If required service procedures include the adding or removing of refrigerant, the service technician must comply with all federal, state and local laws. The procedures discussed in this manual should only be performed by a qualified HVAC technician. WARNING: Turn off the power before performing all maintenance procedures (except to check refrigerant pressure and temperature). Lock disconnect switch in OFF position. If the system has a furnace section, when you turn off the power supply, turn off the gas. See Hazard Levels, page Maintenance Requirements This unit will operate with a minimum of maintenance. To ensure long life and satisfactory performance, a system that is operating under normal conditions should be inspected according to the following schedule. If in an area where an unusual amount of dust or soot or other impurities are present in the air, more frequent inspection is recommended. Maintenance Schedule Monthly Inspect filters; clean or replace as needed. See Paragraph 25. Inspect and clean the condensate drains. See Paragraph 9. Semi-Annually Inspect the blower belt for tension, wear, and alignment. See Paragraph 26. If equipped with a Class 2 blower, lubricate the bearings. See Paragraph 26. Annually Beginning of the cooling season or more frequently in year-round cooling climate: Inspect the wiring for any damaged wire. Replace damaged wiring. Inspect the condensate drain pan and drains. Clean the coil cabinet and fill the traps. See Paragraph 9. Inspect/clean all coils. See Paragraph 2. Check refrigeration system. Follow compressor manufacturer's instructions. Model AHDA - Check dehumidifying refrigeration system. See Paragraphs 28 and 29. Model AHCA - If equipped with an evaporative cooling module, clean the media, the distribution lines, and the pump. See Evaporative Cooling Module Maintenance in Paragraph 20. If there is a gas-fired furnace section, refer to Form 415/416-GF (beginning of the heating season): Clean all dirt and grease from the primary and secondary combustion air openings. Check the pilot burner, main burners, and heat exchanger for scale, dust, or lint accumulation. Clean as needed. If there is a hot water or steam coil (beginning of the heating season): Clean the coil. See Paragraph Filters Inlet Air Filters The system is equipped with either 2" permanent filters or 2" pleated disposable filters. See inlet air filter arrangements in Figure 41. If filters are replaced, use only these types of filters. Do not use flat disposable filters. If equipped with permanent aluminum filters, remove the filters, wash, rinse, allow to dry, and put them back in the cabinet. If equipped with disposable filters, replace dirty filters. Exposure to humid makeup air can accelerate filter degradation; therefore, systems with pleated disposable filters require more frequent filter inspection and replacement. Replacement Inlet Air Filter Sizes Models AHCA and AHDA 30 and 40 Filter Disposable Permanent Size Qty Pleated Aluminum 16" x 20" 2 P/N P/N " x 16" 1 P/N P/N " x 20" 1 P/N P/N Models AHCA and AHDA 55 and 0 Filter Disposable Permanent Size Qty Pleated Aluminum 25" x 20" 2 P/N P/N " x 25" 2 P/N 1198 P/N Form RZ-NA 416, Mfg No , Page 41

42 25. Filters (cont'd) Inlet Air Filters (cont'd) Figure 41 - Inlet Air Filter Arrangements and Removal Instructions Removal Instructions To remove filters, remove the small filter access panel shown. Airflow Filter Access Panel (one on each side, except with chilled water or custom DXcoil then filter access is from non-control side only) On each level (upper and lower), the filters fit into a sliding frame. To remove the upper set of filters, slide the upper frame out. To remove the lower set of filters, slide the lower frame out. Filter Arrangements (w x h) Models AHCA and AHDA 30 and x x x x 20 Filter Arrangements (w x h) Models AHCA and AHDA 55 and 0 25 x x x x 20 Outside Air Hood Filter (Option AS16) If equipped with outside air hood Option AS16, there is a 1" permanent, aluminum filter at the entrance of the hood. The filter acts as a moisture eliminator. When inspecting the inlet air filters, inspect the outside air hood filter. If cleaning is needed, remove the filter, clean, rinse, dry and re-install. Refer to Figure 42 for removal and installation instructions. Figure 42 - Filters in Outside Air Hood Option AS16 Remove two screws. DO NOT remove this screw on either side. CAUTION: If the blower is unused for more than three months, pillow block bearings should be purged with new grease prior to startup. Belt Check belt for proper tension and wear. Adjust belt tension as needed. Replace worn belts. Proper belt tension and alignment is important to the long life of the belt and motor. A loose belt will cause wear and slippage. Too much tension will cause excessive motor and bearing wear. Proper tension should allow the belt to be depressed 1/2-3/4" (13-19mm). If adjustment is required, the adjustment screw is on the motor base. When adjustment is correct, tighten the lock nut on the adjusting screw. Be sure the belt is aligned in the pulleys. Figure 43 - Check belt tension 26. Drive Components Blower Bearings Systems with a Class 1 blower have permanently lubricated cartridge ball bearings. Systems with a Class 2 blower have pillow block bearings that require cleaning and lubricating. Clean the fitting and add type NLG-2 or -2 standard grade grease. Add grease with a handgun until a slight bead forms at the seal. Be careful not to unseat the seal by over lubricating. If the system operates at an RPM less than 1000, lubricate the bearings every six months. If the system operates above 1000 RPM, lubricate the bearings every four to five months. NOTE: If unusual environmental conditions exist (temperatures below 32 F/0 C or above 200 F/93 C, moisture, or contaminants), more frequent lubrication is required. Form RZ-NA 416, Mfg No , Page 42 Remove one screw on each side. Remove and Re-install Filters 1. Remove four screws as illustrated. Lower the tray. 2. Pull out filters. Clean with soap and water. Rinse and allow filters to dry. 3. Slide clean dry filters into tray. 4. Re-position tray and replace screws. 3/4 (19mm) 2. Coil Maintenance Inspect all cooling coils at the beginning of the cooling season or more often if needed. If equipped with optional steam or hot water coil, inspect it at the beginning of the heating season or more often if needed. Main Cooling Coil Access Models AHCA and AHDA - If the cooling coils are piped to the upper face of the cabinet toward the blower, the coil can be accessed by removing both coil cabinet doors and the filters. If the coil connections are through the side, remove the small access panel, the door on the side opposite the connections, and the filters. Heating Coil Access The optional hot water coil can be accessed by removing both of the heat module cabinet doors. An optional steam coil can be accessed by removing the door on the side opposite the connections.

43 Dehumidifier Coils Access Model AHDA Only - To inspect the dehumidifier coils, remove the coil cabinet doors and the coil inspection plate. The inspection plate is located opposite the control side of the coil cabinet between the dehumidifier evaporator coil and the main evaporator coil. Coil Maintenance Inspect all coils for debris, dirt, grease, lint, pollen, mold, or any element which would obstruct heat transfer or airflow. Inspect coils and tubing for physical damage. Inspect feeders, piping connections, coil headers, and return bends for signs of fatigue, rubbing, and physical damage. Clean the coils annually, or more often if needed. Use the proper tools and follow the instructions carefully to avoid damaging the coil. Use of a non-acid based coil cleaner is recommended. Due to possible damage to the coil, high pressure spray is not recommended. 1. Verify that the power has been turned off and the disconnect switch locked. 2. Remove the cabinet door panels and any blockoff plates or access panels that need to be removed to reach the coils. When cleaning cooling coil, remove the filters. 3. Use a soft brush to remove any dirt and debris from both sides of the coil. 4. Spray with cold or warm (not hot) water and a cleaning solution (non-acid based coil cleaner is recommended). Due to possible damage to the coil, high pressure spray is not recommended. First spray the leaving airflow side, then the inlet airflow side. As much as possible, spray the solution perpendicular to the face of the coil. Follow the instructions on the cleaning solution. When cleaning process is complete, rinse both sides with cool, clean water. 5. Replace the panels. 28. Model AHDA - Check Dehumidifier Refrigerant Pressure and Temperatures IMPORTANT: Do not release refrigerant to the atmosphere! If service procedures include the adding or removing of refrigerant, the qualified HVAC service technician must comply with all federal, state, and local laws. Check Refrigerant Pressures Refer to Paragraph 15 for the correct operating pressures. Connect the pressure gauge and check the pressures. Check Refrigerant Temperatures Check the dehumidifier circuit superheat; recommended superheat temperature is 10 F to 20 F. Check the dehumidifier circuit refrigerant subcooling. Acceptable range is 15 F to 25 F. 29. Model AHDA - Compressor Maintenance and Replacement Handling A 3/8" eye bolt can be used to facilitate handling of the compressor. Use lifting eyes only; do not lift by copper tubing. To prevent internal damage, compressors must ALWAYS be held upright. CAUTION: When lifting compressor, use lifting eyes only. DO NOT LIFT compressor by copper tubing. Compressor MUST remain upright. DANGER: Refrigeration circuits are high pressure systems. Hazards exist that could result in personal injury or death. It is therefore required that the removal and installation of a hermetic compressor be performed by qualified personnel only. DANGER: Never use oxygen to pressurize a refrigeration system. Oxygen can explode on contact with oil and could result in personal injury or death. When using high pressure gas such as nitrogen for this purpose, ALWAYS USE A PRESSURE REGULATOR that can control the pressure down to 1 or 2 psig. Failure to use a regulator will result in extremely high pressure which could exceed the burst pressure of the compressor or other system components and result in personal injury or death. WARNINGS: For your safety, wear eye protection and gloves when handling refrigerant and when brazing. Have a fire extinguisher nearby when sweating tubing. The following instructions include major points of consideration that will ensure proper installation and protect you from potential personal injury. Please use the following 13 steps as a checklist, taking each item in order before proceeding to the next. If more information is required, call the Reznor Service Department. WARNING: To avoid electrical shock, power to the compressor must remain off during performance of Steps 1 through 8 below. LOCK DISCONNECT SWITCH OPEN. 1. Verify Proper Application Verify that the replacement compressor is identical to the model being replaced. Replacing a compressor with a model other than the Reznor supplied replacement will void the product warranty. Model AHDA Dehumidifier Compressor P/N's Voltage 208/ Tons P/N Model AP16A-ZA3-x CRA xxx Tons P/N Model Tons GP283-xxx P/N Model Tons GP33-xxx P/N Model GP513-xxx Form RZ-NA 416, Mfg No , Page 43

44 29. Model AHDA - Compressor Maintenance and Replacement (cont'd) 2. Determine Cause of Initial Failure and Remove the Compressor In order to prevent a second failure, the cause of the original failure must be determined. Identify the cause and make the necessary repairs. CAUTION: When lifting compressor, use lifting eyes only. DO NOT LIFT compressor by copper tubing; damage will occur. WARNING: Wear eye protection and gloves when handling refrigerant and when brazing. a) BEFORE REMOVING THE FAULTY COMPRESSOR, remove refrigerant charge using proper recovery procedures. Call for the name of the nearest Dupont authorized distributor or ASK-KLEA (IGI) for information on their refrigerant reclaim programs. b) Mark the terminals and remove the electrical leads from the compressor. c) Open access ports so that pressure does not build up in the system. Before unsweating stubs from the compressor, cut suction and discharge tubing with a tubing cutter. WARNING: Have a fire extinguisher near. The compressor contains oil. There is a risk of fire when unsweating stubs. Use a high temperature torch to sweat the suction line and the discharge line loose from the compressor. d) To assure excess oil does not remain in the system, measure the oil in the failed compressor, see the table below. NOTE: If oil level is found to be significantly lower than noted below, the excess oil should be flushed from the system prior to installing the new compressor. Oil Charge Each compressor ships with a full oil charge. The only approved replacement oil for each compressor is shown below. The oils are highly refined with special additives for high and low temperature stability and high pressure stability. Dehumidifier / Reheat Circuit Compressor Compressor Oil Charge Nominal P/N's Type (cc) (oz) Oil Type Circuit Capacity Single Trane Oil # tons 1219 Single Sunisco or Alkyl Benzene tons 120 / 1208 Single Trane Oil # tons 1205 / 1206 Single Trane Oil # tons 1203 / 1204 Single Trane Oil # tons CAUTIONS:The compressor may contain harmful acids - be sure to handle with extreme care using proper protective equipment. After checking the oil charge level, return the oil to the compressor being replaced. Braze the discharge and suction copper closed. On most compressors the connections are made with rotalock threaded fittings, these fittings should be properly capped. Form RZ-NA 416, Mfg No , Page 44 Brazing closed or capping off the compressor connections is desirable in order to prevent further contamination of the compressor and to prevent spillage from the compressor. Use an approved disposal method to dispose of the compressor and any excess oil. 3. Mount the Replacement Compressor Do not remove the dust cover or rubber shipping plugs until all other system connections are complete (i.e. new liquid line filter drier(s) installed and all tubing changes made - see Steps 4 and 5). The compressor should not be open to the atmosphere for more than 15 minutes. Be sure to use the new mounting grommets that were shipped with the compressor. If the mounting sleeves shipped with the compressor are used, the mounting bolts will bottom out when tight. Use care not to overcompress the mounting grommets when the mounting sleeves cannot be used. The mounting diagram shown in Figure 44 illustrates a typical isolator installation. 5/16 Mounting Bolt* Lockwasher*. (1.8mm) Figure 44 - Installation of a Typical Isolator on a Compressor Foot *Field supplied 4. Install New Filter Driers Nut Sleeve Flat Washer* Compressor Foot Vibration Isolator Mounting Plate Unit Base When a compressor is replaced, Reznor recommends the replacement of the liquid line filter drier (dehumidifier compressor circuit, Replacement P/N 1380) and the temporary addition of a field supplied suction line filter drier. If the new compressor is replacing a compressor with a burned motor, installation of a high acid neutralizing filter drier is recommended. Use an acid test kit to determine contamination level. Size the suction line drier 20% greater than nominal circuit capacity; see the table on the left. When cleanup procedures are complete, remove the temporary suction filter drier. If the suction filter drier is not removed, liquid accumulation may occur in the suction filter drier and cause damage to the compressor. NOTE: Always remove the old liquid line filter drier. 5B. Rotalock Fittings (illustrated in Figure 45) on Suction and Discharge Lines - Applies to all Model AHDA dehumidifier circuit compressors The compressors used on these models have rotalock threaded fittings. The rotalock nuts ship on the compressor and should be used to mount the sleeves. See illustration in Figure 45. When opening and closing the rotalock fittings, use care to avoid damage to seals and surfaces. After tightening the fittings, inspect joints for leaks - See Step 6.

45 Figure 45 - Compressor with Rotalock Fittings Rotalock Fittings at both Suction and Discharge Line Connections - Use care not to damage seals and surfaces 6. Check System for Leaks After installation is complete, pressurize the system to approximately 5 psig using nitrogen and a few ounces of R22 refrigerant. Check for leaks using a halide torch, soap bubbles, or an electronic halogen leak detector. When all connections test satisfactorily, release pressure using proper recovery procedures, then proceed to the next step. CAUTION: Do not use the replacement compressor as an evacuation assist and never apply voltage to a compressor while it is in a vacuum.. Evacuate the System Use a vacuum pump rated for a minimum capacity of 6 cfm. Vacuum must be pulled on both the discharge (high) and suction (low) sides of the system. Evacuate to 500 microns or lower. Moisture and air are harmful to the system because they increase the condensing temperature, raise the discharge gas temperature, cause formation of acids, and cause oil breakdown. Acids are corrosive to the components in the refrigeration system. This includes the piping, refrigerant specialties, and the compressor s mechanical and electrical components. The elevated temperatures can cause copper plating resulting in premature mechanical failure of the compressor. To establish that the unit is leak-free and moisture-free, a standing vacuum test is recommended. The maximum allowable rise over a 15-minute period is 200 microns. If the rise exceeds this, either there is a leak or moisture still exists in the system. See the chart in Figure Check the Electrical System While the system is being evacuated, connect the electrical leads to the compressor terminals. Verify that the electrical connections at the compressor terminals are consistent with the Model AHDA wiring diagram on page 19 (or the diagram on the system). It is a normal practice to replace all starting components any time a compressor is changed. Check all connections and terminals to be sure they are tight. Connect the crankcase heater. The crankcase heater is energized continuously and is extremely important to proper compressor operation and long life. Figure 46 - Pressure Rise vs Time 2,400 2,200 NOTE: Always check gauge hose connections for leaks prior to evacuation. Pressure (microns) 2,000 1,800 1,600 1,400 1,200 1, If system pressure continues to rise the system has leaks. T he leaks must be found and sealed prior to re-evacuating. If system holds a steady vacumm in this region, there are no leaks. But the system is not sufficiently dry. Reevacuate to remove excess moisture If system holds a vacumm at or below 00 microns, the system is sufficiently dry and has no leaks. 200 Evacuate to 500 microns or lower. 0-20Time varies by moisture level. Time (minutes) Form RZ-NA 416, Mfg No , Page 45

46 29. Model AHDA - Compressor Maintenance and Replacement (cont'd) Crankcase Heaters The crankcase heaters are belly band type. The belly band type is an external heater attached to the lower portion of the welded shell. The external band heaters require a ground wire to the unit. WARNING: Voltage should not be applied to the compressor with the terminal cover and retainer removed as personal injury could result. It is recommended that tin plated or silver plated phosbronze connectors be used. Brass connectors are NOT acceptable. Only copper wire should be used for the power wiring to the compressor terminals. Figure 4 - Compressor Crankcase Heater Applies to all dehumidifier circuit compressors "Bellyband" Crankcase Heater Voltage Utilization Range The voltage utilization range for all compressors is plus or minus 10 percent of the nominal compressor voltage. For dual voltage compressors (208/230) the voltage utilization range is (-10%) from the low voltage and (+10%) from the high voltage. EXAMPLE: 208/230 voltage utilization range is volts. 9. Charge the System When a vacuum of at least 500 microns is reached, close gauge valve, remove vacuum pump, and break the vacuum using system refrigerant VAPOR. LIQUID can be used to break the vacuum if it is connected to the liquid line ONLY. Charge the system according to the weights given in the table. Be sure to compensate the charge for the addition of the suction line filter drier. The preferred superheat should be F at the compressor, but may vary based on ambient conditions. NOTE : Weighing in the system charge to the specifications will help point out system faults that may still exist. 10. System Startup Assure voltage to compressor does not drop below minimum allowable voltage (eg. 18 volts for 230/ , 415 volts for ) during the period the compressor is trying to start. If a low voltage or voltage imbalance condition exists, the electrical problem MUST BE determined and corrected prior to operating the unit. Voltage Imbalance - Voltage imbalance is becoming a more common problem. In a 3-phase system, excessive voltage imbalance between phases will cause motors to overheat and compressors to fail. Maximum allowable imbalance is 2%. To determine voltage imbalance, measure and record the voltage of all three phases. Take Form RZ-NA 416, Mfg No , Page 46 Capacity (tons) and Model R22 Charge (lbs) AHDA Tons Lbs the measurements at the compressor terminals with the compressor operating. Voltage Imbalance Formula: Key: V1, V2, V3 = line voltages as measured at the compressor terminals VA (average) = (V1 + V2 + V3) / 3 VD = Line voltage (V1, V2, or V3) that deviates farthest from average (VA) Formula: % Voltage Imbalance = [100 x (VA-VD)] / VA If the imbalance is within the 2% tolerance, voltage imbalance is not a problem and the system may be operated. If the imbalance exceeds the 2% tolerance, follow the procedures below. Solutions to Voltage Imbalance: The cause for a voltage imbalance problem can originate at the power company or can be caused inside the building. Try the following on-site solution to determine if the problem can be easily resolved. Roll the connections at the compressor terminals one forward. Connect the wire now on Terminal 1 to Terminal 2, 2 to 3, and 3 to 1. Re-measure and re-calculate the voltage imbalance. If the imbalance is within 2%, the system may be operated. If the imbalance is not within tolerance, roll the connections one more forward. Re-measure and re-calculate the voltage imbalance. If the imbalance is within 2%, the system may be operated. If the voltage imbalance still exceeds 2%, do not start the system. Contact the building owner or person responsible to have an electrician analyze the buildings's power supply and load distribution. 11. Check Suction Pressures and Superheat Suction pressures and superheat are measured at the compressor inlet; see Paragraph 15. EXAMPLE: Step 1. Measurements - Temperature = 55 F Pressure = 6 psig Step 2. From Table below, convert Pressure to Saturation Temperature 6 psig = 45 F Step 3. Subtract Saturation Temperature from Measured Value 55 F - 45 F = 10 F degrees of Superheat REFRIGERANT (R-22) Temperature Saturation Temperature Saturation ( F) ( C) Pressure (psig) ( F) ( C) Pressure (psig)