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AHU Series

Installation and Maintenance Manual

Revised 11-11

6720220327

Unitary

Air Handler

DX AND HYDRONIC SERIES

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Summary of Contents for DX Series

Page 1: ...AHU Series Installation and Maintenance Manual Revised 11 11 6720220327 Unitary Air Handler DX AND HYDRONIC SERIES ...

Page 2: ...stallation Operation Safety Rules 7 Minimum Clearances 8 Arrangement 8 Upflow Application 8 Horizontal Application 8 Downflow Application 9 Downflow Conversion Kit 10 Furnace Installation 11 Electrical Wiring 11 Line Voltage Wiring 11 Field Installed Electric Heater Kits 12 Variable Speed Motor 13 Replacing ECM Motor 13 ECM Interface Board Thermostat Connections 14 Control Wiring 15 Condensate Dra...

Page 3: ...0 Blower Motor HP 1 3 1 2 3 4 1 1 Blower Motor Type ECM Style Constant CFM Variable Speed Available Electrical v p h 208 230 1 60 Shipping Weight lbs 120 145 202 212 217 Installation Weight lbs 108 132 170 172 180 HY025 HY035 HY049 HY061 HY071 Nominal Capacity Tons 2 3 4 5 6 Water In Connection Size in 7 8 7 8 1 1 8 1 1 8 1 1 8 Standard Filter Size 16 x 20 x 2 20 x 20 x 2 20 x 24 x 2 20 x 24 x 2 2...

Page 4: ...50 12 50 13 50 11 00 6 75 16 75 14 00 11 00 10 75 2 00 1 50 5 00 DX035 21 00 48 00 21 00 19 00 12 50 14 50 13 00 6 75 20 00 17 00 12 75 10 30 2 30 4 35 5 00 DX049 24 50 58 75 21 75 23 35 21 25 19 75 17 25 6 75 26 00 23 00 16 75 14 35 2 30 4 35 4 50 DX061 24 50 58 75 21 75 23 35 21 25 19 75 17 25 6 75 26 00 23 00 16 75 14 35 2 30 4 35 4 50 DX071 24 50 58 75 21 75 23 35 21 25 19 75 17 25 6 75 26 00 ...

Page 5: ...8 75 2 00 HY035 21 00 48 00 21 00 19 00 12 50 15 50 13 00 6 75 20 25 19 75 14 25 12 75 10 25 7 50 2 25 4 25 10 50 2 50 HY049 24 50 58 75 21 75 19 50 16 25 19 75 17 25 6 75 28 25 27 75 19 75 16 00 13 50 10 25 2 25 4 25 12 50 2 25 HY061 24 50 58 75 21 75 19 50 16 25 19 75 17 25 6 75 28 25 27 75 19 75 16 00 13 50 10 25 2 25 4 25 12 50 2 25 HY071 24 50 58 75 21 75 19 50 16 25 19 75 17 25 6 75 28 25 27...

Page 6: ...red or moved in the normal upright position as indicated by the UP arrows on each carton at all times If unit stacking is required no more than stacking 2 units are permissible Safety Considerations Installationandservicingofthisequipmentcanbe hazardousduetosystempressureandelectrical components Onlytrainedandqualifiedpersonnel shouldinstall repair orservicetheequipment Untrainedpersonnelcanperfor...

Page 7: ... not approved for outdoor installation therefore they must be installed inside the structure being conditioned Do not locate in areas that are subject to freezing Caution If electric heat is used a minimum clearance of 1 must be maintained on all sides of the supply air duct and or plenum continuously for up to 3 INSTALLATION OPERATION SAFETY RULES 1 Read these rules and instructions carefully Fai...

Page 8: ...he front of the unit The unit can be serviced entirely from the front including replacing the filter Be sure to route primary and secondary condensate drain piping so as not to obstruct replacement of filter ARRANGEMENT Units are shipped from the factory arranged to be installed in an upflow or horizontal right to left air flow position Horizontal right to left means when facing the front of the u...

Page 9: ...at will be noticeable If the unit is located in a crawl space the bottom of the unit must be at least 4 above grade to prevent flooding of the electrical parts due to heavy rains The unit is shipped to be installed without modification in a right to left configuration See ARRANGEMENT for details For left to right applications 1 Remove the unit access panels 2 Remove the cooling coil 3 Move the con...

Page 10: ...n in Figure 2 3 Remove the 6 screws 3 on each side of the unit securing the evaporator coil rails Unit is ready to be reassembled in the downflow configuration Figure 2 Evaporator Coil Disassembly for conversion to downflow Assembly Instructions 1 Invert the air handler 180 and reinstall the coil support rails just above the blower Use the six 6 screws that were removed in the disassembly instruct...

Page 11: ...ners of the cabinet Use two screws to secure the furnace to the floor B If the Combustible Floor Base is not used you secure the unit to the floor by drilling two holes through the furnace base at the left and right front inside corners of the cabinet Use two screws to secure the unit to the floor 7 Use caulking sealers and or tape to seal between the combustible floor base and the opening on the ...

Page 12: ...top and tighten the set screw to clamp down on the wire 12 You will need to insert both green wires into the ground lug and tighten the set screw 13 Tighten the screws on the cable connectors until the power supply wires are securely fastened to the connector The 15kW and 20kW models may be connected to a single or dual branch circuit Caution Refer to the NEC National Electrical Code NFPA 70 or th...

Page 13: ...pply Connections If the air handler has been installed prior to installing the electric heaters or if an older unit is being replaced the supply power wires must be checked to make sure the wires are the proper sizes to handle the current load for the heaters If the supply power wire size is incorrect new wires will need to be installed Follow the Power Supply Wiring instructions for proper instal...

Page 14: ...ng section for proper connection methods when utilizing the malfunction light 6 Loosen the wheel set screw by placing wrench on the screw head and turning counter clockwise Loosen the wheel set screw until the shaft can spin freely 360 while inside the wheel hub The wheel set screw is located on the wheel hub on the opposite side of the motor 7 Remove the blower motor from the blower housing by re...

Page 15: ...mper to the TEST position and energize G on the thermostat connection block If the motor ramps up to 100 power then the motor itself is functioning normally Always remember to replace the jumper to NORM or after testing and reset the unit thermostat to restore normal operation Caution Do not set the ADJ jumper to the setting when electric heaters are installed Doing so may cause the heaters to cyc...

Page 16: ...wards the drain in both directions to facilitate condensate removal See Figure 7 Figure 6 ELEVATION LINE WHEN MOUNTED LEVEL 1 4 Figure 7 DUCT SYSTEM A supply air outlet collar is provided on all units to facilitate duct connections Refer to the dimensional sheet at the beginning of this manual for physical dimensions of the collar A flexible connector is recommended for supply air duct connections...

Page 17: ...ully for water leaks and repair appropriately Units are equipped with female pipe thread fittings Consult the specification sheets of the paired condensing section for sizes Teflon tape sealer should be used when connecting water piping connections to the units to insure against leaks and possible heat exchanger fouling Do not over tighten the connections Flexible hoses should be used between the ...

Page 18: ...cturer to be held libel for any water damage in connection with this air handler Total piping should not exceed 140 feet All piping should be ID 7 8 OD copper CPVC piping may be used in applications where the water temperature does not exceed 150 F It is recommended that the water shut off valve for the water heater be located close to the water heater Isolation valves are also recommended It is r...

Page 19: ...at about 4 or 8 o clock B If bulb installation is made on a vertical run the bulb should be located at least 6 inches from any bend and on the tubing side opposite the plane of the bend On vertical bulb installations the bulb should be positioned with the bulb capillary tube at the top C The bulb should be insulated using thermal insulation to protect it from the effect of the surrounding ambient ...

Page 20: ...qualified service technician should insure that the air handler and coil are completely drained of water PERIODIC MAINTENANCE The filter must be changed monthly to permit proper airflow for safe and efficient operation All other maintenance should be performed by a licensed technician CONNECTING THE UNIT MOUNTED CONTROLLER WATER TO WATER UNIT TO YOUR HYDRONIC HY AIR HANDLER Unit Mounted Controller...

Page 21: ... being added to the system then locate the two wires connected to the S2 connections on the back of the unit mounted controller and follow them to where they are attached to the side of the water pipe the point of contact will be underneath some insulation tape Carefully remove the insulation tape to free the loose ends of the wire Crimp on 1 4 insulated terminal connections to the wires and proce...

Page 22: ...5 B 2549 2549 2549 2513 2489 2464 2426 2401 2375 2336 C 2537 2537 2537 2537 2513 2476 2451 2413 2375 2336 D 2525 2525 2525 2501 2476 2451 2413 2388 2349 2323 PART LOAD Y1 BLOWER PERFORMANCE DX UNITS MODEL NOMINAL TONS MOTOR HP VOLTS 1 PH 50 60 HZ BLOWER WHEEL JUMPER CFM 0 1 CFM 0 2 CFM 0 3 CFM 0 4 CFM 0 5 CFM 0 6 CFM 0 7 CFM 0 8 CFM 0 9 CFM 1 0 DX025 2 1 3 240 9X6 A 849 849 849 849 849 849 849 841...

Page 23: ...S SETTING FOR NORMAL OPERATION ADJUSTMENT SETTING NORM OR PART LOAD AIR FLOW FULL LOAD AIR FLOW MOTOR BOARD JUMPERS SETTING FOR NORMAL OPERATION ADJUSTMENT SETTING NORM OR DX025 750 950 JUMPER B NORM 500 800 JUMPER D NORM DX035 1000 1200 JUMPER C NORM 800 1200 JUMPER C NORM DX049 1300 1700 JUMPER D NORM 1000 1600 JUMPER D DX061 1500 2000 JUMPER D NORM 1400 2000 JUMPER D DX071 1500 2200 JUMPER D NO...

Page 24: ...nge without prior notice Revised 11 11 6720220327 SYSTEM PIPING SCHEMATICS CLOSED LOOP GROUND LOOP SYSTEM With GEOTHERMAL STORAGE TANK RESIDENTIAL APPLICATION OPEN SYSTEM GROUND WATER SYSTEM With GEOTHERMAL STORAGE TANK RESIDENTIAL APPLICATION Piping Schematics ...

Page 25: ...3 26 8 35 35 1 10 36 1 41 7 45 9 52 9 50 60 DX035 1 2 2 03 0 0 2 5 2 5 10 10 1 5 18 0 20 8 24 6 28 1 35 40 1 10 36 1 41 7 47 1 54 1 60 60 2 15 18 0 36 1 20 8 41 7 24 5 47 2 28 0 54 2 30 50 35 60 DX049 3 4 2 5 0 0 3 1 3 1 15 15 1 5 18 0 20 8 25 0 28 5 35 40 1 10 36 1 41 7 47 6 54 6 60 70 2 15 18 0 36 1 20 8 41 7 25 0 47 6 28 5 54 6 30 50 30 60 2 20 36 1 36 1 41 7 41 7 47 6 47 6 54 6 54 6 50 50 60 6...

Page 26: ...26 Unitary Air Handler DX and Hydronic Series Subject to change without prior notice Revised 11 11 6720220327 electrical Diagrams Air Handler without Electric Heat Electrical Diagrams ...

Page 27: ...27 Unitary Air Handler DX and Hydronic Series 6720220327 Revised 11 11 Subject to change without prior notice electrical Diagrams 5Kw Electric Heater Package Electrical Diagrams ...

Page 28: ...28 Unitary Air Handler DX and Hydronic Series Subject to change without prior notice Revised 11 11 6720220327 Electrical Diagrams electrical Diagrams 10Kw Electric Heater Package ...

Page 29: ...29 Unitary Air Handler DX and Hydronic Series 6720220327 Revised 11 11 Subject to change without prior notice Electrical Diagrams electrical Diagrams 15Kw Electric Heater Package ...

Page 30: ...30 Unitary Air Handler DX and Hydronic Series Subject to change without prior notice Revised 11 11 6720220327 electrical Diagrams 20Kw Electric Heater Package Typical Wiring Diagrams ...

Page 31: ...___________________________ Entering Leaving Fluid Temp ______________ _ _____________ ______________ _ _____________ Fluid Flow gpm _______________________________ ______________________________ Fluid Side Pressure Drop _______________________________ ______________________________ Suction Discharge Pressure psig ______________ _ _____________ ______________ _ _____________ Suction Discharge Temp...

Page 32: ...601 N W 65th Court Ft Lauderdale FL 33309 Phone 954 776 5471 Fax 954 776 5529 www boschtaxcredit com www bosch climate us ...

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