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Sophomore Series 4000 & 5000 Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions
5.9 Top Duct Cover
1.
Carefully unpack the top duct cover.
2.
Remove the front access covers from the appropriately selected top duct cover.
3.
Place the back/side portion of the top duct cover on top of the unit and against the wall using screws. (It will be necessary to
push back the insulation to access the bare metal to start the screws.)
4.
Fasten the bottom edges of the cover to the top of the unit using screws.
5.
Complete and test all service connections (electrical, plumbing, refrigeration, etc.) required for the unit operation.
6.
Reinstall the front access cover of top duct cover.
For more information on assembly and installation consult the Information Package that is sent with the Unit.
1.
It is necessary to remove and reassemble the back from the RPA in order to fasten it to the back of the air handler. Remove
the back panel of the RPA.
2.
Field cut openings must be made in the back panel of each rear plenum assembly (RPA). These holes must directly line up
with the wall sleeve openings and must be sized so as not to restrict airflow and still maintain a seal between the unit and the
wall.
Installation Note: When a partition (or partitions) is designed into the RPA and wall sleeve, a separation of air between
two or more air paths must be maintained from the back of the ventilator to the backside of the exterior louver. (refer to
job specific shop or installation drawings)
3.
To assure a tight seal between the air handler and the RPA, apply 3/8” foam tape to the 1” wide front edges of the RPA and
any partitions it may have.
Tip: Keep the tape back from the outside edges by at least ¼” so the tape does not become unsightly when compressed.
4.
Position the Classroom Air Handler directly in front of its final installation position. Allow enough room behind the unit for the
RPA and some room to work. (Once the RPA is mounted it may become more difficult to relocate the ventilator.)
5.
Place the RPA tight against the back of the unit so that it is flush with the sides and top of the unit, as shown in the installation
drawings.
6.
Begin by fastening the RPA to the back of the unit at one of the top corners. Place a screw through the 1” front mounting
flange of the RPA side panel into the back of the unit. Proceed by similarly placing a screw into the opposite top corner and
then down both of the RPA side flanges at approximately 18” apart. (Do not mount the RPA to the air handler through the top
or bottom cover of the RPA as these may interfere with the removal of components during future service maintenance.)
7.
Reinstall the back panel and apply 1”' low density foam tape (supplied with RPA) around the perimeter of the back panel of
the RPA. This provides filler between the RPA and the wall surface.
8.
If the unit has a cooling coil and drain pan, pass the drain hoses that come out the back of the unit through the RPA. These
hoses must gravity drain downward to the outside or to a drain. They must allow condensate to drain freely to the outside
without restriction and without inhibiting the operation of the dampers. (It will be necessary to cut away enough of the bird
screen in the back of the exterior louver to allow the condensate hoses to pass between the blades of the louver to the
exterior.)
Refer to custom shop and installation drawings instructions in the Information Package that was sent with the unit for
exact measurements, descriptions and installation details.
You may require an assistant's help for this procedure.
