Firstco XHD Direct Drive Double Wall Air Handler User Manual

XHD Direct Drive Double Wall Air Handler
User Manual WHD / XHD Direct Drive ECM
DIRECT DRIVE DOUBLE WALL AIR
HANDLER
0-10VDC input controlled

Installation, Operation, and Maintenance Instructions

WARNING TO INSTALLER, SERVICE PERSONNEL, AND OWNER
Altering the product, improper installation, or replacing parts with unauthorized parts voids all warranty or implied warranty and may result in adverse operational performance or possible hazardous conditions to service personnel and occupants. Company employees or contractors are not authorized to waive this warning.
NOTES:

• Read the entire installation instruction manual before starting the installation.
• These instructions are intended as a general guide and do not supersede national, state, or local codes in any way.
• These instructions must be left with the property owner.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified licensed installer, service agency, or your distributor for information or assistance. The qualified licensed installer or service agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with kits or accessories when installing.
Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult and follow all building codes and National Electrical Code (NEC) for special requirements.
Recognize safety information listed below:
WARNING:
This WARNING signifies general hazards which could result in personal injury or death.
WARNING:
This WARNING signifies electrical shock hazards which could result in personal injury or death.
CAUTION:
CAUTION is used to identify unsafe practices which would result in product and property damage.
NOTE:
NOTE is used to highlight suggestions which may result in enhanced installation, reliability, or operation.

GENERAL

The manufacturer does not warrant equipment subjected to abuse. Metal chips, dust, drywall tape, paint overspray, etc. can void warranties and liability for equipment failure, personal injury, and property damage.
The manufacturer assumes no responsibility for equipment installed in violation of any code requirement.
These instructions give information relative to the installation of these air handlers only. For other related equipment refer to proper instructions.
WARNINGS:

• Always wear eye protection when working on equipment.
• Before servicing unit, always turn off all power to unit. There may be more than one disconnect switch. Electrical shock can cause personal injury or death.
• When air handler is operating, some components are operating at high speeds. Personal injury can result from touching these items with any object.
• All electrical and service access panels must be secured in their proper place before operating equipment.
• Clear surrounding area of all tools, equipment and debris before operating unit.

CAUTION:
Unit must not be operated during building construction due to excessive airborne dust and debris. Also, the unit must never run under any circumstances without an air filter  in place. Material in this shipment has been inspected at the factory and released to the transportation agency in good condition. When received, a visual inspection of all cartons should be made immediately. Any evidence of rough handling or apparent damage should be noted on the delivery receipt and the material inspected in the presence of the carrier’s representative. If damage is found, a claim should be filed against the carrier immediately.
ll models are designed for indoor installation only. The installation of this unit, field wiring, duct system, and other related equipment must conform to the requirements the National Electric Code, ANSI/NFPA No. 70 (latest edition) in the United States, as well as any state laws and local codes. Local authorities having jurisdiction should be consulted before installation is made. Such applicable regulations take precedence over the general instructions contained in this manual.

INTRODUCTION

Model nomenclature for the air handlers described in this installation instruction are as follows:
WHD – Belt Drive Horizontal Air Handler with water coils and double wall lined construction.
XHD – Belt Drive Horizontal Air Handler with direct expansion, water coil and double wall lined construction.
The direct drive air handler units are designed for horizontal left or right applications with nominal air capacities of 3000 through 4000 CFM. Models incorporate a positive slope plastic drain pan with 3/4” PVC drain coupling. Optional equipment includes, multiple coil combinations in water and direct expansion, one and two row hot water coils, multiple filter box combinations, and mixing boxes. Motor offerings are 3.5HP for 30WH, 5HP for 40WH.

INSTALLATION PRECAUTIONS

WARNING:
Some units are very heavy. Use two or more people when moving and installing these units. Failure to do so could result in personal injury or death. Contact with metal edges and corners while applying excessive force can result in personal injury. Use gloves when handling equipment. Use caution during installation or while servicing equipment.
Installation of this air handler should be performed only by a licensed contractor to ensure proper installation and the safety of the installer. Observe the following precautions for typical installations:

1. Always use proper tools and equipment.
2. No wiring or other work should be attempted without first ensuring air handler is completely disconnected from the power source and locked out. Always verify that a good permanent, uninterrupted ground connection exists prior to energizing any power sources.
3. Always review the nameplate and wiring diagram on each unit for proper voltage and control configurations. This information is determined from the components and wiring of the unit and may vary from unit to unit.
4. When soldering or brazing to the unit, it is recommended to have a fire extinguisher readily available. When soldering close to water valves or other components, heat shields or wet rags are required to prevent damage.
5. When the air handler unit is in operation components are rotating at high speeds.
6. Units must be installed level or angled toward the drain nipple to ensure proper drainage and operation.
7. Check unit prior to operation to ensure that the condensate water will drain toward the drain connection. An overflow drain or an auxiliary drain pan under the air handler  may be required as a back up to a clogged primary drain. Condensate overflow switches may be used as well, under certain conditions
8. Be sure that the drain pan is free from foreign material prior to start up.
9. Check filter media installation to ensure that it is installed correctly. Use the directional arrows or other information on the filter to determine the proper flow direction.
10. Ensure air distribution system does not exceed the external static rating of the unit.

AIR HANDLER UNIT INSTALLATION

The installer must adhere strictly to all local and national code requirements pertaining to the installation of this equipment.
Sufficient clearance must be provided around the unit for proper maintenance, filter removal, lubrication, belt adjustment, removal of coils, drain pan and blower assembly. Flexible connections on the inlet and outlet duct connections of the unit are recommended.
Checking equipment
Unpack unit and move to final location. Remove packaging taking care not to damage unit. Inspect air handler unit for damage prior to installation. File a claim with shipping company if shipment is damaged.
Carefully inspect blower for rough handling that can cause misalignment or shaft damage. Locate unit nameplate which contains proper installation information. Check nameplate to be sure unit matches job specifications.
Mounting
WARNING:
Do not suspend the air handler unit from the top panel. The unit top will not support the weight of the unit. Equipment damage and severe personal injury or death could result.
The unit can be floor mounted or suspended with hanging rods. If hanging rods are used the unit has knockouts in each corner of the top and base panel for the suspension rods to pass through. It is recommended that angle iron or unistrut be used under the unit for support when suspension rods are used. 15T and 20T units have base channels of their own, but add angle iron to these as well. Unit vibration isolators are recommended for all installations. Flexible duct connections on the inlet and outlet duct connections of the unit are recommended.  WARNING:
Before installing the unit, determine whether unit weight can be safely supported by the structure. Failure to follow this WARNING could result in product or property damage and personal injury.
Safety Considerations
Sufficient clearance must be provided around the unit for proper maintenance, filter removal, lubrication, belt adjustment, removal of coils, drain pan and blower assembly. This clearance distance should be approximately the same width as the unit.
NOTES:

• Before mounting unit remove red headed shipping bolts and metal bushings under blower base rails.
• When unit is installed over a finished ceiling and/or living area, building codes may require a field-supplied secondary condensate pan to be installed under the entire unit. Some localities may allow the alternative of running a separate secondary condensate line or applying a field mounted condensate overflow switch. Consult and follow all local codes for additional restrictions or precautions.
• When installing any air handler over a finished ceiling and/or living area, installation of a secondary drain pan under entire unit is recommended to avoid damage to ceiling.

CAUTION:
Extreme caution must be taken that no internal damage will result if screws or holes are drilled into the cabinet. Failure to follow this CAUTION could result in product or
property damage and minor personal injury.
CAUTION:
The unit should be leveled in such a way that there is slope toward the condensate drain nipple to assure positive drainage. Failure to follow this CAUTION could result in product or property damage

AIR DISTRIBUTION DUCTS

All duct work must be installed in accordance with National Fire Protection Association Codes 90A and 90B. In many cases it is acceptable to use ducting of the same size as the air handler connections. However, unique arrangements or long duct runs must be confirmed by a local professional. The manufacturer will not be responsible for misapplied equipment. It is recommended to use flexible connectors between ductwork and the air handler to prevent transmission of vibration. Connect supply air duct over outside of flanges provided on supply air opening. Secure duct to flange with proper fasteners for type of duct used, and seal duct-to-unit joint. Ducts should be adequately insulated to prevent condensation during the cooling cycle and to minimize heat loss during the heating cycle. All return air must be filtered to prevent dirt buildup on the coil surface.
Ductwork Acoustical Treatment
Metal duct systems that do not have a 90 degree elbow and 10 ft. of main duct to first branch takeoff may require internal acoustical insulation lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with National Fire Protection Association Standards 90A or 90B as tested by UL Standard 181 for Class 1 air ducts.

ELECTRICAL

NOTES:

• Before proceeding with electrical connections, make certain that supply voltage, frequency, and phase are as specified on unit rating plate
• Be sure that electrical service provided by the utility is sufficient to handle the additional load imposed by this equipment.
• See unit wiring label for proper field high and low voltage wiring.
• Make all electrical connections in accordance with NEC and any local codes or ordinances that may apply. Use copper wire only.

WARNINGS:
Electric Shock Hazard

• Disconnect all power supplies before servicing; lock out/tag out to prevent accidental electrical shock. Note: there may be multiple power sources.
• Use copper conductors only.
• Install all parts and panels before operating.
• Failure to follow these warnings can result in injury or death.
• If a disconnect switch is to be mounted on the unit, select a location where drill or fastener will not contact electrical or internal components.

WARNING:
Service and maintenance to internal components and wiring must not be performed until the main disconnect switch is turned off. Failure to do so will result in electrical shock causing personal injury or death
All wiring must comply with local and national code requirements. Units are provided with wiring diagrams and nameplate data to provide information required for necessary field wiring.
These direct drive air handler units are provided with a control box with 0-10V low voltage terminal connections, for in-field installation. ECM motor speed adjustments will be done through the field installed 0-10V signal. Unit must be permanently grounded in accordance with NEC and local codes. Check all factory wiring per unit wiring diagram and inspect factory wiring connections to be sure none were loosened in transit or installation.
WARNING:
Any devices such as starter controls or thermostats that have been furnished by the manufacturer for field installation must be wired in strict accordance with the wiring diagram that is supplied with the unit. Failure to do so could result in electrical shock causing personal injury, death or damage to components and will void all warranties. NOTE:
Use agency listed conduit and conduit connector to connect supply wire(s) to unit and obtain proper grounding. If conduit connection uses reducing washers, a separate ground wire must be used.
WARNING:
The cabinet must have an uninterrupted or unbroken ground according to NEC, ANSI/NFPA 70 and local codes to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes. (See Ground/Conduit Note above.) Failure to follow this warning could result in an electrical shock, fire, or death.
Reference Wiring Diagrams (Check product for applicable wiring diagram)

Figure 2: Standard wiring diagram, 3 phase Figure 3: Condensate switch option, 3 phase

PIPING

PIPING PRECAUTIONS

1. Flush all field piping prior to connection to remove all debris.

2. Use wet cotton rags to cool valve bodies when soldering.

3. Open all valves (mid-way for hand valves, manually open on motorized valves) prior to soldering.

4. When soldering to bronze or brass, heat the piping while in the socket/cup and begin introducing the solder when the flux boils rapidly. Avoid direct flame into the solder joint.

5. Heat can only be applied to the cup of the valve body for a minimal time before damage occurs (even with the use of wet rags).

6. Avoid rapid quenching of solder joints as this will produce joints of inferior quality.

7. The valve package will not support the weight of the connecting pipes. All pipes connected to the units must be completely supported prior to connection to the unit.

8. Provisions must be made for expansion and contraction of piping systems. All horizontal and vertical risers, including runouts, must be able to withstand significant movement with temperature changes. Failure to do so will result in damage and failure of piping, fittings and valves throughout the building.

9. Never insulate the heads or motorized portion of control valves. Damage can occur in the form of excessive heat build up and interference to the operation and moving parts will result.

10. All piping made in the field should be installed with consideration of additional space for any electrical routing that may be required.

11. Connect all piping per accepted industry standards and observe all regulations governing installation of piping systems.
    CAUTION:
    Hydronic systems are not designed to hold pressurized air and should only be tested with water. Pressurizing system with air could damage equipment.

12. When all connections are complete, pressure test system. Repair any solder joint leaks and gently tighten any leaking valve packing nuts and piping accessories, as required.

PIPING INSTALLATION
These units employ a hydronic coil designed for use with either hot or chilled water.

• All piping must be adequately sized to meet the design water flow requirements as specified for the specific installation. Piping must be installed in accordance with all applicable codes.
• The piping connections on the equipment are not necessarily indicative of the proper supply and return line sizes. To minimize restrictions, piping design should be kept as simple as possible.

CAUTIONS:

• When connecting piping to air handler units, do not bend or reposition the coil header tubing for alignment purposes. This could cause a tubing fracture resulting in a water leak when pressure is applied to the system.
• Prior to connecting to the air handler all external piping must be purged of debris.
• All chilled water piping must be insulated to prevent property damage from condensation.

Condensate drain lines must be installed with adequate slope away from the unit to assure positive drainage. Since the drain pan is located on the suction side of the blower, a negative pressure exists at the drain pan and a minimum trap of 1-1/2 inches must be provided in the drain line to assure proper drainage.
PIPING INSULATION
Installing Contractor – After the system has been proven leak free, all lines and valve control packages must be insulated to prevent condensate drippage or insulated, as specified on the building plans.
NOTE:
Many valve packages will not physically allow all components to fit over an auxiliary drain pan. It is the installers responsibility to insulate all piping to ensure adequate condensation prevention.
NOISE
These air handler units are designed for quiet operation, however, all air handling equipment will transfer some amount of noise to the conditioned space. This should be taken into consideration when planning the location of the equipment.
DRAIN PAN
Drain pans have a 3/4 in primary and a 1/2 in secondary PVC coupling for condensate drain connection. Pans are designed with positive slope to the drain couplings and can be removed from the unit for cleaning. To facilitate cleaning, unions should be installed on the drain lines close to the drain pan coupling so the drain pan and drain pan door can be removed together. See figure 4 for reference.
For drain pan removal refer to the maintenance section.
NOTE:
When unit is installed over a finished ceiling and/or living area, building codes may require a field-supplied secondary condensate pan to be installed under the entire unit. Some localities may allow the alternative of running a separate secondary condensate line or applying a field mounted condensate overflow switch. Consult and follow all local codes for additional restrictions or precautions.![Firstco XHD Direct Drive Double Wall Air Handler

• fig 4](https://manuals.plus/wp-content/uploads/2023/03/Firstco-XHD-Direct- Drive-Double-Wall-Air-Handler-fig-4.png)Figure 4: Drain pan with access door removed

CONDENSATE DRAIN

Units are equipped with a 3/4 in primary and a 1/2 in secondary PVC coupling for condensate drain connection. Condensate drain lines must be installed with adequate slope away from the unit to assure positive drainage. Drain lines and traps should run full size from the drain pan connection. The drain lines must have a properly designed trap. The trap depth and distance between the trap outlet and the drain pan outlet should be twice the static pressure in the drain pan section under normal operation for the trap to remain sealed. See figure 5. Prime all traps, test for leaks, and insulate traps if located above a living area.
WHD / XHD Direct Drive ECM:: Installation, Operation, and Maintenance Instructions

Figure 5: Recommended trap configuration
CAUTION:
Shallow running traps are inadequate and DO NOT allow proper condensate drainage. See figure 6. Figure 6: Bad trap configuration
NOTES:

• If a Condensate Overflow Shut-off Switch, that is designed to be installed in the drain line, is used in place of a secondary drain line, then the cut- off switch should be located in the primary drain line between the unit and the P-trap.
• Condensate drain lines should be pitched downward at a minimum of 1 in. for every 10 ft. of length. Consult and follow all codes for additional restrictions or precautions.

PRE-STARTUP CHECKS

WARNINGS:

• Electrically ground air handler. Connect ground wire to ground terminal marked “GND”. Failure to do so can result in injury or death.
• Do not touch any rotating component with any object. Damage to the equipment and personal injury can occur.

CAUTION:
Any device such as a fan switch or thermostat that has been furnished by the factory for field installation must be wired in strict accordance with the wiring diagram that is supplied with the unit. Failure to do so could result in damage to components and will void all warranties.
Prior to starting the unit:

1. Ensure supply voltage matches nameplate data.
2. Ensure unit is properly grounded.
3. With power off, check blower wheel set-screws for tightness and ensure blower wheels rotate freely and quietly.
4. Ensure air handler is properly and securely installed.
5. Ensure unit is sloped toward drain line.
6. Ensure unit will be accessible for servicing.
7. Ensure condensate line is properly sized, run, trapped, pitched and tested.
8. Ensure all cabinet openings and wiring connections have been sealed.
9. Ensure a clean filter is in place and of adequate size.
10. Ensure all access panels are in place and secured.
11. Check that coil(s), valves and piping have been leak checked and insulated as required.
12. Ensure that all air has been vented from the system.
13. Ensure polarity is observed for 0-10V low voltage connections (see wiring diagram)

CAUTION:
Leaving air temperature must not exceed 150 degrees. Failure to follow this CAUTION could result in the motor cutting out on over temperature cutout. At high altitude conditions, the blower motor may cutout at a lower LAT.

MAINTENANCE

INSPECTION AND CLEANING
Before start-up all of the components should be given a thorough check. Optimal operation of this equipment requires cleanliness. Often after installation of this equipment additional construction activities occur. Care must be taken to protect the equipment from debris during these construction phases.
HINGED DOORS
Larger units, 7.5 ton and larger, have hinged doors that can be lifted off for component access. This allows free access for blower or motor assembly replacement. Enough side clearance is needed to open the doors at least 80 degrees to remove them. Use the door width as a simple guide for side clearance. FAN
The fan should be inspected and cleaned annually, in conjunction with maintenance of the motor and bearings. It is important to keep the wheels clean in order to avoid imbalance and vibration.
MOTOR
Check motor connections to ensure that they are secure and made in accordance with the wiring diagram.
WARNING:
Units with ECM motors have line voltage power applied at all times. Make sure power is disconnected before servicing.
FILTER
The air filter should be cleaned or replaced every 30 days or more frequently if severe conditions exist. Always replace the filter with the same type as originally furnished.
CAUTION:
Never operate unit without a filter or with filter access door removed. Damage to blower motor or coil can result.
NOTE:

• Factory authorized filters must be used when locating the filter inside the unit. For those applications where access to an internal filter is impractical, a field-supplied filter must be installed in the return duct system

COIL
Any dust or other contaminants which accumulate on the heat transfer surfaces interferes with the air flow and impairs heat transfer. The coil must be kept clean by any of the following methods.

• Cleaning with low-pressure compressed air.
• Cleaning with steam
• Flushing or rinsing with water (an approved coil cleaning detergent is advisable for greasy surfaces).
• Prior to the water system start-up and balancing, the chilled/hot water systems should be flushed to clean out dirt and debris construction. All unit service valves are closed during this process. Strainers are to be installed in the piping mains to prevent this material from entering the units during normal operation.

CAUTION:
Be sure to return valves to their proper operating positions prior to start- up.
DRAIN PIPING
The drain should always be:

• Connected or piped to an acceptable disposal point sloped away from the unit at least 1/8-inch per foot, and kept clean and free from obstructions.
• Checked before summer operation.
• Periodically checked during summer operation.

DRAIN PAN REMOVAL
To access drain pan

• Make sure all condensate of drain pan has been drained
• Make sure condensate lines are disconnected.
• Remove drain pan access door, pull out

PREVENTATIVE MAINTENANCE
To achieve maximum performance and service life of each piece of equipment, a formal schedule of regular maintenance should be established and maintained.
MAINTENANCE UPDATES
Contact Factory for current Maintenance Program Information.

P.O. BOX 270969, Dallas, TX 75227
www.firstco.com or www.ae-air.com
WHD / XHD Direct Drive ECM:
Installation, Operation, and Maintenance Instructions
The manufacturer works to continually improve its products.
It reserves the right to change design and specifications without notice.
©2022 First Co., Applied Environmental Air

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