RedZone DVS400 User manual

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
RZDVSENMAN 2016-11
DVS SERIES
AIR HANDLER
400 600 800 1000 1200
Consumer Safety Information 2
Overview of the RedZoneTM Air Handler 3
Codes and Standards 3
Receiving and Checking Equipment 4
Physical Data 5
Installation
Locating and Mounting 6-10
Plumbing 11-14
Electrical Connections 15-17
Thermostat Installation 18
Start-Up Procedure 19
Troubleshooting 20
Sequence of Operation 21
Maintenance 22
Specifications 23
Accessories 24
Air Delivery Performance 25-29
Parts List 30
Limited Warranty 31-32
1
P.9-11
CERTIFIED!
To register your Air Handler, please visit www.redzone-products.com
IMPORTANT: READ AND SAVE THESE INSTRUCTIONS!

2
CONSUMER SAFETY INFORMATION
SAFETY DEFINITIONS
Indicates safety alerts. When this symbol is seen on the Air Handler and in
all instructions and/or manuals, be alert to the potential for personal injury.
Recognize signal words DANGER, WARNING and CAUTION. These words are used
with the safety alert symbol.
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in
minor or moderate injury. It may also be used to alert against unsafe practices.
This is used to highlight important information which will aid in installation,
improve reliability or enhance operation.
SAFETY CONSIDERATIONS
Before any work is undertaken, it is imperative to
observe all precautions as stated in this manual, on tags,
and/or labels, together with any other safety measures
that may apply.
• Wearsafetyglassesandworkgloves.
• Whenpractical,objectstobebrazedshallbemoved
to a designated safe location or, if the objects to be
brazed cannot be readily moved, all movable fire hazards
in the vicinity shall be taken to a safe place, or otherwise
protected.
• Usequenchingclothforallbrazingandun-brazing
operations.
• Suitablereextinguishingequipmentshallbe
immediately available in the work area and shall be
maintained in a state of readiness for instant use.
Read these installation instructions carefully and adhere to
all WARNINGS and CAUTIONS. Consult local building codes,
Occupational Safety & Health Administration (OSHA) and
Electrical Safety Authority (ESC) for special requirements.
Improper installation, modification, service, maintenance,
or use of Hydronic Systems can cause electrical shock,
burns or other conditions which may cause personal injury
or property damage. Consult a qualified installer, service
agency, or your distributor for information or support. The
qualified installer or agent must use factory authorized kits
and/or accessories when installing this product. Refer to the
appropriate RedZoneTM literature for listing.
DANGER
WARNING
CAUTION
NOTICE
WARNING
Before installing or servicing the Air Handler, always
turn off all power to unit. There may be more than one
disconnect switch. Electrical shock can cause personal
injury or death.
CAUTION
Failure to follow this caution may result in personal
injury. Sheet metal parts may have sharp edges or
burrs. Use care and wear appropriate protective
clothing.
NOTICE
Application of this Air Handler should be indoors.
Special attention should be given to unit sizing and
piping, filling, and purging.
Read the entire instruction manual
before starting the installation.
REDZONETM DVS SERIES AIR HANDLER MANUAL

3
OVERVIEW OF THE REDZONETM AIR HANDLER
INTRODUCTION
The optimum in hydronic technology: the newly designed
RedZoneTM multi-position Air Handlers offer a unique
solution for a wide variety of small and medium sized
residential and light commercial applications. They are
compact and ready to fit in tight spaces which may include,
but not limited to, basements, closets, crawlspaces and
utility rooms.
The RedZoneTM DVS unit has a flow restrictor to manage
the water that’s needed to heat. Therefore, domestic flow
is not affected.
These Air Handlers will work with virtually any tankless
water heater. The RedZoneTM DVS Series are CSA-P.9-11
Certified to work in combination with specific Rinnai and
Bosch Tankless products to deliver a wide variety of heating
capacities that cover the entire residential and light
commercial heating spectrum.
CSA P.9-11 Certified models are:
Rinnai: RU80i
Bosch: C950 ES
CODES AND STANDARDS
It is the responsibility of the installer to follow all national
codes, standards and local ordinances, in addition to
instructions laid out in this manual. The installation must
comply with regulations of the local building, heating,
plumbing and other codes. Where local codes are not
applicable, the installation must comply with the national
codes and any and all authorities having jurisdiction.
The following is a suggested list of codes and standards
for the United States and Canada:
General Installation
Installation of Air Conditioning and Ventilating Systems
NFPA 90A (latest edition)
Duct Systems
Sheet Metal and Air Conditioning Contractors National
Association (SMACNA)
American Society of Heating, Refrigeration, and Air
Conditioning Engineers (ASHRAE)
2001 Fundamentals Handbook Chapter 34 or 2000 HVAC
Systems and Equipment Handbook Chapters 9 and 16
US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D
Acoustical Lining and Fibrous Glass Duct
US and CANADA: current edition of SMACNA; NFPA 90B
as tested by UL Standard 181 for Class I Rigid Air Ducts
Electrical Connections
CANADA: Canadian Electrical Code CSA C22.1
(latest edition)
Plumbing Systems
US and CANADA: ICC International Plumbing Code (IPC);
Uniform Mechanical Code (UMC); Uniform
Plumbing Code (UPC)
REDZONETM DVS SERIES AIR HANDLER MANUAL

4
RECEIVING AND CHECKING EQUIPMENT
INSTALLATION
IDENTIFY UNIT
The unit model number and serial number are located
on the unit identification label (located on the left side
of the unit). Check this information against shipping
papers and job requirements.
INSPECT SHIPMENT
Upon receipt of a DVS Series Air Handler, the packaging
should be checked for peripheral signs of transportation
damage while unit is still in the shipping package. If unit
appears to be damaged or is torn loose from its anchorage,
theunitshallbeimmediatelyexaminedbythereceiving
party before removal. If damage is found, the receiving
party must sign the driver’s delivery receipt noting all
damage (i.e. carton damage and/or product damage) as
well as contact the last carrier immediately, preferably in
writing, requesting inspection by the carrier’s agent. All
claim papers MUST be forwarded to your local distributor
for processing. In general, upon receipt of product, be
sure to check all items against shipping list; if items are
found to be missing, it should be noted as such on the
driver’s delivery receipt; and the receiving party shall
also immediately notify the area distributor. To prevent
loss or damage, leave all parts in original packages until
installation.
The DVS Series Air Handler needs to be
installed and commissioned by a knowledgeable
qualified professional.
NOTES:
1. This Air Handler is approved for upflow, downflow,
and horizontal configurations.
2. Clearance arrows do not change with Air Handler
orientation.
3. This Air Handler is for indoor installation only.
4. Unit(s) shall be installed in such a way as to ensure
that the electrical components are protected from
any contact with water.
5. Unit(s) shall not be installed directly on any combustible
material other than wood flooring.
6. This unit is designed to be used with an air distribution
system (ductwork). Refer to the Air Distribution
Ductwork section.
7. The installer shall provide ample space for servicing
and cleaning. Always comply with minimum fire
protection clearances shown in Figure 1.
8. The DVS units are designed to be installed vertically
or horizontally on the floor; units may also be hung
from the ceiling or wall. Be sure to allow appropriate
clearances for wiring, piping and servicing.
REDZONETM DVS SERIES AIR HANDLER MANUAL
WARNING
Do not install this unit if the unit is damaged.
Do not install this unit if any part or all of unit has
been under water. Refer to the Receiving and Checking
Equipment section.
TOP/PLENUM
zero
SIDE
zero
BACK
zero
SIDE
zero
FRONT
zero
BOTTOM
zero
SERVICING
24” (610 mm)
FIGURE 1 Minimum Clearance to Combustible Construction

5
UNIT SIZE
A B C D E F G H
in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm
DVS400 17 432 23 584 35.5 902 20 508 12 305 18 457 11 279 10 254
DVS600 17 432 23 584 35.5 902 20 508 12 305 18 457 11 279 10 254
DVS800 17 432 23 584 35.5 902 20 508 12 305 18 457 11 279 10 254
DVS1000 21.25 540 23 584 43.75 1111 20 508 16 406 18 457 15 381 14 356
DVS1200 21.25 540 23 584 43.75 1111 20 508 16 406 18 457 17 432 16 406
Table 1 – Physical Data
DIMENSIONS
REDZONETM DVS SERIES AIR HANDLER MANUAL
E
D
A
18 "
Water In
Water Out
1/2” Dia. Pipe
1/2” Dia. Pipe
B
C
H
F
G
FIGURE 2

6
INSTALLATION
REDZONETM DVS SERIES AIR HANDLER MANUAL
LOCATING AND MOUNTING
THE AIR HANDLER
General
The multi-position DVS Series Air Handlers are shipped
requiring only minor modifications to the cabinet.
The appropriate return air opening must be cut out
and the supplied filter rack installed. For instructions
on required modifications and assembly refer to
Figures 3 and 4.
SIDE FILTER
RACK ASSEMBLY SCREW FILTER RACK
TO SIDE OF CABINET
USING MOUNTING HOLES
CUT SIDE RETURN OPENING
AS REQUIRED
BOTH SIDES
AND BOTTOM KNOCKOUTS
USE EXISTING SCREW HOLE
TO LOCATE FILTER RACK
G
F
DIMENSIONS
ON PREVIOUS PAGE
DIMENSIONS
ON PREVIOUS PAGE
FIGURE 3 Modification of Unit to Accommodate
Side Filter Rack Installation
FIGURE 4 Side Filter Rack Installation
( See Figure 2 for dimensions )

7
INSTALLATION
Upflow Installations
The DVS Air Handler is ready to install once the appropriate
return air panel is selected and cut out.
If you use the bottom return, the unit must be
supported on the bottom only and set on a field supplied
supporting frame or plenum. Supporting frame or plenum
must be anchored to the unit and to the floor or wall.
Install the filter rack on the bottom of the unit or if
supporting frame interferes install a duct mounted filter
and filter rack (field supplied).
For side return installations install the filter rack on the
side of the cabinet that the return air knockout has been
removed. Attach ductwork to the filter rack flange.
Downflow Installation
The DVS Air Handler is ready to install once the appropriate
return air panel is selected and cut out.
In a downflow installation the unit must be supported on
the top only and set on a field supplied supporting frame or
plenum. Supporting frame or plenum must be anchored to
the unit and to the floor or wall. Mount the filter rack on
the side or bottom of the cabinet that the return air
knockout has been removed.
Horizontal Left and Right Installations
The DVS Air Handler is ready to install once the appropriate
return air panel is selected and cut out.
In a horizontal installation the unit must be supported on
the side only and set on a field supplied supporting frame.
The supporting frame must be anchored to the unit and to
the floor, wall or ceiling. Mount the filter rack on the side
or bottom of the cabinet that the return air knockout has
been removed.
REDZONETM DVS SERIES AIR HANDLER MANUAL
Blower located to the right of
coil section. Conditioned air
is discharged to the left.
Blower located below coil
section. Conditioned air is
discharged upward.
Blower located to the left of
coil section. Conditioned air
is discharged to the right.
Blower located above coil
section. Conditioned air is
discharged downward.
Note: Filter rack attaches
externally to the bottom
or either side of the cabinet
DOWNFLOW
UPFLOW
HORIZONTAL LEFT HORIZONTAL RIGHT
FIGURE 5 Multi Purpose Orientation

8
INSTALLATION
REDZONETM DVS SERIES AIR HANDLER MANUAL
CLOSET INSTALLATION
(RETURN AIR THRU OPENING
OR GRILL)
The DVS Air Handler can be installed in a closet on a
supporting stand or be mounted from the closet wall
using the closet as the return air plenum. Unit should be
high enough from the floor to provide unimpeded return
airflow into the bottom of the cabinet.
Closet return air opening can be on the front (in closet
door), side (thru the wall) or a combination of both,
providing there is clearance on the sides between unit’s
cabinet and closet. Refer to ACCA Manual D or SMACNA
for sizing and free area recommendations.
NOTE:
Local codes may limit application of systems without a
ducted return to single story dwellings.
SUSPENDED CABINET
INSTALLATION
If the cabinet cannot be supported on a frame or supported
from the wall, it may be suspended.
Use metal strapping or threaded rod with angle iron
supports under cabinet for support. These supports
MUST run parallel with the length of the cabinet
(see Figures 6 and 7).
Ensure that there is adequate room to remove service
and access panels after installing supporting brackets.
Ifanauxiliarydrainpanisrequired,thesupportis
to be placed under a drain pan. In such installations,
the unit will need to be supported on vibration isolators
(rubber or Styrofoam blocks).
IMPORTANT:
When a DVS unit is matched with an evaporative
type (cased coil/condensing unit) split system for cooling
application and the system is installed above a finished
ceiling and/or an occupied space, building codes may call
for a secondary insulated condensate pan (by others)
to be installed under the entire unit. In other instances,
some local codes may allow the running of a separate,
secondary condensate line in lieu of the required drain pan.
It is the responsibility of the installer to consult local codes
for compliance.
DOOR
ASSEMBLY
8” MIN FOR
DOOR REMOVAL
(2) HEX NUTS, (2) WASHERS & (2)
LOCK WASHERS REQ. PER ROD
USE 1” SQUARE, 1-1/4 x 1-1/4 x 1/4
ANGLE IRON OR EQUIVALENT
SECURE ANGLE
IRON TO BOTTOM
OF AIR HANDLER
WITH 3 #8 x 3/4”
SCREWS TYPICAL
FOR 2 SUPPORTS
1/4” THREADED ROD
(4 REQUIRED)
FIGURE 6 Horizontal Unit Suspension
WARNING
It is the installer’s responsibility to use an appropriate
hanging method capable of supporting the unit’s weight.
Refer to the specification section of this document for
the respective unit’s installed weights.
NOTICE
For seismic hanging requirements, refer to local codes.

9
INSTALLATION
Attachment Methods Using Straps
Method 1
Use(4)#8x3/4sheetmetalscrewsforeachstrap.
The straps should be vertical against the Air Handler sides
and not pull away from the Air Handler sides.
Method 2
Fold all straps under the Air Handler and secure with (4)
#8x3/4sheetmetalscrews(2screwsatthesideand
2 screws at the bottom. (Care must be taken not to drive
the screw through the coil.)
DUCT CONNECTIONS
Supply Duct
The supply ductwork must be attached to the outside of the
angeontheairdischargeendofunit.Flexibleconnectors
may be used if desired.
Return Duct
The return ductwork should be attached to the air return
side (bottom or side) of unit using sheet metal screws or
other fasteners.
For side return air inlet installation, see Figures 3 and 4.
FILTER INSTALLATION
Externallterrackanda1inchdisposablelterare
standard on all models. Refer to the Specifications
section for dimensions.
AIR DISTRIBUTION SYSTEM
Existing Ductwork
It is the responsibility of the installer to inspect all
previously installed air distribution system to determine
its suitability for the new heating and/or cooling system.
Existingductworkmayhavetobemodiedand/orinsulated
to provide satisfactory air distribution.
Ductwork Installation
Connect the supply-air duct over the outside of 3/4-in.
flange on the unit’s discharge side. Secure the duct to the
flange with proper fasteners for the type of duct used.
Support the duct independently.
Useexibleconnectors(ifdesiredbetweentheductwork
and the unit to prevent transmission of vibration.
Use insulation with vapor barrier for ductwork passing
through unconditioned spaces.
PROHIBITED INSTALLATIONS
REDZONETM DVS SERIES AIR HANDLER MANUAL
DOOR
ASSEMBLY
1 INCH x 22 GAUGE
GALVANIZED STRAPS
TYPICAL FOR 4 STRAPS
SUPPLY AIR OPENING
BACK
COIL AREA
RETURN AIR
OPENING
FIGURE 7 Horizontal Unit Suspension with Straps
FRONT
BACK
FIGURE 8
The air inlet is not allowed to
be at the front or back of the
Air Handler.
FIGURE 9
Do not position the Air Handler
on its back or with its face
down.
WARNING
Multiple Air Handlers configured for installation with a
single Tankless Water Heater is prohibited.

10
INSTALLATION
REDZONETM DVS SERIES AIR HANDLER MANUAL
NO MORE THAN
0.6” H20 SUPPLY
SIDE EXTERNAL
STATIC
FILTER RACK
(SUPPLIED WITH UNIT)
NO MORE THAN
0.2” H2O RETURN SIDE
EXTERNAL STATIC
3“ FLEX DUCT
SEE ACCOMPANYING CHART FOR TYPICAL
NUMBER OF 3” DUCTS REQUIRED
TYPICAL DUCTING USING 3” DIAMETER FLEX
METHOD A METHOD B
TYPICAL MAIN MINIMUM # TYPICAL # OF 3” DIA. MAXIMUM EXT.
MODEL TYPICAL DUCT DIAMETER OF 3” DIA. FLEX FLEX DUCT RUNS STATIC ON
CFM OR EQUIVALENT DUCT RUNS AT 6-10 FEET EACH SUPPLY SIDE
DVS400 400 6“ + 6” 8 10 0.6” H2O
DVS600 600 8“ + 6” 12 14 0.6” H2O
DVS800 800 8” + 8“ 16 18 0.6” H2O
DVS1000 1000 8” + 10“ 20 22 0.6” H2O
DVS1200 1200 10” + 10“ 24 26 0.6” H2O
OR
TYPICAL DVS MID-V INSTALLATION WITH A-COIL
BRANCH DUCTWORK
After the floor and ceiling holes have all been located
and drilled, it’s time to install the 3” branch ducts. Run
the 3” duct parallel to the joists whenever possible as this
takes less space. The 3” duct should then be fastened to
the joist with strapping material. If the 3” duct is in an
unconditioned space, it must be insulated to local code
then all connections must be tapped to ensure a continuous
vapor seal. Do not damage the vapor barrier on the 3” duct.
If it is damaged, the holes must be taped with foil tape.
If possible run the 3” duct between the insulation and
the vapor barrier. Use of non-insulated ductwork can be
used in conditioned spaces.
Theminimumlengthof3”ductis5’andthemaximum
idealis15’.Ifarunisshorterthantheexlength,
then the 3” duct can be coiled in the cavity. The minimum
bend radius is 4”. When installing a branch duct with
aminimumradiusensuretheductisextendedfully
to allow full airflow through the elbow.
Pleasedonotabusethe3”exasthehelixwillcrush
and unravel.
The RedZoneTM DVS Air Handler was tested with the
above fittings. Use of other fittings may result in
improper air flow and air noise.
RZROUGHKIT
Rough-in Assembly
including Elbow,
Saddle and Dust
Cap
RZGRILL
Round Grill
including
Damper
NOTICE