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

INSTALLATION
When connecting the 3” duct to the 3” saddle, attach
the fitting into the inner core of the 3” duct with 2 evenly
spaced TEK screws. Ensure the head of the TEK screw is on
thewirehelixasthecorewilltear.Thenpulltheinsulation
and vapor barrier over the inner core and secure around
the outside of the vapor barrier with tape, or a cable or
wire tie. Tighten the tie securely around the connector tube,
inner core and vapor barrier.
Wheninstallingthe3”exductinareasinwhichyou
must run counter to the direction of solid joists, some
drilling may by required. It is recommended to drill the
smallest hole possible in order to maintain the structural
integrity.Ifpossibleruntheexductunderthejoistsand
avoid drilling any holes.
NOTE:
When installing the rough-in kit, saddles, elbows and
grills should be fastened in this manner.
PLUMBING
Codes:
Observe all local sanitary codes when installing
water lines. The water supply mating connections
to the DVS Air Handling Units are made via the two
(1/2 in. Dia.) copper stubs to the front-left of the unit
labeled “WATER IN” and “WATER OUT” (see Figure 2).
Mating connectors to be two field supplied 1/2 in.
FNPT-sweat ends or two field supplied 1/2 in. SharkBite
type FNPT-push fitting ends or equivalent.
All associated hydronic piping MUST comply with ICC, UPC
and any other local codes or ordinances having jurisdiction.
USE POTABLE GRADE COPPER PIPING AND BRASS
APPURTENANCES ONLY.
NOTE:
Recommended piping, fittings, valves and other
appurtenances(exclusiveofthoseindictedasaccessories
that are available through RedZoneTM distribution) called for
in piping schematics to be field-supplied.
Soldering Copper Tubing
The common method of joining copper tubing in hydronic
heating systems is soft soldering. Plumbing codes do not
allow solders containing lead to be used for domestic water
service. USE ONLY 95/5 tin/antimony solder for all piping
systems that incorporate a domestic water supply.
NOTE:
Precautions must be taken during soldering to avoid debris
or solder from lodging in piping system.
Mechanical Joining of Tubing
Where used, refer to respective mechanical system
manufacturer’s installation instructions.
Tubing Insulation
Any tube conveying fluid at a temperature greater than
that of the surrounding air releases heat.
Insulate all accessible hot water lines and associated valves
withmaterial,suchasexpandedneopreneorpolyurethane
3/8-in. to 1⁄2-in. thick.
Match the pipe sleeve’s inside diameter to the pipe’s
outside diameter for a snug fit. Place the pipe sleeve so
the seam will be face down on the pipe. Tape, wire, or
clamp insulation every foot or two to secure it to the pipe.
If taping is desired, use acrylic or aluminum foil tape
instead of cloth-type duct tape.
Copper Tubing Support
Copper tubing must be properly supported to prevent
sagging or buckling. On horizontal runs with hard temper
tubing,thefollowingmaximumsupportspacingis
suggested:
• 1/2in.to3/4in.tube:5feetmaximumspacing
Theabovesuggestedspacingdoesnotaccountforextra
weightofpipingcomponentssuchasanexpansiontank,
etc. When such components are present, the piping should
be supported immediately adjacent to the component.
On vertical runs, copper tubing should be supported at each
oorleveloratamaximumofevery10feet.
Thermal Expansion of Piping:
In all hydronic systems, piping undergoes temperature
swings as the system operates. This causes changes in the
lengthofthepipingduetothermalexpansion.
Ifthepipingisrigidlymounted,thisexpansioncancause
annoyingpoppingorsqueakingsoundsandinextreme
cases, the piping can even buckle.
Tocounterexpansionmovement,designpipingcircuits
withsufcientelbows,teesorexpansionloops(onlyused
in large systems) or piping supports that allow the tubing
toexpandandcontractfreely.
Anotheralternativeistoinstallanexpansiontank
compensator fitting capable of absorbing the movement.
11
REDZONETM DVS SERIES AIR HANDLER MANUAL

12
INSTALLATION
Hydraulic Resistance of Fittings, Valves,
and Other Devices
Before the total hydraulic resistance of a piping circuit can
be found, the individual hydraulic resistances of all fittings,
valves, or other such components must be determined.
One approach is to consider each fitting, valve, or other
device as an equivalent length of copper tube of the same
pipe size (see Table 2).
By using the equivalent length of piping for all components
in the circuit, the circuit can be treated as if it were a
single piece of pipe having a length equal to the sum of
the actual pipe length, the total equivalent lengths of all
fittings, valves, or other devices. Refer to Figure 10 and
the calculation of equivalent lengths.
Pipe Sizing Considerations
Atwaterowvelocitiesofapproximately2feetpersecond,
flowing water will carry air bubbles along a vertical pipe.
Average flow velocities of 2 feet per second or higher can
draw along air bubbles in a downward flow. At the above
stated velocities, air bubbles shall be routed to an air
separator where they can be collected and discharged
from the system. Use Taco 4900 series air separator,
Model 49-075, or equivalent (field supplied).
Average flow velocities higher than 4 feet per second could
cause flow noise and should be avoided.
Expansion Tanks
Allliquidsusedinhydronicheatingsystemsexpand
when heated. For all practical purposes, liquids are
incompressible. Any container completely filled with a
liquidandsealedfromtheatmospherewillexperience
a rapid increase in pressure as the liquid is heated.
To prevent this from occurring, all closed loop hydronic
systemsMUSTbeequippedwithanexpansiontank.
Refertoexpansiontankmanufacture’sinstructionsfor
proper sizing and installation.
REDZONETM DVS SERIES AIR HANDLER MANUAL

REDZONETM DVS SERIES AIR HANDLER MANUAL
13
INSTALLATION
PROCEDURE FOR CALCULATING
THE TOTAL EQUIVALENT
LENGTH OF PIPE
Given piping assembly as shown in Figure 10 below,
what is the total equivalent length of the system?
First,determinethetotalstraightpipelengths;next
refer to Table 2 to determine the equivalent straight pipe
length for each fitting shown. Add together the
equivalent lengths of piping and fittings.
Where possible the length of pipe should not
exceed60feetequivalentlength1/2”pipeor
120 feet equivalent length 3/4” pipe.
Any piping running through unconditioned
space MUST be insulated to prevent heat loss,
and possible freezing of the line.
Stickers indicating direction of flow, (WATER IN,
and WATER OUT) are labeled on the outside of the
cabinet. DO NOT reverse these lines, as this will
cause the unit to malfunction.
NOTICE
ball valves
cap
3/4 in. type M copper tubing
13 ft 15 ft
5 ft
10 ft
3 ft
3ft
3 ft3 ft3 ft3 ft
12 ft
10 ft
Air separator
(optional)
Fitting or Valve 1/2” 3/4”
90 deg. elbow 1 2
45 deg. elbow 0.5 0.75
Straight thru tee 0.3 0.4
Side port tee 2 3
Reducer coupling 0.4 0.5
Gate valve 0.2 0.25
Globe valve 15 20
Angle valve 3.1 4.7
Ball valve 1.9 2.2
Swing check valve 2 3
Butterfly valve 1.1 2
Air separator (optional) NA 0.3
Table 2: Equivalent Length of Straight Pipe
for Valves and Fittings (ft)
3/4” Tubing (total straight pipe length) 68 ft.
(6) 3/4” 90 deg. Elbows 6(2) = 12 ft.
(2) 3/4” Side port tee 2(3) = 6.0 ft.
(1) 3/4” Air separator (optional) 1(0.3) = 0.3 ft.
(2) 3/4” Ball valves 2(2.2) = 4.4 ft.
Total Equivalent Length 90.7 ft.
FIGURE 10
Equivalent Length Calculation

14
INSTALLATION
Piping Configuration
When employing a Tankless Water Heater in a hydronic
system, the system is considered an Open Loop System
when configured to simultaneously deliver both domestic
hot water and space heating. By definition, if the circuit
is sealed off from the atmosphere at all locations (as is true
for most modern hydronic systems) it is called a closed
loop system. If the circuit is open to the atmosphere at
any point, it is called an open loop system. Current
tankless products are not certified for closed loop
applications.
Open Loop System
If piping is done in accordance with the recommended
schematic diagram shown in Figure 11, the following purge
and priming procedure applies.
PURGING AND
PRIMING THE SYSTEM
The following procedure describes how the RedZoneTM
system may be piped to eliminate the need for a “purge
cart” to fill the system and remove entrapped air bubbles.
STEP 1: CLOSE ball valve 3 (BV3).
STEP 2: OPEN drain valve 3 (DV3) to which a hose
MUST be connected and draining to a sink,
drain or outdoors.
STEP 3: CLOSE drain valves 1 and 2 (DV1 and DV2) and
OPEN ball valve 2 (BV2).
STEP 4: OPEN cold water supply main valve
(ball valve 1 - BV1). The system will begin the
prime/purge process using the street pressure.
Entrapped air bubbles being pushed out of
the system will be evident by a slight vibration
of the discharge hose connected to drain valve
3 (DV3). The hose will stop vibrating when
laminar flow is achieved.
STEP 5: CLOSE drain valve 3 (DV3).
STEP 6: OPEN ball valve 3 (BV3). The system is now
purged, primed and ready to go.
NOTE:
Foranopenloopsystem,useexpansiontankandmixing
valve approved for potable water use only.
Field Supplied
A Coil and Ducting
Field Supplied
Refrigerant Lines to
Condensing Unit
Hydronic Air Handler
Blower Assemby
Pump with Removable
Check Valve
REDZONE
Air Handler
Hydronic
Heating Coil
(Optional)
(Optional)
Air Separator
Control Box
Thermostat
Anti-Scald
Mixing Valve
Domestic
Hot Water
Tankless
Water
Heater
Gas Supply
Cold Water
Supply
Optional
Check Valve
(If Required by Local
Municipality)
Expansion
Tank
FIGURE 11
Typical Piping Arrangement For Direct Space Heating
and Domestic Water Supply with Tankless
REDZONETM DVS SERIES AIR HANDLER MANUAL
WARRANTY NOTICE
ExpansionTankandThermostaticMixingValvemustbe
installed with every open loop installation or warranty
on product becomes null and void.

15
INSTALLATION
ELECTRICAL CONNECTIONS
Line-Voltage Connections
CANADIAN INSTALLATIONS: Make all electrical connections
in accordance with Canadian Electrical Code CSA C22.1 and
all authorities having jurisdiction.
Check all factory wiring per unit wiring diagram and inspect
factory wiring connections to be sure none were loosened
in transit.
NOTE:
Prior to making any electrical connections, ensure that
supply voltage, frequency, and phase are as specified on
unit rating plate.
Checktoensurethattheexistingelectricalserviceis
adequate to handle the additional load imposed by the
DVS Air Handler. Refer to unit wiring diagram for proper
electrical connections.
All electrical connections MUST comply with NEC and any
other local codes or ordinances having jurisdiction. USE
COPPER WIRE ONLY. Provide separate branch electric
circuit with field supplied disconnect switch.
Location of disconnect switch to be in clear site, accessible
andincloseproximitytotheunit.CorrectpolarityMUSTbe
maintained for 115 V wiring. If polarity is incorrect unit will
NOT operate.
WARNING
Before installing or servicing system, always turn
off all power to system. There may be more than one
disconnect switch. Electrical shock can cause personal
injury or death.
CAUTION
If a disconnect switch is to be mounted on the unit,
select a location where a drill or fastener will not
contact electrical or hydronic components.
Electrical shock can cause personal injury or death.
REDZONETM DVS SERIES AIR HANDLER MANUAL

16
INSTALLATION
Electrical Connection to Control Box
1. Route the Air Handler power wires through aligned
 holesincasingandControlBoxandmakeeldwire
 connectionsinControlBox.Usebestpracticesforwire
bushings, strain relief, etc. Field wiring to the unit must
be grounded and conform to the National Electrical Code
C22.1 Part 1 - latest edition. Use only CSA or UL listed
conduit and conduit connectors to connect supply wires
to the unit and provide appropriate grounding.
Grounding may also be accomplished by grounding the
 controlboxperappropriatelocalcodes.Electricwires
that are field installed shall conform to the temperature
limitation for 63° F (35° C) rise wire when installed in
accordance with instructions. Refer to Table 3 in for
specific Air Handler electrical data.
2. Route and secure field ground wire to ground screw
 onControlBox.
3. Connect line voltage leads as shown in Figure 12.
4. ReinstallcovertoControlBox.Ensurethatwiresare
 notpinchedbetweencoverandedgeofControlBox.
24V Control System Connections to Unit’s
Printed-Circuit Board (PCB):
Refer to Figure 12 for factory wiring details.
For low voltage connections between the unit and the
thermostat, use No. 18 AWG colour-coded, insulated
(63° F / 35°C minimum) wires.
Low Voltage Connections
These units use a grounded 24 volt AC low voltage circuit
and require at least a 1 stage heating and a 1 stage cooling
thermostat.
The “R” terminal is the hot terminal and the “C” terminal
is grounded.
“G” terminal is the fan input.
“Y” terminal is the compressor.
“R” terminal is 24 VAC hot.
“C” terminal is 24 VAC grounded.
“W” terminal is the heat input.
WARNING
Failure to follow this warning could result in a fire.
Do not use aluminum wire between the DVS Air
Handler and the disconnect switch. USE COPPER
WIRE ONLY.
NOTES:
1. Connect Y terminal as
shown for proper operation.
2. Some thermostats require a
“C” terminal connection as
shown.
3. If any of the original wire, as
supplied, must be replaced,
use the same type or
equivalent wire.
WGR C Y
Y
W
G
R
C
BLK BLK
WHTWHT
GND
GND
AIR HANDLER
115 Volt Fuse Disconnect
(Field Supplied)
5 Wire
3 Wire Heating Only
Single Stage
Thermostat
(Available Accessory)
24 Volt Terminal BlockDisconnect
(Field Supplied)
208 / 230 Volt
Single Phase
Control Box
PCB
Condensing Unit
(Field Supplied)
Field 115, 208 / 230 Volt Wiring
Field 24 Volt Wiring
Factory 24 Volt Wiring
Factory 115 Volt Wiring
Junction Box
L1
L2
FIGURE 12 Field Wiring Diagram
REDZONETM DVS SERIES AIR HANDLER MANUAL

17
INSTALLATION
System Low Voltage Wiring Diagrams
NOTE:
Local codes may require thermostat wiring to be routed
through conduit or raceways. In such instances, splices can
be made inside the DVS Air Handler. All wiring must be NEC
Class l and must be separated from incoming power leads.
IMPORTANT:
Where possible, use a White Rogers factory authorized
thermostat with the DVS Air Handler. If a thermostat other
than specified is used then refer to the manufacturer’s
installation instructions. Avoid using any power robbing/
stealing thermostats.
Wire Gauge Maximum Distance (feet)
20 gauge 45
18 gauge 60
16 gauge 100
14 gauge 160
12 gauge 250
DVS EC MOTOR AIR HANDLERS
Tap 1 - LOW CONTINUOUS SPEED - RED/TRACE
Tap 2 - LOW VELOCITY (0.4”) NORMAL - YELLOW/TR
Tap 3 - LOW VELOCITY (0.4”) BOOST - BLUE/TR
Tap 4 - MID VELOCITY (0.8”) NORMAL - PURPLE/TR
Tap 5 - MID VELOCITY (0.8”) BOOST - BLACK-TR
MOTOR SPEED 24VAC PLUG
MOTOR 120VAC PLUG
WHITE 120 COMMON
GREEN - GROUND
BLACK 120 VAC
BROWN - 24VAC COMMON
MOTOR TAP
SELECTION TREE
LOW CONT. SPEED
SPARE
HEAT/COOL SPEED
EC
MOTOR
5
4
3
2
1
ORANGE PUMP WHITE
WHITE
BLACK
WHITE
GREEN/TR
ORANGE/TR
N/O
N/C
COM
PUMP
BROWN
24V
120V
TRANSFORMER
RED
120VAC/60Hz
SUPPLY
GL1 N
BLACK
WHITE
BLACK
DOOR
SWITCH
N/O
N/C
COM
HIGH FAN
YELLOW
WHITE/TR
N/O
N/C
COM
LOW FAN
BROWN RED
PUMP
HIGH FAN
LOW FAN GREEN/TR
ECB
CIRCUIT
BOARD
W
24VAC
SEPTEMBER 2014
FIELD INSTALLED WIRING
THERMOSTAT
24VAC
HUMIDIFIER
Y
G
W
C
R
A/C OUTDOOR
CONDENSER
AIR HANDLER
TERMINAL
STRIP
Y
G
W
C
R
GREEN/TR
BROWN
WHITE
RED
YELLOW
FIGURE 13 DVS Wiring Diagram
REDZONETM DVS SERIES AIR HANDLER MANUAL

18
INSTALLATION
THERMOSTAT INSTALLATION
Safety Considerations
All wiring must conform to local and national electrical
codes. Improper wiring or installation may damage
thermostat.
INSTALLATION CONSIDERATIONS
Air Conditioner Model
Refer to Figures 12 through 13 for factory wiring details.
The Standard Model A/C thermostat may be wired with
or without connecting a common wire between the
indoor equipment and the thermostat. However, it is
recommended to use a common wire whenever possible.
Do not use a power-stealing thermostat. If an evaporating
coil is installed above the hot water coil, then a Freeze stat
must be installed to prevent potential freeze damage to
the hot water coil and subsequent waster escape.
Installation
Thermostat should be mounted:
• approximately5ft.(1.5m)fromoor;
• closetoorinafrequentlyusedroom,preferablyonan
inside partitioning wall;
• onasectionofwallwithoutpipesorductwork.
Thermostat should NOT be mounted:
• closetoawindow,onanoutsidewall,ornexttoadoor
leading to the outside;
• exposedtodirectlightandheatfromalamp,sun, 
fireplace, or other heat-radiating object which may
cause a false reading;
• closetoorindirectairowfromsupplyregisters
and return-air grills;
• inareaswithpooraircirculation,suchasbehindadoor
or in an alcove.
Refer to Figure 12 for thermostat wiring
diagram and thermostat installation instructions for
further details.
WARNING
Before installing thermostat, turn off all power to unit.
There may be more than one power disconnect.
Electrical shock can cause personal injury or death.
REDZONETM DVS SERIES AIR HANDLER MANUAL

19
INSTALLATION
START-UP PROCEDURE
(HEATING ONLY)
The following conditions must be met prior to unit start-up.
Debris from soldering and/or other installation activities
can cause equipment failure. Ensure that all associated
lines and appurtenances are free of debris.
Check to ensure that unit is secure.
Check that blower wheel rotates freely within the
scroll housing.
Check all wiring to ensure that connections are tight.
Check all ductwork and pipe connections to ensure
proper seal.
Check to ensure that all packaging wraps are removed
from equipment.
Ensure that front access doors are properly installed.
Check to ensure proper connection(s) to the appropriate
blower speed tap. To do this, reference page 25 thru 29 and
select the correct model and desired fan speed data. Refer
to Figure 13 for appropriate motor tap/wire colour to use.
Perform all safety and start-up checks for Tankless Water
Heater as per manufacturer’s instructions.
Having verified all preceding checks, the Air Handler’s
Start-Up Procedure is as follows:
STEP 1: Purge and fill system; follow appropriate purging
procedure as laid out in this manual in section
titled “Purging and Priming the System”.
STEP 2: Turn on power supply to Air Handler. Caution:
blower and/or circulator may start to operate
if thermostat is on and a call is present.
STEP 3: Turn thermostat on and switch system to the
heating mode. The thermostat shall be set higher
than the actual room temperature; this will
cause the circulator to energize and initiate
the heating cycle. (If the pump does not start,
or the Air Handler is not producing heat, refer to
the Troubleshooting Section in this manual).
STEP 4: Program room thermostat as desired by
homeowner.
START-UP PROCEDURE
(COOLING SYSTEM)
Refer to field supplied evaporator coil and outdoor unit
manufacturer’s Installation Instructions for system
hook-up, start-up instructions and refrigerant charging
method details.
TROUBLESHOOTING BLOWER
AND/OR PUMP MOTOR AND
CONTROLS
If blower and/or pump motor does not run:
Turn off power and check the following:
1. Check that door switch is in the CLOSED position.
2. Check for 24 VAC between COM and 24 VAC on
terminal strip. If no voltage is present, check transformer.
3. Check all connections for kinks which could cause loose
connections. Ensure connections are secure.
4. Verifythatapproximately120VACispresentacross
L1 and L2.
CAUTION
High voltage is at all times present at motor.
Disconnect power to AHU before removing,
or replacing, or servicing motor. Wait at least 5 min
after disconnecting power before opening motor.
Failure to follow this CAUTION could result in minor
personal injury or product and property damage.
REDZONETM DVS SERIES AIR HANDLER MANUAL

20
TROUBLESHOOTING
MOST LIKELY PROBLEMS
AND CAUSES
Important:
For system to operate properly power should be turned
ON and all shut-off valves/isolation valves must be open.
If Pump Does Not Run:
1. Circuit board controls operation of pump.
Check that pump LED is illuminated.
Check for 24VAC at pump terminal on circuit board.
If faulty refer to “Faulty Circuit Board” section.
2. Check line voltage wiring to pump. Check for 120 VAC
 atpumprelayandinsidethepumpelectricalbox.
Pump is Noisy:
Air may be trapped in the water circuit. Purge air from the
system as described under “start-up procedure”.
Insufficient or No Heat:
1. Air may still be trapped in heating loop. Purge air from
the system as described under “start-up procedure”.
2. Water heater thermostat not turned up high enough.
 (Remember,higherthan120°F=mixingvalvefor
domestic service).
3. Inlet and outlet piping connection at the Air Handler
may be reversed. See Figure 2.
4. Water heater thermostat not calibrated properly.
5. Excessivepressuredropcausedbyrestriction
somewhere in the hot water loop does not allow
sufficient water to flow to Air Handler.
6. Air Handler not sized large enough for heat load.
7. Water heater not large enough to satisfy heat load.
ECM Motor Won’t Start:
Disconnect power before plugging/ unplugging
motor cables.
CAUTION – motor is supplied with 120 VAC continuously.
24VAC thermostat signals communicate with the motor
to initiate operation.
1. Circuit board controls the blower motor in Heating mode.
Check that LOW FAN or HIGH FAN LED is illuminated.
Also check for 24VAC at these terminals on the circuit
board. If faulty refer to “Faulty Circuit Board” section.
2. Ensure motor cables are properly installed and firmly
plugged into the motor. Check voltages in the cables.
3. Check door switch depressed, power supply, and
thermostat lines are wired properly. Refer to the
electrical diagram supplied with each Air Handler.
4. Check the voltages at motor plugs (120VAC and 24VAC).
5. There may be a faulty TAP on the motor. Select a
different speed on the motor tap selection tree.
Refer to Figure 13.
Possible defective motor. Contact RedZoneTM for assistance.
When ordering a new motor the Air Handler model number
and serial number will be required.
Each EC motor must be programmed with the same
torque settings as the original motor to operate properly.
Faulty Circuit Board:
The circuit board has a Green power LED and 3
function LEDs. When any of the 3 output LEDs are
illuminated 24VAC is supplied to the corresponding
¼” Spade terminal on the board.
If the Green power LED is not illuminated check that the
board fuse is not blown and replace if necessary.
If there is malfunction a temporary circuit board bypassed
can be utilized until a replacement circuit board is installed.
With the power off:
1. Remove the fuse from the circuit board
2. Move the “PUMP” wire (Orange/Black stripe) and the
 “HighFan”wire(White/RedStripe)tothetwoextra
W terminals.
This will allow the pump and blower to run with a call
for heat from the thermostat.
REDZONETM DVS SERIES AIR HANDLER MANUAL