Suntherm AHW1 Series User manual

MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 1
INSTALLATION MANUAL
LIST OF SECTIONS
LIST OF FIGURES
LIST OF TABLES
SECTION 1: GENERAL
7 – Thermostat Wiring and Connections ..............................................................23
8 – Blower Motor Speed Selection..........................................................................26
9 – Final System Checkout and Start-Up...............................................................26
10 – Blower Performance .............................................................................................28
11 – Wiring Diagrams.....................................................................................................29
21 –TXV Installed in Air Handler ........................................................................................ 14
22 – Flowrator Distributor...................................................................................................... 14
23 – Typical Condensate Trap......................................................................................15
24 – Typical Hot Water Tank and Refrigerant Line Connections.....................19
25 – Typical Hot Water Tank Connections.................................................................... 19
26 – Line Voltage Wire Knockout & Tstat Wire Entrances – AHW1..................19
27 – Line Voltage Wire Knockout & Tstat Wire Entrances – AHW2.................20
28 – Pull-Out Disconnect Location – AHW1 .........................................................20
29 – Component Locations – Electric Heat Control Box ...................................22
30 – Component Locations – No Electric Heat Control Box.............................22
31 – Component Locations – Hydronic Heat Control Box .................................. 22
32 – Heat/Cool Low Voltage Wiring Connections – Single Tfmr ....................24
33 – Heat/Cool Low Voltage Wiring Connections – Separate Tfmrs .............24
34 – Heat Pump Low Voltage Wiring Connections – Single Tfmr ..................24
35 – Heat Pump Low Voltage Wiring Connections – Separate Tfmrs...........24
36 – Constant Torque Motor Terminals....................................................................26
37 – No Electric Heat Wiring Diagram......................................................................29
38 – 3, 5 & 6 kW Electric Heat Wiring Diagram......................................................29
39 – 8 & 10 kW Electric Heat Wiring Diagram........................................................30
40 – Hydronic Heat Wiring Diagram.........................................................................30
10 – Electric Heater Element Capacities.................................................................. 21
11 – Wiring Requirements – 115 VAC – Hydronic Heat...................................... 21
12 – Low Voltage Wire Gauge and Max Lengths.................................................. 23
13 – Air Handler Low Voltage Pigtail Wire Colors/Tstat Connections........... 24
14 – Typical Heat/Cool T-stat Wire Color Codes & Connections...................... 25
15 – Typical Heat Pump T-stat Wire Color Codes & Connections ................... 25
16 – Constant Torque Motor Terminals – Electric & No Heat Models ........... 26
17 – Constant Torque Motor Terminal – Hydronic Heat Models .................... 26
18 – Blower Performance – Without Air Filters..................................................... 28
1 – General..........................................................................................................................1
2 – Safety, General, Dimensional & Model Number Nomenclature ..............2
3 – Air Handler Installation ...........................................................................................6
4 – TXV, Flowrator Distributor, and Refrigerant Lines ...................................... 11
5 – Hydronic (Hot Water) Heat.................................................................................. 15
6 – Line Voltage Wiring................................................................................................ 19
1. Models with electric heat and not heat are rated for 208/240 VAC, 60
Hz, 1-Phase.
2. Models with hydronic heat are rated for 115 VAC, 60 Hz, 1-Phase.
3. Air handler control circuit is rated at 24 VAC, 60 Hz.
4. Air handler size varies by model.
5. Four-wire thermostat operation for heat/cool applications.
6. Seven wire thermostat operating for heat pump applications.
7. Air handler is designed for both cooling only and heat pump
applications.
8. Air handler is designed for upflow applications only.
9. Air handler must not be operated without the access door installed.
10. Air handler is listed by ETL for the United States and Canada.
SAVE THIS MANUAL FOR FUTURE REFERENCE
1 – Air Handler Dimensions.........................................................................................4
2 – Clearance – Access for Service.............................................................................6
3 – Closet Clearances .....................................................................................................7
4 – Air Handler Top Dimensions – AHW1................................................................8
5 – Air Handler Duct Mounting Flange Dimensions...........................................8
6 – Air Handler Base Dimensions ..............................................................................8
7 – Typical Wall Mount Installation ...........................................................................8
8 – Wall Mount Panel Door....................................................................................................9
9 – Typical Wall Mount Installation with Wall Panel Door – AHW1..................9
10 – Typical Wall Mount Installation with Wall Panel Door – AHW2 ................9
11 – Side View For TypicalWall Mount Installation w/ Wall Panel Door – AHW1...9
12 – Side View For TypicalWall Mount Installation w/ Wall Panel Door – AHW2 10
13 – Wall Panel Door Dimensions.................................................................................. 10
14 – Wall Panel Door Frame Dimensions..................................................................... 10
15 – Wall Panel Door Frame Depth ............................................................................... 10
16 – Typical 1”Pleated Air Filter...................................................................................... 10
17 – Refrigerant Lines For Air Handler Below Outdoor Unit........................................11
18 – TXV Bulb Placement ................................................................................................ 12
19 – TXV Sensing Bulb Location .................................................................................... 13
20 – Typical TXV Connections ........................................................................................ 14
1 – Air Handler Specifications......................................................................................4
2 – Dimensional Data......................................................................................................4
3 – Model Number Nomenclature .............................................................................5
4 – Clearances to Combustibles..................................................................................6
5 – AHW2-18, 24-2N and AHW2-18, 24-3N Hot Water Capacities................ 16
6 – AHW2-18, 24-4N and AHW2-30, 36-2N Hot Water Capacities................ 17
7 – AHW2-30, 36-3N and AHW2-30, 36-4N Hot Water Capacities................ 18
8 – Wiring Requirements – 208/240 VAC – No Electric Heat.......................... 20
9 – Wire Requirements - 208/240 VAC Electric Ht – 1 Branch Circuit.......... 21
The following list includes important facts and information regarding this air handler.
Vertical Wall Mount Installation – Models With DX Cooling and Electric or Hot Water Heat
AHW1 and AHW2 SERIES

MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 2
Improper installation may create a condition where the
operation of the product could cause personal injury or
property damage.
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage. Refer
to this manual for assistance; or for additional information
consult a qualified contractor, installer, or service agency.
FIRE OR ELECTRICAL HAZARD
Failure to follow the safety warnings exactly could result
in serious injury, death, or property damage.
A fire or electrical hazard may result causing property
damage, personal injury or loss of life.
This product must be installed in strict compliance with the
installation instructions and any applicable local, state, and
national codes including, but not limited to; building,
electrical, and mechanical codes.
Safety Requirements
This air handler should be installed in accordance with all
national and local building/safety codes and requirements, local
plumbing or waste water codes, and other applicable codes.
In the absence of local codes, install in accordance with the
following codes.
• Standard for the Installation of Air Conditioning and
Ventilating Systems (NFPA 90A)
• Standard for the Installation of Warm Air heating and Air
Conditioning Systems (NFPA 90B)
• National Electrical Code (NFPA 70)
• Canadian Electrical Code, Part I (CSA C22.2) or ANSI/NFPA
No. 70
• All local codes (State, City, and Township)
NOTE: All applicable codes take precedence over any
recommendation made in these instructions. SunTherm
assumes no responsibility for units installed in violation of any
code or regulation.
1. Refer to the Figure 5 of this manual for the bottom return air
opening dimensions for installations with the return air
entering the bottom of the air handler. The plenum must be
installed according to the above listed codes or the
instructions in this manual.
2. Refer to Figure 1, Figure 4, and Table 2 of this manual for the
outlet duct ange dimensions on top of the air handler. The
outlet duct must be installed according to the instructions in’
this manual.
The Clean Air Act of 1990 bans the intentional venting of
refrigerant (CFC’s and HFC’s) as of July 1, 1992. Approved
methods of reclaiming must be followed. Fines and/or
incarceration may be levied for non-compliance
AHW DX Cooling With or Without Hot Water Heat
AHW DX Cooling With or Without Electric Heat
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal injury.
Understand and pay particular attention to the signal words
DANGER, WARNING, or CAUTION.
DANGER: Indicates an imminently hazardous situation, which if
not avoided, will result in death or serious injury.
WARNING: Indicates a potentially hazardous situation, which if
not avoided, could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation, which if
not avoided, may result in minor or moderate injury. It is also
used to alert against unsafe practices and hazards involving
property damage.
SECTION 2: SAFETY

MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 3
GENERAL INFORMATION
This air handler provides the flexibility for installation in most
upflow or vertical wall mount applications and can be configured
with or without electric heat or with hydronic heat. The constant
torque motor provides a selection of air volume to match most
applications. The air handler may be positioned for bottom air
return or front return.
Inspection
As soon as the air handler is received, it should be inspected for
possible damage during transit. If damage is evident, the extent
of the damage should be noted on the carrier’s freight bill. A
separate request for inspection by the carrier’s agent should
be made in writing. Before installing the air handler, check the
cabinet for screws or bolts which may have loosened in transit.
There are no shipping or spacer brackets that need to be removed
before installation.
Check to be sure all accessories such as heater kits and coils
are available. Installation of these accessories should be
accomplished before the air handler is set in place or the
connecting of the wiring, ductwork, or piping.
See local distributor for more information. Mortex Products, Inc
assumes no liability for freight damage.
3. These models are not ETL listed or approved for installation
into a manufactured (mobile) home.
4. Provide clearances from combustible materials as shown
in Table 4: Clearances to Combustibles and Figure 3: Closet
Clearances.
5. Provide clearances for servicing ensuring service access is
allowed for the control box, electric elements, hot water coil
and the blower (See Figure 2: Clearance - Access for Service).
6. Conrm that the power supply complies with the electrical
characteristics listed on the air handler rating plate.
7. Failure to carefully read and follow all instructions in this
manual can result in malfunction of the air handler, death,
personal injury, and/or property damage.
8. The air handler must be installed so the electrical components
are protected from water.
9. Installing and servicing heating/cooling equipment can be
hazardous due to electrical components.
10. Only trained and qualied personnel should install, repair, and
service heating/cooling equipment. Untrained service
personnel can perform basic maintenance functions such as
cleaning of exterior surfaces and replacing the air lters.
Observe all precautions listed in this manual and on the labels
when installing and servicing this air handler.
11. These instructions cover minimum requirements and conform
to existing national standards and safety codes. In some cases,
these instructions exceed certain local codes and ordinances,
especially those who have not kept up with changing home
and/or HUD construction practices. These instructions are
to be followed and are the minimum requirement for a safe
installation.
12. The size of the system should be based on an acceptable
heat loss calculation for the structure. ACCA Manual J or other
approved methods may be used.
13. Models with electric heat use a nominal 208 or 240 VAC, 1-
Phase, 60-Hz power supply.
14. Models with hydronic heat use a nominal 115 VAC 1- Phase, 60
Hz power supply.
NOTE: DO NOT CONNECT THIS AIR HANDLER TO A 50 HZ
POWER SUPPLY OR A VOLTAGE ABOVE 250 VOLTS FOR
ELECTRIC HEAT MODELS OR ABOVE 132 VOLTS FOR
HYDRONIC HEAT MODELS.
15. Ground connections must be securely fastened to the ground
lug located inside the control box.
ALWAYS SHUT OFF ELECTRICAL POWER AT THE PULL-OUT
DISCONNECT (ELECTRIC HEAT MODELS) LOCATED ON THE
AIR HANDLER AND TURN OFF THE CIRCUIT BREAKERS IN THE
MAIN ELECTRICAL PANEL BEFORE PREFORMING ANY SERVICE
ON THE AIR HANDLER.
Hot water from a boiler used to satisfy heating requirements
can be heated to temperatures of 180°F. Parts containing
water this hot can quickly scald. Use extreme caution
when servicing or performing maintenance on any parts
containing hot water.

Model
No. Nominal Tons Blower Code
Blower
Motor
HP
Cooling
Blower
Speed
Tap
Blower
Size
Nominal
Cooling
CFM @
0.30 inwc
ESP With
Coil
Nominal
Heating
Speed
(CFM) @
0.30 inwc
ESP /
Speed Tap
Electric
Heater
Kw
Voltage / PH /
HZ
Thermostat
Circuit
Voltage /
PH / HZ
Max.
External
Static
Duct
Pressure
(in.
W.C.)
AHW1 1.5 - 2.0 LM 1/3 5 10 x 7T 850 600 / 2 * 0 - 8 208-240 / 1 / 60 24 / 1 / 60 0.30
AHW1 2.5 LG 1/3 5 10 x 7T 1000 750 / 1 0 - 8 208-240 / 1 / 60 24 / 1 / 60 0.30
AHW1 3 LI 1/2 5 10 x 8T 1250 975 / 1 0 - 10 208-240 / 1 / 60 24 / 1 / 60 0.30
AHW2 1.5 - 2.0 LK 1/2 5 10 x 8T 1100 830 / 1 N/A 115 / 1 / 60 24 / 1 / 60 0.30
AHW2 2.5 - 3.0 LL 1/2 5 12 x 8T 1235 796 / 1 N/A 115 / 1 / 60 24 / 1 / 60 0.30
MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 4
Table 1: Air Handler Specifications
AHW1 Electric Heat AHW2 Hydronic Heat
Figure 1: Air Handler Dimensions
Table 2: Air Handler Dimensional Data
*Indicates minimum heating speed tap for that blower motor code. Do not use a lower speed tap for the heating speed as it will result in
insufficient airflow and possible safety limit tripping.
Available Blower Motors
1. Blower Motor – 1/3 HP 5 Speed Constant Torque
2. Blower Motor – 1/2 HP 5 Speed Constant Torque
Cabinet Dimensional Data in inches
Model A B C D E
AHW1 22 15.75 14 11 36
AHW2 22 15.75 20 10 39

MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 5
AHW Vertical Wall Mounted Air Handler
DX Cooling / Electric Heat / Hot Water
Air Handler
Unit Type
AHW - Vertical Wall Mount
Example: 24 - 24,000 btu
Condential
B - Breaker
1 - DX Coil with Electric Heat
2 - DX Coil with Hot Water Heat
A - 115V (Hot Water Heat)
C - 208/240V (Electric Heat)
D - R410a 1.5 thru 2.5 tons
Y - R410a 3 ton
LG - 1/3 HP, 208/240V, Constant Torque, with 10 x 7T blower assembly
LM - 1/3 HP, 208/240V, Constant Torque, with 10 x 7T blower assembly
LI - 1/2 HP, 208/240V, Constant Torque, with 10 x 8T blower assembly
LK - 1/2 HP, 115V, Constant Torque, with 10 x 8T blower assembly
LL - 1/2 HP, 115V, Constant Torque, with 12 x 8T blower assembly
00 - Electric Heating Capacity (kW)
2P - 2 Row Hot Water Coil
3P - 3 Row Hot Water Coil
4P - 4 Row Hot Water Coil
2N - 2 Row Hot Water Coil No Pump
3N - 3 Row Hot Water Coil No Pump
4N - 4 Row Hot Water Coil No Pump
Standard Features:
Factory Installed TXV
Factory Installed Time Delay Relay (TDR)
Factory Installed Disconnect
Front“Return Air”Application
Optional Features:
BR - Solid Front Panel (Bottom “Return Air” Application)
AWH 1 24 1 C LG 03 D
Series
Nominal Cooling BTUs
Unit Voltage
Blower Motor & Blower Package
Heating Capacity
TXV Code
Options / OEM Manufacturers Code
Slant Coil Conguration (Rows, FPI, Ried/Smooth, Fin Type, Etc.)
Table 3: Model Number Nomenclature

MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 6
Table 4: Clearances to Combustibles
Figure 2: Clearance – Access for Service
The air handler can be installed in a closet, an alcove, a framed
in wall mount, or in a basement. The air handler must be level to
allow for proper condensate drainage.
Air Handler Orientation (Upflow Only):
This air handler is designed to be installed in an upflow air flow
position only. It must not be installed in horizontal or downflow
applications.
Location
Access for servicing is an important factor in the location of any
air handler. Provide a minimum of 30 inches in front of the air
handler for access to the control box, heating elements, hot water
coil, blower and air filters. This access may be provided by a closet
door or by locating the air handler so that a wall or partition is not
less than 30 inches from the front access panel.
Location is usually predetermined. Check with owner’s or dealer’s
installation plans before installation. If a location has not been
determined, consider the following in choosing a suitable
location.
1. Select a location with adequate structural support, space for
service access, clearance for return and supply duct
connections.
2. Normal operating sound levels may be objectionable if the
air handler is placed directly over or under some rooms such as
bedrooms, study, etc.
3. Caution should be taken to locate the air handler so that supply
ducts are about the same length to achieve even air distribution
of supply air to the living spaces.
4. Locate the air handler where electrical supply wiring can be
easily routed to main electrical panel and where electrical
wiring will not be damaged.
5. Locate the air handler where the thermostat wiring can be
easily routed to the thermostat and where the wiring will not be
damaged.
6. Locate the air handler where the refrigerant lines can be easily
routed to the outdoor unit.
7. Locate the air handler where the condensate lines can be easily
routed to an available drain or to the exterior of the building.
Route condensate drain piping so it does not obstruct access to
the air filter or servicing of the air handler.
8. When the indoor coil is installed in a draw-through application
as is the case with this air handler, a negative pressure will
be created in the condensate drain system. To assure proper
condensate drainage and to prevent condensate from being
drawn into the air handler, the primary and secondary
(overflow) condensate drains must be trapped as described in
Section 5: Air Handler Installation and Figure 25 in these
instructions. If the secondary drain is not used, it must be
capped.
9. The exterior surface of air handler cabinet will likely sweat
when it is installed in a non-conditioned space such as an attic
or garage. The installer must install an auxiliary drain pan under
on all air handlers installed in a non-conditioned space to
prevent damage from condensation runoff.
10. It is recommended that air handlers installed in non
conditioned spaces be insulated on the exterior of the entire
cabinet, including the front access panel with one (1) inch
thick fiberglass with the vapor barrier on the outside. Some
states, cities and counties require additional insulation to be \
installed on the exterior casing of the air handler installed in
an unconditioned space to prevent sweating. Refer to the
state, city, county or local code for insulation requirement to
be sure the installation is in compliance.
Clearances
This air handler is approved for zero (0) inches clearance to
combustible material on any part of the air handler exterior
casing and the inlet or outlet ducts providing no electric heater
is being used. There is a one (1) inch clearance requirement on
the supply air duct or plenum when an electric heater is installed
in the air handler. Refer to Table 4 and Figure 4 for clearance to
combustibles information.
SECTION 3: AIR HANDLER INSTALLATION
FRONT OF FURNACE
Model Top (in) Back (in) Sides (in) Wall Panel Door (in) Alcove (in) Closet Door (in) Duct (in)
AHW 0 0 0 6 30 6 1

SUPPLY AIR DUCT 1" Clearance between the wall
WALL WALL
FLOOR
0" Clearance to the sides
and the supply air duct.
of the air handler and the wall
1" Clearance between the wall
0" Clearance to the sides
and the supply air duct
of the air handler and the wall
1" clearance between supply air
duct and combustible material
must be maintained for the first
36" of the supply air duct.
MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 7
Return Air and Filter Requirements
Provisions must be provided for the air in the living spaces to
return to the air handler. Failure to comply may cause a reduction
in the amount of return air available to the blower, causing
reduced air flow and improper heating or cooling of the living
space. The reduced air flow may also cause the air handler to cycle
on the heating over-temperature limit and premature heating
element failure.
For wall mount installations, the front return air opening and
internal return air filter is utilized. For closet installations, the front
return air opening and internal return air filter may also be utilized
if the closet door has a sufficiently sized return air grille with at
least 6 inches of clearance between the closet door and the front
of the air handler to allow the free flow of return air into the air
handler. The closet door grille must have a minimum amount
of total free area opening for the return air to pass through
unrestricted.
For AHW Air Handlers With 1/3 HP Blower Motor
• Minimum 200 in² free return air grille area opening
For AHW Air Handlers With 1/2 HP Blower Motors
• Minimum 250 in² free area return air grille opening
Recommended Closet Door Return Grille Size
800 CFM – 20 X 20 Grille – 324 in²
1000 CFM – 20 X 25 Grille - 414 in²
1200 CFM – 25 X 25 Grille - 414 in²
NOTE: Installation codes may limit the installation to a single level
residence when no return air duct is used.
Closet installations may also utilize the bottom return air opening
with a return duct located in the floor or platform under the air
handler. Basement installations require the air handler to be
installed on a return air base or enclosed platform for the return
air duct to connect to.
Bottom return applications require the bottom return opening
block-off panel to be removed and the installation of a field
fabricated sheet metal block-off panel to cover the front return
opening. The bottom return opening block-off panel can be
removed by cutting the tabs that attach it to the air handler. For
bottom return applications, a return air filter grille attached to the
return duct may be used instead of the factory installed internal
air filter.
NOTE: If a return air filter grille or return air base with an integral
filter is utilized, remove the factory internal filter when the air
handler is installed.
If a return air filter grille or return air base with integral filter is
utilized, follow the minimum filter sizing requirements below.
Standard Disposable Air Filter @ 300 ft/min or less
800 CFM = 20 x 20 x 1
1000 CFM = 20 x 25 x 1
1200 CFM = 20 x 30 x 1
Pleated Disposable Air Filter @ 500 ft/min or less
800 CFM = 16 x 16 x 1
1000 CFM = 18 x 20 x 1
1200 CFM = 20 x 20 x 1
Supply Air Duct
The supply air outlet is located on the top of the air handler.
Connect a supply air duct/plenum system to the supply air outlet
flanges around the supply air outlet. See Figure 1, Figure 4, and
Table 2 for the supply air opening dimensions. Use a non-tape
sealant such as mastic or an aerosol sealant to prevent duct
leakage.
Wall Mount Installations
This air handler is designed for recessed mounting in a wall or for
hanging on the wall in a closet. Recessed mounted air handlers
must be supported by 2x4 header between 2x4 studs as shown
in Figure 8 below. Use the factory provided nail holes in the
front edge of the air handler to attach cabinet to the framed
opening. Be careful to locate the air handler so the drywall surface
will be flush with edges of cabinet, permitting the wall panel
accessory to be attached to cover the opening and edges of the
drywall. Consider the routing of the electrical wiring, refrigerant
lines, condensate lines, and hot water piping when framing the
opening and cut the necessary holes prior to installing the air
handler.
Closet Installations With Bottom Return Air
For closet installations that utilize the air handler bottom return
air opening, the air handler may be installed directly on the
floor or on a platform framed within the closet with a return air
opening cut in the floor or platform for the return air plenum or
duct. Cut the holes in the floor or ceiling for the refrigerant tubing,
electrical wiring, thermostat wiring, and outdoor unit control
wiring and cut the hole(s) for the condensate drain line(s) in the
floor or wall prior to installing the air handler. Bottom return
installations require the use of a non-tape sealant such as mastic
or an aerosol sealant to seal between the air handler and the floor
or platform to prevent air leakage.
Figure 3: Closet Clearances

MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 8
Figure 4: Air Handler Top Dimensions –AHW1 Figure 6: Air Handler Base Dimensions
Figure 5: Air Handler Duct Mounting Flange Height
Figure 7: Typical Wall Mount Installation

MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 9
Figure 9: Wall Mount Installation With Wall Panel
Door - AHW1
Figure 10: Wall Mount Installation With Wall Panel
Door - AHW2
Figure 8: Wall Panel Door
Figure 11: Side View For Typical Wall Mount
Installation With Wall Panel Door - AHW1

MORTEX PRODUCTS INC. 501 TERMINAL RD FORT WORTH, TX 76106 Page 10
Figure 12: Side View For Typical Wall Mount
Installation With Wall Panel Door - AHW2
Figure 13: Wall Panel Door Dimensions
Figure 15: Wall Panel Door Frame Depth
Figure 14: Wall Panel Frame Dimensions
Figure 16: Typical 1” Pleated Air Filter