Vortex combo-pac User manual

CP-1605
Installation Instructions
combo-pacTM
hot water air handler
with high efficiency EC motor and
iStat6 Control
45 Cowansview d.
Cambridge, Ontario
N1 7L2
Phone: [phone]
Fax: [phone]
[email protected]
www.vortexsource.com

CP-1605

CP-1605
Table of Contents
TYPICAL PLUMBING CONNECTIONS .......................................................................................................... 5
ELECT ICAL WI ING DIAG AM .................................................................................................................. 7
INT ODUCTION ............................................................................................................................................ 10
HOW IT WO KS ........................................................................................................................................... 11
COOLING.......................................................................................................................................................... 11
HEATING .......................................................................................................................................................... 11
CONTINUOUS FAN ............................................................................................................................................ 11
P ODUCT DESC IPTION ............................................................................................................................ 11
CABINET .......................................................................................................................................................... 11
HEATING COILS ................................................................................................................................................ 12
FAN AND MOTO .............................................................................................................................................. 12
CI CULATING PUMP .......................................................................................................................................... 12
CHECK VALVE .................................................................................................................................................. 12
CONNECTING TO A WATE HEATE ................................................................................................................... 12
CONNECTING TO A BOILE ................................................................................................................................ 12
EQUIPMENT SELECTION AND SIZING ...................................................................................................... 13
HEAT LOSS ...................................................................................................................................................... 13
AI HANDLE SELECTION ................................................................................................................................. 13
DUCT LAYOUT .................................................................................................................................................. 13
PLUMBING LAYOUT ........................................................................................................................................... 14
INSTALLATION ............................................................................................................................................. 14
AI HANDLE MOUNTING .................................................................................................................................. 15
DUCTWO K ...................................................................................................................................................... 15
ISK OF FEEZING ........................................................................................................................................... 16
ELECT ICAL ................................................................................................................................................ 16
THE MOSTAT ................................................................................................................................................... 16
A/C CONDENSING UNIT .................................................................................................................................... 17
STA T-UP P OCEDU ES........................................................................................................................... 17
SE VICE AND MAINTENANCE ................................................................................................................... 19
T OUBLESHOOTING ................................................................................................................................... 20
EFE TO THE CONT OLS MANUAL AS WELL. ..................................................................................................... 20
THE MOSTAT CALL EO ............................................................................................................................... 20
PUMP DOES NOT UN ........................................................................................................................................ 20
PUMP IS NOISY AT STA T-UP ............................................................................................................................. 20
WATE HEATE T&P IS WEEPING ...................................................................................................................... 20
INSUFFICIENT O NO HEAT ................................................................................................................................ 20
COLD WATE AT HOT FAUCET ............................................................................................................................ 21
FAN UNS FO COOLING BUT NOT HEATING ........................................................................................................ 21
HEATING DU ING STANDBY MODE ..................................................................................................................... 21
combo-pac AI HANDLE PA TS & ACCESSO Y LIST ........................................................................ 22
P ODUCT WA ANTY ............................................................................................................................... 23

CP-1605
Important notes For the Installer

A Quick Check List
 Are the water connections to the water heater oriented in a way to
avoid trapping air in the heating circuit? (see diagram on next page)
 Is the purge valve installed on the return line from the air handler
upstream from the isolation valve?

Is the air handler hung and isolated to avoid transmitting vibration
through framing and duct work? Or is the air handler on a
housekeeping pad?
 Are the isolation valves full-port? estrictive valves will limit
performance.
 Are Thermostat connections correct, including cooling and continuous
run connections?
 Have the packing materials been removed from the blower and the
pump ?
 Is there an installation manual for the home owner ?
 Is the unit accessible? Are there clearances for service and component
replacement?

Are the supply plenum and return duct/drop acoustically lined ? (at
least 6ft. of the return duct/drop and the supply plenum are
recommended)
 Is the filter cover in place? Is a clean filter in place? Is the supplied
filter rack installed?

CP-1605
TYPICAL PLUMBING CONNECTIONS

CP-1605

CP-1605
ELECT ICAL WI ING DIAG AM
Motor choke required for 3/4hp only

CP-1605
Physical Properties
Cabinet dimensions Supply air eturn air water
inlet Shipping
Model Type A
depth
B
width
C
height
d x e f x g and
outlet Weight
CP30 20” 14” 24” 12”x16” 14”x18” 1/2” 80 lb.
CP63, CP70,
CP80 22” 25” 31.5” 20”x20” 18”x23” 3/4” 110 lb.
CP100 22” 25” 53.5” 20”x20” 18”x23” 1” 120 lb.
Unit Specifications: combo-pac ECTM air handlers
MODEL: CP30-EC CP63-EC CP70-EC CP80-EC CP100-EC
*Heating Capacity (Btu/h) 120F water 21,000 45,000 51,000 59,000 76,000
*Heating Capacity (Btu/h) 130F water 28,000 58,000 65,000 73,000 91,000
*Heating Capacity (Btu/h) 140F water 30,000 63,000 70,000 80,000 106,000
*Heating Capacity (Btu/h) 160F water 37,000 80,000 90,000 103,000 135,000
*Heating Capacity (Btu/h) 180F water 48,000 99,000 110,000 125,000 164,000
(USGPM) Heating 3.0 4.8 4.8 4.8 7.0
Maximum Heating Airflow (CFM) 800 1200 1400 1800 2000
Max. External Static Pressure (“wc)** 1.2 0.6 1.1 0.7 1.0
Max. Cooling Capacity (Tons) 2.0 3.0 3.5 5.0 5.0
Blower Motor Full Load (Amps) 5.5 5.5 7.7 9.6 9.6
Circulator Full Load (Amps) 0.6 0.8 0.8 0.8 0.8
* Based on 70F return air and high fan speed. Contact Vortex for performance at lower water
temperatures.
** Air handler can deliver maximum programmed airflow at any static pressure below this value.

CP-1605
Unit Specifications: combo-pacTM air handlers with small-D TM
MODEL CP30 CP30 CP63 CP63 CP70 CP70 CP80 CP80 CP100 CP100
Number of 4”
outlets1 5 7 8 10 9 12 12 17 15 20
Cooling Capacity
(Tons) 1.5 2.0 2.0 2.5 2.5 3.5 4.0 5.0 4.0 5.0
Heating Capacity
(MBH) 130F water3 24 28 48 58 56 65 66 73 77 91
Heating Capacity
(MBH) 140F water3 26 30 51 63 60 70 73 80 90 106
Heating Capacity
(MBH) 160F water3 32 37 65 81 76 90 94 103 115 135
Heating Capacity
(MBH) 180F water3 41 48 81 100 93 110 114 125 139 164
(USGPM) Heating 3.0 3.0 4.8 4.8 4.8 4.8 4.8 4.8 7.0 7.0
Max. Heating
Airflow2 600 800 900 1200
1050 1400 1350 1800 1350 1800
Max. ESP (in.WC) 2
2.3 0.9 1.5 0.6 1.8 1.1 1.8 0.7 1.8 0.6
Blower Motor Full
Load (Amps) 5.5 5.5 5.5 5.5 7.7 7.7 9.6 9.6 9.6 9.6
Circulator Full
Load (Amps) 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
1. Minimum number of outlets required at rated airflow. efer to SmallD Design for options.
2. These are example air flows and ESP based on number of outlets and programmed
heating/cooling speed. Higher ESPs are available at lower airflows. Contact Vortex for
performance at lower speeds.
3. Based on 70F return air. Contact Vortex for performance at lower water temperatures.

CP-1605
INT ODUCTION
combo-pac ™ air handlers are state-of-
the-art units designed for use with
hydronic (boiler) systems or in
combination space and water heating
systems (Combo Systems). Two key
features include automatic heating
capacity adjustment and automatic
cooling dehumidification adjustment.
The programmable control allows for
customization and adjustment of air
speeds and capacity. Combo heating
systems use the home’s water heater to
provide both the space heating and
domestic hot water, eliminating the need
for a furnace.
Combo heating systems are ideally
suited for single-family homes,
townhouses and apartments where the
cost of a furnace does not make sense or
space requirements are limited. They
are also great for additions, renovation
and finished basements as a
replacement for, or in addition to the
existing heating system. Vortex air
handlers are also great for hydronic
heating systems using ground-source
heat pumps. They are the smallest units
available in their capacity range.
combo-pac ™ air handlers are designed
to take the guesswork out of system
sizing and installation. Matched
specifically to common water heater
sizes, Vortex air handlers can be quickly
sized using the quick sizing information
in our spec sheets or from air handler
performance curves. For applications
requiring special consideration, call
888-781-8151 for answers to questions
related to sizing, installation or trouble-
shooting for any of Vortex air handlers.
Vortex provides you with the quietest
operating air handler available. By using
large capacity, high output heating coils,
these air handlers deliver more heating
per volume of air, which means warmer
delivered air temperatures.
combo-pac™ air handlers are intended
for conventional and small-D™ duct
systems with higher operating static
pressure. efer to the small-D™ design
manual for more details on duct design
and installation.