Whalen VW series Assembly instructions

Installation, Operating &
Maintenance Instructions
Vertical Models: VW

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Table of Contents
Table of Contents ...................................................................................................................................... 2
Product Safety ........................................................................................................................................... 2
Important Information About Safety Instructions ...................................................................................... 2
Receiving ..................................................................................................................................................... 2
Installation ................................................................................................................................................... 3
Normal Piping Practice ............................................................................................................................ 3
Start-Up ........................................................................................................................................................ 4
Fan Coil Piping Instructions ................................................................................................................... 4
Maintenance/Repair Introduction ......................................................................................................... 6
Preventative Maintenance ................................................................................................................... 6-7
Replacement Parts Instructions ............................................................................................................ 7
Maintenance/Repair Log ......................................................................................................................... 8
Filter Replacement Log ........................................................................................................................... 9
Checklist .................................................................................................................................................... 10
Product Safety
Important Information About Safety Instructions
The Important Safety Instructions and warnings in these instructions are not meant to cover all
possible problems and conditions that can occur. Use common sense and caution when
installing, maintaining or operating the equipment.
Always contact The Whalen Company Applied Support Team about any problems or conditions
that you do not understand.
Safety Symbols and Labels used in these instructions
Receiving
Upon delivery, examine each unit carefully for shipping damage. Immediately report any freight
damage to the freight carrier and file a freight claim with the carrier. All units are shipped FOB
factory; therefore The Whalen Company is not responsible for damage during transit.
It is the responsibility of the installing contractor to inspect and verify that the unit received is the
correct model number, voltage, etc. Any discrepancies should be resolved before uncrating
and/or installation. The Whalen Company is not responsible for any back charges due to
an incorrect unit being installed.
WARNING
Hazards or unsafe practices that COULD result in
severe personal injury or death.
CAUTION
Hazards or unsafe practices that COULD result in
minor personal injury or property damage.

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Returns require written authorization from The Whalen Company. Unauthorized returns will be
refused. All material returned will be inspected. Any damage, missing parts, rework or
repackaging resulting from prior installation, abuses or neglect will constitute just cause for The
Whalen Company to issue partial credit.
Installation
Prior to installation check to make sure unit is as ordered and that the fan rotates freely. This
unit must be installed in a manner which will allow the blower access panel to be removed in
order to clean the coil surface, blower, or motor. When installed in a concealed building space
acting as return-air plenum, the installation must conform to the requirements of NFPA Standard
90B. It must be installed level and condensate drain lines must be trapped with proper slope for
rapid drainage. Water and drain connections must be made to the unit in accordance with local
codes.
Normal Piping Practice
The bottom coil connection, on the leaving-air-side, is the water-supply inlet. All piping must be
supported independently from the coil to prevent damage to the soldered joints. Chilled water
and condensate drain lines must be insulated for efficient operation and to prevent condensate
formation. Pipe insulation must be closed-cell or have a vapor barrier. All joints must be
properly sealed against air leaks to the piping. Control valves, shut-off valves, and un-insulated
water piping must be installed over the drain pan or utilize an accessory drain pan extension.
Condensate lines, one primary and one secondary, must be properly pitched to the building
drain. The Whalen Company will not assume any liability for damage caused as a result of the
condensate drain line not being properly pitched or trapped. The use of a secondary drain pan
under the entire unit, with a separate drain line, is advised in areas where water damage is very
critical. See the Fan Coil Piping Instructions on Page 5.
CAUTION
It is the sole responsibility of the customer to provide the necessary protection to prevent vandalism
and weather protection of the equipment. Under no circumstance should the fan coil be left exposed to
the elements. Protect the units from dirt, plaster and other debris during the entire construction phase.
Prior to start-up, the entire interior of the unit should be inspected for debris and dirt. Clean, if
necessary. Any failure of the unit or damage to the building as a result of improperly protecting and
cleaning the unit is not covered by the warranty.
WARNING
These units weigh 140-307 lbs., a minimum of two people are recommended for handling and
installation.
WARNING
If the unit is installed during the winter months, care must be taken so that the unit is not subject to
freezing temperatures while filled with water during construction. Coils damaged due to freezing are not
covered by the warranty. The Whalen Company fan coil units are suitable for zero clearance to
combustible material. All air must be bled out of the water system. Any air trapped in the hot- or
chilled-water coil can be released from the system by using the manual air vent on the coil.
For hot and humid areas: Do not operate during construction or renovation with windows and doors
open causing outside air to enter the building. When the outside air enters the building, it imposes high
cooling and dehumidifying loads on the units.

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Start-Up
After the fan coil and piping have been installed, pressure test for 24 hours with a minimum of
2½ times the working pressure to insure that there are no leaks in the system. This test should
be performed prior to hanging or installation of ceilings, floor coverings, drapes, etc. Any
damage caused due to leaks is not covered under the warranty.
Wiring: The motor must be properly wired prior to start-up. The Wiring diagrams are provided
with each unit and/or are part of the job submittals. The warranty on all motors is void if the
motor is burned-out due to incorrect wiring. Wire used for connections to the fan coil must be
rated for at least 90° degrees centigrade. All wiring connections must be tight. Check the rating
of the unit to determine: volts, hertz, horsepower, phase, amps per motor, appropriate switching,
maximum circuit fuse amps, and minimum circuit fuse amps. All wiring must be done in
accordance with applicable local electrical codes and/or standards.
1. Be sure the long line on the Valve Stem Marking runs parallel to the water flow. The
small intersecting line will be aimed toward the Water Direction Arrow.
2. The large black lever should be parallel to the long line on the Valve Stem Marking as
shown. If not, pivot the gray Release Lever and while pivoted, turn the large black
lever accordingly.
3. Set both dip switches in the position toward the black lever
4. Place the green actuator assembly onto the valve and re-insert the pins.
Fan Coil Piping Instructions
CHILLED- AND HOT-WATER COILS
Purpose This data is intended to explain piping arrangements for chilled- and hot-water coils to
the correct inlet and outlet locations.
Two-Pipe Coils Two-pipe coils have one inlet and outlet. Fan coils may have one- to six-rows.
The coil may be 100% chilled water, 100% hot water, or with the addition of a pipe sensor
changeover control, it may use chilled water when the chiller is operating or hot water when the
boiler is operating. A two-pipe system allows for the chiller or boiler to operate independently,
one at a time. The pipe sensor must be clamped onto the supply water line as close to the
incoming water source as possible. The purpose of the pipe sensor is to sense the water
temperature in the inlet pipe and detect the water temperature at its set point of approximately
88°F. The pipe sensor will change the thermostat control from the cooling mode to the heating
mode and vice versa.
WARNING
Failure to follow these instructions exactly when replacing the actuator valve may create a
misalignment of the valve, resulting in leaking and subsequent property damage.

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The inlet is always at the bottom of the coil and the outlet is always at the top of the coil. All
coils are piped so that the inlet is always on the row farthest downstream from the incoming air
(See diagram 1).
All coils have one or more circuits. Circuits are added to reduce the water pressure drop to an
acceptable level (usually 10-ft. H²O pressure drop or less). Due to the various circuit options
available, the inlet, and outlet may change position making the inlet and outlet locations vary.
Four-Pipe Coils
Four-pipe coils have a dedicated, chilled-water coil, and a dedicated hot-water coil, each with its’
own inlet and outlet, equaling four pipes. All coils have a common tube sheet for four-pipe coils.
Example: A four-row, chilled-water coil and a one-row, hot-water coil would use a five-row coil
with four rows for chilled-water and one row for hot-water. Normally the one-row, hot-water coil
is in the reheat position or downstream from the cooling coil. The hot-water coil may also be
ordered in the preheat position or upstream from the chilled-water coil. The controls are wired so
that either the chilled-water coil is operating or the hot-water coil is operating, but not both at the
same time. When the conditioned space thermostat is satisfied, both the chilled- and hot-water
control valves are deactivated. The same rule applies for inlet and outlet locations as explained
above in “Two-Pipe Coils” (See diagram 2). Each chilled- and hot-water coil is controlled
individually so a pipe sensor is not required.
Hose Kits
When hose kits are being used on units it is important to make sure the hoses are not installed
over any electrical components, such as j-boxes, actuators, etc. Hoses are not sweat proof so
they can condensate. It is recommended that the flex hoses be field insulated during installation.
Failure to follow these directions may cause unit operation failure.
Coil Identification
The following diagrams indicate the number of rows and type of chilled- and hot-water coils.
Standard coil has the hot-water coil located in the reheat position.
Because of the variations of circuiting available, the location of the inlet and outlet connections
may vary up and down. However, always use the following rule to be correct. The inlet is
always the lower connection and the farthest away from the entering-air-side. The outlet
connection is always the higher connection closest to the entering-air-side.

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Maintenance/Repair Introduction
By nature, heating, ventilation and air conditioning equipment deteriorates with normal use. To
help alleviate this, preventive maintenance is required. When properly maintained, the systems
will experience improved efficiency and increased equipment life.
Failure to perform preventive maintenance of The Whalen Company equipment, by a licensed
HVAC technician per the recommended schedule, will result in loss of factory warranty. Logs
are provided in this manual and are to be filled out documenting all repairs and maintenance
performed.
Preventive Maintenance
 General (Annually)
o Visual Inspection for corrosion and proper mounting, alignment and sealing
 Installation of unit
 Air Connections
 Water connections
 Condensate drainage pitch
o Functional Inspection of operation
 Heating mode
 Cooling mode
 Amperage draw
 Supply voltage
 Coils (Annually)
o Clean the coils by removing the blower panel and brushing the fins with a stiff, plastic
bristle brush, taking care not to bend or damage the fin surface. After brushing, the
coil should be vacuumed to remove loose dirt.
o Check insulation for proper coverage to maintain efficiency and prevent sweating.
o Piping – inspect all connections for leaks and corrosion.
o Valves – Check for proper operation, corrosion and leaking.
 Motor (Annually)
o If there are no oil tubes present, the motor is permanently lubricated.
o If oil tubes are provided on the motor, lubricate every six months with SAE-10 weight,
non-detergent oil. Inspect the motor and blower assembly every time the motors are
oiled for excessive accumulation of dust and dirt. If necessary, remove the blower
and vacuum. If this situation does occur, increase routine filter maintenance. “DO
NOT OVER OIL”
o Check amperage draw against the nameplate information
o Check bearings for wear and noise.
o Wheel – Check for free spinning movement
o Check for tightness of set screws.
o Check blades for damages.
 Drain Pan (Annually)
o The drain pan must be inspected before summer operation. All debris in the drain
pan should be removed so the condensate will flow out easily. Periodic inspection of
the drain pan and condensate piping should be performed during the summer

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operation to prevent any possibility of it becoming clogged. The Whalen Company
will assume no liability for damage caused as a result of the condensate line
becoming plugged.
o Corrosion – Check for signs of rust; heavy flake indicate that replacement is needed.
o Float Switch – The optional drain pan float switch position is not adjustable. The float
switch must be mounted flush with the edge of the drain pan for optimum
performance. Any attempt in moving the float switch in any other position can result in
unit failure.
o P-trap and Piping – be sure these areas are free of debris that could block drainage.
o Drainage – test functionality by pouring water into the pan and observing proper
operation.
 Electrical (Annually)
o Inspect for signs of arcing or overheated wires.
o Check ground connection for signs of corrosion.
o Check all connections for a tight fit.
 Filters (6 Months)
o Disposable - Change throwaway filters a minimum of twice a year and recorded on
the Filter Replacement Log. Once before the heating season and once before the
cooling season. Periodic checks should be made during the cooling season to insure
that excessive dust or lint is not accumulating to the extent of interrupting free air flow.
If excessive dirt accumulates, the filter should be changed more frequently.
o Reusable/Cleanable - Filters should be thoroughly cleaned a minimum of twice a year
and have the same periodic checks as throwaway filters.
 Hoses, if equipped (Annually)
o Check all fittings for leaks.
o Check for frayed braiding
 Replacement Parts
o It is strongly recommended that genuine Whalen parts be used when replacement is
required. When ordering replacement parts, refer to the model and serial number
located on the blower and motor housing.
Replacement Parts Instructions
When ordering replacement parts, refer to the model and serial number located on the blower
and motor housing.
WARNING
RISK OF ELECTRICAL SHOCK. CAN CAUSE INJURY OR DEATH.
Disconnect all remote electric power supplies before servicing. Placing the thermostat in
the “OFF” position should not be used for disconnect purposes.

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Maintenance/Repair Log
Address: Unit No.:
Model Description:
Model No.: Serial No.:
Voltage: Amps: Start-Up Date:
Date Descri
p
tion of Service Parts Re
q
uired Si
g
nature

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Filter Replacement Log
Address: Unit No.:
Model Description:
Model No.: Serial No.:
Replacement
Date/Signature
Replacement
Date/Signature
Replacement
Date/Signature

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Checklist
Receiving & Inspection 

Ductwork Connections 

1 Unit Received Undamaged 32 Install Ductwork, Fittings & Grilles As Required
2 Unit Received Complete As Ordered 33 Flexible Duct Connections At Unit
3 Parts Accounted For 34 Proper Supply and Return Grille Type & Size Used
4 Unit Arrangement/Hand Correct 35 Control Outside Air For Low/High Limit Protection
5 Unit Structural Support Complete & Correct 36 Insulate All Ductwork & Dampers As Required
Handling & Installation 

Electrical Connections 

6 Mounting Grommets/Isolators Used 37 Refer To Unit Wiring Diagram
7 Unit Mounted Level & Square 38 Connect Incoming Power Service(s)
8 Proper Access Provided For Unit & Accessories 39 Install & Connect Parts
9 Proper Electrical Service Provided 40 All Field Wiring With Proper Gauge & In Code
10 Proper Overcurrent Protection Provided Compliance
11 Proper Service Switch/Disconnect Provided
12 Proper Chilled Water Line Size to Unit Unit Startup 

13 Proper Hot Water Line Size To Unit 41 General Visual Unit & System Inspection
14 Proper Refrigerant Line Sizes To Unit 42 Check For Proper Fan Belt Tension
15 Proper Steam Line Sizes To Unit 43 Check For Proper Fan Rotation
16 Proper Steam Condensate Trap On Return Line 44 Record Electrical Supply Voltage
17 Proper Steam Supply Pressure To Unit (15 PSI Max) 45 Record Ambient Temperatures
18 All Services To Unit In Code Compliance 46 Check All Wiring For Secure Connections
19 All Shipping Screws & Brace Removed 47 Close All Unit Isolation Valves
20 Unit Protected From Dirt & Foreign Matter 48 Flush Water Systems
21 Filter Is Clean & Free Of Construction Debris 49 Fill Systems With Water/Refrigerant
50 Vent Water Systems As Required
Cooling/Heating Connections 

51 All Ductwork & Grilles In Place
22 Protect Valve Package Components From Heat 52 All Unit Panels And Filters In Place
23 Mount/Check Valve Packages 53 Start Fans, Pumps, Chillers, Etc.
24 Connect Field Piping To Unit 54 Check For Overload Conditions Of All Units
25 Pressure Test All Piping For Leaks 55 Check All Ductwork & Units For Air Leaks
26 Install Drain Line & Traps As Required 56 Balance Air Systems As Required
27 Insulate All Piping As Required 57 Record All Final Settings For Future Use
28 Install Drip Lip Under Piping As Required 58 Balance Water Systems As Required
29 Expansion Joint For Risers Assembly If Required, 59 Record All Final Settings For Future Use
Properly Anchored 60 Check Piping & Ductwork For Vibration
30 Drain Line Properly Sloped & Not Clogged 61 Check All Dampers For Proper Operation
31 Modulating valve Properly Calibrated 62 Verify Proper Cooling Operation
63 Verify Proper Heating Operation
64 Reinstall All Covers & Access Panel