Zehnder Rittling FV-06 Product specifications

Vertical Hi-Stack
Fan Coil
Installation, Operation and Maintenance
Heating
Cooling
Fresh Air
Clean Air
i
Airflow arrangements
1
General data
2
Dimensions and data
3
General information
6
Installation9
Wiring diagram
13
Start-up15
Maintenance19
Replacement parts
21
Equipment start-up checklist 22
Troubleshooting26
Warranty33
IMPORTANT: Approved submittal documentation,
specific to each project, supersedes the general
guidelines contained within this document.
Airflow
arrangements
BACK
Riser and supply air discharge
designations
TOP
LEFT
Example: BFNN
B = Riser location
F = Supply air 1 location
N = Supply air 2 location
N = Outside air location
RIGHT
O.A.
O.A.
FRONT
B
Back
F
Front
L
Left
R
Right
T
Top
N
None
Single supply
LBNN
BLNN
BFNN
RLNN
RFNN
BRNN
LRNN
LFNN
BTNN
LTNN
RBNN
RTNN
Double supply
BFLN
Notes:
„„ Return air always in front of unit.
„„ Access to internal components always
through front panel.
„„ Sight and sound baffles provided as required,
ordered separately.
„„ Sight and sound baffle not available with top
outlet configurations.
„„ The above arrangements apply to hideaway
and master units only. Slave units and
hideaway units without risers have piping
connections where pipes are shown in
diagrams to the right.
„„ Outside air available on left or right side of
unit opposite riser side. Available on both
sides with back riser location.
„„ Optional riser chase available for hideaway
units. Contact factory for pricing.
RLBN
BLRN
RFBN
LFBN
LRBN
BLTN
BFTN
BRTN
RLTN
RFTN
BFRN
LFRN
RFLN
LRTN
LBTN
LFTN
RBTN
Airflow arrangements
1
General data
Unit size
Certified cooling capacity
(3 row main coil)
Certified cooling capacity
(4 row main coil)
Heating capacity
(3 row main coil)
Heating capacity
(4 row main coil)
Heating capacity
(optional 1 row reheat coil)
Heating capacity
(optional 2 row reheat coil)
03
04
06
08
10
12
Total MBH
12.4
14.3
22.2
25.7
35.0
38.2
Sensible MBH
8.4
9.5
14.8
17.2
24.8
26.1
GPM
2.5
3.0
4.7
5.4
7.4
8.0
PD, ft. of H2O
6.7
9.7
23.8
13.6
24.5
28.3
Total MBH
14.3
17.2
24.3
32.6
44.3
47.0
Sensible MBH
9.6
11.7
16.5
20.6
30.1
32.4
GPM
2.8
3.5
4.9
6.8
9.1
9.7
PD, ft. of H2O
11.1
16.3
30.6
18.3
44.2
49.9
MBH
34.2
43.7
66.1
75.7
105.6
116.3
GPM
3.5
4.5
6.8
7.8
10.8
11.8
PD, ft. of H2O
10.7
16.9
36.8
22.5
42.1
50.4
MBH
36.3
47.3
74.3
83.1
119.5
133.0
GPM
3.7
4.8
7.6
8.5
12.2
13.6
PD, ft. of H2O
15.1
24.8
57.7
32.6
64.3
78.6
MBH
19.9
23.7
31.6
38.6
48.6
52.0
GPM
2.1
2.4
3.2
4.0
4.9
5.3
PD, ft. of H2O
7.5
10.3
17.3
7.1
10.9
12.3
MBH
29.2
36.3
52.1
61.2
80.7
88.8
GPM
3.0
3.7
5.3
6.3
8.3
9.1
PD, ft. of H2O
5.8
8.7
17.3
8.2
13.8
16.5
1280
CFM
320
425
680
700
1120
250
290
450
600
700
850
Low
170
200
330
510
600
630
High
300
420
790
825
970
1230
Medium
255
350
480
515
575
1020
Low
230
290
350
415
400
530
FPI
12
12
12
12
12
12
Face area, ft.2
2.5
2.5
2.5
3.75
3.75
3.75
Coil connections
1/2" Cu
1/2" Cu
1/2" Cu
1/2" Cu
1/2" Cu
1/2" Cu
Quantity
1
1
1
1
1
1
Diameter
6.6
6.6
6.6
8.8
8.8
8.8
9.5
CFM, high static
(@ 0.2" ESP)
Coil
High
Medium
Blower
Filter
Width
7.0
7.0
7.0
9.5
9.5
Number
1
1
1
1
1
1
Length, in.
30
30
30
30
30
30
18.5
Width, in.
12.5
12.5
12.5
18.5
18.5
Thickness, in.
1
1
1
1
1
1
Height, in.
88
88
88
88
88
88
Cabinet size
Length, in.
18
18
18
18
18
18
Width, in.
18
18
18
24
24
24
Inlet, in.2
314
314
314
450
450
450
Outlet, in.2
168
168
168
224
224
224
Base unit shipping weight, lbs.
170
170
170
225
225
225
(4) 2" risers and (1) 1" riser shipping weight, lbs.
185
185
185
245
245
245
(4) 2" risers and (1) 1" riser shipping weight, lbs.
100
100
100
100
100
100
Minimum free area
Notes:
„„ Airflow under dry conditions. Inlet air 70-80 °F DB.
„„ Cooling capacity based on inlet air 80 °F DB, 67 °F WB, 45 °F entering
water, 55 °F leaving water, high fan speed.
„„ Heating capacity based on inlet air 60 °F DB, 180 °F entering water,
„„ 160 °F leaving water, high fan speed.
„„ Pressure drop (PD) shown in feet of water.
2
Dimensions and data
Model FVH, hideaway
2-pipe system
2-1/2"
1-1/4"
F
3"
C
4-3/8"
CS
R
D
S
1-9/16"
2-9/16"
D
4-3/8"
R D S
E
HR HS D CR CS
CS
CR
D
HS
CR
D
HS
HR
HR
2-3/16"
2-3/16"
C
Swage
C
F
E
D
G
2-1/2"
1-9/16"
2-9/16"
2-1/2"
1-1/4"
2-1/2"
R
D
S
4-pipe system
Control
box
2-11/16"
2-1/4"
2-11/16"
Motor blower
63-5/8"
Heating coil
Acceptable riser combinations
3-1/2"
37-1/2"
Cooling/
heating coil
5"
Throwaway
filter
Drain pan
18"
13" - 24"
Piping
range
Outside
air damper
1-1/4"
5-3/4"
5"
1-3/8"
„„ Left: 08-12 blower/motor,
viewed from front
„„ Above: 03-06 blower/motor,
viewed from front
Valve package
55-3/16"
(Door 53-3/4")
57-1/8"
104" - 115"
88"
Front
access
panel
“P” trap
B
A
Side view
Notes:
„„ All dimensions are in inches
„„ All dimensions are +/- 1/4"
„„ Wiring from electrical entry point to control enclosure is furnished
and installed by others in field
„„ Risers available from 3/4" to 2-1/2" diameter with 1/2" or 3/4" thick
insulation
„„ Riser length is 104"-115" standard
Front view
Supply and return
(insulation)
Condensate
(insulation)
≤2-1⁄2" (1⁄2")
≤3⁄4" (1⁄2")
≤2" (1⁄2")
≤1" (1⁄2")
≤2" (1⁄2")
≤1-1⁄2" (1⁄2")
≤1-1⁄2" (3⁄4")
≤3⁄4" (1⁄2")
≤1-1⁄4" (3⁄4")
≤1" (1⁄2")
≤1" (3⁄4")
≤1-1⁄4" (1⁄2")
≤1-1⁄4" (3⁄4")
≤3⁄4" (3⁄4")
≤1" (3⁄4")
≤1" (3⁄4")
Dimensional data
Unit size
A
B
C
D
E
F
G
03, 04, 06
18
12-1⁄2
14
12
6
2
2
08, 10, 12
24
18-1⁄2
16
14
7
4
1
„„ Back riser location shown. See arrangement drawings for available
unit configurations.
„„ Factory mounted risers shown
„„ Outside air damper opening is located on left or right side of unit
„„ All listed dimensions are approximate and are subject to change
without notice. Modifications to the product specifications must be
accepted by Zehnder Rittling at its base office.
Dimensions and data
3
Dimensions and data
Model FVM, master
2-pipe system
2-1/2"
CS
R
D
S
F
1-9/16"
2-9/16"
E
D
R D S
R
D
S
2-1/2"
4-3/8"
2-1/2"
4-3/8"
HR HS D CR CS
CS
CR
D
HS
CR
D
HS
HR
HR
1-9/16"
2-9/16"
2-1/2"
1-1/4"
4-pipe system
2-3/16"
2-3/16"
C
Swage
3"
C
G
E
D
F
1-1/4"
C
Control
box
2-11/16"
2-1/4"
2-11/16"
Motor blower
37-1/2"
Cooling/
heating coil
5"
Throwaway
filter
3-1/2"
Drain pan
13" - 24"
Piping
range
5-3/4"
1-1/4"
18"
Outside
air damper
“P” trap
Side view
Notes:
„„ All dimensions are in inches
„„ All dimensions are +/- 1/4"
„„ Wiring from electrical entry point to control enclosure is furnished
and installed by others in field
„„ Risers available from 3/4" to 2-1/2" diameter with 1/2" or 3/4" thick
insulation
„„ Riser length is 104"-115" standard
4
63-5/8"
Heating coil
5"
1-3/8"
„„ Left: 08-12 blower/motor,
viewed from front
„„ Above: 03-06 blower/motor,
viewed from front
Valve package
55-3/16"
(Door 53-3/4")
57-1/8"
104"- 115"
88"
Front
access
panel
Acceptable riser combinations
Supply and return
(insulation)
Condensate
(insulation)
≤2-1⁄2" (1⁄2")
≤3⁄4" (1⁄2")
≤2" (1⁄2")
≤1" (1⁄2")
≤2" (1⁄2")
≤1-1⁄2" (1⁄2")
≤1-1⁄2" (3⁄4")
≤3⁄4" (1⁄2")
≤1-1⁄4" (3⁄4")
≤1" (1⁄2")
≤1" (3⁄4")
≤1-1⁄4" (1⁄2")
≤1-1⁄4" (3⁄4")
≤3⁄4" (3⁄4")
≤1" (3⁄4")
≤1" (3⁄4")
Dimensional data
B
Unit size
A
B
C
D
E
F
G
A
03, 04, 06
18
12-1⁄2
14
12
6
2
2
Front view
08, 10, 12
24
18-1⁄2
16
14
7
4
1
„„ Back riser location shown. See arrangement drawings for available
unit configurations.
„„ Factory mounted risers shown
„„ Outside air damper opening is located on left or right side of unit
„„ All listed dimensions are approximate and are subject to change
without notice. Modifications to the product specifications must be
accepted by Zehnder Rittling at its base office.
Dimensions and data
Model FVS, slave
2-pipe system
1-1/4"
4-pipe system
C
1-9/16"
2-9/16"
2-3/16"
2-3/16"
C
C
F
E
D
G
1-1/4"
D
1-9/16"
2-9/16"
E
F
Control
box
2-11/16"
2-1/4"
2-11/16"
Front
access
panel
3-1/2"
37-1/2"
Heating coil
5"
Cooling/
heating coil
Throwaway
filter
Drain pan
„„ Left: 08-12 blower/motor,
viewed from front
„„ Above: 03-06 blower/motor,
viewed from front
5-3/4"
Outside
air damper
1-1/4"
5"
1-3/8"
63-5/8"
Valve package
57-1/8"
55-3/16"
(Door 53-3/4")
88"
Motor blower
18"
B
A
“P” trap
Side view
Front view
Dimensional data
Unit size
A
B
C
D
E
F
G
03, 04, 06
18
12-1⁄2
14
12
6
2
2
08, 10, 12
24
18-1⁄2
16
14
7
4
1
Notes:
„„ All dimensions are in inches
„„ All dimensions are +/- 1/4"
„„ Wiring from electrical entry point to control enclosure is furnished
and installed by others in field
„„ Outside air damper opening is located on left or right side of unit
„„ All listed dimensions are approximate and are subject to change
without notice. Modifications to the product specifications must be
accepted by Zehnder Rittling at its base office.
Dimensions and data
5
Dimensions and data
Model FVA/FVB: Back to back
1-9/16"
2-9/16"
C
5/8" Type “X” drywall
Support frame
42"
C
G
Support
frame
E
Support
frame
2-1/2"
1-1/4"
D
C
Swage
F
1-1/4"
E
D
3"
Hr
Hs
D
Cr
Cs
2-1/2"
F
5/8" Type “X” drywall
4-3/8" 4-3/8"
6"
R
D
S
2-3/8"
4-pipe system
3"
1-9/16"
2-9/16"
2-3/8"
2-pipe system
Control
box
2-11/16"
2-1/4"
Motor
blower
Front
access
panel
„„ Left: 08-12 blower/motor,
viewed from front
„„ Above: 03-06 blower/motor,
viewed from front
63-5/8"
Valve
package
57-1/8"
55-3/16"
(Door 53-3/4")
104" -115"
88"
2-11/16"
Throwaway
filter
5"
Drain pan
Outside
air damper
18"
13" - 24"
Piping
range
1-1/4"
5-3/4"
5"
1-3/8"
Cooling/
heating coil
3-1/2"
37 1/2"
Heating coil
Support
frame
5/8" Type “X”
drywall
“P” trap
Side view
B
A
Front view
Acceptable riser combinations
Supply & Return
(Insulation)
Condensate
(Insulation)
≤2-1⁄2" (1⁄2")
≤3⁄4" (1⁄2")
≤2" (1⁄2")
≤1" (1⁄2")
≤2" (1⁄2")
≤1-1⁄2" (1⁄2")
≤1-1⁄2" (3⁄4")
≤3⁄4" (1⁄2")
≤1-1⁄4" (3⁄4")
≤1" (1⁄2")
≤1" (3⁄4")
≤1-1⁄4" (1⁄2")
≤1-1⁄4" (3⁄4")
≤3⁄4" (3⁄4")
≤1" (3⁄4")
≤1" (3⁄4")
Dimensional data
Unit Size
Notes:
„„ All dimensions are in inches
„„ All dimensions are +/- 1/4"
„„ Wiring from electrical entry point to control enclosure is furnished
and installed by others in field
„„ Risers available from 3/4" to 2-1/2" diameter with 1/2" or 3/4" thick
insulation
„„ Riser length is 104"-115" standard
6
C
D
E
F
03, 04, 06 18 12-1⁄2
A
B
14
12
6
2
G
2
08, 10, 12 24 18-1⁄2
16
14
7
4
1
„„ Back riser location shown. See arrangement drawings for available
unit configurations.
„„ Factory mounted risers shown
„„ Outside air damper opening is located on left or right side of unit
„„ All listed dimensions are approximate and are subject to change
without notice. Modifications to the product specifications must be
accepted by Zehnder Rittling at its base office.
Dimensions and data
Single deflection grille
Features
„„ Aluminum construction
„„ Epoxy powder coat finish
„„ Dimensions are in inches
Side view
Standard grille sizes
Model size
Height x width
Single supply
Double supply
03
6" x 14"
6" x 14"
04
6" x 14"
6" x 14"
06
12" x 14"
6" x 14"
08
14" x 16"
7" x 16"
10
14" x 16"
14" x 16"
12
14" x 16"
14" x 16"
Face view
Notes:
„„ Grilles are shipped loose for field installation
„„ Standard finish is “powder coated” and will be the same color as
the return grille
„„ Installation of grille on adjacent unit sides may require furring one
side away from unit to prevent interference of frames
„„ Mounting hardware included
„„ Negligible air pressure drop is experienced, regardless of quanity
and type of grille used, leaving airflow unaffected
„„ All listed dimensions are approximate and are subject to change
without notice. Modifications to the product specifications must be
accepted by Zehnder Rittling at its base office.
Dimensions and data
Double deflection grille
Features
„„ Aluminum borders and blades
„„ Vertical front blades
„„ Epoxy powder coat finish
„„ Dimensions are in inches
Side view
Standard grille sizes
Model size
Height x width
Single supply
Double supply
03
6" x 14"
6" x 14"
04
6" x 14"
6" x 14"
06
12" x 14"
6" x 14"
08
14" x 16"
7" x 16"
10
14" x 16"
14" x 16"
12
14" x 16"
14" x 16"
Face view
Notes:
„„ Grilles are shipped loose for field installation
„„ Standard finish is “powder coated” and will be the same color as
the return grille
„„ Installation of grille on adjacent unit sides may require furring one
side away from unit to prevent interference of frames
„„ Mounting hardware included
„„ Negligible air pressure drop is experienced, regardless of quanity
and type of grille used, leaving airflow unaffected
„„ All listed dimensions are approximate and are subject to change
without notice. Modifications to the product specifications must be
accepted by Zehnder Rittling at its base office.
7
Dimensions and data
Aluminum discharge grille, double deflection
with opposed blade damper
5/32"
Individually adjustable blades on 2/3" spacing
1-1/4"
Slide
operator
C
D
5/8"
2-13/16"
A
2/3"
One piece extruded frame
B
Dimensional data
Grille size
H
W
A
B
14" x 16"
13-11/16"
15-11/16"
17-11/16"
17-11/16"
12" x 14"
11-11/16"
13-11/16"
15-11/16"
15-11/16"
7" x 16"
6-11/16"
15-11/16"
17-11/16"
17-11/16"
6" x 14"
5-11/16"
13-11/16"
15-11/16"
15-11/16"
Supply grille arrangements
Unit size
Notes
„„
Vertical blades in the front, horizontal blades in the back, both
individually adjustable and on 2/3" spacing
„„
Opposed blade damper with slide operator
„„
Aluminum roll formed blade with semi-airfoil design
„„
Pressure fit nylon pivot pins (rattle-free and non-loosening)
„„
Aluminum extruded frame with mechanically locked corners
„„
Countersunk screw holes complete with painted mounting screws
„„
Sealing gasket to prevent streaking on walls or ceiling
„„
Durable powdercoat painted finish
„„ Negligible air pressure drop is experienced, regardless of quanity
and type of grille used, leaving airflow unaffected
„„ All listed dimensions are approximate and are subject to change
without notice. Modifications to the product specifications must be
accepted by Zehnder Rittling at its base office.
8
Height x width
Single supply
Double supply
03
6" x 14"
6" x 14"
04
6" x 14"
6" x 14"
06
12" x 14"
6" x 14"
08
14" x 16"
7" x 16"
10
14" x 16"
14" x 16"
12
14" x 16"
14" x 16"
Dimensions and data
Return air grille
Standard louver
03-06
Frame 03-06
Optional grille
03-06
Optional ADA
thermostat
location
4-7/8"
2-11/16"
1/2"
2-1/4"
55-3/16"
53-3/4"
45°
55-11/16"
53-9/16"
53-13/16"
41-1/16"
Ø3/16
Mounting hole
(typical)
27-7/8"
3/4"
4-7/8"
17-5/16"
8-7/8"
15-13/16"
17-11/16"
16"
1-1/16"
15-13/16"
Frame 08-12
Standard louver
08-12
Optional ADA
thermostat
location
1-1/8"
1-1/16"
Optional grille
08-12
4-7/8"
1/2"
2-11/16"
2-1/4"
53-3/4"
45°
55-11/16"
55-3/16"
53-13/16"
53-9/16"
Ø3/16
Mounting hole
(typical)
41-1/16"
27-7/8"
3/4"
4-7/8"
23-5/16"
21-13/16"
11-7/8"
1-1/8"
23-11/16"
22"
1-1/16"
Notes:
„„ Frame and return grilles are shipped loose for field installation
„„ Optional grille does not come with a frame
„„ Contact the factory regarding extended front panels for additional
control panel access and/or ADA mounting of thermostats
21-13/16"
1-1/16"
„„ All listed dimensions are approximate and are subject to change
without notice. Modifications to the product specifications must be
accepted by Zehnder Rittling at its base office.
Dimensions and data
9
General information
Safety considerations
This installation and start-up
instructions literature is for Vertical
Hi-Stack Fan Coil units. Fan coils
are hydronic terminal units designed
for year-round cooling or cooling/
heating. Your equipment is initially
protected under the Zehnder Rittling
standard 2-year warranty provided
the steps outlined in this manual
for initial inspection, installation,
periodic maintenance and normal
every day operation of the equipment
are followed. This manual should
be thoroughly reviewed prior to the
installation, start-up or maintenance
of the equipment. If any questions
arise, please contact your local
Zehnder Rittling sales representative
or the factory before proceeding any
further.
The installation of Vertical
Hi-Stack Fan Coil units and all
associated components, parts
and accessories which make
up the installation, shall be in
accordance with the regulations
of all authorities having
jurisdiction and must conform to
all applicable codes. Only trained
and qualified service personnel
using good judgment and safe
practices should install, repair
and/or service air conditioning
equipment.
There are a multitude of options
and accessories available with the
equipment covered in this manual.
For more specific details on the
included options and accessories,
refer to the order acknowledgment,
approved submittals and catalogs.
Untrained personnel can perform
basic maintenance functions
such as cleaning coils and
cleaning or replacing filters.
All other operations should be
performed by trained service
personnel. When working on air
conditioning equipment, observe
precautions in the literature,
tags and labels attached to the
equipment and all other safety
precautions that may apply.
Improper installation, adjustment,
alteration, service, maintenance,
or use can cause explosion,
fire, electrical shock or other
hazardous conditions which
may cause serious personal
injury and/or property damage.
Consult a qualified installer,
service agency, or your sales
representative for information or
assistance.
The equipment must always be
properly supported by rigging and
lifting equipment. Any temporary
supports used during installation
or maintenance must be designed
to adequately hold the equipment
in place until equipment is
permanently fastened and set
in its final location. All supports
must meet applicable local codes
and ordinances.
10
All fastening devices must be
designed to mechanically hold
the assembly in place without
the ability to loosen or break
away due to system operation or
vibration.
All power must be disconnected
and locked out before any
installation or service is
performed to avoid electrocution
or shock. More than one power
source may be supplied to a unit.
Power to remote mounted units
may not be supplied through the
unit.
Electric resistance heating
elements must be disconnected
prior to servicing to avoid burns.
Never use bulky or loose fitting
clothing when working on any
mechanical equipment. Gloves
should always be worn for
protection against heat, sharp
edges and all other possible
hazards. Safety glasses should
always be worn, especially when
drilling, cutting or working with
chemicals.
Never pressurize equipment
beyond specified pressures
as shown on unit rating plate.
Always pressure test with an
inert fluid such as water or
dry nitrogen to avoid possible
damage or injury in the event of a
leak or component failure during
testing.
Always protect adjacent
flammable material when welding
or soldering. Use a suitable heat
shield material to contain sparks
or drops of solder. Have a fire
extinguisher readily available.
Safety considerations
Please follow standard safe
practices regarding the
handling, installing or servicing
of mechanical equipment.
Read these instructions
thoroughly and follow all
warnings or cautions attached
to the equipment. Consult local
building codes and the National
Electrical Code(NEC) for special
installation requirements.
Understand the signal words:
danger, warning and caution.
Identifies the most serious hazards
which will result in severe personal
injury or death.
Signifies hazards that could result in
personal injury or death.
Used to identify unsafe practices,
which would result in minor personal
injury or product and property
damage.
The manufacturer assumes
no responsibility for personal
injury or property damage
resulting from improper or
unsafe practices during the
handling, installation, service or
operation of the equipment. The
installation of fan coils and all
associated components, parts
and accessories shall be in
accordance with the regulations
of all authorities having
jurisdiction and must conform
to all applicable codes. It is the
responsibility of the installing
contractor to determine and
comply with all applicable codes
and regulations.
Receiving
Upon delivery, examine each unit
carefully for shipping damage.
Any damage should be reported
to the freight carrier and a claim
should be filed with them. Ensure
the shipping company makes
proper notation of any shortages
or damage on all copies of
the freight bill. Concealed
damage not discovered during
unloading must be reported to
the shipping company within 15
days of receipt of the shipment.
All units are shipped F.O.B.
factory. Therefore, Zehnder
Rittling is not responsible for
damage during transit. It is the
responsibility of the installing
contractor to inspect and verify
that the unit shipped was in
fact the correct model number,
voltage, etc. Any discrepancies
should be reported to the local
Sales Representative for immediate
resolution prior to uncrating and
installation. The factory should be
notified of any warranty repairs
required in writing before any
corrective action is taken. The
factory must be fully informed of
the expected costs before the
work is begun. Zehnder Rittling is
not responsible for any repairs or
alterations made by the purchaser
without Zehnder Rittling’s written
consent and will not accept any
back charges associated with
these repairs or alterations. The
return of damaged equipment will
not be accepted without written
authorization from Zehnder Rittling.
A unit that has received a written
Return Goods Authorization will be
inspected by Zehnder Rittling upon
receipt. Any damage, missing
parts, reworking or re-crating
resulting from prior installation
will constitute just cause for
Zehnder Rittling to issue partial
credit.
Several components are shipped
loose for field installation and
to offer added protection during
shipment and job site storage.
These items may include:
thermostats, supply grilles,
return air access doors, risers,
etc.
General information
11
Unpacking and
preparation
All units are carefully inspected
at the factory throughout the
entire fabrication and assembly
processes under Zehnder
Rittling’s stringent quality
assurance program. All major
components and subassemblies
such as motors, blowers,
coils, controls, valve packages
and paint quality are carefully
tested for proper operation,
visually inspected and verified
for full compliance with factory
standards. Operational testing
for some customer furnished
components such as pneumatic
valves and DDC controllers may
be a possible exception.
Vertical Hi-Stack Fan Coil units
are usually shipped on pallets of
up to six units. Since equipment
is normally moved to each floor
on the shipping pallet, units
can be palletized by floor at the
request of the customer, thereby
avoiding field handling of the
equipment. Should the number
of units per floor not be divisible
by six, then one pallet will have
units for multiple floors.
Each unit is factory tagged
according to the customer’s
purchase order. This allows the
unit, upon removal from the
pallet, to be taken directly to its’
assigned space for immediate
installation. Units should not be
installed at locations other than
that designated on the tag.
It is the sole responsibility
of the customer to provide
the protection necessary to
prevent vandalism and weather
deterioration of the equipment.
Under no condition should the
units be left unprotected from
the elements. The equipment
is NOT suitable for outdoor
installations.
12
Once the equipment is properly
positioned on the job site, cover
the unit openings with either a
shipping carton, vinyl film, or an
equivalent protective covering.
Take special care to prevent
foreign materials from entering
the units in areas where painting,
dry walling, or spraying of
fireproof material, etc. has not
yet been completed as these
materials may accumulate in the
drain pan or on the motors and
blower wheels. Foreign material
that accumulates within the
units can prevent proper startup, necessitate costly clean-up
operations, or result in immediate
or premature component failure.
Before installing any of the
system components, be sure
to examine each pipe, fitting
and valve, and remove any dirt
or foreign material found in
or on these components. All
manufacturer’s warranties are
void if foreign material is allowed
to be deposited in the drain pan
or on the motor or blower wheels
of any unit.
DO NOT store or install units in
corrosive environments or in
locations subject to temperature
or humidity extremes (e.g., attics,
garages, rooftops, etc.).
Corrosive conditions and high
temperature or humidity can
significantly reduce system
performance, reliability and
overall service life.
Handling and
installation
While all equipment is designed
for durability and fabricated
with heavy gauge materials
and may present a robust
appearance, great care must
be taken to assure that no
undue force is applied to the
coil, piping, drain connection
or other delicate components
such as control boards during
handling. Wherever possible, all
units should be maintained in
an upright position and must be
handled by the cabinet.
At no time during handling
should the unit be supported or
lifted by the risers. Damage to
riser pipe or leaking connections
resulting from improper handling
is not covered under the
warranty.
Preliminary
installation
Although Zehnder Rittling does
not become involved with the
design and selection of support
methods and/or components,
it should be recognized that
unacceptable operating
characteristics and/or
performance may result from
poorly implemented unit support.
Lifting or supporting the cabinet
only at the top and bottom
should be avoided to maintain
a straight and square cabinet.
When lowering the cabinet into
place, take care to properly align
the risers so they engage the
swage connection on the risers
below. Never bend or push risers
together to pass through the
opening in the floor.
Zehnder Rittling assumes no
responsibility for personal injury
or property damage resulting from
improper or unsafe practices during
the handling, installation, servicing or
operation of equipment.
Installation of the Vertical Hi-Stack
Fan Coil should begin on the lowest
floor and progress upward, floor by
floor, to the top. Tip the unit over the
riser hole in the building floor. As the
unit is righted, align the risers with
the unit below.
In the case of shipped loose risers,
install from the lowest floor to the
highest floor. After the risers are field
tested for leaks, the Fan Coils can
then be installed in any order. Risers
are supported, anchored and isolated
in the field by others.
Field-furnished isolator pads, if
required, should be positioned
beneath the unit at this time.
On certain units, shipping screws or
braces for valves should be removed
before attaching any drywall to the
unit. Be sure to check all labels on
the unit to determine which, if any, of
these supports need to be removed.
General information
13
Installation positioning,
fastening and testing
Each riser is supplied with a 3-inch swaged portion
on the top and sufficient extension at the bottom for
an inserted length of approximately 2 inches. This
unit-to-unit joint is not intended for full bottoming in
the joint. When installing the Vertical Hi-Stack unit
to the unit below, the risers should never be pulled
down to engage in the swage connection. This is
already accounted for in the riser lengths and allows
for variations in floor-to-floor dimensions and correct
riser positioning.
Some jobs require that the unit risers be supplemented
with “between-the-floor” extensions. These pieces
should be assembled into position at this time.
“Between-the-floor” extensions may be field or factory
supplied. If the latter, insulation is also provided.
Once the units are positioned with the risers centered
in the pipe chase, each unit should be positioned
perfectly vertical (plumb) in two planes and anchored
to the building structure. All assemblies must be
adequately secured during lifting and rigging until
equipment is permanently fastened and set in its
final location. All temporary and permanent supports
must be capable of safely supporting the equipment’s
weight along with any additional live or dead loads
that may occur. All supports must be designed to
meet applicable local codes. All fastening devices
must be designed to mechanically lock the equipment
in place without the possibility of loosening or
breaking away due to system operation or vibration.
It is imperative that the unit be properly leveled
to assure condensate drainage and proper coil
operation. Once all units on a riser are anchored,
unit-to-unit riser joints may be made as follows: Each
branch run out in the coil section must be centered in
the expansion slot in the side or back panel prior to
joining risers. Ensure that clamps on drain pan P-trap
are secured and have not loosened during shipment
or installation.
Make sure the branch run out is pitched slightly
downward inside the unit so condensate, if formed,
will run back into the condensate pan and not out
toward the riser. Any water damage caused by not
following this procedure is not covered under the
warranty.
14
Each riser joint must be in vertical alignment, with a
minimum of 1" penetration (although 2" is preferable
and allowed for) into each swaged joint. This condition
will be met if floor-to-floor dimension is as specified
and if each branch run out is properly centered. Riser
joints must be made with phos-copper, silfos, or
other high temperature alloys. Soft solders (50-50,
60-40, 85-15) or other low temperature lead alloys are
not suitable for this application. Use flame and heat
protection barriers where needed during soldering
or brazing process to protect adjacent flammable
materials. Care should be taken to assure that no
valve package components are subjected to high
temperature, which may damage seals or gaskets.
If the valve package connection at the coil is made
with a union, the coil side of the union must be
prevented from twisting during tightening to prevent
damage to the coil tubing. Over-tightening must be
avoided to prevent distorting the union seal surface
and destorying the union, ultimately causing a leak.
Secure the union nut hand-tight and then tighten no
more than an additional 1/4 turn.
Wide variations in floor-to-floor dimensions may
necessitate cutting off or extending individual risers.
Such modifications are the full responsibility of the
installing contractor.
The risers must not be rigidly fastened within each
unit, but must be free to move within the pipe chase
with normal vertical expansion and contraction
movements.
The installing contractor must anchor the built-in
risers at some point to the building structure. The
unit design will accommodate up to a 1" expansion
and contraction (2" total movement). The installing
contractor must provide and install additional
expansion compensation devices in each riser. Venting
of risers must be provided by installing contractors.
Once all field riser joints are completed and the riser
assembly is properly anchored, a hydrostatic test for
leaks should be made, but test pressure must not
exceed 250 psi, measured at the bottom of the riser.
At this time, prior to insulating and furring in of any
Installation
positioning, fastening
and testing
risers or piping connections, all
coils should be vented, and the
interior unit piping checked for
visible signs of leakage due to
possible shipping damage or
mishandling. The coil manual
air vent is accessible through
the return-air opening. After
the test, insulate all risers
continuously from top to bottom,
if not provided by factory. All
unit piping and water coils must
be protected from freezing after
filling with water. All leaks should
be repaired before proceeding
with installation.
All field-furnished and installed
riser insulation must have
a vapor barrier cover, or be
closed-cell foam insulated. All
joints should be properly sealed
(taped or glued) so no air can
pass through to the cold riser
pipe. Any water damage caused
by not following this procedure is
not covered under the warranty.
To assure compliance with
existing building codes, the
installing contractor must restore
the original fire resistance rating
of the structure by sealing
the access space around the
risers with material having the
same fire ratings as structure.
Applicable local installation
codes may limit this unit to
installation in single-story
residences only. Any fireproofing
requirements where risers or
piping penetrate the floors or
walls are the responsibility of
the installing contractor. This
work should only be done after
all pressure testing is complete.
Whatever method is used for
fireproofing must be able to
accommodate pipe expansion
and contraction. The piping
must be protected from abrasion
and/or chemical attack. Pipe
insulation must be maintained to
prevent condensation and should
be protected from damage at the
joint between the insulation and
fireproofing material.
The riser connection joints
should be hydrostatically tested
for leaks before furring in the
unit.
Pressure of water column alone
is approximately 0.43 psi per
foot; i.e., 43 psi for each 100 feet.
DO NOT EXCEED 250 PSI or that
which the supplied components
were designed.
Installation
15
Ductwork
connections
All ductwork and or supply and
return grilles should be installed
in accordance with the project
plans and specifications. If not
included on the unit or furnished
from the factory, supply and
return grilles should be provided
as recommended in the product
catalog.
All units must be installed in
non-combustible and nonhazardous areas.
Some models are designed
to be connected to ductwork
with a minimum amount of
external static pressure. These
units may be damaged by
operation without the proper
ductwork connected. Consult
the approved submittals and the
product catalog for unit external
static pressure limitations.
Units provided with outside
air should have some form of
low temperature protection to
prevent coil(s) from freezing.
This protection may be a lowtemperature thermostat to
close the outside air damper,
a preheat coil to temper the
outside air before it reaches
the unit, or any other protective
method.
It should be noted that none of
these methods will adequately
protect a coil in the event of
power failure. The safest method
of freeze protection is to use
glycol in the proper percent
solution for the coldest expected
air temperature.
16
Flexible duct connections should
be used on all air handling
equipment to minimize vibration
transmissions. Insulation and
ductwork should be installed to
allow servicing of equipment.
It is recommended to have sight/
sound baffles installed on
dual, opposite side, discharge
units with the exception
of top discharge. It is also
recommended to have at
least one discharge grille with
damper to aid in air balancing.
Dual discharge units with top
discharge require a field supplied
and installed damper in the top
discharge duct.
Zehnder Rittling assumes no
responsibility for undesirable
system operation due to improper
design, equipment or component
selection, and/or installation of
base unit, ductwork, grilles and
other related components.
Special application
Operation of the unit with fieldfabricated outside air provision,
or operation in coastal areas
of high humidity may make it
necessary to add insulation
and/or a suitable vapor barrier
between the drywall material and
the air handling compartment.
Such recommendations will
be made by the factory upon
request.
Wiring diagram
120V
L
T1
M
H
MOTOR QUICK
CONNECT
SEE MOTOR CHART
FOR WIRE COLORS
YELLOW
BLUE
YELLOW
BLOWER
MOTOR
WHITE
RED
CONTROL PACKAGE LOCATION
D
DAMPER
MOTOR
F
BLUE
IF A CONTROL PACKAGE IS ORDERED,
REFER TO CORRESPONDING SCHEMATIC
FOR WIRING LAYOUT
E
BLACK
L1
WHITE
T2
BLUE
L2
HEATER
MANUAL MOTOR
STARTER
WHITE
*BROWN
3-SPEED SWITCH
YEL
GFCI
RECEPTACLE
HOT
120V
L2 NEUTRAL
WHITE
WHITE
*BROWN TERMINATED
IF NO DAMPER MOTOR
120V
L1 HOT
LINE
HOT
WHITE
LOAD
DISCONNECT
SWITCH
YELLOW
WHITE
YELLOW
L1 HOT (YELLOW)
WHITE
120VAC
L2 NEUTRAL (WHTIE)
A
B
SPARE TERMINALS
C G H I
NOTES:
■ THERMOSTAT SHIPPED LOOSE IF WALL MOUNTED.
■ CONTROL VALVE AND CHANGEOVER SWITCH ARE
SHIPPED LOOSE.
■ COMPLETE THE WIRING IN ACCORDANCE WITH
NATIONAL AND LOCAL CODES.
■ IF REMOTE TEMPERATURE SENSOR IS USED,
WIRE TO THERMOSTAT TB1, TERMINALS 1 AND 2.
Field wired
Factory wired 18AWG
Factory wired 16AWG
Wire connection
Factory wire, not connected
Wire termination
CAUTION: Not following proper wiring procedure can cause injury or death
Wiring schematics
17
Wiring schematic
208V/240V/277V
BLACK
BLACK
BLACK
BLOWER
MOTOR
L
H
MOTOR QUICK
CONNECT
SEE WIRE CHART
FOR WIRE COLORS
RED
D
CONTROL PACKAGE LOCATION
E
F
BLACK
BLACK
BLUE
BLACK
M
IF A CONTROL PACKAGE IS ORDERED,
REFER TO CORRESPONDING SCHEMATIC
FOR WIRING LAYOUT
*BROWN
3-SPEED SWITCH
BLACK
BLACK
*BROWN TERMINATED
DISCONNECT
SWITCH
BLACK
BLACK
L1 HOT (BLACK)
BLACK
BLACK
L2 HOT (BLACK)
A
208 / 240 / 277VAC
B
C G H I
SPARE TERMINALS
NOTES:
■ THERMOSTAT SHIPPED LOOSE IF WALL MOUNTED.
■ CONTROL VALVE AND CHANGEOVER SWITCH ARE
SHIPPED LOOSE.
■ COMPLETE THE WIRING IN ACCORDANCE WITH
NATIONAL AND LOCAL CODES.
■ IF REMOTE TEMPERATURE SENSOR IS USED,
WIRE TO THERMOSTAT TB1, TERMINALS 1 AND 2.
Field wired
Factory wired 18AWG
Factory wired 16AWG
Wire connection
Factory wire, not connected
CAUTION: Not following proper wiring procedure can cause injury or death
18
Wire termination
Electrical connections
The electrical service to the unit
should be compared to the unit
nameplate to verify compatibility.
The type and sizing of all wiring
and other electrical components
such as circuit breakers,
disconnect switches, etc. should
be determined by the individual
job requirements and should
not be based on the size and/or
type of connection(s) provided
on the equipment. Verify the
electrical conductor size is
suitable for the distance to the
equipment connection and will
support the equipment electrical
load. All installations should
be made in compliance with all
governing codes and ordinances.
Compliance with all codes is the
responsibility of the installing
contractor.
The unit serial tag lists the unit
electrical characteristics such
as the required supply voltage,
motor and heater amperage and
required circuit ampacities. The
unit wiring diagram shows all
unit and field wiring. The installer
must be familiar with the wiring
diagram before beginning any
wiring as the wiring can change
from project to project.
All field wiring connecting to this
type of unit must be 105 °F
rated copper conductor and
should be in accordance with
the National Electrical Code
and any applicable local codes.
Branch circuit fusing and
electrical disconnect means (if
required) must be furnished and
installed by others. All unitmounted control components
and electrical heater elements
(when furnished) are factory
wired to the unit junction control
box located in the center of the
unit. Remote-mounted control
components are shipped loose
for field installation and wiring.
All wiring connections should
be checked prior to start-up to
ensure connections have not
come loose during shipment or
installation.
The electrical components,
located in the upper portion of
the unit, facilitate field wiring.
The applicable wiring diagram
for the unit ships with each unit
and must be strictly followed.
See unit wiring diagram,
provided with unit, for proper
voltage and for proper control
packages if used. Field power
supply wiring should be through
knockouts supplied in the side
and/or top of the unit.
Electrical shock can cause
personal injury or death. When
installing or servicing system,
always turn off main power to
system. There may be more than
one disconnect switch.
Thermostat “OFF” should not be
used for disconnect purposes.
Only qualified personnel should
perform service and installation.
Zehnder Rittling assumes no
responsibility for any damages
and/or injuries from improper
field installation and/or wiring.
Electrical
19
Enclosing unit
All wall framing is the
responsibility of others.
Normally the units are enclosed
in the field-furnished drywall
enclosure. The enclosure can
be furred out from the unit with
studs or the drywall can be
attached directly to the sheetmetal cabinet. For maximum
sound attenuation, units should
be furred out and insulated. If
the riser pipes and electrical
conduit face the room interior,
then an enclosure must be furred
out from the unit to provide
proper clearance. If the drywall
is attached directly to the sheet
metal cabinet, use sheet metal
low-profile pan-head or drywall
screws, no longer than is
required to provide proper grip
to secure drywall to the sheet
metal cabinet. The front of the
unit is designed to have
drywall flush against the front of
the sheet metal cabinet. Either
1⁄2" or 5⁄8" drywall may be
used. Be sure to keep drywall
dust out of the unit. Drywall
dust is hard on motors, and coil
efficiency is reduced if drywall
dust is allowed to collect on the
coil fins. The manufacturer will
not be responsible for damaged
components due to drywall dust.
Do not apply sheet metal screws
or nails where they are subject to
penetrating the coil, riser pipes,
electrical junction boxes, and
raceways or where they may
impede the removal of internal
components.
20
Extreme care is necessary when
driving screws in the vicinity of
the control box, heat exchange
coils and drain pan to prevent
electrical shorts and water leaks.
The drywall material should not
be screwed to either the drain
pan edges or to the control-box
enclosure.
This unit is not intended for
direct attachment of wood,
chipboard, or similar paneling.
All wall finishes must be
preceded with drywall.
When cutting out supply and
return holes for grilles, be sure
to clean all drywall dust from
coils, drain pans, and blower
discharge plenum. After drywall
is in place and rooms are
prepared for final wall treatment,
the supply and return air
openings and control component
opening should be securely
covered to prevent introduction
of foreign material. If the wall
texture and/or color are to be
sprayed, cover the coil, fan, or
other unit parts. Unit warranties
are voided if paint or foreign
materials of any kind are present
on coil, fan, piping, wiring, or
other internal components.
A return air grille/access door
and discharge grille (if ordered)
are typically furnished with
each unit. These items are
usually shipped at time of finish
to the contractor’s specified
destination.
The units should not be operated
at anytime without complete
enclosure, supply grille, return
air grille, and filter in place.
Operation in any other condition
could result in motor overloading
or burnout, clogging of coil
surface, fan blade damage, or all
of the above.
Prior to installation of the return
grille, the following final checks
should be made:
1. Rotate the fan wheel by
hand to ensure that it is
free and does not rub the
housing. Rough handling
during shipment may have
caused the wheel to shift.
Adjust, if necessary.
2. Check to see that the
service valves are opened
and that the motorized
control valve (if supplied) is
set for automatic operation,
if of such type.
3. Vent all air from the coil and
related piping.
4. Check the drain line to see
that it is not clogged and
that it is properly positioned
with a downward pitch and
secured. Ensure that all
hose clamps are properly
connected and tightened
down. These connections
can come loose during
shipment and/or installation.
5. If the unit is equipped with
a combination stop and
balance valve in the return
line, the proper flow should
be set at this time.
Back-to-back (FVA/FVB) installation
The installation instructions included in this manual
are provided to meet the requirements of UL1479.
Some jurisdictions may require additional or different
installation methods; therefore, consult with the
authority having jurisdiction for specific differences.
For these cases, the requirements defined by the
authority having jurisdiction will take precedence over
the documents contained herein.
Riser
chase
plate
FVA
FVB
2" x 4"
wall stud
A
Wood
screws
A
Figure 2:
Recess detail
The mounting lines for the drywall channel and wall
studs should be laid out on the floor and ceiling
(see Figure 1:A).
5/8" Type X drywall, field supplied
Tracking may be installed now or after the unit is set.
Position the back-to-back Fan Coil assembly between
two rooms with the unit drywall separation spotted
over the wall control lines. Check unit tagging against
mechanical drawings to ensure proper location. If not
already installed, install the floor and ceiling tracks up
to and over the back-to-back Fan Coil unit. Channels
up to the unit sides at riser chase plate and ceiling
channels over the unit floor assembly, leaving space
for the riser penetrations.
Next, position the vertical studs and fasten into
each of the stud pockets formed into the riser chase
plates (see Figure 1:B and Figure 3). Spacing of the
vertical studs should be done in accordance with
local, state and national codes while meeting project
specifications.
A. Drywall channel and
stud mounting lines
B. Install wall stud
into recess formed
by rise chase plate
Wall studs
E. Install drywall to sides
of unit with optional cut
outs for supply, outside
air and thermostat
F. Install drywall to face
of unit with optional
cut outs for supply,
return and thermostat
FVA
C. Install studs from top of unit
to ceiling (4 corners)
D. Install drywall to walls
FVB
See detail
5/8" Type X drywall, factory supplied
The wall studs may be mechanically
fastened to the back-to-back Fan Coil
within the riser chase plate recess.
Install studs from top of unit to ceiling
at all four corners (see Figure 1:C).
Care should be taken, however, not to
penetrate the supply or return water
risers or internal piping. Anchor unit
to floor through bottom of unit.
1/2" typ.
Space as
needed
Given the levelness of the floor and/
or the Fan Coil assembly, some
Figure 3:
shimmming may be necessary to
Cross section A
make the unit square to floor and
ceiling. Make any remaining electrical and plumbing
connections. Assemble the specified wall construction
up to and over the top of the Fan Coil unit.
With the fire-wall separation being complete (see
Figure 1:D and Figure 2), the drywall skin on the
surface of the individual Fan Coils can be applied
(see Figure 1:E). Drywall can be applied directly to the
surface, or, if necessary, studding may be installed on
the corners for vertical control.
For ease of installation of the access panel, apply
drywall on the return air side directly to the surface of
the unit (see Figure 1:F). When applying the drywall
directly to the unit cabinet, it may be necessary to
shim in some areas to achieve the desired finished
wall surface.
After all drywalling and painting is complete, install
thermostats, supply air grilles and return air panels.
Figure 1: Installation
Installation
21
Start-up
22
Before beginning any startup, the start-up personnel
should take the time to
familiarize themselves with
the unit, options, accessories
and control sequence to fully
understand how the unit should
operate properly under normal
conditions. All personnel should
have a good working knowledge
of general start-up procedures.
After installation and prior to
start-up, be sure filter is clean
and free of any construction
dirt, etc. If not, the filter should
be replaced. Failure to do so
could result in damage to the
equipment or building while
voiding all manufacturer’s
warranties.
All internal doors and walls
should be in place. In some
cases, the internal decorations
and furniture may influence
overall system performance.
The entire building should be
as complete as possible before
beginning any system balancing.
if the unit is installed during
the winter months, care must
be taken so that the unit is
not subjected to freezing
temperatures while filled with
water during construction. Coils
damaged due to freeze-ups are
not covered by the warranty.
The building must be completely
finished including doors,
windows and insulation before
system start-up and balancing.
A final visual inspection of
equipment should be done
before commencing with startup. This includes checking for
debris, loose wires at terminal
block connections and quick
connects, free blower wheel
operation, leaks, proper drain
connections, loose or missing
access panels, clean filters, etc.
Except as required during startup and balancing, no fan coils
should be operated without all
the proper ductwork attached,
supply and return grilles in place
and all the access doors and
panels secured in place. Failure
to do so could result in damage
to the equipment or building
and furnishings and will void the
manufacturer’s warranty.
Water system
Prior to water system start-up
and balancing, the chilled and
hot water systems should be
flushed to clean out dirt and
debris which may have collected
in the piping during construction.
All unit service valves should be
in the closed position during
this procedure to prevent debris
from entering metering devices
and coils. Strainers are
recommended to help protect
against debris entering units
during normal operation.
During system filling, air venting
from the unit is accomplished by
the use of the standard, manual
air vent or the optional automatic
air vent that is installed at the
top of each coil’s header. Manual
air vents are capped Schrader
valves. To vent the air from the
coil, unscrew the cap, turn the
cap over and insert the pointed
Water treatment
Proper water treatment is
a specialized industry and
therefore it is recommended
to consult an expert in this
field to analyze the water for
compliance with the water
quality parameters listed below
and to specify the appropriate
water treatment program. The
expert may recommend rust
inhibitors, scaling preventative,
antimicrobial growth agents or
algae preventatives. Anti-freeze
solutions, glycols, may also be
used to lower the freezing point.
All Zehnder Rittling water coils are
constructed of copper tubes and
headers while multiple brass and
bronze alloys may be present in
the valve packages. It is the end
user’s responsibility to ensure
that any of the water delivery
components are compatible with
the treated water.
end of the cap into the vent to
depress the valve until all of the
air has been vented from the coil.
When water begins to escape
from the vent, release the valve
and replace the cap. Automatic
air vents may be unscrewed one
turn counterclockwise to speed
up the initial venting but should
be screwed in for automatic
venting during normal operation.
The air vents provided are not
intended to replace the main
system air vents and may not
release air trapped in other parts
of the system. Inspect the entire
system for potential air traps and
independently vent those areas
as required. In addition, some
systems may require repeated
venting over time to fully
eliminate air in the system.
Failure to provide proper water
quality will void the fan coil unit’s
warranty.
Water content
Required
concentration
Sulphate
< 200 ppm
pH
7.0 – 8.5
Chlorides
< 200 ppm
Nitrate
< 100 ppm
Iron
< 4.5 mg/L
Ammonia
< 2.0 mg/L
Manganese
< 0.1 mg/L
Dissolved solids
< 1000 mg/L
Calcium carbonate
hardness
300 – 500 ppm
Calcium carbonate
alkalinity
300 – 500 ppm
Particulate quantity
< 10 ppm
Particulate size
800 micron max
Start-up
23
Water system
balancing
A complete knowledge of the
hydronic system, including its
components and controls, is
essential to proper water system
balancing and should only be
completed by a qualified expert.
The system must be complete,
and all components must be
in operating condition before
beginning the water system
balancing procedures.
Each hydronic system has
different operating conditions
depending on the devices
and controls installed for the
particular application. The actual
balancing technique may vary
from one system to another.
Air system balancing
24
All ductwork must be complete
and connected and all grilles,
panels and filters installed before
the start of balancing. System
balancing is to be conducted by
a qualified balance specialist.
Non-ducted units do not require
balancing except to select fan
speeds. Ensure that the units
are not obstructed by window
treatments, drapes or furniture.
After the proper system
operation is established, the
appropriate operating conditions
such as water temperatures, flow
rates and pressure drops should
be recorded for future reference.
Before and during water system
balancing, conditions may
exist due to incorrect system
pressures which may result
in noticeable water noise or
undesired valve operation. After
the entire system is balanced,
these conditions will not exist on
properly designed systems. If
any of these conditions persist,
recheck the system for air that
may not have been properly
vented during start-up.
After proper system operation
is established, the actual unit
air delivery and the actual fan
motor amperage draw for each
unit should be measured and
recorded for future reference.
EC Motor
If the unit is equipped with an EC
motor, additional steps may be
required during the air balancing
process. Review project submittals
or order acknowledgment to
determine what type of EC motor
control is provided. Alternatively,
match the control board to the
illustrations.
The unit has been factory configured
to produce the same airflow as the
standard PSC motor on all speeds
when using the 3-speed control card
and a maximum of 10% higher than
the high speed setting when using
the 0-10 VDC control card. If these
settings are acceptable, then no
further configuring is required.
The control box needs to be powered
while adjustments are made. Line
voltage components are concealed
within a covered junction box.
However, the installer should take
all necessary precautions to avoid
contact with live voltage wires.
Controls operation
3-speed control
card
0-10 VDC control
card
The unit has been factory
configured to produce the same
airflow as the standard PSC
motor on all speeds when using
the 3-speed control card with a
maximum of 10% higher than the
high speed setting available on
most units during readjustment.
If these settings are acceptable,
then no further configuring is
required.
The 0-10 VDC control card is
not configured at the factory
and needs to be used in
conjunction with a field installed/
provided thermostat and/or DDC
controller.
If alternative airflows are
desired, use board mounted
potentiometers, marked as FL01,
FL02, FL03, to adjust the airflow
associated with each input. Each
output can be adjusted from 0
to 100% of the motor’s factory
programmed operating range
using an instrument screwdriver.
Insert the screwdriver into
the white center of the
potentiometer and turn clockwise
for an increase in airflow or
counterclockwise for a decrease
in airflow.
Before proper control operation
can be verified, all other systems
must be operating properly.
The correct water and air
temperatures must be present
to determine if the control
function is operating to design.
Some controls and features are
designed to not operate under
certain conditions. For example,
a 2-pipe cooling/heating system
with auxiliary electric heat, the
electric heat will not energize
when hot water is present.
A wide range of controls,
electrical options and
accessories may be used
with the units covered in this
manual. Review the approved
project submittals or order
acknowledgment for detailed
information regarding each
individual unit and its controls.
Since controls may vary from
one unit to another, care should
be taken to identify the controls
being used with each individual
unit and its proper control
sequence.
Start-up
25
Maintenance
General
Each unit on a project will
have its own unique operating
environment and conditions
which dictate a maintenance
schedule for that unit that
may be different from other
equipment on the project. A
formal regular maintenance
schedule and an individual
unit log should be established
and maintained. Following this
schedule will help maximize the
performance and service life of
each unit on the project.
The safety considerations listed
in the front of this manual should
be followed during any service
and maintenance operations.
For more detailed service
information consult your Sales
Representative or the factory.
Disconnect power supply from
the unit before servicing.
■■
Filter
Since the Vertical Hi-Stack
Fan Coil is a draw-through coil
type, filter must be changed
or cleaned a minimum of four
times a year. Under certain
operating conditions, it may be
necessary to change or clean
the filters more frequently
to obtain maximum unit
performance.
Brushing should be followed
by cleaning with a vacuum
cleaner. Compressed air can
also be used by blowing air
through the coil fins from
the leaving air side, again
followed by vacuuming. If
fins are damaged during the
cleaning process, a 12 fins
per inch fin comb can be used
to straighten the fins. For a
deeper cleaning, spray the
finned surface with a mild alkali
cleaning solution and rinse
thoroughly. Failure to maintain
a clean coil surface will result
in reduced airflow, reduced
performance and increased
power consumption. Clean the
coil at every inspection. Units
provided with the proper type
of air filters, replaced regularly,
will require less frequent coil
cleaning. Before performing
service at or near any
heating coil, piping or valve,
disconnect all power, close all
isolation valves and allow the
equipment to cool.
Drain
■■
Once yearly, preferably at the
start of the cooling season, the
drain pan should be checked
and cleaned if necessary. A
flexible probe for 3/4-inch
pipe may be used to clear any
obstruction from the line, or
the drain tube may be removed
through the lower area of the
return-air opening, should
more thorough cleaning be
needed.
Coil
■■
Coils may be cleaned by
removing the motor/blower
assembly and air filter,
providing access to the air
entry side of the coil. Brush
the entire finned surface with
a soft bristled brush, brushing
parallel to the fins, taking
care not to damage the fins.
26
off plate of each unit for that
unit’s individual operating
characteristics.
All motors have permanently
lubricated bearings so no
further field lubrication is ever
required.
The unit motor/blower is directdrive assembly. Remove the air
block-off plate to gain access
to the motor/blower assembly.
The entire motor/blower
assembly can be removed from
its track through the returnair grille for field servicing by
removing a single screw and
quick connect. Disconnect all
remote electric power supplies
before servicing as motors can
start automatically.
Dirt and dust should not be
allowed to accumulate on
the blower wheel or housing.
Failure to keep this clean may
result in an unbalanced wheel
condition which can lead to
a damaged blower wheel or
motor. The wheel and housing
may be cleaned periodically
using a brush and vacuum
cleaner, taking care not to
dislodge the factory applied
balancing weights on the
blower wheel blades. Clean
the blower at every inspection.
Any blower or motor that is
not properly maintained will
not be covered under the
manufacturer’s warranty.
■■
Electric heating element
■■
Motor/blower assembly
The type of fan operation is
determined by the control
components and their method
of wiring. This may vary from
unit to unit. Refer to the wiring
diagram located in a zip-lock
plastic bag on the air block-
Finned tubular type heaters
generally require no normal
periodic maintenance when
unit air filters are changed
properly. The operation and
service life may be affected
by other conditions and
equipment in the system.
The two most important
Maintenance
operating conditions for an
electric heater are proper
airflow and proper supply
voltage. High supply voltage
and/or poorly distributed or
insufficient airflow over the
heater will result in the element
overheating. This condition
may result in the heater cycling
on the primary automatic high
limit thermal cutout. If the
temperature becomes too high,
the secondary high limit thermal
cutout may be activated,
breaking the circuit and leaving
the unit non-operational.
The primary automatic thermal
cutout will reset automatically
after the heater has cooled
down, allowing the unit to run
again without intervening.
The secondary thermal cutout
is a safety device only, is
not intended for continuous
operation and will need to be
replaced before the unit will
operate again. With proper
unit application and operation,
the primary high limit thermal
cutout will not operate. This
device only operates when
there is a problem and ANY
condition that causes the high
limit cutout to operate MUST
be corrected immediately. High
supply voltage also causes
excessive amperage draw and
may trip the circuit breaker or
blow the fuses on the incoming
power supply.
After proper airflow and supply
power are verified, regular
filter maintenance is important
to provide clean air over the
heater. A dirty filter will inhibit
the proper airflow, leading to
high temperature situations.
Improper filtration will also lead
to dirt being deposited on the
heating element, causing hot spots
and eventual element burn through.
These hot spots will generally not
be enough to cause the high limit
switches to trip and may not be
evident until the element actually
fails. Dirt deposited on the element
will also cause unwanted odors in
the air-conditioned space as the
foreign material is burned off.
■■
Electrical wiring & controls
The electrical operation of
each unit is determined by the
components and wiring of the unit.
This may vary from unit to unit.
Refer to the wiring diagram located
in a zip-lock plastic bag on the air
block-off plate of each unit for the
actual type and number of controls
provided on each unit.
The integrity of all electrical
connections should be verified at
least twice during the first year of
operation. Afterwards, all controls
should be inspected regularly
for proper operation. Some
components may experience erratic
operation or failure due to age.
Thermostats may become clogged
with dust and lint, and should be
periodically inspected and cleaned
to provide reliable operation.
When replacing any electrical
components such as fuses,
contactors, relays or transformers,
use only the exact type, size and
voltage component as furnished
from the factory. Any deviation
from this could result in personnel
injury or damage to the unit. This
will also void the manufacturer’s
warranty. All repair work should be
done in such a way as to maintain
the equipment in compliance with
governing local and national codes,
ordinances and safety testing
agency listings.
■■
Valves and piping
No formal maintenance is
required on the valve package
components other than a
visual inspection for possible
leaks during normal periodic
unit maintenance. Strainers,
when included, should be
checked regularly for buildup and rinsed as needed. In
the event that a valve should
need replacement, the same
precautions taken during the
initial installation to protect the
valve package from excessive
heat should be implemented
during replacement
■■
Throwaway filters
These types of filters should
be replaced on a regular basis.
The time interval between
replacement is dependent
upon the environment in
which the unit is operating
and should be set established
based on regular inspection
of the filter. Record the time
interval in the maintenance
log for future reference. Refer
to the product catalog for the
recommended filter size. If
the replacement filters are not
purchased from the factory,
the same type and size filters
should be obtained. MERV9
or higher pleated media
or extended surface filters
should not be used without
consent from the factory due
to the high air pressure drops
associated with these types of
filters, negatively affecting unit
performance.
■■
Cleanable filters
These types of filters should
be inspected and cleaned
on a regular basis, similar to
the maintenance schedule
Maintenance
27
Maintenance
used for throwaway filters.
The time interval between
cleaning is dependent upon
the environment in which the
unit is operating and should
be set established based on
regular inspection of the filter.
Record the time interval in the
maintenance log for future
reference. Unlike throwaway
filters, cleanable filters may be
cleaned and reinstalled in the
unit instead of being disposed
of when dirty. The cleanable
filters may be washed in hot,
soapy water and then set aside
to dry before recharging and
reinstalling.
Before replacing the filter,
it should be recharged with
some type of entrapment film
Replacement parts
such as “Film-Car recharging Oil.”
The filter should be sprayed on
both sides or submerged in the film
to assure complete coverage. The
filter should not be soaked in the
film but should be quickly dunked
and removed, allowing the excess
to drain off of the surface before
reinstalling in the unit.
It should be noted that cleanable
filters tend to have less air pressure
drop than throwaway filters.
■■
Drain
The drain pan and drain should be
checked during initial start-up and
at the beginning of each cooling
season to ensure that the pan,
drain, trap and line are all securely
connected and clear. If clogged,
steps should be taken to clear the
Periodic checks of the drain
should be made during the
cooling season to maintain a
free-flowing condensate.
Should the growth of algae
and/or bacteria be a concern,
consult an air-conditioning and
refrigeration supply company
familiar with local conditions
for chemicals or other
solutions available to control
these substances.
Factory replacement parts
should be used wherever
possible to maintain unit
performance, it’s normal
operating characteristics and its
safety testing agency listings.
When ordering parts, the
following information should be
supplied to ensure proper part
identification:
■■
Complete unit model number
Replacement parts may
be purchased through the
local Zehnder Rittling Sales
Representative.
■■
Complete part description
Contact the local Sales
representative or factory
before attempting any unit
modifications. Any modifications
not authorized by the factory
could result in personnel injury,
damage to the unit, and will void
the manufacturer’s warranty.
28
foreign debris to allow proper
flow of condensate. Failure to
strictly follow this instruction,
will void the manufacturer’s
warranty and the manufacturer
will not be responsible for any
consequential damages due
to water.
■■
Unit serial number
including any identifying
numbers on the part
On warranty replacements, it
is often necessary to return the
faulty component to receive
credit. Contact the local Sales
Representative who will get
authorization from the factory
including an RGA (Returned
Goods Authorization) to be used
when sending components back
for inspection. Any returned
components sent back to the
factory without the proper
RGA attached will cancel any
outstanding credit.
Troubleshooting
Symptom
Unit not operating
Unit blows fuse
when power is
applied to unit
Fan doesn’t
operate
Possible cause
Corrective action
No power to unit.
Apply proper power to unit.
Incorrect power to unit.
Apply correct power to unit and check for damaged components and/or blown
fuses, if furnished.
Power distribution panel switch
or circuit breaker in “OFF”
position.
Unit toggle disconnect switch
in “OFF” position.
Fan switch or thermostat
system switch in “OFF”
position.
Blown or defective unit main
fuse, if furnished.
Defective toggle, fan or
thermostat
system switch.
Turn power distribution panels switch or circuit breaker to “ON” position.
Turn unit toggle disconnect switch to “ON” position.
Turn fan switch or thermostat system switch to “ON” position.
Check for possible defective component or improper wiring and replace fuse.
Momentarily jumper suspected component to simulate closed contacts and
achieve unit operation. Replace defective device with known good part.
Loose or improper wiring
from power distribution and/
or remote mounted control
devices.
Verify all wiring connections and terminations, and verify proper wiring of all
incoming power devices and remote mounted controls.
Level switch activated, drain
pan clogged
Remove debris from drain pan, unclog pan, unclog drain and emtpy.
Defective or improperly wired
component.
Using a battery powered continuity tester, check for shorted or grounded
components starting at incoming power. Note position of all controls during
various component checks. Caution: some voltages have isolated common
which may not show a short to chassis ground. Be sure to isolate each control
to eliminate faulty reading through a parallel wired component.
Thermostat system switch in
“OFF” position.
Turn thermostat system switch to “ON” position.
Remote “start/stop” switch in
“OFF” position.
Turn remote “start/stop” switch to “ON” position.
Loose or improper wiring from
fan switch or thermostat to
unit.
Verify all wiring connections and terminations, and verify proper wiring of all
control devices.
Loose or improper wiring from
remote “start/stop” switch to
unit “start/stop” relay.
Verify all wiring connections and terminations, and verify proper wiring of
remote “start/stop” switch.
Defective “start/stop” relay.
Momentarily jumper “start/stop” relay to simulate proper relay operation.
Replace defective “start/stop” relay.
Defective fan motor.
Verify proper fan switch operation and replace defective fan motor.
Troubleshooting
29
Troubleshooting
Symptom
Possible cause
Incorrect power applied to unit.
Fan motor hums
Defective motor capacitor.
and/or gets hot, but
Defective fan motor.
operates at reduced
speed or not
Blower wheel stuck in housing.
at all
Foreign object in blower wheel.
Fan operates but
vibrates
Fan operates but
blower wheel rubs
housing
Fan operates but
air delivery is low
Corrective action
Apply correct power to unit.
Replace with known good capacitor.
Replace defective motor.
Reposition blower wheel for proper alignment in housing, or replace if
damaged.
Remove foreign object and replace blower wheel if damaged.
Blower wheel dirty.
Remove and clean blower wheel taking care not to remove or reposition
balance weights.
Blower wheel bent.
Replace blower wheel.
Blower wheel out of balance.
Replace blower wheel.
Foreign object in blower wheel. Remove foreign object and replace blower wheel, if damaged.
Loose motor mount screws.
Verify proper motor and blower wheel position, tighten motor mount and set
screws.
Broken motor mount frame or
mounting screws.
Replace motor or mounting screws.
Bent blower wheel.
Replace blower wheel.
Blower wheel not positioned
properly on motor shaft.
Incorrect fan speed has been
selected.
Check for damage to blower wheel. Reposition blower wheel on motor shaft
or replace as required.
Dirty air filter.
Replace air filter.
Dirty coil.
Clean coil.
Obstruction in ductwork.
Actual E.S.P. higher than
design.
No chilled/hot water flow in
system.
Unit isolation valves closed.
Re-select proper fan speed as required.
Check for improperly positioned balancing or fire dampers. Check for fallen
duct liner. Repair as required. Check that supply grilles are open.
Check installation for proper supply and/or return grilles, and compliance with
plans and specifications.
Establish chilled/hot water flow in system as designed.
Open unit isolation valves.
Debris in water piping blocking
Locate and clear debris from water piping as required.
flow.
Plugged strainer.
Fan operates but
no cooling/heating
(hydronic units)
Riser or main flushing loop
open.
Loose or improper wiring from
thermostat to control valve.
Close flushing loop valve as required.
Defective control valve
actuator.
Verify all wiring connections and terminations, and verify proper wiring of
thermostat.
Momentarily jumper thermostat contacts to simulate proper operation.
Replace thermostat as required.
Manually place control valve in “open” position using lever on actuator
housing. Replace actuator as required.
Improper aquastat operation.
Verify proper aquastat position and operation. Replace as required.
Defective thermostat.
30
Clean or remove strainer screen as required.
Symptom
Possible cause
No power to electric heating
circuit on units with dual point
power.
Loose or improper wiring from
thermostat to electric heating
contactor.
Loose or improper wiring of
electric
heating element.
Defective electric heating
contactor.
Tripped or defective primary
Fan operates but
no heating (electric high limit switch.
heating units)
Tripped secondary high limit
switch.
Defective thermostat.
Defective electric heating
element.
Improper aquastat or change
over relay operation on units
so equipped. (Note: electric
heat will not operate when hot
water is present at the unit.)
Corrective action
Establish power to electric heating circuit.
Verify all wiring connections and terminations, verify proper wiring of
thermostat.
Verify all wiring connections and terminations, verify proper wiring of electric
heating element.
With electric heating contactor energized, verify proper voltage on contactor
load terminals. Replace as required.
Turn thermostat to lowest set point and allow fan to run 10-15 minutes for limit
switch to cool and rest. Then turn thermostat to highest set point and check
for proper heating operations. If high limit trips again, check for the following
conditions: improper voltage to heating element; obstructed fan or unit outlet
reducing air flow over heating element; dirty or defective heating element
causing hot spot. If heater does not operate after sufficient time for limit
switch to cool, disconnect power and check continuity across primary high
limit switch. Replace if defective.
Secondary high limit switches are designed to trip only during extreme failure
conditions. Contact factory before attempting any corrective action. Limit
switch will require replacement.
Momentarily jumper thermostat contacts to simulate proper operation.
Replace thermostat as required.
Disconnect power and check continuity through
heating element. Replace as required.
Verify proper aquastat position on piping, and verify proper aquastat and
change over relay operation.
Replace as required.
Troubleshooting
Equipment start-up checklist
Receiving and inspection
Electrical connections
■■
Unit received undamaged
■■
Refer to unit wiring diagram
■■
Unit received complete as ordered
■■
Connect incoming power service or services
■■
Unit arrangement and handing is correct
■■
Install and connect “shipped loose” components
■■
Unit structural support is complete and correct
Handling and installation
Unit start-up
■■
Mounting grommets/isolators are used
■■
General visual inspection and system inspection
■■
Unit mounted level and square
■■
Check for free and proper fan rotation
■■
Proper access is provided for unit and accessories
■■
Record electrical supply voltage and amperage
■■
Proper overcurrent protection is provided
■■
Proper service switch/disconnect is provided
■■
Proper chilled/hot water line sizes to unit
■■
All services to unit in code compliance
■■
All shipping screws and braces are removed
■■
Unit protected from dirt and foreign matter
draw
■■
Check all wiring for secure connections
■■
Close all unit isolation valves
■■
Flush water systems
■■
After system has been flushed, ensure all isolation
valves are open
■■
Vent water systems, as required
■■
All ductwork and grilles are in place
Cooling/heating connections
■■
All unit panels are in place
■■
Protect valve package components from excessive
■■
Filters are in place
heat
■■
Pressure test all piping for leaks
■■
Ensure all valve package piping is sloped towards
inside of unit
■■
Install drain lines and traps, as required
■■
Insulate all piping, as required
■■
Connect risers from master FVM models to slave
FVS models
■■
If risers are shipped separately or are field provided,
connect risers to valve packages
Ductwork connections
■■
Install ductwork, fittings and grilles, as required
■■
Flexible duct connections at unit
■■
Proper supply and return grille type and size
■■
Control outside air for freeze protection
■■
Insulate all ductwork, as required
32
■■
Start blowers, pumps, chillers, etc.
■■
Check for overload conditions on all units
■■
Check all ductwork and units for air leaks
■■
Balance water systems, as required
■■
Balance air systems, as required
■■
Record all final settings for future reference
■■
Check piping and walls for excessive vibration
■■
Check all dampers for proper operation
■■
Verify cooling operation
■■
Verify heating operation, where applicable
■■
Ensure all access covers and grilles are properly
installed
■■
Verify proper condensate flow
Warranty
Zehnder Rittling guarantees its
products to be free from defects
in material and workmanship for
a period of two years from date
of shipment from our factory.
Defects arising from damage
due to shipment, improper
installation, negligence or misuse
by others are not covered by this
warranty.
Should there be any defects
in the good(s), the purchaser
should promptly notify Zehnder
Rittling. Upon receipt of written
consent from Zehnder Rittling,
the purchaser shall return the
defective good(s) to the factory
for inspection with freight
prepaid. If inspection shows the
goods to be defective, Zehnder
Rittling will at its discretion repair
or replace the said item(s).
This warranty is extended only to
the original purchaser from
Zehnder Rittling.
Warranty
33
© Zehnder Rittling September 2014, English, subject to change without notice
Zehnder Rittling · 100 Rittling Boulevard · Buffalo, NY USA 14220
T 716-827-6510 · F 716-827-6523 · sales@zehnder-rittling.com
www.zehnder-rittling.com