Airmark GAW18 Manuel

IO-123084-GAW-063017

GAW SERIES

INSTALLATION & OPERATING INSTRUCTIONS

VERTICAL WALL MOUNT AIR HANDLER

(ELECTRIC HEAT)

MODEL

(INCLUDING HEATER MODEL #) ________________________________

SERIAL #____________________________________________________

INSTALLER __________________________________________________

INSTALLATION DATE _________________________________________

These instructions should be retained and kept adjacent to the unit for future use

373 Atascocita Rd.

Humble, TX 77396

Phone 800.423.9007

Fax 281.441.6510

www.airmark-ac.com

IO-123084-GAW-063017 - 2 -

Safety Instruction

Potential safety hazards are alerted using 

symbol. The symbol is used in conjunction with

terms that indicate the intensity of the hazard.

WARNING This symbol indicates a potentially

hazardous situation which if not avoided, could

result in serious injury, property damage, product

damage or death.

CAUTION This symbol indicates a potentially

hazardous situation which if not avoided, may

result in moderate injury or property damage.

WARNING Certified technicians or those

individuals meeting the requirements specified

by NATE may use this information. Property

and product damage or personal injury hazard

may occur without such background.

WARNING All power sources should be

disconnected prior to servicing. Failure to do so

may cause personal injury or property damage.

WARNING Product designed and

manufactured to permit installation in accordance

with local and national building codes. It is the

installer’s responsibility to ensure that product is

installed in strict compliance with national and

local codes. Manufacturer takes no responsibility

for damage (personal, product or property) caused

due to installations violating regulations. In

absence of local/state codes, refer to National

Electric Code: NFPA 90A & 90B Uniform

Mechanical Code.

WARNING When this unit is installed in an

enclosed area, such as a garage or utility room

with any Carbon Monoxide producing devices (i.e.

automobile, space heater, water heater etc.)

ensure that the enclosed area is properly

ventilated.

CAUTION Only factory authorized kits and

accessories should be used when installing or

modifying this unit unless it is so noted in these

instructions. Some localities may require licensed

installer/service personnel.

WARNING Unit is not approved for outdoor

installations.

WARNING The unit is designed for operation

with 208/240 V, single phase, 60 Hz power supply.

Airmark will not be responsible for damages

caused due to modification of the unit to operate

with alternative power sources.

Inspection

On receiving the product, visually inspect it for any

major shipping related damages. Shipping

damages are the carrier’s responsibility. Inspect

the product labels to verify that the model number

and options are in accordance with your order.

Manufacturer will not accept damage claims for

incorrectly shipped product.

Installation Preparation

Read all the instructions in this guideline carefully

while paying special attention to the WARNING

and CAUTION alerts. If any of the instructions are

unclear; clarify with certified technicians. Gather all

the tools needed for successful installation of the

unit prior to beginning the installation.

This unit is designed for zero clearance installation

on three sides and adequate clearance to provide

access for service in the front. A min of 2.5 – 3.5

feet clearance is recommended on the front end.

These units are designed to be installed on top of

a water heater or recessed into a wall. The unit

should be installed in Vertical Upflow position

ONLY. While installing the unit into a recessed

wall, attach unit to

"4"2 ×

framing stud along the

front flange. These air handlers are provided with

an offset hanging bracket at the rear for certain

wall mount applications.

The drain lines must be installed with ¼” per foot

pitch to provide free drainage. A condensate trap

MUST be installed on the primary drain line to

ensure proper drainage of the condensate. The

trap must be installed in the drain line below the

bottom of the drain pan. Figure 1 illustrates the

typical drain trap installation.

These units are equipped with a bottom primary

and secondary drain and a single side primary OR

secondary. When utilizing the unit, disable switch

on the secondary line. It must be located on the

side connection to avoid a false shutdown created

by condensate droplets falling into the bottom

secondary connection. The switch should be

adjusted to permit normal operation of the unit and

disable the unit in the event of a clogged primary

before the condensate spills over the pan. In lieu

of this a hood may be field fabricated to slide over

IO-123084-GAW-063017 - 3 -

the secondary to keep droplets out but allow

trapped condensate into secondary fittings.

CAUTION Since coil is upstream of the

blower; all drains MUST be trapped or sealed.

Failure to do so will result in condensate overflow

from the drain pan. Airmark will NOT be

responsible for any damages resulting from failure

to follow these instructions.

2" MINIMUM

3" MINIMU

FLEXIBLE

TUBING-HOSE

OR PIPE

A POSITIVE

LIQUIDSEALIS

REQUIRED

DRAIN

CONNECTION

Fig.1. Typical drain line trap set up

Ductwork

Duct systems should be installed in accordance

with standards for air-conditioning systems,

National Fire Protection Association Pamphlet No.

90A or 90B. They should be sized in accordance

with National Environmental System Contractors

Association Manual K, or whichever is applicable.

On any job, non-flammable flexible collars should

be used for the return air and discharge

connections to prevent transmission of vibration.

Although these units have been specially designed

for quiet vibration-free operation, air ducts can act

as soundboards can, if poorly installed, amplify the

slightest vibration to the annoyance level.

All main supply and return air drops should be

properly sized as determined by the designer of

the duct system and should not necessarily be the

size of the duct flange openings of the unit.

These models have a bottom or front return.

Discard the drain access panel in the bottom of

the unit if this is a bottom return application. In

case of a front return application, the front access

panel should be removed and discarded. If an

accessory grill as shown in Fig 2. is being used;

the front access panel should be removed and

discarded.

A filter rack is provided for

"20"20"1 ××

nominal

size filter. Inspect and clean or replace fliter every

month. A blocked filter can reduce air flow to the

coil and hinder the performance of the system.

It is recommended that wherever supply and

return air sheet metal duct pass through

unconditioned areas, they be insulated to prevent

excessive heat loss during heating operation.

When applied in conjunction with summer air

conditioning, sheet metal duct routed through

unconditioned areas should be insulated and have

an outside vapor barrier to prevent formation of

condensation.

Fig.2. GAW air handler grill and drain connections

Installation

CAUTION Ensure that the unit is adequately

sized. The tonnage of the outdoor unit should

never exceed the tonnage of this unit.

WARNING The coil was manufactured with

dry nitrogen pre-charge. Release the pressure

through the Schrader valve test port prior to

installation. If holding pressure is not present,

return coil to distributor for exchange.

IO-123084-GAW-063017 - 4 -

Clean coil fins with degreasing agent or mild

detergent and rinse fins clean prior to installation.

All connection joints should be burr-free and clean.

Not removing burrs and cleaning may increase

chances of a leak. It is recommended to use a

pipe cutter to remove the spun closed end of the

suction line.

To avoid damage to grommets (where present),

remove these prior to brazing by sliding over the

lines. Use a quenching cloth or allow the lines to

cool before reinstalling the grommets.

CAUTION Some Airmark coils may include a

Schrader valve on the suction manifold. Ensure

that the Schrader valve and valve core (where

present) are protected from heat during brazing

and installation to prevent leakage.

Metering Device

Airmark coils are available with two kinds of

metering devices a) flowrator or b) TXV.

Instructions below are separated in sections

according to the metering device. Ensure that the

applicable section is thoroughly read and

understood.

Flowrator Coils:

PISTON

DISTRIBUTOR

TAIL PIECE

13/16" NUT

TEFLONO-RING

Fig.3. Flowrator assy components

CAUTION Use Piston sizes recommended

by the outdoor unit manufacturer whenever

possible. The piston should be sized according to

the capacity of the outdoor unit.

WARNING Failure to install the proper piston

can lead to poor system performance and possible

compressor damage.

During some installations a piston change may be

required. If so the installer MUST change the

piston. As stated earlier, use piston sizes

recommended by the outdoor unit manufacturer. If

a sizing chart is not available, use Table 1 below

to size the required piston. The size of the piston

is stamped on the piston body.

Table.1. Piston Size Chart

Instruction for piston change

1) Turn the 13/16 nut once to release any

residual pressure in the coil.

2) After ensuring that the coil is free of any

residual pressure, disassemble the

flowrator body completely using two

wrenches. Distortion of the feeder tubes

SHOULD be avoided.

3) The wrench used to clasp the nut should

be turned in a counter-clockwise direction

to unscrew the nut.

4) Slide the 13/16 nut over the line set and

separate the two halves of the flowrator.

CAUTION Pay close attention to the Teflon

O-ring. Be sure to replace the O-ring to attain a

proper seal. (The Teflon O-ring is located between

the two halves of the flowrator)

5) Pull the piston out using a small wire or

pick. Verify the piston size (size is typically

stamped on the body of the piston). If a

different piston size is required by the

outdoor unit manufacturer replace the

piston using the small wire provided with

the piston kit.

Outdoor

Capacity

Orifice

Size–R22

Orifice

Size-R410A

12,000

0.041

N/A

18,000

0.055

0.049

24,000

0.059

0.055

30,000

0.068

0.059

36,000

0.074

0.068

42,000

0.080

0.074

48,000

0.084

0.080

60,000

0.092

0.089

IO-123084-GAW-063017 - 5 -

CAUTION Pay close attention to the piston

orientation. The pointed end of the piston

MUST go into the distributor body/towards the

coil. Failure to ensure this orientation will

cause the piston to be bypassed during

operation which might damage the outdoor

unit.

6) Assemble the two halves correctly and

ensure that the white Teflon O-ring is

present between the two halves.

7) Slide the 13/16 nut onto the distributor

body.

8) Tighten the nut to a torque of

approximately 10-30 ft-lbs. Do NOT over

tighten the nut. This will hamper the piston

movement during operation.

9) Slide the grommet back to position to

prevent air leakage.

TXV Coils:

WARNING The sensing bulb and TXV body

MUST be protected from overheating during

brazing. The sensing bulb and TXV body must be

covered using a quench cloth or wet cloth when

brazing. Pointing the brazing flame away from the

valve and sensing bulb provide partial protection

only.

CAUTION Ensure that the TXV selected is

compatible with the refrigerant used in the outdoor

system (R22 or R410A). TXV caps are painted

green for R22 or pink for R410A. In absence of

color, the caps will be marked with the compatible

refrigerant.

CAUTION The valves should be sized

according to the capacity of the outdoor unit.

Failure to install the right valve can lead to poor

performance and possible compressor damage.

TXV Bulb Mounting

The orientation and location of the TXV bulb has a

major influence on the system performance.

CAUTION Ensure that the TXV bulb is in

direct contact with the suction/vapor line. Gaps

between the bulb and tube should be avoided.

Failure to eliminate gaps will impair the proper

functioning of the TXV valve.

It is recommended that the TXV bulb be installed

parallel to the ground (in a horizontal plane). The

bulb position should be above and between 4

o’clock and 8 o’clock. Fig. 4 shows the

recommended position for the TXV bulb

installation in the horizontal plane.

The TXV sensing bulb SHOULD be mounted

using the metal clamp provided. In order to obtain

a good temperature reading and correct superheat

control, the TXV sensing bulb must conform to

ALL of the following criteria:

1) The sensing bulb MUST be in direct and

continuous contact with the suction line

2) The sensing bulb should be mounted

horizontally on the suction line.

3) The sensing bulb must be mounted above

and between the 4 and 8 o’clock position

on the circumference of the suction line.

4) The sensing bulb MUST be insulated from

outside air.

TXV BULB POSITION

4 O'CLOCK OR

8 O'CLOCK

METAL STRAP

SUCTION/VAPORLINE

Fig.4. Recommended location of the TXV bulb in a

horizontal orientation

The mounting location and insulation guards the

sensing bulb from false reading due to hot outside

air or liquid refrigerant formed inside the

suction/vapor line.

As recommended earlier, the TXV sensing bulb

should be mounted in a horizontal plane in relation

to the suction/vapor line. However, in case such a

mounting is not feasible and the sensing bulb has

IO-123084-GAW-063017 - 6 -

to be mounted vertically; then place the bulb as

shown in Fig.5.

Fig.5. Figure showing the sensing bulb mounted in

a vertical orientation

CAUTION If the TXV sensing bulb is mounted

vertically; the capillary MUST be directed upwards.

The bulb must be mounted on the wall opposite to

that being directly hit by the refrigerant and oil

leaving the distributor tubes.

Field – Installed Expansion Valve Coils

Remove the valve identification sticker from the

valve and place it adjacent to the Airmark model

number on unit name plate.

When installing an expansion valve, it is not

necessary to remove all the access panels and

slide the coil out of the housing.

1) Disassemble the flowrator body using two

wrenches. Unscrew the body with a

counter-clockwise motion.

2) Replace the white Teflon seal in place

(located between the halves).

3) Remove the existing flowrator piston using

a small wire or pick.

4) Inspect the TXV box to confirm that the

valve is compatible with the refrigerant in

the system.

5) Remove the valve from the box and note

the location of the inlet side (threaded

male port) and the outlet side (female

swivel nut port).

6) After ensuring that the white Teflon seal is

still in place inside the flowrator body,

screw the female swivel nut onto the

flowrator body.

7) Place the attachment nut on the liquid line.

8) Braze the stub-out portion to the liquid line

and let cool.

WARNING Do not attempt to touch the braze

joint while hot. Touching it may cause sever burns.

9) Remove the additional white Teflon seal

ring from the box and place on the

shoulder just inside the inlet port. Screw

the nut attached to the stub-out portion of

the flowrator body onto the inlet port of the

TXV.

10) Tighten all connections taking care to use

proper back up.

Some Airmark coils come with a Schrader valve

on the suction line. If a Schrader port is present

11) Remove valve stem from the Schrader

port mounted on the suction line

12) Screw flare nut on TXV equalization tube

in to the Schrader valve stem

Coils without Schrader Ports

13) Locate a convenient spot on the suction

line and punch a ¼” hole with a pick or

other suitable tool.

CAUTION Do NOT drill a hole as chips will

enter suction manifold.

14) Insert TXV equalizer tube approximately

3/8” into the hole and apply solder to seal.

IO-123084-GAW-063017 - 7 -

Fig. 6. Shows the components of a typical TXV

assembly

TXV BULB

TAIL PIECE

DISTRIBUTOR

TEFLON O-RINGS

Fig.6. Components of a typical TXV assembly

CAUTION Using a non-bleed expansion valve

may require the use of a hard-start kit. Follow the

outdoor unit manufacturer’s guidelines.

Electrical Installation

These units are designed for single or three phase

208/240 volts, 60 Hz power supply. Wire selection

and wiring must be in accordance with the

National Electric Code and/or local codes. Unit

terminals are designed to accommodate copper

and aluminum wirings. If aluminum wiring is used;

please observe special precautions relative to

sizing, wire connections and corrosion protection.

All models with 5, 8 or 10 kW electric heat are

arranged for single circuit connections. Models

larger than 10 kW are arranged for multi-circuit

protection. Fig. 7 shows the typical electrical

connections required for the air handler unit.

Fig.7. Typical electrical connections required

System Charging

CAUTION An improperly charged system

may cause degradation in system performance

and damage the compressor.

After installing the coil, refer to the outdoor unit

manufacturer’s instructions for charging

techniques and amount of charge. If outdoor unit

manufacturers charging instructions are

unavailable; then refer to instructions below to

charge the system.

1) Bring airflow up to the maximum CFM

possible according to Table 2 below.

2) Flowrator coils – Add refrigerant until the

superheat measured at the outdoor unit

suction/vapor line matches the superheat

listed in Table 2.

Expansion valve coils – Add refrigerant until the

subcooling measured at the outdoor unit liquid line

matches the subcooling recommendation of the

outdoor manufacturer (typically 7º – 10º F). If

chart is unavailable, charge unit to a subcooling

value of 8ºF +/- 1ºF."

IO-123084-GAW-063017 - 8 -

Outdoor Temp

°F D.B. Superheat °F

Min Nom Max

65 35 40 45

70 31 35 39

75 26 30 34

80 22 25 28

85 17 20 23

90 13 15 17

95 8 10 12

100 4 5 6

Table.2. Superheat chart

Start up

After all connections are made, start-up and

check-up of the unit must be performed before

proper evaluation of the entire system can be

made. Make sure that heat anticipator is properly

set as noted on thermostat instructions.

Load requirements can vary in each residence and

it may be necessary for the installer or homeowner

to make slight adjustments to the heat anticipator

setting for longer or shorter cycles. It is

recommended to change the setting no more than

plus or minus 0.05 amps at a time. Greater

changes can cause the unit to rapid cycle or

remain on excessively. To properly check the

unit's operation, the installer should have an

electrical current measuring device (0-10 amp

Amprobe, Fluke), air pressure measuring device

(0-1.0 in slope gauge), and a temperature-

measuring device (0-200ºF thermometer).

Install the Amprobe to measure blower current, the

slope gauge to measure static air pressure at the

units and the temperature device to measure unit

supply and return air temperature. Before taking

measurements, be sure that all registers, grilles

and dampers are open or are set to their proper

positions. Be sure that clean filters are in place.

Temperature measuring device must be installed

to obtain average temperature at both inlet and

outlet. For outlet, measure temperature of each

main trunk at a location far enough away to avoid

heater radiation and read the average

temperatures. Table 3 below shows the CFM that

should be achieved at various external static

pressures

Table 3. CFM delivered at various external statics

Electrical Heat Controls:

•Turn on power supply. Set thermostat fan

switch to on. Set the cooling indicator to

maximum, heating to minimum. System switch

may be on heat or cool. Check slope gauge

measurement against appropriate air flow

chart. Make damper, register and motor speed

adjustments to obtain required airflow.

•Set thermostat fan switch to auto, system to

heat and thermostat heating indicator to

maximum heat. Blower should start and all

heat be energized.

•Check air flow using temperature rise method.

( )

RISE

TEMP

BTUHOUTPUT

CFM ×

=08

NOTE: BTUH output should be computed by

VOLT x AMPS x 3.4 = BTUH OUTPUT. Since line

volt can vary, do not use nameplate rating to

determine output.

OPERATION AND MAINTENANCE

Below are brief descriptions of the key

components of the unit and installation. This

manual only provides general idea of the

components and recommended practices. The

installer should use best judgment to ensure safe

installation and operation of the unit.

1) Room Thermostat- This is the device that

controls that operation of your heating and/or

cooling unit. It senses the indoor temperature

and signals the equipment to start or stop

0.10

0.20

0.30

0.40

0.50

LOW

873

860

834

800

746

HIGH

1000

972

930

888

823

LOW

1123

1094

1062

1034

1000

HIGH

1396

1358

1313

1261

1200

2.8

5.4

SPEED

TAP

MOTOR

AMP

GAW18/24

GAW30/36

MODEL

CFM V. EXTERNAL STATIC

PRESSURE

IO-123084-GAW-063017 - 9 -

maintaining the temperature you have

selected for your comfort. The room

thermostat should be in a central, draft free

inside wall location for best operation. Do not

place any heat producing apparatus such as

lights, radio, etc., near the thermostat as this

will cause erratic operation of the comfort

system. The thermostat can accumulate dust

or lint which can affect its accuracy. It should

be cleaned annually.

2) Air Filter(s) - All central air moving comfort

systems must include air filter(s). These filters

will be located either in the equipment or in the

return air duct system upstream of the

equipment. The filter(s) removes dust and

debris from the air thus helping to keep your

air-conditioned space clean. More important,

the filter keeps dust and debris from collecting

on the heat transfer surfaces thus maintaining

optimum equipment efficiency and

performance. Inspect and clean or replace

filters every month. This routine maintenance

procedure will pay big dividends in reduced

operating cost and reduced service expense.

Never operate comfort equipment without

filter(s).

3) Fuses and/or Circuit Breakers- This comfort

equipment should be connected to the building

electric service in accordance with local and

National Electric codes. This electrical

connection will include over-current protection

in the form of circuit breakers. Have your

contractor identify the circuits and the location

of over-current protection so that you will be in

a position to make inspections or

replacements in the event the equipment fails

to operate.

4) WARNING

a) Do not store combustible materials or use

gasoline or other flammable liquids or

vapors in the vicinity of this appliance.

b) Do not operate the comfort equipment with

panels removed.

c) Have your contractor point out and identify

the various cut-off devices, switches, etc.,

that serve your comfort equipment. There

is a main switch that will cut off energy to

your heating system. Know where they are

so that you may cut off the flow of energy

in the event of overheating.

5) Periodic Checkup and Service- This product is

designed to provide many years of

dependable, trouble-free comfort when

properly maintained. Proper maintenance will

consist of annual check-ups and cleaning of

the internal electrical and heat transfer

components by a qualified service technician.

Failure to provide periodic checkup and

cleaning can result in excessive operating cost

and/or equipment malfunction.

6) Lubrication- Direct drive blower motors are

equipped with permanently lubricated bearings

and do not require further lubrication.

7) Air filter replacement: An air filter can restrict

the airflow of air to the fan coil if it is not

cleaned or replaced periodically. When

replacing the air filter, always replace with the

same type and size as originally furnished with

the unit.

IO-123084-GAW-020113

WARNING

HIGH VOLTAGE disconnect all power sources prior to servicing. Failure might lead to safety hazard

Wiring diagram for GAW models

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