SystemAir Freshman Series Installation, Operation And Service Instructions
SystemAir Freshman Series Installation, Operation And Service Instructions

SystemAir Freshman Series Installation, Operation And Service Instructions

Classroom air handler non-compressorized and split vertical air conditioner

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Freshman Series (A2L)
1000A & 1600A Cabinet
Classroom Air Handler Non-Compressorized
and Split Vertical Air Conditioner
Conforms to Standard UL 60335-2-40, Fourth Edition
Certified to Standard CSA C22.2 No. 60335-2-40, Fourth Edition
This manual contains instructions specific to the installation, operation and service of your unit. Keep the manual(s) in a safe place and at the ready
for future reference.
Should you require further information contact the factory or your Systemair representative.
Owner's Manual - Installation,
Operation, and Service Instructions
Version 1.0
Improper installation, adjustment,
alteration, service or maintenance
can cause property damage,
personal injury or loss of life,
and could cause exposure to
substances which have been
determined by various state
agencies to cause cancer, birth
defects or other reproductive
harm.
Read and understand the
Installation, Operation,
Maintenance and Service
Instructions thoroughly before
installing or servicing this
equipment.
Installation and maintenance must
be done by a qualified installer,
service agency, or authorized
dealer competent in working with
flammable refrigerant.
OPERATION OF UNIT DURING
CONSTRUCTION MAY VOID THE
WARRANTY.

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Summary of Contents for SystemAir Freshman Series

  • Page 1 This manual contains instructions specific to the installation, operation and service of your unit. Keep the manual(s) in a safe place and at the ready for future reference. Should you require further information contact the factory or your Systemair representative.
  • Page 2: Table Of Contents

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions List of Sections 7.0 Installation Drawings ............28 1.0 Symbols and Warnings ............3 7.1 Figure 13 | Freshman - CA H 1000A NA VP DD ....28 2.0 Identification ..............5...
  • Page 3: Symbols And Warnings

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 1.0 Symbols and Warnings This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury.
  • Page 4 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions • These instructions are intended as an aid to qualified service personal for proper installation, adjustment and operation of this appliance, read these instructions thoroughly before attempting installation or operation.
  • Page 5: Identification

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 2.0 Identification 2.1 General Information 2.2 Unit Inspection Please keep this page for future reference Inspected For Freight Damages You have just purchased a Systemair Freshman Series, Air Your air handling unit was carefully packed for shipping.
  • Page 6: Limited Warranty

    Systemair. A new or remanufactured part may be provided to replace any defective part at Systemair’s sole option. Any defective part will be replaced without charge for the part itself, FOB the shipping point. THE EXCHANGED PART WILL BE WARRANTED FOR ONLY THE UNEXPIRED PORTION OF THE ORIGINAL WARRANTY.
  • Page 7 Systemair head office. Warranty authorization number must be quoted on all correspondence, returns and claims. Reimbursement will only be made for field supplied parts and labor if authorized by Systemair on the warranty claim form. If Systemair determines that the alleged...
  • Page 8: Model Number Nomenclature

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 4.0 Model Number Nomenclature 4.1 Table 1 | Freshman Series - Nomenclature 7. Refrigerant Type Blank – R410A 1 – R454B 2 –...
  • Page 9: General Preventative Maintenance

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.0 General Preventative Maintenance Before beginning with any preventative maintenance, you MUST follow these safety precautions. Failure to do so may result in personal injury or death 5.1 General Information...
  • Page 10: Filter Maintenance

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.3 Filter Maintenance Filtering Out Trouble Dirty air filters will cause airflow reduction through your unit. If excessive air loss occurs, the unit may freeze up when in the air conditioning mode, or cycle on high limit safety controls during heating mode.
  • Page 11: Removing Supply Fan(S)

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.4 Removing Supply Fan(s) Remove SUPPLY FAN MOTOR ASSEMBLY as follows A qualified service technician Turn OFF electrical supply to the unit.
  • Page 12: Cleaning Supply And Relief Fans

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.5 Cleaning Supply and Relief Fans Remove Fan from unit (refer to Section 5.4). Take a brush or similar cleaning tool and clean blades of fan to remove built up attached dirt.
  • Page 13: Coil Maintenance

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.6 Coil Maintenance Heating Coil (Open Access) Using a coil brush remove/dislodge excess foreign matter. Coil fins are delicate and Vacuum loosened foreign matter.
  • Page 14: Cleaning Energy Recovery Filters

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.7 Cleaning Energy Recovery Filters Dirty air filters will cause airflow reduction through your unit. If excessive air loss occurs, the unit may freeze up when in the air conditioning mode, or cycle on high limit safety controls during heating mode.
  • Page 15: Removing Fixed Core Plates

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.8 Removing Fixed Core Plates Turn OFF electrical power to the air handler. Open front service panels with the key provided.
  • Page 16: Cleaning Fixed Core Plates

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.9 Cleaning Fixed Core Plates If cores are wet allow them to dry before cleaning Using low psi compressed air blow dirt out of cores in the opposite direction of the airflow (Fig.
  • Page 17 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.10 Removing Relief Fan(s) Assemblies - continued Unplug the electrical wires running to the recovery fan motor. Remove the 4 bolts located on top of the return air damper pan that holds the recovery fan motor.
  • Page 18: Cleaning The Energy Recovery Wheel

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.11 Cleaning The Energy Recovery Wheel Cleaning Instructions Turn OFF electrical supply to the unit. Open front service panels using key provided.
  • Page 19: Installation Guide

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 5.11 Cleaning The Energy Recovery Wheel - continued Figure 10 | Removing Relief Fan(s) Assemblies Relief Fan(s) Sound Dampening Panel 6.0 Installation Guide 6.1 General Pre-Installation...
  • Page 20: General Assembly And Installation

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 6.3 General Assembly and Installation It is important to read and understand the instructions outlined in this document, as well as any job specific documentation pro- vided in the Information Package before proceeding with the installation.
  • Page 21 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 6.3 General Assembly and Installation - continued The condensate hose is supplied with a loop (trap). DO NOT REMOVE THIS LOOP. If the loop is removed the drain pan may overflow causing water damage inside and outside the ventilator.
  • Page 22: Electrical Connections

    Units drawing 80 or more amps, as per serial tag, the local disconnect, provided upon installation, (the circuit breaker) will be considered the main disconnect. If an electric duct heater is supplied either by others or by Systemair it must have its own supply line voltage. It can not be connected to the unit.
  • Page 23: Exterior Louver

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 6.5 General Wall Sleeve - continued Figure 11 | General Wall Sleeve Assembly Wall Sleeve Assembly Exterior Louver A. Wall Sleeve with a divider for relief air B.
  • Page 24: Relief Damper

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 6.7 Relief Damper Systemair recommends the use of a relief damper assembly be Cut or construct an opening through the wall adherent to used in conjunction with all units installations unless balanced the appropriate size.
  • Page 25: Rear Standoff (Rso)

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 6.8 Rear Standoff (RSO) We recommend the use of 19mm (¾”) x #10 round head self- NOTE: tapping sheet metal screws to fasten the accessories to the unit.
  • Page 26: Top Plenum

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 6.9 Top Plenum 6.10 Rear Plenum Assembly (RPA) We recommend the use of 19mm (¾”) x #10 round head self- If provided, carefully unpack the plenum assembly. The...
  • Page 27: Field Refrigerant Piping Installation

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 6.10 Rear Plenum Assembly (RPA) - continued front edges of the RPA and any partitions it may have. RPA. These hoses must drain downward to the outside or to a drain.
  • Page 28: Installation Drawings

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 7.0 Installation Drawings 7.1 Figure 13 | Freshman - CA H 1000A NA VP DD www.systemair.net...
  • Page 29 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 7.2 Figure 14 | Freshman - CA H 1000A NA VPS DD www.systemair.net...
  • Page 30 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 7.3 Figure 15 | Freshman - CA H 1600A NA VP DD www.systemair.net...
  • Page 31 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 7.4 Figure 16 | Freshman - CAH 1600A NA VPS DD www.systemair.net...
  • Page 32 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 7.5 Figure 17 | Dimensions - CAH 1000A NA VPS DD www.systemair.net...
  • Page 33 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 7.6 Figure 18 | Dimensions - CAH 1600A NA VP DD www.systemair.net...
  • Page 34: Troubleshooting Guide

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 8.0 Troubleshooting Guide Installation, adjustment, alteration, service and/or maintenance must be done by a qualified installer, service agency or authorized dealer. Failure to abide may cause property damage, personal injury or loss of life.
  • Page 35: General Unit Sequence Of Operations

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions There may be up to two automatic reset thermal cut-out snap The type of valve (modulated or on/off) dictates the type of discs, which open at 65°C (150°F).
  • Page 36: General Air Handler Troubleshooting

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 8.6 General Air Handler Troubleshooting Problem - Unit Tripped Breakers Incorrect fuse; check fuse size. NOTE: Replacement Fuses must Short circuit or incorrect unit wiring line voltage; check wiring (see diagram be of the same rating, located in unit electrical box).
  • Page 37: Cooling Troubleshooting

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions Systemair is not responsible for injury to untrained or unauthorized personnel who attempt to do repairs based on the troubleshooting procedures outlined in this section.
  • Page 38: Electrical Device Checks & Safety

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 8.8 Electrical Device Checks & Safety Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the Systemair maintenance and service guidelines shall be followed.
  • Page 39: Minimum Room Area Limits

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 9.0 Refrigerant Detection System (RDS) - continued Sensors used in RDS, the specified end-of-life and replacement instructions: • Locate the sensors:...
  • Page 40 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 10.1 Figure 19 | A2L Refrigerant charge (R32 OR R454B) Vs Required Min Room Area (Metric) Refrigerant Charge (KG) www.systemair.net...
  • Page 41 Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 10.2 Figure 20 | A2L Refrigerant charge (R32 OR R454B) Vs Required Min Room Area 1400 1200 1000 Refrigerant Charge (LB)
  • Page 42: Service & Charging/Recovery-A2L Refrigerant

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 11.0 Service & Charging/Recovery-A2L Refrigerant 11.1 Safety Precaution-Servicing Prior to beginning work on systems containing FLAMMABLE REFRIGERANTS, safety checks are necessary to ensure that the risk of ignition is minimized.
  • Page 43: Refrigerant Removal & Evacuation

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions • Extreme care shall be taken not to overfill the REFRIGERATING SYSTEM. Prior to recharging the system, it shall be pressure- tested with the appropriate purging gas.
  • Page 44: Decommissioning

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 12.0 Decommissioning Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail.
  • Page 45: Addendum - Ecm Controller

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions Addendum - ECM Controller ECM Controller 2.33 Operating Instructions Operation On power up the green Run LED will light indicating the control board is ready to receive an input signal on any of the inputs.
  • Page 46: Component Locations

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions Component Locations LEDs Fan Speed 1 / Analog Input (flashing) Fan Speed 2 Fan Speed 3 Programming Buttons Increase / Up...
  • Page 47: Replacement Parts

    Freshman Series 1000A & 1600A Cabinet - Classroom Air Handler - Owner's Manual - Installation, Operation, and Service Instructions 13.0 Replacement Parts 13.1 Obtaining Parts Contact your dealer or the factory for questions concerning prices and policies on replacement parts.
  • Page 48 1-800-263-7081 service@systemair.net www.systemair.net Systemair reserves the right to update or continually improve their products, specifications or information without notice.

This manual is also suitable for:

Freshman 1000aFreshman 1600a

Table of Contents