Airmark GFW SERIES Manual

IO-123090-GFW-020113

GFW SERIES

INSTALLATION & OPERATING INSTRUCTIONS

HIGH EFFICIENCY X13

VERTICAL WALL MOUNT AIR HANDLER

(HYDRONIC)

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-123090-GFW-020113 - 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 a licensed

installer/service personnel.



WARNING

Unit is not approved for outdoor

installations.



WARNING

The unit is designed for operation

with 108/120 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 on 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 the

IO-123090-GFW-020113 - 3 -

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" MINIM

FLEXIBLE

TUBING-HOSE

OR PIPE

A POSITIVE

LIQUID SEAL IS

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 ducts 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. GFW 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 a

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.

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 burr and cleaning may increase the

chance of a leak. It is recommended to use a pipe

cutter to remove the spun closed end of the

suction line.

IO-123090-GFW-020113 - 4 -

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

TEFLON O-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.

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.

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

Table.1. Piston Size Chart



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.



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.

IO-123090-GFW-020113 - 5 -

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

SUCTI O N/ VA PO R LI NE

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

to be mounted vertically; then place the bulb as

shown in Fig.5.

IO-123090-GFW-020113 - 6 -

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 severe

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-123090-GFW-020113 - 7 -

Fig. 6. shows the components of a typical TXV

assembly

TXV BULB

TAIL PIECE

DISTRIBUTOR

TEFL ON 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 phase 120

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.

Fig.7 shows the typical electrical connections

required for A/C only and heat pump applications.

The unit ships with a micro-processor based board

which controls the electrical functioning of the unit.

An inspection of the controls is recommended prior

to start-up.

Fig.8 provides a schematic of the control board

present in the unit. The units ship from the factory

with the aquastat jumper in the OFF position (right

two pins) and the heating selector in the HW

position (right two pins). If an aquastat is used in

the application; the jumper should be changed to

ON position (left two pins).

Note: Terminals T and N located on the top right

side of the board are not intended for field use and

should be left un-connected.



CAUTION

The aquastat (AQ) jumper must be

in the OFF position at all times; except for when an

aquastat is used. If the jumper is moved to the ON

position without installing an aquastat the blower

will not be energized.

When an aquastat is present, the blower will be

energized at the aquastat temperature settings.

Fig 7. Electric connections

On units shipped from factory with a pump installed

the pump will be energized on call for heat.

In units that were shipped without factory installed

pumps, two black wires should be connected to the

boiler terminals T T. In applications where a boiler

provides the hot water supply, these wires shouId

be connected to the boiler. Terminals T T are

normally open dry contacts.

In applications where a valve is used to regulate

hot water supply, the two black wires located on

the T T terminals should be removed and placed

on the two terminals reading “VALVE”. The open

ends of the wires should be connected to the valve

according to local requirements and instructions of

the valve manufacturer. On call for heat, 24V will

be sent to the field-installed valve or pump relay.

On call for heat water will circulate through the

water (hydronic) coil for 60 secs prior to energizing

the blower. After the thermostat is satisfied, the

blower will continue to stay energized for a

minimum of 30 secs. This helps maximize heating

efficiency.

IO-123090-GFW-020113 - 8 -

The freeze protection sensor is connected to the

FP and R terminals. These are normally open and

will close when the sensor sees 40ºF. The pump

stays ON for a minimum of 30 secs.

The board has a built-in timer which circulates hot

water 6 times a day for 60 secs each time to

prevent the coil from freezing.

Fig.8. Micro-processor control board

Start up

Ensure that motor is pre-loaded with program from

factory.



WARNING

The hot water (hydronic) coil and

all water lines MUST be purged of air prior to

starting the pump. Failure to do so could result in

pump damage. Airmark will not be responsible for

any property or personnel damage caused by

failure to follow this instruction.



WARNING

Hot water flowing to the coil

should be in the range of 120º - 180º F. Water at

these temperatures can cause first-degree burns.

Use of proper safety gear while installing or

servicing the equipment is strongly recommended

as is installation of a water-tempering valve (for

water temperatures of above 140ºF) to supply

lower temperature water to fixtures in the house.

N170L series or equivalent should be used.

Connect the hydronic coil to the water heater

system as shown in Fig 9. Use flexible piping and

insulate all pipes. Plumbing must be in compliance

with state or local codes (Code CMR248 in

Massachusetts). The units for hydronic heat have

different top and heater box configurations. This

configuration is not suitable for electric heat. DO

NOT try to install hydronic heater in a unit not

equipped for it. Verify connections: hot water to “in”

and cold water to “out”. 7/8” ODstubs are provided

for plumbing connections. Bleed the air flow

system through the bleeder port or optional valve.

Purging The System

1) Open air vent and allow water heater to fill with

water. Close air vent when water heater is full

and all air has been purged.

2) Ignite water heater. Set thermostat on water

heater to 140 degrees.

3) Close the valve on the hot water supply from

the water heater ("A") and open the valve on

the cold-water return to the water heater ("B").

Then open the air vent in the fan coil. Use

bucket or hose to discard water during purging

process at air bleed valve. Purge air

completely from line.

4) Once air is purged, close return valve ("B") and

open supply valve ("A"). Purge the coil and

lines of air completely.

5) After air is purged from the system and filled

with water, open the return valve ("B") and the

supply valve ("A"). Then close the air vent in

the fan coil.

6) Apply power to the fan coil and set the room

thermostat on heat. Raise the temperature

setting to activate the circulating pump

IO-123090-GFW-020113 - 9 -

7) Check the pump to ensure proper operation.

The water inlet of the unit should be hot if the

water temperature in the water heater has

reached the set point. If water is not being

circulated through the coil but the pump is

running, then open the air bleed valve in the

unit and purge any air left in the system.

8) Adjust the water heater thermostat so that the

water temperature entering the hot water coils

is 120 – 180ºF depending on the amount of

heat required by the structure. This is done

with the unit energized and operating long

enough for all temperatures to stabalize.

After all connections are made, start-up and check-

up 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 2 below shows the CFM that

should be achieved at various external static

pressures

Fig.9. Schematic of hydronic unit set up

0.10 0.20 0.30 0.40 0.50

Tap 5 900 851 800 742 682

Tap 4 652 630 591 556 530

Tap 3 500 476 452 421 400

Tap 2 900 851 800 742 682

Tap 1 400 381 360 339 312

Tap 5 1150 1087 1030 975 910

Tap 4 1080 1048 1010 960 895

Tap 3 900 862 825 796 745

Tap 2 700 663 632 600 552

Tap 1 500 473 449 421 395

AFW18-24

AFW30-36

SPEED

TAP

MODEL

CFM V. External Static

Pressure

Table 2. CFM delivered at various external statics

GFW18-24

GFW30-36

IO-123090-GFW-020113 - 10 -

Electric 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.



RISETEMP

BTUHOUTPUT

CFM



08.1

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 Maintainance

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

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.

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