®

Installation and Application Manual

for
Aquatherm ®
Combo Heaters

FIRST CO. - P.O. BOX 270969 - DALLAS, TEXAS 75227 - 1Ph. (214) 388-5751 - Fax (214) 388-2255 - www.firstco.com
 Table of Contents
Page
Introduction
3

Sequence of Operation 3

General Description:
Air handler cabinet 3
Heating and cooling coils 3
Add-on hot water coil 3
Circulating pump 3
Flow control module 3
Check valve 3
Air purge valve 4
Blower door safety switch 4
Water heater 4
Boiler 4

Accessories:
Thermostat 4
Freeze protector 4

Equipment Sizing:
Condensing unit 4
Air handler 4
Water heater 5

Installation:
Duct work 5
Electrical 5
Water piping 6
1. Material 6
2. Solder connections 6
3. Insulation 6
4. Length 6
5. Shut-off valves 6
6. Piping connections 6,8-10
Air handler 6
Flow control module 6
Water heater 6
Multiple water heaters 7
Anti-scald valve 7

Start-up Procedure (heating cycle) 7

Troubleshooting 12

2
 The Aquatherm® is a First Co. air handler that
converts a properly sized gas or oil-fired water heater Add - on hot water coil: First Co. HWC series add-on
into a highly efficient, dual - purpose appliance that hot water coils are designed to be installed in either
can heat your home as well as provide hot water for existing or new duct work and operate in conjunction
domestic purposes. with the existing fan motor to provide complete or
supplemental space heating from a gas or oil - fired
Any properly sized water heater (for heating) and water heater. These coils are completely cased and
split system type condensing unit (for cooling) will utilize the separate “flow control module” which can
work with First Co. Aquatherm® air handlers and be installed at the water heater for easy access and
are to be supplied by others. NO SPECIAL WATER service (see “flow control module”).
HEATER IS REQUIRED!
Circulating pump: All circulating pumps circulate
Aquatherm® air handlers are even compatible water at a rate of 3 to 6 gallons per minute and are
with boiler systems. either factory installed or included as part of the field
installed “flow control module”. These pumps are
Aquatherm® air handlers include a fan motor for designed to circulate a precise amount of hot water
air circulation, hot water circulating pump, hot water between the water heater and air handler or add - on
heating coil, air purge valve, check valve, compo- coil.
nents for low voltage control and most include a
cooling coil for air conditioning. All components in the Flow control module: This U.L. Listed device con-
water piping meet NSF61 and/or california AB1953 sists of the circulating pump, check valve, air purge
requirements. valve, 6' plug - in line cord and pump relay. The
module is sold & shipped separately with HWC add
SEQUENCE OF OPERATION - on hot water coils. The module can be field installed
(Heating mode) anywhere in the hot water heating loop between the
water heater and hot water coil and offers the advan-
When space heating is needed, the wall thermostat tage of being able to install the pump assembly in
energizes a small pump which circulates hot water the most appropriate location for service and main-
(135 to 140 degrees ) from the water heater to the hot tenance. Modules must be installed with the motor
water coil in the air handler. As the fan motor forces in a horizontal position. Junction box should not be
the cool return air from the home over the hot water located underneath the pump.
coil, the air absorbs heat from the hot water and this FLOW CONTROL MODULE - WIRING DIAGRAM
warm air (about 105 to 110 degrees) is then circulated
throughout the duct system and into the home.
IMPORTANT. . . . . in most applications the water will
lose only 15 to 25 degrees in temperature while cir-
culating through the hot water coil and will RETURN
to the water heater at about 115 to 125 degrees to
be reheated.

GENERAL DESCRIPTION

Air handler cabinet: Air handlers with cabinets are

made of galvanized steel and fully insulated to reduce
noise and maximize efficiency. Throwaway filters are
factory installed in most air handlers.

Heating and cooling coils: All heating and cooling

coils are made of copper tubes with mechanically
bonded aluminum fins for maximum heat transfer.
Manual air vents are included on all hot water coils.
Cooling coils have either piston - type metering de-
vices or field installed expansion valves. Primary Check valve: A check valve is factory installed in
and secondary condensate drain connections are the hot water loop to eliminate any thermosyphoning
provided on each cooling coil. All primary connections (hot water circulating through the heating coil) while
are 3/4 inch MPT. operating in the cooling mode. The check valve is
installed within the air handler or as part of the “flow

3
control module”. All other air handlers require a 24 volt thermostat
Air purge valve: All air handlers and / or “flow control that energizes the fan motor on a requirement for cool-
modules” include a large manual air purge valve to ing and heating. This is commonly called an "electric
facilitate air removal from the heating loop prior to heat" thermostat. CAUTION . . . . . a gas furnace
system start - up. When the air handler and water thermostat will NOT work with these units because
heater are piped according to First Co. instructions, the fan motor will not come on when the thermostat
the air in the hot water coil and piping will only need calls for heat.
to be removed before initial start - up or after air has Normal heat anticipator setting should be 0.3 to 0.4.
gotten into the system because of a plumbing leak If a set-back thermostat is used, allow extra time for
or break in a water main. This can be accomplished recovery in the morning.
by using the 2 - step process described under “start
-up procedure”. Freeze protector: Kit number 941-1 can be field
installed on any Aquatherm® air handler or add -on
Blower delay relay: FWA-HW,HBXB-HW,HBQB,UC- coil and is highly recommended when the air handler
HW and UCQB series air handlers include a blower or hot water coil is installed in a space that may be
delay relay that allows the circulating pump to operate subjected to freezing temperatures such as in an attic
on a call for heat for 20 to 45 seconds before the fan or crawl space. The sensor attaches to the hot water
motor comes on to deliver warm air quicker when the coil and is wired to R and W in the low voltage circuit.
heating system starts. This relay also keeps the fan If for any reason the temperature of the hot water coil
motor on for 20 to 45 seconds after the thermostat falls below 38 degrees the sensor will bring on the
is satisfied in the heating cycle to maximize the ef- pump to circulate hot water. This will occur even if
ficiency of the heating coil. the thermostat is in the "off" position.

Flue gas safety switch: All "Q" type air handlers, EQUIPMENT SIZING
as well as FWA-xx series air handlers, include a
factory installed flue gas safety switch (except 5 ton Condensing unit: The condensing unit should be
models). When the blower door is removed for any sized to meet the calculated heat gain according to
reason the air handler fan motor will not operate. an approved heat gain formula.
This is especially important when the water heater Air handler: Select an air handler with a heating
is in the same closet as the air handler because BTUH that exceeds the structure's calculated heat
products of combustion from the water heater flue loss and a cooling coil matched to the tonnage size
pipe could be circulated throughout the duct system of the outdoor condensing unit.
if the air handler were allowed to operate without the Special note . . . . . the actual heating output of the
door in place. air handler (BTUH) will not be greater than the heating
output of the water heater (water heater BTUH input
Water Heater: Any properly sized gas or oil - fired multiplied by it's recovery efficiency) regardless of the
water heater will work ( even direct vent or powered listed heating BTUH of the air handler.
vent types ). Electric water heaters are not recom-
mended because of their slow recovery rate. Water
heater warranties are not affected by this system
since no modification of the water heater is necessary.
Selection of higher efficiency water heaters will result
in even greater savings.

Boiler: Most First Co. Aquatherm® air handlers

and add - on hot water coils are also compatible with
boilers and instantaneous water heaters. Please con-
tact the factory for assistance in selecting the proper
equipment for these applications. (See Page 10 for
wiring diagram of multiple air handlers.)

ACCESSORIES Water heater: Add 10 to 20% to the structure's heat

loss to obtain the minimum output of the required
Thermostat: All "Q" type air handlers will operate water heater (output = input x recovery efficiency).
with any standard 24 volt heat / cool or heat pump A minimum 40 gallon high recovery and / or high ef-
thermostat. ficiency gas or oil-fired water heater is recommended.
In addition to the above formula, the following vol-

4
ume sizing guide is satisfactory in most parts of the each component of the system and should also be
country: (minimum requirements) followed in detail.
1.5 and 2 ton air handlers = minimum 40 gallon Duct work: The return air duct must have the same
2.5 and 3 ton air handlers = minimum 50 gallon free area as the opening provided on the air handler.
3.5 and 4 ton air handlers = either two 40 gallon wa- If there is no ducted return, applicable installation
ter heaters piped together, one high input (63,000 to codes may limit the unit to installation only in a single
75,000 BTUH) 50 gallon or one 72 to 75 gallon. story residence.
5.0 ton air handlers = multiple water heaters or boiler
with at least 105,000 BTUH output. Electrical: Units are provided with wiring diagrams
For additional assistance in water heater sizing, and nameplate data to provide information required
contact the factory or a qualified profession engi- for necessary field wiring. Knockouts are provided in
neer. the cabinet for connection of power supply. See “ac-
cessories” for thermostat information. All air handlers
INSTALLATION operate on 115 volt - 1phase - 60 cycle line voltage
and 24 volt control.
The installer must adhere strictly to all local and
national code requirements pertaining to the installa-
tion of this equipment.
Detailed installation instructions are shipped with

5
(See figures 3, 4, 5, 14 and 15 for typical wiring This insures that any air in the water heater will
diagrams.) bypass the heating loop and then be purged each
Water piping: time hot water is used in the dwelling. If this pip-
1. Material: It is recommended that all piping be- ing procedure is not followed the pump may “air
tween the water heater and hot water coil be lock” and fail to pump hot water. Any other piping
3/4 inch nominal (7/8 O.D.) copper except the procedure must address the elimination of air in
60HBQB and 60HBXB-HW is 1" nominal (1-1/8"O. the heating loop. See figures 8 through 9 for ap-
D.). Other material approved for potable hot water proved piping variations. Contact the factory for
systems may also be used if approved by local assistance with alternate piping procedures.
code authorities.
2. Solder connections: All copper joints in the water Air handler: Holes should not be drilled into the air
lines must be made with low temperature, non handler or coil cabinets (except through duct flanges)
lead solder! since damage to the coils could result. Multiple air
3. Insulation: It is recommended that all piping handlers may be installed on one water heater pro-
be adequately insulated to prevent freezing and vided the water heater and piping are sized properly.
“freeze protector” ( see “accessories” ) be installed Piping should be similar to that required for individual
on the hot water coil to prevent freezing when air handler.
piping is run in a space subjected to freezing
temperatures. Flow control module (if required): The flow control
4. Length: Piping should not exceed 200 total feet of module can be installed anywhere in the hot water
length. Air handlers should not be installed more loop to or from the air handler (between the water
than 40 feet above the water heater. heater and air handler). Modules must be installed
5. Shut - off valves: In addition to the main cold with the motor in a horizontal position. Junction box
water valve supplying the water heater, it is rec- should not be installed underneath the pump. Water
ommended that one shut - off valve be installed should flow from the outlet (hot) side of the water
on the hot water supply line to the air handler and heater to the air handler and then back to the supply
one on the return line from the air handler (or hot (cold ) side of the water heater. Arrow on bottom of
water coil). These valves will facilitate air purging pump indicates the direction of flow when pump is
during start - up ( see “start - up” ) and allow unit energized. The module is furnished with a 6 foot cord
isolation for repair. and plug for convenient connection to a wall outlet.
6. Piping connections: On all cased type air han- For those areas where local codes require “hard”
dlers the water inlet or “supply” connection to the wiring, discard the cord assembly and wire directly to
hot water coil is the one on the right as you face the connections within the 4 x 4 box using acceptable
the the air handler and will be marked accordingly. wiring materials.
Air handlers with internally installed circulating
pumps will not circulate water if piped back- Water heater: Water heaters should be installed ac-
wards. Water lines to and from the air handler cording to the manufacturer’s installation instructions.
must be connected to the horizontal connection If a “back flow preventer” is required by code,
of the “T” fittings in the vertical hot and cold water the T & P valve on the water heater may tend to
supply lines at the water heater. (See figure 6). drip water because of pressure build-up in the water

6
heater. This problem is a direct result of the back 4. Purge the air handler’s hot water coil and lines: The
flow preventer . . . . . not the heating system. An following procedure allows the use of city water
expansion tank may need to be installed to solve this pressure to purge the air handler hot water coil and
problem. Most water heaters are now labeled with lines even when the air handler is located higher
this information. than the water heater. Once the air is completely
Multiple water heaters: When sizing requirements removed upon start - up, the circulating pump
call for more than one water heater per air handler, will circulate the required amount of hot water
water heaters may be connected together according through the heating loop.
to the water heater manufacturer’s instructions. (See Note: It may require purging several gallons of water
figure 10 page 9) so either have a bucket available or connect a gar-
den hose to the purge valve and route to a drain.
Anti-scald valve: A water heater is designed to Close valve number 2 and open valve number 3
produce hot water. Hot water represents a serious (See figure 7). Next , open the air purge valve
safety hazard due to the potential of scalding. The located either on the flow control module or inside
temperature of water normally required to provide the air handler. When all the air is purged, close
space heating (135 to 140 degrees) may be hotter valve number 3 and open valve number 2. When
than certain codes allow for domestic hot water. An all the air is purged, open both valves and close
“anti-scald valve” can be installed in the hot water the air purge valve.
piping that would allow the domestic water to be sup- 5. On Grundfos pumps, vent the air from the pump
plied at a lower temperature than the space heating chamber by loosening the large screw plug on
water. These can be obtained locally and should be top of the pump motor until water appears. Then
installed according to the manufacturer’s installation retighten the plug.
instructions. (See figure 12) 6. Switch the room thermostat to “heat” and set it high
enough to energize the fan motor and pump. It
START - UP PROCEDURE may be necessary to “feel” the pump to determine
(Heating cycle) if it is operating. If the pump is operating properly
and the water temperature in the water heater has
1. Open the main shut - off valve to the water heater reached the set point, the hot water line going into
and the two shut - off valves to and from the air the air handler will begin to get hot. If the pump
handler or hot water coil. is running but hot water is not circulating, refer to
2. Fill the water heater. Open a hot water faucet "troubleshooting”.
somewhere in the house while filling the water 7. Adjust the water heater thermostat so that the water
heater in order to vent the air. When the tank is entering the hot water coil is 135 to 140 degrees
full and all the air is purged, close the faucet. with the system energized and operating long
3. Ignite the water heater according to the manu- enough for all temperatures to stabilize.
facturer’s instructions and allow it to come up to
temperature (about 45 minutes). DO NOT IGNITE
THE WATER HEATER WITHOUT WATER IN
THE TANK!

7
 Conventional Piping Diagram

FIGURE 8

Side Tap (4 Pipe) Water Heater Piping

FIGURE 9

8
 FIGURE 10

9
Zone Valves Install a motorized valve with each air handler to control flow to that zone as
required.

FIGURE 11

TYPICAL WIRING SCHEMATIC

FOR MULTIPLE ZONE CONNECTIONS
WITH ZONE VALVES

24 VOLT 24 VOLT
4 CONDUCTOR
CLASS 2 WIRING CLASS 2 WIRING
CLASS 2 WIRING

T T
G G G G
T T
HBXB-HW HBXB-HW
W W FAN COIL FAN COIL W W

R 24V 24V R R
R
24V 24V
Y C C Y
BRN BRN
24V REMOTE 24V REMOTE
THERMOSTAT PIGTAIL LEADS FOR T T PIGTAIL LEADS FOR THERMOSTAT
MOTORIZED VALVE MOTORIZED VALVE

NOTE: CAP OFF BOILER NOTE: CAP OFF

CONDENSER BROWN IF NO BROWN IF NO CONDENSER
MV MV
CONTACTOR CONDENSING UNIT CONDENSING UNIT CONTACTOR
IS USED IS USED
24V MOTORIZED 24V MOTORIZED
ZONE VALVE ZONE VALVE

TYPICAL WIRING SCHEMATIC

FOR MULTIPLE ZONE CONNECTIONS TO
TACO SR-504/506 SWITCHING RELAY

24 VOLT 24 VOLT
CLASS 2 WIRING CLASS 2 WIRING
CLASS 2 WIRING

T T
G G G G
T T
HBXB-HW HBXB-HW
W W FAN COIL FAN COIL W W

24V 24V
R R R R
24V 24V
Y C C Y
BRN BRN
24V REMOTE 24V REMOTE
TACO
THERMOSTAT SR 504
ZONE 1 ZONE 2 ZONE 3 ZONE 4 THERMOSTAT

SWITCHING
RELAY XX
NOTE: CAP OFF NOTE: CAP OFF
CONDENSER BROWN IF NO BROWN IF NO CONDENSER
CONDENSING UNIT 120V CIRCULATOR CONDENSING UNIT
CONTACTOR CONNECTIONS CONTACTOR
IS USED IS USED
T
BOILER
T

10
 3. Water heater thermostat not turned up high
TROUBLESHOOTING enough.
(Most likely problems and cause) 4. Water heater thermostat not calibrated properly.
5. Restricted or improperly installed dip tube in water
Important: For system to operate properly power heater.
should be turned ON and all shut - off valves should 6. Restriction somewhere in heating loop. Confirm
be OPEN. that no other check valves or devices have been
installed in the heating loop except as supplied by
Pump does not run: These pumps may sometimes First Co.
“stick” due to non - use and fail to start. Before replacing Note: Some water heaters come with a normally
pump: closed spring-loaded check valve factory installed
1. Turn off power. On Grundfos pumps remove large on one of the space heating connections. Since
screw plug in end of pump motor and turn shaft sev- the circulating pump in the Aquatherm® system
eral times with a small screwdriver. Replace plug and may not be able to open this valve in addition to
start system. Pump should start. the Aquatherm® check valve, this valve should
2. If pump has to be replaced, first shut off all isolation be removed before installation.
valves between the water heater and air handler 7. Air handler or hot water coil not large enough.
and relieve the city water pressure by opening the 8. Water heater not large enough.
air purge valve. Then remove the four screws that
attach the pump motor to the pump volute rather than Hot water circulates through hot water coil during
un-soldering the entire pump assembly. cooling cycle:
1. Check valve may be stuck open allowing "thermo-
Fan motor runs on cooling but not on heating: syphoning" (circulation) of hot water. This occurs
Thermostat is wrong type (a gas furnace type ther- when the hot water pipes are not capped-off dur-
mostat will not bring on the fan motor in the heating ing installation, allowing foreign debris such as
cycle on certain air handlers). For correct type of solder, insulation, and other building materials to
thermostat, see “accessories”. enter the piping. If not completely purged from the
Note: FWA-HW air handler has a blower delay. system, this "debris" can lodge under the check
valve seat and allow hot water to flow through the
Pump is noisy: hot water coil even in the summer. To solve this
Air may still be in the heating loop. Re-purge the problem, flush the heating loop several times as
system as described under “start - up procedure". indicated in the "start-up procedure" on Page 7.

Water heater T & P valve “weeping”: note: Check valve in models made after year 1999
This situation usually occurs in those systems located are located in the pump itself.
in areas where local codes require the installation of
a “backflow preventer” in the cold water supply line
CONCLUSION
to the water heater. This situation is caused by the
expansion of the water when heated. An expansion
Always leave the appropriate literature and / or
tank may be required to solve this problem. Contact
manual with the homeowner and whenever possible
local plumbing authorities for assistance.
take the time to explain the operation and advantages
Insufficient or no heat:
of the system.
1. Air still in heating loop. Re-purge system.

2. Inlet and oulet piping connections at the air handler
may be piped backwards. (See "Piping connec-
tions").

All technical specifications subject

to change without notice.

11
Catalog No. IAM1010 (Replaces IAM309)

12