Coleman Single Piece Air Handlers FFP User Manual
INSTALLATION MANUAL
SINGLE PIECE
AIR HANDLERS
MODELS: F*FP
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPECIFIC SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . 2
SAFETY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HORIZONTAL DRAIN PAN CONVERSION . . . . . . . . . . . . . . . . . . . .3
DUCT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SUSPENSION KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LIST OF FIGURES
Plenum Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Filter Access & Drain Pan Conversion / Coil Baffle . . . . . . . . . . . . . . . 4
Dimensions & Duct Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Typical Horizontal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TXV Bulb Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ISO 9001
Certified Quality
Management System
COIL METERING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
REFRIGERANT LINE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . .6
ELECTRIC HEATERS & OPERATING CONTROLS . . . . . . . . . . . . . .6
LOW VOLTAGE CONTROL CONNECTION . . . . . . . . . . . . . . . . . . . .8
LINE POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
BLOWER SPEED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .8
DRAIN CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
CONDENSATE DRAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Electric Heaters in Horizontal Configuration - Right Hand Air Flow . . .6
Line Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Blower Speed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Cooling Models with Electric Heat Wiring . . . . . . . . . . . . . . . . . . . . . .14
Single Stage Heat Pump Control Wiring . . . . . . . . . . . . . . . . . . . . . . .14
LIST OF TABLES
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installed TXV Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Physical and Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Data - Cooling Only (50 & 60 Hz) . . . . . . . . . . . . . . . . . . . . . 9
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Data - 1 Ø - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Data - (For Single Source Power Supply) -
Copper Wire 1 Ø - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or mo derate injury.
alert against unsafe practices and hazards involving only property damage.
.
.
It is also used to
Electrical Data - (For Multi-Source Power Supply) -
Copper Wire 1 Ø - 208/230-1-601 . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Electrical Data - 3 Ø - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . .12
Electrical Data - (For Single Source Power Supply) -
Copper Wire 3 Ø - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Airflow Data for 230 Volt - Heat Pump Models . . . . . . . . . . . . . . . . . .13
Airflow Data for 208 Volt - Heat Pump Models . . . . . . . . . . . . . . . . . .14
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified contractor, installer or service agency.
This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
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SPECIFIC SAFETY RULES AND PRECAUTIONS
FIRE OR ELECTRICAL HAZARD
Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
A fire or electrical hazard may result causing property damage, per-
sonal injury or loss of life.
1. Install this air handler only in a location and position as specified in
SECTION I of these instructions.
2. Always install the air handler to operate within the air handler’s
intended maximum outlet air temperature. Only connect the air
handler to a duct system which has an external static pressure
within the allowable range, as specified on the air handler rating
plate.
3. When an air handler is installed so that supply ducts carry air circulated by the air handler to areas outside the space containing
the air handler, the return air shall also be handled by duct(s)
sealed to the air handler casing and terminating outside the space
containing the air handler.
4. The air handler is not to be used for temporary heating of buildings
or structures under construction.
5. The size of the unit should be based on an acceptable heat loss
calculation for the structure. ACCA, Manual J or other approved
methods may be used.
SAFETY REQUIREMENTS
• This air handler should be installed in accordance with all national
and local building/safety codes and requirements, local plumbing
or wastewater codes, and other applicable codes.
• Refer to the unit rating plate for the air handler model number,
and then see the dimensions page of this instruction for supply air
plenum dimensions in Figure 1. The plenum must be installed
according to the instructions.
• Provide clearances from combustible materials as listed under
Clearances to Combustibles.
• Provide clearances for servicing ensuring that service access is
allowed for both the burners and blower.
• Failure to carefully read and follow all instructions in this
manual can result in air handler malfunction, death, personal
injury and/or property damage.
• Check the rating plate and power supply to be sure that the electrical characteristics match.
• Air handler shall be installed so the electrical components are
protected from water.
• Installing and servicing heating equipment can be hazardous due
to the electrical components. Only trained and qualified personnel
should install, repair, or service heating equipment. Untrained
service personnel can perform basic maintenance functions such
as cleaning and replacing the air filters. When working on heating
equipment, observe precautions in the manuals and on the labels
attached to the unit and other safety precautions that may apply.
• These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances
these instructions exceed certain local codes and ordinances,
especially those who have not kept up with changing residential
and non-HUD modular home construction practices. These
instructions are required as a minimum for a safe installation.
GENERAL INFORMATION
This Single Piece Air Handler provides the flexibility for installation in
any upflow or horizontal application. These versatile models may be
used for cooling or heat pump operation with or without electric heat.
BRAND LABEL (available from Distribution) apply to center of the
blower access panel.
The unit can be positioned for bottom return air in the upflow position,
and right or left return in the horizontal position.
Top and side power wiring and control wiring, accessible screw terminals for control wiring, easy to install drain connections and electric
heaters all combine to make the installation easy, and minimize installation cost.
INSPECTION
As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage
should be noted on the carrier’s freight bill. A separate request for
inspection by the carrier’s agent should be made in writing. Also, before
installation the unit should be checked for screws or bolts, which may
have loosened in transit. There are no shipping or spacer brackets
which need to be removed.
Also check to be sure all accessories such as heater kits, suspension
kits, and coils are available. Installation of these accessories or field
conversion of the unit should be accomplished before setting the unit in
place or connecting any wiring, electric heat, ducts or piping.
LIMITATIONS
These units must be wired and installed in accordance with all national
and local safety codes.
Voltage limits are as follows:
1
Air Handler Voltage Voltage code
208/230-1-60 06 187-253
1. Rated in accordance with ARI Standard 110, utilization range “A”.
Airflow must be within the minimum and maximum limits approved for
electric heat, evaporator coils and outdoor units.
Entering Air Temperature Limits
Wet Bulb Temp.°F Dry Bulb Temp. °F
Min. Max. Min. Max.
57 72 65 95
Normal Operating
Voltage Range
CLEARANCES
Clearance must be provided for:
1. Refrigerant piping and connections - minimum 12” recommended.
2. Maintenance and servicing access - minimum 36” from front of unit
recommended for blower motor / coil replacement.
3. Condensate drain line.
4. Filter removal - minimum 36” recommended.
LOCATION
Location is usually predetermined. Check with owner’s or dealer’s
installation plans. If location has not been decided, consider the following in choosing a suitable location:
1. Select a location with adequate structural support, space for service access, clearance for air return and supply duct connections.
2. Use hanging brackets to wall mount unit as shown under suspension kits section.
3. Normal operating sound levels may be objectionable if the air handler is placed directly over some rooms such as bedrooms, study,
etc.
4. Precautions should be taken to locate the unit and ductwork so
that supply air does not short circuit to the return air.
5. Select a location that will permit installation of condensate line to
an open drain.
NOTE: When the coil is installed in a draw-thru application, it is recommended to trap the primary and secondary drain line. If the secondary
drain line is not used, it must be capped.
The coil is provided with a secondary drain. It should be piped to a location that will give the occupant a visual warning that the primary drain is
clogged. If the secondary drain is not used it must be capped.
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6. When an evaporator coil is installed in an attic or above a finished
ceiling, an auxiliary drain pan should be provided under the coil as
is specified by most local building codes.
7. Proper electrical supply must be available.
8. Clearances must also be taken into consideration, and provided
for as follows:
A. Refrigerant piping and connections are located in the front.
B. Maintenance and servicing through the front or access side
of unit with both sides and rear of unit having zero inch clearance.
C. Condensate drain lines are connected in the front (clear of fil-
ter).
D. Filter removal.
E. When no electric heat is used, the unit as well as all duct
work and plenum are designed for zero clearance to combus-
tible materials.
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If electric heat is used, a minimum clearance of 1” must be maintained on all sides of the supply air duct and/or plenum continuously
for up to 3’ (See Figure 1).
MINIMUM CLEARANCE
OF 1” ALL SIDES
POWER WIRING
TO MAIN
POWER SOURCE
REFRIGERANT
LINES
TO
CONDENSATE
DRAIN
SUPPLY
AIR
ELECTRIC HOT WATER HEATER
(Must comply with water heater installation instructions)
FIGURE 2: Typical Installation
HORIZONTAL DRAIN PAN CONVERSION
These air handler units are supplied ready to be installed in a right hand
horizontal position. If unit requires left hand positioning, the unit must
have the pan installed in the correct position.
1. Remove blower access, coil access, and center access panels.
NOTE: Conversion must be made before brazing the refrigerant con-
nections to the coil.
2. See Figure 3, remove two screws from horizontal drain pan, to
remove pan from position “3A” if factory installed.
3. Position horizontal pan, as required in either “A” or “B” position,
locking it into the vertical drain pan as shown.
4. Horizontal drain pans have 4 plugged drains. Remove plugs from
connections being used.
NOTE: If this step is overlooked, it can lead to a water problem later.
5. Use removed plug to plug primary of upflow drain pan.
6. Attach horizontal pan with 2 screws removed in step no. 2 or supplied with the unit. Ensure that the drain pan is lying flat against the
insulation of the cabinet.
7. Horizontal drain cutout in the center access panel should be
removed by using a utility knife (if not previously cut out).
8. Re-position and replace access panels.
FLEXIBLE
DUCT COLLAR
3’
FIGURE 1: Plenum Clearances
POWER WIRING
CONTROL
WIRING
THERMOSTAT
FILTER
ACCESS
LOUVERED
DO NOT TRY TO KNOCK OUT PANEL OPENING FOR SECONDARY DRAIN PAN. SEE ITEM 7.
Models F*FP045,048,060 have a coil baffle and support bracket
factory installed for right hand horizontal application (refer to Figure
3C). For left hand applications the coil support bracket must be
moved to the right side of the coil, and the coil baffle must be
rotated to avoid water blow-off.
To rotate baffle, remove the coil assembly from the unit (remove
front two screws holding the coil support bracket and the two
screws holding the drain pan). Remove four screws in coil baffle
and remove the coil baffle and rotate ends.
Resecure the baffle and reinstall the coil assembly ensuring that
the rear of the drain pan is secured under the back flange of the
unit. Reinstall the coil support bracket on the right side of the coil.
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BLOWER
COMPARTMENT
(ACCESS PANEL
REMOVED)
PRIMARY
DRAIN
SECONDARY
DRAIN
HORIZONTAL
DRAIN PAN
POSITION "B”
VERTICAL
DRAIN PAN
SECONDARY
DRAIN UPFLOW
3/4" THREADED
DUCT WORK MAY BE FASTENED
CAUTIOUSLY WITH SCREWS TO
THE SIDES AND REAR OF UNIT
4A - FRONT VIEW
BLOWER
HOUSING
FILTER
PRIMARY DRAIN UPFLOW
3/4” THREADED
FIGURE 3: Filter Access & Drain Pan Conversion / Coil Baffle
SHIPPING BRACKET*
REMOVE PRIOR TO
INSTALLATION (2 SCREWS)
10-3/8
J
DRAIN CONNECTIONS
FOR HORIZONTAL
APPLICATIONS
PRIMARY
DRAIN
3/4" PVC SOCKETS
FOR HORIZONTAL
DRAIN APPLICATION
SECONDARY
DRAIN
CENTER ACCESS PANEL
COIL COMPARTMENT
(ACCESS PANEL REMOVED)
HORIZONTAL
DRAIN PAN
POSITION "A”
"S" BRACKET MUST BE USED TO
FASTEN DUCT WORK TO FRONT OF UNIT
ALL DIMENSIONS ARE IN INCHES. THEY ARE SUBJECT TO CHANGE
WITHOUT NOTICE. CERTIFIED DIMENSIONS WILL BE PROVIDED
F
K
UPON REQUEST.
SUPPORT
BRACKET
060 COIL BAFFLE
(SHOWN IN
RIGHT-HORIZONTAL
POSITION)
4C - FRONT VIEW
4B - SIDE VIEW
FILTER
RETURN AIR DUCT
3/4
TOP VIEW (ALL MODELS)
F
7-1/2
4-1/8
10-3/8
VAPOR
OPENING
LIQUID
OPENING
2
DRAIN CONNECTIONS
FOR UPFLOW APPLICATIONS
FIGURE 4: Dimensions & Duct Sizes
TABLE 1:
Dimensions
MODELS F*FP
ABC
Height Width Depth Power Control Liquid Vapor
024 40-3/4 18
030 40-3/4 18 14-7/8 16-1/2 3/4
036 40-3/4 21-1/2 18-3/8 20 3/4
040 40-3/4 21-1/2 18-3/8 20 7/8
042 40-3/4 21-1/2 18-3/8 20 7/8
045 50-3/4 24
048 50-3/4 24 20-7/8 22-1/2 7/8
060 50-3/4 24 20-7/8 22-1/2 7/8
A
4
D
C
B
FILTER
ACCESS
=DRAIN PAN FOOTPRINT
MAX. FILTER LENGTH
(21 INCHES)
MAX. FILTER WIDTH
(B MINUS 1-1/2 INCHES)
3/4
REAR
18-3/8
E
BOTTOM VIEW
3/4
Dimensions Wiring K.O.’s* Refrigerant
Connections
Line Size
5/8
7/8
22
DEF
14-7/8 16-1/2
12-1/8
20-7/8 22-1/2
17-3/8
JK
7/8 (1/2)
1-3/8 (1)
7/8 (1/2) 3/8
7/8 (1/2)
1-3/8 (1),
1-23/32 (1-1/4)
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292043-UIM-B-0707
DUCT CONNECTIONS
Use 1/2" screws to connect ductwork to bottom of unit. Longer
screws will pierce the drain pan and cause leakage. If pilot holes
are drilled, drill only though field duct and unit bottom flange.
NOTE: The electric heat accessory should be installed before the supply air duct is attached to the supply air openings. Refer to the electric
heater kit instructions for proper installation.
Air supply and return may be handled in one of several ways best
suited to the installation. See Figure 4 for dimensions for duct inlet and
outlet connections.
The vast majority of problems encountered with combination heating
and cooling systems can be linked to improperly designed or installed
duct systems. It is therefore highly important to the success of an installation that the duct system be properly designed and installed.
Use flexible duct collars to minimize the transmission of vibration/noise
into the conditioned space. If electric heat is used, non-flammable
material must be used.
Where return air duct is short, or where sound may be a problem,
sound absorbing glass fiber should be used inside the duct. Insulation
of duct work is a must where it runs through an unheated space during
the heating season or through an uncooled space during the cooling
season. The use of a vapor barrier is recommended to prevent absorption of moisture from the surrounding air into the insulation.
The supply air duct should be properly sized by use of a transition to
match unit opening. All ducts should be suspended using flexible hangers and never fastened directly to the structure. This unit is not
designed for non-ducted (freeblow) applications. Size outlet plenum or
transition to discharge opening sizes shown in Figure 4.
Duct work should be fabricated and installed in accordance with local
and/or national codes. This includes the standards of the National Fire
Protection Association for Installation of Air-Conditioning and Ventilating Systems, NFPA No. 90B.
A suspension kit is available. Models 1BH0601 (unit sizes 018-060) is
designed specifically for the units contained in this instruction (upflow
application only). For installation of these accessory kits, see the
instructions packed with the kit.
For suspension of these units in horizontal applications, it is recommended to use angle steel support brackets with threaded rods, supporting the units from the bottom, at the locations shown in Figure 5.
COIL METERING DEVICES
The coil in this Air Handler unit will have a TXV metering device
installed at the factory.
The model number will have the following format:
F*FPxxxH06T2y - The coil will have a Thermal Expansion Valve (TXV)
installed. The y character specifies which TXV is installed at the factory.
Please refer to the TXV Metering Device section for installation notes.
.
TABLE 2:
TXV Metering Device
Installed TXV Sizes
Indoor Coil Model Metering Device
F4FP024H06T2A TXV 2A
F4FP024H06T2B TXV 2B
F4FP030H06T2A TXV 2A
F4FP036H06T2A TXV 2A
F4FP040H06T2A TXV 2A
F4FP040H06T2C TXV 2C
F4FP042H06T2A TXV 2A
F4FP042H06T2C TXV 2C
F4FP045H06T2C TXV 2C
F5FP048H06T2C TXV 2C
F5FP060H06T2C TXV 2C
EXPANSION
INSULATION
ROLL
BULB TUBING
AIR FILTERS
Air filters must be field supplied. A 1" filter access rack has been built
into the unit. See Figure 4. Remove filter access cover shown. Install
proper size filter. Standard 1" size permanent or throw away filter may
be used, or, permanent washable filters are available using model numbers: 1PF0601, 602, 603BK. See Table 3 for filter size.
Equipment should never be operated without filters.
SUSPENSION KITS
SUSPENSION SUPPORT LOCATIONS FOR HORIZONTAL APPLICATIONS*
2
WW
NOTE: USE SUPPORTS UNDER UNIT.
XX
Units
(Nominal Tons)
WW XX
018, 024, 030, 036, 040, 042 14” 40-3/4”
045, 048, 060 19-1/2” 50-3/4”
FIGURE 5: Typical Horizontal Installation
1-1/2
Dimension
EXPANSION
BULB
EXPANSION
BULB CLAMP
FIGURE 6: TXV Bulb Installation
Please refer to Table 2 to verify which TXV is installed in this Air Handler unit and that this AHU is a valid system match for the AC or HP unit
installed.
The TXV is bolted into the coil assembly of this Air Handler unit at the
factory. The temperature sensing bulb will need to be attached to the
coil suction header line after the line set is brazed to the coil.
• Make sure the TXV bulb is outside of the Air Handler cabinet.
Excess tubing should remain inside the cabinet.
• Take caution not to apply high temperatures to the TXV assembly
or equalizer line while brazing.
• Attach field line sets and braze to coil connections. Replace
access panels & secure.
• Secure the TXV bulb to the suction line with the clamp provided.
Choose a horizontal location as close to the cabinet as possible,
but not directly on the brazed connection joint. Refer to Figure 7.
• The bulb should be in direct contact with the coil suction line
along the length of the bulb.
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