Johnson Controls AVC Installation Manual
INSTALLATION MANUAL
VARIABLE SPEED ECM
SINGLE PIECE MULTI-POSITION
AIR HANDLERS
MODELS: A VC SERIES
LIST OF SECTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DUCT WORK AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . .8
COIL METERING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
REFRIGERANT LINE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . .11
CONDENSATE DRAIN CONNECTIONS . . . . . . . . . . . . . . . . . . . . .12
ELECTRIC HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .13
LINE POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
LIST OF FIGURES
Return Air Duct Attachment & Component Location . . . . . . . . . . . . . .2
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Dimensions & Duct Connection Dimensions . . . . . . . . . . . . . . . . . . . .3
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Horizontal Pan Adjustment Strap Hole Reference . . . . . . . . . . . . . . . .5
Coil Condensate Deflector Installation . . . . . . . . . . . . . . . . . . . . . . . . .6
Recommended Position of Coil to Install Downflow/Horizontal Right
Condensate Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation of Downflow Condensate Diverter Shields . . . . . . . . . . . . .7
60C Horizontal Right Condensate Deflectors . . . . . . . . . . . . . . . . . . .7
60C Horizontal Right Coil Condensate Final Assembly . . . . . . . . . . . .7
Condensate Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Horizontal Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Duct Work Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Recommended Distributor Adjustment . . . . . . . . . . . . . . . . . . . . . . .10
Piston Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
LOW VOLTAGE CONTROL CONNECTIONS . . . . . . . . . . . . . . . . . 13
REQUIRED CONTROL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AIRFLOW AND COMFORT SETTING SELECTION . . . . . . . . . . . . 17
UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
AIR SYSTEM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TXV Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TXV Bulb and Equalizer line Installations . . . . . . . . . . . . . . . . . . . . . 11
Proper Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Vertical Temperature Bulb Orientation . . . . . . . . . . . . . . . . . . . . . . . 11
Vapor Line Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Line Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cooling Models with and without Electric Heat Wiring . . . . . . . . . . . 15
Two-Stage Heat Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air Handler with Communicating AC or HP . . . . . . . . . . . . . . . . . . . 16
Multi-wire Terminal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Duct Static Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drain Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Location of Coil Trapped and Plugged Drain Connections . . . . . . . . 26
Wiring Diagram - ECM - Single Phase Heat Kits . . . . . . . . . . . . . . . 27
Wiring Diagram - Three Phase Heat Kits 208-230V . . . . . . . . . . . . . 28
ISO 9001
Certified Quality
Management System
LIST OF TABLES
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Horizontal Pan Strap Settings for Horizontal Left . . . . . . . . . . . . . . . . .5
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Heat Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Comfort Setting Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Physical and Electrical Data - Cooling Only . . . . . . . . . . . . . . . . . . . .18
Electrical Data - Cooling Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
SECTION I: GENERAL
The single piece air handler series provides the flexibility for installation
in any position. This unit may be used for upflow, downflow, horizontal
right, or horizontal left applications.
These units may be located in a closet, utility room, attic, crawl space,
or basement. These versatile models may be used for cooling or heat
pump operation with or without electric heat.
Top or side power and control wiring, color coded leads for control
wiring, easy to install drain connections, and electric heaters all
combine to make the installation easy and minimize installation cost.
Electric heat kits are available as field installed accessories. Single
phase kits are available from 2.5 kW to 25 kW. 208-230 volt three
phase kits are available from 10kW to 25kW.
Electrical Heat: Minimum Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . 18
KW & MBH Conversions - For Total Power Input Requirement . . . . 19
Electric Heat Performance Data: 208/230-1-60 & 208/230-3-60 . . . 19
Electrical Data For Single Source Power Supply: 208/230-1-60 . . . 20
Electrical Data For Multi-source Power Supply: 208/230-1-60 . . . . . 22
Electrical Data For Single Source Power Supply: 208/230-3-60 . . . 23
Electrical Data For Multi-source Power Supply: 208/230-3-60 . . . . . 24
Air Flow Data (CFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION II: 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 moderate injury. It is also used to
alert against unsafe practices and hazards involving only property
damage.
Johnson Controls Ducted Systems 5493974-UIM-B-0419
5493974-UIM-B-0419
!
WARNING
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, personal injury or loss of life.
!
WARNING
The air handler area must not be used as a broom closet or for any other
storage purposes, as a fire hazard may be created. Never store items
such as the following on, near or in contact with the furnace.
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners or other cleaning tools.
2. Soap powders, bleaches, waxes or other Cleaning compounds;
plastic items or containers; gasoline, kerosene, cigarette lighter
fluid, dry cleaning fluids or other volatile fluid.
3. Paint thinners and other painting compounds.
4. Paper bags, boxes or other paper products
Never operate the air handler with the blower door removed. To do so
could result in serious personal injury and/or equipment damage.
!
WARNING
Improper installation, adjustment, alteration, or maintenance may create a condition where the operation of the product could cause personal injury or property damage. Refer to this manual for assistance,
or for additional information, consult a qualified contractor, installer, or
service agency.
!
CAUTION
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.
SAFETY REQUIREMENTS
1. Failure to carefully read and follow all instructions in this manual
can result in air handler malfunction, death, personal injury and/or
property damage.
2. 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.
3. This air handler should be installed only in a location and position
specified in the “Unit Installation” section of this Instruction Manual.
4. The air handler is not to be used for temporary heating of buildings
or structures under construction.
5. Always install the air handler to operate within the air handler’s
intended maximum outlet air temperature.
6. The unit rating plate displays the air handler model number. The
unit dimensions for the supply air plenum are provided in Figure 3
and Table 1 of this Instruction Manual. The plenum must be
installed according to the instructions.
7. Clearance from combustible material is provided under “Clearances” in the “Unit Installation” section.
!
CAUTION
DO NOT lift air handler by the cabinet braces. The cabinet braces are
held in place by the coil channels. The cabinet braces could become
disengaged from the cabinet causing the air handler to fall, potentially
causing injury or damaging property. See Figure 1 for location of cabinet braces. Lift the air handler by tightly gripping the casing.
8. It is necessary to maintain clearances for servicing. Access must be
allowed for electric heaters and blower.
9. The unit rating plate and power supply must be verified to ensure
that the electrical characteristics match.
10. Air handler shall be installed so the electrical components are pro-
tected from water.
11. Installing and servicing heating/cooling equipment can be hazard-
ous due to the electrical components. Only trained and licensed
personnel should install, repair, or service heating/cooling equipment. Unlicensed service personnel can perform basic maintenance functions such as cleaning and replacing the air filters. When
working on heating/cooling equipment, the precautions in the manuals and on the labels attached to the unit and other safety precautions must be observed as applicable.
!
CAUTION
These air handlers should be transported & handled in an upright,
upflow position. Failure to do so may result in unit damage and personal injury. Configuration conversions should be done at site of
installation.
12. 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.
HORIZONTAL
DRAIN PAN
VAP OR
REFRIGERANT
LINE CONNECTION
LIQUID
REFRIGERANT
LINE CONNECTION
SECONDARY DRAIN
HORIZONTAL FLOW
3/4” NATIONAL PIPE
THREAD (NPT)
PRIMARY DRAIN
3/4” NPT
DUCTWORK MAY
BE FASTENED
CAUTIOUSLY WITH
SCREWS TO THE
SIDES AND REAR OF UNIT
FIGURE 1: Return Air Duct Attachment & Component Location
FRONT VIEW
SECONDARY DRAIN
UPFLOW 3/4” NPT
BLOWER
COMPAR TMENT
COIL COMPART MENT
(Access panel removed)
CABINET BRACE
VERTICAL
DRAIN PAN
CABINET BRACE
FILTER DOOR
WHEN ATTACHING DUCTWORK WITH
SCREWS - KEEP SCREWS WITHIN 5/8”
OF SIDES AND BACK OF AIR HANDLER
SIDE VIEW
RETURN AIR
DUCT
A0328-001
2 Johnson Controls Ducted Systems
INSPECTION
As soon as a coil is received, it should be checked to insure it is still
under pressure per Figure 2. The coil 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. The Local
Distributor should be consulted for more information. The drain pan
should be checked for cracks or breakage. Before installation, the unit
should be checked for screws or bolts which may have loosened in
transit. There are no internal shipping or spacer brackets that need to
be removed.
It should be verified that all accessories such as heater kits 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, duct work or piping.
DEPRESS SCHRADER
CORE TO CHECK FOR
PRESSURE ONE TIME.
NOTE:
Verify that the coil is under
pressure when received.
FIGURE 2: Pressure Check
5493974-UIM-B-0419
A0271-001
F
BLOWER
COMPAR TMENT
COIL
COMPAR TMENT
7-11/32
1-1/2”
FILTER ACCESS
C
G
B
20-1/2”
21-7/16”
FIGURE 3: Dimensions & Duct Connection Dimensions
TABLE 1: Dimensions
Dimensions
Models
AB
Height Width Power Control Liquid Vapor
18B 41 17-1/2 12-7/8 14-1/4 16-1/2
24B 41 17-1/2 12-7/8 14-1/4 16-1/2
30B 47-1/2 17-1/2 19-1/2 14-1/4 16-1/2
36B 47-1/2 17-1/2 19-1/2 14-1/4 16-1/2
36C 51-1/2 21 22-5/8 17-3/4 20
42C 51-1/2 21 22-5/8 17-3/4 20
48C 51-1/2 21 22-5/8 17-3/4 20
48D 55-1/2 24-1/2 26-5/8 21-1/4 23-1/2
49C 51-3/4 21 26-5/8 17-3/4 20
60C 55-3/4 21 26-7/8 17-3/4 20
60D 55-1/2 24-1/2 26-5/8 21-1/4 23-1/2
1. All dimensions are in inches.
2. Actual size (Conduit size in parenthesis).
REFRIGERANT CONNECTIONS
DRAIN CONNECTIONS
FOR UPFLOW APPLICATIONS
A
1
SERVICE
DISCONNECT
PANEL
CDE
1-23/32 (1-1/4)
12-3/16”
18-5/8”
Wiring Knockouts
D
2
FG
7/8 (1/2)
1-3/8 (1)
7/8 (1/2) 3/8
TOP OUTLET
DIMENSIONS
E
BOTTOM INLET
DIMENSIONS
A0329-001
Refrigerant
Connections
Line Size
3/4
7/8
Johnson Controls Ducted Systems 3
5493974-UIM-B-0419
SECTION III: UNIT INSTALLATION
NOTICE
Avoid handling aluminum coil components after handling the copper
line set or other tubing without first cleaning hands.
UNIT SIZING
1. The size of the unit should be based on an acceptable heat loss or
gain calculation for the structure. The ACCA – Manual J or other
approved methods may be used. Reference Figure 3 & Table 1.
2. Only connect the air handler to a duct system which has an external
static pressure within the allowable range.
3. Airflow must be within the minimum and maximum limits approved
for electric heat, indoor coils and outdoor units.
Entering Air Temperature Limits
Wet Bulb Temp. °F Wet Bulb Temp. °F
Min. Max. Min. Max.
57 72 65 95
4. 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 in the space to be cooled/
heated.
5. 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. The plenum must be installed according to the
instructions.
6. The installer must check available supply power and verify that it is
within the normal operating voltage range for the unit. The acceptable voltage range for these units is as follows:
Air Handler Voltage
208V-230V-1-60 187V-253V
1. Rated in accordance with ARI Standard 110, utilization range “A”.
Normal Operating 1 Voltage Range
3. Normal operating sound levels may be objectionable if the air handler is placed directly over some rooms such as bedrooms, study,
etc.
4. Select a location that will permit installation of condensate line to an
open drain or outdoors allowing condensate to drain away from
structure.
NOTICE
The primary and secondary drain line must be trapped to allow proper
drainage of condensate water. The secondary drain line should be
piped to a location that will give the occupant a visual warning that the
primary drain is clogged. If the secondary drain line is not used, it
must be capped.
5. When an indoor coil is installed in an attic or above a finished ceiling, an auxiliary drain pan should be provided under the air handler
as is specified by most local building codes.
6. Proper electrical supply must be available.
7. If unit is located in an area of high humidity (i.e. an unconditioned
garage or attic), nuisance sweating of casing may occur. On these
installations, unit duct connections and other openings should be
properly sealed, and a wrap of 2” fiberglass insulation with vinyl
vapor barrier should be used.
AIR HANDLER CONFIGURATION
These air handler units are supplied ready to be installed in an upflow
or horizontal left position. Refer to Figure 4. If the unit requires either
downflow or horizontal right airflow configurations, the unit must have
the coil assembly repositioned. Refer the Downflow or Horizontal Right
Conversion procedures.
UPFLOW
HEAT
DOWNFLOW
HEAT
HORIZONTAL RIGHT
CLEARANCES
Clearances must be taken into consideration, and provided for as
follows:
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 lines routed to clear filter and panel access.
4. Filter removal - minimum 36” recommended.
5. The duct work connected to this unit is designed for zero clearance
to combustible materials.
6. A combustible floor base accessory is available for downflow applications of this unit, if required by local code.
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, and clearance for air return and supply duct connections.
2. Using hanging brackets to wall mount this single piece air handler
unit is not recommended.
T
HEAT
FIGURE 4: Typical Installation
HEA
HORIZONTAL LEFT
A0330-001
Horizontal Left Conversion
NOTICE
For horizontal left applications, high airflow can prevent the collected
condensate from draining properly since the direction of the airflow
opposes the direction of the draining condensate. The horizontal pan
must be angled properly in order to ensure proper drainage in high
airflow applications. Ensure that the pan is angled properly by checking that the correct hole is used on the pan straps per TABLE 2. Use
FIGURE 5 to identify the "BACK" and "FRONT" straps since, in some
cases, these settings are not the same.
4 Johnson Controls Ducted Systems
5493974-UIM-B-0419
$77$&+0(17+2/()25
+25,=217$/'5$,13$1
FIGURE 5: Horizontal Pan Adjustment Strap Hole Reference
TABLE 2:
Horizontal Pan Strap Settings for Horizontal Left
Model
AP RFCX-P2 AE RFCX-E2 AVC CM
AP24B
AP30B
AP36B
AP60C RFCX60CP AE60C RFCX60CE AVC60C CM60C 3 4
AP36C
AP37C
AP42C
AP48C
– – AE60D RFCX60DE AVC60D CM64D 4 5
– – AE36C RFCX36CE AVC36C
–––––CM24C 6 6
AP18B RFCX18BP AE18B RFCX18BE AVC18B CM18B 7 7
AP48D
AP60D
RFCX24BP
RFCX30BP
RFCX36BP
RFCX36CP
RFCX37CP
RFCX42CP
RFCX48CP
RFCX48DP
RFCX60DP
AE24B
AE30B
AE36B
AE42C
AE48C
AE48D RFCX48DE AVC48D
RFCX24BE
RFCX30BE
RFCX36BE
RFCX42CE
RFCX48CE
AVC24B
AVC30B
AVC36B
AVC42C
AVC48C
CM24A
CM24B
CM25B
CM30A
CM30B
CM36A
CM36B
CM42C
CM48C
CM37C
CM30C
CM36C
CM30D
CM36D
CM42D
CM48D
CM60D
+2/(/2&$7,21
180%(56
$
Back Front
22
44
55
88
Downflow or Horizontal Right Conversion
NOTICE
NOTICE
Convert air handler to the desired orientation prior to installation.
Conversion must be made before brazing the refrigerant connections
to the coil.
1. Remove coil access panel.
2. Slide coil/drain pan assembly out of air handler.
Johnson Controls Ducted Systems 5
The center support bar for the coil/drain pan has a position identifier
embossed into the cabinet structure between the two forward fingers
of the support bar. There are four position identifiers: A, B, C, or D.
The lettered hole location can differ from unit to unit due to the cabinet width of the air handler. After removal and re-installation, the center support bar must be installed in the same lettered position that it
was originally.
3. Note the lettered position of the center support bar for the coil/drain
pan. Remove the center support bar by sliding the forward end of
the support bar to the right or left until the lower finger clears the
structure.
5493974-UIM-B-0419
NOTICE
The position identifier for the coil slide rail is embossed into the back
corner vertical angle of the cabinet structure. There are four position
identifiers: 1, 2, 3, or 4. The numbered attachment location can differ
from unit to unit due to the cabinet height of the air handler. After
removal and re-installation, the coil slide rail must be installed in the
same numbered position that it was originally.
4. Note the numbered position of the coil slide rail located at the upper
right hand side of the indoor coil compartment. Remove slide rail
from air handler cabinet by removing front screw and lowering
bracket down to disengage hook on back of slide rail.
5. Turn air handler cabinet upside down (downflow position).
6. Install coil slide rail by hooking the hook end into holes at the numbered position the slide rail was originally in right rear corner post,
and secure rail into right front edge of cabinet with screw in the predrilled hole.
NOTICE
The rear of the center support bar are longer than the fingers on the
forward end of the support bar.
7. Install center support bar for the coil/drain pan onto the lettered
position that it was originally mounted.
NOTICE
When installing a coil condensate deflector, make sure that each
notch in the coil condensate deflector slides around the anchor screw
with the bottom of the notch fully set against the screw.
Ensure that the coil condensate deflector is installed with the flange
bending away from the coil delta plate.
8. For horizontal right applications, install front and back coil condensate deflectors (condensate deflectors shipped as loose parts with
the unit). Locate 4 screws securing coil delta plates to coil drain
pan. Loosen the screws. Slide each coil condensate deflector
between the drain pan and the coil delta plate. Tighten screws to
securely anchor coil condensate deflectors. Refer to Figure 6.
NOTICE
Some models contain condensate deflectors that are not symmetrical
and must be installed in the correct orientation. If this air handling unit
is a **60C model, refer to the horizontal right conversion section on
the next page.
9. Slide the coil back into the cabinet. Be sure to engage the side coil
slide into the slide rail on the air handler cabinet.
10. Install coil access panel. Conversion is now complete.
COIL
DELTA PLATE
CONDENSATE
BLOW OFF WING
DEFLECTOR
SCREWS
(2 per deflector)
(2 per blow off wing)
INSTALL COIL CONDENSATE
INSTALL COIL BLOW
OFF WING ON FRONT
DEFLECTOR ON FRONT
AND BACK OF COIL
AND BACK OF COIL
DRAIN PAN
FIGURE 6: Coil Condensate Deflector Installation
Handling Coil Assemblies when Removed from Casing
When the coil assembly is removed from its casing, it must be handled
in such a manner that does not compromise the foam gasket that seals
the attachment point of the horizontal drain pan and primary drain pan.
DO NOT position the coil so that the coil weight rests on the horizontal
drain pan. By doing so, the horizontal drain pan straps could deform or
become damaged which will not allow the pan to be positioned/angled
correctly when the unit is horizontally installed, and if the foam gasket
that seals the attachment point becomes compromised by the movement of the horizontal drain pan, condensate may leak at this point and
cause damage to the unit/property.
Positioning the Unit in Horizontal Applications
Set unit so that it is sloped 1/4” towards the drain plug.
A0417-001
A0417-002
AVC60C Downflow or Horizontal Right
The AVC60C model contains a unique coil assembly in that additional
pieces are required to be installed in horizontal right and downflow
applications to reduce the potential for condensate blow-off. The large
cooling capacity and high volumetric airflow (1800 CFM and above)
required for these coils put them more at risk of condensate blow-off.
The installation of additional shields should mitigate condensate management issues while allowing the coil to perform adequately for proper
cooling/heating.
When installing any of the shield provisions, it is advised to position the
coil such that the primary drain pan opening can be easily accessed to
attach the shields. See Figure 7.
IMPORTANT: DO NOT position the loose coil so that it rests on the
horizontal drain pan. The weight of the coil will deform the horizontal
pan straps, and the movement of the horizontal pan could potentially
compromise the foam gasket that seals the horizontal drain pan to the
primary drain pan. This could lead to water leaking at this attachment
point and damaging the insulation/cabinet/property.
6 Johnson Controls Ducted Systems
5493974-UIM-B-0419
A1076-001
FIGURE 7: Recommended Position of Coil to Install Downflow/
Horizontal Right Condensate Components
Condensate Shield
- Downflow Only
Condensate Shield
(Factory Installed)
(Field Installed)
A1074-001
FIGURE 8: Installation of Downflow Condensate Diverter Shields
AVC60C Horizontal Right
1. Attach the additional condensate deflectors that were included in
the loose parts kit to the coil assembly by loosening the screws that
secure the front and rear delta plates to the primary drain pan. DO
NOT remove the screws completely. Loosen them enough so that
you can insert the deflectors between the drain pan and the delta
plate.
IMPORTANT: FOR 60C (21.0”) COIL ASSEMBLIES: While the
shields may appear similar, they are actually different in that there is a
front and rear shield. Due to their asymmetry, these shields will not fit
correctly if they are oriented incorrectly. See Figure 9 for details.
Front Deflector
(Orient Towards Bottom Coil Slab)
Drip Leg
Rear Deflector
A1075-001
FIGURE 9: 60C Horizontal Right Condensate Deflectors
2. Insert the deflectors between the primary drain pan and the delta
plates. Make sure that the slots in the deflectors nest firmly against
the loosened screws between the primary drain pan and delta
plates.
3. Tighten the screws that secure the delta plates to the primary drain
pan. The interactive fit of the delta plate, primary drain pan, and
screws will hold the shields firmly in place during operation. Figure
10 shows the final assembly.
Condensate Deectors
A1077-001
FIGURE 10: 60C Horizontal Right Coil Condensate Final Assembly
Johnson Controls Ducted Systems 7
5493974-UIM-B-0419
Upflow or Downflow Applications (All Models)
NOTICE
For maximum performance, if an air handling unit is being installed in
Upflow or Downflow orientation, it is recommended that the horizontal
drain be removed from the assembly. This can be achieved by removing the horizontal drain pan support straps, cutting the foam gasket
that seals the attachment point of the horizontal drain pan and primary drain pan, and removing the entire horizontal drain pan assembly.
AVC60C Downflow Conversion
1. Rotate equipment cabinet so that the bottom of the primary (plastic)
drain pan can be accessed.
2. Locate the downflow condensate shield (as shown in Figure 11)
and foam gasket strip shipped in the loose parts kit included with
the coil.
A1073-001
FIGURE 11: Condensate Shield
3. Install the condensate shield to the primary drain pan (as shown in
Figure 8). There should be an identical condensate shield that was
factory installed on the opposite side of the primary drain pan.
4. Apply the foam gasket strip to the condensate shield evenly so that
it covers the condensate shield and primary drain pan.
Horizontal Left Applications (All Models)
NOTICE
For horizontal left applications, high airflow can prevent the collected
condensate from draining properly since the direction of the airflow
opposes the direction of the draining condensate. The horizontal pan
must be angled properly in order to ensure proper drainage in high
airflow applications. Ensure that the pan is angled properly by checking that the correct hole is used on the pan straps per TABLE 2. Use
FIGURE 5 to identify the FRONT and REAR straps since, in some
cases, these settings are not the same.
The vast majority of problems encountered with 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.
When installing a central air return grille in or near the living space, it is
advisable to design the duct work so that the grille is not in direct line
with the opening in the unit. One or two elbows and acoustical duct liner
assures a quieter system. Operation where return air duct is short or
where sound may be a problem, acoustical duct liner should be used
inside the duct. Use flexible duct connectors to minimize the
transmission of vibration/noise into the conditioned space.
!
WARNING
Do not bring in return air from a location which could introduce hazardous substances into the airflow.
Use 1/2” screws to connect duct work to cabinet. If pilot holes are
drilled, drill only through field duct and unit flange.
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.
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. Duct systems should be designed
in accordance with the Air Conditioning Contractors of America (ACCA)
– Manual D.
!
CAUTION
This unit is not designed for non-ducted (freeblow) applications. Do
not operate without duct work attached to unit.
Equipment should never be operated without filters.
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.
All ducts should be suspended using flexible hangers and never
fastened directly to the structure.
HORIZONTAL SUSPENSION
These air handlers may be suspended in horizontal applications. It is
recommended to use angle steel support brackets with minimum 3/8”
threaded rods, supporting the unit from the bottom. Attach the threaded
rods at the locations shown in the Figure 12, leaving enough clearance
between door and rod so that doors maybe easily removed for service.
Air handling units are supplied ready to be installed in a horizontal left
position. A horizontal drain pan is factory installed. If horizontal right
application, refer to the horizontal right conversion before proceeding.
See sections on “Refrigerant Line Connections” and “Condensate Drain
Connections” for further installation instruction.
SECTION IV: DUCT WORK AND
DO NOT lift air handler by the cabinet brace. The cabinet brace is
held in place by the coil channel. The cabinet brace could become
disengaged from the cabinet causing the air handler to fall, potentially
causing injury or damaging property. See Figure 1 for location of cabinet braces.
!
CAUTION
CONNECTIONS
Air supply and return may be handled in one of several ways best
suited to the installation. Upflow, horizontal or downflow applications
may be used.
When assembling the support structure, make sure to size to provide
clearance for access door removal.
8 Johnson Controls Ducted Systems
NOTICE
SUSPENSION SUPPORT LOCATIONS FOR HORIZONTAL APPLICATIONS
MIN. 3/8”
THREADED ROD
MIN. 1-1/2” x 1-1/2”
Angle Recommended
length 26” minimum
with 2” clearance
on both sides
of Air Handler
5493974-UIM-B-0419
2”
MIN. 3/8”
THREADED ROD
1-1/2”
X
H
MIN. 1-1/2” x 1-1/2”
Angle Recommended
length 26” minimum
with 2” clearance on
both sides of
Air Handler
H
1-1/2”
X
1-1/2”
A0331-001
Dimension in Inches
Air Handler Cabinet Size X H
17-1/2 Width-Short H 21 41
17-1/2 Width-Long H 21 47-1/2
21 Width-Short H 21-1/2 51-1/2
21 Width-Long H 21-1/2 55-3/4
24-1/2 Width 21-1/2 55-1/2
FIGURE 12: Horizontal Suspension
DUCT FLANGES
Three duct flanges are provided to assist in positioning and attaching
duct work to the air handler. These flanges are included in the unit parts
bag. With the screws from the parts bag, install one of the duct flanges.
Duct flanges have holes on both legs with one leg longer than the other.
The longer leg can be used to mate against the air handler so that
different thicknesses of duct board can be made flush with the outer
surface of the air handler. Repeat the procedure for the other two
flanges. Refer to Figure 13. If the flanges are not used, they may be
discarded.
DUCT FLANGES
(Shipped in bag with unit)
RECOMMENDED
TRANSITION
SUGGESTED LOCATION
OF BLOCK OFF PLATE
A0332-001
FIGURE 14: Duct Work Transition
UNIT CONNECTIONS
There are several ways to handle the supply and return air duct
connections. The location and sizing of the connections depends on the
situation and the method best suited to the installation. Upflow,
horizontal or downflow applications may be used.
The supply air duct should be properly sized by use of a transition to
match unit opening. Refer to Table 1 for air handler unit inlet and outlet
dimensions.
!
CAUTION
Use 1/2” screws to connect duct work to unit. Longer screws will
pierce the drain pan and cause leakage. If pilot holes are drilled, drill
only though field duct and unit bottom duct flange.
Duct work that is not designed to match the supply air opening can
cause turbulence inside the plenum. This turbulence can change the air
flow patterns across the electric heater limit switches. If the factory
suggested transition cannot be fabricated, it is recommended that a
block off plate (approximately 8" high and running the full width of the
plenum) be attached to the supply opening. Refer to Figure 14 as a
visual aid. The use of this block off plate will enable better air circulation
across the limit switches.
AIR FILTERS
Return air filters are required and must be field supplied. Filtration can
be accomplished external to the unit or the integral filter rack may be
used. A 1" filter access rack has been built into the unit. 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 or 603. See
Table 7 for filter size.
.
!
CAUTION
Equipment should never be operated without filters.
SECTION V: COIL METERING DEVICES
A0445-001
FIGURE 13: Duct Attachment
Johnson Controls Ducted Systems 9
A piston or a TXV is to be installed in the field. There is an installation
manual that comes with the TXV kit. It is recommended to install the
piston or TXV kit prior to installation of coil and brazing of line set. Until
brazing is completed and cooled, the TXV sensing bulb must not be
installed.
The outdoor technical guide for outdoor units should be consulted for
required piston or TXV on the indoor coil. The piston and the Schrader
core are supplied with the outdoor unit. When the piston is used instead
of the TXV, the Schrader core is installed in the suction line equalizer
connection port and is capped with the supplied plastic cap. The
Schrader core must not be installed if the TXV is installed, because the
TXV equalizer line attaches to the equalizer connection port.
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