Johnson Controls AVC Installation Manual

INSTALLATION MANUAL

VARIABLE SPEED ECM

SINGLE PIECE MULTI-POSITION

AIR HANDLERS

MODELS: AVC SERIES

LIST OF SECTIONS

ISO 9001

Certified Quality

Management System

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

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

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

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

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

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 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.

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.

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! 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 protected from water.

11.Installing and servicing heating/cooling equipment can be hazardous 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

VAPOR

REFRIGERANT

LINE CONNECTION

LIQUID

REFRIGERANT

LINE CONNECTION

SECONDARY DRAIN HORIZONTAL FLOW 3/4” NATIONAL PIPE THREAD (NPT)

PRIMARY DRAIN 3/4” NPT

DUCT WORK MAY

BE FASTENED CAUTIOUSLY WITH SCREWS TO THE

SIDES AND REAR OF UNIT

FRONT VIEW

BLOWER

COMPARTMENT

COIL COMPARTMENT (Access panel removed)

CABINET BRACE

VERTICAL

DRAIN PAN

CABINET BRACE

SIDE VIEW

		RETURN AIR
		DUCT
		FILTER DOOR
		WHEN ATTACHING DUCT WORK WITH
	SECONDARY DRAIN	SCREWS - KEEP SCREWS WITHIN 5/8”
		OF SIDES AND BACK OF AIR HANDLER
	UPFLOW 3/4” NPT
		A0328-001

FIGURE 1: Return Air Duct Attachment & Component Location

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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.

A0271-001

FIGURE 2: Pressure Check

	F			REFRIGERANT CONNECTIONS
					DRAIN CONNECTIONS				TOP OUTLET
					FOR UPFLOW APPLICATIONS
	BLOWER								DIMENSIONS
								12-3/16”
	COMPARTMENT								E
	COIL
	COMPARTMENT	G
				A
	C					SERVICE
						DISCONNECT
						PANEL
	7-11/32							18-5/8”
									D
	1-1/2”
	FILTER ACCESS	B	20-1/2”						BOTTOM INLET
									DIMENSIONS
			21-7/16”
									A0329-001
	FIGURE 3: Dimensions & Duct Connection Dimensions
	TABLE 1: Dimensions
				Dimensions1			Wiring Knockouts2		Refrigerant
	Models	A	B				F	G	Connections
				C	D	E			Line Size
		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			3/4
	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	7/8 (1/2)
	42C	51-1/2	21	22-5/8	17-3/4	20	1-3/8 (1)	7/8 (1/2)	3/8
	48C	51-1/2	21	22-5/8	17-3/4	20	1-23/32 (1-1/4)
	48D	55-1/2	24-1/2	26-5/8	21-1/4	23-1/2			7/8
	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).

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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 circu-
	lated 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 ple-
	num 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 accept-
	able voltage range for these units is as follows:
	Air Handler Voltage		Normal Operating 1 Voltage Range
	208V-230V-1-60			187V-253V

1. Rated in accordance with ARI Standard 110, utilization range “A”.

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.

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	DOWNFLOW
HEAT
	<![if ! IE]> <![endif]>HEAT
	HORIZONTAL RIGHT
	<![if ! IE]> <![endif]>HEAT
	HEAT
	HORIZONTAL LEFT
	A0330-001

FIGURE 4: Typical Installation

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.

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$77$&+0(17 +2/( )25	+2/( /2&$7,21
+25,=217$/ '5$,1 3$1	180%(56

							$
FIGURE 5: Horizontal Pan Adjustment Strap Hole Reference
TABLE 2: Horizontal Pan Strap Settings for Horizontal Left
		Model					Back	Front
AP	RFCX-P2	AE		RFCX-E2	AVC	CM
						CM24A
						CM24B
AP24B	RFCX24BP	AE24B		RFCX24BE	AVC24B	CM25B
AP30B	RFCX30BP	AE30B		RFCX30BE	AVC30B	CM30A	2	2
AP36B	RFCX36BP	AE36B		RFCX36BE	AVC36B	CM30B
						CM36A
						CM36B
AP60C	RFCX60CP	AE60C		RFCX60CE	AVC60C	CM60C	3	4
AP36C	RFCX36CP
AP37C	RFCX37CP	AE42C		RFCX42CE	AVC42C	CM42C	4	4
AP42C	RFCX42CP	AE48C		RFCX48CE	AVC48C	CM48C
AP48C	RFCX48CP
–	–	AE60D		RFCX60DE	AVC60D	CM64D	4	5
						CM37C
–	–	AE36C		RFCX36CE	AVC36C	CM30C	5	5
						CM36C
–	–	–		–	–	CM24C	6	6
AP18B	RFCX18BP	AE18B		RFCX18BE	AVC18B	CM18B	7	7
						CM30D
AP48D	RFCX48DP					CM36D
		AE48D		RFCX48DE	AVC48D	CM42D	8	8
AP60D	RFCX60DP
						CM48D
						CM60D

Downflow or Horizontal Right Conversion

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.

NOTICE

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.

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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

CONDENSATEBLOWOFF WING

DEFLECTOR

SCREWS

(2 per deflector)blow off wing)

INSTALLLCOILCONDENSATEBLOW

DEOFFLECTORWING ONONFRONT

ANDANDBACKBACKOFOFCOILCOIL

DRAIN PAN

A0417-001A0417-002

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.

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.

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A1076-001

FIGURE 7: Recommended Position of Coil to Install Downflow/ Horizontal Right Condensate Components

Condensate Shield	Condensate Shield
- Downflow Only	(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	Rear Deflector
Drip Leg
(Orient Towards Bottom Coil Slab)	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 Deflectors

A1077-001

FIGURE 10: 60C Horizontal Right Coil Condensate Final Assembly

Johnson Controls Ducted Systems

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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.

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 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.

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.

! CAUTION

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.

NOTICE

When assembling the support structure, make sure to size to provide clearance for access door removal.

8	Johnson Controls Ducted Systems

					5493974-UIM-B-0419
SUSPENSION SUPPORT LOCATIONS FOR HORIZONTAL APPLICATIONS
MIN. 3/8”	MIN. 1-1/2” x 1-1/2”
	Angle Recommended
THREADED ROD
	length 26” minimum
	with 2” clearance
	on both sides
	of Air Handler
2”	1-1/2”
	X
	H
MIN. 3/8”	MIN. 1-1/2” x 1-1/2”		RECOMMENDED
THREADED ROD	Angle Recommended				SUGGESTED LOCATION
			TRANSITION
	length 26” minimum				OF BLOCK OFF PLATE
	with 2” clearance on				A0332-001
	both sides of		FIGURE 14: Duct Work Transition
	Air Handler
			UNIT CONNECTIONS
1-1/2”	1-1/2”		There are several ways to	handle	the supply and return	air duct
			connections. The location and sizing of the connections depends on the
X
			situation and the method	best suited to the installation.		Upflow,
	H
		A0331-001	horizontal or downflow applications may be used.

Dimension in Inches					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
Air Handler Cabinet Size		X	H
					dimensions.
17-1/2 Width-Short H		21	41
21 Width-Short H		21-1/2	51-1/2		! CAUTION
17-1/2 Width-Long H		21	47-1/2
21 Width-Long H		21-1/2	55-3/4		Use 1/2” screws to connect duct work to unit. Longer screws will
24-1/2 Width		21-1/2	55-1/2		pierce the drain pan and cause leakage. If pilot holes are drilled, drill
					only though field duct and unit bottom duct flange.
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)

A0445-001

FIGURE 13: Duct Attachment

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

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.

Johnson Controls Ducted Systems

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