Johnson Controls MP Installation Manual
STANDARD PSC
INSTALLATION MANUAL
ISO 9001
Certified Quality
Management System
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MODULAR MULTI-POSITION
AIR HANDLERS
MODELS: MP SERIES
LIST OF SECTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
DUCT WORK AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRIC HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .6
LINE POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
LOW VOLTAGE CONTROL CONNECTIONS . . . . . . . . . . . . . . . . . .8
LIST OF FIGURES
Return Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Coil and Air Handler Attachment Details . . . . . . . . . . . . . . . . . . . . . . .3
Gasket Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Dimensions & Duct Connection Dimensions . . . . . . . . . . . . . . . . . . . .4
Typical Horizontal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Duct Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
LIST OF TABLES
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Physical and Electrical Data - Cooling Only . . . . . . . . . . . . . . . . . . . . .8
Electrical Data - Cooling Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Electrical Heat: Minimum Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . .9
KW & MBH Conversions - For Total Power Input Requirement . . . . . 9
BLOWER SPEED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
AIR SYSTEM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TYPICAL THERMOSTAT CONNECTIONS . . . . . . . . . . . . . . . . . . . 16
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Duct Work Transition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blower Delay Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Line Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Blower Speed Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Duct Static Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram - PSC - Single Phase Heat Kits . . . . . . . . . . . . . . . 15
Typical Wiring Diagram - PSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electric Heat Performance Data: 208/230-1-60 . . . . . . . . . . . . . . . . . 9
Electrical Data For Single Source Power Supply: 208V-230V-1-60 . 10
Electrical Data For Multi-Source Power Supply: 208V-230V-1-60 . . 11
Air Flow Data (CFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION I: GENERAL
The MP modular 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 or indoor coil.
Top or side power and control wiring, color coded leads for control
wiring, 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 20 kW.
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.
alert against unsafe practices and hazards involving only property
damage.
.
.
It is also used to
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 li ghter
fluid, dry cleaning fluids or other volatile fluid.
3. Paint thinners and other pain ting 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.
1190828-UIM-G-0915
1190828-UIM-G-0915
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SIDE VIEW
RETURN AIR
DUCT
A0398-001
When attaching duct work with
screws - keep screws within 5/8”
of sides and back of air handler.
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 5
and Table 1 of this Instruction Manual. The plenum must be
installed according to the instructions. The return air duct attachment is shown in Figure 1.
7. Clearance from combustible material is provided under “Clearances” in the “Unit Installation” section.
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.
FIGURE 1: Return Air Duct Attachment
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.
It should be verified that the appropriate coil and accessories (such as
heater kit and thermostatic expansion valve kit) are available as
required. 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.
SECTION III: UNIT INSTALLATION
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 5 and 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 Dry 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
208-230-1-60 187-253
1. Rated in accordance with ARI Standard 110, utilization range “A”.
Normal Operating
1
Voltage Range
2 Johnson Controls Unitary Products
CLEARANCES
A0346-001
UPFLOW
DOWNFLOW
HORIZONTAL RIGHT
HEAT
HORIZONTAL LEFT
HEAT
HEAT
HEAT
HEAT
A0347-001
OUTER TIE PLATE (3 PLACES)
AIR
HANDLER
COIL
NOTE:
External tie plates
are installed on both
sides and the back
Clearances must be taken into consideration, and provided for as
follows:
1. Maintenance and servicing access - minimum 36” from front of unit
recommended for blower motor / coil replacement.
2. The duct work connected to this unit is designed for zero clearance
to combustible materials.
3. 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. If using the air handler unit with an indoor coil, select a location that
will permit installation of condensate line to 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.
1190828-UIM-G-0915
FIGURE 2: Typical Installation
AIR HANDLER AND COIL UPFLOW, DOWNFLOW,
AND HORIZONTAL POSTIONS
1. Apply neoprene gasket to the return air end of air handler.
2. Attach three tie plates to external sides and back of air handler
casing using screws. Refer to Figure 3.
3. Position blower casing over appropriate coil opening (depending
on configuration). Refer to Figure 2.
4. Attach the three tie plates to coil casing using screws. Refer to Figure 3.
5. Remove coil access panel.
6. Slide the coil out of the coil cabinet, and set coil to the side.
7. Locate 2” wide foam gasket.
8. Apply foam gasket over the air handler and coil mating seams on
the interior of both unit sides and back. Refer to Figure 4.
9. Slide the coil into the housing, and install the coil access panel.
AIR HANDLER CONFIGURATION
These air handler units are supplied ready to be installed in an upflow,
downflow, horizontal right or horizontal left position. Refer to Figure 2.
The unit requires no conversion procedures.
FIGURE 3: Coil and Air Handler Attachment Details
Johnson Controls Unitary Products 3
1190828-UIM-G-0915
FOAM GASKET
AIR HANDLER
E
F
A
A0327-001
SERVICE DISCONNECT
PANEL
TOP OUTLET
DIMENSIONS
BOTTOM INLET
DIMENSIONS
C
D
12-3/16”
19-1/8”
B
20-1/2”
21-1/2”
FIGURE 4: Gasket Location
FIGURE 5: Dimensions & Duct Connection Dimensions
MP
1
ABCDEF
TABLE 1:
Dimensions
MODELS
Height Width Bottom Opening Top Opening Power Control
08B 21-1/2 17-1/2 16-1/2 16-1/2
12B 21-1/2 17-1/2 16-1/2 16-1/2
14D 22-1/2 24-1/2 23-1/2 23-1/2
16C 22-1/2 21 20 20
20D 22-1/2 24-1/2 23-1/2 23-1/2
1. All dimensions are in inches.
2. Actual size (Conduit size).
Dimensions
Wiring Knockouts
2
7/8 (1/2)
1-3/8 (1)
7/8 (1/2)
1-23/32 (1-1/4)
4 Johnson Controls Unitary Products
1190828-UIM-G-0915
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SUSPENSION SUPPORT LOCAT IONS FOR HORIZONTAL RIGHT
2”
1-1/2”
MIN. 1-1/2” x 1-1/2”
Angle Recommended
length 26” minimum
with 2” clearance on both
sides of Air Handler
MIN. 3/8”
THREADED ROD
H
1”
1-1/2”
A0348-002
X
H
SUSPENSION SUPPORT LOCAT IONS FOR HORIZONTAL LEFT
X
TIE PLATE
SECTION IV: DUCT WORK AND
CONNECTIONS
WARNING
Use only 1/2” screws to connect duct work to bottom of unit.
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. If electric heat is used, non-flammable material must be
used.
Use flexible duct connectors to minimize the transmission of vibration/
noise into the conditioned space. Never fasten duct work directly to the
structure.
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.
HORIZONTAL SUSPENSION
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 6.
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.
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.
(Cabinet Width) Position
(17-1/2”) Horizontal Left 40-1/2” – 47-1/2” 20”
(21” thru 24-1/2”) Horizontal Left 43-1/2” – 55-1/2” 21”
(17-1/2”) Horizontal Right 40-1/2” – 47-1/2” 20”
(21” thru 24-1/2”) Horizontal Right 43-1/2” – 55-1/2” 21”
FIGURE 6: Typical Horizontal Installation
Dimensions
HX
Johnson Controls Unitary Products 5
1190828-UIM-G-0915
A0445-001
DUCT FLANGES
(Shipped in bag with unit)
A0332-001
RECOMMENDED
TRANSITION
SUGGESTED LOCATI ON
OF BLOCK OFF PLATE
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PSC CONTROLBOARD
A0356-001
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 7. If the flanges are not used, they may be
discarded.
FIGURE 7: Duct Attachment
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 8 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 must
be accomplished external to the unit.
.
CAUTION
Equipment should never be operated without filters.
SECTION V: ELECTRIC HEATER
INSTALLATION
If the air handler requires electric heat, install the electric heat kit
according to the installation instructions included with the kit. After
installing the kit, mark the air handler nameplate to designate the heater
kit that was installed. If no heater is installed, mark the name plate
appropriately to indicate that no heat kit is installed.
Use only 6HK Revision C or later heater kits, as listed on air handler
name plate and in these instructions. Use data from Tables 4 through 9
for information on required minimum motor speed tap to be used for
heating operation, maximum over-current protection device required as
listed for combination of air handler and heater kit.
FIGURE 8: 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.
FIGURE 9: Blower Delay Control Board
6 Johnson Controls Unitary Products
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