The AV single piece air handler provides the flexibility for installation in
any upflow, downflow, or horizontal application.
These versatile models may be used for cooling or heat pump operation
with or without electric heat.
A BRAND LABEL (available from Distribution) may be applied to the
center of the blower access panel on AVG models.
The unit can be positioned for bottom return air in the upflow position,
top return air in the downflow position, and right or left return in the horizontal position.
Top and side power wiring and control wiring, accessible screw terminals for control wiring, easy to install drain connections and electric
heaters all combine to make the installation easy, and minimize installation cost.
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.
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance
can cause injury or property damage. Refer to this manual for assistance or for additional information, consult a qualified contractor,
installer or service agency.
This product must be installed in strict compliance with the installation
instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical codes.
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.
It is also used to
536636-UIM-D-1211
536636-UIM-D-1211
NOTICE
1.Install this air handler only in a location and position as specified in
SECTION III of these instructions.
2.Always install the air handler to operate within the air handler’s
intended maximum outlet air temperature. Only connect the air
handler to a duct system which has an external static pressure
within the allowable range, as specified on the air handler rating
plate.
3.When an air handler is installed so that supply ducts carry air circulated by the air handler to areas outside the space containing
the air handler, the return air shall also be handled by duct(s)
sealed to the air handler casing and terminating in the space to be
cooled/heated.
4.The air handler is not to be used for temporary heating of buildings
or structures under construction.
5.The size of the unit should be based on an acceptable heat loss or
gain calculation for the structure. ACCA, Manual J or other
approved methods may be used.
SAFETY REQUIREMENTS
1.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.
2.Refer to the unit rating plate for the air handler model number, and
then see the dimensions page of this instruction for supply air plenum dimensions in Figure 3. The plenum must be installed according to the instructions.
3.Provide clearances from combustible materials as listed under
Clearances to Combustibles.
4.Provide clearances for servicing ensuring that service access is
allowed for electric heaters and blower.
5.Failure to carefully read and follow all instructions in this manual
can result in air handler malfunction, death, personal injury and/or
property damage.
6.Check the rating plate and power supply to be sure that the electrical characteristics match.
7.Air handler shall be installed so the electrical components are protected from water.
8.Installing and servicing heating/cooling equipment can be hazardous due to the electrical components. Only trained and qualified
personnel should install, repair, or service heating/cooling equipment. Untrained service personnel can perform basic maintenance
functions such as cleaning and replacing the air filters. When
working on heating/cooling equipment, observe precautions in the
manuals and on the labels attached to the unit and other safety
precautions that may apply.
9.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.
INSPECTION
As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage
should be noted on the carrier’s freight bill. A separate request for
inspection by the carrier’s agent should be made in writing. Also, before
installation the unit should be checked for screws or bolts, which may
have loosened in transit. There are no shipping or spacer brackets
which need to be removed.
Also check to be sure all accessories such as heater kits, suspension
kits, and coils are available. Installation of these accessories or field
conversion of the unit should be accomplished before setting the unit in
place or connecting any wiring, electric heat, ducts or piping.
LIMITATIONS
These units must be wired and installed in accordance with all national
and local safety codes.
Voltage limits are as follows:
1
Air Handler VoltageVoltage code
208/230-1-6006187-253
1. Rated in accordance with ARI Standard 110, utilization range “A”.
Airflow must be within the minimum and maximum limits approved for
electric heat, evaporator coils and outdoor units.
Entering Air Temperature Limits
Wet Bulb Temp.°FDry Bulb Temp. °F
Min.Max.Min.Max.
57726595
Normal Operating
Voltage Range
SECTION III: UNIT INSTALLATION
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 ductwork and plenum connected to this unit are 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, clearance for air return and supply duct connections.
2.Use 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.
The primary and secondary drain line must be trapped to allow proper
drainage of condensate water. If the secondary drain line is not used,
it must be capped. The coil is provided with a secondary drain. It
should be piped to a location that will give the occupant a visual warning that the primary drain is clogged. If the secondary drain is not
used it must be capped.
5.Proper electrical supply must be available.
6.If unit is located in an area of high humidity (ie: 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.
2Johnson Controls Unitary Products
536636-UIM-D-1211
NOTICE
UPFLOWDOWNFLOW
HORIZONTAL RIGHT
HORIZONTAL LEFT
NOTICE
FRONT VIEW
SIDE VIEW
BLOWER
COMPARTMENT
VERTICAL
DRAIN PAN
REFRIGERANT LINE
CONNECTIONS
PRIMARY DRAIN
UPFLOW 3/4”
THREADED
DUCT WORK MAY
BE FASTENED
CAUTIOUSLY WITH
SCREWS TO THE
SIDES AND REAR OF UNIT
SECONDARY DRAIN
UPFLOW 3/4” THREADED
COIL COMPARTMENT
(Access panel removed)
HORIZONTAL
DRAIN PAN
HORIZONTAL
SECONDARY DRAIN
HORIZONTAL
PRIMARY DRAIN
ALTERNATE
DRAIN CONNECTIONS
UPFLOW/DOWNFLOW
FILTER DOOR
RETURN AIR
DUCT
WHEN ATTACHING DUCT WORK WITH
SCREWS - KEEP SCREWS WITHIN 5/8”
OF SIDES AND BACK OF AIR HANDLER
When an evaporator coil is installed in an attic or above a finished
ceiling, an auxiliary drain pan should be provided under the coil as is
specified by most local building codes.
FIGURE 1: Typical Installation
DOWNFLOW AND HORIZONTAL CONVERSION
(AV ONLY)
These air handler units are supplied ready to be installed in a upflow
and right hand horizontal position. If unit requires left hand positioning,
the unit must have the coil assembly repositioned.
1.Remove blower, coil, and filter access panels.
Conversion must be made before brazing the refrigerant connections
to the coil.
For downflow and horizontal left installations, follow steps 2 - 8.
2.Remove tubing connection panel.
3.Remove front drain pan, hold down bracket.
4.Slide coil assembly out of air handler.
5.Rotate cabinet 180º so blower outlet is facing down.
In severe high humidity, high temperature indoor unit environments,
an accessory insulation blanket is available to supplement the standard cabinet insulation. Insulate with UPG Kit: 1VJ0117 for B cabinets, 1VJ0121 for C cabinets or 1VJ0124 on D cabinets or seal
completely with adequate fiberglass insulation using vapor barrier on
the outside.
6.Re-install coil assembly on downflow bracket.
7.Re-attach front drain pan, hold down bracket.
8.Re-attach tubing connection panel.
9.For horizontal applications, rotate air handler 90º into desired ori-
entation.
10. Re-position drain plugs as necessary based on air handler orienta-
tion.
11. Re-position and replace access panels.
12. For downflow installations, the cladding should be reconfigured so
that the grille and circuit breaker covers having logos and/or black
coloring are at the top of the unit on the coil access panel. See
below.
13. Apply branding label to air handler in recessed area provided on
blower access panel cladding. This label should be applied after
the air handler is placed in its proper orientation so the label is
right side up.
CLADDING CONFIGURATION FOR DOWNFLOW
INSTALLATION (IF USED)
To reconfigure the cladding parts, remove the grille by pulling gently at
the top. Once the grille is removed, the circuit breaker cover can also be
removed. Remove the gray, non-branded grille and circuit breaker
cover from the cladding on the coil access panel. Next, remove the
black and/or branded grille and circuit breaker cover from the blower
access panel. Install these pieces into the coil access panel cladding so
they are at the top of the air handler. Install the gray, non-branded grille
and circuit breaker cover in the blower access panel cladding.
If a heat kit with a circuit breaker is installed in the air handler, the circuit breaker cover cladding must be removed to gain access to the
sheet metal cover plate. Some local codes may require that the circuit
breaker remain visible. If so, do not re-install circuit breaker cover
cladding.
Use an appropriate tool to pry out water deflector with two or three sclips from the vertical drain pan. See Figure 4. Relocate the deflector
with s-clips on the Horizontal Drain Pan lined up to the coil support
brackete. See Figure 5. This positions the deflector below the feeder
tubes to channel the condensate to the drain pan.
The condensate deflector should be installed in the s-clip section
which is inside the drain pan edge. See Figure 6.
Wiring Knockouts
JK
7/8” (1/2”)
1 3/8” (1”)
7/8” (1/2”)3/8”
1 23/32” (1 1/4”)
1
Refrigerant
Connections
Line Size
3/4”
FIGURE 4: Condensate Deflector on Vertical Drain Pan
4Johnson Controls Unitary Products
FIGURE 5: Condensate Deflecctor on Horizontal Drain Pan Edge
S-CLIPS ON HORIZONTAL PAN
FEEDER
TUBES
CONDENSATE
DEFLECTOR
DEFLECTOR
S-CLIP
DRAIN PAN
WALL
SUGGESTED LOCATION
OF BLOCK OFF PLATE
RECOMMENDED
TRANSITION
536636-UIM-D-1211
ers and never fastened directly to the structure. This unit is not
designed for non-ducted (freeblow) applications. Size outlet plenum or
transition to discharge opening sizes shown in Figure 3.
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 WORK TRANSITION
Duct work that is not designed to match the supply air opening can
cause turbulence inside the plenum box. This turbulence can change
the air flow patterns across the heat kit limit switch. If the factory suggested transition can not be fabricated, it is recommended a block off
plate (approximately 8” in height and running the full width of the plenum) be attached to the supply opening Please refer to Figure 7 as a
visual aid. The use of this block off plate will keep better air circulation
across the limit switch.
FIGURE 6: S-Clip Installation
DUCT CONNECTIONS
Use 1/2" screws to connect ductwork to bottom of unit. Longer screws
will pierce the drain pan and cause leakage. If pilot holes are drilled,
drill only though field duct and unit bottom flange.
Air supply and return may be handled in one of several ways best
suited to the installation. See Figure 3 for dimensions for duct inlet and
outlet connections.
The vast majority of problems encountered with combin ation heating
and cooling systems can be linked to improperly designed or installed
duct systems. It is therefore highly important to the success of an installation that the duct system be properly designed and installed.
Use flexible duct collars to minimize the transmission of vibration/noise
into the conditioned space. If electric heat is used, non-flammable
material must be used.
Where return air duct is short, or where sound may be a problem,
sound absorbing glass fiber should be used inside the duct. Insulation
of duct work is a must where it runs through an unheated space during
the heating season or through an uncooled space during the cooling
season. The use of a vapor barrier is recommended to prevent absorption of moisture from the surrounding air into the insulation.
The supply air duct should be properly sized by use of a transition to
match unit opening. All ducts should be suspended using flexible hang-
FIGURE 7: Duck Work Transition
The above suggestions will not alleviate problems caused by improper
installation. When receiving intermittent fault codes pertaining to the
limit switch, always double check your airflow CFM, motor speed and
static pressures.
AIR FILTERS
Air filters must be field supplied. A 1" filter access rack has been built
into the unit. See Figure 3. Remove filter access cover shown. Install
proper size filter. Standard 1" size permanent or throw away filter may
be used, or, permanent washable filters are available using model numbers: 1PF0601, 602, 603BK. See Table 8 for filter size.
Equipment should never be operated without filters.
HORIZONTAL SUSPENSION (AV ONLY)
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 8.
When an evaporator 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.
Johnson Controls Unitary Products5
536636-UIM-D-1211
WW
XX
SUSPENSION SUPPORT LOCATIONS FOR HORIZONTAL APPLICATIONS
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
YY
VAPOR
LINE
THERMAL
EXPANSION
VALVE BULB
(Required insulation
not shown for clarity)
THERMAL
EXPANSION
VALV E
DISTRIBUTOR BODY
LIQUID
LINE
TXV
EQUALIZER
LINE
TXV BULB
(Cover completely
with insulation)
SCREW
CLAMP
NUT
SUCTION LINE
NOTICE
NOTICE
Units
(Nominal Tons)
WWXX
24B2046
36C2452
AV*48D, 60D2857
FIGURE 8: Typical Horizontal Installation
Dimension
TXV METERING DEVICES
If the model (C) number is of the following format: 4F, 4G, 4H, 4J,
and 4K will have the coil with R410A TXV metering device installed at
the factory.
If the model (C) number is of the 3X model series:
The coil will require an orifice or R410A TXV to be installed in the field.
Refer to installation manual with TXV kit. It is recommended to install a
orifice or TXV kit prior to brazing line sets.
COIL UNDER PRESSURE.
Relieve pressure by depressing schrader core. Coil may have factory
installed TXV or may require orifice or TXV to be added. See outdoor
unit documentation for correct orifice or TXV to be used. Refer t o coil
nameplate for TXV identification for this unit.
The coil should be open to the air for no more than 2 minutes to keep
moisture and contaminates from entering the system. If the coil cannot be installed into the refrigeration system in that time, the ends
should be temporarily closed or plugged. For a short term delay, use
masking tape over the ends of the copper tubing to close the tube to
the air. For a longer term delay, use plugs or caps. There is no need
to purge the coil if this procedure is followed.
REFRIGERANT LINE CONNECTION
Coil is under inert gas pressure. Relieve pressure from coil by
depressing schrader core.
Dry nitrogen should always be supplied through the tubing while it is
being brazed, because the temperature required is high enough to
cause oxidation of the copper unless an inert atmosphere is provided.
The flow of dry nitrogen should continue until the joint has cooled.
Always use a pressure regulator and safety valve to insure that only
low pressure dry nitrogen is introduced into the tubing. Only a small
flow is necessary to displace air and prevent oxidation.
Connect lines as follows:
FIGURE 9: TXV
Please refer to Outdoor Unit Tech Guide to verify which metering device
is installed in this coil and that this is a valid system match for the AC or
HP unit installed.
The temperature sensing bulb is attached to the coil suction header
line.
FIGURE 10: Proper Bulb Location
Route the refrigerant lines to the coil in a manner that will not obstruct
service access to the coil, air handling system, or filter.
1.Suction and liquid line connections are made outside the cabinet.
Leave the tubing connection panel attached to the cabinet with the
tubes protruding through it. Coil access panel should be removed
for brazing. The lines are swedged to receive the field line set
tubes.
2.Cut the end of the suction tube using a tube cutter. Place the tube
cutter as close as possible to the end of the tube to allow more
space for the connection and brazing of the suction line.
3.Remove the heat shield from the Customer Packet, soak in water,
and install over coil tubing to prevent overheating of cabinet.
4.Wrap a water soaked rag around the coil connection tubes inside
the cabinet to avoid damaging the TXV bulb.
5.Remove grommets where tubes exit the cabinet to prevent burning
them during brazing.
6.Purge refrigerant lines with dry nitrogen. Follow outdoor unit brazing instructions.
7.Braze the suction and liquid lines.
8.Remove the heat shield.
9.Re-attach the grommets to the lines carefully to prevent air leakage.
10. Attach the coil access panel to the cabinet.
Refer to Outdoor unit Installation Manual for evacuation, leak check and
charging instructions.
Lines should be sound isolated by using appropriate hangers or strapping.
All evaporator coil connections are copper-to-copper and should be
brazed with a phosphorous-copper alloy material such as Silfos-5 or
equivalent. DO NOT use soft solder.
6Johnson Controls Unitary Products
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