Johnson Controls Inc. Humidifier AV*(C) Series User's Manual
Contents
1. SINGLE PIECE VARIABLE SPEED AIR HANDLERS MODELS AV C SERIES gt AS ee cul m mS ion 4 _ A A AA di x E bh ES 882 AA oO A A YA aA e A M A SS A gt E y o b MEE NM 42M leat 1 M ll LO 4 I 83 1 hLA A O F WA Nw SA 4 Pai NHN 7 Y 3 2M EM MD iO i OO Ee lis Eel Ul gt SN sl N LEM A EMEN WEN ee RR WOE ARD IMEEM DX A ell OCC ClO eee A NL NN Y 5BE Z2 NM LEM 0 1L 10 1L 5D A DN LL LLL OL LLL A EC LN EM ww EA Z MY MOM MY AA LAW A y B0 ui 0 A WM AM DUM 1 0 A LA 11 IM 1 LOU LH EM 88 1 ll SA A A A El M EM w j L I 1 EM OP p 4 a l Uu M UG Q l Am Uu UE uU uU M LN M M I 3 LL P8U E A l M2 DES C CCD UM 1 1 UEM i SO D o EM LM ae I LES A i M A E D i E A D M aaan S A EEE oa LL L A A A gt A NELLE 0M 598 P 8L CY 0 NV 9600 REGISTRY e CE o AS CERTIFIED www ahridirectory org ISO 9001 Certified Quality Management System o ER m E LIST OF SECTIONS GENERAL 414532524 9 ardor ora recta idear ee 1 LINE POWER CONNECTIONS ccoo 11 SARELY arriero EER A Rc deu eases 1 AIRFLOW AND COMFORT SETTING SELECTION 12 UNIT INSTALLATION 4 455499 92k RR RR a CR n 2 UNIT DATA diu iss wan UE A Rec VUE AR Rc eben Red a diat dod a 12 ELECTRIC HEATER INSTALLATION eere 7 MAINTENANC2. 9 9 4HK16501506 amem 0 74 75 83 75 4HK16501806 89 19 100 38 90 110 aires 3642 10878 aKes 1000 11806 15378 5 19 3 38 1 O C P Over Current Protection device must be HACR type Circuit Breaker or Time Delay fuse May be 0 no breaker or 1 with breaker TABLE 12 Electrical Data For Multi Source Power Supply Copper Wire 208 230 1 60 Min Circuit IPRC Max O C P gt Amps Type 75 C Wire Size AWG Heater Models e NN circu a mi m m T m 8g OT md OW MEL aceso isse 19585 060208 88 1200 sHKTesNTSOS 478535 247250 S080 258 86 ORO A 2 gt 4HK16501506 48 5 55 4 21 7 25 0 E 50 60 25 25 E 8 6 akese 449512 398458 4550 4950 NC keso 429491 238262 soso sum 96 395 Em aktes 510559 207250 6060 2925 96 0 akese 4741527 388458 5060 4060 96 86 4HKie502006 510559 434500 sored 4550 96 88 sHKTGSD2S06 keso 439501 248272 sven 309 96 ao ees 4HK16501806 49 5546 39 8458 50 60 40 60 6 6 8 6 89 86 arKreso2006 3588 434m00 8080 4880 86 88 4HK16502506 53 1 58 8 43 4 50 0 21 7 25 0 60 60 45 50 25 25 66 88 10 10 1 O C P Over Current Protection device must be HACR type Ci
3. blinks are approximate 10 of actual CFM ie Johnson Controls Unitary Products SECTION X MAINTENANCE Filters must be cleaned or replaced when they become dirty Inspect at least once per month The frequency of cleaning depends upon the hours of operation and the local atmospheric conditions Clean filters keep unit efficiency high COIL CLEANING If the coil needs to be cleaned or replaced it should be washed with Calgon CalClean mix one part CalClean to seven parts water Allow solution to remain on coil for 30 minutes before rinsing with clean water Solution should not be permitted to come in contact with painted sur faces Johnson Controls Unitary Products 536636 UIM D 1211 LUBRICATION The bearings of the blower motor are permanently lubricated CONDENSATE DRAINS During the cooling season check the condensate drain lines to be sure that condensate is flowing from the primary drain but not from the sec ondary drain If condensate ever flows from the secondary drain the unit should be promptly shut off and the condensate pan and drains cleaned to insure a free flowing primary drain 17 WIRING DIAGRAM SECTION XI 6060 V GMN LES9IVS dVl A806 JHL Ol avi A0tc JHL WOUF JAIM MOTI3A 31V390138 NOIIVOI Iddy A80c 404 NOIIVI1dO ADEE HOF Q38UIM AYOLIVA OdddlHS J3AJOJSNVUI v TWYLNAN OL 27 LOINNOD YOLINGNOD TVHLNIN 1 JNO INV YOLINGNOD LIOA OE2 1 JNO SVH ATddAS YAMOd 343HM INATVAIANO
4. 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 combination heating and cooling systems can be linked to improperly designed or installed duct systems It is therefore highly important to the success of an instal lation 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 absorp tion 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 Johnson Controls Unitary Products 536636 UIM D 121 1 ers and never fastened directly to the structure This
5. The jumper must be in the HEAT position if a heat kit is installed with the air handler With the jumper in the NO HEAT position the control will not energize the heat relay outputs or sense the limit switch input If the jumper is not present the control will operate as if the jumper is in the HEAT position If the jumper is not present and a heat kit is not pres ent the control will sense an open limit condition and the blower will run continuously Hum Stat Jumper The HUM STAT jumper configures the control to monitor the humidity switch input With the jumper in the NO position the control will ener gize the HUM terminal with 24 VAC continually With the jumper in the YES position the control will monitor the HUM input to control the HUM OUT output to control an external humidifier If the jumper is not present the control will operate as if the jumper is in the YES position 10 Mode Jumper The MODE jumper configures the control to operate properly with an air conditioner AC position or heat pump HP position With the jumper in the AC position the control will energize the O terminal with 24 VAC continually With the jumper in the HP position the O input signal is received from the room thermostat If the jumper is not present the control will operate as if the jumper is in the HP position SPARE Jumper The control includes a spare jumper that can be used if a jumper is lost The SPARE jumper does not have a
6. 2 5 10 KW GND LUG GND Hl LUG Is TERMINAL BLOCK CONNECT TRANSFORMER LEADS WITH WIRE NUTS TYPICAL ALL HEAT KITS SUPPLY ES Bw SL Ll gt S POWER de SUPPLY JUMPER BAR MAY BE 1 2 OR3 CIRCUIT BREAKERS POWER WIRING 208 230 1 60 11 536636 UIM D 1211 SECTION VIII AIRFLOW AND COMFORT SETTING SELECTION AIRFLOW SELECTION The airflow and comfort setting selection jumpers must be set properly at the time of installation for proper system operation Place jumpers in the proper locations based on the information shown in Table 16 and Figure 11 Inputs to air handler control board are passed to the motor which deter mines the target CFM to be delivered The following inputs will produce the CFM per the appropriate table and selected tap settings NOTICE Incorrect airflow and comfort settings may result in decreased system efficiency and performance These variable speed air handlers are designed to deliver constant air flow CFM regardless of the external static pressure ESP in the duct work Therefore if too many supply registers are closed a filter becomes clogged or there is a restriction in the ductwork the motor will automatically operate at a higher speed to compensate for the higher ESP This may result in a higher operating sound level To Set Cooling Airflow Refer to the outdoor unit technical guide for the recommended airflow with the matching
7. 60 e Heat kW Staging Heater Min Models Speed Tap KW MBH_ WiOnly W2 Only W1 amp W2 209v gt es ea os 19 es i 25 18 2 4HK 6500506 05 Hean 38 HK 6800806 92250 28 975 50 TS TS Lese os Hess 72 8 ws 38 35 48 72 38 72 38 aK 08 HexA S8 e 353 aa 33 43 amp HKTSNTSOS es max ps wa pss pr 3e pus T2 3p 10900 B AHK 6800806 78 cos os Meno 72 we fae see oe 48 TEL 38 TE ake os Feo 98 te eas 44 33 43 65 87 88 13 amem os hec 168 waa oes wer 56 48 72 88 108 18 Keo 08 Wah Tox 17e A5T cor 35 4 68 85 oa 176 AHK 6800806 78 cos os Wear 72 we as 8 35 48 TEL 88 TE akeo 05 Heat 98 18 383 444 33 43 65 87 88 19 akeo 05 HeatC 108 i44 358 493 38 48 72 98 108 144 akese 05 Fear 732 176 451 oor 33 44 8 88 132 akso us Feat iaa Tex 492 eos 56 48 T2 ee 144 reses 05 Wess ar mr ss sry ss as we ver vo gt ames os Heat 35 48 ves rea se 45 96 48 55 3 akeo 08 Pead 8 75 792 286 28 375 6 75 58 E avem os Hero 72 es eee 02836 48 Tz 5 2 96 akoe os heno 98 m oss aaa as 45 65 S S8 r AHKI6501505 05 Heat 108 144 368 aor 38 48 72 96 08 144 sHKTGSDT80S i ss a4 6s ee 162 05 arikreso2006_ 05 HearO i44
8. Be sure that all of the A terminals are connected together all of the B terminals are connected together all of the GND or C terminals are connected together and all of the R terminals are connected together See Figure 13 When using a fully communicating system the large screw terminals C G R etc on the air handler control are not used The four small screw terminals in the terminal block on the end of the air handler control should be used Air Handler Communicating Control Touch Screen Communicating Control Air Conditioner Heat Pump Communicating Control FIGURE 14 Air Handler with Communicating AC or HP Johnson Controls Unitary Products HUMIDITY SWITCH INPUT The air handler control is designed to work with a humidity control that closes when the humidity is below the set point The control is open when the humidity is above the set point This humidity control may be referred to as a humidistat or a dehumidistat The humidity switch controls both humidification and de humidification operation of the control The control provides humidification using the HUM OUT relay output and de humidification by lowering the blower speed This is accomplished using the de humidification input of the motor for variable soeed models The humidity switch should be con nected to the R and HUM terminals of the control See Figures 11 and 12 The 24 volt power supply is pr
9. 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 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 follow ing in choosing a suitable location 1 Select a location with adequate structural support space for ser vice 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 han dler 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 If the secondary arain 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 gi
10. the occupant a visual warning that the primary drain is clogged lf the secondary drain is not used it must be capped When an exterior secondary drain pan is used that secondary drain should br piped to a location that will give the occupant a visual warning that the primary drain is clogged The drain pan connections are designed to ASTM Standard D 2466 Schedule 40 Use 3 4 PVC or steel threaded pipe Since the drains are not subject to any pressure it is not necessary to use Schedule 40 pipe for drain lines DO NOT use teflon tape pipe dope or other sealants The use of a sealant may cause damage and premature failure of hte drain pan SECTION IV 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 The HEAT ENABLE jumper See Figure 10 must be moved to the HEAT position to enable operation of the heater Use only 4HK heater kits as listed on Air Handler name plate and in these instructions Use data from Tables 10 and 13 for information on required minimum motor speed tap to be used for heating operation maximum over current protection device required and minimum electri cal supply wiring size required for l
11. 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 Ventilat ing 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 sug gested transition can not be fabricated it is recommended a block off plate approximately 8 in height and running the full width of the ple num 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 RECOMMENDED TRANSITION SUGGESTED LOCATION OF BLOCK OFF PLATE 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 perma
12. 182 492 oss 36 48 72 98 i44 192 4HKiesozs06 08 Heic 180 240 15 819 36 48 108 144 180 240 1 See conversion Table 9 May be 0 no breaker or 1 with breaker Johnson Controls Unitary Products 13 536636 UIM D 1211 TABLE 11 Electrical Data For Single Source Power Supply Copper Wire 208 230 1 60 Heater Field Wiring Amps Min Circuit Ampacity Max O C P Amps Type 75 C Wire Size AWG 240V 208V 230V oe 2 208V 230V Meee OOO 1528 C A ee ee power 4HK 6500506 a zu a II A E Heater Models arrcs50080s 33 3785 4289 4 4 8 9 4HKes00 400 4733 538 5 9 8 akene S42 628 713 79 8 4 2 akeno 300 6900 788 o 9 4 3 4HKesB0 33 3978 4458 4 4 98 9 4HKes0Q 400 4021 5539 5 9 8 akene S42 a 7288 70 8 4 2 eem oo ms ws m 9 3 3 akese 783 3532 9700 9 39 4 3 4HKes0506 200 929 318 35 35 8 9 4HKes0806 3i3 4148 460 4 95 98 e 4HK65006 400 5096 5888 9 9 6 6 akese S42 e4 782 o 8 4 2 eom ss ee wm w 9 3 3 akese 783 8707 985 9 ww 3 2 aires 25 10688 6 9s 3 3 aires 1000 m9 mr 39 5 1 4HKess0 200 aaa 3375 35 3 8 9 4HK6s0806 33 438 4785 4 599 casos 09 5m 575 9
13. 3 Low Voltage Connections Terminal Comment R 24vaCpower used SCS Continuous Fan operation compressor operation Y4 First stage compressor Not used with outdoor units operation having one stage compressors Secondstegeheatoperaon Firststage heat operation i 24 VAC will be present at this terminal when the MODE jumper is in the AC position This is normal 24 VAC will be present at this terminal when the HUM STAT jumper is in the NO position This is normal This terminal is a connection point only and does not affect air handler control operation Reversing valve operation Humidity switch input Connection point for heat pump fault indicator 24 VAC common SECTION VI REQUIRED CONTROL SET UP X L IMPORTANT The following steps must be taken at the time of installation to insure proper system operation 1 Consult system wiring diagram to determine proper thermostat wiring for your system 2 If heat kit is installed change HEAT NO HEAT jumper from NO HEAT to HEAT position 3 If a humidistat is installed change HUM STAT jumper from NO to YES 4 Set the MODE jumper to A C Air Conditioner or HP Heat Pump position depending on the outdoor unit included with the system 5 Setairflow and comfort setting jumper to proper positions FUNCTIONALITY AND OPERATION Jumper Positions HEAT NO HEAT Jumper The HEAT NO HEAT jumper configures the control for heat kit opera tion
14. E eeeeeeeeeeeeee n n n n nnn 17 LOW VOLTAGE CONTROL CONNECTIONS 7 WIRING DIAGRAM enn n Kn 18 REQUIRED CONTROL SET UP leess 10 Typical InstallallOli cuc Peden ay sus o rn eee dead eun ee tw er es 3 TV uoi eeu oe ee ee Ce NDS UNS WEE d CET NNS NE Mq 6 Return Duct Attachment amp Component Location 3 Proper Bulb Location 0 0 cc eee eee 6 Dimensions amp Duct Connection Dimensions 4 Air Handler Control Board Communications Connections 7 Condensate Deflector on Vertical Drain Pan 4 Cooling Models with and without Electric Heat Wiring 8 Condensate Deflecctor on Horizontal Drain Pan Edge 5 Two Stage Heat Pump Wiring 000 eee eee eee 9 S Clip InstallallOlt 222 4 o aed adea ge sees 3n a x ambos 5 Air Handler with Communicating AC or HP 08 9 Duck Work Transition 0 00000 cee ee 5 Line Power Connections 000 cee eects 11 Typical Horizontal Installation 0 0000 ee eee 6 Wiring Diagram s ses ccu ado tn rec eoo SS ae m e eR 18 LIST OF TABLES DIMENSIONS 3 dace ie d don ito ao io een de deb derer RR E d pu a 4 Electrical Data For Single Source Power Supply Low Voltage Connections 0 0000 eee 8 Copper Wire 208 230 1 60 0 0 ee 14 Low Voltage Connections 000 0c eee 10 Electrica
15. ERMOSTAT 1 Y Y2 Terminal on air handler control board must be connected for full CFM and applications requiring 60 second blower off delay for SEER enhancement 2 Remove humidistat jumper on air handler control board 3 For heat pump applications set MODE jumper on air handler control board to the HP position 4 To change quantity of heat during HP defrost cycle reverse connections at W1 and W2 on air handler control board 8 Johnson Controls Unitary Products 536636 UIM D 1211 CONTROL WIRING Air Handler amp UPG HP Systems Two Stage H P with York Guard VI Board amp Copeland Ultra Tech Conventional Application Not Hot Heat Pump AIR HANDLER THERMOSTAT FIGURE 13 Two Stage Heat Pump Wiring Optional dehumidification humidistat switch contacts open on humidity rise NOTES 2 STAGE SCROLL HEAT PUMP 1 Y Y2 Terminal on air handler control board must be connected for full CFM and applications requiring 60 second blower off delay for SEER enhancement 2 Remove humidistat jumper on air handler control board 3 For heat pump applications set MODE jumper on air handler control board to the HP position 4 To change quantity of heat during HP defrost cycle reverse connections at W1 and W2 on air handler control board CONTROL WIRING USING COMMUNICATING CONTROLS Use the wiring diagram below to connect the air handler control Com municating Control wall thermostat and communicating outdoor unit
16. FLOW DOWNFLOW DUCT BE FASTENED CAUTIOUSLY WITH gt ba abd SCREWS TO THE SECONDARY DRAIN WHEN ATTACHING DUCT WORK WITH SIDES AND REAR OF UNIT UPFLOW 3 4 THREADED SCREWS KEEP SCREWS WITHIN 5 8 OF SIDES AND BACK OF AIR HANDLER FIGURE 2 Return Duct Attachment amp Component Location Johnson Controls Unitary Products 3 536636 UIM D 1211 CLADDING CONFIGURATION FOR DOWNFLOW INSTALLATION IF USED NOTICE To reconfigure the cladding parts remove the grille by pulling gently at If a heat kit with a circuit breaker is installed in the air handler the cir the top Once the grille is removed the circuit breaker cover can also be cuit breaker cover cladding must be removed to gain access to the removed Remove the gray non branded grille and circuit breaker sheet metal cover plate Some local codes may require that the circuit cover from the cladding on the coil access panel Next remove the breaker remain visible If so do not re install circuit breaker cover black and or branded grille and circuit breaker cover from the blower cladding 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 CLADDING TOP OUTLET CIRCUIT DIMENSIONS BREAKER PANEL BLOWER EME BOTTOM INLET DIMENSIONS DRAIN CONNECTIONS FOR UPFLOW AND DOWNFLOW APPLICATIONS REFRI
17. FT SLI YO OIISVIdONS3HI 9 601 HLIM 039V 1438 38 LSAW LI 13941438 38 ISAW LINA SIHL HLIM Gal 1ldd S 381M 1VNIOISO FHL JO ANY dl C 4009 WOOT INV IVNOIIVN Ol WJOJNOD ISAW ONTYIM ASNENI TWNOSUdd ONY INAWdINOF JHL OL 39VNVO 1819504 1IN3A34d OL 9NI2IAS3S 4404138 YAMOd V2I8412313 440 NANI GYVZVH MOOHS 839NVO SO Tg CI TOCINA TU Cc DO N49 IHM M18 038 gh LLL 04VO8 TOULNOD NOD WAVE JONVYO 940 jLIHM LHM MOTIJA 13A 034 038 31d4Nd und N3J189 NYS NMOYg NYG 49418 418 3009 40109 d INIOd 43N30 1X NOI123NNOO 0 2 902 11 1V3H n WvVu9vid H3QQV 1 id i pn roa T UNI JINJO FX B 12 FEE 0000000 6 o d uu TAA NI 9N WVYOVIC ONIJIM ano H A INO SYOLINGNOD 434409 JSN NIOd l NOI123NNO2 V LIM 1V3H AlddNAS 3SVHd ZH 09 IVA 0 80 FIGURE 16 Wiring Diagram 536636 UIM D 1211 Supersedes 536636 UIM C 1010 Copyright 2011 by Johnson Controls Inc All rights reserved Subject to change without notice Published in U S A Johnson Controls Unitary Products 5005 York Drive Norman OK 73069
18. GERANT _ FIGURE 3 Dimensions amp Duct Connection Dimensions TABLE 1 Dimensions Dimensions Inches Wiring Knockouts Refrigerant Models Connections Height Width Depth Power Control Liquid Vapor 2488 46 17412 l 12 3 8 13 29 32 14 1932 34 huoc 171 8 17 13 82 1 amp 8 82 6 112 718 1 3 8 1 7 8 1 2 24 1 2 2244 2 22 1 8 20 29 32 21 19 32 1 23 30 1 1 4 7 8 6D 57 2412 with cladding 22 1 8 20 29 32 21 19 32 7 8 1 Actual size Conduit size SUCTION FEEDER TUBE CONDENSATE Horizontal Left or Right DEFLECTOR Use an appropriate tool to pry out water deflector with two or three s UPFLOW OR DOWNFLOW clips from the vertical drain pan See Figure 4 Relocate the deflector l l l with s clips on the Horizontal Drain Pan lined up to the coil support No action required See Figure 4 brackete See Figure 5 This positions the deflector below the feeder tubes to channel the condensate to the drain pan NOTICE The condensate deflector should be installed in the s clip section which is inside the drain pan edge See Figure 6 o Sala si N SN U VERTICAL CONDENSATE DRAIN PAN DFFI ECTOR FIGURE 4 Condensate Deflector on Vertical Drain Pan 4 Johnson Controls Unitary Products aa qc 2 f bI ne f ITE gt into E CONDENSATE DEFLECTOR FIGURE 6 S Clip Installation DUCT CONNECTIONS A WARNING
19. Limit Switch Operation If the HEAT ENABLE jumper is in the HEAT position and the limit switch opens fault code 1 the control will immediately de energize all electric heat relay outputs and energize the blower if it wasn t already ener gized When the limit switch closes the control will re energize electric heat according to the thermostat inputs using normal timings Fan On Lock Condition If the limit switch opens multiple times during a single call for electric heat fault code 3 or if the limit switch opens for a long duration fault code 4 the control will energize the blower until power is removed from the control The control will cycle the heat outputs on and off as the limit re closes and opens The constant fan operation will signal the home owner that a problem has occurred and a service call is required Soft Lockout If the limit switch opens for a second long duration period during a sin gle call for heat fault code 5 the control will keep the blower locked on and lock out the heat outputs for one hour The control will only reset this one hour lockout when the power is removed from the control After the one hour period has passed the control will re energize electric heat according to the thermostat inputs using normal timings The blower will remain locked on from the first long duration limit opening TYPICAL WIRING WITHOUT ELECTRIC HEAT GnD LuG H PNG d GND LUG SUPPLY 1 PHASE ELECTRIC HEAT SUPPL
20. RS O SPARE JUMPER THERMOSTAT CONNECTIONS FIGURE 11 Air Handler Control Board Communications Connections Johnson Controls Unitary Products CONTINUOUS FAN JUMPER 536636 UIM D 1211 CONVENTIONAL LOW VOLTAGE CONTROL WIRING 24 VAC The 24 volt power supply is provided by an internally wired low voltage transformer which is standard on all models However if the unit is con nected to a 208 volt power supply the low voltage transformer must be rewired to the 208 volt tap See the unit wiring label Field supplied low voltage wiring can exit the unit on the top right hand corner or the right hand side panel Refer to Figure 3 Remove desired knockout and pierce foil faced insulation to allow wir ing to pass through Use as small of a hole as possible to minimize air leakage Install a 7 8 plastic bushing in the selected hole and keep low voltage wiring as short as possible inside the control box To further minimize air leakage seal the wiring entry point at the outside of the unit The field wiring is to be connected at the screw terminals of the control board Refer to Figure 11 and 12 NOTICE All wiring must comply with local and national electrical code require ments Read and heed all unit caution labels NOTICE It is possible to vary the amount of electric heat turned on during the defrost cycle of a heat pump Standard wiring will only bring on the first stage of electric heat during def
21. SETTINGS HEAT Tap ADJ Tap an 47 2868 1488 598 401 es er A Ay ig iz 214 i2 526 sa as 354 B Aw 1480 1868 1061 1250 im es 354 as 393 ss D w 1 Airflow at nominal voltage bottom return at 0 5 external static pressure tested without filter installed dry coil conditions 2 These units have variable speed motors that automatically adjust to provide constant CFM from 0 0 to 0 6 w c static pressure 3 From 0 6 to 1 0 static pressure CFM is reduced by 2 per 0 1 increase in static 4 Operation on duct systems with greater than 1 0 w c external static pressure is not recommended 5 Both the COOL and the ADJUST tap must be set to obtain the cooling airflow desired CFM 6 The ADJ tap does not affect the HEAT tap setting 7 8 9 1 gt n O Low speed cooling used only with two stage outdoor units Speed is preset to 65 of high speed Dehumidification speed is 85 of jumper selected COOL tap and ADJUST tap When operating in both heat pump and electric heat modes the airflow CFM will be per HEAT Tap CFM values only 0 At some settings LOW COOL and or LOW HEAT airflow may be lower than what is required to operate an airflow switch on certain models of electronic air cleaners Consult the instructions for the electronic air cleaner for further details 11 Airflow CFM indicator light LED2 flashes once for every 100 CFM i e 12 Flashes is 1200 CFM
22. Y WITH CIRCUIT BREAKER amp BREAKER BAR REMOVED ELECTRIC HEAT WITHOUT CIRCUIT BREAKER 3 PHASE 10 15 KW 536636 UIM D 1211 Hard Lockout The control has a hard lockout condition during which the control will keep all heat outputs de energized until power is removed from the con trol The control de energizes the blower five minutes after entering the hard lockout condition If the limit switch closes and re opens during the one hour soft lockout period the control will enter a hard lockout condition and continue to indicate a fault code 5 If the limit switch opens twice when no call for electric heat is present fault code 2 the control will enter a hard lockout condition If the limit switch opens multiple times soon after a soft lockout reset fault code 6 the control will enter a hard lockout condition Wiring Related Faults If the control receives a simultaneous call for heating and cooling fault code 7 the control will perform both heating and cooling operations SECTION VII LINE POWER CONNECTIONS Power may be brought into the unit through the supply air end of the unit top when unit is vertical or the left side panel Use the hole appro priate to the unit s orientation in each installation to bring conduit from the disconnect The power lead conduit should be terminated at the electrical control box Refer to Tables 11 12 14 and 15 to determine proper wire sizing To minimize air leakage seal the
23. evaporator coil Refer to Table 16 for the possible high speed cooling and heat pump airflow selections Find the recommended system airflow in Table 16 for the installed air handler model Select the COOL airflow you need from Table 16 Set the COOL and ADJUST Jumpers on the control as indicated in Table 16 To Set Heat Pump Airflow The heat pump airflow setting is the same as the cooling airflow setting No additional airflow setting is required However you must set the MODE jumper to the HP position for proper system operation See Fig ure 11 To Set Electric W1 Heat Airflow The blower speed required for 1st stage electric heat is different than cooling Refer to Table 16 for the possible CFM selections Refer to Table10 for the minimum required airflow for the electric heater installed Find the desired airflow in Table 16 for low heat Set the HEAT jumper on the control as indicated in Table 16 To Set W2 Electric Heat Airflow Airflow for any W2 input which is for Stages 2 amp 3 of electric heat is the indicated CFM for high heat tap selection on Table 16 DO NOT change the ADJUST tap position on the control as this will change your cooling airflow previously selected SECTION IX UNIT DATA TABLE 7 Physical and Electrical Data Cooling Only 60 Hz Fan Only CFM When the connection is made from R to G the fan only mode is acti vated In this mode the airflow will depend on the position of the CONT Fan jumpe
24. hand horizontal position If unit requires left hand positioning 9 For horizontal applications rotate air handler 90 into desired ori the unit must have the coil assembly repositioned entation 1 Remove blower coil and filter access panels 10 Re position drain plugs as necessary based on air handler orienta tion N OTI C E 11 Re position and replace access panels l l 12 For downflow installations the cladding should be reconfigured so dol ua must be made before brazing the refrigerant connections 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 For downflow and horizontal left installations follow steps 2 8 2 Remove tubing connection panel 13 3 Remove front drain pan hold down bracket 4 Slide coil assembly out of air handler 5 Rotate cabinet 180 so blower outlet is facing down 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 FRONT VIEW BLOWER COMPARTMENT COIL COMPARTMENT Access panel removed VERTICAL 7 DRAIN PAN HORIZONTAL DRAIN PAN SIDE VIEW REFRIGERANT LINE CONNECTIONS HORIZONTAL SECONDARY DRAIN PRIMARY DRAIN HORIZONTAL UPFLOW 3 4 a PRIMARY DRAIN THREADED S ALTERNATE T la ae AA DRAIN CONNECTIONS RETURN AIR DUCT WORK MAY RA A UP
25. iquid lines 8 Remove the heat shield 9 Re attach the grommets to the lines carefully to prevent air leak age 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 strap ping 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 Johnson Controls Unitary Products DRAIN CONNECTIONS All drain lines should be trapped a minimum of three inches should be pitched away from unit drain pan and should be no smaller than the coil drain connection ACAUTION Threaded drain connection should be hand tightened plus no more than 1 16 turn Route the drain line so that it does not interfere with accessibility to the coil air handling system or filter and will not be exposed to freezing temperatures See Figures 2 and 3 for drain connection locations NOTICE When the coil is installed in an attic or above a finished ceiling an auxiliary drain pan should be provided under the coil if specified by local building codes Coils should be installed level or pitched slightly toward the drain end Suggested pitch should not exceed 1 4 inch per foot of coil The coil is provided with a secondary drain that should be trapped and piped to a location that will give
26. isted combination of Air Handler and Heater Kit HEAT ENABLE JUMPER y SNOULVOINFIINDO o p i gr eE Com RARE G Y Y2 Yi W2 Wi O HUM XL COM HUMIDIFIER OUT PUT 536636 UIM D 121 1 For Upflow Downflow and Horizontal right hand applications the kits can be installed without modification Field modification is required for Horizontal left hand airflow application only Follow instructions with heater kits for modification NOTICE If a heat kit with a circuit breaker is installed in the air handler the cir cuit 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 SECTION V LOW VOLTAGE CONTROL CONNECTIONS This air handler can be connected to the wall thermostat and outdoor air conditioner or heat pump using either conventional low voltage 24 VAC thermostat wiring OR using four wire digital communications wir ing To use conventional low voltage wiring see the section below enti tled Conventional Low Voltage Control Wiring To use four wire communications control wiring see the section below entitled Control Wiring using Communicating Controls The Communicating System consists of several intelligent communicat ing components including the Communicating Thermostat Control touch screen wall thermostat variable speed air handler air co
27. l Data For Multi Source Power Supply EQUINOS 4b amuses aW ga ER chee eed io he annem Ea bie ees p 10 Copper Wire 208 230 1 60 0 0 ee 14 Heat Relays 0 4 22 dd chee Cee Aene dde ay Gd oie de Hoek ada 11 Electrical Data 208 230 3 60 2 0 0 ccc ee eee 15 Comfort Setting Selection 0 0 12 Electrical Data For Single Source Power Supply Physical and Electrical Data Cooling Only 60 Hz 12 Copper Wire 208 230 3 60 0 ccc ees 15 Electrical Data Cooling Only 60 Hz 2022000 eee 13 Electrical Data For Multi Source Power Supply Sono ta MOR ee ae eRe Gone ee BRE 13 Copper Wire 208 230 3 60 0 0 0 ees 15 Electrical Data 208 230 1 60 0 2 00 ee 13 Air Handler Air Flow Data 00 00 cee eee 16 SECTION I GENERAL 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 hor izontal position Top and side power wiring and control wiring accessible screw termi nals for control wiring easy to install drain c
28. low the safety warnings exactly could result in serious injury death or property damage A fire or electrical hazard may result causing property damage per sonal injury or loss of life 536636 UIM D 1211 536636 UIM D 1211 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 cir culated 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 Theair 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 dime
29. mperature 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 NOTICE 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 braz ing instructions 7 Braze the suction and l
30. ndi tioner 15 and 18 SEER premium air conditioners or heat pump 13 15 and 18 SEER premium heat pumps which continually communicate with each other via a four wire connection called the A R Gnd or C B bus Commands operating conditions and other data are passed con tinually between components over the A R Gnd or C B bus See Figure 13 The result is a new level of comfort versatility and simplicity In order to use this air handler in full communications COMM mode it MUST be installed with the matching touch screen Communicating Control wall thermostat and an outdoor air conditioner or heat pump with a fully communicating control This air handler may also be used along with the Communicating Ther mostat Control and a non communicating outdoor air conditioner through the addition of a communicating Outdoor Aux Control board to the outdoor unit This system allows full communication between the air handler and thermostat and limited communication to the outdoor unit This air handler may also be used along with the Communicating Ther mostat Control and a non communicating outdoor air conditioner or heat pump using COMM between the air handler and thermostat and conventional 24V wiring to the outdoor unit This system allows full communication between the air handler and thermostat but no digital communication with the outdoor unit See Figure 14 EAC OUTPUT AC HP JUMPER HUMIDSTAT JUMPER MODEL PLUG BLOWER SPEED JUMPE
31. nent or throw away filter may be used or permanent washable filters are available using model num bers 1PF0601 602 603BK See Table 8 for filter size ACAUTION Equipment should never be operated without filters HORIZONTAL SUSPENSION AV ONLY For suspension of these units in horizontal applications it is recom mended to use angle steel support brackets with threaded rods sup porting 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 ceil ing an auxiliary drain pan should be provided under the air handler as is specified by most local building codes 536636 UIM D 1211 SUSPENSION SUPPORT LOCATIONS FOR HORIZONTAL APPLICATIONS MIN 3 8 THREADED ROD ae MIN 1 1 2 x 1 1 2 Angle Recommended length 26 minimum with 2 clearance on both gp sides of Air Handler Units Dimension Nominal Tons FIGURE 8 Typical Horizontal Installation 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 VAPOR THERMAL we EXPANSION VALVE BULB Required insulati
32. nsions page of this instruction for supply air ple num dimensions in Figure 3 The plenum must be installed accord ing 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 electri cal characteristics match 7 Air handler shall be installed so the electrical components are pro tected from water 8 Installing and servicing heating cooling equipment can be hazard ous due to the electrical components Only trained and qualified personnel should install repair or service heating cooling equip ment 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 cons
33. ny effect on the operation of the control Airflow and Comfort Setting Jumpers See separate section Status and Fault Codes The control includes an LED that displays status and fault codes These codes are shown in Table 4 The control will display the fault codes until power is removed from the control or the fault condition is no longer present TABLE 4 Fault Codes LED1 RED Flash Code No power to control OFF Normal operation 2s ON 2s OFF Control in test mode Rapid Flash Control failure ON Limit Faults Limit switch currently open not in lockout Fault or Status Condition Multiple limit openings with no call for heat Multiple limit openings during one call for heat Single long duration limit opening Multiple long duration limit openings Fan failure Simultaneous call for heating and cooling nternal Control Faults Control recovered from internal event External Relay Outputs The control includes two outputs to drive external relays having 24 VAC coils The outputs have a maximum rating of 1 0 Amp pilot duty at 24 VAC HUM OUT The HUM OUT output can be used to drive an external relay or solenoid 24 VAC coil to control a humidifier The output is energized when the HUM input is energized the HUM STAT is in the YES position and the control has a thermostat call for heating heat pump or electric heat EAC The EAC output can be used to drive an external relay 24 VAC coil to control an electronic air cleaner The
34. on LIQUID LINE THERMAL EXPANSION VALVE EQUALIZER LINE DISTRIBUTOR BODY 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 TXV BULB Cover completely with insulation SUCTION LINE FIGURE 10 Proper Bulb Location ACAUTION 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 to coil nameplate for TXV identification for this unit NOTICE 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 can not 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 ACAUTION Coil is under inert gas pressure Relieve pressure from coil by depressing schrader core ACAUTION Dry nitrogen should always be supplied through the tubing while it is being brazed because the te
35. onnections and electric heaters all combine to make the installation easy and minimize installa tion cost SECTION II SAFETY This is a safety alert symbol When you see this symbol on A 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 dam A WARNING 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 assis tance or for additional information consult a qualified contractor installer or service agency ACAUTION 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 AWARNING FIRE OR ELECTRICAL HAZARD Failure to fol
36. output is energized whenever the blower relay on the control is energized Heat Output and Limit Connections The control is connected to the heater relays and limit switch using the 6 pin connector The relay outputs and the limit switch signal are 24 VDC The control energizes the heat relays and senses the limit switch input as shown in Table 5 when the HEAT ENABLE jumper is in the HEAT position Johnson Controls Unitary Products TABLE 5 Heat Relays pu Heat Relay Output W2 HT1 and HT2 W1 and W2 HT1 and HT2 and HT3 The control energizes the first stage of electric heat immediately the second stage 10 seconds after the call for second stage heat and the third stage 20 seconds after the call for third stage heat Depending on the heat kit installed in the air handler the control pro vides the flexibility to configure the amount of heat delivered with the first stage heating call As an example when the control s W1 input is connected to the room thermostat s first stage heat signal a call for first stage heat will energize one heating element HT1 If the control s W2 input is connected to the room thermostat s first stage heat signal a call for first stage heat will energize two heating elements HT1 and HT2 With either configuration the control will energize three heating ele ments HT1 HT2 and HT3 when it receives a first and second stage heat input from the thermostat Limit Switch and Lockout Operation
37. ovided by an internally wired low voltage transformer which is standard on all models However if the unit is con nected to a 208 volt power supply the low voltage transformer must be rewired to the 208 volt tap See the unit wiring label Field supplied low voltage wiring can exit the unit on the top right hand corner or the right hand side panel Refer to Figure 3 Remove desired knockout and pierce foil faced insulation to allow wir ing to pass through Use as small of a hole as possible to minimize air leakage Install a 7 8 plastic bushing in the selected hole and keep low voltage wiring as short as possible inside the control box To further minimize air leakage seal the wiring entry point at the outside of the unit The field wiring is to be connected at the screw terminals of the control board Refer to Figures 11 or 12 NOTICE All wiring must comply with local and national electrical code require NOTICE It is possible to vary the amount of electric heat turned on during the defrost cycle of a heat pump Standard wiring will only bring on the first stage of electric heat during defrost See Heat Output and Limit Connections and Table 5 for additional information on heat during defrost cycle 536636 UIM D 1211 The low voltage connections may be connected to the screw terminals or the quick connect terminals The screw terminals and the quick con nect terminals are physically connected on the control board TABLE
38. r In the H position the blower will deliver 85 90 of full capacity In the M position the blower will deliver 60 65 of full capacity In the L position the blower will deliver 30 35 of full capac ity Blower Ramp Up Ramp Down To minimize the sound made by the blower when it speeds up or slows down the blower will slowly ramp up or down from one speed to another Changes in blower speed during A C or heat pump heating can take up to 30 seconds Changes in blower speed during electric strip heating can take up to 15 seconds COMFORT SETTINGS TABLE 6 Comfort Setting Selection DELAY TAP COMFORT SETTING Normal a rais Normal The normal setting provides a ramp up from zero airflow to full capacity and a ramp down from full capacity back to zero airflow Humid The humid setting is best suited for installations where the humidity is frequently very high during cooling season such as in the southern part of the country On a call for cooling the blower will ramp up to 5096 of full capacity and will stay there for two minutes then will ramp up to 82 of full capacity and will stay there for five minutes and then will ramp up to full capacity where it will stay until the wall thermostat is sat isfied Dry The dry setting is best suited to parts of the country where excessive humidity is not generally a problem where the summer months are usu ally dry On a call for cooling the motor
39. rcuit Breaker or Time Delay fuse T4 Anson Controls Unitary Products 536636 UIM D 1211 TABLE 13 Electrical Data 208 230 3 60 4HKOG501025 72 6 es 3 8 72 98 Total TotalHeat kW Staging rad des LUN wrong WO WEE Tap 05 72 96 72 96 BRE 35 henc T2 s6 HT ea Tz osre 38 T2 08 amp HKUGSUTS2S 05 HeatO 108 i44 389 49 1 108 144 108 i44 108 144 amemus os HesrC 72 os eae sts Tz 98 Tz 86 72 95 iHKOGSUTSZS 4HK06501825 osos 05 Feic 72 8 2s 28 72 95 72 98 72 98 iHKOGSUTSZS iHKOGSUTEZS aTeo 03 HewrC 180 240 514 814 90 120 180 249 180 240 1 See conversion Table 9 TABLE 14 Electrical Data For Single Source Power Supply Copper Wire 208 230 3 60 oe S Lee arse ts 3HKOGBoiROS LE Less 4HKooT 34 438 498 LEE are 559 a E 33 8 Ko 414 458 588 Lame 97 383 a 8 a pp 1 O C P Over Current Protection device must be HACR type Circuit Breaker or Time Delay fuse Heat Kit Three Phase TABLE 15 Electrical Data For Multi Source Power Supply Copper Wire 208 230 3 60 Minimum Circuit Ampacity Max O C P Amps Type 75 C Wire Size AWG Heater Model Circuit it f md 3rd WE E 208 230 208 230 208 230 208 230 208 230 208 230 208 230 Lr ML 90 esos p sus sar 398 95 8 5 f 1 O C P Over Cur
40. rent Protection device must be HACR type Circuit Breaker or Time Delay fuse Johnson Controls Unitary Products 15 536636 UIM D 1211 TABLE 16 Air Handler Air Flow Data HIGH LOW SPEED COOLING AND HEAT PUMP AIRFLOW 3 EEM JUMPER SETTINGS 8 350 3 8 360 Low Low Low Low COOL Tap ADJ Tap 1088 707 1887 908 830 542 w 188 8326 3 B 348 783 716 465 657 208 182 386 186 B 854 566 708 612 462 953 622 697 460 ao sS 180 Bo 255 166 8 5m 460 754 Bo ro as mo D 542 462 ss 540 462 462 667 460 ei wi 86 no D 474 460 751 494 ag 464 588 wi 3181 11 1686 181 OD 48 95 a o JUMFERSETTNGS Hugh iow Aa iw m iow Huh low COOL Tap ADJTap 218 1042 284 158 os 408 es 4837 A 8 i75 ne i92 iz 498 328 ss o B B i622 102 63 46 456 298 es 8334 B A 1580 38 77 58 483 289 508 3288 B 39 9 1580 i 43 258 447 2389 B 0 i859 886 1596 105 388 25i 482 22 D B 158 sw 183 tor 53 56 448 288 0 A 122 C ME iz 84 se s se oe bo c O HIGH LOW SPEED ELECTRIC HEAT AIRFLOW CFM 8 350 o 350 1088 95 7 18 8M 270 202 348 28 B w e s 95 8e 192 48 261 172 48 80 O 38 JUMPER
41. rost See Heat Output and Limit Connections and Table 5 for additional information on heat during defrost cycle Air Handler Control Wiring Typical A C Cooling only Applications AIR HANDLER THERMOSTAT 4 STAGE AIR CONDITIONING FIGURE 12 Cooling Models with and without Electric Heat Wiring Optional dehumidification humidistat switch contacts open on humidity rise NOTES TABLE 2 Low Voltage Connections Terminal Signal Comment 24 VAC power use Continuous Fan operation compressor operation Y1 First stage compressor Not used with outdoor units operation having one stage compressors Secondstageheatoperalon oo Fist stage heat operation i Reversing valve operation 24 VAC will be present at this terminal when the MODE jumper is in the AC position This is normal 24 VAC will be present at this terminal when the HUM STAT jumper is in the NO position This is normal This terminal is a connection point only and does not affect air handler control operation Humidity switch input Connection point for heat pump fault indicator COM 24 VAC common X L The low voltage connections may be connected to the screw terminals or the quick connect terminals The screw terminals and the quick con nect terminals are physically connected on the control board Air Handler Control Wiring Typical A C with Electric Heat Applications AIR HANDLER BOARD 1 STAGE AIR CONDITIONING TH
42. truction 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 dam age during transit If damage is evident the extent of the damage should be noted on the carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing Also before installation the unit should be checked for screws or bolts which may have loosened in transit There are no shipping or spacer brackets which need to be removed Also check to be sure all accessories such as heater kits suspension kits and coils are available Installation of these accessories or field conversion of the unit should be accomplished before setting the unit in place or connecting any wiring electric heat ducts or piping LIMITATIONS These units must be wired and installed in accordance with all national and local safety codes Voltage limits are as follows 1 Air Handler Voltage Voltage code Normal Operating Voltage Range 187 253 asesoro 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 Dry Bulb Temp F Vin 65 SECTION lll UNIT INSTALLATION CLEARANCES Clearances must be taken into consideration and provided for as fol lows 1 Refrigerant piping and connections
43. ve the occupant a visual warn ing that the primary drain is clogged If the secondary arain is not used it must be capped Proper electrical supply must be available 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 Johnson Controls Unitary Products 536636 UIM D 1211 ACAUTION NOTICE When an evaporator coil is installed in an attic or above a finished In severe high humidity high temperature indoor unit environments ceiling an auxiliary drain pan should be provided under the coil as is an accessory insulation blanket is available to supplement the stan specified by most local building codes dard cabinet insulation Insulate with UPG kit 1VJ0117 for B cabi nets 1VJ0121 for C cabinets or 1VJ0124 on D cabinets or seal completely with adequate fiberglass insulation using vapor barrier on the outside UPFLOW DOWNFLOW HORIZONTAL LEFT LEFT FIGURE 1 Typical Installation DOWNFLOW AND HORIZONTAL CONVERSION 6 Re install coil assembly on downflow bracket AV ONLY 7 Re attach front drain pan hold down bracket These air handler units are supplied ready to be installed in a upflow 9 Re attach tubing connection panel and right
44. will ramp up to full capacity and will stay there until the thermostat is satisfied At the end of the cooling cycle the blower will ramp down to 509 of full capacity where it will stay for 60 seconds Then it will ramp down to zero Temperate The temperate setting is best suited for most of the country where nei ther excessive humidity nor extremely dry conditions are the norm On a call for cooling the motor will ramp up to 63 of full capacity and will stay there for 90 seconds then will ramp up to full capacity At the end of the cooling cycle the motor will ramp down to 63 of full capacity and will stay there for 30 seconds then will ramp down to zero Bower Diameter x WE T8 fox 1 3 Motor Voltage vonage Fiter 1 Field Supplied 16 x 20 x1 1PF0601BK 12 1 2 3 4 RPM 1200 1200 1200 20 DISPOSABLE OR PERMANENT 20 x 20 x1 22 x 20 x1 1PF0602BK 1PFO603BK 22 x 20 x1 1PFO603BK Johnson Controls Unitary Products 536636 UIM D 1211 TABLE 8 Electrical Data Cooling Only 60 Hz Li Total Motor Amps Minimum Circuit Ampacity Max O C P Wi O C P inimum Wire Amps Type Size A W G 208V 230V 208V 230V 1 OCP Over Current Protection device must be HACR type Circuit Breaker or Time Delay fuse TABLE 9 Conversion Table kW 8 MBH Conversions for Total Power Input Requirement FOR 230V OPERATION MULTIPLY 240V TABULATED kW amp MBH BY TABLE 10 Electrical Data 208 230 1
45. wiring entry point at the outside of the unit All electrical connections to air handlers must be made with copper con ductors Direct connection of aluminum wiring to air handlers is not approved If aluminum conductors are present all applicable local and national codes must be followed when converting from aluminum to copper con ductors prior to connection to the air handler If wire other than uncoated non plated 75 C ambient copper wire is used consult applicable tables of the National Electic Code ANSI NFPA 70 The chosen condutor and connections all must meet or exceed the amperage rating of the overcurrent protector circuit breaker or fuse in the circuit Additionally existing aluminum wire within the structure must be sized correctly for the application according to National Electric Code and local codes Caution must be used when sizing aluminum rather than copper conductors as aluminum conductors are rated for less current than copper conductors of the same size 1 PHASE ELECTRIC HEAT WITH CIRCUIT BREAKER AS SHIPPED FROM FACTORY SINGLE SOURCE 2 5 25 KW 25 KW SHOWN GND LUG CH se TERMINAL BLOCK MULTI SOURCE 15 25 KW 25 KW SHOWN GND LUG GND B LUG PE SUPPLY14 __ POWER SUPPLY24 POWER SUPPLY 3 MAY BE 1 2 OR3 CIRCUIT BREAKERS FIGURE 15 Line Power Connections Johnson Controls Unitary Products ELECTRIC HEAT WITHOUT CIRCUIT BREAKER SINGLE SOURCE
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