Coleman Single Piece Air Handlers F*FP User's Manual
Contents
1. 292043 UIM B 0707 292043 UIM B 0707 SPECIFIC SAFETY RULES AND PRECAUTIONS 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 per sonal injury or loss of life 1 Install this air handler only in a location and position as specified in SECTION 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 outside the space containing the air handler 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 calculation for the structure ACCA Manual J or other approved methods may be used SAFETY REQUIREMENTS e 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 appl2. if By h y nid y d y l a yy Mul 101 i prema ll UD Ban SINGLE PIECE AIR HANDLERS MODELS F FP y d lt Iiii y d Mha Daa Th Lhe TL LT T ee ih 000 REGISTRA ISO 9001 Certified Quality Management System CC Ca Ca pa TABLE OF CONTENTS e eS ocenonnescd seb eons eee eee necas sashes ckues 1 SPECIFIC SAFETY RULES AND PRECAUTIONS 2 SAFETY REQUIREMENTS vecinos ss 2 GENERAL INFORMATION o occcccccoccccccc 2 INSPECTION sor srassassdurs ads ados da oe ee 2 LIMITATIONS 4 20 cee tects tereedegeeaed sore rte 2 CLEARANCES faicdeseds cet eeund stedeebeceegceetueteeees 2 LOCACI N yas cet gasas desatada dedo a es 2 HORIZONTAL DRAIN PAN CONVERSION occ 3 DUCT CONNECTIONS soii dare 5 a A o EE PR 5 SUSPENSION KINGS i cccusctedecincanraedvteas ds Sebedese ees 5 COIL METERING DEVICES zerik rai aeda a a a e ee D REFRIGERANT LINE CONNECTION 054 6 ELECTRIC HEATERS 8 OPERATING CONTROLS 6 LOW VOLTAGE CONTROL CONNECTION 4 8 LINE POWER CONNECTIONS 00000 eee eee 8 BLOWER SPEED CONNECTIONS 00 0000050 8 DRAIN CONNECTIONS ooo 16 MAINTENANCE son secuaces sico pia liada 16 COIL CLEANING creer ce tar 16 LUBRICATION 505200 datea retrasa ia 16 CONDENSATE DRAINS
3. LINES TO CONDENSATE DRAIN 292043 UIM B 0707 A CAUTION If electric heat is used a minimum clearance of 1 must be main tained on all sides of the supply air duct and or plenum continuously for up to 3 See Figure 1 MINIMUM CLEARANCE OF 1 ALL SIDES FLEXIBLE DUCT COLLAR CONTROL WIRING THERMOSTAT FILTER ACCESS LOUVERED ELECTRIC HOT WATER HEATER Must comply with water heater installation instructions FIGURE 2 Typical Installation HORIZONTAL DRAIN PAN CONVERSION These air handler units are supplied ready to be installed in a right hand horizontal position If unit requires left hand positioning the unit must have the pan installed in the correct position 1 Remove blower access coil access and center access panels NOTE Conversion must be made before brazing the refrigerant con nections to the coil 2 See Figure 3 remove two screws from horizontal drain pan to remove pan from position 3A if factory installed 3 Position horizontal pan as required in either A or B position locking it into the vertical drain pan as shown 4 Horizontal drain pans have 4 plugged drains Remove plugs from connections being used NOTE If this step is overlooked it can lead to a water problem later 5 Use removed plug to plug primary of upflow drain pan 6 Attach horizontal pan with 2 screws removed in step no 2 or sup plied with t
4. om eae zee ere 568 Meco 1088 1044 099 945 a82 a29 760 66a 76 400 tow o ee 197 nse 1085 1056 1008 ose 909 860 NOTE Air flow data shown above 0 50 W C external static pressure is for REFERENCE ONLY Maximum allowable external static when electric heat is used is limited to 0 50 W C Maximum allowable external static pressure may also be limited by minimum CFM requirements for proper Heat Pump operation Blower Motor Speed 1 Includes Return Air Filter and Largest Electric Heater All F FP series air handler units are UL Listed up to 0 50 w c external static pressure including air filter wet coil and largest KW size heater LoS D nitary Products Group 292043 UIM B 0707 F SERIES F SERIES Air Handler Control Wiring Air Handler Control Wiring Typical A C Cooling only Applications Typical A C with Electric Heat Applications AIR HANDLER THERMOSTAT ANS 1 STAGE THERMOSTAT BOARD 1 STAGE AIR CONDITIONING AIR CONDITIONING HUMIDISTAT 1 CFM selection 1 CFM selection 1 board only on NOTE board only on NOTE FAFV model Dehumidification FAFV model Dehumidification control connection control connection Humidistat jumper on Humidistat jumper on CFM selection board CFM selection board must be removed must be removed FIGURE 12 Cooling Models with Electric Heat Wiring AIR HANDLER THERMOSTAT HEAT PUMP CFM selection board only on F4FV model 1
5. 2 2 0 0 0 000 16 LIST OF FIGURES Plenum Clearances ooo 3 Control Board AAA 6 Typical installation secu 555 eos cere nee Re paws os das i 3 Electric Heaters in Horizontal Configuration Right Hand Air Flow 6 Filter Access amp Drain Pan Conversion Coil Baffle 4 Line Power Connections 000 cee eee ees 7 Dimensions Duct Sizes 0 0 0 es 4 Blower Speed Connections 000 ee ees 7 Typical Horizontal Installation o o ooooooooooo 5 Cooling Models with Electric Heat Wiring 14 TXV Bulb Installation sisc200 ch2e8dee rra a 5 Single Stage Heat Pump Control Wiring 14 BUIDNLOCANIOM 25 sumisa tora a 56S oui da rca e 6 LIST OF TABLES DIMENSIONS es cis acu da ech 2 dee aora RASE ia ia R 4 Electrical Data For Multi Source Power Supply Installed TXV SIZES sierra e Cds eee k ees SH eee Ge 5 Copper Wire 1 208 230 1 601 00000 0 eee 11 Physical and Electrical Data 1 2 0 cee 9 Electrical Data 3 208 230 3 60 0 eee 12 Electrical Data Cooling Only 50 amp 60 Hz 2 0 9 Electrical Data For Single Source Power Supply Conversi n Tables coi a eee Ree eee eee 9 Copper Wire 3 208 230 3 60 00 0 00 eee 12 Electrical Data 1 208 230 1 60 00000005 10 Airflow Data for 230 Volt Heat Pump Models 13 Electrical D
6. 75 se 75 aeeoo tom rs 100 ass oat as eo rs roo 75 ioo m rs LE tor ee eo peo r ee so fee 50 38 30 R low se 7s rer ase se f 50 58 7s se 75 036 tor as spre irr aa sae oo as BO 040 os low se 75 161 06 38 so se 7s 56 75 aeeoe tom 78 10028 oat as 50 re 100 7s Toc Tow 38 50 00 09 ae oop oe so 38 50 ma Aaa tow 56 7s 11 86 95 50 se 7s se 75 AR ESOOSOSS 53 50 T DIEL IEA a acesso Weston se 7s Ter ass aa 5058 7s se 75 ses o IE woo fase oat se 50 7s 100 75 Toc akee tw se 50 757 00 13 50 akie esto TES IR Mes 38 50 eo fit as 80 oe Ts 38 50 Mes se 7s rer fase aa 50 se 7s se 75 ene o wed frs too ose oer aa so rs roo 7s oc esos reso reos Heat amps shown at 240V represents maximum heater rating See conversion Table 5 If first stage heat or 66 is connected to W1 otherwise refer to this table 2HK16501906B only applies to F4FP036 model May be 0 no breaker or 1 with breaker dede E 1 _ ____ itary Products Group 292043 UIM B 0707 TABLE 7 Electrical Data For Single Source Power Supply Copper Wire 1 208 230 1 60 Field Wiring 2AR 65005088 208 247 y7 28 ao 10 oo 024 2HK 65008068 313 s 407 6 a _2HK 6501006B_ 417 469 537 50 6 83 6 r o o o o 2riksesoos0s8 313
7. FP Model EWN Circuit O a p cc cc aa oo a r 4811821 3080 5060 100 36 akese 6 8085 48182113080 5060 ono TaniKi6s0i9066 8 0426 46 7626 4045 5060 88 86 2HK165015068_ 25 8 28 7 45 1621 3080 50160 1mo se 2HKT65015068 28 1 80 5 45 1621 soss 50 60 1e se is arcos fasas erer 30803080 00 ae 2HKT65015068_ 92 8 85 6 4511521 3540 5060 88 86 55 0616 45 1521 ewo 5060 64 66 2HK165025068 92 8 35 6 451 521 45 1521 35 40 50 60 50160 ee 86 e o eee HK 765020068 55 9 61 6 45 1521 60770 5060 64 se gt 2HKT6502506B 33 8 85 6 45 1521 45 1621 35 40 5060 5060 88 86 86 1 O C P Over Current Protection device must be HACR type Circuit Breaker or Time Delay fuse 2 2HK16501906B only applies to F4FP036 model Unitary Products Group A 292043 UIM B 0707 TABLE 9 Electrical Data 3 208 230 3 60 eb an a e LAT 73 2KOSSO1S258 os jee na eor as se se 5975 00 52 150 2065010258 os tow frs foot 050 oat ae so 78 se 781007 siz es 60 rs 100 Hs iso ma a os tow 75 100 ose ear aa so rs s0 7s ioe 2HKOSSOIS258 05 tow 13 150 386 512 38 50 75 00 3 150 7 o5 Med 75 100 28 341 38 50 75 50 75 100 zmko os Medion 78 00 ase fear es 50 f 7s feo 78 ie
8. jumper plug to the control board to bypass the heater limit controls This jumper plug is secured to the duct cover near the 4 pin power plug harness Failure to install the plug will cause the blower to run continuously See Figure 8 FAN RELAY FAN CONNECTIONS TRANSFORMER CONNECTIONS HIGH VOLTAGE 4 PIN POWER CONNECTOR 6 PIN CONNECTOR LIMIT 2ND 3RD 8 4TH HEAT RELAY 1 STAGE DRIVER HEAT RELAY BREAK TAB FOR VARIABLE SPEED MOTOR 24 VOLT R 2 SPEED LTRIPECM 0 0O 5 AMP 24 VOLT CONTROL COMMON VOLTAGE FUSE FIGURE 8 Control Board Mark the unit nameplate with the appropriate heater selection on the space provided or NONE to indicate cooling only To operate these units with electric heat it is necessary to field install an electric heater kit 2HK See Electric Heater Kit Accessory Installation instructions for proper installation procedure Prior to installing electric heat it is neces sary to perform the following procedure 1 Remove the 4 pin power plug from the control board See Figure 8 NOTE This pin must not be used when electric heaters are installed 2 Remove the four 4 screws from the duct cover and remove the duct cover from the air handler Right hand Airflow Application Only Models with Circuit Breakers See Figure 9 If unit is to be installed for right hand air flow the circuit breakers in the heat kit will need to be removed and rotated 180 so the OF
9. no need to purge the coil if this procedure is followed REFRIGERANT LINE CONNECTION See the outdoor unit installation instructions for the procedure to install field supplied tubing for systems with sweat fittings Stub adapters are available to adapt sweat connections to quick con nections Connect lines as follows NOTE 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 line connections are made outside the center access panel Center access panel is recessed to assure sufficient room for brazing or it can be removed and slid over the suction line dur ing brazing 2 Plan for TXV bulb placement 3 Remove rubber plugs from refrigerant lines 4 Braze the suction line Re attach the center access panel if it had been removed 5 Braze the liquid line 6 Install supplied grommets on both the suction and liquid lines to complete the air seal 7 See previous section for TXV bulb Lines should be sound isolated by using the appropriate hangers or strapping When field supplied lines are used be sure to insulate the suction line only ELECTRIC HEATERS amp OPERATING CON TROLS The low voltage transformer and fan heater control are standard on all models See Figure 8 The air handlers are shipped pre wired to oper ate as cooling only applications To complete the installation for cooling only install the 6 pin
10. with changing residential and non HUD modular home construction practices These instructions are required as a minimum for a safe installation GENERAL INFORMATION This Single Piece Air Handler provides the flexibility for installation in any upflow or horizontal application These versatile models may be used for cooling or heat pump operation with or without electric heat BRAND LABEL available from Distribution apply to center of the blower access panel The unit can be positioned for bottom return air in the upflow position and right or left return in the horizontal position Top and side power wiring and control wiring accessible screw termi nals for control wiring easy to install drain connections and electric heaters all combine to make the installation easy and minimize installa tion cost 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 accom
11. 367 a7 40 4 8 8 2HK 65010068 a7 481 547 50 o 8 6 _2HK16501506B 625 709 808 80 o 4 3 2HK65008068 313 377 426 40 4 8 8 2HK 6501006B 47 491 se 50 o 68 6 2HK165015068_ 625 719 816 80 9 a 3 _2 K16501906B83 733 833 92 90 wo 3 3 2HK 65008068 313 367 417 40 4 68 8 2HKT65010088 a7 481 547 s 60 8 e 2HKi6s01500B 625 709 sos 60 0 4 3 2 HR 755005088 208 81 soo oo o 8 2HK 65008068 313 39 436 a 8 8 2HK 65010068 a7 503 566 60 60 6 e BRST E AAA as o o AO CO aem aa e ao akeo A o akes 208 s28 se oo 2HKT65008088 313 430 484 45 2HK165010068 a7 553 615 2HK165015068 625 773 878 80 akes 208 s28 se 35 8 akies ara 429 aaa 45 0 70 2HKT65015068 625 785 878 80 90 2HK165020068 83 3 1010 nss no 1285 2 Heat amps shown at 240V represents maximum heater rating O C P Over Current Protection device must be HACR type Circuit Breaker or Time Delay fuse 2HK16501906B only applies to F4FP036 model May be 0 no breaker or 1 with breaker TABLE 8 Electrical Data For Multi Source Power Supply Copper Wire 1 208 230 1 60 Min Circuit Ampacity Max O C P Amps Type 75 C me oei AWG 7 Heater Models F
12. F position will be down when the cabinet is positioned on the right side This is an NEC requirement Do One Breaker At A Time to make sure wires are reconnected properly Loosen terminal screws on the wires and gently pull the wires back from the breaker Remove screws securing the breaker plate and rotate 180 then secure the breaker plate and reconnect the wires to the breaker Proper torque for terminal screws is 35 in lbs HEAT KIT ASSEMBLY REMOVE 3 SCREWS TO REMOVE THE CIRCUIT BREAKER BRACKET FROM HEAT KIT ASSEMBLY FIELD SUPPLY WIRING WILL BE ATTACHED TO THIS SIDE OF THE CIRCUIT BREAKER S CIRCUIT BREAKER BRACKET CIRCUIT BREAKER S THERE MAY BE ONE TWO OR THREE HEAT KIT WIRING WILL BE ATTACHED TO THIS SIDE OF THE CIRCUIT BREAKER S FIGURE 9 Electric Heaters in Horizontal Configuration Right Hand Air Flow Unitary Products Group 292043 UIM B 0707 Unitary Products Group 7 292043 UIM B 0707 LOW VOLTAGE CONTROL CONNECTION 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 see Fig 5 item K Install a 7 8 plastic bushing in the selected hole and keep low voltag
13. NOTE Dehumidification control connection Humidistat jumper on CFM selection board must be removed FIGURE 13 Single Stage Heat Pump Control Wiring NOTES 1 Y Terminal on Air Handler Control Board must be connected for full CFM and applications requiring 60 second Blower Off Delay for SEER enhancement 2 Optional Dehumidification Humidistat contacts open on rise 3 For F4FV model Remove Humidistat Jumper on CFM Selection Board if used 4 For F4FV model For Heat Pump Applications Remove Heat Pump Jumper on CFM Selection Board 5 To change quantity of heat during HP defrost cycle Reverse connections at W1 and W2 on Air Handler Control Board Unitary Products Group 15 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 A CAUTION Threaded drain connection should be hand tightened plus no more than one turn A CAUTION Horizontal drain cutout in the center access panel should be removed by using a utility knife DO NOT TRY TO KNOCK OUT 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 3 and 4 NOTE When the coil is installed in an attic or above a finished ceiling an auxiliary drain pan should be provided under the c
14. TER ACCESS PANEL DRAIN PAN 4C FRONT VIEW PE COIL COMPARTMENT ACCESS PANEL REMOVED VERTICAL E DRAIN PAN j 4B SIDE VIEW L PRIMARY DRAIN UPFLOW F K FILTER SECONDARY ___ OO gt ma a DRAIN PAN DRAIN UPFLOW FILTER POSITION A 3 4 THREADED p HORIZONTAL 3 4 THREADED A i DUCT WORK MAY BE FASTENED 4 RETURN AIR DUCT gt CAUTIOUSLY WITH SCREWS TO S BRACKET MUST BE USED TO THE SIDES AND REAR OF UNIT FASTEN DUCT WORK TO FRONT OF UNIT FIGURE 3 Filter Access amp Drain Pan Conversion Coil Baffle SHIPPING BRACKET ALL DIMENSIONS ARE IN INCHES THEY ARE SUBJECT TO CHANGE REMOVE PRIOR TO WITHOUT NOTICE CERTIFIED DIMENSIONS WILL BE PROVIDED INSTALLATION 2 SCREWS UPON REQUEST DRAIN CONNECTIONS FOR HORIZONTAL APPLICATIONS TOP VIEW ALL MODELS VAPOR ey DRAIN PAN FOOTPRINT OPENING MAX FILTER LENGTH 21 INCHES MAX FILTER WIDTH B MINUS 1 1 2 INCHES LIQUID OPENING DRAIN CONNECTIONS FILTER FOR UPFLOW APPLICATIONS ACCESS BOTTOM VIEW FIGURE 4 Dimensions amp Duct Sizes TABLE 1 Dimensions MICA K O s Refrigerant Connections ES MA ee ara 78 16172 lt aa 40 40 3 4 14 mr s EG E eae eae 1 38 41 1 3 8 1 ara art ae 7 8 1 2 3 8 arar CELE arja EZ 7 22 005 50 Po 17 3 8 20 KEXEN 22 1 2 1 3 8 1 80 a 1 282 1 14 4 Unitary Products Grou
15. ata For Single Source Power Supply Airflow Data for 208 Volt Heat Pump Models 14 Copper Wire 1 208 230 1 60 0 eee 11 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 age 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 mainte nance can cause injury or property damage Refer to this manual for assistance or for additional information consult a qualified con tractor installer or service agency A CAUTION This product must be installed in strict compliance with the installa tion instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes
16. drooms study etc 4 Precautions should be taken to locate the unit and ductwork so that supply air does not short circuit to the return air 5 Select a location that will permit installation of condensate line to an open drain NOTE When the coil is installed in a draw thru application it is recom mended to trap the primary and secondary drain line 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 loca tion 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 Unitary Products Group 6 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 Proper electrical supply must be available Clearances must also be taken into consideration and provided for as follows A Refrigerant piping and connections are located in the front B Maintenance and servicing through the front or access side of unit with both sides and rear of unit having zero inch clear ance C Condensate drain lines are connected in the front clear of fil ter D Filter removal E When no electric heat is used the unit as well as all duct work and plenum are designed for zero clearance to combus tible materials POWER WIRING TO MAIN POWER SOURCE REFRIGERANT
17. e wiring as short as possible inside the control box The field wiring is to be connected at the screw terminals of the control board Refer to Figure s 12 and 13 NOTE All wiring must comply with local and national electrical code requirements Read and heed all unit caution labels TYPICAL WIRING WITHOUT ELECTRIC HEAT GND a LUG GND LUG 1 PHASE ELECTRIC HEAT SUPPLY WITH CIRCUIT BREAKER amp BREAKER BAR REMOVED MULTI SOURCE 15 25 KW 25 KW SHOWN GND LUG a GND A LUG AN O Q SUPPLY 1 a POWER SUPPLY24 _ __ POWER SUPPLY 3 SUPPLY FIGURE 10 Line Power Connections BLOWER SPEED CONNECTIONS Except for F4FP045 which has a 4 speed motor and F5FP which has a 5 speed high efficiency X 13 motor all air handlers contain three speed blower motors which are pre wired to the control board Adjust blower motor speed to provide airflow within the minimum and maximum limits approved for evaporator coil electric heat and outdoor unit Soeed tap adjustments are made at the motor terminal block See Figure 11 Airflow data is shown in Tables 6 and 11 4 5 TON HIGH EFFICIENCY MOTOR X 13 TO CONTROL BOARD C ELECTRIC HEAT WITHOUT CIRCUIT BREAKER 3 PHASE 10 15 KW GND LUG ELECTRIC HEAT WITHOUT CIRCUIT BREAKER SINGLE SOURCE 2 5 10 KW GND LUG NOTE It is possible to vary the amount of electric heat turned on during the defrost cycle of a heat pump Standard wiring will only br
18. he unit Ensure that the drain pan is lying flat against the insulation of the cabinet 7 Horizontal drain cutout in the center access panel should be removed by using a utility knife if not previously cut out 8 Re position and replace access panels Unitary Products Group A CAUTION ARY DRAIN PAN SEE ITEM 7 A CAUTION Models F FP045 048 060 have a coil baffle and support bracket factory installed for right hand horizontal application refer to Figure 3C For left hand applications the coil support bracket must be moved to the right side of the coil and the coil baffle must be rotated to avoid water blow off To rotate baffle remove the coil assembly from the unit remove front two screws holding the coil support bracket and the two screws holding the drain pan Remove four screws in coil baffle and remove the coil baffle and rotate ends Resecure the baffle and reinstall the coil assembly ensuring that the rear of the drain pan is secured under the back flange of the unit Reinstall the coil support bracket on the right side of the coil 292043 UIM B 0707 BLOWER 4A FRONT VIEW COMPARTMENT ACCESS PANEL PRIMARY REMOVED y Mio ee DRAIN SUPPORT Y BLOWER BRACKET PRIMARY E HOUSING 3 4 PVC SOCKETS DRAIN E FOR HORIZONTAL W DRAIN APPLICATION 060 COIL BAFFLE SECONDARY A Yo O SHOWN IN DRAIN ih SECONDARY RIGHT HORIZONTAL DRAIN POSITION HORIZONTAL CEN
19. icable codes e 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 1 The plenum must be installed according to the instructions e Provide clearances from combustible materials as listed under Clearances to Combustibles e Provide clearances for servicing ensuring that service access is allowed for both the burners and blower e Failure to carefully read and follow all instructions in this manual can result in air handler malfunction death personal injury and or property damage e Check the rating plate and power supply to be sure that the elec trical characteristics match e Air handler shall be installed so the electrical components are protected from water e Installing and servicing heating equipment can be hazardous due to the electrical components Only trained and qualified personnel should install repair or service heating equipment Untrained service personnel can perform basic maintenance functions such as cleaning and replacing the air filters When working on heating equipment observe precautions in the manuals and on the labels attached to the unit and other safety precautions that may apply e 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
20. ing on 5 KW of electric heat during defrost see Table 6 and Figures 12 and 13 for alternate staging 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 4 8 amp 10 for wire requirements Also see Figure 10 1 PHASE ELECTRIC HEAT WITH CIRCUIT BREAKER AS SHIPPED FROM FACTORY SINGLE SOURCE 2 5 25 KW 25 KW SHOWN GND LUG GND a Hir LUG T POWER SUPPLY a we POWER WIRING 208 230 1 60 NOTE USE ONLY COPPER CONDUCTORS Higher efficiencies will be obtained if the indoor air volume is as high as possible provided the CFM does not exceed limitations and the sound level is not objectionable Connect motor wires to motor speed tap receptacle for speed desired See wiring label for motor wiring details See Figure 11 The unit control is designed for the addition of a two speed fan kit See accessory kit for details 1 1 2 TON TO 4 TON STANDARD MOTOR FACTORY WIRED TO TRANSFORMER Common 208 2300 gt FAN MOTOR lw BLOWER FIGURE 11 Blower Speed Connections FACTORY WIRED TO FAN MOTOR RELAY TERMINAL ON CONTROL BOARD TRANSFORMER 230V 230 VOLT BLOWER MOTOR Unitary Products Gr
21. installation of these accessory kits see the instructions packed with the kit 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 5 COIL METERING DEVICES The coil in this Air Handler unit will have a TXV metering device installed at the factory The model number will have the following format F FPxxxHO6T2y The coil will have a Thermal Expansion Valve TXV installed The y character specifies which TXV is installed at the factory Please refer to the TXV Metering Device section for installation notes TABLE 2 Installed TXV Sizes F4FP024H06T2B F4FP040H06T2A TXV 2A TXV 2B TXV 2A TXV 2A TXV 2A TXV Metering Device EXPANSION BULB TUBING INSULATION EXPANSION BULB EXPANSION BULB CLAMP FIGURE 6 TXV Bulb Installation Please refer to Table 2 to verify which TXV is installed in this Air Han dler unit and that this AHU is a valid system match for the AC or HP unit installed The TXV is bolted into the coil assembly of this Air Handler unit at the factory The temperature sensing bulb will need to be attached to the coil suction header line after the line set is brazed to the coil e Make sure the TXV bulb is outside of the Air Handler cabinet Excess tubing should remain inside the cabinet e Take caution not to apply high temperatures to the TXV assembly o
22. o 512 A o Heat amps shown at 240V represents maximum heater rating a Heaters are 3 Phase 3 If first stage heat or 66 is connected to W1 otherwise refer to this table TABLE 10 Electrical Data For Single Source Power Supply Copper Wire 3 208 230 3 60 Field Wiring Models F FP pr Min Circuit Ampacity Max O C P Amps Type 75 C Wire Size AWG aT 240V 208V 240V 208V 240V O RAS 2HK06501025B 47 4 O mo e ICC 05 2HIKOB5010258 MEE aee aragonesa 2HIKOB5015258 2HK06501025B 49 1 A een O E aes Ie a as HA eee 2HK06501025B 48 3 srkossovsas8 03 ss so e sj 1 Heat amps shown at 240V represents maximum heater rating 2 Heaters are 3 Phase 3 O C P Over Current Protection device must be HACR type Circuit Breaker or Time Delay fuse 3 _ _ _ _ _ _ _ _ _ itary Products Group 292043 UIM B 0707 TABLE 11 Airflow Data for 230 Volt Heat Pump Models 230 Volt CFM External Static Pressure IWC 010 020 030 040 050 080 070 oo p 090 100 500 F4FPO24HO6T2 A E E E tow e e 605 575 so o 460 068 25 168 e75 FaFPosoHoet2 Med 1050 7 040 895 980 s eos ma ea 44 35 im e e ve re 60 eee 60 7 osa 190 Fig 810 17280 ae a 10089 o 894 77855 FarPOSGHOGTZ Med 1200 1 60 1 00 1 040 885 8883 879 785 m ser 5 FAFPOAOHOST2 Fig 1781800 1420 1350 1278 1 92 1 02 986 877 FaFPo
23. oil as is specified by most 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 the occupant a visual warning that the primary drain is clogged If the secondary drain is not used it must be capped The drain pan connections are designed to ASTM Standard D 2466 Schedule 40 3 4 PVC is preferred Since the drains are not subject to any pressure it is not necessary to use Schedule 40 pipe for drain lines It is recommended that all drain connections be sealed with teflon tape or equivalent 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 ten parts water Allow solu tion 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 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
24. oup 292043 UIM B 0707 TABLE 3 Physical and Electrical Data Models F FP Blower Diameter x Wich m f n 2 C E IE Amps DISPOSABLE OR PERMANENT Filter Motor Size 16 x 20 x 1 16 x 20 x 1 20 x 20x 1 20 x 20 x 1 Permanent ee Kit 1PFO601BK 1PFO601BK 1PFO602BK 1PFO602BK Shipping Operating Weight Ibs 98 93 105 100 115 109 121 115 Models FFP a Blower Dameterxwath S a S 0 17 Volags Locked Rotor 208 230 MOS Fiter 1 Field Supplied TABLE 4 Electrical Data Cooling Only 50 amp 60 Hz Total Motor Amps Minimum Circuit Ampacity i o oHe ohe ampse Se AWG Amps T Size A W G oe MIE ci Te 1 6 1 5 2 0 3 2 4 2 Motor Models F FP 1 OCP Over Current Protection device must be HACR type Circuit Breaker or Time Delay fuse TABLE 5 Conversion Table KW amp MBH Conversions for Total Power Input Requirement FOR 230V OPERATION MULTIPLY 240V TABULATED KW amp MBH BY Unitary Products Group 9 292043 UIM B 0707 TABLE 6 Electrical Data 1 208 230 1 60 eee MESA Static Heat KW Staging voces re Mette amnem aw O We Only Wi W Static Tap 208V 240V 208V 240V 208V 240V 208V 240V 208V 240V ae _ low 38 so Tso ii 3s so 3B so 38 50 024 os tew Se 75 ter ose as so se 7s 56 78 tow 75 100 ae sar 38 80 75 oo 75 100 tors eo 680 W4 3950 38 50 38 80 m os low 8 rs ret ase ss so se
25. p 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 NOTE The electric heat accessory should be installed before the sup ply air duct is attached to the supply air openings Refer to the electric heater kit instructions for proper installation Air supply and return may be handled in one of several ways best suited to the installation See Figure 4 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 p
26. plished 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 Normal Operating Voltage Range 187 253 Air Handler Voltage Voltage code aseo O ooo 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 F Dry Bulb Temp a E F CLEARANCES Clearance must be provided for 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 line 4 Filter removal minimum 36 recommended 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 unit as shown under suspen sion kits section 3 Normal operating sound levels may be objectionable if the air han dler is placed directly over some rooms such as be
27. r equalizer line while brazing e Attach field line sets and braze to coil connections Replace access panels amp secure e Secure the TXV bulb to the suction line with the clamp provided Choose a horizontal location as close to the cabinet as possible but not directly on the brazed connection joint Refer to Figure 7 e The bulb should be in direct contact with the coil suction line along the length of the bulb 292043 UIM B 0707 e If the suction line is 3 4 diameter position the bulb near the top of the copper tube as shown If the tube is 7 8 diameter position the bulb near the bottom of the tube Refer to Figure 7 e Wrap the clamp bulb amp line securely with insulation provided ROTATE BULB TO KEEP TAIL AT BOTTOM VERTICAL RISER FIGURE 7 Bulb Location A CAUTION COIL UNDER PRESSURE Relieve pressure by removing plug from piping connection Coil will have factory installed TXV See outdoor unit documentation for cor rect TXV to be used Refer to unit nameplate for TXV identification for this unit NOTE 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 brazed 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
28. roperly sized by use of a transition to match unit opening All ducts should be suspended using flexible hang 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 4 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 AIR FILTERS Air filters must be field supplied A 1 filter access rack has been built into the unit See Figure 4 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 num bers 1PF0601 602 603BK See Table 3 for filter size A CAUTION Equipment should never be operated without filters SUSPENSION KITS SUSPENSION SUPPORT LOCATIONS FOR HORIZONTAL APPLICATIONS NOTE USE SUPPORTS UNDER UNIT Dimension Nominal Tons XX 018 024 030 036 040 042 40 3 47 045 048 060 19 172 50 3 47 FIGURE 5 Typical Horizontal Installation Unitary Products Group 292043 UIM B 0707 A suspension kit is available Models 1BH0601 unit sizes 018 060 is designed specifically for the units contained in this instruction upflow application only For
29. saHoeT2 Med 1480 1 395 1330 1260 1 190 1425 1082 960 842 685 High 157511855 1 475 1390 1310 1245 1 47 1090 897 785 carpossmostz _MedHan 1375 1318 1255 1 185 1 90 1060 o4 e 782 006 ito ieo io tomo wo een aro tow 7 035 990 o eo e 770 608 616 52 082 FSFPOASHOST2 1353 tow 1206 1288 1077 1042 1082 1089 067 060 888 02 Fh 1762 FSFPOGOHOST2 lor ss mes veo veo ra IN F4FVOSOHO6T2 175 en Fees 1005 1560 1500 1060 1888 1828 126 1160 TEE NOTE Air flow data shown above 0 50 W C external static pressure is for REFERENCE ONLY Maximum allowable external static when electric heat is used is limited to 0 50 W C Maximum allowable external static pressure may also be limited by minimum CFM requirements for proper Heat Pump operation Blower Motor Speed 1 Includes Return Air Filter and Largest Electric Heater All F FP series air handler units are UL Listed up to 0 50 w c external static pressure including air filter wet coil and largest KW size heater Unitary Products Group 13 292043 UIM B 0707 TABLE 12 Airflow Data for 208 Volt Heat Pump Models 208 Volt CFM External Static Pressure IWC cme External Static Pressure WG O O O O omo 020 030 om oso oso ovo oso 080 7 00 tow ora er es ma 788 066 sos 55 408 r EI s O A e tow 1125 1060 1040 oeo oas
30. 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 TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE 1 No heat units do not have 6 pin connector installed 2 Limit open or not connected Blower Runs all of the time 3 Variable speed break out tab broken out 4 Blower OFF delay approx 1 min 5 Thermostat fan switch in ON position 1 Low voltage short to C or ground from R Y G W or O 1 4 pin connector loose No 24V 3 Blown fuse on control board No 2nd stage heat 1 Check filter 2 Closed registers No Heat or Limited Heating 4 Check blower motor operation 2 Loose wire from control to transformer 24V and 230V 1 Check 6 pin connector and connections to panel mount relays 2 Verify that both W1 amp W2 are connected at the terminal strip 3 Restricted airflow supply registers or return registers 5 If the safety limit opens 4 times the control will not permit the heating element to operate for 1 hour Subject to change without notice Printed in U S A Copyright by York International Corp 2007 All rights reserved Unitary Product Group 292043 UIM B 0707 Supersedes 292043 UIM A 0507 5005 Norman York OK Drive 73069
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