Johnson Controls MAHP18B21S Manual

PMGB0406B
Installation and
Maintenance
Manual
Air Handler
with DX-Kit
Air Handler
Standard PSC
Single Piece, Multi-Position
IMPORTANT:
READ AND UNDERSTAND
THIS MANUAL BEFORE
USING THIS DX-KIT.
KEEP THIS MANUAL FOR
FUTURE REFERENCE.
DX-Kit and Air Handler
Combined Model
DX-Kit Air Handler
Model
(H, Y) MAHP18B21S
(H, Y) MAHP24B21S
(H, Y) MAHP30B21S
(H, Y) MAHP36B21S
(H, Y) MAHP36C21S
(H, Y) MAHP48C21S
(H, Y) MAHP48D21S
(H, Y) MAHP60C21S
(H, Y) MAHP60D21S
EXV-018E
EXV-024E
EXV-030E
EXV-036E
EXV-036E
EXV-048E
EXV-048E
EXV-060E
EXV-060E
AP18BX21
AP24BX21
AP30BX21
AP36BX21
AP36CX21
AP48CX21
AP48DX21
AP60CX21
AP60DX21
Compatibility
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PMGB0406B rev.1 2
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PMGB0406B rev.1 3
Table of Contents
Air Handler.....................................................................................................................................................5
1. Introduction..............................................................................................................................................5
2. Safety ......................................................................................................................................................6
3. Unit Installation........................................................................................................................................9
4. Duct Work and Connections.................................................................................................................. 13
5. Electronic Expansion Valve ................................................................................................................... 15
6. Refrigerant Line Connection.................................................................................................................. 16
7. Condensate Drain Connections ............................................................................................................18
8. Electric Heater Installation.....................................................................................................................18
9. Line Power Connections .......................................................................................................................19
10. Blower Speed Connections .................................................................................................................20
11. Unit Data..............................................................................................................................................20
12. Maintenance........................................................................................................................................29
13. Air System Adjustment ........................................................................................................................29
14. Installation Veri¿cation.........................................................................................................................30
DX Kit..............................................................................................................................................................31
15. Introduction..........................................................................................................................................32
16. Safety Instructions...............................................................................................................................32
17. Before Installation................................................................................................................................38
18. Installation Location............................................................................................................................. 42
19. Installation Work.................................................................................................................................. 43
20. Refrigerant Piping Work ......................................................................................................................46
21. Electrical Wiring...................................................................................................................................49
22. Test Run .............................................................................................................................................. 71
23. Cautions ..............................................................................................................................................74
24. Startup Sheet ......................................................................................................................................75
List of Tables
Table 1. Dimensions .........................................................................................................................................9
Table 2. Physical and Electrical Data - Cooling Only..............................................................................20
Table 3. Electrical Data - Cooling Only ...................................................................................................21
Table 4. Electrical Heat - Minimum Fan Speed.......................................................................................21
Table 5. KW & MBH Conversions - For Total Power Input Requirement ................................................ 21
Table 6. Electric Heat Performance Data: 208/230-1-60 & 208/230-3-60 ..............................................22
Table 7. Electrical Data For Single Source Power Supply: 208/230-1-60...............................................23
Table 8. Electrical Data For Multi-source Power Supply: 208/230-1-60 .................................................25
Table 9. Electrical Data for Single Source Power Supply: 208/230-1-60................................................26
Table 10. Electrical Data For Multi-source Power Supply: 208/230-3-60 .................................................27
Table 11. Air Flow Data (CFM1) ...............................................................................................................28
Table 12. Piping Size ................................................................................................................................46
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PMGB0406B rev.1 4
List of Figures
Figure 1. Return Air Duct Attachment and Component Location ........................................................................ 7
Figure 2. Pressure Check................................................................................................................................... .8
Figure 3. Dimensions and Duct Connection Dimensions.................................................................................... 8
Figure 4. Typical Installation.............................................................................................................................. 11
Figure 5. Coil Blow Off Wing Installation........................................................................................................... 12
Figure 6. Horizontal Suspension ....................................................................................................................... 14
Figure 7. Duct Attachment................................................................................................................................ .14
Figure 8. Duct Work Transition.......................................................................................................................... 15
Figure 9. Line Power Connections .................................................................................................................... 19
Figure 10. Factory Wired Blower Connections.................................................................................................... 20
Figure 11. Duct Static Measurements................................................................................................................. 29
Figure 12. Drain Traps......................................................................................................................................... 30
Figure 13. Location of Coil Trapped and Plugged Drain Connections ................................................................ 30
Figure 14. DX-Kit in the VRF system .................................................................................................................. 38
Figure 15. Installation Space............................................................................................................................... 42
Figure 16. Installation Dimensions ...................................................................................................................... 43
Figure 17. Mounting the Control Box................................................................................................................... 44
Figure 18. Mounting Valve Box ........................................................................................................................... 45
Figure 19. Details of Mounting Hole .................................................................................................................... 45
Figure 20. Piping Connections ............................................................................................................................ 47
Figure 21. Flare Dimensions ............................................................................................................................... 47
Figure 22. Applying Refrigerant Oil ..................................................................................................................... 48
Figure 23. Insulating Piping................................................................................................................................. 48
Figure 24. Electrical Wiring Diagram of Transformer (TF) ..................................................................................49
Figure 25. Electrical Wiring Connections: Heat Pump and Heat Recovery Systems.......................................... 51
Figure 26. Positions of Electrical Wiring Connection........................................................................................... 52
Figure 27. Reconnect Wiring............................................................................................................................... 53
Figure 28. Wired Controller Connections ............................................................................................................ 54
Figure 29. Wired Connections from the Control Box........................................................................................... 55
Figure 30. Attaching Cable Holders to Air Handler.............................................................................................. 56
Figure 31. Wiring Holes of Air Handler................................................................................................................ 57
Figure 32. Thermistor Positions .......................................................................................................................... 58
Figure 33. Thermistor Connectors....................................................................................................................... 59
Figure 34. Thermistor Installation with Details .................................................................................................... 60
Figure 35. Air Inlet and Outlet Thermistors ......................................................................................................... 61
Figure 36. Positions of Air Inlet and Outlet Thermistors...................................................................................... 62
Figure 37. Thermistor Extension Installation ....................................................................................................... 62
Figure 38. Connection to Fan Motor.................................................................................................................... 63
Figure 39. Connection to Fan Motor Inside Air Handler ...................................................................................... 64
Figure 40. Connection to Expansion Valve Box .................................................................................................. 65
Figure 41. Connection for Power Supply............................................................................................................. 66
Figure 42. Terminal Box Connection ................................................................................................................... 67
Figure 43. Expansion Valve Box Terminal Block ................................................................................................. 68
Figure 44. Position of DIP Switches .................................................................................................................... 69
Figure 45. Unit Setting......................................................................................................................................... 69
Figure 46. Capacity Code Setting (DSW3).......................................................................................................... 69
Figure 47. Refrigerant Cycle Setting ................................................................................................................... 70
Figure 48. Test Run Menu................................................................................................................................... 71
Figure 49. Test Run: 2 Units................................................................................................................................ 72
Figure 50. RUN Indicator..................................................................................................................................... 72
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PMGB0406B rev.1 5
1. Introduction
ƔFor details on wiring between the indoor unit and the outdoor unit, refer to the installation documentation for
the outdoor unit.
ƔFor details on the optional controller, refer to the installation documentation for that product.
Provide this manual and the warranty to all installers and users. Ask end users to maintain copies for future
reference.
This manual is for this Air Handler and the DX Kit.
Read this "Installation and Maintenance Manual" carefully before installing this product. Read through the
applicable product documentation for other units in the system as well.
For installation of this Air Handler and DX-Kit, start with the air handler unit as described in the ¿rst sec-
tions of this document. Then, proceed to install the DX-Kit as described in the later part of this document.
The single piece air handler series provides the Àexibility for installation in any position. You may use this
unit for upÀow, downÀow, horizontal right, or horizontal left applications. Locate these units in a closet,
utility room, attic, crawl space, or basement. Use these versatile models for cooling or heat pump opera-
tion with or without electric heat.
Top or side power and control wiring, color-coded leads for control wiring, easy to install drain connec-
tions, and electric heaters all combine to make installation easy and minimize installation cost.
Electric heat kits are available as ¿eld installed accessories. Single phase kits are available from 2.5 kW to
25 kW. 208-230 volt 3-phase kits are available from 10kW to 25kW.
2. Safety
Signal Words
Indicates a hazardous situation that, if not avoided, could result in death or
serious injury.
Indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.
Indicates information considered important, but not hazard-related (for
example, messages relating to property damage).
This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the
potential for personal injury.
To reduce the risk of serious injury or death, read these instructions
thoroughly and follow all warnings or cautions included in all manuals that
accompanied the product and are attached to the unit. Refer back to these
safety instructions as needed
General Precautions
Air Handler
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PMGB0406B rev.1 6
ƔThis system should be installed by personnel certi¿ed by Johnson Controls, Inc. Personnel must be
quali¿ed according to local, state and national building and safety codes and regulations. Incorrect
installation could cause leaks, electric shock, ¿re or explosion. In areas where Seismic ‘’Performance
requirements are speci¿ed, the appropriate measures should be taken during installation to guard
against possible damage or injury that might occur in an earthquake if the unit is not installed correctly,
injuries may occur due to a falling unit.
ƔUse appropriate Personal Protective Equipment (PPE), such as gloves and protective goggles and,
where appropriate, have a gas mask nearby. Also use electrical protection equipment and tools suited
for electrical operation purposes. Keep a quenching cloth and a ¿re extinguisher nearby during brazing.
Use care in handling, rigging, and setting of bulky equipment.
ƔWhen transporting, be careful when picking up, moving and mounting these units. Although the unit may
be packed using plastic straps, do not use them for transporting the unit from one location to another.
Do not stand on or put any material on the unit. Get a partner to help, and bend with your knees when
lifting to reduce strain on your back. Sharp edges or thin aluminum ¿ns on the air conditioner can cut
¿ngers, so wear protective gloves.
FIRE OR ELECTRICAL HAZARD. Failure to follow the safety warnings
exactly could result in serious injury, death or property damage. A ¿re or
electrical hazard may result causing property damage, personal injury or loss
of life..
The air handler area must not be used as a broom closet or for any other
storage purposes, as a ¿re hazard may be created. Never store items such
as the following on, near or in contact with the furnace.
• Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners or
other cleaning tools.
• Soap powders, bleaches, waxes or other Cleaning compounds; plastic
items or containers; gasoline, kerosene, cigarette lighter Àuid, dry
cleaning Àuids or other volatile Àuid.
• Paint thinners and other painting compounds.
• Paper bags, boxes or other paper products
Never operate the air handler with the blower door removed. To do so could
result in serious personal injury and/or equipment damage.
Improper installation, adjustment, alteration, or maintenance may create a
condition where the operation of the product could cause personal injury or
property damage. Refer to this manual for assistance, or for additional infor-
mation, consult a quali¿ed contractor, installer, or service agency
This product must be installed in strict compliance with the installation instructions and any applicable local,
state, and national codes including, but not limited to building, electrical, and mechanical codes.
Safety Requirements
1. Failure to carefully read and follow all instructions in this manual can result in air handler malfunction, death,
personal injury and/or property damage.
2. This air handler should be installed in accordance with all national and local building/safety codes and
requirements, local plumbing or wastewater codes, and other applicable codes.
3. This air handler should be installed only in a location and position speci¿ed in the “Unit Installation” section of
this Instruction Manual.
4. The air handler is not to be used for temporary heating of buildings or structures under construction.
5. Always install the air handler to operate within the air handler’s intended maximum outlet air temperature.
6. The unit rating plate displays the air handler model number. The unit dimensions for the supply air plenum
are provided in Figure 3 and Table 1 of this Instruction Manual. The plenum must be installed according to the
instructions.
7. Clearance from combustible material is provided under “Clearances” in the “Unit Installation” section.
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PMGB0406B rev.1 7
DO NOT lift air handler by the cabinet braces. The cabinet braces are held in place by the coil channels. The
cabinet braces could become disengaged from the cabinet causing the air handler to fall, potentially causing
injury or damaging property. See Figure 1 for location of cabinet braces. Lift the air handler by tightly gripping
the casing.
8. It is necessary to maintain clearances for servicing. Allow access to electric heaters and blower.
9. Verify the unit rating plate and power supply to ensure that the electrical characteristics match.
10. You must install air handler so the electrical components are protected from water.
11. Installing and servicing heating/cooling equipment can be hazardous due to the electrical components.
Only trained and licensed personnel should install, repair, or service heating/cooling equipment. Unlicensed
service personnel can perform basic maintenance functions such as cleaning and replacing the air ¿lters.
When working on heating/cooling equipment, the precautions in the manuals and on the labels attached
to the unit and other safety precautions must be observed as applicable.
These air handlers should be transported and handled in an upright, upÀow position. Failure to do so may result
in unit damage and personal injury. Con¿guration conversions should be done at site of installation.
12. These instructions cover minimum requirements and conform to existing national standards and safety
codes. In some instances these instructions exceed certain local codes and ordinances, especially those
that have not kept up with changing residential and non-HUD modular home construction practices. These
instructions are required as a minimum for a safe installation.
Figure 1. Return Air Duct Attachment and Component Location
SIDE VIEW
RETURN AIR
DUCT
FRONT VIEW
SECONDARY DRAIN
UPFLOW 3/4” NPT
FILTER DOOR
WHEN ATTACHING DUCT WORK WITH
SCREWS - KEEP SCREWS WITHIN 5/8”
OF SIDES AND BACK OF AIR HANDLER
DUCT WORK MAY
BE FASTENED
CAUTIOUSLY WITH
SCREWS TO THE
SIDES AND REAR OF UNIT
PRIMARY DRAIN
3/4” NPT
VAPOR
REFRIGERANT
LINE CONNECTION
LIQUID
REFRIGERANT
LINE CONNECTION
HORIZONTAL
DRAIN PAN
VERTICAL
DRAIN PAN
COIL COMPARTMENT
(Access panel removed)
BLOWER
COMPARTMENT
SECONDARY DRAIN
HORIZONTAL FLOW
3/4” NATIONAL PIPE
THREAD (NPT)
A0328-001
CABINET BRACE
CABINET BRACE
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PMGB0406B rev.1 8
Inspection
As soon as you receive the Air Handler, check to be sure it is still under pressure per Figure 2. Inspect the coil
for possible damage during transit. If damage is evident, note the extent of the damage on the carrier’s freight
bill. A separate request for inspection by the carrier’s agent should be made in writing. Consult the Local
Distributor for more information. Check the drain pan for cracks or breakage. Before installation, check the unit
for screws or bolts that may have loosened in transit. There are no internal shipping or spacer brackets that
need to be removed. Verify that all accessories are available as required. Complete the Installation of these
accessories or ¿eld conversion of the unit before setting the unit in place or connecting any wiring, duct work
or piping.
When installing the air handler, it is important to note that the Schrader core on the suction line stub-out must
be relocated to the equalizer connection port located on the coil. See the circled ports in the ¿gure below.
Figure 2. Pressure Check
G
A
1-1/2”
7-11/32”
C
FILTER ACCESS
DRAIN CONNECTIONS
FOR UPFLOW APPLICATIONS
REFRIGERANT CONNECTIONS
BLOWER
COMPARTMENT
BOTTOM INLET
DIMENSIONS
12-3/16”E
D
18-5/8”
TOP OUTLET
DIMENSIONS
SERVICE
DISCONNECT
PANEL
A0329-001
B20-1/2”
21-7/16”
F
COIL
COMPARTMENT
Figure 3. Dimensions and Duct Connection Dimensions
A0271-001
DEPRESS SCHRADER
CORE TO CHECK FOR
PRESSURE ONE TIME.
NOTE:
VERIFY THAT THE COIL IS UNDER
PRESSURE WHEN RECEIVED.
A02
7
1
-
001
D
EPRE
SS
SC
HRADER
CORE
T
O CHECK FO
R
P
RESSURE ONE
TIME
.
NOTE
:
V
ERIFY THAT THE
CO
IL I
S
UNDE
R
P
RESSURE WHEN RECEIVED.
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PMGB0406B rev.1 9
Table 1. Dimensions
Models Dimensions1Wiring Knockouts2Refrigerant
Connections
Line Size
ABCDEFG
Height Width Power
(Conduit)
Control
(Conduit)
Liquid Vapor
18B 41 17-1/2 12-7/8 14-1/4 16-1/2
7/8 (1/2)
1-3/8 (1)
1-23/32
(1-1/4)
7/8 (1/2) 3/8 3/4
24B 41 17-1/2 12-7/8 14-1/4 16-1/2
30B 47-1/2 17-1/2 19-1/2 14-1/4 16-1/2
36B 47-1/2 17-1/2 19-1/2 14-1/4 16-1/2
36C 51-1/2 21 22-5/8 17-3/4 20
7/8
48C 51-1/2 21 22-5/8 17-3/4 20
48D 55-1/2 24-1/2 26-5/8 21-1/4 23-1/2
60C 55-3/4 21 26-7/8 17-3/4 20
60D 55-1/2 24-1/2 26-5/8 21-1/4 23-1/2
1. All dimensions are in inches.
2. Knockout size (conduit size in parentheses).
3. Unit Installation
NOTICE
Avoid handling aluminum coil components after handling the copper line set or other tubing without ¿rst
cleaning hands.
Unit Sizing
Base the size of the unit on an acceptable heat loss or gain calculation for the structure. Use the ACCA
Manual J or other approved methods. Reference Figure 3 and Table 1.
1. Only connect the air handler to a duct system that has an external static pressure within the allowable range.
2.
AirÀow must be within the minimum and maximum limits approved for electric heat, indoor coils and out-
door units. Refer to the Dx-Kit section for details.
3.
Install the air handler so that supply ducts carry air circulated by the air handler to areas outside the
space containing the air handler. The return air must also be handled by duct(s) sealed to the air handler
casing and terminating in the space to be cooled/ heated.
4. 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. You must install the plenum according to the instructions.
5. The installer must check available supply power and verify that it is within the normal operating voltage
range for the unit. The acceptable voltage range for these units is as follows:
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PMGB0406B rev.1 10
Air Handler Voltage Normal Operating* Voltage Range
208V/230V-1-60 188V-253V
*Rated in accordance with ARI Standard 110, utilization range "A."
Clearances
You must take clearances into consideration, and provide for them as follows:
1. Refrigerant piping and connections - minimum 12” recommended for clearances to braze and service the
joint.
2. Maintenance and servicing access - minimum 36” from front of unit recommended for blower motor/ coil
replacement.
3. Condensate drain lines routed to clear ¿lter and panel access.
4. Filter removal - minimum 36” recommended.
5. The duct work connected to this unit is designed for zero clearance to combustible materials.
6. A combustible Àoor-base accessory is available for downÀow applications of this unit, as required by local
code.
7. Refer to the Dx-Kit section 18 for clearance of the DX-Kit.
Location
Location is usually predetermined. Check with owner’s or dealer’s installation plans. If location is not decided,
consider the following in choosing a suitable location:
1. Select a location with adequate structural support, space for service access, and clearance for air return
and supply duct connections.
2. Using hanging brackets to wall mount this single piece air handler unit is not recommended.
3. Normal operating sound levels may be objectionable if the air handler is placed directly over some rooms
such as bedrooms, study, etc.
4. Select a location that will permit installation of condensate line to an open drain or outdoors allowing con-
densate to drain away from structure.
NOTICE
The primary and secondary drain line must be trapped to allow proper drainage of condensate water. The
secondary drain line should be piped to a location that will give the occupant a visual warning that the primary
drain is clogged. If the secondary drain line is not used, it must be capped.
5. When an indoor coil is installed in an attic or above a ¿nished ceiling, an auxiliary drain pan should be
provided under the air handler as is speci¿ed by most local building codes.
6. Proper electrical supply must be available.
7. If unit is located in an area of high humidity (i.e. an unconditioned garage or attic), nuisance sweating of
casing may occur. On these installations, unit duct connections and other openings should be properly
sealed, and a wrap of 2” ¿berglass insulation with vinyl vapor barrier should be used.
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PMGB0406B rev.1 11
Air Handler Con¿guration
These air handler units are supplied ready to be installed in an upÀow or horizontal left position.
Refer to Figure 4. If the unit requires either downÀow or horizontal right airÀow con¿gurations, the unit must
have the coil assembly repositioned. Refer to the DownÀow or Horizontal Right Conversion procedures.
Figure 4. Typical Installation
DownÀow or Horizontal Right Conversion
1. Remove the coil access panel.
2. Slide coil/drain pan assembly out of air handler.
NOTICE
Convert air handler to correct orientation prior to installation. You must make the conversion before brazing the
refrigerant connections to the coil.
NOTICE
The center support bar for the coil/drain pan has a position identi¿er embossed into the cabinet structure between
the two forward ¿ngers of the support bar. There are four position identi¿ers: A, B, C, or D. The lettered hole
location can differ from unit to unit due to the cabinet width of the air handler. After removal and re-installation,
install the center support bar in the same lettered position that it was originally.
3. Note the lettered position of the center support bar for the coil/drain pan. Remove the center support bar
by sliding the forward end of the support bar to the right or left until the lower ¿nger clears the structure.
NOTICE
The position identi¿er for the coil slide rail is embossed into the back corner vertical angle of the cabinet struc-
ture. There are four position identi¿ers: 1, 2, 3, or 4. The numbered attachment location can differ from unit to
unit due to the cabinet height of the air handler. After removal and reinstallation, install the coil slide rail in the
same numbered position that it was originally.
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PMGB0406B rev.1 12
4. Note the numbered position of the coil slide rail located at the upper right hand side of the indoor coil com-
partment. Remove slide rail from air handler cabinet by removing front screw and lowering bracket down
to disengage hook on back of slide rail.
5. Turn air handler cabinet upside down (downÀow position).
6. Install coil slide rail by hooking the aft end into holes at the numbered position the slide rail was originally
in right rear corner post, and secure rail into right front edge of cabinet with screw in the pre- drilled hole.
NOTICE
The position identi¿er for the coil slide rail is embossed into the back corner vertical angle of the cabinet struc-
ture. There are four position identi¿ers: 1, 2, 3, or 4. The numbered attachment location can differ from unit to
unit due to the cabinet height of the air handler. After removal and reinstallation, install the coil slide rail in the
same numbered position that it was originally.
NOTICE
When installing a coil blow off wing, make sure that each notch in the coil blow off wing (see Figure 5) slides
around the anchor screw with the bottom of the notch fully set against the screw. Ensure that coil blow off wing
is installed with the Àange bending away from the coil data plate.
7. Install center support bar for the coil/drain pan onto the lettered position that it was originally mounted.
8. For horizontal right applications, install front and back coil blow off wings (blow off wings shipped as loose
parts with the unit). Locate 4 screws securing coil data plates to coil drain pan. Loosen the screws. Slide
each coil blow off wing between the drain pan and the coil data plate. Tighten screws to securely anchor
coil blow off wings. Refer to Figure 5.
9. Slide the coil back into the cabinet. Be sure to engage the side coil slide into the slide rail on the air han-
dler cabinet.
10. Install coil access panel. Conversion is now complete..
Figure 5. Coil Blow Off Wing Installation
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PMGB0406B rev.1 13
4. Duct Work and Connections
For air supply and return, use upÀow, horizontal, or downÀow, as applicable to the installation.
The vast majority of problems encountered with heating and cooling systems are linked to improperly
designed or installed duct systems. The success of an installation highly depends upon the proper design and
installation of the duct system.
When installing a central air or return grill in or near the living space, design the duct work so the grille is not
in direct line with the opening in the unit. Ensure a quieter system by using one or two elbows and acoustical
duct liner. Where the return air duct is short or where sound may be a problem, use acoustical duct liner inside
the duct. Use Àexible duct connectors to minimize the transmission of vibration/noise into the conditioned
space.
Do not bring in return air from a location which could introduce hazardous substances into the airÀow. Use 1/2”
screws to connect duct work to cabinet. If pilot holes are drilled, drill only through ¿eld duct and unit Àange.
Insulation of duct work is a must where it runs through an unheated space during the heating season or
through an uncooled space during the cooling season. The use of a vapor barrier is recommended to prevent
absorption of moisture from the surrounding air into the insulation.
Properly size the supply air duct by use of a transition to match unit opening. Suspend all ducts using Àexible
hangers and never fastened directly to the structure.
Fabricate and install duct work in accordance with local and/or national codes. This includes the standards of
the National Fire Protection Association for Installation of Air-Conditioning and Ventilating Systems, NFPA No.
90B. Design duct systems in accordance with the Air Conditioning Contractors of America (ACCA) – Manual D.
This unit is not designed for non-ducted (freeblow) applications. Do not operate without duct work attached to
unit. Never operate equipment without ¿lters.
Horizontal Suspension
These air handlers may be suspended in horizontal applications. Use angle steel support brackets with
minimum 3/8” threaded rods, supporting the unit from the bottom. Attach the threaded rods at the locations
shown in the Figure 6, leaving enough clearance between door and rod so that doors easily remove for
service.
DO NOT lift air handler by the cabinet brace. The cabinet brace is held in place by the coil channel. The cabinet
brace could become disengaged from the cabinet causing the air handler to fall, potentially causing injury or
damaging property. See Figure 1 for location of cabinet braces.
NOTICE
When assembling the support structure, be sure to size and provide clearance for removal of the access door.
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PMGB0406B rev.1 14
Dimension in Inches
Air Handler Cabinet
Size
XH
17-1/2 Width-Short H 21 41
17-1/2 Width-Short H 21 47-1/2
21 Width –Short H 21-1/2 51-1/2
21 Width –Short H 21-1/2 55-3/4
24-1/2 Width 21-1/2 55-1/2
Figure 6. Horizontal Suspension
Duct Flanges
Three duct Àanges are provided to assist in positioning and attaching duct work to the air handler. These Àanges are
included in the unit parts bag. With the screws from the parts bag, install one of the duct Àanges. Duct Àanges have
holes on both legs with one leg longer than the other. You can use the longer leg to mate against the air handler
so that different thicknesses of duct board are made Àush with the outer surface of the air handler. Repeat the
procedure for the other two Àanges. Refer to Figure 7. If you do not use the Àanges, you may discard them.
A0445-001
DUCT FLANGES
(Shipped in bag with unit)
Figure 7 Duct Attachment
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PMGB0406B rev.1 15
There are several ways to handle the supply and return air duct connections. The location and sizing of the
connections depends on the situation and the method best suited to the installation. UpÀow, horizontal or
downÀow applications may be used.
Properly size the supply air duct by use of a transition to match unit opening. Refer to Table 1 for air handler
unit inlet and outlet dimensions.
Use 1/2” screws to connect duct work to unit. Longer screws will pierce the drain pan and cause leakage. If
you drill pilot holes, drill only though ¿eld duct and unit bottom duct Àange.
Duct work that is not designed to match the supply air opening can cause turbulence inside the plenum. This
turbulence can change the air Àow patterns across the electric heater limit switches. If the factory suggested
transition cannot be fabricated, it is recommended that you attach a block off plate to the supply opening (ap-
proximately 8" high and running the full width of the plenum). Refer to Figure 8. The use of this block off plate
enables better air circulation across the limit switches.
Air Filters
Return air ¿lters are required and must be ¿eld supplied. Filtration can be accomplished external to the unit or
the integral ¿lter rack may be used. A 1" ¿lter access rack is built into the unit. Remove the ¿lter access cover.
Install proper size ¿lter. Use a Standard 1" size permanent or throw away ¿lter, or permanent washable ¿lters
are available using model numbers: 1PF0601, 602 or 603. See Unit Data, section 11) for ¿lter size.
Never operate equipment without ¿lters.
5. Electronic Expansion Valve
When this air handler is used on a VRF (Variable Refrigerant Flow) system, an EEV (Electronic Expansion
Valve) is used. The EEV is included with the DX Kit that is shipped with the air handler.
Unit Connections
A0332-001
RECOMMENDED
TRANSITION
SUGGESTED LOCATION
OF BLOCK OFF PLATE
Figure 8 Duct Work Transition
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PMGB0406B rev.1 16
NOTICE
Before handling aluminum coil components, clean your hands after handling the copper lines set or other tubing.
6. Refrigerant Line Connection
Coil is under inert gas pressure. Relieve pressure from coil by depressing Schrader core at the end of the
suction-manifold stub out.
Always supply dry nitrogen through the tubing while it is being brazed. Unless an inert atmosphere is provided,
the temperature required is high enough to cause oxidation of the copper. Continue the Àow of dry nitrogen
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 Àow is necessary to displace air and prevent oxidation.
Instructions for Liquid Refrigerant Line of the Air Handler
Step 1. Remove bottom front cover. The heat ex-
changer is exposed.
Step 2. See accessory piping that is shipped with
the unit. This piping is used for the unit's Liquid
Refrigerant Line.
Step 3. Remove the brass nut on the distributor body. Step 4. Remove Piston, TeÀon Ring, and Brass Nut.
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PMGB0406B rev.1 17
Step 5. Attach the brass nut to the accessory piping.Step 6. Attach the TeÀon ring to seal the two connec-
tions together. Do not re-install the piston.
Step 7. Attach the accessory piping to the distributor
body. Tighten the nut with a torque of 16-20 ft-lbs.
Then, manually raise the distributor body to align with
the liquid line connection hole.
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PMGB0406B rev.1 18
7. Condensate Drain Connections
Trap all drain lines a minimum of three inches, pitch them away from unit drain pan, and ensure they are not
smaller than the coil drain connection.
DO NOT use TeÀon™ tape, pipe thread compound, or other sealants. The use of a sealant may cause damage
and premature failure of the drain pan. Threaded drain connection should be hand-tightened, no more than 1 turn.
Avoid Double Trapping of a single drain line.
Route the drain line so that it does not interfere with accessibility to the coil, air handling system or ¿lter and
will not be exposed to freezing temperatures. See Figures 12 & 13 for drain connection locations.
When the unit is installed in an attic or above a ¿nished ceiling, an auxiliary drain pan should be provided under
the coil as speci¿ed by most local building codes. When this exterior secondary drain pan is used that drain
should be piped to a location that will give the occupant a visual warning that the primary drain is clogged.
If the coil is provided with a secondary drain pipe it to a location that will give the occupant a visual warning
that the primary drain is clogged. If a secondary drain is not used it must be plugged.
Instruct the owner that the evaporator coil drain pan should be inspected and cleaned regularly to prevent
odors and assure proper drainage. If a secondary drain is not used it must be plugged. See Figures 12 & 13.
Install coils level or pitched slightly toward the drain end. Suggested pitch should not exceed 1/4 inch per foot
of coil.
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.
8. Electric Heater Installation
If the air handler requires electric heat, install the electric heat kit according to the installation instructions
included with the kit. After installing the kit, mark the air handler nameplate to designate the heater kit that was
installed. If no heater is installed, mark the name plate appropriately to indicate that no heat kit is installed.
Use only 6HK Revision C or later heater kits, as listed in this manual. Use data from Tables 4 through 8 for
information on required minimum motor speed tap to be used for heating operation, maximum over-current
protection device required as listed for combination of air handler and heater kit.
For UpÀow, DownÀow and Horizontal left-hand applications, install the kits without modi¿cation.
Field modi¿cation is required for Horizontal right-hand airÀow applications only. Follow instructions with heater
for modi¿cation.
NOTICE
In some horizontal applications, the service disconnects on the electric heat kits must be rotated 180° so the
up position of the disconnect is in the ON position. This service disconnect orientation change is required by
UL1995, Article 26.19 (in reference to all circuit breakers).
Refer to the Cautions section 23 for Heater Kit wiring information.
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PMGB0406B rev.1 19
You must make all electrical connections to air handlers with copper conductors. Direct connection of
aluminum wiring to air handlers is not approved.
If aluminum conductors are present, you must follow all applicable local and national codes when converting
from aluminum to copper conductors prior to connection to the air handler.
The chosen conductor and connections all must meet or exceed the amperage rating of the overcurrent
protector (service disconnect or fuse) in the circuit.
Existing aluminum wire within the structure must be sized correctly for the application. Refer to your local
codes to determine the correct wire size. Use Caution when sizing aluminum rather than copper conductors,
as aluminum conductors are rated for less current than copper conductors of the same size.
Figure 9. Line Power Connections
Power may be brought into the unit through the supply air end of the unit (top left when unit is in the upÀow
vertical position) or the left side panel. Use the hole appropriate to the unit’s orientation in each installation
to bring conduit from the disconnect. Terminate the power lead conduit at the electrical control box. Refer to
Tables 6 through 9 to determine proper wire sizing. Refer to local codes to determine the correct wire size. To
minimize air leakage, seal the wiring entry point at the outside of the unit.
9. Line Power Connections
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PMGB0406B rev.1 20
10. Blower Speed Connections
Adjust blower motor speed to provide airÀow within the minimum and maximum limits approved for indoor
coil, electric heat and outdoor unit. Speed tap adjustments are made by the optional controller. AirÀow data is
shown in Unit Data, (Section 11), Table 11.
Connect motor wires from the control box of the DX-Kit to motor speed tap receptacle according to the DX-Kit
wiring label.
Figure 10. Factory Wired Blower Connections
Models 18B 24B 30B 36B 36C
Blower - Diameter x Width 10 x 8 10 x 8 10 x 8 10 x 8 10 x 10
Motor
HP 1/8 HP 1/4 HP 1/3 HP 1/2 HP 1/2 HP
Nominal RPM 867 850 950 1085 1050
Voltage 208/230 208/230 208/230 208/230 208/230
Full Load Amps @230V 1.0 1.4 2.3 2.6 2.2
Filter*Type DISPOSABLE OR PERMANENT
Size 16 x 20 x 1 16 x 20 x 1 16 x 20 x 1 16 x 20 x 1 20 x 20 x 1
Permanent Type Kit 1PF0601 1PF0601 1PF0601 1PF0601
1PF0602
Shipping/Operating Weight (lbs.) 91/85 93/87 119/113 119/113 120/114
Models 48C 48D 60C 60D
Blower - Diameter x Width 10 x 10 10 x 10 10 x 10 10 x 10
Motor
HP 1/2 HP 1/2 HP 1 HP 1 HP
Nominal RPM 1040 1040 1007 1007
Voltage 208/230 208/230 208/230 208/230
Full Load Amps @230V 2.9 2.9 4.1 4.1
Filter*Type DISPOSABLE OR PERMANENT
Size 20 x 20 x 1 22 x 20 x 1 20 x 20 x 1 22 x 20 x 1
Permanent Type Kit 1PF0602 1PF0603 1PF0602
1PF0603
Shipping/Operating Weight (lbs.) 158/150 163/153 156/146 180/170
*Field Supplied
11. Unit Data
Table 2. Physical and Electrical Data - Cooling Only
PSCSTANDARDMOTOR
PSC STANDARD MOTOR
FACTORYWIREDTO
FAN MOTOR
RELAY
TERMINAL ON
FACTORY WIREDTO
BLK
CAP
PRP PRP H M L
CAP
230 VOLT
FACTORY WIREDTO
FAN MOTOR RELAY
TERMINAL
O
N
HIGH
MOTOR
BLK
RC
MED
BRN
230 VOLT
GND.
FACTORYWIREDTO GND.
A
LTERNATE CONNECTION
A
LL OTHER AIR HANDLER
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