Lennox BCE3M*C SERIES User manual

507621-01 Issue 1720 Page 1 of 23
This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in
manuals, be alert to the potential for personal injury or death.
These instructions must be read and understood completely before attempting installation.
THIS MANUAL MUST BE LEFT WITH THE
HOMEOWNER FOR FUTURE REFERENCE
Table of Contents
Unit Dimensions ..........................................................2
Shipping and Packing List ...........................................3
General........................................................................3
Requirements ..............................................................3
Installation Clearances ................................................4
Installation ...................................................................4
Condensate Drain........................................................8
Duct System and Filters ............................................10
Brazing Refrigerant Lines..........................................11
Sealing the Unit .........................................................13
Electrical Connections...............................................13
Air Flow — Cooling Blower Speed ............................17
Check-Out Procedures..............................................19
Operation...................................................................19
Maintenance..............................................................20
Cabinet Insulation......................................................20
Use of Air Handler During Construction.....................21
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must be
performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
WARNING
215 Metropolitan Drive
West Columbia, SC 29170
*P507621-01*
(P) 507621-01
INSTALLATION INSTRUCTIONS
BCE3M*C & BCS3M*C SERIES AIR HANDLER
This product contains a chemical known to the State
of California to cause cancer, birth defects or other
reproductive harm.
WARNING
The Clean Air Act of 1990 bans the intentional venting
of refrigerant (CFCs, HCFCs and HFCs) as of July
1, 1992. Approved methods of recovery, recycling or
reclaiming must be followed. Fines and/or incarceration
may be levied for noncompliance.
CAUTION

507621-01Issue 1720Page 2 of 23
A
CB
F
G
FRONT VIEW SIDE VIEW
LINE VOLTAGE INLETS
(Top and Right Side)
LOW VOLTAGE INLETS
(Either Side)
SUCTION
LINE
LIQUID
LINE FILTER ACCESS
CONDENSATE DRAIN
PIPING PLATE (4)
(2-1/4 x 3-3/4)
3/4 (19)
AIR FLOW
CIRCUIT
BREAKER
COVER
5 (102)
3-5/8
(92)
JH
1-1/8
(29)
1/2
(13)
D
E
LINE VOLTAGE
INLETS
(Top and Left Side)
LOW VOLTAGE
INLETS
(Top and Right Side)
1 (25)
SUPPLY AIR
OPENING
TOP VIEW
OPENING OPENING
1 (25) 1 (25)
1-1/8
(29)
1-1/8
(29)
Unit Dimensions
Dimension 018 024 030 036 042 048/060
in. mm in. mm in. mm in. mm in. mm in. mm
A 38 965 40-1/2 1029 43 1092 52-1/2 1334 48 1219 52-1/2 1334
B 15 381 18-1/2 470 18-1/2 470 21-7/8 556 21-7/8 556 21-7/8 556
C 22 559 22 559 22 559 22 559 26-1/4 667 26-1/4 667
D 13 330 16-1/2 419 16-1/2 419 19-7/8 505 19-7/8 505 19-7/8 505
E 14-1/2 368 14-1/2 368 14-1/2 368 14-1/2 368 18-3/4 476 18-3/4 476
F 8 203 8 203 8 203 8 203 9-1/4 235 9-1/4 235
G 5-5/8 143 5-5/8 143 5-5/8 143 5-5/8 143 4-1/2 114 4-1/2 114
H 12-3/4 324 16-1/4 413 16-1/4 413 19-5/8 498 19-5/8 498 19-5/8 498
J 20-3/8 518 20-3/8 518 20-3/8 518 20-3/8 518 24-5/8 625 24-5/8 625
Note: Unit is shipped congured for horizontal left-hand air discharge. Unit may be converted to horizontal right-hand air
discharge by repositioning horizontal drain pan.
Dimensions remain the same in all congurations.

507621-01 Issue 1720 Page 3 of 23
NOTE: These instructions are intended as a general guide and
do not supersede national, state or local codes in any way.
Shipping and Packing List
Package 1 of 1 contains the following:
1 - Assembled air handler unit factory-equipped for upow
or horizontal air discharge application (includes upow
and horizontal drain pans and pre-installed air lter).
Check equipment for shipping damage. If found,
immediately report damage to the last carrier. Check the
unit rating plate to conrm that delivered unit matches
order.
General
These air handlers are designed for indoor installation
only. As shipped, the unit is ready for installation in either
upow or horizontal left-hand air discharge applications.
Horizontal drain pan may be repositioned in the eld to
allow installation in the horizontal right-hand air discharge
position. Downow applications can be accomplished by
purchasing the available downow kit (see table 1).
All units come with a metering device installed.
Physical contact with metal edges and corners while
applying excessive force or rapid motion can result in
personal injury. Be aware of, and use caution when
working near these areas during installation or while
servicing this equipment.
CAUTION
These instructions are intended as a general guide and do
not supersede local or national codes in any way. Consult
authorities having jurisdiction before installation.
Compliance with all local, state, or national codes
pertaining to this type of equipment should be determined
prior to installation. Read this instruction manual, as well
as the instructions supplied in separate equipment, before
starting the installation.
In addition to conforming to manufacturer’s installation
instructions and local municipal building codes, installation
of Allied Air air handler units (with or without optional
electric heat), MUST conform with National Fire Protection
Association (NFPA) standards: “Standard for Installation of
Air Conditioning and Ventilation Systems” (NFPA No. 90A)
and “Standard for Installation of Residence Type Warm Air
Heating and Air Conditioning Systems” (NFPA No. 90B).
All models are designed for indoor installation only. The
installation of the air handler, eld wiring, duct system, etc.
must conform to the requirements of the National Electrical
Code, ANSI/NFPA No. 70 (latest edition) in the United
States, and any state laws, and local ordinances (including
plumbing or waste water codes). Local authorities having
jurisdiction should be consulted before installation is
made. Such applicable regulations or requirements take
precedence over the general instructions in this manual.
Install the conditioned air plenum, ducts and air lters
(provided) in accordance with NFPA 90B Standard for
the Installation of Warm Air Heating and Air-Conditioning
Systems (latest edition).
The air handler is shipped from the factory completely
assembled. The unit is provided with anges for the
connection of the duct system.
Do not remove the cabinet knockouts until it has been
determined which knockouts will need to be removed for
the installation.
Select the air discharge position which best suits the site
conditions. Consider required clearances, space, routing
requirements for refrigerant line, condensate disposal,
lters, duct system, wiring, and accessibility for service.
Refer to the rating plate on the air handler for specic
information.
Model Downow Kit
-018 96W37
-024, -030 96W38
-036 97W95
-042, -048, -060 97W96
Table 1. Downow Kits
Requirements
These units are designed to match, and must be
used with, outdoor units as rated. The indoor sections
are manufactured with a metering device installed
to provide optimum refrigerant control and system
performance with a variety of different capacities of
outdoor units.
IMPORTANT
Excessive Weight Hazard - Use two or more people
when moving and installing the unit. Failure to do so
can result in back or other type of injury.
WARNING

507621-01Issue 1720Page 4 of 23
Danger of explosion. Keep ammable
materials and vapors, such as gasoline, away
from air handler. Place air handler so that
heating elements are at least 18 inches (46
cm) above the oor for a garage installation.
Failure to follow these instructions can result
in death, explosion, or re.
WARNING
Excessive condensation may occur if the unit is installed
in a warm, humid place. When the unit is installed in
an unconditioned space, apply sealant around the
electrical wires, refrigerant piping, and condensate
lines at the point where they enter the cabinet.
Apply sealant on the inside of the cabinet at the
point where the electrical wires exit through the
conduit opening. This will also keep warm and moist
unconditioned air out of the air handler cabinet where
it will form condensate on the cooler control box and
electrical controls.
IMPORTANT
This unit is approved for installation clearance to
combustible material as stated on the unit rating
plate. Accessibility and service clearances must take
precedence over combustible material clearances.
The air handler must be installed so that free access
is allowed to the coil/lter compartment and blower/
control compartment.
IMPORTANT
Horizontal applications of the air handler must be
installed sloped (approximately 5/8 inch) toward the
drain pan openings to ensure proper condensate
drainage.
IMPORTANT
Installation Clearances
Non-Ducted Return Closet Installation
The air handler can be installed in a closet with a false
bottom to form a return air plenum. It may also be installed
with a return air plenum under the air handler.
Louvers or return air grilles are eld-supplied. Local codes
may limit application of systems without a ducted return to
single-story buildings.
When a BCE3M*C or BCS3M*C unit is installed in a closet
with a louvered return opening, the minimum open area for
the louvers will be:
• 320 square inches for -018 and -024 models;
• 360 square inches for -030 and -036 models;
• 450 square inches for -042 thru -060 models.
If the free area is not known, assume a 25% free area for
wood or a 75% free area for metal louvers or grilles. Using
the louver dimensions and the 25% or 75% assumption,
determine if the open area meets the minimum open area
listed above.
If a return air plenum is used, the return air grille should be
immediately in front of the opening in the plenum to allow
for the free ow of return air. When not installed in front of
the opening, there must be adequate clearance around the
air handler to allow for the free ow of return air.
Installation
General Information
Improper installation, adjustment, alteration, service,
or maintenance can cause property damage, personal
injury, or loss of life. Installation and service must be
performed by a qualied installer or service agency.
WARNING
These units are factory-assembled and congured for
installation in upow or horizontal left-hand air discharge
applications. Horizontal drain pan may be repositioned in
the eld to allow installation in the horizontal right-hand air
discharge position.
Each unit consists of a blower assembly, refrigerant coil,
and controls in an insulated galvanized steel factory-
nished enclosure. Knockouts are provided for electrical
wiring entrance.
For ease in installation, it is best to make any necessary
coil conguration changes before setting air handler in
place.

507621-01 Issue 1720 Page 5 of 23
For all performance testing, units must be tested in the
upow orientation with the horizontal drain pan removed.
Refrigerant Metering Device
These units are equipped with a factory-installed metering
device (TXV or piston). Ensure the indoor coil metering
device is properly sized for the outdoor unit being used.
Upow Application
1. The air handler must be supported on the bottom only
and set on solid oor or eld-supplied support frame.
Securely attach the air handler to the oor or support
frame.
2. If installing a unit in an upow application, remove the
horizontal drain pan.
IMPORTANT - The horizontal drain pan is not required
in upow air discharge installations; its removal
provides the best efciency and air ow.
3. Place the unit in the desired location and slope unit.
Connect return and supply air plenums as required
using sheet metal screws.
4. Install units that have no return air plenum on a stand
that is at least 14” from the oor. This will allow proper
air return.
Figure 1. Upow Conguration
HORIZONTAL DRAIN PAN
IMPORTANT - REMOVE PAN
FOR BEST EFFICIENCY
AND AIR FLOW.
UP-FLOW
DRAIN PAN
UP-FLOW DRAIN
CONNECTIONS (BOTH
SIDES; USE ONE SIDE
OR OTHER)
HORIZONTAL DRAIN
CONNECTIONS
(BOTH SIDES; NOT
USED)
Horizontal Applications
When removing the coil, there is possible danger of
equipment damage and personal injury. Be careful
when removing the coil assembly from a unit installed
in right- or left-hand applications. The coil may tip into
the drain pan once it is clear of the cabinet. Support the
coil when removing it.
IMPORTANT
NOTE: When the unit is installed in horizontal applications,
a secondary drain pan is recommended. Refer to local
codes.
NOTE: This unit may be installed in left-hand or right-hand
air discharge horizontal applications. Adequate support
must be provided to ensure cabinet integrity. Ensure that
there is adequate room to remove service and access
panels if installing in the horizontal position.
Left-Hand Air Discharge
1. Determine which plugs are required for drain line
connections.
2. With access door removed, remove drain line plugs to
install drain lines.
3. Set unit so that it is sloped toward the drain pan end of
the unit (see gure 11).
4. The left-hand air discharge horizontal conguration is
shown in gure 2.
Drains
AIR FLOW
PLUGS LEFT‐HAND DRAINS
Figure 2. Left-Hand Discharge Conguration
5. If the unit is suspended, the entire length of the cabinet
must be supported. If you use a chain or strap, use a
piece of angle iron or sheet metal attached to the unit
(either above or below) to support the length of the
cabinet. Use securing screws no longer than 1/2 inch
to avoid damaging the coil or lter. See gure 3. Use
sheet metal screws to connect the return and supply
air plenums as required.
FRONT VIEW
ANGLE IRON OR SHEET METAL
4 IN. (102 MM)
MAXIMUM 1/2”
LONG SCREW
AIR FLOW
ELECTRICAL INLET CLEARANCE
END VIEW
Figure 3. Suspending Horizontal Unit

507621-01Issue 1720Page 6 of 23
Right-Hand Air Discharge
For horizontal right-hand air discharge, the following eld
modications are required.
1. Remove and set aside blower and coil access panels.
2. Remove brackets securing pan to unit. See gure 4.
Figure 4
3. Remove coil assembly, bottom drain pan and
horizontal drain pan as one unit from the air handler.
See gure 5.
4. Remove the blow-off prevention brackets, top cap and
drip pan between slabs. Move the horizontal drain pan
to the opposite side of the coil. See gure 6.
NOTE: The 1.5- and 2-ton units do not have or require
blow-off prevention brackets or drip pan.
Figure 5
Figure 6

507621-01 Issue 1720 Page 7 of 23
5. Reinstall the top cap. Rotate the blow-off prevention
brackets 180º and reinstall using the same screws.
Use the correct mounting holes; the brackets must
cover the hairpins. See gure 7.
Figure 7
6. Slide coil assembly, bottom drain pan and horizontal
drain pan as one unit back into the air handler. See
gure 8.
Figure 8
7. Reinstall the brackets that hold the coil and horizontal
drain pan in place. See gure 9.
Figure 9
8. Reinstall the blower and coil access panels.

507621-01Issue 1720Page 8 of 23
Condensate Drain
The air handler is provided with ¾” NPT condensate drain connections.
On units of this type, where the blower “draws” rather than “blows” air through the coil, traps must be installed in the
condensate drain lines (primary and auxiliary, if used). Traps prevent the blower from drawing air through the drain
lines into the air supply.
IMPORTANT
ABOVE
FINISHED
SPACE?
SECONDARY (OVERFLOW) DRAIN LINE
ALWAYS RUN A SECONDARY (OVERFLOW) DRAIN LINE. IF NOT
POSSIBLE, INSTALL LOW VOLTAGE OVERFLOW SWITCH KIT.
WIRE KIT TO SHUT DOWN COMPRESSOR PER INSTRUCTIONS.
NO
YES
PART #
X3169 CLEAN OUT
VENT
PRESS IN
(DO NOT GLUE)
VENT MUST EXTEND
ABOVE HEIGHT OF
COIL DRAIN PAN BY
TWO INCHES (51MM)
1” X 3/4” X 3/4”
REDUCING
TEE WITH
PLUG
P-TRAP1 #49P66,
J-TRAP # 91P90
OR ANY PVC SCH
40 P- OR J-TRAP 3/4”
AIR HANDLER DRAIN PAN
WHEN A COIL IS LOCATED ABOVE A FINISHED
SPACE, A 3/4” (19.1MM) SECONDARY DRAIN LINE
MUST BE:
●CONNECTED TO SECONDARY DRAIN PAN
OR
●CONNECTED TO THE SECONDARY
(OVERFLOW) DRAIN OUTLET OF THE AIR
HANDLER DRAIN PAN.
TRAP MUST BE DEEP ENOUGH TO OFFSET MAXIMUM STATIC DIFFERENCES — GENERALLY,
TWO INCHES (51MM).
DRAIN LINE SHOULD
SLOPE A MINIMUM OF
ONE INCH PER 10 FEET
(25MM PER 3 METERS)
NOTE - WHEN AN AIR HANDLER IS LOCATED
ABOVE A FINISHED SPACE, THE SECONDARY
DRAIN PAN MUST HAVE A LARGER FOOTPRINT
THAN THE AIR HANDLER.
MAIN DRAIN
TO APPROVED
DRAIN
FOR NEGATIVE PRESSURE COILS (BLOWER
AFTER COIL), A TRAP IS REQUIRED ON THE
MAIN DRAIN LINE CONNECTED TO COIL.
REQUIREMENTS ON SECONDARY DRAINS.
USE TWO-PART 3/4” FEMALE SLIP INLET AND MALE ADAPTER
WHEN OBSTRUCTIONS PREVENT DIRECT THREADING OF
OVERFLOW SWITCH.
SECONDARY
DRAIN PAN
2”
(51MM)
TRAP DEPTH
1P-TRAP 49P66 REQUIRES A LARGER INSTALLATION SPACE THAN THE J-TRAP 91P90.
2PIPE NIPPLE PROVIDED IN BAG ASSEMBLY - SCH 80, 3/4” I. D. X 5” - 34K7401 (1): CUT THE PIPE
IN HALF AND USE IT TO ROUTE THE MAIN DRAIN.
SEE LOCAL CODES FOR TRAP
Figure 10. Typical Main and Overow Drain
A eld-fabricated secondary drain pan, with a drain
pipe to the outside of the building, is required in all
installations over a nished living space or in any area
that may be damaged by overow from the main drain
pan. In some localities, local codes may require a
secondary drain pan for any horizontal installation.
IMPORTANT

507621-01 Issue 1720 Page 9 of 23
Sloping the Unit
Make sure the unit is sloped (similar to the slope shown in
gure 11) (horizontal or upow) so that the drain pan will
empty completely without water standing in the pan.
THIS CORNER SHOULD BE 5/8” (+/- 1/8”) HIGHER
THAN DRAIN CORNER
DRAIN CORNER
THIS CORNER SHOULD BE
5/8” (+/- 1/8”) HIGHER THAN
DRAIN CORNER
LEVEL PLANE
LEVEL PLANE
Figure 11. Sloping the Drain
Install Condensate Drain
The air handler is equipped with ¾” NPT condensate drain
connections.
On some pans, the primary and secondary drain holes
have knockouts. Conrm primary and secondary drains
are open.
IMPORTANT
1. These units are equipped with a drain pan, which
includes green (main drain) and red (secondary drain)
plugs. Unscrew the plugs to remove them before
inserting condensate drain ttings. See gure 12.
DRAIN PANRED SECONDARY
DRAIN PLUG
UNSCREW PLUGS
AND CONNECT
PROPERLY SIZED
FIELD-PROVIDED
FITTINGS AND
DRAIN LINES.
GREEN MAIN
DRAIN PLUG
Figure 12
2. After removal of drain pan plugs, check the drain port
to see if holes have been drilled. If not drilled, use a
19/32” bit to drill out the primary drain hole; use a 3/8”
drill bit for the secondary drain hole. Remove all drill
shavings.
3. Install properly-sized, eld-provided connection ttings
and connect primary drain line to the main drain pan
connection.
NOTE: When installing drain line connection ttings
to the drain pan, hand tighten the tting and use a
thread sealant. Over-tightening the ttings can split
connections on the drain pan.
4. If the secondary drain line is to be used, remove the
plug or the knockout and route the drain line so that
water draining from the outlet will be easily noticed
by the homeowner. Refer to local codes for drain trap
requirements on the secondary drain line.
5. Check again to ensure drain ports and drain pan are
free of all debris.
6. Plug and check any unused drain pan openings for
tightness. Torque plugs to 30 in. lb. to prevent water
leaks or seepage from the drain pan.
7. Install a 2” trap in the main (primary) drain lines as
close to the unit as practical (see gure 10). Make sure
the top of the trap is below the connection to the drain
pan to allow complete drainage of the pan.
NOTE: Horizontal runs must have an anti-siphon air
vent (standpipe) installed ahead of the horizontal run.
See gure 10. An extremely long horizontal run may
require an oversized drain line to eliminate air traps.
NOTE: Do not operate air handler without a trap in
the main (primary) drain. The condensate drain is on
the negative pressure side of the blower; therefore, air
being pulled through the condensate line will not allow
positive drainage without a proper trap.
8. Route the drain line to the outside or to an appropriate
drain. Drain lines must be installed so they do not block
service access to the front of the air handler. A 24”
clearance is required for lter, coil, or blower removal
and service access.
NOTE: Check local codes before connecting the drain
line to an existing drainage system.
9. Insulate the drain lines where sweating could cause
water damage.
Test Condensate Drain
Test the drain pan and drain line after installation:
1. Pour several quarts of water into drain pan. Use
enough water to ll both the drain trap and the line.
2. Check the installed drain pan. Drain pan must be
draining completely. Drain line ttings must not be
leaking. Water must be draining from the end of the
primary drain line.
3. Correct any leaks found.

507621-01Issue 1720Page 10 of 23
Duct System and Filters
Duct System
The air handler is provided with anges for the connection
of the plenum and ducts. The air handler is equipped with
anges that can form a lter rack for the installation of the
air lter, or the lter may be installed as part of the return
air duct system.
Supply and return duct system must be adequately sized
to meet the system’s air requirements and static pressure
capabilities. The duct system should be insulated with
a minimum of 1” thick insulation with a vapor barrier in
conditioned areas or 2” minimum in unconditioned areas.
Supply plenum should be the same size as the anged
opening provided around the blower outlet and should
extend at least 3 ft. from the air handler before turning or
branching off plenum into duct runs. The plenum forms
an extension of the blower housing and minimizes air
expansion losses from the blower.
Filters
A lter is provided. Table 2 lists the lter size for each unit.
Installing Duct System
Install the conditioned air plenum, ducts and air lters
(not provided) in accordance with NFPA 90B Standard for
the Installation of Warm Air Heating and Air-Conditioning
Systems (latest edition).
Connect supply air duct to the ange on top of the air
handler. If an isolation connector is used, it must be
nonammable.
Field-Fabricated Return Air Duct Flange for
Horizontal Applications
A return air duct system is recommended, but not factory-
provided. If the unit is installed in a conned space or
closet, run a full-size return connection to a location outside
the closet.
Model Filter Size Actual Minimum
Filter Size
-018 12” x 20” x 1 11.50” x 19.50” x .75”
-024 and -030 15” x 20” x 1 14.50” x 19.50” x .75”
-036 18” x 20” x 1 17.50” x 19.50” x .75”
-042, -048 and -060 18” x 24” x 1 17.50” x 23.50” x .75”
Table 2. Filters
If a high -efciency lter is being installed as part of
this system to ensure better indoor air quality, the lter
must be properly sized. High -efciency lters have a
higher static pressure drop than standard- efciency
glass/foam lters. If the pressure drop is too great,
system capacity and performance may be reduced.
The pressure drop may also cause the limit to trip
more frequently during the winter and the indoor coil
to freeze in the summer, resulting in an increase in the
number of service calls.
Before using any lter with this system, check the
specications provided by the lter manufacturer
against the data given in the appropriate Allied Air
Product Specications bulletin.
IMPORTANT
BOTTOM OF
CABINET
DUCT
ADAPTER
1−1/2
(38)
“A”
BRAKE DOWN 90 DEGREES
1/4 (6) DIA.
2−HOLES
“A”
−018 14−7/8 (378)
−024 & −030 18−3/8 (467)
−036 to −060 21−3/4 (552)
1−1/2(38)
3/4
(19)
3/4
(19)
1−1/2
(38)
3/4
(19)
1/2
(13)
3/4
(19)
DUCT
FLANGE
CABINET
DOOR FLANGE
UNIT SIZE
Figure 13. Cabinet and Duct Flange

507621-01 Issue 1720 Page 11 of 23
Brazing Refrigerant Lines
Refrigerant lines must be connected by a qualied
technician in accordance with established procedures.
Refrigerant lines must be clean, dehydrated,
refrigerant-grade copper lines. Air handler coils should
be installed only with specied line sizes for approved
system combinations.
Handle the refrigerant lines gently during the installation
process. Sharp bends or possible kinking in the lines
will cause a restriction.
Do not remove the caps from the lines or system
connection points until connections are ready to be
completed.
IMPORTANT
Polyolester (POE) oils used with HFC-410A refrigerant
absorb moisture very quickly. It is very important that the
refrigerant system be kept closed as much as possible.
DO NOT remove line set caps or service valve stub
caps until you are ready to make connections.
WARNING
Danger of re. Bleeding the refrigerant
charge from only the high side may result in
the low side shell and suction tubing being
pressurized. Application of a brazing torch
while pressurized may result in ignition of the
refrigerant and oil mixture - check the high
and low pressures before unbrazing.
WARNING
When using a high pressure gas, such as dry
nitrogen, to pressurize a refrigeration or air
conditioning system, use a regulator that can
control the pressure down to 1 or 2 psig (6.9
to 13.8 kPa).
WARNING
To prevent the build-up of high levels of nitrogen when
purging, be sure it is done in a well ventilated area.
Purge low pressure nitrogen (1 to 2 psig) through
the refrigerant piping during brazing. This will help to
prevent oxidation and the introduction of moisture into
a system.
IMPORTANT
Brazing alloys and ux contain materials which are
hazardous to your health.
Avoid breathing vapors or fumes from brazing
operations. Perform operations only in well ventilated
areas.
Wear gloves and protective goggles or face shield to
protect against burns.
Wash hands with soap and water after handling brazing
alloys and ux.
CAUTION
NOTE: Recommended line length is 50’ or less. If more
than 50’ line set is required, contact Technical Services.
1. Route the suction and liquid lines from the ttings on
the indoor coil to the ttings on the outdoor unit. Run
the lines in a direct path, avoiding unnecessary turns
and bends.
2. Make sure that the suction line is insulated over the
entire exposed length and that neither suction nor
liquid lines are in direct contact with oors, walls, duct
system, oor joists, or other piping.
3. Connect the suction and liquid lines to the evaporator
coil. Take care to protect the cabinet and internal
components as detailed in gure 14.
4. To avoid damaging the rubber grommets in the cabinet
while brazing, slide the rubber grommets over the
refrigerant lines until they are away from the heat
source.
NOTE: Place wet rags against piping plate and around
suction line connections.
5. Braze using an alloy of silver or copper and phosphorus
with a melting point above 1,100°F (593°C).
NOTE: Do not use soft solder.
6. Allow refrigerant pipes to cool to room temperature.
NOTE: Make sure to route copper refrigerant tubing
away from sharp edges and make sure that it does
not touch other metal surfaces. This prevents damage
caused by vibration or metal-on-metal contact.
7. Reinstall the rubber grommets into the refrigerant
piping panel.
NOTE: Make sure expansion valve capillary tube is
not touching metal edges or copper tubing.
8. Make sure outdoor unit has been placed according
to the Installation Instructions and is connected to the
refrigerant lines.

507621-01Issue 1720Page 12 of 23
REMOVE ACCESS PANEL
A
REMOVE RUBBER PLUG FROM BOTH LIQUID
AND SUCTION LINES
B
NITROGEN
HIGH
LOW
EITHER REMOVE OR PUSH PIPE WRAPPING BACK
THROUGH HOLE IN PIPING PLATE BEFORE LINE
SET CONNECTION AND BRAZING.
C
DCONNECT PIPES ECONNECT GAUGES AND
START NITROGEN FLOW
FPLACE A WET RAG AGAINST PIPING
PLATE AND AROUND THE SUCTION
LINE CONNECTION. A
GBRAZE CONNECTION. ALLOW PIPE TO
COOL BEFORE REMOVING WET RAG
FROM CTXV SENSING BULB AND PIPING
PANEL AREA.
HREPEAT PREVIOUS PROCEDURE FOR
LIQUID LINE.
NOTE - REFER TO OUTDOOR UNIT INSTALLATION
INSTRUCTIONS FOR REFRIGERANT PIPING SIZE
REQUIREMENTS.
NOTE - REFRIGERANT LINE SETS
SHOULD BE ROUTED TO ALLOW
FILTER ACCESSIBILITY.
NOTE - BCE3M*V SERIES UNITS USE NITROGEN OR DRY AIR
AS A HOLDING CHARGE. IF THERE IS NO PRESSURE WHEN
THE RUBBER PLUGS ARE REMOVED, CHECK THE COIL FOR
LEAKS BEFORE INSTALLING.
REFER TO INSTRUCTIONS PROVIDED WITH OUTDOOR
UNIT FOR LEAK TESTING, EVACUATING AND CHARGING
PROCEDURES
FLOW REGULATED NITROGEN (AT 1 TO 2 PSIG)
THROUGH THE REFRIGERATION GAUGE SET INTO THE
VALVE STEM PORT CONNECTION ON THE OUTDOOR
UNIT LIQUID LINE SERVICE VALVE AND OUT OF THE
VALVE STEM PORT CONNECTION ON THE SUCTION
SERVICE VALVE.
PIPING
PLATE
PLEASE READ IMPORTANT ISSUES CONCERNING BRAZING
OPERATIONS ON PREVIOUS PAGES BEFORE PROCEEDING.
NOTE - Use silver alloy brazing rods with five or six percent
minimum silver alloy for copper-to-copper brazing, 45
p
ercent alloy for copper-to-brass and copper-to-steel
brazing.
Figure 14. Brazing

507621-01 Issue 1720 Page 13 of 23
Sealing the Unit
Seal the unit so that warm air is not allowed into the cabinet.
Warm air introduces moisture, which results in water blow-
off problems. This is especially important when the unit is
installed in an unconditioned area.
If installed in an unconditioned space, sealant should be
applied around the electrical wires, refrigerant tubing, and
condensate lines where they enter the cabinet.
There must be an airtight seal between the bottom of
the air handler and the return air plenum. Use berglass
sealing strips, caulking, or equivalent sealing method
between the plenum and the air handler cabinet to
ensure a tight seal. Return air must not be drawn
from a room where this air handler or any gas-fueled
appliance (ie., water heater), or carbon monoxide-
producing device (ie., wood replace) is installed.
WARNING
When sealing the cabinet, be sure to seal closed any
space around the holes where the drain lines exit the
cabinet using duct tape and/or Permagum. Warm air
must not be allowed to enter through any gaps or
holes in the cabinet.
IMPORTANT
Make sure the liquid line and suction line entry points
are sealed with either Armaex material or with
Permagum. Permagum may also be used to seal
around the main and auxiliary drains and around open
areas of electrical inlets.
IMPORTANT
Electrical Connections
Electric shock hazard! - Disconnect all
power supplies before servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
WARNING
Run 24V Class II wiring only through specied low
voltage opening. Run line voltage wiring only through
specied high voltage opening. Do not combine
voltage in one opening.
WARNING
WARNING
ELECTRIC SHOCK HAZARD
Can cause injury or death.
Foil-faced insulation has conductive characteristics
similar to metal. Be sure there are no electrical
connections within a 1/2” of the insulation. If the foil-
faced insulation comes in contact with electrical
voltage, the foil could provide a path for current to pass
through to the outer metal cabinet. While the current
produced may not be enough to trip existing electrical
safety devices (e .g. fuses or circuit breakers), the
current can be enough to cause an electric shock
hazard that could cause personal injury or death.
ELECTRIC SHOCK HAZARD
Can cause injury or death. Unit must be
grounded in accordance with national
and local codes.
Line voltage is present at all components
when unit is not in operation on units
with single-pole contactors. Disconnect
all remote electric power supplies before
opening access panel. Unit may have
multiple power supplies.
WARNING
• Wiring must conform to the current National Electric
Code ANSI/NFPA No. 70, or Canadian Electric Code
Part I, CSA Standard C22.1, and local building codes.
Refer to following wiring diagrams. See unit nameplate
for minimum circuit ampacity and maximum over-
current protection size.
• Electrical wiring, disconnect means and over-
current protection are to be supplied by the
installer. Refer to the air handler rating plate
for maximum over-current protection, minimum
circuit ampacity, as well as operating voltage.
Select the proper supply circuit conductors in
accordance with tables 310-16 and 310-17 in the
National Electric Code, ANSI/NFPA No. 70 or tables 1
through 4 in the Canadian Electric Code, Part I, CSA
Standard C22.1.

507621-01Issue 1720Page 14 of 23
• The power supply must be sized and protected
according to the specications supplied on the product.
• This air handler is factory-congured for 240 volt,
single phase, 60 cycles. For 208-volt applications, see
“208 Volt Conversion” later in this section.
• Separate openings have been provided for 24V low
voltage and line voltage. Refer to the dimension
illustration for specic location.
• This unit is provided with holes for conduit. Use
provided caps to seal holes not used.
• Typical unit wiring (as well as wiring of optional eld-
installed electric heat) is given in gure 18. Refer to
the instructions provided with the electric heat section
for proper installation.
• For optional eld-installed electric heat applications,
refer to the instructions provided with the accessory
for proper installation.
USE COPPER CONDUCTORS ONLY!
WARNING
1. Disconnect all power supplies.
2. Remove the air handler access panel.
3. Route the eld supply wires to the air handler electrical
connection box.
4. Use UL-listed wire nuts to connect the eld supply
conductors to the unit black and yellow leads, and the
ground wire to ground terminal marked GND.
5. Replace the air handler access panel.
Figure 15
NOTE: To avoid the possibility of moisture damage to the
control in some right-hand discharge congurations, the
control panel can be relocated to the end panel as shown
in gure 16.
Figure 16
208 Volt Conversion
1. Disconnect all power supplies.
2. Remove the air handler access panel.
3. Using the wiring diagram located on the unit access
panel as a reference, move the 2 connected black
transformer leads from the 240 volt terminal on the
transformer to the 208 volt terminal on the transformer.
Electrically ground air handler. Connect
ground wire to ground terminal marked
“GND”.
Failure to do so can result in death or
electrical shock.
WARNING
208 / 240 VOLT TRANSFORMER
PRIMARY SECONDARY
240 Volts
208 Volts
Figure 17

507621-01 Issue 1720 Page 15 of 23
Figure 18. Typical Wiring Diagram
WARNING
USE COPPER CONDUCTORS
ONLY
15 AMP
SUPPLY
VOLTAGE
L1
L2 OR
NEUT.
WIRING DIAGRAM: NO HEAT
WIRE NUTS
BY OTHERS
14 GRN
2
14 BLK
1
TO
GROUND LUG
14 YEL(240V)
14 WHT(120V)
6-PIN
PLUG
6
14 YEL(COM)
14 BLK(HI)
14 RED(LO)
2YEL
1CAP
MTR
BLK
RED
3
BRN/WHT
BRN
GND
+
120V
OR
220V
4
1
56
23
1st STAGE
C
24
18 BLK
20 KW = HE1,HE2,HE3 & HE4
15 KW = HE1,HE2 & HE3
7.5 & 10 KW = HE1 & HE2
5 KW = HE1
HEATERS USED
2nd STAGE
1st STAGE
L2B
L1B
(OPT.)
TB = TERMINAL BLOCK
GND.
12 BLK
12 BLK
12 YEL
HE3
LS3
HE4
LS4
12 YEL
1
3
2
4
18 BLU
SEQUENCER 2
CIRCUIT BREAKER 2
12 BLK
3
2
65
1
4
HE1
HE2
LS1
LS2
12 BLK
12 YEL
12 YEL
6-PIN
PLUG
3
14 RED
(OPT.)
LOCATION
PLUG PIN
SEQUENCER 1
1
4
5
3
12 BLK
12 BLK
GND
CIRCUIT
BREAKER 1
L1A
L2A
5
18 WHT
4
14 GRN
18 BLU
2
1
14 YEL 14 BLK
CONTROL (FIELD WIRED)
CONTROL (FACTORY WIRED)
POWER (FIELD WIRED)
POWER (FACTORY WIRED)
GROUND LUG
TO BLOWER
BE 24 VOLT, N.E.C. CLASS 2
CONTROL CIRCUIT WIRING TO
WIRING DIAGRAM - ELECTRIC HEAT
HE = HEATER ELEMENT
LS = LIMIT SWITCH
GND = GROUND LUG
CB = CIRCUIT BREAKER
SEQ = SEQUENCER
TR = TRANSFORMER
TD = TIME DELAY (OPT.)
BR = BLOWER RELAY
MTR = BLOWER MOTOR
GND = GROUND CONNECTION
CAP = MOTOR CAPACITOR
W2
BLU
WHT
GRN
RED
BY OTHERS
THERMOSTAT
TO
W1
C
18 BLU
18 WHT
G
R
18 GRN
18 RED
BLK
14 YEL L2
14 BLK L1
24V
COM
208V
18 BLU
240V
14 BLK
1
3
5
2
6
4
18 BLU
65432
1
18 GRN
18 BLK
14 RED
18 BLU
18 RED
**
220
208/240
VOLTAGE
BY OTHERS
PART NO. 067203400
12 BLK
12 BLK
12
35
14 BLUE (MED) BLUE
4
#
18 BLU
18 WHT
18 BLU
12 YEL
12 YEL
18 BLK
18 BLK
14 RED
TRANSFORMER
BLOWER REALY
TIME DELAY
***SEQ4
***SEQ3
*** SEQUENCER USED: WIRED AS SHOWN
RELAY USED: WIRED PER RELAY POLE
TO BREAK CIRCUIT
NO DEVICE PRIOR TO 10-15-2014
2
6
THREE POLE SEQUENCER
TIMING - SEC
ON
1-20
20-60
20-60
OFF
40-110
1-30
1-30
12
34
12
34
TWO POLE SEQUENCER
TIMING - SEC
ON
30-90
30-90
OFF
1-30
1-30
# FACTORY SPEED SET TO MEDIUM (BLUE) FOR -018, -024, -030, -036,
-042, AND -060. FACTORY SPEED SET TO LOW (RED) FOR -048

507621-01Issue 1720Page 16 of 23
Figure 19. Low Voltage Connections
R
G
AIR
CONDITIONER
UNIT
R
R
G
G
BU
W
W
BK
COOLING‐ONLY APPLICATION
AIR HANDLERTHERMOSTAT
HEAT‐ONLY APPLICATION
AIR HANDLERTHERMOSTAT
COOLING APPLICATION WITH
ELECTRIC HEAT
AIR HANDLERTHERMOSTAT
HEAT PUMP APPLICATION WITH
ELECTRIC HEAT
NOTE - Connect common wire only if required (Refer to the appropriate thermostat installation instructions).
BU
BU
SEE
NOTE
SEE
NOTE
SEE
NOTE
Y
Y
AIR CONDITIONER
UNIT
R
G
BU
W
BK
CONNECT COMMON
WIRE ONLY IF
REQUIRED
(REFER TO THE
APPROPRIATE
THERMOSTAT
INSTALLATION
INSTRUCTIONS)
AIR HANDLER
THERMOSTATHEAT PUMP
UNIT

507621-01 Issue 1720 Page 17 of 23
Air Flow — Cooling Blower Speed
The cooling blower speed is factory congured to provide
correct air ow for an outdoor unit that matches the cooling
capacity rating of the air handler.
If the outdoor unit is smaller than the maximum cooling
capacity rating for the air handler, the cooling blower speed
may need to be changed. Refer to blower performance
chart (table 3).
ELECTRIC SHOCK HAZARD!
Disconnect all power supplies before
servicing.
Replace all parts and panels before
operating.
Failure to do so can result in death or
electrical shock.
WARNING
Figure 20
2
BLUE (MED)RED (L0)
BLACK (HI)
YELLOW (COM)
5BLOWER RELAY
BLOWER RELAY
PLASTIC CAPS
4-PIN
BLOWER CONNECTOR
HARNESS
NOTE -Refer to wiring diagram located on the
unit access panel, this figure, and blower
p
erformance (table 2).
All air data measured external to unit with 1
inch non-pleated air filter in place.
All factory settings are medium speed except
the -48 which is set to low speed from the
factory.
All data given while air handler is operating
with a dry DX coil.
3
6
4
2
4
3
1
GND
BRN / WHT
BRN
BLUE
RED
BLK
YEL+
MTR
Change Blower Speed
1. Disconnect all power supplies.
2. Remove the air handler access panel.
3. Locate pin number 2 on the blower relay. Two black
wires are connected to this terminal pin. One connects
to pin number 5 on the blower relay, one connects to
an in-line splice connecting to a blue wire.
4. Select the required blower motor speed connect red-
LO or black-HI and plug it into the 4-pin blower relay
harness connector.
NOTE: Reuse the factory-installed wire nut on the
unused wires.
5. Replace all panels.
6. Reconnect power.

507621-01Issue 1720Page 18 of 23
Air Handler
Model Blower Speed .10” WC .20” WC .30” WC .40” WC .50” WC
-018
Low (Red) 510 495 475 420 325
Med (Blue) 670 650 630 595 505
High (Black) 905 865 820 770 705
-024
Low (Red) 630 625 615 610 580
Med (Blue) 885 875 850 820 780
High (Black) 1130 1100 1070 1010 950
-030
Low (Red) 900 865 830 780 740
Med (Blue) 1075 1060 1030 985 940
High (Black) 1240 1210 1170 1135 1085
-036
Low (Red) 1075 1040 1000 950 900
Med (Blue) 1300 1250 1205 1145 1085
High (Black) 1510 1450 1390 1320 1245
-042
Low (Red) 1325 1315 1300 1275 1225
Med (Blue) 1490 1465 1440 1395 1315
High (Black) 1820 1770 1690 1600 1500
-048
Low (Red) 1775 1710 1645 1565 1470
Med (Blue) 1995 1895 1800 1685 1560
High (Black) 2070 1970 1850 1719 1595
-060
Low (Red) 1675 1630 1580 1520 1450
Med (Blue) 1965 1925 1875 1800 1695
High (Black) 2140 2085 2000 1895 1795
• Blower Performance (CFM vs. ESP inches H2O)
• Cooling speeds should not be reduced below factory setting.
• Units with electric heat approved at 0.5” maximum and medium blower speed minimum.
• Downow units should be set to high speed minimum.
• Different speeds can be set for heating mode.
Table 3. Blower Performance

507621-01 Issue 1720 Page 19 of 23
Check-Out Procedures
NOTE: Refer to outdoor unit installation instructions for
system start-up instructions and refrigerant charging
instructions.
Pre-Start-Up Checks
• Is the air handler properly and securely installed?
• If horizontally congured, is the unit sloped up to 5/8
inch toward drain lines?
• Will the unit be accessible for servicing?
• Has an auxiliary pan been provided under the unit
with separate drain for units installed above a nished
ceiling or in any installation where condensate overow
could cause damage?
• Have ALL unused drain pan ports been properly
plugged?
• Has the condensate line been properly sized, run,
trapped, pitched, and tested?
• Is the duct system correctly sized, run, sealed, and
insulated?
• Have all cabinet openings and wiring been sealed?
• Is the indoor coil metering device properly sized for the
outdoor unit being used?
• Have all unused parts and packaging been disposed
of properly?
• Is the lter clean, in place, and of adequate size?
• Is the wiring neat, correct, and in accordance with the
wiring diagram?
• Is the unit properly grounded and protected (fused)?
• Is the thermostat correctly wired and in a good
location?
• Are all access panels in place and secure?
Check Blower Operation
• Set thermostat to FAN ON.
• The indoor blower should come on.
Check Cooling Operation
• Set thermostat to force a call for cooling (approximately
5ºF lower than the indoor ambient temperature).
• The outdoor and indoor units should come on
immediately.
• Check the air ow from a register to conrm that the
system is moving cooled air.
• Set the thermostat 5ºF higher than the indoor
temperature. The indoor blower and outdoor unit
should cycle off. Air handler should cycle off 45
seconds after the outdoor unit shuts off.
Check Electric Heater (if used)
• Set thermostat to call for auxiliary heat (approximately
5°F above ambient temperature). The indoor blower
and auxiliary heat should come on together. Allow a
minimum of 3 minutes for all sequencers to cycle on.
• Set the thermostat so that it does not call for heat.
Allow up to 5 minutes for all sequencers to cycle off.
Operation
Time Delay Relay
Blower time delay operation:
1. When cooling demand is initiated, there is a 1 second
motor-on delay.
2. After the motor-on delay expires, motor ramps up
to 100% and runs at 100% until cooling demand is
satised.
3. Once demand is met, motor runs at 100% for 45
seconds.
4. Motor ramps down to stop.
Figure 21
1
SECOND
DELAY
OFF
100%
CFM 100%
CFM
45
SECS
COOLING
DEMAND
12
34
Cooling (Cooling Only or Heat Pump)
When the thermostat calls for cooling, 24 volts is put on
the blower time-delay relay coil and then the indoor blower
relay energizes. The normally open contacts close, causing
the indoor blower motor to operate. The circuit between R
and Yis completed, closing the circuit to the contactor in
the outdoor unit, starting the compressor and outdoor fan
motor.
On heat pumps, circuit Rand Oenergizes the reversing
valve, switching the valve to the cooling position. (The
reversing valve remains energized as long as the
thermostat selector switch is in the COOL position.)
At the completion of the cooling demand, the indoor blower
and outdoor unit should cycle off. Air handler should cycle
off 45 seconds after the outdoor unit shuts off.
Heating (Electric Heat Only)
When the thermostat calls for heat, the circuit between R
and Wis completed, and the heat sequencer is energized.
A time delay follows before the heating elements and the
indoor blower motor come on. Units with a second heat
sequencer can be connected with the rst sequencer to W
on the thermostat sub-base, or they may also be connected
to a second stage on the sub-base.

507621-01Issue 1720Page 20 of 23
Heating (Heat Pump)
When the thermostat calls for heating, 24 volts is applied to
the blower time-delay relay coil. The normally open contacts
close, causing the indoor blower motor to operate. The
circuit between Rand Yis completed, closing the circuit to
the contactor in the outdoor unit, starting the compressor
and outdoor fan motor.
If the room temperature continues to decrease, the circuit
between R and W1 is completed by the second-stage heat
room thermostat. Circuit R-W1 energizes a heat sequencer.
The completed circuit will energize supplemental electric
heat (if applicable). Units with a second heat sequencer
can be connected with the rst sequencer to W1 on the
thermostat. They may also be connected to a second
heating stage W2 on the thermostat sub-base.
Emergency Heat (Heating Heat Pump)
If the selector switch on the thermostat is set to the
emergency heat position, the heat pump will be locked out
of the heating circuit, and all heating will be electric heat (if
applicable). A jumper should be placed between W2 and E
on the thermostat sub-base so that the electric heat control
will transfer to the rst-stage heat on the thermostat. This
will allow the indoor blower to cycle on and off with the
electric heat when the fan switch is in the AUTO position.
Maintenance
Do not operate system without a lter. A lter is
required to protect the coil, blower, and internal parts
from excessive dirt and dust. The lter is placed in the
return duct by the installer.
IMPORTANT
• Inspect air lters at least once a month and replace or
clean as required. Dirty lters are the most common
cause of inadequate heating or cooling performance.
• Replace disposable lters. Cleanable lters can be
cleaned by soaking in mild detergent and rinsing with
cold water.
• Install new/clean lters with the arrows on the side
pointing in the direction of air ow. Do not replace a
cleanable (high velocity) lter with a disposable (low
velocity) lter unless return air system is properly
sized for it.
• If water is seen dripping from the secondary drain line,
contact a qualied service technician. This is a sign
of a problem that must be investigated and corrected.
Cabinet Insulation
DAMAGED INSULATION MUST BE REPAIRED
OR REPLACED before the unit is put back into
operation. Insulation loses its insulating value when
wet, damaged, separated or torn.
IMPORTANT
Matte- or foil-faced insulation is installed in indoor equipment
to provide a barrier between outside air conditions
(surrounding ambient temperature and humidity) and the
varying conditions inside the unit. If the insulation barrier is
damaged (wet, ripped, torn or separated from the cabinet
walls), the surrounding ambient air will affect the inside
surface temperature of the cabinet. The temperature/
humidity difference between the inside and outside of the
cabinet can cause condensation on the inside or outside
of the cabinet, which leads to sheet metal corrosion and
subsequently, component failure.
Repairing Damaged Insulation
Areas of condensation on the cabinet surface are an
indication that the insulation is in need of repair.
If the insulation in need of repair is otherwise in good
condition, the insulation should be cut in an X pattern,
peeled open, glued with an appropriate all-purpose glue
and placed back against the cabinet surface, being careful
to not overly compress the insulation so the insulation can
retain its original thickness. If such repair is not possible,
replace the insulation. If using foil-faced insulation, any
cut, tear, or separations in the insulation surface must be
taped with a similar foil-faced tape.
GLUE - Make sure there is
full coverage of glue on the
metal or insulation so there
are no areas where air
pockets may form, which
can lead to sweating.
1. Cut insulation in X pattern
2. Apply glue
3. Press glued tabs against cabinet
Figure 22. Repairing Insulation