SINGLE PIECE
VARIABLE SPEED AIR HANDLERS
ISO 9001
Certified Quality
Management System
MODELS: AV*(C) SERIES
LIST OF SECTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ELECTRIC HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .7
LOW VOLTAGE CONTROL CONNECTIONS . . . . . . . . . . . . . . . . . .7
REQUIRED CONTROL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
LINE POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AIRFLOW AND COMFORT SETTING SELECTION . . . . . . . . . . . . 12
UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LIST OF FIGURES
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Return Duct Attachment & Component Location . . . . . . . . . . . . . . . . .3
Dimensions & Duct Connection Dimensions . . . . . . . . . . . . . . . . . . . .4
Condensate Deflector on Vertical Drain Pan . . . . . . . . . . . . . . . . . . . .4
Condensate Deflecctor on Horizontal Drain Pan Edge . . . . . . . . . . . .5
S-Clip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Duck Work Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Typical Horizontal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TXV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Proper Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Handler Control Board – Communications Connections . . . . . . . . 7
Cooling Models with and without Electric Heat Wiring . . . . . . . . . . . . 8
Two-Stage Heat Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Handler with Communicating AC or HP . . . . . . . . . . . . . . . . . . . . 9
Line Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LIST OF TABLES
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heat Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Comfort Setting Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Physical and Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . . . . 12
Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Data - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Data - (For Single Source Power Supply) -
Copper Wire - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Data - (For Multi-Source Power Supply) -
Copper Wire - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Data - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Data - (For Single Source Power Supply) -
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Data - (For Multi-Source Power Supply) -
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air Handler Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
SECTION I: GENERAL
The AV single piece air handler provides the flexibility for installation in
any upflow, downflow, or horizontal application.
These versatile models may be used for cooling or heat pump operation
with or without electric heat.
A BRAND LABEL (available from Distribution) may be applied to the
center of the blower access panel on AVG models.
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance
can cause injury or property damage. Refer to this manual for assis-
tance or for additional information, consult a qualified contractor,
installer or service agency.
The unit can be positioned for bottom return air in the upflow position,
top return air in the downflow position, and right or left return in the hor-
izontal position.
Top and side power wiring and control wiring, accessible screw termi-
nals for control wiring, easy to install drain connections and electric
heaters all combine to make the installation easy, and minimize installa-
tion cost.
SECTION II: SAFETY
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.
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
FIRE OR ELECTRICAL HAZARD
Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
A fire or electrical hazard may result causing property damage, per-
sonal injury or loss of life.
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NOTICE
In severe high humidity, high temperature indoor unit environments,
an accessory insulation blanket is available to supplement the stan-
dard cabinet insulation. Insulate with UPG Kit: 1VJ0117 for B cabi-
nets, 1VJ0121 for C cabinets or 1VJ0124 on D cabinets or seal
completely with adequate fiberglass insulation using vapor barrier on
the outside.
When an evaporator coil is installed in an attic or above a finished
ceiling, an auxiliary drain pan should be provided under the coil as is
specified by most local building codes.
UPFLOW
DOWNFLOW
HORIZONTAL RIGHT
HORIZONTAL LEFT
FIGURE 1: Typical Installation
6. Re-install coil assembly on downflow bracket.
7. Re-attach front drain pan, hold down bracket.
8. Re-attach tubing connection panel.
DOWNFLOW AND HORIZONTAL CONVERSION
(AV ONLY)
These air handler units are supplied ready to be installed in a upflow
and right hand horizontal position. If unit requires left hand positioning,
the unit must have the coil assembly repositioned.
9. For horizontal applications, rotate air handler 90º into desired ori-
entation.
10. Re-position drain plugs as necessary based on air handler orienta-
tion.
1. Remove blower, coil, and filter access panels.
11. Re-position and replace access panels.
12. For downflow installations, the cladding should be reconfigured so
that the grille and circuit breaker covers having logos and/or black
coloring are at the top of the unit on the coil access panel. See
below.
NOTICE
Conversion must be made before brazing the refrigerant connections
to the coil.
For downflow and horizontal left installations, follow steps 2 - 8.
2. Remove tubing connection panel.
13. Apply branding label to air handler in recessed area provided on
blower access panel cladding. This label should be applied after
the air handler is placed in its proper orientation so the label is
right side up.
3. Remove front drain pan, hold down bracket.
4. Slide coil assembly out of air handler.
5. Rotate cabinet 180º so blower outlet is facing down.
FRONT VIEW
BLOWER
COMPARTMENT
COIL COMPARTMENT
(Access panel removed)
VERTICAL
DRAIN PAN
HORIZONTAL
DRAIN PAN
SIDE VIEW
REFRIGERANT LINE
CONNECTIONS
HORIZONTAL
SECONDARY DRAIN
HORIZONTAL
PRIMARY DRAIN
PRIMARY DRAIN
UPFLOW 3/4”
THREADED
ALTERNATE
DRAIN CONNECTIONS
UPFLOW/DOWNFLOW
RETURN AIR
DUCT
DUCT WORK MAY
BE FASTENED
CAUTIOUSLY WITH
FILTER DOOR
SCREWS TO THE
SIDES AND REAR OF UNIT
WHEN ATTACHING DUCT WORK WITH
SCREWS - KEEP SCREWS WITHIN 5/8”
OF SIDES AND BACK OF AIR HANDLER
SECONDARY DRAIN
UPFLOW 3/4” THREADED
FIGURE 2: Return Duct Attachment & Component Location
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CLADDING CONFIGURATION FOR DOWNFLOW
INSTALLATION (IF USED)
NOTICE
To reconfigure the cladding parts, remove the grille by pulling gently at
the top. Once the grille is removed, the circuit breaker cover can also be
removed. Remove the gray, non-branded grille and circuit breaker
cover from the cladding on the coil access panel. Next, remove the
black and/or branded grille and circuit breaker cover from the blower
access panel. Install these pieces into the coil access panel cladding so
they are at the top of the air handler. Install the gray, non-branded grille
and circuit breaker cover in the blower access panel cladding.
If a heat kit with a circuit breaker is installed in the air handler, the cir-
cuit breaker cover cladding must be removed to gain access to the
sheet metal cover plate. Some local codes may require that the circuit
breaker remain visible. If so, do not re-install circuit breaker cover
cladding.
F
10-3/8”
J
K
TOP OUTLET
DIMENSIONS
CLADDING
CIRCUIT
BREAKER
PANEL
18-9/32”
BLOWER
E
COMPARTMENT
BOTTOM INLET
A
DIMENSIONS
DRAIN CONNECTIONS
FOR UPFLOW AND
DOWNFLOW APPLICATIONS
D
REFRIGERANT
FIGURE 3: Dimensions & Duct Connection Dimensions
TABLE 1: Dimensions
Wiring Knockouts1
Refrigerant
Connections
Line Size
Dimensions (Inches)
Models
AV
A
B
C
J
K
D
E
F
Height
46
Width
17 1/2
21
Depth
Power
Control
Liquid
Vapor
24B
36C
48D
60D
12-3/8
17-1/8
22-1/8
22-1/8
13-29/32 14-19/32
17-13/32 18-3/32
20-29/32 21-19/32
20-29/32 21-19/32
3/4”
7/8”
7/8”
7/8’
21-1/2
(w/o cladding)
22-1/2
7/8” (1/2”)
1 3/8” (1”)
1 23/32” (1 1/4”)
52
7/8” (1/2”)
3/8”
57
24 1/2
24 1/2
(with cladding)
57
1. Actual size (Conduit size).
SUCTION FEEDER TUBE CONDENSATE
DEFLECTOR
Horizontal Left or Right
Use an appropriate tool to pry out water deflector with two or three s-
clips from the vertical drain pan. See Figure 4. Relocate the deflector
with s-clips on the Horizontal Drain Pan lined up to the coil support
brackete. See Figure 5. This positions the deflector below the feeder
tubes to channel the condensate to the drain pan.
UPFLOW OR DOWNFLOW
No action required. See Figure 4.
NOTICE
The condensate deflector should be installed in the s-clip section
which is inside the drain pan edge. See Figure 6.
S-CLIPS (3)
VERTICAL
CONDENSATE
FIGURE 4: Condensate Deflector on Vertical Drain Pan
4
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ers and never fastened directly to the structure. This unit is not
designed for non-ducted (freeblow) applications. Size outlet plenum or
transition to discharge opening sizes shown in Figure 3.
Duct work should be fabricated and installed in accordance with local
and/or national codes. This includes the standards of the National Fire
Protection Association for Installation of Air-Conditioning and Ventilat-
ing Systems, NFPA No. 90B.
DUCT WORK TRANSITION
FEEDER
TUBES
Duct work that is not designed to match the supply air opening can
cause turbulence inside the plenum box. This turbulence can change
the air flow patterns across the heat kit limit switch. If the factory sug-
gested transition can not be fabricated, it is recommended a block off
plate (approximately 8” in height and running the full width of the ple-
num) be attached to the supply opening Please refer to Figure 7 as a
visual aid. The use of this block off plate will keep better air circulation
across the limit switch.
CONDENSATE
DEFLECTOR
S-CLIPS ON HORIZONTAL PAN
FIGURE 5: Condensate Deflecctor on Horizontal Drain Pan Edge
DEFLECTOR
DRAIN PAN
WALL
S-CLIP
FIGURE 6: S-Clip Installation
RECOMMENDED
TRANSITION
SUGGESTED LOCATION
OF BLOCK OFF PLATE
DUCT CONNECTIONS
FIGURE 7: Duck Work Transition
The above suggestions will not alleviate problems caused by improper
installation. When receiving intermittent fault codes pertaining to the
limit switch, always double check your airflow CFM, motor speed and
static pressures.
Use 1/2" screws to connect ductwork to bottom of unit. Longer screws
will pierce the drain pan and cause leakage. If pilot holes are drilled,
drill only though field duct and unit bottom flange.
Air supply and return may be handled in one of several ways best
suited to the installation. See Figure 3 for dimensions for duct inlet and
outlet connections.
AIR FILTERS
Air filters must be field supplied. A 1" filter access rack has been built
into the unit. See Figure 3. Remove filter access cover shown. Install
proper size filter. Standard 1" size permanent or throw away filter may
be used, or, permanent washable filters are available using model num-
bers: 1PF0601, 602, 603BK. See Table 8 for filter size.
The vast majority of problems encountered with combination heating
and cooling systems can be linked to improperly designed or installed
duct systems. It is therefore highly important to the success of an instal-
lation that the duct system be properly designed and installed.
Use flexible duct collars to minimize the transmission of vibration/noise
into the conditioned space. If electric heat is used, non-flammable
material must be used.
Equipment should never be operated without filters.
Where return air duct is short, or where sound may be a problem,
sound absorbing glass fiber should be used inside the duct. Insulation
of duct work is a must where it runs through an unheated space during
the heating season or through an uncooled space during the cooling
season. The use of a vapor barrier is recommended to prevent absorp-
tion of moisture from the surrounding air into the insulation.
HORIZONTAL SUSPENSION (AV ONLY)
For suspension of these units in horizontal applications, it is recom-
mended to use angle steel support brackets with threaded rods, sup-
porting the units from the bottom, at the locations shown in Figure 8.
When an evaporator coil is installed in an attic or above a finished ceil-
ing, an auxiliary drain pan should be provided under the air handler as
is specified by most local building codes.
The supply air duct should be properly sized by use of a transition to
match unit opening. All ducts should be suspended using flexible hang-
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SUSPENSION SUPPORT LOCATIONS FOR HORIZONTAL APPLICATIONS
COIL UNDER PRESSURE.
MIN. 3/8”
Relieve pressure by depressing schrader core. Coil may have factory
installed TXV or may require orifice or TXV to be added. See outdoor
unit documentation for correct orifice or TXV to be used. Refer to coil
nameplate for TXV identification for this unit.
THREADED ROD
MIN. 1-1/2” x 1-1/2”
Angle Recommended
length 26” minimum with
2” clearance on both
sides of Air Handler
NOTICE
The coil should be open to the air for no more than 2 minutes to keep
moisture and contaminates from entering the system. If the coil can-
not be installed into the refrigeration system in that time, the ends
should be temporarily closed or plugged. For a short term delay, use
masking tape over the ends of the copper tubing to close the tube to
the air. For a longer term delay, use plugs or caps. There is no need
to purge the coil if this procedure is followed.
1-1/2
2
YY
WW
XX
Dimension
Units
(Nominal Tons)
WW
20
XX
46
52
57
24B
36C
REFRIGERANT LINE CONNECTION
24
AV*48D, 60D
28
FIGURE 8: Typical Horizontal Installation
Coil is under inert gas pressure. Relieve pressure from coil by
depressing schrader core.
TXV METERING DEVICES
If the model (C) number is of the following format: 4F, 4G, 4H, 4J,
and 4K will have the coil with R410A TXV metering device installed at
the factory.
If the model (C) number is of the 3X model series:
Dry nitrogen should always be supplied through the tubing while it is
being brazed, because the temperature required is high enough to
cause oxidation of the copper unless an inert atmosphere is provided.
The flow of dry nitrogen should continue until the joint has cooled.
Always use a pressure regulator and safety valve to insure that only
low pressure dry nitrogen is introduced into the tubing. Only a small
flow is necessary to displace air and prevent oxidation.
The coil will require an orifice or R410A TXV to be installed in the field.
Refer to installation manual with TXV kit. It is recommended to install a
orifice or TXV kit prior to brazing line sets.
VAPOR
LINE
THERMAL
EXPANSION
VALVE BULB
(Required insulation
Connect lines as follows:
LIQUID
LINE
not shown for clarity)
NOTICE
Route the refrigerant lines to the coil in a manner that will not obstruct
service access to the coil, air handling system, or filter.
THERMAL
EXPANSION
VALVE
1. Suction and liquid line connections are made outside the cabinet.
Leave the tubing connection panel attached to the cabinet with the
tubes protruding through it. Coil access panel should be removed
for brazing. The lines are swedged to receive the field line set
tubes.
TXV
EQUALIZER
LINE
DISTRIBUTOR BODY
FIGURE 9: TXV
2. Cut the end of the suction tube using a tube cutter. Place the tube
cutter as close as possible to the end of the tube to allow more
space for the connection and brazing of the suction line.
3. Remove the heat shield from the Customer Packet, soak in water,
and install over coil tubing to prevent overheating of cabinet.
4. Wrap a water soaked rag around the coil connection tubes inside
the cabinet to avoid damaging the TXV bulb.
Please refer to Outdoor Unit Tech Guide to verify which metering device
is installed in this coil and that this is a valid system match for the AC or
HP unit installed.
The temperature sensing bulb is attached to the coil suction header
line.
SCREW
5. Remove grommets where tubes exit the cabinet to prevent burning
them during brazing.
6. Purge refrigerant lines with dry nitrogen. Follow outdoor unit braz-
ing instructions.
7. Braze the suction and liquid lines.
TXV BULB
(Cover completely
with insulation)
8. Remove the heat shield.
9. Re-attach the grommets to the lines carefully to prevent air leak-
age.
10. Attach the coil access panel to the cabinet.
NUT
SUCTION LINE
CLAMP
FIGURE 10: Proper Bulb Location
Refer to Outdoor unit Installation Manual for evacuation, leak check and
charging instructions.
Lines should be sound isolated by using appropriate hangers or strap-
ping.
All evaporator coil connections are copper-to-copper and should be
brazed with a phosphorous-copper alloy material such as Silfos-5 or
equivalent. DO NOT use soft solder.
6
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For Upflow, Downflow and Horizontal right hand applications the kits
can be installed without modification.
DRAIN CONNECTIONS
All drain lines should be trapped a minimum of three inches, should be
pitched away from unit drain pan and should be no smaller than the coil
drain connection.
Field modification is required for Horizontal left hand airflow application
only. Follow instructions with heater kits for modification.
NOTICE
If a heat kit with a circuit breaker is installed in the air handler, the cir-
cuit breaker cover cladding must be removed to gain access to the
sheet metal cover plate. Some local codes may require that the circuit
breaker remain visible. If so, do not re-install circuit breaker cover
cladding.
Threaded drain connection should be hand-tightened, plus no more
than 1/16 turn.
Route the drain line so that it does not interfere with accessibility to the
coil, air handling system or filter and will not be exposed to freezing
temperatures. See Figures 2 and 3 for drain connection locations.
SECTION V: LOW VOLTAGE CONTROL
CONNECTIONS
NOTICE
This air handler can be connected to the wall thermostat and outdoor air
conditioner or heat pump using either conventional low voltage (24
VAC) thermostat wiring OR using four-wire digital communications wir-
ing. To use conventional low voltage wiring, see the section below enti-
tled “Conventional Low Voltage Control Wiring”. To use four-wire
communications control wiring, see the section below entitled “Control
Wiring using Communicating Controls”.
When the coil is installed in an attic or above a finished ceiling, an
auxiliary drain pan should be provided under the coil if specified by
local building codes.
Coils should be installed level or pitched slightly toward the drain end.
Suggested pitch should not exceed 1/4 inch per foot of coil.
The coil is provided with a secondary drain that should be trapped and
piped to a location that will give the occupant a visual warning that the
primary drain is clogged. If the secondary drain is not used it must be
capped. When an exterior secondary drain pan is used that secondary
drain should br piped to a location that will give the occupant a visual
warning that the primary drain is clogged.The drain pan connections are
designed to ASTM Standard D 2466 Schedule 40. Use 3/4" PVC or
steel threaded pipe. Since the drains are not subject to any pressure it
is not necessary to use Schedule 40 pipe for drain lines.
The Communicating System consists of several intelligent communicat-
ing components including the Communicating Thermostat Control
(touch-screen wall thermostat), variable speed air handler, air condi-
tioner (15 and 18 SEER premium air conditioners) or heat pump (13, 15
and 18 SEER premium heat pumps), which continually communicate
with each other via a four-wire connection called the A-R-Gnd or C-B
bus. Commands, operating conditions, and other data are passed con-
tinually between components over the A-R-Gnd or C-B bus. See Figure
13. The result is a new level of comfort, versatility, and simplicity.
DO NOT use teflon tape, “pipe dope” or other sealants. The use of a
sealant may cause damage and premature failure of hte drain pan
In order to use this air handler in full communications (COMM) mode, it
MUST be installed with the matching touch-screen Communicating
Control (wall thermostat) and an outdoor air conditioner or heat pump
with a fully communicating control.
SECTION IV: ELECTRIC HEATER
INSTALLATION
This air handler may also be used along with the Communicating Ther-
mostat Control and a non-communicating outdoor air conditioner
through the addition of a communicating Outdoor Aux Control board to
the outdoor unit. This system allows full communication between the air
handler and thermostat and limited communication to the outdoor unit.
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.
This air handler may also be used along with the Communicating Ther-
mostat Control and a non-communicating outdoor air conditioner or
heat pump using COMM between the air handler and thermostat and
conventional 24V wiring to the outdoor unit. This system allows full
communication between the air handler and thermostat but no digital
communication with the outdoor unit. See Figure 14.
The HEAT/ENABLE jumper (See Figure 10) must be moved to the
HEAT position to enable operation of the heater.
Use only 4HK heater kits, as listed on Air Handler name plate and in
these instructions. Use data from Tables 10 and 13 for information on
required minimum motor speed tap to be used for heating operation,
maximum over-current protection device required and minimum electri-
cal supply wiring size required – for listed combination of Air Handler
and Heater Kit.
HUMIDIFIER OUT PUT
HEAT ENABLE JUMPER
EAC OUTPUT
AC/HP JUMPER
HUMIDSTAT
JUMPER
BLOWER SPEED
JUMPERS
SPARE JUMPER
CONTINUOUS FAN JUMPER
THERMOSTAT CONNECTIONS
FIGURE 11: Air Handler Control Board – Communications Connections
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CONVENTIONAL LOW VOLTAGE CONTROL WIRING
(24 VAC)
TABLE 2: Low Voltage Connections
Terminal Signal
Comment
The 24 volt power supply is provided by an internally wired low voltage
transformer which is standard on all models, However, if the unit is con-
nected to a 208 volt power supply, the low voltage transformer must be
rewired to the 208 volt tap. See the unit wiring label.
R
G
24 VAC power (fused)
Continuous Fan operation
Second or full stage
compressor operation
Y/Y2
Y1
First stage compressor
operation
Not used with outdoor units
having one stage compressors.
Field supplied low voltage wiring can exit the unit on the top right hand
corner or the right hand side panel. Refer to Figure 3.
W2
W1
Second stage heat operation
First stage heat operation
Remove desired knockout and pierce foil faced insulation to allow wir-
ing to pass through. Use as small of a hole as possible to minimize air
leakage.
24 VAC will be present at this
terminal when the MODE
jumper is in the AC position.
This is normal.
O
Reversing valve operation
Humidity switch input
Install a 7/8” plastic bushing in the selected hole and keep low voltage
wiring as short as possible inside the control box.
24 VAC will be present at this
terminal when the HUM STAT
jumper is in the NO position.
This is normal.
To further minimize air leakage, seal the wiring entry point at the outside
of the unit.
HUM
The field wiring is to be connected at the screw terminals of the control
board. Refer to Figure 11 and 12.
This terminal is a connection
point only and does not affect
air handler control operation.
Connection point for
heat pump fault indicator
X/L
COM
24 VAC common
NOTICE
.All wiring must comply with local and national electrical code require-
ments. Read and heed all unit caution labels.
The low voltage connections may be connected to the screw terminals
or the quick connect terminals. The screw terminals and the quick con-
nect terminals are physically connected on the control board.
NOTICE
It is possible to vary the amount of electric heat turned on during the
defrost cycle of a heat pump. Standard wiring will only bring on the
first stage of electric heat during defrost. See Heat Output and Limit
Connections and Table 5 for additional information on heat during
defrost cycle.
Air Handler Control Wiring
Typical A/C - Cooling only Applications
Air Handler Control Wiring
Typical A/C with Electric Heat Applications
AIR HANDLER
AIR HANDLER
THERMOSTAT
1 - STAGE
BOARD
THERMOSTAT
1 - STAGE
BOARD
AIR CONDITIONING
AIR CONDITIONING
R
G
R
G
R
G
Y
R
G
Y
Y / Y2
Y
Y / Y2
Y
W1
W2
C
Y1
Y1
W2
W2
W2
*
*
W1
O
W1
O
HUMIDISTAT
HUMIDISTAT
W1
C
HUM
X / L
COM
HUM
X / L
COM
C
C
FIGURE 12: Cooling Models with and without Electric Heat Wiring
* Optional dehumidification humidistat switch contacts open on humidity rise.
NOTES:
1. “Y/Y2” Terminal on air handler control board must be connected for full CFM and applications requiring 60 second blower off delay for SEER enhancement.
2. Remove humidistat jumper on air handler control board.
3. For heat pump applications - set MODE jumper on air handler control board to the HP position.
4. To change quantity of heat during HP defrost cycle - reverse connections at W1 and W2 on air handler control board.
8
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.
CONTROL WIRING - Air Handler & UPG HP Systems
Two Stage H/P with York Guard VI Board & Copeland “Ultra Tech”
Conventional Application - Not Hot Heat Pump
AIR HANDLER
BOARD
2 - STAGE SCROLL
HEAT PUMP
THERMOSTAT
R
G
R
G
R
Y2
Y2
Y / Y2
Y1
Y2 OUT
Y1
Y1
W2 OUT
W2
W1
E
W1 OUT
W
O
W
O
O
*
HUM
X / L
COM
BS
X / L
C
HUMIDISTAT
X / L
C
FIGURE 13: Two-Stage Heat Pump Wiring
* Optional dehumidification humidistat switch contacts open on humidity rise.
NOTES:
1. “Y/Y2” Terminal on air handler control board must be connected for full CFM and applications requiring 60 second blower off delay for SEER enhancement.
2. Remove humidistat jumper on air handler control board.
3. For heat pump applications - set MODE jumper on air handler control board to the HP position.
4. To change quantity of heat during HP defrost cycle - reverse connections at W1 and W2 on air handler control board
CONTROL WIRING USING COMMUNICATING
CONTROLS
HUMIDITY SWITCH INPUT
The air handler control is designed to work with a humidity control that
closes when the humidity is below the set-point. The control is open
when the humidity is above the set-point. This humidity control may be
referred to as a humidistat or a dehumidistat.
Use the wiring diagram below to connect the air handler control, Com-
municating Control (wall thermostat) and communicating outdoor unit.
Be sure that all of the “A” terminals are connected together, all of the “B”
terminals are connected together, all of the “GND” or “C” terminals are
connected together and all of the “R” terminals are connected together.
See Figure 13. When using a fully communicating system, the large
screw terminals (C, G, R, etc.) on the air handler control are not used.
The four small screw terminals in the terminal block on the end of the air
handler control should be used.
The humidity switch controls both humidification and de-humidification
operation of the control. The control provides humidification using the
HUM OUT relay output and de-humidification by lowering the blower
speed. This is accomplished using the de-humidification input of the
motor for variable speed models. The humidity switch should be con-
nected to the R and HUM terminals of the control. See Figures 11 and
12.
Touch Screen
Communicating
Control
Air Handler
Communicating
Control
Air Conditioner/Heat Pump
Communicating Control
The 24 volt power supply is provided by an internally wired low voltage
transformer which is standard on all models, However, if the unit is con-
nected to a 208 volt power supply, the low voltage transformer must be
rewired to the 208 volt tap. See the unit wiring label.
A+
R
A+
R
A+
R
Field supplied low voltage wiring can exit the unit on the top right hand
corner or the right hand side panel. Refer to Figure 3.
C
C
C
Remove desired knockout and pierce foil faced insulation to allow wir-
ing to pass through. Use as small of a hole as possible to minimize air
leakage.
B-
B-
B-
Install a 7/8” plastic bushing in the selected hole and keep low voltage
wiring as short as possible inside the control box.
R
G
To further minimize air leakage, seal the wiring entry point at the outside
of the unit.
Y/Y2
Y1
The field wiring is to be connected at the screw terminals of the control
board. Refer to Figures 11 or 12.
W2
W1
O
NOTICE
All wiring must comply with local and national electrical code require-
ments. Read and heed all unit caution labels.
HUM
X/L
COM
NOTICE
It is possible to vary the amount of electric heat turned on during the
defrost cycle of a heat pump. Standard wiring will only bring on the
first stage of electric heat during defrost. See Heat Output and Limit
Connections and Table 5 for additional information on heat during
defrost cycle.
FIGURE 14: Air Handler with Communicating AC or HP
Johnson Controls Unitary Products
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The low voltage connections may be connected to the screw terminals
or the quick connect terminals. The screw terminals and the quick con-
nect terminals are physically connected on the control board.
Mode Jumper
The MODE jumper configures the control to operate properly with an air
conditioner (AC position) or heat pump (HP position). With the jumper in
the AC position, the control will energize the O terminal with 24 VAC
continually. With the jumper in the HP position, the O input signal is
received from the room thermostat.
TABLE 3: Low Voltage Connections
Terminal Signal
Comment
R
G
24 VAC power (fused)
If the jumper is not present, the control will operate as if the jumper is in
the HP position.
Continuous Fan operation
Second or full stage
compressor operation
Y/Y2
Y1
SPARE Jumper
First stage compressor
operation
Not used with outdoor units
having one stage compressors.
The control includes a spare jumper that can be used if a jumper is lost.
The SPARE jumper does not have any effect on the operation of the
control.
W2
W1
Second stage heat operation
First stage heat operation
Airflow and Comfort Setting Jumpers
24 VAC will be present at this
terminal when the MODE
jumper is in the AC position.
This is normal.
See separate section.
O
Reversing valve operation
Humidity switch input
Status and Fault Codes
24 VAC will be present at this
terminal when the HUM STAT
jumper is in the NO position.
This is normal.
The control includes an LED that displays status and fault codes. These
codes are shown in Table 4. The control will display the fault codes until
power is removed from the control or the fault condition is no longer
present.
HUM
This terminal is a connection
point only and does not affect
air handler control operation.
Connection point for
heat pump fault indicator
X/L
TABLE 4: Fault Codes
LED1 (RED)
Fault or Status Condition
COM
24 VAC common
Flash Code
SECTION VI: REQUIRED CONTROL
SET-UP
Status
No power to control
OFF
2s ON/2s OFF
Rapid Flash
ON
Normal operation
Control in test mode
Control failure
The following steps must be taken at the time of installation to insure
proper system operation.
Limit Faults
Limit switch currently open (not in lockout)
Multiple limit openings with no call for heat
Multiple limit openings during one call for heat
Single long duration limit opening
Multiple long duration limit openings
Fan failure
1
2
3
4
5
6
1. Consult system wiring diagram to determine proper thermostat
wiring for your system.
2. If heat kit is installed, change HEAT/NO HEAT jumper from NO
HEAT to HEAT position.
3. If a humidistat is installed, change HUM STAT jumper from NO to
YES.
Wiring Related Faults
Simultaneous call for heating and cooling
Internal Control Faults
7
9
4. Set the MODE jumper to A/C (Air Conditioner) or HP (Heat Pump)
position depending on the outdoor unit included with the system.
Control recovered from internal event
5. Set airflow and comfort setting jumper to proper positions.
FUNCTIONALITY AND OPERATION
Jumper Positions
External Relay Outputs
The control includes two outputs to drive external relays having 24 VAC
coils. The outputs have a maximum rating of 1.0 Amp pilot duty at 24
VAC.
HEAT/NO HEAT Jumper
The HEAT/NO HEAT jumper configures the control for heat kit opera-
tion. The jumper must be in the HEAT position if a heat kit is installed
with the air handler.
HUM OUT
The HUM OUT output can be used to drive an external relay or solenoid
(24 VAC coil) to control a humidifier. The output is energized when the
HUM input is energized, the HUM STAT is in the YES position, and the
control has a thermostat call for heating (heat pump or electric heat).
With the jumper in the NO HEAT position, the control will not energize
the heat relay outputs or sense the limit switch input.
If the jumper is not present, the control will operate as if the jumper is in
the HEAT position. If the jumper is not present and a heat kit is not pres-
ent, the control will sense an open limit condition and the blower will run
continuously.
EAC
The EAC output can be used to drive an external relay (24 VAC coil) to
control an electronic air cleaner. The output is energized whenever the
blower relay on the control is energized.
Hum Stat Jumper
The HUM STAT jumper configures the control to monitor the humidity
switch input. With the jumper in the NO position, the control will ener-
gize the HUM terminal with 24 VAC continually. With the jumper in the
YES position, the control will monitor the HUM input to control the HUM
OUT output to control an external humidifier.
Heat Output and Limit Connections
The control is connected to the heater relays and limit switch using the
6-pin connector. The relay outputs and the limit switch signal are 24
VDC.
The control energizes the heat relays and senses the limit switch input
as shown in Table 5 when the HEAT ENABLE jumper is in the HEAT
position.
If the jumper is not present, the control will operate as if the jumper is in
the YES position.
10
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Hard Lockout
TABLE 5: Heat Relays
The control has a hard lockout condition during which the control will
keep all heat outputs de-energized until power is removed from the con-
trol. The control de-energizes the blower five minutes after entering the
hard lockout condition.
Input
W1
Heat Relay Output
HT1
W2
HT1 and HT2
HT1 and HT2 and HT3
W1 and W2
If the limit switch closes and re-opens during the one hour soft lockout
period, the control will enter a hard lockout condition and continue to
indicate a fault code 5.
The control energizes the first stage of electric heat immediately, the
second stage 10 seconds after the call for second stage heat, and the
third stage 20 seconds after the call for third stage heat.
If the limit switch opens twice when no call for electric heat is present
(fault code 2), the control will enter a hard lockout condition.
Depending on the heat kit installed in the air handler, the control pro-
vides the flexibility to configure the amount of heat delivered with the
first stage heating call. As an example, when the control’s W1 input is
connected to the room thermostat’s first stage heat signal, a call for first
stage heat will energize one heating element (HT1). If the control’s W2
input is connected to the room thermostat’s first stage heat signal, a call
for first stage heat will energize two heating elements (HT1 and HT2).
With either configuration, the control will energize three heating ele-
ments (HT1, HT2, and HT3) when it receives a first and second stage
heat input from the thermostat.
If the limit switch opens multiple times soon after a soft lockout reset
(fault code 6), the control will enter a hard lockout condition.
Wiring Related Faults
If the control receives a simultaneous call for heating and cooling (fault
code 7), the control will perform both heating and cooling operations.
SECTION VII: LINE POWER
CONNECTIONS
Power may be brought into the unit through the supply air end of the
unit (top when unit is vertical) or the left side panel. Use the hole appro-
priate to the unit’s orientation in each installation to bring conduit from
the disconnect. The power lead conduit should be terminated at the
electrical control box. Refer to Tables 11, 12, 14 and 15 to determine
proper wire sizing. To minimize air leakage, seal the wiring entry point at
the outside of the unit.
Limit Switch and Lockout Operation
Limit Switch Operation
If the HEAT ENABLE jumper is in the HEAT position and the limit switch
opens (fault code 1), the control will immediately de-energize all electric
heat relay outputs and energize the blower (if it wasn’t already ener-
gized). When the limit switch closes, the control will re-energize electric
heat according to the thermostat inputs using normal timings.
All electrical connections to air handlers must be made with copper con-
ductors. Direct connection of aluminum wiring to air handlers is
not approved.
Fan On Lock Condition
If the limit switch opens multiple times during a single call for electric
heat (fault code 3) or if the limit switch opens for a long duration (fault
code 4), the control will energize the blower until power is removed from
the control. The control will cycle the heat outputs on and off as the limit
re-closes and opens. The constant fan operation will signal the home-
owner that a problem has occurred and a service call is required.
If aluminum conductors are present, all applicable local and national
codes must be followed when converting from aluminum to copper con-
ductors prior to connection to the air handler.
If wire other than uncoated (non-plated), 75° C ambient, copper wire is
used, consult applicable tables of the National Electic Code (ANSI/
NFPA 70). The chosen condutor and connections all must meet or
exceed the amperage rating of the overcurrent protector (circuit breaker
or fuse) in the circuit.
Soft Lockout
If the limit switch opens for a second long duration period during a sin-
gle call for heat (fault code 5), the control will keep the blower locked on
and lock out the heat outputs for one hour. The control will only reset
this one hour lockout when the power is removed from the control. After
the one hour period has passed, the control will re-energize electric
heat according to the thermostat inputs using normal timings. The
blower will remain locked on from the first long duration limit opening.
Additionally, existing aluminum wire within the structure must be sized
correctly for the application according to National Electric Code and
local codes. Caution must be used when sizing aluminum rather than
copper conductors, as aluminum conductors are rated for less current
than copper conductors of the same size.
ELECTRIC HEAT
WITHOUT CIRCUIT BREAKER
3 PHASE (10 - 15 KW)
1 PHASE ELECTRIC HEAT
WITH CIRCUIT BREAKER
AS SHIPPED FROM FACTORY
SINGLE SOURCE
TYPICAL WIRING WITHOUT ELECTRIC HEAT
GND.
LUG
GND. LUG
GND.
LUG
GND. LUG
(2.5 - 25 KW) - 25 KW SHOWN
POWER
SUPPLY
GND. LUG
GND.
LUG
POWER
SUPPLY
1 PHASE ELECTRIC HEAT
WITH CIRCUIT BREAKER
& BREAKER BAR REMOVED
TERMINAL
BLOCK
ELECTRIC HEAT
WITHOUT CIRCUIT BREAKER
SINGLE SOURCE (2.5 - 10 KW)
MULTI-SOURCE (15 - 25 KW) - 25 KW SHOWN
GND. LUG
POWER
SUPPLY
GND.
LUG
GND.
LUG
GND. LUG
(JUMPER BAR)
POWER
SUPPLY 1
MAY BE 1, 2, OR 3
CIRCUIT BREAKERS
POWER
SUPPLY 2
POWER
SUPPLY
POWER
SUPPLY 3
POWER WIRING (208/230-1-60)
TERMINAL
BLOCK
MAY BE 1, 2, OR 3
CIRCUIT BREAKERS
CONNECT TRANSFORMER LEADS WITH
WIRE NUTS (TYPICAL ALL HEAT KITS)
FIGURE 15: Line Power Connections
Johnson Controls Unitary Products
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Fan Only CFM:
SECTION VIII: AIRFLOW AND COMFORT
SETTING SELECTION
When the connection is made from "R" to "G", the fan only mode is acti-
vated. In this mode, the airflow will depend on the position of the CONT
Fan jumper. In the “H” position, the blower will deliver 85-90% of full
capacity. In the “M” position, the blower will deliver 60-65% of full
capacity. In the “L” position, the blower will deliver 30-35% of full capac-
ity.
AIRFLOW SELECTION
The airflow and comfort setting selection jumpers must be set properly
at the time of installation for proper system operation. Place jumpers in
the proper locations based on the information shown in Table 16 and
Figure 11.
Blower Ramp-Up /Ramp-Down:
Inputs to air handler control board are passed to the motor which deter-
mines the target CFM to be delivered. The following inputs will produce
the CFM per the appropriate table and selected tap settings.
To minimize the sound made by the blower when it speeds up or slows
down, the blower will slowly ramp up or down from one speed to
another. Changes in blower speed during A/C or heat pump heating
can take up to 30 seconds. Changes in blower speed during electric
strip heating can take up to 15 seconds.
NOTICE
Incorrect airflow and comfort settings may result in decreased system
efficiency and performance.
COMFORT SETTINGS
TABLE 6: Comfort Setting Selection
These variable speed air handlers are designed to deliver constant air-
flow (CFM) regardless of the external static pressure (ESP) in the duct-
work. Therefore, if too many supply registers are closed, a filter
becomes clogged, or there is a restriction in the ductwork, the motor will
automatically operate at a higher speed to compensate for the higher
ESP. This may result in a higher operating sound level.
DELAY TAP
COMFORT SETTING
Normal
A
B
C
D
Humid
Dry
Temperate
To Set Cooling Airflow:
Refer to the outdoor unit technical guide for the recommended airflow
with the matching evaporator coil. Refer to Table 16 for the possible
high speed cooling and heat pump airflow selections.
Normal
The normal setting provides a ramp-up from zero airflow to full capacity
and a ramp-down from full capacity back to zero airflow.
Find the recommended system airflow in Table 16 for the installed air
handler model.
Humid
The humid setting is best-suited for installations where the humidity is
frequently very high during cooling season, such as in the southern part
of the country. On a call for cooling, the blower will ramp up to 50% of
full capacity and will stay there for two minutes, then will ramp up to
82% of full capacity and will stay there for five minutes, and then will
ramp up to full capacity, where it will stay until the wall thermostat is sat-
isfied.
Select the COOL airflow you need from Table 16. Set the COOL and
ADJUST Jumpers on the control as indicated in Table 16.
To Set Heat Pump Airflow:
The heat pump airflow setting is the same as the cooling airflow setting.
No additional airflow setting is required. However, you must set the
MODE jumper to the HP position for proper system operation (See Fig-
ure 11).
Dry
To Set Electric W1 Heat Airflow:
The dry setting is best suited to parts of the country where excessive
humidity is not generally a problem, where the summer months are usu-
ally dry. On a call for cooling the motor will ramp up to full capacity and
will stay there until the thermostat is satisfied. At the end of the cooling
cycle, the blower will ramp down to 50% of full capacity where it will stay
for 60 seconds. Then it will ramp down to zero.
The blower speed required for 1st stage electric heat is different than
cooling. Refer to Table 16 for the possible CFM selections. Refer to
Table10 for the minimum required airflow for the electric heater
installed. Find the desired airflow in Table 16 for low heat. Set the HEAT
jumper on the control as indicated in Table 16.
Temperate
To Set W2 Electric Heat Airflow:
The temperate setting is best suited for most of the country, where nei-
ther excessive humidity nor extremely dry conditions are the norm. On
a call for cooling, the motor will ramp up to 63% of full capacity and will
stay there for 90 seconds, then will ramp up to full capacity. At the end
of the cooling cycle, the motor will ramp down to 63% of full capacity
and will stay there for 30 seconds, then will ramp down to zero.
Airflow for any W2 input, which is for Stages 2 & 3 of electric heat, is the
indicated CFM for high heat tap selection on Table 16.
DO NOT change the ADJUST tap position on the control as this will
change your cooling airflow previously selected.
SECTION IX: UNIT DATA
TABLE 7: Physical and Electrical Data - Cooling Only (60 Hz)
Models
24B
10 x 7
1/3
36C
10 x 7
1/2
48D
10 x 10
3/4
60D
10 x 10
1
Blower - Diameter x Width
HP
Motor
Nominal RPM
1200
1200
1200
1200
Voltage
Amps
230
Full Load (230)
Type
2.8
4.3
5.5
7.0
DISPOSABLE OR PERMANENT
Filter1
Size
16 x 20 x1
1PF0601BK
140/134
20 x 20 x1
1PF0602BK
170/164
22 x 20 x1
1PF0603BK
AV - 196/185
22 x 20 x1
1PF0603BK
AV - 199/188
Permanent Type Kit
Shipping/Operating Weight (lbs.)
1. Field Supplied.
12
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TABLE 8: Electrical Data - Cooling Only (60 Hz)
Total Motor Amps
Minimum Circuit Ampacity
60 Hertz
Max. O.C.P.
Amps/Type1
Minimum Wire
Size A.W.G.
Models
60 Hertz
208V
3.2
230V
2.8
208V
4.0
230V
3.5
24B
36C
48D
60D
15
15
15
15
14
14
14
14
4.7
4.3
5.9
5.4
6.1
5.0
7.6
6.9
7.8
7.0
9.7
8.8
1. OCP = Over Current Protection device, must be HACR type Circuit Breaker or Time Delay fuse.
TABLE 9: Conversion Table
kW & MBH Conversions - for Total Power Input Requirement
208V
FOR 230V
220V
240V
240V
240V
.751
.918
.840
OPERATION MULTIPLY
TABULATED kW & MBH BY
TABLE 10: Electrical Data - 208/230-1-60
Total Heat1
kW Staging
W2 Only
Heater
Models
Max.
Static
Min.
Speed Tap
kW
MBH
W1 Only
W1 & W2
Models*
208v 230v 208v 230v 208v 230v 208v 230v 208v 230v
4HK*6500206
4HK*6500506
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Heat-D
Heat-D
Heat-C
Heat-B
Heat A
Heat-A
Heat-C
Heat-C
Heat-C
Heat C
Heat-C
Heat-A
Heat-D
Heat-C
Heat-C
Heat C
Heat-C
Heat-B
Heat-B
Heat-B
Heat-D
Heat-D
Heat-C
Heat C
Heat-C
Heat-C
Heat-C
Heat-C
1.9
3.6
2.5
4.8
6.4
8.5
1.9
3.6
2.8
3.6
3.3
3.6
3.6
2.8
3.6
3.3
3.6
3.3
3.6
2.8
3.6
3.3
3.6
3.3
3.6
3.6
3.6
2.8
3.6
3.3
3.6
3.3
3.6
3.6
2.5
4.8
3.75
4.8
4.3
4.8
4.8
3.75
4.8
4.3
4.8
4.4
4.8
3.75
4.8
4.3
4.8
4.4
4.8
4.8
4.8
3.75
4.8
4.3
4.8
4.4
4.8
4.8
1.9
3.6
5.6
7.2
6.5
7.2
3.6
5.6
7.2
6.5
7.2
6.6
3.6
5.6
7.2
6.5
7.2
6.6
7.2
10.8
3.6
5.6
7.2
6.5
7.2
6.6
7.2
10.8
2.5
4.8
7.5
9.6
8.7
9.6
4.8
7.5
9.6
8.7
9.6
8.8
4.8
7.5
9.6
8.7
9.6
8.8
9.6
14.4
4.8
7.5
9.6
8.7
9.6
8.8
9.6
14.4
1.9
3.6
2.5
4.8
12.3
19.2
24.6
33.3
36.9
12.3
19.2
24.6
33.3
36.9
45.1
12.3
19.2
24.6
33.3
36.9
45.1
49.2
61.5
12.3
19.2
24.6
33.3
36.9
45.1
49.2
61.5
16.4
25.6
32.8
44.4
49.1
16.4
25.6
32.8
44.4
49.1
60.1
16.4
25.6
32.8
44.4
49.1
60.1
65.5
81.9
16.4
25.6
32.8
44.4
49.1
60.1
65.5
81.9
4HK*6500806
5.6
7.5
5.6
7.5
24B
4HK*6501006
7.2
9.6
7.2
9.6
4HK16501306
4HK165N1506
4HK*6500506
4HK*6500806
9.8
13
9.8
13
10.8
3.6
14.4
4.8
10.8
3.6
14.4
4.8
5.6
7.5
5.6
7.5
4HK*6501006
36C
7.2
9.6
7.2
9.6
4HK16501306
9.8
13
9.8
13
4HK16501506
4HK16501806
4HK*6500506
4HK*6500806
4HK*6501006
10.8
13.2
3.6
14.4
17.6
4.8
10.8
13.2
3.6
14.4
17.6
4.8
5.6
7.5
5.6
7.5
7.2
9.6
7.2
9.6
4HK16501306
9.8
13
9.8
13
48D
4HK16501506
10.8
13.2
14.4
18.0
3.6
14.4
17.6
19.2
24.0
4.8
10.8
13.2
14.4
18.0
3.6
14.4
17.6
19.2
24
4HK16501806
4HK16502006
4HK16502506
4HK*6500506
4HK*6500806
4HK*6501006
4.8
5.6
7.5
5.6
7.5
7.2
9.6
7.2
9.6
4HK16501306
9.8
13
9.8
13
60D
4HK16501506
10.8
13.2
14.4
18.0
14.4
17.6
19.2
24.0
10.8
13.2
14.4
18.0
14.4
17.6
19.2
24.0
4HK16501806
4HK16502006
4HK16502506
1. See conversion Table 9.
*
May be 0 (no breaker) or 1 (with breaker).
Johnson Controls Unitary Products
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TABLE 11: Electrical Data - (For Single Source Power Supply) - Copper Wire - 208/230-1-60
Field Wiring
Heater
Heater
Models*
Max. O.C.P. Amps/Type1
Models
Amps
240V
Min. Circuit Ampacity
75°C Wire Size - AWG
208V
15.28
25.67
37.85
47.33
62.6
230V
16.53
28.50
42.63
53.50
71.3
208V
20
230V
20
208V
12
10
8
230V
12
10
8
4HK*6500206
4HK*6500506
4HK*6500806
4HK*6501006
4HK16501306
4HK165N1506
4HK*6500506
4HK*6500806
4HK*6501006
4HK16501306
4HK16501506
4HK16501806
4HK*6500506
4HK*6500806
4HK*6501006
4HK16501306
4HK16501506
4HK16501806
4HK16502006
4HK16502506
4HK*6500506
4HK*6500806
4HK*6501006
4HK16501306
4HK16501506
4HK16501806
4HK16502006
4HK16502506
10.4
20.0
31.3
40.0
54.2
60.0
20.0
31.3
40.0
54.2
60.0
73.3
20.0
31.3
40.0
54.2
60.0
73.3
80.0
100.0
20.0
31.3
40.0
54.2
60.0
73.3
80.0
100.0
30
30
45
45
24B
50
60
8
6
70
80
4
2
69.00
27.54
39.73
49.21
64
78.50
30.38
44.50
55.38
72.8
70
90
4
3
30
35
10
8
10
8
45
45
50
60
8
6
36C
70
80
4
2
70.88
85.32
29.29
41.48
50.96
66.4
80.38
97.00
31.88
46.00
56.88
75.2
70
90
4
3
90
100
35
4
3
35
8
8
45
50
8
8
60
60
6
6
70
80
4
2
48D
72.63
87.07
94.29
115.96
31.42
43.60
53.08
68.4
81.88
98.50
106.88
131.88
33.75
47.88
58.75
77.2
90
90
3
3
90
100
125
150
35
3
2
100
125
35
3
1
1
1/0
8
8
45
50
8
8
60
60
6
6
70
80
4
2
60D
74.75
89.19
96.42
118.08
83.75
100.38
108.75
133.75
90
90
3
3
90
110
125
150
3
2
100
125
3
1
1
1/0
1. O.C.P. = Over Current Protection device, must be HACR type Circuit Breaker or Time Delay fuse.
May be 0 (no breaker) or 1 (with breaker).
*
TABLE 12: Electrical Data - (For Multi-Source Power Supply) - Copper Wire - 208/230-1-60
Max. O.C.P. Amps/Type1
Circuit
Min. Circuit Ampacity
75°C Wire Size - AWG
Heater
Models
Circuit
2nd
Circuit
Models
1st
3rd
1st
2nd
3rd
1st
2nd
3rd
208/230
208/230
208/230
208/230 208/230 208/230 208/230 208/230 208/230
4HK16501306
4HK165N1506
4HK16501306
4HK16501506
4HK16501806
4HK16501306
4HK16501506
4HK16501806
4HK16502006
4HK16502506
4HK16501306
4HK16501506
4HK16501806
4HK16502006
4HK16502506
43.1/48.6
47.5/53.5
41.7/47.9
48.5/55.4
44.9/51.2
42.9/49.1
51.0/56.9
47.4/52.7
51.0/56.9
51.0/56.9
43.9/50.1
53.1/58.8
49.5/54.6
53.1/58.8
53.1/58.8
19.5/22.5
21.7/25.0
22.4/25.0
21.7/25.0
39.8/45.8
23.6/26.2
21.7/25.0
39.8/45.8
43.4/50.0
43.4/50.0
24.6/27.2
21.7/25.0
39.8/45.8
43.4/50.0
43.4/50.0
–
45/50
50/60
50/50
50/60
45/60
50/50
60/60
50/60
60//60
60/60
50/60
60/60
50/60
60/60
60/60
20/25
25/25
30/30
25/25
40/50
30/30
25/25
40/60
45/50
45/50
30/30
25/25
40/60
45/50
45/50
–
6/6
8/6
6/6
8/6
8/8
6/6
6/6
6/6
6/6
6/6
6/6
6/6
6/6
6/6
6/6
12/10
10/10
12/10
10/10
8/8
–
24B
36C
–
–
–
–
–
–
–
–
–
–
–
–
–
–
12/10
10/10
8/6
–
–
–
–
48D
60D
–
–
–
–
–
8/8
–
21.7/25.0
25/25
8/8
10/10
–
–
10/10
10/10
8/6
–
–
–
–
–
–
–
–
–
8/8
–
21.7/25.0
25/25
8/8
10/10
1. O.C.P. = Over Current Protection device, must be HACR type Circuit Breaker or Time Delay fuse.
14
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536636-UIM-D-1211
TABLE 13: Electrical Data - 208/230-3-60
Total Heat1
MBH
kW Staging
W2 Only
208V 230V 208V 230V 208V 230V 208V 230V 208V 230V
Min.
Speed
Tap
Heat Kit -
Models
Max.
Static
kW
W1 Only
W1 + W2
Three Phase
24B
36C
4HK06501025
4HK06501025
4HK06501525
4HK06501025
4HK06501525
4HK06501825
4HK06501025
4HK06501525
4HK06501825
4HK16502525
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Heat-B
Heat-C
7.2
7.2
9.6
9.6
24.6
24.6
36.9
24.6
36.9
44.7
24.6
36.9
44.7
61.4
32.8
32.8
49.1
32.8
49.1
58.7
32.8
49.1
58.7
81.4
7.2
7.2
9.6
9.6
7.2
7.2
9.6
9.6
7.2
7.2
9.6
9.6
Heat-C 10.8
Heat-C 7.2
14.4
9.6
10.8
7.2
14.4
9.6
10.8
7.2
14.4
9.6
10.8
7.2
14.4
9.6
48D
Heat-C 10.8
Heat-B 12.9
14.4
17.2
9.6
10.8
12.9
7.2
14.4
17.2
9.6
10.8
12.9
7.2
14.4
17.2
9.6
10.8
12.9
7.2
14.4
17.2
9.6
Heat-C
7.2
Heat-C 10.8
Heat-B 12.9
Heat-C 18.0
14.4
17.2
24.0
10.8
12.9
9.0
14.4
17.2
12.0
10.8
12.9
18.0
14.4
17.2
24.0
10.8
12.9
18.0
14.4
17.2
24.0
60D
1. See conversion Table 9.
TABLE 14: Electrical Data - (For Single Source Power Supply) - Copper Wire - 208/230-3-60
Field Wiring
Max. O.C.P.1 Amps/Type
Heater
Amps
240V
Heat Kit -
Three Phase
Models
Min. Circuit Ampacity
75°C Wire Size - AWG
208V
28.5
30.4
42.9
31.3
43.8
51.0
33.8
48.8
46.3
230V
32.4
34.3
48.8
35.1
49.6
58.0
37.6
56.9
52.1
208V
30
230V
35
208V
10
10
8
230V
24B
36C
4HK06501025
4HK06501025
4HK06501525
4HK06501025
4HK06501525
4HK06501825
4HK06501025
4HK06501825
4HK06501525
23.1
23.1
34.7
23.1
34.7
41.4
23.1
41.4
34.7
8
8
8
8
8
6
8
6
6
30
35
45
50
35
35
8
48D
60D
45
50
8
60
60
6
35
40
8
50
60
8
50
60
8
1. O.C.P. = Over Current Protection device, must be HACR type Circuit Breaker or Time Delay fuse.
TABLE 15: Electrical Data - (For Multi-Source Power Supply) - Copper Wire - 208/230-3-60
Max. O.C.P.1 Amps/Type
Circuit
Minimum Circuit Ampacity
75°C Wire Size - AWG
Heater
Model
Models
1st
2nd
3rd
1st
2nd
208/230
25/30
3rd
1st
2nd
208/230
10/10
8/8
3rd
208/230
32.5/36.0
41.0/44.9
208/230
22.4/25.9
31.3/36.1
208/230
208/230
35/40
208/230
208/230
8/8
208/230
4HK06501825
4HK16502525
–
–
–
–
–
–
60D
45/45
35/40
8/8
1. O.C.P. = Over Current Protection device, must be HACR type Circuit Breaker or Time Delay fuse.
Johnson Controls Unitary Products
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536636-UIM-D-1211
TABLE 16: Air Handler Air Flow Data
HIGH/LOW SPEED COOLING AND HEAT PUMP AIRFLOW
m3/min
CFM
24B
JUMPER SETTINGS
36C
24B
36C
High
1088
830
948
716
854
612
637
531
542
462
474
461
Low
707
542
617
465
556
462
460
460
462
462
460
464
High
1387
1151
1201
1009
1086
953
Low
905
753
783
657
703
622
588
493
540
460
494
461
High
30.8
23.5
26.8
20.3
24.2
17.3
18.0
15.0
15.3
13.1
13.4
13.1
Low
20.0
15.3
17.5
13.2
15.7
13.1
13.0
13.0
13.1
13.1
13.0
13.1
High
39.3
32.6
34.0
28.6
30.7
27.0
25.5
21.3
23.5
18.6
21.3
16.6
Low
25.6
21.3
22.2
18.6
19.9
17.6
16.6
14.0
15.3
13.0
14.0
13.1
COOL Tap
ADJ Tap
A
B
A
B
A
C
B
D
C
D
C
D
B
B
A
A
C
B
C
B
A
A
C
C
901
754
831
657
751
588
48D
60D
48D
60D
JUMPER SETTINGS
High
2138
1759
2009
1612
1773
1530
1459
1359
1388
1221
1244
1118
Low
1442
1162
1311
1052
1166
989
High
2364
1962
2123
1763
1905
1777
1580
1596
1583
1413
1412
1277
Low
1545
1271
1374
1146
1237
1158
1021
1030
1019
929
High
60.5
49.8
56.9
45.6
50.2
43.3
41.3
38.5
39.3
34.6
35.2
31.6
Low
40.8
32.9
37.1
29.8
33.0
28.0
26.8
25.1
25.6
22.8
22.9
20.2
High
66.9
55.5
60.1
49.9
53.9
50.3
44.7
45.2
44.8
40.0
40.0
36.2
Low
43.7
36.0
38.9
32.4
35.0
32.8
28.9
29.2
28.8
26.3
26.2
23.8
COOL Tap
ADJ Tap
A
B
A
B
A
C
B
D
C
D
C
D
B
B
A
A
C
B
C
B
A
A
C
C
947
886
904
806
808
926
715
841
HIGH/LOW SPEED ELECTRIC HEAT AIRFLOW
m3/min
CFM
JUMPER SETTINGS
24B
48D
36C
24B
36C
High
1088
954
Low
828
714
614
523
High
1387
1228
1151
923
Low
908
804
756
609
High
30.8
27.0
23.5
19.2
Low
23.4
20.2
17.4
14.8
High
39.3
34.8
32.6
26.1
Low
25.7
22.8
21.4
17.2
HEAT Tap
ADJ Tap
Any
A
B
C
D
Any
829
Any
678
60D
48D
60D
JUMPER SETTINGS
High
2111
1858
1480
1250
Low
1417
1252
985
High
2363
2174
1868
1387
Low
1488
1252
1061
823
High
59.8
52.6
41.9
35.4
Low
40.1
35.4
27.9
23.8
High
66.9
61.5
52.9
39.3
Low
42.1
35.4
30.0
23.3
HEAT Tap
ADJ Tap
Any
A
B
C
D
Any
Any
840
Any
1. Airflow at nominal voltage, bottom return at 0.5 external static pressure, tested without filter installed, dry coil conditions.
2. These units have variable speed motors that automatically adjust to provide constant CFM from 0.0” to 0.6” w.c. static pressure
3. From 0.6” to 1.0” static pressure, CFM is reduced by 2% per 0.1” increase in static.
4. Operation on duct systems with greater than 1.0” w.c. external static pressure is not recommended.
5. Both the COOL and the ADJUST tap must be set to obtain the cooling airflow desired (CFM).
6. The ADJ tap does not affect the HEAT tap setting.
7. Low speed cooling used only with two stage outdoor units. (Speed is preset to 65% of high speed).
8. Dehumidification speed is 85% of jumper selected COOL tap and ADJUST tap.
9. When operating in both heat pump and electric heat modes, the airflow (CFM) will be per HEAT Tap CFM values only.
10. At some settings, LOW COOL and/or LOW HEAT airflow may be lower than what is required to operate an airflow switch on certain models of electronic air
cleaners. Consult the instructions for the electronic air cleaner for further details.
11. Airflow (CFM) indicator light (LED2) flashes once for every 100 CFM (i.e.: 12 Flashes is 1200 CFM) – blinks are approximate +/- 10% of actual CFM.
16
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LUBRICATION
The bearings of the blower motor are permanently lubricated.
SECTION X: MAINTENANCE
Filters must be cleaned or replaced when they become dirty. Inspect at
least once per month. The frequency of cleaning depends upon the
hours of operation and the local atmospheric conditions. Clean filters
keep unit efficiency high.
CONDENSATE DRAINS
During the cooling season check the condensate drain lines to be sure
that condensate is flowing from the primary drain but not from the sec-
ondary drain. If condensate ever flows from the secondary drain the unit
should be promptly shut off and the condensate pan and drains cleaned
to insure a free flowing primary drain.
COIL CLEANING
If the coil needs to be cleaned or replaced, it should be washed with
Calgon CalClean (mix one part CalClean to seven parts water). Allow
solution to remain on coil for 30 minutes before rinsing with clean water.
Solution should not be permitted to come in contact with painted sur-
faces.
Johnson Controls Unitary Products
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SECTION XI: WIRING DIAGRAM
FIGURE 16: Wiring Diagram
Subject to change without notice. Published in U.S.A.
536636-UIM-D-1211
Copyright © 2011 by Johnson Controls, Inc. All rights reserved.
Supersedes: 536636-UIM-C-1010
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
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