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INSTALLATION MANUAL
SINGLE PIECE
VARIABLE SPEED AIR HANDLERS
MODELS: AV*(C) SERIES
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ELECTRIC HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .7
LOW VOLTAGE CONTROL CONNECTIONS . . . . . . . . . . . . . . . . . .7
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Return Duct Attachment & Component Location . . . . . . . . . . . . . . . . .3
Condensate Deflector on Vertical Drain Pan . . . . . . . . . . . . . . . . . . . .5
Condensate Deflecctor on Horizontal Drain Pan Edge . . . . . . . . . . . .5
S-Clip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Typical Horizontal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Heat Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Comfort Setting Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Physical and Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . . . . 14
Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Data - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION I: GENERAL
The AV single piece air handler provides the flexibility for installation in
any upflow, downflow, or horizontal application.
These versatile models may be used for cooling or heat pump operation
with or without electric heat.
A BRAND LABEL (available from Distribution) may be applied to the
center of the blower access panel on AVG models.
The unit can be positioned for bottom return air in the upflow position,
top return air in the downflow position, and right or left return in the hor-
izontal position.
Top and side power wiring and control wiring, accessible screw termi-
nals for control wiring, easy to install drain connections and electric
heaters all combine to make the installation easy, and minimize installa-
tion cost.
SECTION II: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
LIST OF SECTIONS
REQUIRED CONTROL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LINE POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
AIRFLOW AND COMFORT SETTING SELECTION . . . . . . . . . . . . 13
UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LIST OF FIGURES
TXV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Proper Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Handler Control Board - Communications Connections . . . . . . . . 8
Cooling Models with and without Electric Heat Wiring . . . . . . . . . . . . 9
Two-Stage Heat Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Handler with Communicating AC or HP . . . . . . . . . . . . . . . . . . . 10
Line Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LIST OF TABLES
Copper Wire - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Copper Wire - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Data - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air Handler Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or mainte-
nance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified con-
tractor, installer or service agency.
This product must be installed in strict compliance with the installa-
tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
ISO 9001
Certified Quality
Management System
536636-UIM-A-1209
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Summary of Contents for Johnson Controls AV Series
-
Page 1: Table Of Contents
INSTALLATION MANUAL SINGLE PIECE VARIABLE SPEED AIR HANDLERS MODELS: AV*(C) SERIES ISO 9001 Certified Quality Management System LIST OF SECTIONS GENERAL ..........1 REQUIRED CONTROL SET-UP . -
Page 2: Safety
There are no shipping or spacer brackets properly sealed and a wrap of 2” fiberglass insulation with vinyl which need to be removed. vapor barrier should be used. Johnson Controls Unitary Products... -
Page 3: Typical Installation
WHEN ATTACHING DUCT WORK WITH SECONDARY DRAIN SIDES AND REAR OF UNIT SCREWS - KEEP SCREWS WITHIN 5/8” UPFLOW 3/4” THREADED OF SIDES AND BACK OF AIR HANDLER FIGURE 2: Return Duct Attachment & Component Location Johnson Controls Unitary Products... -
Page 4: Dimensions & Duct Connection Dimensions
3/4” 7/8” (1/2”) 17-1/8 17-13/32 18-3/32 7/8” (w/o cladding) 1 3/8” (1”) 7/8” (1/2”) 3/8” 24.5 22-1/8 20-29/32 21-19/32 7/8” 1 23/32” (1 1/4”) (with cladding) 24.5 22-1/8 20-29/32 21-19/32 7/8’ 1. Actual size (Conduit size). Johnson Controls Unitary Products... -
Page 5: Condensate Deflector On Vertical Drain Pan
1PF0601, 602, 603BK. See Table 8 for filter size. CONDENSATE DEFLECTOR S-CLIPS ON HORIZONTAL PAN FIGURE 5: Condensate Deflecctor on Horizontal Drain Pan Edge Equipment should never be operated without filters. DEFLECTOR DRAIN PAN WALL S-CLIP FIGURE 6: S-Clip Installation Johnson Controls Unitary Products... -
Page 6: Typical Horizontal Installation
Wrap a water soaked rag around the coil connection tubes inside the cabinet to avoid damaging the TXV bulb. Remove grommets where tubes exit the cabinet to prevent burning them during brazing. Johnson Controls Unitary Products... -
Page 7: Electric Heater Installation
After communication with the outdoor unit. See Figure 14. installing the kit, mark the air handler nameplate to designate the heater Johnson Controls Unitary Products... -
Page 8: Low Voltage Connections
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. Johnson Controls Unitary Products... -
Page 9: Cooling Models With And Without Electric Heat Wiring
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 Johnson Controls Unitary Products... -
Page 10: Low Voltage Connections
Field supplied low voltage wiring can exit the unit on the top right hand position depending on the outdoor unit included with the system. corner or the right hand side panel. Refer to Figure 3. Set airflow and comfort setting jumper to proper positions. Johnson Controls Unitary Products... -
Page 11: Fault Codes
With either configuration, the control will energize three heating ele- Control failure ments (HT1, HT2, and HT3) when it receives a first and second stage Limit Faults heat input from the thermostat. Limit switch currently open (not in lockout) Johnson Controls Unitary Products... -
Page 12: Line Power Connections
POWER WIRING (208/230-1-60) POWER TERMINAL SUPPLY 3 BLOCK NOTE: USE ONLY COPPER CONDUCTORS MAY BE 1, 2, OR 3 CONNECT TRANSFORMER LEADS WITH WIRE NUTS CIRCUIT BREAKERS (TYPICAL ALL HEAT KITS) FIGURE 14: Line Power Connections Johnson Controls Unitary Products... -
Page 13: Comfort Setting Selection
DO NOT change the ADJUST tap position on the control as this will of the cooling cycle, the motor will ramp down to 63% of full capacity change your cooling airflow previously selected. and will stay there for 30 seconds, then will ramp down to zero. Johnson Controls Unitary Products... -
Page 14: Physical And Electrical Data - Cooling Only (60 Hz)
17.6 45.1 60.1 13.2 17.6 4HK16502006 Heat-C 14.4 19.2 49.2 65.5 14.4 19.2 4HK16502506 Heat-C 18.0 24.0 61.5 81.9 10.8 14.4 18.0 1. See conversion Table 10. May be 0 (no breaker) or 1 (with breaker). Johnson Controls Unitary Products... -
Page 15: Electrical Data - (For Single Source Power Supply) - Copper Wire - 208/230-1-60
21.7 / 25.0 60 / 60 45 / 50 25 / 25 6 / 6 8 / 8 10 / 10 1. O.C.P. = Over Current Protection device, must be HACR type Circuit Breaker or Time Delay fuse. Johnson Controls Unitary Products... -
Page 16: Electrical Data - 208/230-3-60
- / - 45 / 45 35 / 40 - / - 8 / 8 8 / 8 - / - 1. O.C.P. = Over Current Protection device, must be HACR type Circuit Breaker or Time Delay fuse. Johnson Controls Unitary Products... -
Page 17: Air Handler Air Flow Data
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. Johnson Controls Unitary Products... -
Page 18: Maintenance
During the cooling season check the condensate drain lines to be sure that condensate is flowing from the primary drain but not from the secondary 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. Johnson Controls Unitary Products... - Page 19 536636-UIM-A-1209 NOTES Johnson Controls Unitary Products...
- Page 20 Subject to change without notice. Published in U.S.A. 536636-UIM-A-1209 Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: 282849-UIM-E-0309 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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