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INSTALLATION MANUAL
SINGLE PIECE
VARIABLE SPEED AIR HANDLERS
MODELS: AV AND SV SERIES
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRIC HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 6
LOW VOLTAGE CONTROL CONNECTIONS . . . . . . . . . . . . . . . . . . 7
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Filter Access & Drain Pan Conversion / Coil Baffle . . . . . . . . . . . . . . . 3
Dimensions & Duct Connection Dimensions . . . . . . . . . . . . . . . . . . . . 4
Condensate Deflector on Vertical Drain Pan . . . . . . . . . . . . . . . . . . . . 4
Condensate Deflecctor on Horizontal Drain Pan Edge . . . . . . . . . . . . 4
S-Clip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heat Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cooling and Heat Pump Airflow Selection . . . . . . . . . . . . . . . . . . . . . . . . 10
Electric Heat Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Comfort Setting Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Physical and Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . . . . 11
Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Data - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION I: GENERAL
The AV single piece air handler provides the flexibility for installation in
any upflow, downflow, or horizontal application. The SV 48 and 60 mod-
els may be installed in upflow application only.
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.
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
ISO 9001
Certified Quality
Management System
LIST OF SECTIONS
REQUIRED CONTROL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
LINE POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
AIRFLOW AND COMFORT SETTING SELECTION . . . . . . . . . . . . . .9
UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
LIST OF FIGURES
Typical Horizontal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TXV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Proper Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Line Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Cooling Models with and without Electric Heat Wiring . . . . . . . . . . . .15
Two-Stage Heat Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
LIST OF TABLES
Copper Wire - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Copper Wire - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Data - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cooling Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Heating Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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.
FIRE OR ELECTRICAL HAZARD
Failure to follow the safety warnings exactly could result in serious
injury, death or property damage.
A fire or electrical hazard may result causing property damage, per-
sonal injury or loss of life.
282849-UIM-C-0808
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Summary of Contents for Johnson Controls AV Series
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Page 1: Table Of Contents
INSTALLATION MANUAL SINGLE PIECE VARIABLE SPEED AIR HANDLERS MODELS: AV AND SV SERIES ISO 9001 Certified Quality Management System LIST OF SECTIONS GENERAL ..........1 REQUIRED CONTROL SET-UP . -
Page 2: Safety
1VJ0121 for C cabinets or 1VJ0124 on 57” height or 1VJ0224 on 52” height D cabinets or seal completely with adequate fiberglass insu- lation using vapor barrier on the outside. Johnson Controls Unitary Products... - Page 3 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. Johnson Controls Unitary Products...
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Page 4: Condensate Deflector On Vertical Drain Pan
See Figure 6. FEEDER TUBES S-CLIPS (3) CONDENSATE DEFLECTOR VERTICAL DRAIN PAN CONDENSATE DEFLECTOR S-CLIPS ON HORIZONTAL PAN FIGURE 4: Condensate Deflector on Vertical Drain Pan FIGURE 5: Condensate Deflecctor on Horizontal Drain Pan Edge Johnson Controls Unitary Products... - Page 5 Figure 7. 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. Johnson Controls Unitary Products...
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Page 6: Electric Heater Installation
If so, do not re-install circuit breaker cover cladding. Braze the suction and liquid lines. Remove the heat shield. Re-attach the grommets to the lines carefully to prevent air leak- age. Attach the coil access panel to the cabinet. Johnson Controls Unitary Products... -
Page 7: Low Voltage Control Connections
The humidity switch should be connected to the R and HUM terminals of the control. See Figure 10. Johnson Controls Unitary Products... -
Page 8: Fault Codes
(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. Johnson Controls Unitary Products... -
Page 9: Electric Heat Airflow
Fan only airflow (CFM) = 63% of high speed cooling. static. Operation on duct systems with greater than 1.0” w.c. external static pressure is not recommended. Low speed cooling used only with two stage outdoor units. (Speed is preset to 65% of high speed). Johnson Controls Unitary Products... -
Page 10: Comfort Setting Selection
30 seconds, then will ramp down to zero. In every DO NOT change the ADJUST tap position on the control as this will case, it will take the motor 30 seconds to ramp from one speed to change your cooling airflow previously selected. another. Johnson Controls Unitary Products... -
Page 11: Electrical Data - Cooling Only (60 Hz)
1. OCP = Over Current Protection device, must be HACR type Circuit Breaker or Time Delay fuse. TABLE 10: Conversion Table kW & MBH Conversions - for Total Power Input Requirement 208V 240V .751 230V OPERATION MULTIPLY 240V TABULATED kW & MBH BY .918 220V 240V .840 Johnson Controls Unitary Products... -
Page 12: Electrical Data - 208/230-1-60
89.19 100.38 4HK16502006 80.0 96.42 108.75 4HK16502506 100.0 118.08 133.75 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). Johnson Controls Unitary Products... -
Page 13: Electrical Data - (For Multi-Source Power Supply) - Copper Wire - 208/230-1-60
- / - 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 14 NOTE: 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 clean- ers. Consult the instructions for the electronic air cleaner for further details. * The ADJ “D” tap should not be used. Johnson Controls Unitary Products...
- Page 15 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...
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Page 16: Maintenance
Subject to change without notice. Printed in U.S.A. 282849-UIM-C-0808 Copyright © 2008 by Johnson Controls, Inc. All rights reserved. Supersedes: 282849-UIM-B-0507 Johnson Controls Unitary Products 5005 York Drive...
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