INSTALLATION MANUAL

SECTION I: GENERAL

The AHR/AHE single piece air handler provides the flexibility for installation in any upflow 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. The unit can be positioned for bottom return air in the upflow position, and right or left return in the horizontal position. Top and side power wiring and control wiring, accessible screw terminals for control wiring, easy to install drain connections and electric heaters all combine to make the installation easy, and minimize installation 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.

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 damage.

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 assistance or for additional information, consult a qualified contractor, installer or service agency.

This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes including, but not limited to building, electrical, and mechanical codes.

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, personal injury or loss of life.

SECTION III: UNIT INSTALLATION

CLEARANCES

1. Refrigerant piping and connections - minimum 12" recommended.
2. Maintenance and servicing access - minimum 36" from front of unit recommended for blower motor / coil replacement.
3. Condensate drain lines routed to clear filter and panel access.
4. Filter removal - minimum 36" recommended.
5. The ductwork and plenum connected to this unit are designed for zero clearance to combustible materials.
6. A combustible floor base accessory is available for downflow applications of this unit, if required by local code.

LOCATION

Location is usually predetermined. Check with owner's or dealer's installation plans. If location has not been decided, consider the following in choosing a suitable location:

1. Select a location with adequate structural support, space for service access, clearance for air return and supply duct connections.
2. Use hanging brackets to wall mount this single piece air handler unit, is not recommended.
3. Normal operating sound levels may be objectionable if the air handler is placed directly over some rooms such as bedrooms, study, etc.
4. Select a location that will permit installation of condensate line to an open drain or outdoors allowing condensate to drain away from structure.

NOTICE: The primary and secondary drain line must be trapped to allow proper drainage of condensate water. If the secondary drain line is not used, it must be capped. The coil is provided with a secondary drain. It should be 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 evaporator coil is installed in an attic or above a finished ceiling, an auxiliary drain pan should be provided under the air handler as is specified by most local building codes.

Proper electrical supply must be available.

If unit is located in an area of high humidity (i.e. an unconditioned garage or attic), nuisance sweating of casing may occur. On these installations, unit duct connections and other openings should be properly sealed, and a wrap of 2" fiberglass insulation with vinyl vapor barrier should be used.

HORIZONTAL CONVERSION

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.

NOTICE: For both horizontal applications, the condensate deflector should be positioned as shown in Figure 5.

1. Remove blower, coil, and filter access panels.

NOTICE: Conversion must be made before brazing the refrigerant connections to the coil.

For horizontal left installations, follow steps 2 - 8.

1. Remove tubing connection panel.
2. Slide coil assembly out of air handler.
3. Rotate cabinet 180° so blower outlet is facing down.
4. Re-install coil assembly on coil support bracket.
5. Re-attach tubing connection panel.
6. For horizontal applications, rotate air handler 90° into desired orientation.
7. Re-position drain plugs as necessary based on air handler orientation.
8. Re-position and replace access panels.

SUCTION FEEDER TUBE/CONDENSATE DEFLECTOR UPFLOW

No action required. See Figure 6.

DUCT FLANGES

Four flanges are provided to attach ductwork to the furnace. These flanges are rotated down for shipment. In order to use the flanges, remove the screw holding an individual flange, rotate the flange so it is in the upward position and reinstall the screw then repeat this for all 4 flanges. If the flanges are not used, they must remain in the rotated down position as shipped.

DUCT CONNECTIONS

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 5 for dimensions for duct inlet and outlet connections. 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 installation 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. 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 ductwork is a must where it runs through an unheated space during the heating season or through an uncooled space during the cooling season. The use of a vapor barrier is recommended to prevent absorption of moisture from the surrounding air into the insulation.

The supply air duct should be properly sized by use of a transition to match unit opening. All ducts should be suspended using flexible hangers 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 5.

Ductwork 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 Ventilating Systems, NFPA No. 90B.

DUCTWORK TRANSITION

Ductwork 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 suggested transition can not be fabricated, it is recommended a block off plate (approximately 8" in height and running the full width of the plenum) be attached to the supply opening Please refer to Figure 9 as a visual aid. The use of this block off plate will keep better air circulation across the limit switch.

HORIZONTAL SUSPENSION

For suspension of these units in horizontal applications, it is recommended to use angle steel support brackets with threaded rods, supporting the units from the bottom, at the locations shown in Figure 10. When an evaporator coil is installed in an attic or above a finished ceiling, an auxiliary drain pan should be provided under the air handler as is specified by most local building codes.

TXV METERING DEVICES

If the model number is of the following model series: 3X, the coil will require a R22 or R410A Orifice or TXV to be installed in the field. Refer to installation manual with TXV kit. It is recommended to install the TXV kit prior to brazing line sets.

AIR FILTERS

Air filters must be field supplied. A 1" filter access rack has been built into the unit. See Figure 5. 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 numbers: 1PF0601, 602 or 603BK. See Table 2 for filter size.

CAUTION: Equipment should never be operated without filters.

SECTION IV: ELECTRIC HEATER INSTALLATION

If the air handler requires electric heat, install the electric heat kit according to the installation instructions included with the kit. After installing the kit, mark the air handler nameplate to designate the heater kit that was installed. If no heater is installed, mark the name plate appropriately to indicate that no heat kit is installed.

Use only 6HK heater kits, as listed on Air Handler name plate and in these instructions. Use data from Tables 5 through 9 for information on required minimum motor speed tap to be used for heating operation, maximum over-current protection device required and minimum electrical supply wiring size required - for listed combination of Air Handler and Heater Kit.

SECTION V: 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 appropriate 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. Also see Figure 3. To minimize air leakage, seal the wiring entry point at the outside of the unit.

All electrical connections to air handlers must be made with copper conductors. Direct connection of aluminum wiring to air handlers is not approved.

If aluminum conductors are present, all applicable local and national codes must be followed when converting from aluminum to copper conductors 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 Electric Code (ANSI/ NFPA 70). The chosen conductor and connections all must meet or exceed the amperage rating of the overcurrent protector (circuit breaker or fuse) in the circuit. 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.

SECTION VI: LOW VOLTAGE CONTROL CONNECTIONS

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 connected to a 208 volt power supply, the low voltage transformer must be rewired to the 208 volt tap. See the unit wiring label.

Field supplied low voltage wiring can exit the unit on the top right hand corner or the right hand side panel. Refer to Figure 5.

Remove desired knockout and pierce foil faced insulation to allow wiring to pass through. Use as small of a hole as possible to minimize air leakage. Install a 7/8" plastic bushing in the selected hole and keep low voltage wiring as short as possible inside the control box.

To further minimize air leakage, seal the wiring entry point at the outside of the unit.

The field wiring is to be connected at the pigtails supplied with the control board harness. Refer to SECTIONS X and XI for system wiring.

SECTION VII: BLOWER SPEED CONNECTIONS

Adjust blower motor speed to provide airflow within the minimum and maximum limits approved for evaporator coil, electric heat and outdoor unit. Speed tap adjustments are made at the motor terminal block. Airflow data is shown in Table 15.

Connect motor wires to motor speed tap receptacle for speed desired. See unit wiring label for motor wiring details.

SECTION VIII: UNIT DATA

Physical and Electrical Data

AHE MODELS

Electrical Data - Cooling Only (60 Hz)

Electrical Data - 208/230-1-60

Electrical Data - (For Single Source Power Supply) - Copper Wire - 208/230-1-60 (AHR)

Electrical Data - (For Single Source Power Supply) - Copper Wire - 208/230-1-60 (AHE)

Electrical Data - 208/230-3-60

Electrical Data - (For Single Source Power Supply) - Copper Wire - 208/230-3-60 (AHR)

Electrical Data - (For Single Source Power Supply) - Copper Wire - 208/230-3-60 (AHE)

Air Flow Data - 60 Hz Models - 208/230 Volt (AHR)

Air Flow Data - 60 Hz Models - 208 Volt (AHE)

SECTION IX: 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.

COIL CLEANING

If the coil needs to be cleaned, it should be wash with a evaporator coil cleaner. Follow directions from coil cleaner.

LUBRICATION

The bearings of the blower motor are permanently lubricated.

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 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.

SECTION X: WIRING DIAGRAM

Figure 15: Wiring Diagram - PSC - Single Phase Heat Kits

Figure 16: Wiring Diagram - ECM - Single Phase Heat Kits

Figure 17: Wiring Diagram - ECM - 3 Phase Heat Kits

SECTION XI: TYPICAL THERMOSTAT CONNECTIONS

Figure 18: Typical Wiring Diagram - PSC

Figure 19: Typical Wiring Diagram - ECM

Figure 20: Typical Thermostat Wiring for 2-Stage Heat Pump with ECM Blower Motor - AHE