Installer's Guide - Air Handler-Convertible Models Series ...

1 18-GJ07D1-2 Convertible Air Handlers2 5 Ton*AM8A0A24V21CA*AM8A0B30V21CA*AM8A0C36 V31CA*AM8A0C42V31CA*AM8A0C48V41CA*AM8A0C 60V51CA* May be A or T The *AM8 air handlers will only use the following internal electric heaters:BAYEVAC05BK1AA, BAYEVAC05LG1 AABAYEVAC08BK1AA, BAYEVAC08LG1 AABAYEVAC10BK1AA, BAYEVAC10LG1 AABAYEVBC15BK1AA, BAYEVBC20BK1 AABAYEVCC25BK1AA, BAYEVAC10LG3 AABAYEVBC15LG3 AAInstaller s GuideALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODESI mportant: This Document is customer property and is to remain with this unit. Please return to service information pack upon completion of : These instructions do not cover all variations in systems nor provide for every possible contingency to be met in connection with the installation. Should further infor-mation be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes, the matter should be referred to your installing dealer or local : The manufacturer recommends installing ONLY approved, matched indoor and outdoor systems.

2 Some of the benefits of installing approved matched indoor and outdoor split systems are maximum efficiency, optimum performance, and the best overall system : Condensation may occur on the surface of the air handler when installed in an unconditioned space. When units are installed in unconditioned spaces, verify that all electrical and refrigerant line penetrations on the air handler are sealed : Duct heaters cannot be applied with this air : This unit as shipped is ONLY compatible with Trane and American Standard communicating thermostats and outdoor units. (24 VAC thermostats cannot be used)With the addition of a BAYCC24VK01 accessory, this unit can be compatible with a 24 VAC single or multistage heat pump or air 1. Safety Information WARNING!SAFETY HAZARD! This information is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience.

3 Any attempt to repair a central air condition-ing product may result in personal injury and/or property damage. The manufacturer or seller cannot be responsible for the interpreta-tion of this information, nor can it assume any liability in connection with its ELECTRICAL COMPONENTS! During instal-lation, testing, servicing, and troubleshooting of this product, it may be necessary to work with live electrical components. Failure to fol-low all electrical safety precautions when exposed to live electrical components could result in death or serious injury. CAUTION! WARNING!CORROSION HAZARD! To prevent shortening its service life, the air handler should not be used during the finishing phases of construction. The low return air temperatures can lead to the formation of condensate. Condensate in the presence of chlorides and fluorides from paint, varnish, stains, adhesives, cleaning com-pounds, and cement creates a corrosive condition which may cause rapid deterioration of the cabinet and internal : Due to the unique design of this unit, which allows the electrical wiring to be routed within the insula-tion, do not screw, cut, or otherwise puncture the unit cabinet in any location other than the ones illustrated in this Installer Guide or in an approved accessory s In-staller : Under no conditions should metal strapping be attached to the unit to be used as support mecha-nisms for carrying or suspension of ContentsSection 1.

4 Safety Information..2 Section 2. Unit Design..3 Section 3. Unit Preparation..5 Section 4. Optional Cabinet Disassembly..6 Section 5. Place Unit at Location..10 Section 6. Unit Location Considerations..11 Section 7. Setting the Unit - Vertical Installation..16 Section 8. Setting the Unit - Horizontal Installations..18 Section 9. Connecting the Duct work..19 Section 10. Refrigerant Line..20 Section 11. Refrigerant Line Brazing..21 Section 12. Condensate Drain Piping..24 Section 13. Electrical - Low Voltage..26 Section 14. Electrical - High Voltage..31 Section 15. Filters..32 Section 16. Display Assembly (DA)..33 Section 17. Unit Outline Drawing..40 Section 18. Start Up..41 Section 19. Sequence of Operation..42 Section 20 Checkout : Representative illustrations only included in this document. Most illustrations display the upflow HAZARD!

5 Sharp Edge Hazard. Be careful of sharp edges on equipment or any cuts made on sheet metal while install-ing or servicing. Personal injury may result. CAUTION! CAUTION!HAZARDOUS VAPORS! Do not install an air handler with a non-ducted return in the same closet, alcove, or utility room as a fossil fuel device. Hazardous vapors can be distributed throughout the conditioned space and equipment damage can 2. Unit Cabinet PenetrationImportant: Due to the unique design of this unit, which allows the electrical wiring to be routed within the insulation, do not screw, cut, or otherwise punc-ture the unit cabinet in any location other than the ones : Under no conditions should metal strap-ping be attached to the unit to be used as support mechanisms for carrying or suspension Panel RemovalThe unit contains four (4) access panels: Blower/Fil-ter, Coil, Line Set, and Blower/Filter panel is removed using 1/4 turn thumb Turn thumb screws on Blower/Filter Pull top of panel out, away from Lift panel up out of Set can be drilled into bottom of unit.

6 (1/2 max. screw length)(Typical all sides)Screws, saw cuts, and other penetrations are allowed in the blower section for installation of Side Return Kit. (Typical both sides)Screws are allowed up to 3- 3/4 from the top of the cabinet (heater compartment).(Typical both sides)Screws for ange kitattachment are allowedalong the interior of the cabinet (see arrows)(Typical all sides)No penetrations allowed.(Typical all sides)Screws allowed only in the rst 3/4 of front bottom of unit (in cross member)4 The Coil, Line Set, and Heater panels are removed using Phillips head screws. #3 Size PhillipsCoil and Heater panels must be removed prior to re-moving the Line Set remove Coil Panel:1. Turn screws on Coil Rotate the top of the panel away from cabinet and disconnect the display assembly wire harness plug near the bottom of the Remove the panel from the Set remove Heater Panel:1.

7 Turn screws on Heater Pull panel straight out, away from Set of the Line Set panel is required for all refrig-erant line brazing and some condensate line assembly depending on your remove Line Set panel:1. Remove both Heater and Coil Turn screws on Line Set Pull panel straight out, away from Set Plug5 Section 3. Unit Prepare The Unit For InstallationSTEP 1 - Check for damage and report promptly to the carrier any damage found to the : The unit is shipped upside-down in the down-flow orientation and may be easiest to transport to the job site in that orientation. If the unit must be trans-ported in a horizontal position, it must be laid on its back (marked REAR on carton). Note: After the unit is removed from the carton, de-press the Schrader valve to verify coil is : Remove the document pack from the heater.

8 Remove the shipping block from the blower NumberDescriptionFits Cabinet SizeBAYEVAC05BK1 AAElectric Heater, 5kW, Breaker, RS-485 Control, 1 PhA to CBAYEVAC05LG1 AAElectric Heater, 5kW, Lugs, RS-485 Control, 1 PhA to CBAYEVAC08BK1 AAElectric Heater, 8kW, Breaker, RS-485 Control, 1 PhA to CBAYEVAC08LG1 AAElectric Heater, 8kW, Lugs, RS-485 Control, 1 PhA to CBAYEVAC10BK1 AAElectric Heater, 10kW, Breaker, RS-485 Control, 1 PhA to CBAYEVAC10LG1 AAElectric Heater, 10kW, Lugs, RS-485 Control, 1 PhA to CBAYEVBC15BK1 AAElectric Heater, 15kW, Breaker, RS-485 Control, 1 PhB to CBAYEVBC20BK1 AAElectric Heater, 20kW, Breaker, RS-485 Control, 1 PhB to CBAYEVCC25BK1 AAElectric Heater, 25kW, Breaker, RS-485 Control, 1 PhCBAYEVAC10LG3 AAElectric Heater, 10kW, Lugs, RS-485 Control, 3 PhA to CBAYEVBC15LG3 AAElectric Heater, 15kW, Lugs, RS-485 Control, 3 PhB to CBAYSUPFLGAAS upply Duct Flange AABAYSUPFLGBAS upply Duct Flange BBBAYSUPFLGCAS upply Duct Flange CCBAYRETFLGAAR eturn Duct Flange AABAYRETFLGBR eturn Duct Flange BBBAYRETFLGCAR eturn Duct Flange CCTASB175 Plenum Stand AATASB215 Plenum Stand BBTASB235 Plenum Stand CCBAYSRKIT100 ASide Return KitA to CBAYICSKIT01 AInternal Condensate Switch KitA to CBAYHHKIT001 AHorizontal Hanger KitA to CBAYUVCLK001 AUVC LightsA to CBAYLVKIT100 ALow Voltage Conduit Entry KitA to CBAYSPEKT200 ASingle Point Power Entry KitA to CBAYWVAA05SC1AA*Hydronic Coil - 50,000 BTUH - Slide-in with controlA to ABAYWVBB07SC1AA*Hydronic Coil - 70,000 BTUH - Slide-in with controlB to BBAYWVCC08SC1AA*Hydronic Coil - 80.

9 000 BTUH - Slide-in with controlC to CBAYWACC11SC1AA*Hydronic Coil - 100,000 BTUH - Add-onC to CBAYWVBRD485RS-485 Control for BAYWACC11SC1 AAC to CBAYCC24VK01 AOutdoor unit Comm to 24 VAC kitA to C* The A/TCONT900 thermostat cannot be used with a Hydronic CoilTable Unit Accessories6 Note: The unit is shipped upside-down in the downflow orientation and may be easiest to transport to the job site in that orientation. If the unit must be transported in a horizontal position, it must be laid on its back (marked REAR on carton). Note: To reassemble cabinet, follow the steps in reverse order. Ensure electrical connections are secure and the plug clips are Disassemble cabinet for installation in tight areas or as 4. Optional Cabinet DisassemblySTEP 1 - Remove all four front panels. See Section Blower Electrical ConnectionsDiverterSTEP 4 - If supplied, remove airflow diverter from the bottom of coil drain pan by gripping the plastic diverter, using your thumbs to spread the top of the diverter slightly outwards, and then pulling down and out through the blower opening as illustrated.

10 STEP 2 - Disconnect the two wiring connections routed to the blower 3 - Slide Blower assembly out of unit using built-in blower support channels and set : Not all Models have an air Support ChannelSTEP 5 - Disconnect wires to the EEV motor and sensors inside the coil assembly. Cut the wire ties on those wire : Wire ties must be replaced after the coil is placed back into the 6 - Slide Coil assembly out of unit using built-in coil support channels and set aside. STEP 7 - Use a 5/16 Allen wrench on the locking mechanism on each side of the bottom half of the cabinet to loosen the locking mechanism. The locks loosen by turning counter-clockwise approximately 3/4 of a 8 - Lift the Coil section up and away from the Blower section. Set 9 - For extremely tight spaces where the cabinet needs to be rotated through a small opening, remove the top panel and all cross members.