8 Air Handler Installation Requirements
A professional should perform indoor air handler installation. The air handler is a complex machine. Aside from a fan, the unit includes ductwork hookups, electrical connections, and refrigerant lines that connect it to the outdoor condenser. Some air handlers include built-in heating elements. Regardless of the installation type, there’s a lot to know about air handlers.
A trained contractor knows all the air handler installation requirements, codes, and regulations. But we’ll consider the top requirements to help you understand the installation process.
The Unit’s Size
Compatibility with Existing HVAC Components
Positioning of the Unit
Condensate Drain
Sealing
Thermostat Placement
Electrical
Testing
What Does an Air Handler Look Like?
An air handler looks similar to a furnace. It allows conditioned air to move from an AC or heater into your ductwork. The blower mechanism is the main component. However, the assembly often includes an evaporator coil, filter rack, damper, and sound attenuator. Depending on the model, it may also include heat strips, especially in areas that don’t normally see extremely cold weather.
What’s Required for Proper Air Handler Installation?
Choosing the right air handler ensures your HVAC system runs smoothly and efficiently. If it’s mismatched, energy costs can go up, comfort levels may decline, and the system may have a shorter lifespan. The following eight requirements must be considered for your air handler to be installed correctly:
1. The Unit’s Size
An air handler’s capacity (in British Thermal Units (BTUs)) must be appropriate for the size of your home. The climate also helps determine the ideal size. If the unit is oversized or undersized, your HVAC system won’t achieve the desired comfort level and will be inefficient. Increased wear is another concern. It can lead to costly repairs and your heating and cooling system may not last as long.
To meet your specific air handler installation requirements, a contractor will calculate the right-sized unit based on the following:
- Square footage
- Ceiling height
- Insulation type/level
- Window size/placement
- Number of occupants
2. Compatibility with Existing HVAC Components
The air handler must be compatible with the outdoor condenser unit, ductwork, and thermostat. Otherwise, it may still run, but there may be performance issues and inefficiencies. A mismatched system may also void the warranty.
All components must match in capacity. The unit’s compatibility with your ductwork, ventilation elements, and your home electrical system are also important factors. In addition to capacity and a proper fit with other components, the air handler and HVAC system should also be of the same brand.
3. Positioning of the Unit
The air handler must be installed and positioned in accordance with the manufacturer’s specifications. However, some general rules must be considered. If a unit is installed in a compartment or alcove, it should have at least 3 inches of clearance along the back, top, and sides. The total width of the enclosing space should be at least 12 inches wider than the unit. An air handler must also be securely mounted, whether it’s placed in a housing or on a wall, ceiling, or near the floor.
4. Condensate Drain
The International Mechanical Code (IMC) is used widely across the U.S. (although state and local codes must also be considered). It covers various requirements regarding condensate drainage. Some of its guidelines to consider during air handler installation include the following:
- Condensate Disposal: Condensate shouldn’t be drained anywhere it can cause people to slip, such as a street or walkway. It should also not be drained around foundations, basements, or other places it can lead to ponding and leakage.
- Drain Size: The inside diameter of an AC condensate drain must be at least ¾ inch. It should not be less than the diameter of the drain pan outlet.
- Pitch: The drain’s pitch should be at least 1% or ⅛ inch of drop for every foot. For ideal drainage, ¼ inch of fall per foot is generally the most effective.
- Drain Line Support: Drain line tubes come in various materials, with PVC being the most common. According to the IMC, a PVC line must have a supporting element every 4 feet horizontally and 10 feet vertically.
Other IMC standards call for a cleanout to clear blockages and provide maintenance. The code also requires installing a secondary drain line or condensate overflow switch. A secondary pan with a secondary line is also acceptable. In a ductless system, a drain trap or check valve is required in the condensate line.
5. Sealing
Without properly sealed connections, the most reliable air handlers, ducts, condensate lines, and refrigerant tubing won’t work as designed. Therefore, every component must be securely sealed to the unit. Efficiency issues aren’t the only concern. A poorly sealed system won’t maintain proper temperature control and may allow contaminants in from outdoors.
6. Thermostat Placement
Modern home thermostats have five wires that connect to various HVAC components. The green wire connects to the blower fan in the air handler. A yellow wire initiates the cooling process while the white wire delivers power to the furnace’s gas controls. The common wire powers various thermostat features, including digital screens, sensors, and its ability to communicate with HVAC components via Wi-Fi.
For optimal functionality, a thermostat should be:
- Placed 4 to 5 feet above the floor
- Installed on an interior wall in a frequently occupied area
- In a space with good air circulation
- Not located near any heat sources
7. Electrical
A successful air handler installation requires making the proper electrical connections. These connections can be complex. Any mistakes may result in serious injury and cause the system to malfunction. Only a professional should handle this step (and the entire installation process, for that matter), including setting up the power supply and electrical link to controls such as the thermostat, zoning elements, and smart home automation systems.
Every HVAC unit requires a dedicated circuit to avoid an electrical overload. The required amperage depends on the size of the air handler. A 2-ton unit draws about 15 to 20 amps, while a 3.5-ton model needs 25 to 30 amps. However, a 5-ton system may require up to 40 amps. Consult with a technician to determine if your electrical panel can support the demand. If not, an electrician may have to replace it with a higher-capacity panel.
8. Testing
The system must be thoroughly tested after air handler installation. No matter how meticulous a technician is, following the right installation steps doesn’t guarantee all components will work as expected. Therefore, temperature control, cycling, airflow, and other functions must be tested. Proper testing ensures the job is done correctly and your HVAC system is reliable and efficient.
Does an Air Handler In an Attic Meet Installation Requirements?
Attics often have extreme temperature fluctuations and tight quarters. The harsh environment can strain an air handler, leading to frequent repairs. A utility room or other area in your main living space makes maintenance and service easier for a technician.
However, installing an air handler in an attic has some benefits. It can save space in your home and reduce noise from your HVAC system. It can also help improve indoor air quality since the air handler is isolated. Your AC equipment is also less visible and is protected against accidental damage. Improved air distribution is also possible.
If you’re considering whether to install an air handler in an attic or move it out, consult with an HVAC professional first.
Should I Install an Air Handler Myself?
An HVAC professional must undergo extensive education and training to be licensed. They must also pass a comprehensive exam. Their knowledge and expertise allow them to install a unit safely and correctly.
At the very least, installing an air handler yourself takes more time than necessary. It can also result in mistakes, which can cause a malfunction and major damage requiring repairs (and the system won’t be warranted unless installed by a qualified professional). Even the smallest of errors can result in loss of comfort and reduced efficiency. That’s not to mention the potential for injuries due to an electrical mishap or mishandling of tools and equipment.
Therefore, always hire a licensed HVAC contractor for air handler installation.
Contact Kliemann Brothers Today
Our experienced heating and cooling professionals perform air handler installation throughout Tacoma, WA. Each is fully educated and certified, plus familiar with the latest technology. High-quality installation ensures your air handler provides effective cooling, heating, humidity control, and air filtration. Whether you choose a central HVAC system or a heat pump, we’ll find the right air handler for your home and install and test it to the highest standards. To get started, book an appointment online or call (253) 201-8498.