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HEAT CONTROLLER, INC.
Installation, Operation and
Maintenance Manual
HAH13XX-00-1A Series
Electric Heat
Air Handling Units
HEAT CONTROLLER, INC.
1900 Wellworth Ave., Jackson, Michigan 49203yPh. 517-787-2100yFax 517-787-9341ywww.heatcontroller.com
THE QUALITY LEADER IN CONDITIONING AIR
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A. Introduction
Heat Controller Air Handlers come in a variety of
models and sizes for upflow or horizontal use and
when combined with cooling coils, are ready for air
conditioning and heat pump applications.
These instructions are primarily to assist qualified
individuals trained and experienced in the proper
installation of this type of equipment. Refer to
authorities having jurisdiction for additional
guidance.
B. Rules for Safe Installation and Operation
1. Read these rules and the instructions carefully.
Failure to follow the rules and the instructions could
cause a malfunction of the unit, and a possible safety
hazard. Keep these instructions nearby the unit for
future reference.
2. This unit has been designed and manufactured
to comply with National Codes; however, it is the
installer’s responsibility to install this unit to comply
with prevailing codes and regulations. Heat
Controller, Inc assumes no responsibility for units
installed in violation of any code or regulation.
3. Before servicing, ALWAYS SHUT OFF
ELECTRICITY TO THE UNIT. This will prevent
any electrical shocks.
4. Ground the unit to prevent electric shock. All
electrical wiring should be in accordance with the
National Electrical Code.
5. Duct work must be installed in accordance
with the standards of the National Fire Protection
Association (NFPA) for the installation of Air
Conditioning, Warm Air Heating and Ventilating
Systems (NFPA 90A and 90B). The air distribution
duct system should be sized for 0.2 inches of static
pressure. See National Environmental Systems
Contractors Association Manual K for duct sizing
recommendations. Ductwork in non-conditioned
spaces must be insulated to prevent formation of
condensate and for maximum operating efficiency.
6. The safety testing agency label appearing on
the unit covers the unit and factory installed coil(s)
only. It does not cover any other equipment.
7. Exterior surface of cabinet may sweat when
unit is installed in non-conditioned space such as
attic or garage. Installer
must provide protection such
as full size auxiliary drain pan on all units installed in
non-conditioned space such as attic or garage type
installations to prevent damage from condensation. It
is recommended that units installed in non
conditioned space be insulated on the outside with 1”
thick fiberglass with the vapor barrier on the outside.
8. While designed to operate quietly when
properly installed, several steps should be taken to
insure this. Use of isolation pads when mounting
unit, flexible duct collars for discharge, and use of
acoustical duct liners are all good installation
practices that promote quiet operation.
9. Cabinet insulation is rated for R=4.2 (standard).
Some jurisdictions require R=6.0 on installations in
non-conditioned space. Add insulation 1” thick to
exterior of air handler to comply in these
jurisdictions, putting the vapor barrier on the outside.
C. Unpacking the Unit
The unit should be unpacked on receipt and if
damage is found, a claim should be made
immediately to the shipping carrier. This is the
responsibility of the entity receiving the equipment.
The air handler is completely assembled, as received.
Electric power, thermostat wiring, refrigerant piping
and duct connections are needed to complete an
installation. Additionally, a drain connection will be
needed.
Check the rating plate for unit size, voltage, phase
etc. to make sure unit meets your requirements.
D. Physical Installation
MINIMUM CLEARANCES
These units have a 0” minimum clearance to
combustible materials rating from all cabinet
surfaces. The unit should be installed with
serviceability clearance of 30” from the front of the
unit. The unit can be serviced entirely from the front,
including replacing the filter. Be sure and route
primary and secondary drain connections so as
not to obstruct filter replacement.
ARRANGEMENT
Unit is shipped from the factory arranged to be
installed in a vertical upflow or horizontal right to
left airflow position (standard) or field convertible to
a horizontal left to right airflow position.
Upflow Application
In an upflow installation the discharge outlet is at
the top. Care should be taken to ensure unit is level
to permit proper condensate drainage. Normal
upflow installation will be in a basement or closet. If
installed in a closet, the closet should have a platform
framed in, with an opening on top of the platform
centered in the closet. Connect the supply air outlet
to a discharge air plenum. Install return air grilles
from outside the closet to space below the platform.
Platform must be at least 10” above the floor. Run all
supply and return ductwork in accordance with local
codes.
Caution!! A “P” trap must be installed in the coil
drain line! Cap unused drain fittings.
Horizontal application
Horizontal application will normally be used in an
attic or crawl space. This type installation requires a
return air duct be attached to the air handler inlet.
The opposite end of the return air duct is attached to
a return air filter grill through the ceiling or wall.
Remove filter from unit if filter grill is used. The
unit is shipped in right to left configuration.
(Warning! To ensure unit will not interfere with
drains and refrigerant lines modification must be
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made prior to installing these lines). For left to
right applications.
1. Remove and set aside front panels.
2. Remove the coil support bracket (4-
screws.
3. Remove horizontal drain pan
retaining clip (1-screw).
4. Carefully remove coil assembly and
bottom drain pan.
5. Move horizontal drain pan from left
hand side of coil to right side.
6. Install modified coil assembly back
into unit.
7. Reinstall coil support bracket and
horizontal drain pan retaining clip.
8. Determine drain holes being used and
reposition knockout caps.
9. Reinstall doors.
CAUTION! IT IS MANDATORY TO USE AN
EMERGENCY AUXILIARY DRAIN PAN
WITH ANY COIL OR AIR HANDLER
INSTALLED IN AN ATTIC OR ABOVE A
FINISHED CEIING!
E. ELECTRIC FURNACE
Optional electric heating packages are available, see
the unit label for various sizes.
* See Electric Heater Kit Specifications Table
F. POWER WIRING
Refer to the unit’s nameplate for specific electrical
data.
CAUTION! DISCONNECT POWER AT MAIN
FUSE OR CIRCUIT BREAKER
DISTRIBUTION PANEL BEFORE WIRING
UNIT TO PREVENT SHOCK OR FIRE
HAZARD.
Use copper conductors only.
Tighten all wire connectors. Refer to unit nameplate
for minimum circuit ampacity. For correct wire size,
refer to the National Electrical Code. Use 75˚C
minimum wire in unit wiring compartment.
NOTE: SEE UNIT FOR COMPLETE WIRING
DIAGRAM LOCATED ON BLOWER
HOUSING.
G. CONTROL WIRING
Field connections are made to the low voltage
terminal strip. Consult installation instructions
provided with accessory items for specific
information on control wiring. Use 18 AWG
minimum copper control conductors for control
wiring up to 50 feet between units. 16 AWG control
conductors are recommended for lengths up to 100
feet. Class 2 wiring is acceptable.
Do not short
control leads. Transformer burn-out will result. Set
thermostat heat anticipator at 0.15 amps for air
handler.
H. BLOWER MOTOR
Units are equipped with a three-speed blower motor.
Two factory-selected motor speed leads are
connected to the fan relay (FR) to prov ide automatic
speed change for heating and cooling airflow
volumes. The pre-selected motor speeds would
normally not have to be changed in the field. All
HAH models contain a post purge timer (TDR) that
delays the blower turning off at the end of the
cooling cycle, this improves energy efficiency.
Terminal number 4 on the (FR) fan relay is the
cooling blower speed and terminal number 6 on the
(FR) is the heating blower speed.
I. REFRIGERANT PIPING
All air handlers have DX refrigerant cooling coils
installed, liquid and suction piping should be sized in
accordance with condensing unit manufacturer’s
recommendations. An adapter (by others) may be
required to make the transition between the line set
and the coil connector. The evaporator coil has
sweat copper connections. The suction line is a
swaged solder cup connection. The liquid line
connection is made to a tail piece portion of the
TXV. Remove the nut on the inlet to the expansion
valve and place it on the tail piece prior to brazing
the liquid line. DO NOT connect the tail piece to the
TXV until the liquid line has been brazed to the tail
piece. Refrigerant lines should be soldered with
silver solder or other high temperature brazing alloy.
Dry nitrogen must flow through the refrigerant lines
during the brazing operation to prevent oxidation.
J REFRIGERANT FLOW CONTROL
As shipped, the TXV installed on the A-coil is for the
nominal capacity of a 13 SEER matched with Heat
Controller Inc. condensing units. The TXV is for use
on an R-22 system. For other refrigerants, contact
the factory. TXV has a built-in check valve for
reverse flow and is suitable for heat pump operation.
All are externally equalized with non-adjustable
superheat and have 15% bleed. Hard start capability
for outdoor units is not normally required when a
15% bleed valve is used. The external equalizer line
attached to the TXV has a female flare nut and is
attached to the suction line at the coil. Install the
TXV bulb to the suction line using the bulb clamp
furnished with the kit. The bulb should be installed
on a horizontal run of the suction line if possible. On
a line less than 7/8” OD, the bulb may be installed on
top of the line. With 7/8” OD or over, the bulb
should be installed in a position of about 4 or 8
o’clock. If the bulb installation is made on a vertical
run, the bulb should be located at least 6 inches from
any bend and on the tubing side opposite the plane of
the bend. On vertical bulb installations, the bulbs
should be positioned with the bulb capillary tube at
the top.
The bulb must be insulated using thermal
insulation to protect it from the effects of the
surrounding ambient temperature.
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K. CONDENSATE DRAIN
The air handler drain pan has ¾” FPT primary and
secondary connections whether used in an upflow or
horizontal configuration. Piping from each stub is to
have a 1½” minimum trap and each run pitched so as
to provide for adequate drainage and secondary
fittings together into a common drain. When an air
handler is installed above a finished ceiling, an
auxiliary drain pan must be provided under the unit
as required by most local building codes. The
secondary drain must be piped to a location that
would provide the occupant a warning if the primary
drain is blocked.
L. AIR FILTER
Air handlers are factory equipped with an air filter.
If the return grille has its own filter, the filter
installed in the air handler should be removed. Air
filter should be inspected and cleaned or replaced as
often as is necessary to prevent restriction of air flow
(minimum every three months for normal
installations). Always replace the filter with the
same type originally furnished.
M. CHECK TEST AND START UP
TURN OFF POWER AT BREAKER PANEL
Electric heaters are high current devices. Verify that
all electrical connectors, whether push-on or
compression-type are tight. Loose connections will
cause the wire and/or terminal to fail.
The unit should be tested after the system has been
completely installed to determine proper operation.
Energize the unit by switching on the line voltage
source and the thermostat.
N. PERIODIC MAINTENANCE
Inspect and clean or replace filters at least every three
months to ensure good airflow and optimum system
capacity, efficiency and life. This equipment should
NEVER BE RUN WITHOUT AN AIR FILTER in
place (see Section AIR FILTER). The blower motor
is permanently lubricated. ALWAYS disconnect
power before removing access doors!
AHB 24, 30, 36
HAH 1324, 1336
AHB Dimensions 24-60
Dimensions
AHB 42, 48, 60
HAH 1348, 1360
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ELECTRIC HEATER KIT SPECIFICATIONS
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MODEL
kW@
USED WITH
N/A Without heat 0 0 2.1 1.9 15 15
7800-305B 5.0 3.8 29 25 30 25
7800-306B 8.0 6.0 44 39 45 40
7800-308B
N/A Without heat 0 0 3.5 3.4 15 15
7800-305B 5.0 3.8 30 27 30 30
7800-306B 8.0 6.0 46 40 50 40
7800-308B 10 7.5 56 49 60 50
7800-312B
N/A Without heat 0 0 4.0 3.9 15 15
7800-313B 5.0 3.8 30 27 30 25
7800-314B 8.0 6.0 46 41 50 45
7800-315B 10 7.5 57 50 60 50
HAH1324-00-1A
HAH1336-00-1A
HAH1348-00-1A
240V 208V 240V 208V 240V 208V
10 7.5 55 48 60 50
15 11.3 56/26 49/23 60/30 50/30
MINIMUM CIRCUIT
AMPACITY
MAX. FUSE OR
BREAKER (HACR)
7800-316B 15 11.3 53/30 46/27 60/30 50/30
7800-317B
N/A Without heat 0 0 6.0 5.9 15 15
7800-313B 5.0 3.8 32 29 35 30
7800-314B 8.0 6.0 48 42 50 45
7800-315B 10 7.5 59 52 60 60
7800-316B 15 11.5 53/32 46/29 60/35 50/30
7800-317B
7800-400 4-Pole Jumper Bar Assembly 15 and 20 kW only
HAH1360-00-1A
20 15 57/63 50/46 60/60 50/50
20 15 59/53 52/46 60/60 60/50
HAHIOM062906
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CB
2
2
L
CB
2
CB
1
L
1
CB
LS-4
P-4
RI
ST
EAT
H
2
S
H
LS-3
STRIP-3
HEAT
S-2
H
LS-2
P-2
RI
ST
HEAT
HS-1
LS-1
1
P
HEAT STRI
HS-1
LO
FR
P24P3
4
6
3
P2
6
3
P3
BLOWER
2
FR
VAC
208
P2
P3
OT OR
M
XFMR
FR
TD R
HS-2
S-1
TDR
H
C
P3
2
P2
HI
R
G
Y
W1
W2
ORG
YEL
CON D
AN D
W2
T- STAT
W1
RED
BL K
RED
GRN
YEL
BL U
RED
YEL
13
4
WHT
WHT
HS-1
5
BL U
BL U
BL U
13
4
HS-2
5
BL U
RED
208/240240VAC
XFMR
24VAC
H
TD R
H
YEL
WHT
BL K
24
56
FR
13
GRN
BL K
RED
4 , 5 KW R ESI STI VE H EAT STR IP
RED
GROUN D L UG
FEMALE P2
WHT
LS- 3
LS- 1
WH T / Y EL
LS- 4
4 , 5 KW R ESI STI VE H EAT STR IP
CB 1 CB 2
RED
2
T
1
T
2
T
1
T
RED
RED
12
LL
12
LL
LS- 2
5 KW R ESI STI VE H EAT STR I P
RED
5 KW R ESI STI VE H EAT STR I P
RED
RED
RED
BL K
BL K
BL K
BL K
C OUTD OOR UNIT CONTACTOR
CB CIRCUIT BREAKER
LEGEND
MALE P3
RED
BL K
BL U
BR N
BR N
MOTOR
BLOWER
FIELD WIRING PER LOCAL CODE
18 G A TYPE 1015 600V TEW 105 C
18 G A T Y P E 1015 600V T E W 105 C 24V
12 G A TYPE 1015 600V TEW 105 C
LS LIMIT SWITC H
FR FAN RELAY
TDR TIME DELAY RELAY
XFM R TR AN SFO RM ER
HS HEAT SEQUENCER
HAH - T O 20 KW W IT H TD R
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